TITLE: METALLURGICAL LABORATORY SECTION REPORT

AUTHOR: MUKONDO ATIPAISHE SHAMEL

DISTRIBUTION:

Mr E MUTANDIRO

Mr T MUPFUMI

Miss I NGWENJE

PERIOD OF ENGAGEMENT. 4 weeks

INSTITUTION: ZIMBABWE SCHOOL OF MINES

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TABLE OF CONTENTS
1.0 BACKGROUND OF THE METALLURGICAL LABORATORY......................................3
2.0 SECTIONAL SHEQ ASPECTS..............................................................................................3
3.0 LITERATURE REVIEW.........................................................................................................4
3.1 Metallurgical Services Department.........................................................................................4
3.2 Metallurgical Accounting........................................................................................................4
3.3 Sampling.................................................................................................................................5
3.4 Sampling methods...................................................................................................................5
3.5 Sample preparation.................................................................................................................6
3.6 Responsibilities/Activities Done at Met Lab...........................................................................8
3.6.1 Heavy liquid separation:...................................................................................................8
This process is done to determine to determine the percentage loss of petalite and if there are
any losses measures are taken to minimize the losses. HLS is also done to determine the
correct separating S.G for different ore feed to the DMS2 plant...............................................8
3.6.2 Sample collection.............................................................................................................8
3.6.3 Media loss in Effluent......................................................................................................9
3.6.4 Determination of grits percentage in Media.....................................................................9
3.6.5 Spigot measurement.........................................................................................................9
3.7 Routine Tasks.........................................................................................................................9
3.7.1 Dry Screen Plant............................................................................................................11
3.7.2 Lab scale Heavy Liquid Separation (HLS).....................................................................12

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3.7.3 Tailings Storage Facility Data........................................................................................14

3.7.4 Settling Tests..................................................................................................................14
4.0 TECHNICAL SPECIFICATIONS OF EQUIPMENT........................................................15
5.0 QUALITY CONTROL...........................................................................................................16
REFERENCES.............................................................................................................................18

LIST OF TABLES

Table 1 : Safety, health, environmental and quality aspects..............................................................4

Table 2: Routine tasks being done at the metallurgical laboratory..................................................11
Table 3 showing results obtained on 09/10/2019............................................................................12

LIST OF FIGURES

Figure 1 showing the sequence of activities done at the laboratory..................................................5

Figure 2 :Showing the process of streamflow sampling....................................................................8
Figure 3: Showing a general diagram of a rotary splitter..................................................................9
Figure 4 showing sample collection on a conveyor belt discharge point........................................10
Figure 5 showing an employee doing Heavy Liquid Separation during determination of petalite
losses..............................................................................................................................................15
Figure 6: Crushing of samples using Boyd crusher.........................................................................17

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1.0 BACKGROUND OF THE METALLURGICAL LABORATORY

The metallurgical laboratory (met lab) was first operated in August 2016 at Bikita minerals
by the metallurgical department. The met lab is responsible for optimisation and quality
control of the plant processes at the mine through conducting of routine test works,
conducting analysis and experimental procedures. In this section certain objectives are to
be achieved namely process assurance, plant quality control and optimisation, technical
support to the production department and the geology department. The main aim of the
starting of the laboratory was to ensure quality results in the plant

2.0 SECTIONAL SHEQ ASPECTS

Table 1 : Safety, health, environmental and quality aspects

Risk Effect Mitigation

Safety
Dust particles Pneumoconiosis Wear dust masks.

Sharp edges of the ore Injuries Wear gloves

(lacerations)

Health
Chemicals (TBE and Damaged respiratory system Wear a respirator with a gas
Acetone) cartridge
Pneumoconiosis

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Dust particles Wear dust masks

Environment
Disposal of the chemicals Air and water pollution Proper disposal of used
(damage to the chemicals.
environment)
Media spillages Air pollution (if inhaled by Proper housekeeping.
animals it can lead to
deaths)
Quality
Human error Inaccurate results Accurately read and record
data.
Sample contamination Inaccurate results Follow laid down
procedures
Loss of data Inaccurate results
Archive all data.

3.0 LITERATURE REVIEW.

3.1 Metallurgical Services Department
The department monitors, assesses and controls the plant processes. This section monitors
and evaluates the plant processes and performance and continuous improvement of the
plant processes is their main task.

The following flowchart shows the activities done in the metallurgical lab.

Met
Inspections/
surveying

Sample
Sampling Met test work Results
preparation

Met Accounting

Figure 1 showing the sequence of activities done at the laboratory.

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Plant samples are collected for test works to evaluate the ore extraction process in the
plant. These test work samples can also be done to evaluate the efficiency of equipment
such as pick ability of Dense medium separator (DMS), screens and jaw crushers. Test
works are prepared by further crushing them to a laboratory required size and are
submitted for laboratory analysis in the Assay laboratory. The assay laboratory analyses
the metallurgical test works and reports the results. Evaluation and metallurgical
accounting can then be done basing on these results.

3.2 Metallurgical Accounting

Metallurgical accounting is a procedure which determines the distribution of the various
products of a concentrator and the values contained in them. This procedure is used to
control operations since values of recovery and grade obtained from the accounting
procedure are indicators of process efficiency (Wills 2006). Collection of reliable data
from the process is required to perform successful metallurgical accounting. At Bikita
minerals the metallurgical service department join together with the Production department
in doing metallurgical accounting and data is stored in the form of Microsoft excel sheets.

Essential requirements.

 Efficient and representative sampling of the process stream.

 Accurate analysis of the valuable components

 Reliable and accurate measurements of the mass flow rate of important streams.

3.3 Sampling
Preferably, weighing and sampling should be carried out before the material is subject to
losses in the mill. These operations must be carried out on run-off-mine ore entering the
primary crushing section. Weighing can be done satisfactorily but accurate sampling is not
possible on account of the wide range of particle size and heterogeneity of the material
being handled. Run-off-mine and coarsely crushed ore tends to segregate, and it is very
likely that the fines are of different grade and moisture content from the coarse material.

The student got to appreciate and practice all the work done by laboratory plant samplers,
thus collection of samples from the plant, drying in an oven, particle size distribution,
crushing and splitting. The student had a chance:

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 To carry out manual sampling of plant samples.

 To collect Belt cut samples, feed samples, floats and sinks samples, fines, dry
screening plant samples and TSF samples.

 To perform Particle Size Distribution analysis on the samples.

 To perform moisture removal by oven drying.

 To participate in metallurgical accounting and daily reports.

 To perform general workplace housekeeping and disposal of old samples.

3.4 Sampling methods

In the metallurgical laboratory department, various methods of sampling are implemented
which are stockpile sampling, belt cut.

Belt cut sampling

Is taken during production, in a random manner, single or many samples are taken
according to the scope. Belt cut can be taken when the production has just started or some
hours after. The conveyor belt is stopped then one meter is measured using a meter rule.
Then the feed is removed from the conveyor belt into the sack.

Stockpile sampling

This process is normally done when determining certain mineral content being produced
and, in the feed, (practised at the lump section where petalite content was being
determined in the product). The front-end loader had homogenized the stockpile for about
4 times. Then using shovels, randomly samples were taken at four different corners of the
stockpile. The samples were crushed to -5mm, splitted and then sent for assay.

Stream flow sampling

This is normally considered to be the best method to obtain a representative sample of

coarse aggregate.

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Figure 2 :Showing the process of streamflow sampling

3.5 Sample preparation
Drying of samples

Ore particles containing moisture give inaccurate results and affect the quality of results
hence samples were dried to remove moisture. Sample drying was done in a well-regulated
oven set at a temperature of 100 to 110 ℃ . In the metallurgical laboratory drying of
samples was also done through natural sunlight which is not 100% effective mainly
because of limited oven facilities. Infra-red heaters or hot plates may be used for rapid
control analysis but are not recommended for accurate work.

Crushing of samples

Samples obtained from the plant required further reduction in size to -5mm for accurate
assay results to be produced. Several types of crushing equipment are in use namely Boyd
crusher and laboratory jaw crushers of different size apertures. Errors like loss of fines,
cross contamination from previous samples and excessive heating of the samples must be
avoided during crushing.

Splitting of samples

Crushed samples must be reduced in bulk to a mass convenient for assay. Also,
homogenisation of the samples is also required prior to analysis. Techniques employed

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include coning and quartering, rotary splitter and Jones riffle splitter (built by the
engineering guys at Bikita).

a. Coning and quartering

This method is suitable for both large and small bulk samples. The ore is poured into a
conical heap and relying on its radial symmetry to give four identical samples when the
heap is flattened and divided by a cross shaped cutter. Two opposite corners are taken as
the sample and the remaining are discarded. This process can be repeated until the required
mass is obtained. Accuracy in Coning and quartering depends on the skill of the operator.

b. The Jones riffle

This splitter is an open V-shaped box in which a series of chutes is mounted at right angles
to the long axis to give a series of rectangular slots of equal area alternately feeding two
trays placed on either side of the trough. The sample is poured into the chute and split into
equal portions by the slots. The process is repeated until a sample of the required size is
obtained.

c. Rotary splitter.

