on my point of view lmsl. contents 1.introduction 2.mining & mineral processing 3.renovation of...

On my point of view

LMSL

CO

NTE

NT

S

1. INTRODUCTION2. MINING & MINERAL PROCESSING3. RENOVATION OF WET MILL SPIRAL

UPGRADING PLANT

• Age of wonder metal• LMSL is a government own company under

state resources and enterprise development.• LMSL is a heavy mineral mining and

beneficiation company• Which operate along the eastern coast of SL

INTRODUCTION

• Business encompasses mining, mineral concentration & separation

• The mine is situated in & around Pulmoddai, where open cast strip mining activity is carried out.

• It has been active mine since 1957, operated by Ceylon mineral sand corporation

• It was converted to a fully government own company known as LMSL in 1992

•

INTRODUCTION

The formation of deposit• Long ago heavy mineral bearing rocks were

formed by volcanic action• Then they were broken into pieces as a result of

mechanical and chemical weathering• These weathered rock pieces are eroded and

reach the rivers • These broken pieces break further into small

pieces during transportation by paleo river (Yan Oya) due to the actions of sliding and crawling

INTRODUCTION

INTRODUCTION

• They were transported by river and rain, ultimately reach marine environment and redeposit on the shore as the result of long shore current.

• But even after deposit is mined it redeposit again , How?

paleo river Sea level fluctuation

α

Financial performanceINTRODUCTI

ONRs.’000s 2009 2010

Total sales revenue 908,395 1,003,398

Value added tax (28,331)

880,064

(1,187)

Net revenue 1,002,211

Cost of sales 516,532 390,514

Gross profit 363,532 611,697

Other operating income 218,683 270,520

582,215 882,217

Administrative expenses 116,303 145,495

Distribution cost 5,855 7,670

Unabsorbed plant &

Floating craft overheads

Non operating expenses

134,324

160,000

550 100

Profit before tax for the year 325,183 568,952

Income tax 86,200 140,000

Profit after tax for the year 238,963 428,952

Financial position

INTRODUCTION

Rs.’000s

2009 2010

Assets

Noncurrent assets 56,112 146,000

Current assets 2,099,396 2,291,314

Total assets 2,155,508 2,437,314

Equity &Liabilities

capital 1,881,168 2,107,314

Noncurrent liabilities 58,934 65,000

Current liabilities 215,406 265,000

Total Equity &Liabilities 2,155,508 2,437,314

CO

NTE

NT

S


UPGRADING PLANT

MINING & MINERAL PROCESSING

Dryer

Dryer

Run-of-mine ore

Transportation of beach sand

Washing & screening (-) oversize

Wet gravity upgrading plant (-) Quartz & fines con

Ilmenite drying plant mag Wet magnetic separation plant (-) Magnetite

con non mags

spiral and wet table plant (-) clay & slimes

heavies

mag

s

Non mags

Non cond

Non cond

Ilmenite

High tension separators cond

Magnetic separator

Leucoxene

mag

s

Rutile

Non mags

Wilfley tables plant

High tension separators

Magnetic separator

Crude monazite Zircon

Quartz

PROCESS FLOW CHART

• Heavy mineral sand mining is the initial step for ore dressing

• Open cast strip mining.• Wheel loader is used to collect the sand • Tippers and tractors are used to transport the raw sand

to the raw sand yard .• Earlier Dragline was used to mine sea sand

MINING & MINERAL PROCESSING MINING AND WASHING

MINING & MINERAL PROCESSINGMechanized loading of beach sand

Mechanized unloading of beach sand in processing plant

MINING & MINERAL PROCESSINGThis dragline can be kept for show

MINING & MINERAL PROCESSINGSand washing

Raw sand contain pebbles cobbles and boulders, sea sells and other foreign materials

These have to be screen and discard and rest of Raw sand mix with water and pump to wet gravity upgrading plant

Earlier Trommel screen used

Now a stationary screen used

Wet Gravity upgrading plantMINING & MINERAL

PROCESSING

The wet gravity upgrading plant is designed to concentrate heavy minerals in the raw sand over 95%

Wet gravity upgrading plant consisting almost entirely of four spiral stages , was considered as the successful unit for upgrading the ore.

The plant is designed to accept feed material of varying heavy mineral content and in order to produce 50 t/h of heavy mineral concentrate for feed to the magnetic separation plant

Tailing are pumped to tailing yard. (1-6% heavies)

Function on sea water.

