MINERAL DRESSING

METALLURGY , SEM 3

MODULE 3

LECTURE 2
Ref:
Chapters 7-10 , “ Mineral processing”, S.K.JAIN, CBS PUBLISHERS &
DISTRIBUTORS P Ltd, N Delhi, 2012.
Chapters 8-13, “Principles of Mineral Dressing” , A. M. Gaudin, Tata
Mc Graw Hill, 1993 .
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CLASSIFICATION.

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 CLASSIFICATION.

CLASSIFICATION – THEORY .
Particles of different
sizes,
shapes and
specific gravities
are separated .

Separation is done when they are allowed to settle in a fluid.

The property of their differences in travel rates through a fluid ( air / water ) is used.

- Coarser, heavier, rounder particles settle faster .

Finer, lighter, more angular particles settle slower.

The feed is separated ( sorted ) into OVERSIZE AND UNDERSIZE fractions when each particle
of the feed falls through the column of liquid under controlled conditions.

The overflowing liquid carries the slow settling ( undersize ) particles.

The sediment ( oversize particles) are discharged from the classifier through the bottom.

The particles of intermediate size are held in SUSPENSION ( TEETER COLUMN ) 3

 CLASSIFICATION.

MECHANISM OF CLASSIFICATION –
a) SETTLING IN A STILL COLUMN OF FLUID- Based on the STOKE’S LAW of settling.

A suspension of Fine particles increases

specific gravity and viscosity of the fluid,
decrease their settling velocity and eddying resistance of falling particles.
For fine particles in still water - The surface drag against the surrounding fluid = the gravitational pull.
So they take more time to settle in still water.
Hence settling in still fluid is uneconomical.

b) SETTLING WHEN THE FLUID RISES FROM BOTTOM OF THE VESSEL-

In a CLASSIFIER, PARTICLES FALL UNDER A VERTICALLY ACTING HYDRAULIC FORCE.

This force is provided by the VELOCITY OF THE RISING FLUID ( Water / air ).

The magnitude of this force depends on the VELOCITY ( or VOLUME ) OF THE FLUID PASSING
UPWARD THROUGH THE HORIZONTAL CROSS SECTION of the Classifier AT A GIVEN POINT.

A particle falling against these forces – it overcomes the frictional drag and collisions in the
teeter zone.

Now the particles are separated by Hindered settling. 4

 CLASSIFICATION.
MECHANISM OF CLASSIFICATION –
c) SETTLING WHEN THE FLUID RISES FROM BOTTOM OF THE VESSEL+ HORIZONTAL MOTION

If the classifier provides a horizontal flow to the fluid and the particles in it-

The falling particles will not settle directly at the bottom.

They are displaced horizontally to a distance .
Feed
medium
This distance is α time taken by the particles in passing through
the current of fluid.
water
SO,

When the fluid in the classifier moves up -

it carries away the slow settling grains ( undersize ) ,
it removes the fast settling grains ( oversize ) .

The PARTICLES OF INTERMEDIATE SIZE ARE HELD IN SUSPENSION ( TEETER COLUMN)

MIDDLINGS.
When there is a horizontal movement too- particles settle at different locations. 5
 CLASSIFICATION.
MECHANISM OF CLASSIFICATION –

d) SETTLING IN THE MOVING MEDIUM-

Usually no pure water is used for classification in mineral dressing.

The water may contain dissolved salts to increase its sp.gr.

Other heavier fluids are used.

Water containing fine particles of ores (pulp) are generally used in Mineral Dressing-
This increases the sp.gr of the medium.
The specific gravity can be controlled as per the needs.
Due to increased sp.gr, the fall of particles is slowed down, eddying effects reduced.
The fall of the individual particles of the mineral depends on the packing density of
the pulp ( No of particles / unit vol. of the pulp) .
The factors affecting settling of particles – ref Module 3/ lect 1 , slide #8.
The teeter zone may act as a screen. Particles have to penetrate and settle down.

CRITICAL PACKING DENSITY OF THE PULP-

Below this, unhindered movement of individual particle occurs.
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Above this, intergranular interferences increase.
 CLASSIFICATION.
MECHANISM OF CLASSIFICATION –

Classification depends partly on FRICTIONAL RETARDATION OF THE MOVING PARTICLE IN THE

FLUID ( retardation by velocity of the fluid, interparticle collisions etc).

Hence, very COARSE PARTICLES CANNOT BE CLASSIFIED EFFICIENTLY.

The P.E of the particle gets converted into K.E. when falls in the fluid ( medium) .
This K.E. is used to
overcome the viscosity of the fluid,
start vortices in the fluid,
displace other particles during interparticle collision.