The feed sample is fed at a controlled rate as a falling stream that is divided either into one
part or into equal segments by the action of a circle of segmental buckets being rotated
beneath the stream. The accuracy of the splitter is checked by weighing each container full
of split material (Cleary 2003). The containers should be numbered for easy identification.
Each container is emptied and weighed. The weight of the empty container is subtracted
from the weight of the container and sample. The 10 containers should not vary in weight
more than + or – 1% of the total sample weight (sum of all 10 containers sample weight).
If weight differs more than 1% adjust the speed of the rotary splitter.

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Figure 3: Showing a general diagram of a rotary splitter

3.6 Responsibilities/Activities Done at Met Lab

3.6.1 Heavy liquid separation:

This process is done to determine to determine the percentage loss of petalite and if there
are any losses measures are taken to minimize the losses. HLS is also done to determine
the correct separating S.G for different ore feed to the DMS2 plant.

3.6.2 Sample collection: Sample is continuously cut on the sink, float and de-sliming
screen as shown in the figure below. The composite sample for each day is then collected
for assaying at the Assay Lab. The assay results conclude whether the product for each
shift lies within the specifications required.

Figure 4 showing sample collection on a conveyor belt discharge point.

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3.6.3 Media loss in Effluent: Tests are carried once every day to check on media loss in the
effluent from the secondary drum magnet.

3.6.4 Determination of grits percentage in Media: The grits in the media recovered from
the drum magnets is determined. The media sample is dried and then separate the grits
from the media followed by weighing and calculating the percentage grits. The media
recovered should have no grits since their presence increases media viscosity which is
undesirable.

3.6.5 Spigot measurement: Due to the friction of the material exiting the cyclone, the
spigots wear which result in diameter increase. The increase in diameter is undesirable
because it disturbs the effectiveness of the separation within the cyclone. It is therefore of
necessity to constantly determine the spigots diameter so that worn out spigots can be
replaced. This check-up is done once every week

3.7 Routine Tasks

The routine task works are done daily mainly to monitor the efficiency of the plant
machinery like the dense medium separator. The following tasks are done at the
metallurgical services of Bikita Minerals as routine tasks; belt cuts, particle size
distribution, cyclone measurement, housekeeping, settling tests.

Table 2: Routine tasks being done at the metallurgical laboratory.

Section Task Aim

Dry screening plant -Particle size distribution -to determine screen
efficiency.

Reduction plant -Particle size distribution -to determine the screen

-belt cuts efficiency.
-To determine the feed rate.
-Belt capacity.

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-To determine the crushing

efficiency.

Feed stockpile -Stockpile sampling -to determine the overall

-Bulk density petalite content in the
product.
-volume determination of
the stockpile.

DMS 1 -Particles size distribution

-To determine the screen
efficiency.
-To determine the size
fraction going to DMS 1

DMS 2 -Spigot measurements

-To avoid wear rate of
spigots and schedule for
-Settling tests their replacement.
-To determine the reagent
-Specific gravity concentration of magnetite.
determination(manual) -to compare manual and
automatic specific gravity.

Tantalite primary section

-Particle size distribution
-To determine the feed rate.
-To monitor the screening
efficiency.
Tailing storage facility(TSF)
-
- To account for mass
flowrates and water
discharge into TSF.

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3.7.1 Dry Screen Plant

Aim

-To determine Screen efficiency and Stockpile PSDs

Apparatus: Shovel, Sample bags

Procedures

- Cut across the feed on the vibro-feeder discharge into a sample bag
- Cut the oversize using a shovel on belt discharge into another sample bag
- Cut the undersize using a shovel on belt discharge into another sample bag
- Dry the samples
- Do a full PSD for each sample from +28mm to -850µm
- Weigh each size fraction sample and calculate the weight percentages
- Average the daily percentages

Results and analysis

Table 3 showing results obtained on 09/10/2019.

Aperture Feed(mm) Feed % Oversize( mm) Oversize %

size(mm)

+28 210 4.2 400 7.3

+20 910 18.3 1430 26.3

+15 710 14.4 1840 34

+13 320 6.4 1150 21.2

+10 510 10.3 480 8.8

+5 710 14.3 30 6.2

+2 620 12.5 50 0.5

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+1 350 7 10 0.9

+850 80 1.6 10 0.18

-850 530 10.7 20 0.36

Total 4950 5420

+13mm = 43.2% ; -13mm = 10.9%

3.7.2 Lab scale Heavy Liquid Separation (HLS)

It is done in order to obtain the following key objectives

- Characterizing the density parameters of ore samples;

- Predicting the performance of ores through gravity circuits;
- Pre–concentrating low-grade, high-density minerals prior to further physical or
analytical testing.
- Determination of the density in minerals and separating mixtures

Chemicals include Tetra bromoethane (TBE) with specific gravity of 2.9 and Acetone with
specific gravity of 0.71. Heavy Liquid Separation is done to determine the floats and sinks
according to their specific gravity. Heavy liquid separation tests provide key data, most
commonly data is derived for exploration programs and process design projects.

