55 06b OP App Mining EN (8.0)

OPUS | Ultrasound Extinction
Copper Ore
Particle Size and

Solid Content
on-line Analysis
in Ore Dressing
Kansanshi Mining PTY / Solwezi, Zambia

© Copyright 2015-19, Sympatec GmbH, D-38678 Clausthal-Zellerfeld, Germany | OPUS – Mining | 19H02E16B1EN
Ore Dressing
Process | Application Task
 Crushing | Milling Pit 1 Pit 2 Pit 3 0.8

0.7
Verteilungsdichte q3*
0.6
» Liberation requires a 0.5

0.4
0.3
dedicated particle size

0.2
0.1
0.0
0.5 1.0 5 10 50 100 5001000
Partikelgröße / µm
 Flotation
» Requires tight particle size
and solid content Crusher
specification for smooth

operation
 on-line PSA and solid
Milling Flotation
content analysis required
Comminution Separation
Ore Dressing
Process Control | Demands
 Requirements for analytical technology

» Representative sampling
» Robust sensors
» Simple handling and low maintenance
 … further …
» Combinable with several streams
» Excluding product sedimentation and sanding
» Comparable with sieve analysis
Configuration and Setup
3-Stage Concept
V1
Primary Flush-water
Line 1
Sampling Flush-water
V2
Line 2
Sampling line 1 Sampling line 2
DN50 / material: PVC DN50 / material: PVC
Min.: 0.1 m/s Min.: 0.1 m/s
Typ.: 0.5 m/s Typ.: 0.5 m/s
Secondary Max.: 1.0 m/s Max.: 1.0 m/s
Sampling-box Secondary V3
Flush-water
sampling-box
OPUS OPUS with

Adapter
Sensor Direct drain
to sump
DN25 - 50
DN100
3-Stage Concept | Advantages
 Primary sampler » Permanent flow avoids
» Representative sampling with

sanding and blockages
vertical cross-section sampler » Allows control of flow-speed
shark-fins or pipe sampler
 OPUS sensor
» Large sample amount of
» Continuous analysis on full-
200 - 300 l suspension per
analysis ensures excellent flow without dilution or
statistic sample treatment
» Robust flow-through design
 Secondary sampler
with no moving parts
» Up to 4 lines connectable to
one OPUS sensor
Secondary Sampler | Multiplexer
4 x safety screens
4 x Sample-in from
primary samplers
Flushing lines
Level sensor
OPUS
OPUS FT25
Pneumatic actuators Drainage Back to process
Primary Sampling | Secondary Sampling
Secondary Line 1 - 4
Sampler
Line 4
Line 3
© Sympatec
Line 2
Line 1
OPUS Probe
Primary Sampler © Sympatec
Analysis Results | on-line
Ore Dressing | 3 Days Trend
100 30
 < 45 µm / %
90  < 75 µm / %
Decrease of fine fraction < 75 µm |
 Solid content PSD becomes coarser 25
80
70
20
Solid Content / vol%

Fraction Q3(x) / %
60
50 15
40
10
30
20 Increase of solid content

Decrease of fine fraction < 45 µm | 5
10
PSD becomes coarser
0 0
2/3/| 12:00 2/3/| 18:00 3/3/| 0:00 3/3/| 6:00 3/3/| 12:00 3/3/| 18:00 4/3/| 0:00 4/3/| 6:00 4/3/| 12:00
Date and Time
Observation | Findings
 Observations
» Overloaded mill | Increase of solid content at the mill discharge
» Decrease of particle size distribution values Q3 (xi) | Ground product
becomes coarser
 Conclusion
» Over-charge of the mill by too high feed rate at constant energy | Lower
mass-specific comminution energy | Reduces the milling effect on the
minerals
» Solid content and particle size increase | Influences the efficiency of
flotation | Danger of sanding of the flotation cells
» on-line monitoring helps to avoid process disturbances
Comparison | OPUS vs. Sieve Analysis
100 100
 OPUS Mesh size #400  OPUS Mesh size #325
Fraction Q3(x < 38 µm) / %

80  Sieve 80  Sieve
60 60
40 40
20 20
0 0
0 5 10 15 20 25 0 5 10 15 20 25
Number of Measurements Number of Measurements
100 100

80 80
60 60
40 40
20  OPUS 20  OPUS
 Sieve Mesh size #200  Sieve Mesh size #70
0 0
0 5 10 15 20 25 0 5 10 15 20 25
Number of Measurements Number of Measurements
OPUS | 3-Stage Concept
Application Strengths | Ore Dressing
 The 3-Stage concept with OPUS
allows particle size and solid
content analysis in real-time for
process control
 … in combining
» Representative sample
» Multiplex feasibility | up to 4 streams
» Robust design
» Simple installation and handling
» Very good comparability to other

measurement technologies | Sieving
Kansanshi Mining PTY / Solwezi, Zambia

55 06b OP App Mining EN (8.0)

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OPUS | Ultrasound Extinction

Particle Size and

Kansanshi Mining PTY / Solwezi, Zambia

 Crushing | Milling Pit 1 Pit 2 Pit 3 0.8

» Liberation requires a 0.5

dedicated particle size

specification for smooth

 Requirements for analytical technology

OPUS OPUS with

 Primary sampler » Permanent flow avoids

» Representative sampling with

Pneumatic actuators Drainage Back to process

Solid Content / vol%

20 Increase of solid content

Date and Time

Fraction Q3(x < 45 µm) / %

Fraction Q3(x < 125 µm) / %

» Multiplex feasibility | up to 4 streams

» Simple installation and handling

» Very good comparability to other

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