KE FOR THE COARSE PARTICLES IS DISSIPATED AS SHOWN ABOVE, EFFICIENT SORTING IS NOT
AFFECTED.

Normal range of particle size for classification in a dense medium - 1 mm – 50 microns.

Lesser sizes need application of CENTRIFUGAL FORCES.

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 CLASSIFICATION.
MECHANISM OF CLASSIFICATION –

VERTICALLY ( AND HORIZOTALLY ) MOVING PULP ( WATER + FINE PARTICLES ) –

WET CLASSIFICATION.

VERICAL OR HORIZONTAL CURRENTS OF AIR –

DRY CLASSIFICATION FOR DRY POWDERS.

CENTRIFUGAL CLASSIFICATION –
VERY FINE PARTICLES.

CLASSIFICATION

HINDERED SETTLING FREE SETTLING

( MEDIUM HAS 40-70% SOLIDS) ( MEDIUM HAS 3 – 35 % SOLIDS)

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 CLASSIFICATION.
SETTLING VELOCITIES IN CLASSIFIERS-
Fine particles settle at a velocity
directly proportional to size2
directly proportional to apparent sp.gr.,
inversely proportional to the viscosity of the fluid.

V m = 2 * ( ρs- ρl ) r2 g ( Free settling of fine spheres under Stoke’s law).

9 η
For determining the settling velocity in a classifier three correction factors are to be
considered.

1.Correction factor f1 for solid- liquid ratio of medium. Since thicker media are used, settling
velocity is reduced.

2.Correction factor f2 for shape of particles .

3.Correction factor f3 for viscosity of the fluid and acceleration due to gravity.

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 CLASSIFICATION.
SETTLING VELOCITIES IN CLASSIFIERS-
1. Correction factor f1 for solid- liquid ratio.

Classification is done in a relatively thick suspension.

The settling velocity is reduced in proportion to a correction factor f 1.

f1 = ( 1- x 2/3 ) * ( 1 – x ) * ( 1 – 2.5 x ), x – fraction of the volume of suspension occupied by the

solid.

2. Correction factor f2 for shape of particles .

V m α r2

Settling velocity of spherical particle : settling velocity of irregular particle =

Square of the radius of irregular particle : Square of the radius of sphere.
V m1 = r22 = 1.0 for spheres, 1.19 for cubes, 1.28 for thin disks.
V m2 r12

Normally 1.24 is taken for irregular particles of shape between cubes and disks.
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 CLASSIFICATION.
SETTLING VELOCITIES IN CLASSIFIERS-

3. Correction factor f3 for viscosity of the fluid and acceleration due to gravity.

Correction factor for viscosity of the fluid and the acceleration due to gravity is needed .
The term ( 2/9 ) ( g/η ) is considered as the third correction factor f 3.

V m = 2 * ( ρs- ρl ) r2 g ( Free settling of fine spheres under Stoke’s law).

9 η

v = F * ( ρs- ρl ) r2 F = f1 * f2 * f3

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 CLASSIFICATION.
DESIRABLE CLASSIFICATION CONDITIONS-
Use of the classifier product – used for sorting or sizing.
Sizing – ROM ore
Separating into different sizes.
Crushing

It is done after grinding operations. (+) screening

( -)
Grinding
Effect of differences in sp.gr. Of particles is not used fully.
(+) Classifying
Solid content usually 3-4 % by weight for very fine particles, for sorting
( -)
35% for normal size.

FREE SETTLING conditions ( using dilute solutions ) are achieved.

Sorting – ROM ore

The classifier products are concentrated by Crushing

Gravity concentration methods ( Eg:- Tabling ) .
screening
The differences in the specific gravities of the minerals is used fully.
Grinding

Solid content usually 50-75% by weight. Gravity

concentration
by12
HINDERED SETTLING conditions prevail. Sorting
 CLASSIFICATION.

CLASSIFIERS – CONDITIONS FOR EFFICIENT CLASSIFICATION.

Classifiers fall into three categories.

1.SORTING CLASSIFIERS - Fluid medium used - a dense aqueous suspension ( contains

40-70% solids – HINDERED SETTLING CONDITIONS).
The classifier product is concentrated by GRAVITY
METHODS.

2.SIZING CLASSIFIERS - Fluid medium used - a dilute aqueous suspension

( FREE SETTLING).

3.SIZING CLASSIFIERS - Fluid medium used - Air .

( Sizing classifiers are used to help a grinding mill)

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 CLASSIFICATION.
CLASSIFIERS

SORTING SIZING
CLASSIFIERS CLASSIFIERS

LAUNDER CYLINDRICAL TRAPEZOIDAL HYDROTATOR

TYPE TYPE TYPE TYPE

NON-MECHANICAL MECHANICAL PNEUMATIC CYCLONES

SURFACE HYDRAULIC HINDERED

SORTING SETTLING
RAKE CLASSIFIER HYDROCYCLONE
BOWL DYNOCONE
SPIRAL AIR-CYCLONE
MULTIZONE
OVERDRAIN
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 CLASSIFICATION.
SORTING CLASSIFIERS.
Uses HINDERED SETTLING conditions.
Sizing is modified by specific gravity and shape of particles.
Used for coarse products.

1. LAUNDER ( EVAN’S ) CLASSIFIER-

Has a sloping launder (A).

Many rectangular boxes are attached to it.

They open into the launder at BC.

Discharge is through spigots (G-Taps).

Water ( HYDRAULIC WATER ) enters through pipes controlled by

valves (F).

The faster settling particles are discharged through G.

The slower settling particles overflow at E into the launder.

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 CLASSIFICATION.
SORTING CLASSIFIERS.

2. CYLINDRICAL TYPE CLASSIFIERS

( Eg:- ANACONDA CLASSIFIER , RICHARD’S HINDERED SETTLING CLASSIFIER)

Similar to the Evan’s Classifier.

The rectangular boxes are replaced by

CYLINDRICAL SORTING COLUMNS.

The Hydraulic water is introduced into

the columns from bottom.

The water now enters an INNER

CONICAL COLUMN through tangential and RICHARD’S HINDERED SETTLING CLASSIFIER

radial ports.

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 CLASSIFICATION.
SORTING CLASSIFIERS.
3. HYDROTATOR CLASSIFIER
It has a hindered settling zone at the bottom and a free
settling zone at the top.

The zones are formed when velocity of flow at the

bottom zone is increased . The velocity in the top zone
remains same.

The pulp density control mechanism with its auxiliary

mechanisms remove slime ( soft, moist, slippery
material ) particles from the overflow C and the
underflow D.

There is a continuous circulation of fines through the

classifier.

The sediment is discharged when the pulp density

becomes more than a predetermined value.
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Mostly used in coal classification.
 CLASSIFICATION.
SIZING CLASSIFIERS –
They do not need water than that present in the suspension.
They use free settling conditions generally.
The Sp.gr and particle shape conditions are used to a minimum extent.
The sizing classifiers can be further categorised as – 1)Non Mechanical
type,2)Mechanical type and 3)Centrifugal ( Pneumatic and cyclones) type

NON MECHANICAL TYPE – No moving parts.

1. SURFACE CLASSIFIERS ( PYRAMIDAL BOXES, CONES, BOXES,

THICKENERS ETC)-
Sizing occurs at the water surface.
The water brings materials to the classifier.
Used for fine materials.
SETTLING CONE ( ALLEN CONE ) has a conical shell with apex at the bottom
The material to be classified is charged at the center into the feed shell A.
A is surrounded by a cylindroconical shell C. The float F is within the
cylindroconical shell.
A baffle B works against a spring to keep the spigot J closed. When the sediment
level E is suffcient to prevent passage of pulp from C to the body of the classifier ( or
when the density of the suspension is increased sufficiently ) the float is raised,
spigot opened. After the discharge, the operation continues. 18
 CLASSIFICATION.
SIZING CLASSIFIERS –

NON MECHANICAL TYPE – No moving parts.

2.HYDRAULIC CLASSIFIERS ( UPWARD CURRENT CLASSIFIERS ) –

Coarse Feed
Water rises in a series of cylindrical or tapering vessel from below.
over flow
Feed is introduced from top near the center. medium

Light particles overflow from one column to the next.

Heavy
Particles water
The velocity of the rising fluid in this column is less than in the V1 > V2 > V3 > V4
previous.

Different fractions are obtained in the columns ( graded products ) .

Free and hindered settling conditions are used.

Used for coarse materials. 19

 CLASSIFICATION.
3.HYDROSIZER –
To beneficiate and classify minerals generally < 5 mm in size. Minerals .
It is a hindered settling classifier .
It utilises an upward current of water to create a
bed of material within its cell.
The material held in the cell is in a state of 'teeter'
and it comprises a narrow size band.
When particles that are larger (or heavier) enter the
cell they penetrate the teetering material and those
that are finer or lighter are displaced to the
overflow.
By employing an accurate sensing device with a
constant flow of upward current water, well
defined separation is achieved.

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CLASSIFICATION.
HYDROSIZER

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 CLASSIFICATION.
SIZING CLASSIFIERS –

MECHANICAL TYPE – Have moving parts.

A mechanical classifier has rectangular / bowl shaped tank.

The feed consists of pulp from the grinding mill ( pulp density ~ 30% solids).

If the feed has equal size particles-

easy separation into heavy (sinking) and light (overflowing)
minerals.
Generally the feed has a wide range of sizes.

Some particles will drop fast, some will be flown away , others accumulate in the sorting zone.

The density varies in the sorting zone- the lighter particles at the top and the heavier in the
raking zone.

This material in the raking zone is stirred with rakes or with a spiral.
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 CLASSIFICATION.
SIZING CLASSIFIERS –
MECHANICAL TYPE – DORR CLASSIFIER.
It is a horizontal flow classifier .
It has-
1)a rectangular tank with a sloping bottom ( 12cm/m-Inclined
settling tank),
2)a rake mechanism for moving sands uphill along the
bottom,
Feed is introduced usually at the lower end of the tank.
The heavier materials of sand size settle into the rake zone
and are raked up the slope and out the tank; slime and finer
sands are carried over the rear wall in suspension

The oversize is discharged through the upper part and the

undersize through the lower part.
The raking mechanism has mechanically operated rakes.
They start their climb at the lowest settling portion of the
tank.
The settled sand is gathered and lifted during the rising
stroke of the rake.
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The rake returns and drops the sand. The cycle is repeated.
 CLASSIFICATION.
SIZING CLASSIFIERS –
MECHANICAL TYPE – DORR CLASSIFIER

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 CLASSIFICATION.
SIZING CLASSIFIERS –
MECHANICAL TYPE – DORR BOWL CLASSIFIER
It is a horizontal flow classifier .
It has:
- a shallow cylindrical tank with a sloping
bottom ( 12cm/m),
- a rake mechanism ( scraping member)
revolving slowly in the settling tank to
move the sands uphill along the bottom,
- a Dorr classifier attached to the bowl,
- an inlet for feed in the bowl and outlets
for sand and slime.
The moving rakes bring the material to the center – it
falls to the trough of the classifier.
It is scrapped up to the discharge lip as in Dorr
mechanism.
The slime overflows from the periphery of the bowl.
This classifier has more settling area- more finer
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material can be removed.
 CLASSIFICATION.
SIZING CLASSIFIERS –

MECHANICAL TYPE –SPIRAL CLASSIFIER ( AKINS or

HARDINGE CLASSIFIER ).

It is a SPIRAL RIBBON classifier.

There is a sloping trough.
The pulp is kept in this.
It is gently agitated by one or more spiral ribbons
( 3-20 rpm ) mounted on a shaft.
P156 jain
P210 gaudin
The spirals
move the material settled at the bottom of the
trough, and
acts as an elevator for the material.

The settled solids are turned again and again before

they are discharged – this removes the slime
completely.
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SPIRAL CLASSIFIER ( AKINS or HARDINGE CLASSIFIER ).

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SPIRAL CLASSIFIERS

SUITABLE FOR :
•Separation of fine particles and liquid from coarse particles
•Separation of light particles from heavy particles
•Separation of the particles into a number of products graded according to size
•Separation of liquid from solid particles

ADVANTAGES:
•Energy saving
•Heavy duty, rugged construction
•Powerful self-contained spiral lifting device
•Continuous spiral raking
•Optimal particle size range 800 to 75 microns

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RAKE AND SPIRAL CLASSIFIERS

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 CLASSIFICATION.
SIZING CLASSIFIERS –

MECHANICAL TYPE – MULTIZONE CLASSIFIER

The material is fed at the center.

It is raked with a rake.

It has two zones –
1)The velocity zone ( hindered settling occurs)
2)The Quiescent zone ( Free settling occurs).

Due to the velocity of the down flowing slurry, fine

particles enter the free settling zone.

Free settling zone does sorting in annular spaces

( equi-spaced columns on the deck ) above the
hindered settling zone.

Used for Coarse materials.

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 CLASSIFICATION.
SIZING CLASSIFIERS –

MECHANICAL TYPE – OVERDRAIN CLASSIFIER ( ESPERANZA CLASSIFIER ).

It has a long sloping trough.

Endless belts move in the slurry.

The drag belts have scrapping flights.

When the feed is introduced, the coarser, heavier particles settle at the bottom of the
trough.

They are driven up the slope of the trough by the belts.

The heavier material is discharged from the top.

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THANK YOU
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