Aim

- To separate different mineral species based on their relative Specific gravity

Apparatus

-5000ml beaker, Scale, Sieves, TBE, Acetone, Calculator, Measuring Cylinder, Full face
Mask, Relevant PPE.

Procedure

i. Place a 5000ml beaker on the scale and tare to zero.

ii. Pour the TBE in the beaker.

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iii. Divide total mass and volume of TBE to check the SG.
iv. Use the following equation.
v. If the SG is correct, take the samples and pour them into the 5000ml beaker.
vi. Take floats and sinks, place them in different sieves.
vii. Wash the floats and sinks with water to remove TBE.
viii. Dry the sinks and floats, take product for assay analysis on AAS.
ix. Calculate the percentage of losses.

TBE MASS−( TBE VOLUME−S . G REQUIRED)

Vol acetone =
S .G REQUIRED−0.79( ACETONE S . G)

In figure below the HLS was being done to determine the specific gravity of feed entering
DMS 1.

Figure 5 showing an employee doing Heavy Liquid Separation during determination of

petalite losses.
3.7.3 Tailings Storage Facility Data
Aim

-To account for mass flowrates and water discharge into TSFs

Apparatus: Calibrated beaker, Scale, Stopwatch, Sample bag,20litre bucket

Procedure

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i. Collect the whole stream of effluent and record the collection time using a stopwatch

ii. Pour the collected sample into a measuring beaker and record the volume

iii. Record the mass of the sample in a tared beaker

iv. Calculate the pulp density and mass flowrate

v. Using the above information compute the volumetric water discharge

vi. Decant the water from the beaker

vii. Dry the sample and do a full PSD

viii. Repeat the process 4 times at 60mins intervals.

3.7.4 Settling Tests

Aim

To determine media stability through settling rates

Apparatus

1000ml density can, 2000ml beaker, Density scale, Stopwatch

Procedure

i. Collect sample using 1000ml can of feed media

ii. Measure and record the manual density using a density scale

iii. Pour the media from the 1000ml can into the 200ml cylinder

iv. Lap and record the time taken for the media to settle after every 100ml from 1000ml to
600ml

v. Sum up the lap times and record

vi. Repeat the procedure four times

vii. Average the four readings and record

viii. Divide the time consumed by 74mm (distance) from the beaker and get the settling
velocity

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4.0 TECHNICAL SPECIFICATIONS OF EQUIPMENT

Rocklab Boyd crusher

Motor power : 5.5kW

Width by height by depth : 694mm * 1330mm*1070mm

Weight : 520kg

Jaw width : 300mm

Volts : 400V

RPM (revolution per minute) : 960 rpm

Phases : 3phase induction motor.

Figure 6: Crushing of samples using Boyd crusher

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5.0 QUALITY CONTROL

Close monitoring operations and products is required so that excellent results are obtained.
There is need of avoiding contaminants during test work taking and sample preparations
for quality results to be produced. For quality to be assured there is need of avoiding
parallax errors during entering data and data compiling and also records keeping so that
another trained personnel (supervisors) can verify the results and pin point where there is
need to improve and monitor.

6.0 RECOMMENDATIONS

- I recommend proper handling and disposal of TBE and acetone because it is

harmful to human health and affects the environment.
- I also recommend the use of electric sieve shakers to reduce time spent doing
manual sieving and to also prevent parallax errors during manual sieving.
- Implementing a door at the metallurgical laboratory to avoid contamination of
samples since the lab is close to the road which is mostly used by dumb trucks and
other vehicles.
- I recommend an increase in the number of ovens for drying of samples and avoid
drying the samples at an open space close to a busy road which results in high
contamination of samples thereby producing inaccurate results.
- Well conditioning the met lab to minimise dust and improve good air circulation
since there is an oven within the met lab. Since the oven produces the heat, the
working place is not conducive hence become a hinderance during task
undertaking.
- I recommend use of enough personal protective equipment like dust masks and
respirators during participation in any task.

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REFERENCES

 Wills, B. A. (2006), Wills’ Mineral Processing Technology: An Introduction to the

Practical Aspects of Ore Treatment and Mineral Recovery, Seventh Edition, New
York, Butterworth Heinemann, USA, ISBN-13: 978-0-750-64450-1.
 Cleary, P.W. (2003). DEM as a tool for design and optimization of mineral
processing equipment, Proc. XXII IMPC, 1648-1657.
 ICME/UNEP (1998) Case Studies on Tailings Management. UNEP, Paris.

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