Analysis &SamplingSystem andProcessInstrumentationfor MineralFlotation Plants

Analyze • Detect • Measure • ControlTM

On-Line Analysis

- Light & Heavy Elements

Particle Size Monitors

- 5 Size Fractions & %Solids

Slurry Sampling

- Process Control & Metallurgical

Accounting

Cross Belt Analysers

- Light & Heavy Elements

Process Instruments

- Density, Level, Thickener

Interface, Conveyor,

Weighscales, Tramp Metal

Detectors

Analysis&

Sam

pling System and Process

Instrumentation for M

ineralFlotation PlantsTherm

o Electron Corporation

Thermo – Products

Thermo Electron supplies a complete range ofanalysis and sampling systems.

Weighing Systems

Tramp Metal Detector

Proline Conveyor Safety & Control Equipment

Tank & Bin Level Measurement

Microwave Flow Measurement

CBX Cross Belt Analyser

BLG Bin Level Gauge

NBC Nuclear Ball Counter

HPDG High Performance Density Gauge

MSA Multi-Stream Analyser

AnStat Analysis & Sampling Station

PSM Particle Size Monitor

SamStat Sampling Station

LESA Light Element Slurry Analyser

TIG Thickener Interface Gauge

CBA BLG

CBA

N

NBC

HPDG

HPDG

ANSTAT

ANSTAT

LESA TIG

TIG

PSM

MSA SAMSTAT

SAMSTAT

ANSTAT

HPDG

HPDG

Crushing and Grinding

Blending Control

CBA

The Cross Belt Analyser provideson-line analysis of material on theconveyor feeding the stockpile forcritical light and heavy elements.

Belt Scale

Conveyor Belt Scales and Integratorsfrom general use systems to certifiedfor trade accuracy.

Grinding Process Control

CBX

The Cross Belt Analyser provides on-line analysis of the conveyor feedingthe Grinding circuit to characterisegrindability of the ore and for criticallight and heavy elements to optimisereagent dosing.

NBC

The Nuclear Ball Counter measuresgrinding media addition to SAG andBall mills.

HPDG

The High Performance DensityGauge provides on-line density ofslurry or solution in pipes or tanks,and coupled with a flow-meterprovides mass flow measurementfor control purposes.

PSM

The Multipoint Particle Size Monitorprovides on-line analysis of up to 5particle size fractions and %solidsfor grinding optimisation.

AnStat

The Analysis and Sampling Stationprovides reliable metallurgicalaccounting sampling and elementalanalysis. It can also be designed toprovide distribution to the flotationplant.

Flotation

AnStat

Provides continuous elementalanalysis of critical streams andmetallurgical sampling for inventoryaccounting.

SamStat

The Sampling Station providesprocess or metallurgical qualitysamples for metallurgical accountingor process samples for MultiStream Analysers.

PSM

Provides on-line analysis of up to 5particle size fractions and %solidsfor regrind circuit optimisation.

MSA

The Multi Stream Analyser providesintermittent elemental analysis ofintermediate non-critical processstreams.

LESA

The Light Element Slurry Analyseris particularly suited to analysecritical light contaminant elementsespecially on final product streams.

Dewatering

TIG

The Thickener Interface Gaugeprovides on-line determination ofthe density profile and bed depth inthickeners.

HPDG

Provides on-line density measure-ment of thickener underflows.

Complete analysis and sampling systemsThermo Electron can instrument an entire flotation plant with critical analysis and sampling equipment:

Dedicated Analysers and AnStatsAnalysis and Sampling Station (AnStat)

• A dedicated Analyser used in conjunction with thestatistically correct Sampling Station (SamStat)constitutes an Analysis and Sampling Station(AnStat) to provide full metallurgical accountingsampling and continuous in-stream analysis.

• A cross cut metallurgical sampler is located at theoutlet of each analysis tank for calibration andprocess control sampling.

• Each AnStat is designed to be one complete systemarranged linearly or with parallel sections. AnStatscan be designed for new plants or retrofitted toexisting operations. With no pumps and no sampletransport lines they provide the lowest cost ofownership.

• Can be dimensioned to handle any flow-rate.

• Lowest slurry head loss of any available metallurgicalsampling system with compact footprint and flange-to-flange supply means large savings in engineeringdesign and construction costs for new plants.

• Can be offered with automated filtering systems.

Sampling Station (SamStat)

• These are statistically correct metallurgical SamplingStations that are an AnStat without the analysisprobe and associated equipment.

• SamStats can be easily and economically upgradedto an AnStat.

Multi Element and Single Element Probes (MEP and SEP)

• Elemental analysis from Ca in the periodic tableusing X-Ray Fluorescence.

• Multi Element Probes for simultaneous analysis ofup to 8 elements plus %solids.

• Single Element Probes for the analysis of a singleelement. Used in conjunction with a separatedensity probe for %solids.

• Continuous analysis of each stream providing assayupdates every minute for optimum process controlof critical streams.

• Accepts sampled flow from any of the samplerslisted on the following page.

• Extremely stable operation, minimal recalibration.

• Window change out typically every 3 months.

Skid Mounted Probes

• Either the Multi Element or Single Element probescan be mounted in an integrated tank and samplingsystem to receive a flow rate up to 80 m3/hr.

• Ideal for testing different streams, easily moved fromone stream to another.

Other Sampling SolutionsThe correct presentation of sampled slurry to bothdedicated analysers and Multi Stream analysers isfundamental to the success of any on-line analysissystem.

Continuous Sampling Systems (SamStat(c))

• Applications for closed or open pipes.

• Provides highest quality samples for both metallurgicalbalance samples and process samples to feed on-lineanalysers.

• Compact multistage sampling system (available in 1, 2or 3 stages as a function of flow-rate).

• No flush water or flushing valves required.

• Low velocity through the system which means lowwear and maintenance requirements.

• Open visible system that can be easily monitored forperformance.

• Cutters are replaceable on-line.

• Flexible screens for rejection of oversized particleswith automatic dump valves are available as options.

Launder Samplers

• Applications for open launders (both metal above floor,and in-concrete at floor level).

• Same advantages and characteristics as for SamStat(c).

Gravity Feed Samplers

• Sizes 100 (4") to 900 mm (36")

• Flanged to suit application.

• Replaceable cutters - through inspection port.

• Rubber lined.

• Back flushing valves available.

Pressure Pipe Samplers

• Pressure samples have polyurethane turbulence bars,otherwise same specifications as Gravity Feedsamplers.

Gravity Feed and Pressure Pipe Samplers

• Provide simple, cost effective samples to feed on-lineanalysers.

• Are best suited for lower flow rates (less than 250m3/hr) and smaller pipe sizes (less than 300 mm).

Multi Stream Analysers

• Elemental analysis from Ca in the periodic tableusing X-Ray Fluorescence.

• Can measure 3 to 24 streams.

• Nominal flow rate of 2-12 m3/hr for standard300mm wide tanks.

• Maximum flow rate of 60 m3/hr for 600mm widetanks.

• Cost effective analysis of multiple sample streams.

• Fast assay update times.

• Each sampled stream is kept completely separate init own analysis tank, meaning no multiplexer ordemultiplexer is required.

• Low slurry head loss of less than 1000mm.

• Cross cut metallurgical samplers located at outlet ofeach analysis tank for calibration and process controlsamples.

• When used with statistically correct primarysampler (SamStat(c)) can collect shift compositesamples for metallurgical accounting.

• Simultaneous analysis of up to 8 elements and%solids.

Light Element Slurry Analyser

For the simultaneous analysis ofboth light elements in slurries (ieelements below Ca in the periodictable), and the common heavierelements Thermo Gamma-Metricsoffers the Light Element SlurryAnalyser.

• Elemental analysis of light andheavy elements using PromptGamma-Ray Neutron ActivationAnalysis (PGNAA).

• Unaffected by changes inparticle size, mineralogy andmatrix.

• Available as single stream unitsor multi-stream units for up to 8streams.

• Available with 2 different detectorsystems, NaI scintillator or solidstate Ge.

• Suitable for applications such asIron Ore plants to measure Fe,Si, S; and other light matrixapplications; light elementcontaminants in final productstreams (eg MgO in Ni finalconcentrate, SiO2 in Zn finalconcentrate, S in Cu finalconcentrates).

Multi stream unit uses the SlurryHandling System (SHS), whichconsists of:

• Primary samplers to collect arepresentative sample from theplant process. They can be anyof the devices listed previously(ie gravity feed, pressure pipe orriffle samplers).

• Multiplexer, that collects up to 8samples and prepares them forpresentation to the AnalyserStation. This unit also collectscalibration and shift compositesamples. It consists of 2 mainslurry holding tanks, each fittedwith 1 to 4 sample diverter units.

• A flow cell in the analyserpresents the sample to thedetector.

• Recirculation pump to recyclethe sample (collected andprepared by the multiplexer)through the flow cell.

All of theabove equipment is normally located onsuitable platforms in the plant.

Particle Size Analysis

Multipoint PSM-400• 5 particle sizes plus %solids

every 5 seconds.

• Automatic calibration and shiftcomposite sampler.

• Automatic, scheduled waterstandardisation.

• Advanced calibration models.

• Accurate over wide calibrationranges.

• Sophisticated softwarealgorithms to optimise signalprocessing.

• New updated model for 2004

Integration with AnStat

• Can be combined with an AnStatto provide a 3-wayMeasurement Station forelemental analysis, metallurgicalshift sampling and particle sizeanalysis.

• Particularly suitable for cycloneoverflow streams in flotationplants.

Transmitter A Receiver A

Transmitter B Receiver B

Cross Belt AnalysersThe Cross Belt Analyser provides in-situ analysis ofmineral material directly on the belt. The CBX uses thePGNAA principle of analysis of both light and heavyelements.

• No sampling or sample preparation required.

• Real time elemental information for process control.

Typical Applications

Stockpile Management

Continuous measurements from the CBX can be usedto determine the average grade of a stockpile of ore andthe required reclaim methodology to optimise blend

control.

Blending

On-line blending of different concentrates or materials(ore, flux, return dust, etc) to provide a more constantfeed to a smelter, roaster or sintering plant.

Mine Grade Control

The CBX can monitor ore on the conveyor after crushingto provide timely feed-back to mine management formine grade control.

Sorting

The ore can be sorted onto different stockpiles based onanalyses from the CBX measuring ore on the conveyor

belt.

Comminution

Continuous elemental measurements from the CBX onthe feed to an AG/SAG mill can be used to characterisethe ore into different types to determine which AG/SAGmill control model is most appropriate for that ore type.

Process InstrumentsA complete range of Process Instruments are offered:

• High Performance Density Gauges for densitymeasurement of slurries in pipes. This gauge is alsoavailable as an Immersion Density gauge for specificapplications.

• Continuous Level Measurement for measurementof levels (continuous or switch) in vessels andcontainers.

• Thickener Interface Gauge for measurement of thedensity profile and bed levels in thickeners.

• Radiometric Analysers for the measurement ofnaturally radioactive material on belts or in slurries(eg KCl).

• Nuclear Ball Counters to monitor grinding mediaconsumption.

• Conveyor Belt Scales and Integrators from generaluse systems to certified for trade accuracy.

• Impact Weighers for low cost high accuracymeasurement of mass flow rate and total mass offree flowing solids.

• Tramp Metal Detectors to protect crushers,conveyors and other process machinery fromdamage by tramp metal.

• Proline equipment to monitor belt misalignmentunder/over speed conditions as well as safety pullswitches.

• A variety of level measurement systems to suit anyindustrial application. Measurement techniquesavailable include strain gauge systems, ultrasonic,mechanical and capacitive.

• Microwave Flow/No Flow detectors to monitorsolids flow in pipelines, ducts, airslides or transferpoints of vibrating chutes, conveyors and bucketelevators.

Density Gauge

Analyze • Detect • Measure • ControlTM

www.thermo.com

Head Office for minerals, Adelaide, AustraliaThermo Electron Corporation

Telephone: +61 8 8150 5300Facsimile: +61 8 8234 5882

Email: sales@thermogammametrics.com.au

Web: www.thermo.com

Other branch offices:SydneyPerthMackayBrisbaneShanghaiPune (India)ErlangenGloucesterBahrain