Comminution, Flotation and Physical Separation - 2019 entry

The module gives graduates from a range of disciplines the opportunity to study the fundamentals of mineral processing. This module could be taken on its own to provide a valuable insight into one of the important processes in the mining cycle. When linked to other specific modules, it forms part of the specialist training for the MSc in Minerals Engineering.

If you take this module, you should have a reasonable understanding of physical chemistry, and would benefit from a basic knowledge of mathematics and mineralogy. Support and guidance in self-study to improve understanding in these areas can be provided. This module is suitable for non-specialist students and those on interdisciplinary pathways.

This module has been designed to develop a systematic understanding of the unit processes used in mineral processing and an appreciation of how these unit processes are combined to produce an overall treatment system for a range of minerals and metals. The latest innovations and trends in these subject areas will be discussed and critically assessed.

On successful completion of this module, you should be able to:

Module Specific Skills and Knowledge:

1 Demonstrate a detailed knowledge of the latest processing techniques and equipment developments in mineral processing;

2 Understand how mineral processing techniques are applied in the production of a variety of minerals and in material processing;

3 Undertake specific experimental techniques required for ore evaluation;

4 Calculate metallurgical efficiency, net smelter return and mass balances using the two product formula and understand the relation of these to economic considerations;

Discipline Specific Skills and Knowledge:

5 Demonstrate a systematic and creative approach to problem solving;

6 Select and use appropriate computer based tools for analysis, design and communication of designs;

Personal and Key Transferable/ Employment Skills and Knowledge:

7 Sort, manipulate and present data in a way that facilitates effective analysis and decision making;

8 Communicate effectively and persuasively using the full range of currently available methods.

Introductory and Overview Topics:

- Introduction to minerals processing: overview of mineral processing and its role in the extractive minerals industry;

- Mineralogy: introduction to the link between mineralogy of an ore and the selection of a mineral processing circuit.

- Metallurgical efficiency, smelter contracts and metallurgical balances: Including the use of the 2 product formula, NSR, unaccounted losses and gains;

- Programme expectations: the expectations in terms of prior knowledge as well as learning and private study will be discussed alongside methods to meet these expectations. The reasoning behind the use of e-assessments in modules to gauge prior knowledge and skills will be covered. The use of peer learning, electronic resources and learning tools including Massive Open Online Courses (MOOCs) and other methods of filling gaps in knowledge will be explored;

- Professional skills development: tutorial sessions will be dedicated to developing good practice in team working and peer learning. This will will be formatively assessed by a group presentation on topics related to comminution, physical separation and flotation;

Comminution Topics:

- Comminution: types and application of various crushers, novel comminution methods and pre-weakening and assisted comminution, grinding mills (rod, ball and autogenous), fine grinding equipment, testing of grinding media, methods of comminution circuit control;

- Screening and classification: fixed and vibrating screens, screening surfaces and screen efficiency. Classification fundamentals and review of equipment including hydrocyclones;

- Flotation Topics:

- Classification of reagents, mechanical and pneumatic flotation cells, flotation circuits. Examples of collectors, activators and depressants for a range of mineral ores. electrochemical nature of sulfide flotation and the importance of Eh. Latest mineral specific trends;

- Surface science in mineral processing: stability of particle suspensions – DLVO theory, measurement of zeta potential, the gas-liquid interface, surface tension and contact angle measurement, surface energy through inverse gas chromatography, surface speciation techniques including x-ray photoelectron spectroscopy, physical adsorption of flotation collectors. Methods for recovery of ultrafine particles;

- Current research and innovations in the fundamental understanding of flotation will be covered;

Physical Separation Topics:

- Dense medium separation (DMS): types of medium for plant and laboratory use, Dynamic and gravitational vessels, DMS circuits, partition coefficient and Ep, evaluation of DMS performance;

- Gravity concentration: sluices, cone concentrators, spiral concentrators, jigs, shaking tables and centrifugal separators (Knelson, Falcon and Mozley MGS);

- Sensor-based ore sorting: basic principles, selection of sensors and applications in the minerals industry. Latest innovations in sensor selection and use;

- Magnetic and electrostatic separation: classification and examples of low and high intensity magnetic separators. Superconducting magnetic separation. Particle charging mechanisms (ion bombardment, conductive induction and tribo-electrification) and application in mineral separation

Case Studies:

- A range of mineral and material types to be considered including: complex sulfides, iron ores, clays and carbonates and waste paper;

Laboratory Exercises:

- Laboratory exercises in a selection of appropriate techniques such as size analysis, mass-balancing techniques, classification, froth flotation, gravity and magnetic separation will be undertaken;

Health and Safety Engagement:

- The health and safety implications related to comminution, physical separation and flotation will be covered. This will include discussion of the dangers of working with different mineral types, controlling and handling of chemicals, safety aspects of industrial processes and safe lab practices.

Basic reading:

ELE: http://vle.exeter.ac.uk/

Web based and Electronic Resources:

http://app.knovel.com

https://app.knovel.com/hotlink/toc/id:kpWMPTAI01/wills-mineral-processing/wills-mineral-processing (online version of Wills' book, listed in the Reading List)

Reading list for this module: