landfill mining case studies · pátka mineral processing tailings 2. debrecen msw landfill ......
TRANSCRIPT
SMART data collection and inteGRation platform to enhance availability and accessibility of data and infOrmation in the
EU territory on SecoNDary Raw Materials
Landfill mining case studies
Csaba Vér, Dávid Somfai
University of Pécs
This project has received funding from the European Union’s Horizon 2020 research and innovation programme under Grant Agreement No 641988
Contents
1. Pátka mineral processing tailings
2. Debrecen MSW landfill
3. Rudabánya mineral processing tailings
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Pátka tailings – site description
• Fluorite ore veins were found in Pátka, Velencei mountains, Middle Hungary in 1914.
• Production was made from quartz-fluorite-galena-sphalerite ores hosted by carboniferous granite.
• An ore processing plant with 25 tonnes per day ore capacity was built in 1959 and the mine was subsequently changed to base metal production until its closure in 1972.
• In the meantime, the remained mining and flotation tailings represent a reserve of fluorite for its recycling to supply a part of the European demands.
• The last resource estimates (as of 1 January 2006) showed a total fluorite + base metal ore reserve of 180,000 tonnes with 1.23 % Pb and 4.82 % Zn content, and 5,000 tonnes of fluorite.
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Fig. 1: Sampling points in Pátka
Pátka tailings – material content
• Main driver: 5,000 tonnes of fluorite. Fluorite is a major raw material for hydrogen fluoride production. Hydrogen fluoride is an important commodity of the electronic industry.
Phase Name
Pat
ka F
M 4
X
Pat
ka F
M 4
Pat
ka F
M 1
H
Pat
ka F
M 1
HX
Pat
ka F
M 1
ZSX
Pat
ka F
M 1
ZS
Pat
ka F
M 2
ZS
Pat
ka F
M 2
ZSX
Pat
ka F
M 3
Pat
ka F
M 3
X
Pat
ka F
M 2
H
Pat
ka F
M 2
HX
Pat
ka B
K 1
24
Pat
ka B
K 2
24
Albite 4,9 4,4 1,5 1,0 0,8 0,5 0,3 0,8 0,9 1,6 0,3 0,1 11,3 15,0
Alunite 0,5 0,2
Calcite 0,3 0,1 0,3 0,2 0,4 0,1 0,0 0,7
Dolomite 0,2 0,2 0,5 0,3 0,3 0,1 0,3 0,5
Fluorite 2,8 2,3 0,5 0,3 0,4 0,3 0,4 0,3 0,4 0,6 0,4 0,4 4,2 1,5
Galena 0,3
Gypsum 1,1 0,8
Illite 2M1 7,5 5,5 7,1 7,8 9,7 11,3 8,7 9,1 3,7 0,0 3,8 4,4 14,1 9,9
Ilmenite 0,1 0,4 0,7 0,6
Kaolinite 2,0 1,8 3,1 2,8 4,3 4,7 4,3 3,8 1,4 2,4 1,9 1,7 0,0 1,9
Microcline 6,6 5,7
Orthoclase 5,9 4,7 3,1 4,1 3,3 3,2 3,9 4,1 2,9 4,7 2,6 2,2 12,1 14,0
Quartz 66,8 62,5 84,4 83,6 81,2 79,5 81,7 81,2 90,1 90,5 90,6 89,6 44,9 43,0
Sphalerite 0,1 0,2 0,1 0,1 0,2
smect 15A 2,5 2,2 0,1 0,1 3,9 2,9
amorphous 10,0 8,0 11,0
SUMM 100,0 100,0 100,0 100,0 100,0 100,3 100,0 100,0 100,0 100,0 100,0 100,0 100,0
Table 1: Material distribution (in %) of different tailings samples in Pátka
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Pátka tailings – technology process description
• Tailings material is excavated with a grabber and transported by truck to the processing plant where tailings is stored (quantity enough for one week), here, another grabber feed it to the plate reinforced conveyor belt.
• This transports the material to the feed belt of the hammer crusher.
• The <30 mm product of the hammer crusher is stored (quantity enough for 16 hours), because the crusher operates only 1 shift a day. From this storage silo, a conveyor belt feeds the pre-crushed material to the ball mill that operates in a close circuit with a hydro cyclone.
• The ground fluorspar (80% below 0.1mm) is pre concentrated by hydro cyclone and the sludge below 0.01mm is removed.
• Pre-concentrated fluorspar tailings (grade 3-5%) is then concentrated by two-stage-flotation (rougher and cleaner) into a 95-97% grade product.
• Flotation is done in the presence of soda, flotinor (collector) and Flotol B (frother).
• The material balance of the above described technology is shown in Fig.2.
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Pátka tailings – fluorspar processing technology
Fig.2: Material balance of the Fluorspar processing technology
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Pátka tailings – investment needs
Investment need of pilot Unit (e.g.: pcs, m2, m3
...) A - Number of units B - Unit price (EUR)
Cost of investment needed for
excavation (EUR, (A*B)
Machinery / asset lifespan
(year)
Infrastructure investment (road, water,
electricity, etc.) needed before starting
excavation
Infrastructure investment were estimated by cost rate method using rating indexes.
i - cost index
KB - capital of equipment
660 425 See factoring
Grabber for excavation pcs 1 - hired 4
Truck pcs multiple - hired 4
Covered deposition area m3 100 8 065 8 065
4
Grabber pcs 1 48 387 48 387 4
Feeder with plate reinforced belt and
bunker pcs 1
12 903 12 903 4
Feed conveyor belt of roller crusher pcs 1 9 677 9 677
4
Toothed roller crusher (Light version) pcs 1 27 419 27 419
4
Feed belt of screen pcs 1 8 065 8 065 4
Screen (vibrator, double deck) 300mm;
30mm pcs 1
6 774 6 774 4
Course container pcs 1 484 484 4
Elevator for transporting fines (<30
mm) back to container feeding the mill
(see 15th)
pcs 1 4 839 4 839 4
Conveyor belt feeding 30-250 mm
fraction to hammer crusher pcs 1 8 065 8 065 4
Hammer crusher pcs 1 38 710 38 710 4
Elevator for transporting fines (<40
mm) back to container feeding the mill pcs 1
4 839 4 839
4
B K K K 1a B B B
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Table 2/1: Technology investment needs in Pátka tailings www.smart-ground.eu
Pátka tailings – investment needs II.
Investment need of pilot Unit (e.g.: pcs, m2, m3 ...) A - Number of units B - Unit price (EUR) Cost of investment needed for
excavation (EUR, (A*B)
Machinery / asset lifespan
(year)
Infrastructure investment (road, water,
electricity, etc.) needed before starting
excavation
Infrastructure investment were estimated by cost rate method using rating indexes.
i - cost index
KB - capital of equipment
660 425 See factoring
Container and vibrating feeder for crusher
product and feeding the mill pcs 1 6 774 6 774 4
Ball mill (22t) with balls (5,6t) hydro
cyclone, pump and sump pcs 1 241 935 241 935 4
Container for ground material with pump pcs 1 1 613 1 613
4
hydro cyclone, sludge removal pcs 2 1 371 2 742
4
Slurry (tailing) sump with pump pcs 1 1 613 1 613
4
Conditioning tank before rougher pcs 1 5 806 5 806
4
Cell for rougher flotation pcs 1 11 613 11 613
4
Conditioning tank before cleaner flotation pcs 2 2 097 4 194
4
Cell for cleaner flotation pcs 2 2 903 5 806
4
Vacuum filter and vacuum pump pcs 1 3 871 3 871
4
drying cabinet litre 750 4 194 4 194 4
Fluorspar concentrate tank m3 1 323 323
4
Total 1 129 000
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B K K K 1a B B B
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Table 2/2: Technology investment needs in Pátka tailings
Debrecen MSW Landfill – site description
• MSW landfill of Debrecen was investigated and evaluated based on sample data (average of several drilling):
Table 3: Material composition of Debrecen MSW landfill, based on sampling in 2017.
• Main driver: The potential amount of fuel (RDF - Residue Derived Fuel) and raw
material can be estimated to approximately 35-40% of wet waste, 80 - 85% of
which can be recycled depending on the process efficiency.
Mat
eria
ls
1.
Pap
er
2.
Text
ile
3.
Pla
stic
4.
Co
mb
ust
ible
5a.
Al
5b
. Fe
5c.
Cu
5d
. Sta
inle
ss
stee
l
6.
Iner
t
7.
Bio
logi
cal
8.
<2
0 m
m
Dry
mat
eria
l
rati
o [
%]
Wet-material
composition [%] 4.9 4.6 20.6 5.3 0.6 2.2 0.1 0.0 20,2 0.4 41.4 67.16
Estimated total
wet mass of waste
categories in landfill
[103t]
118.8 111.5 499.3 128.5 14.5 53.3 2.4 0.0 489.6 9.7 1003.5
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Debrecen MSW landfill – processing technology description
• Processing technology has two separated parts:
1. The mobile plant deployed on the landfill itself, close to the excavation;
2. The stationary plant deployed somewhere near the landfill.
• The stationary part of the technology is basically the same as the company uses for processing raw, fresh MSW to produce RDF.
• The mobile plant is used for crushing the excavated MSW in a hammer shredder and screening the crushed material in a drum screen, separating the <40mm (or 75mm) granular part and recover Fe from both fine (<40mm or 75mm) and coarse (>40mm or 75mm) fractions.
• The coarse fraction then is transported to the stationary plant by trucks, where magnetic separators remove the accidentally remained iron particles. Inert particles are separated from light fuel particles by air flow separators.
• This light fuel (RDF) fraction is cleaned from Al using eddy current separators.
Material balances of Debrecen MSW landfill mining technology versions are shown in Fig. 3 and 4.
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Debrecen MSW landfill – processing technology (version I.)
Fig.3: Material balance of Debrecen MSW landfill mining technology (version I.)
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Debrecen MSW landfill – processing technology (version II.)
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Fig.4: Material balance of Debrecen MSW landfill mining technology (version II.)
Debrecen MSW landfill – investment needs (stationary plant)
Investment need of pilot Unit (e.g.: pcs, m2,
m3 ...) A - Number of units
B - Unit price
(EUR)
Cost of investment
needed for
excavation (EUR,
(A*B)
Machinery / asset
lifespan (year)
Infrastructure investment (road, water,
electricity, etc.) needed before starting
excavation
Infrastructure investment were estimated by cost rate method using
rating indexes.
i - cost index
KB - capital of equipment
1 170 419 -
Stationary Plant
1.
Ribbed rubber bands for Pre-RDF product
feeding to stationary plant
+ 1 m3 container for Al product
pcs 1 14 516 14 516 5
2. rubber bands for Pre-RDF product feeding to
air flow separator pcs 1 30 645 30 645 25
3. Magnetic separator on top on No. 7. pcs 1 9 032 9 032 25
4. Air flow separator including dust collector and
filter pcs 1 64 516 64 516 25
5. Ribbed rubber bands for heavy product of air
flow separator pcs 1 10 323 10 323 25
6.
Ribbed rubber bands for light product of air
flow separator conveying it to eddy current
separator
pcs 1 12 903 12 903 25
7. Eddy current separator pcs 1 112 903 112 903 25
8. Ribbed rubber bands for Al product pcs 1 5 806 5 806 25
9. Ribbed rubber band for transporting Non
conductor RDF product to secondary crusher pcs 2 62 903 62 903 25
10. Secondary crusher (two axle rotary shredder) pcs 1 274 194 274 194 25
11. Ribbed rubber band for transporting ground
RDF to its container pcs 1 24 194 24 194 25
12. Press container for RDF product pcs 2 21 729 43 548 25
STATIONARY PLANT TOGETHER 668 709
B K K K 1a B B B
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Table 4/1: Technology investment needs in Debrecen MSW landfill
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Debrecen MSW landfill – investment needs (mobile plant)
Investment need of pilot Unit (e.g.: pcs,
m2, m3 ...) A - Number of units
B - Unit price
(EUR)
Cost of
investment
needed for
excavation (EUR,
(A*B)
Machinery /
asset lifespan
(year)
Infrastructure investment (road, water,
electricity, etc.) needed before starting
excavation
Infrastructure investment were estimated by cost rate
method using rating indexes.
i - cost index
KB - capital of equipment
1 170 419 -
Mobil Plant
1. Claw Grabber excavator pcs 1 96 774 96 774 15
2. Mobile hammer crusher pcs 1 241 935 241 935 25
3.
Mobile drum screen with inbuilt
magnetic separator
(gap size 75mm, )
pcs 1 161 290 161 290 25
4. Container for Fe metal product pcs 2 967.5 1 935 5
5. 360-degree excavators - truck loading pcs 1 96 774 96 774 15
MOBILE PLANT TOGETHER 501 935
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B K K K 1a B B B
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Table 4/2: Technology investment needs in Debrecen MSW landfill
Rudabánya tailings – site description
• Rudabánya is a historic mining town in NE Hungary. Documented medieval mining activities were targeted on copper and silver ore, while iron ores in the 19th century.
• Within the framework of the Smart Ground project, a smaller area had been chosen to be one of the pilot scenarios, a tailings deposit at the close vicinity of the former iron ore processing plant.
• Its amount is estimated to be around 4 million tons and consist of approximately 200,000 tons of quartz; one million tons of iron-oxide; 800,000 tons of barite; 1.8 million tons of dolomite along with cca 200,000 tons of different other metals.
• Main drivers: mining of barite and iron ore (carbonate and oxidic form).
Fig.5: Two tailings at the two ends of Rudabánya (marked with red lines)
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Rudabánya tailings – technology process description
• The tailings is excavated by geotechnical methods well known in open pit operations.
• A normal grabber can be used for this purpose with 20 t/h capacity.
• The grabber loads the excavated granular tailings into a hopper and feed it into a hammer crusher via a conveyor belt.
• The tailings is partially liberated and it is aggregated over time, therefore it has to be crushed below 8 mm. Wet screening process is used to separate materials at 1.6 mm.
• Hydro cyclone has a cut size of 0.2mm. Coarse product (above 0.2 mm) is fed to a ball mill to further reduce its particle size.
• Ball mill product is pumped back to the screen where the fine slurry is used also to wash the feed on the top of the screen surface. In the meanwhile, fine products of the cyclones are fed to a magnetic separator
• Using wet magnetic separation, high Fe content product can be reached and it is possible to utilize as iron bearing additive in cement industry.
• The other product is rich in barite which is good as cover material for environmental purposes or it can be used as heavy fine aggregate for special radiation shielding concrete products.
• Magnetic product is de-watered using vacuum filters, while non-magnetic product is pumped into tailings storage area.
Material balance of Rudabánya tailings Siderite processing technology is shown in Fig. 6.
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Rudabánya tailings – technology flow chart
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Fig.6 : Material balance of the Siderite processing technology in Rudabánya
Rudabánya tailings – investment needs
Investment need of pilot Unit (e.g.: pcs, m2, m3
...) A - Number of units B - Unit price (EUR)
Cost of investment needed for
excavation (EUR, (A*B)
Machinery / asset lifespan
(year)
Infrastructure investment (road,
water, electricity, etc.) needed before
starting excavation
Infrastructure investment were estimated by cost rate method using rating indexes.
i - cost index
KB - capital of equipment
1 354 616 -
Grabber for excavation pcs 1 - hired 20
Truck pcs multiple - hired 20
Covered deposition area m3 100 8 065 8 065 30
Mechanic excavator (grabber) pcs 1 96 774 96 774 80
Feeder with plate reinforced belt and
bunker pcs 1 12 903 12 903 80
Hammer Crusher pcs 1 241 935 241 935 30
Conveyor belt - feeder for screen pcs 1 8 065 8 065 30
Wet Screen (1,6mm) pcs 1 32 258 32 258 80
Conveyor belt for coarse product of
the screen pcs 1 48 387 48 387 30
Slurry tank with agitator and pump pcs 1 2 581 2 581 30
Hydro Cyclone, cut size 0.2mm pcs 1 4 839 4 839 80
Slurry tank for cyclone coarse with
pump pcs 1 1 613 1 613 80
Slurry tank for cyclone fine with
pump pcs 1 2 581 2 581 30
Ball Mill pcs 1 354 839 354 839 80
Slurry sump with pump ground
product back to screen pcs 1 1 613 1 613 30
Wet magnetic separator pcs 1 32 258 32 258 80
Vacuum filter and vacuum pump pcs 1 48 387 48 387
Total 2 251 713
B K K K 1a B B B
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www.smart-ground.eu Table 5: Technology investment needs in Rudabánya