Wet Gravity upgrading plant MINING & MINERAL PROCESSING

Scavenger spiral

Raw sand

Hydrocyclone

Vibrating screen

Primary spiral

Scavenger upgrade spiral

C

Tailing yard

Slimes & fines

M T

C M

T M

Cleaner spiral

C

T

T

C

FINAL PRODUCT

Over size

(-)

(-)

water

ASSAY IS %OF HEAVY MINERALFEED 50-70%, CON OVER 90%, TAILING 1-6%


Figure 2.7: Ground floor of wet gravity upgrading plant

Figure 2.6: First floor of wet gravity upgrading plant

Plan view of plant

SCAVENGER UPGRADE

PRIMARY SPIRAL BANK

CLEANER SPIRAL BANK

PRIMARY SPIRAL BANK

CLEANER SPIRAL BANK

SCAVENGER

SPIRAL BANK

SCAVENGER SPIRAL BANK

A2

A3 A12 A21

CONTROL ROOM

A0

A5

A34 A9 A22 A31

A26 A18 A13

A35 A10 A23 A32

A27 A19 A14

Wet Gravity upgrading plantMINING & MINERAL

PROCESSING The wet gravity upgrading plant is designed to separate heavy minerals from raw sand. Wet gravity upgrading plant consisting almost entirely of several spiral stages was considered as the successful unit for upgrading the ore. The plant is designed to accept feed material of varying heavy mineral content and in order to produce 50 t/h of heavy mineral concentrate for feed to the magnetic separation plant. Tailing are pumped to tailing yard.

Function on sea water.

Foot valve

MSL

4’

Wet Magnetic Separation plant MINING & MINERAL PROCESSING

Wet magnetic separation plant is designed to separate Ilmenite from wet gravity upgrading plant’s concentrate

Wet high intensity magnetic separators(WHIMS) are mounted to separate ilmenite using differing magnetic properties of heavy minerals

The plant was designed to treat up to 50 tonnes/hr of wet gravity upgrading plant’s concentrate. But the plant can only treat up to 30 tonnes/hr feed due to depreciation of plant equipment.

Wet Magnetic Separation plantMINING & MINERAL

PROCESSING

Scavenger WHIMS

Wet Gravity upgrading plant’s concentrate

DSM Screen

Low intensity magnetic drum

Primary Wet High Intensity Magnetic Separators(WHIMS)

NON MAGNETITE

Oversize & foreign trash

(-)

Magnetite (-)

NON MAGS MIDDLINGS

MAGS

MIDDLINGS

NON MAGS

MAGS

ILMENITE

Assay is % of magnaticFeed 60%Mags 90-95%Non mags 30-40

Wet Magnetic Separation plant MINING & MINERAL PROCESSING

Wet Magnetic Separation plantMINING & MINERAL

PROCESSING

MINING & MINERAL PROCESSINGIlmenite Dewatering Go-Down & Drier

Plant Ilmenite dewatering Go-down is designed to store

magnetic (ilmenite) product and to dewater the ilmenite concentrate’s mc upto 4-5%

Dewatering is achieved by drainage slots in the floor The ilmenite concentrate is allowed to store upto 72

hours for proper dewatering. There are four separated heaps can be pile When the stockpile contains enough ilmenite

concentrate, then it will pass through the diesel drier to reduce MC below 2%

Drier feed rate is 20 ton/hr and maximum MC is 6%


Plant Nearly 100 litre of diesel use for one hour operation.

The dryer is equipped with a hot gas generator to dry the ilmenite concentrate

Drying drum is made out of stainless steel to stand for high temperature without expanding.

Drying drum is supported on four rollers. Each roller is supported by two roller bearings.

48 lifters, six paddle lifters and six spiral lifters are welded inner wall of drying drum in six zones.

the length of dryer drum is 7m, inside diameter is 1.4m, inclination of drying drum is 3 degree and the rotational speed of drying drum is 7rpm


Plant

WET MILL MINING & MINERAL PROCESSING

Spiral Upgrading Plant

Plant is designed to treat non magnetic product of wet magnetic

separation plant.

This plant upgrade the feed material for high tension separation

at dry mill.

The surface of minerals grain should be extremely clean for the

high tension separation of minerals.

Main plant rolls are polishing the mineral sand, clay coat removal

and quartz removal.


Wilfley Tabling Plant

This plant to upgrade the dry mill final non conductions (crude zircon).

Final non conductions are treated on two stage of Wilfley table bank

The final Non conductions contain zircon, monazite, quartz and some amount of ilmenite and rutile.

Only quartz are discard

`


Wilfley Tabling Plant

Cone filter

Dry mill Final non conductors

T

Tailing yard

M

C

M

Scavenger six wilfley tables

Primary six wilfley tables T C

Middling yard

Figure. 2.23: Simplified flow sheet of tabling plant

Assay isQuartz%

20-25% in feed0.7-1.7% in cone filter30-40 % in tailing

Figure. 2.24: Detailed flow sheet of tabling plant

Head Distributor

Distributor

6 bank wilfley table

6 bank

wilfley table

Tailing yard Middling yard

Cone filter

Dry mill final non conductors

Bin 328 Bin 329 Bin 333 Bin 325 Bin 320 Bin 330

WET MILLWilfley Tabling Plant


WET MILLMINING & MINERAL

PROCESSING Training Experiences

Earth Resources Engineering

`

Zircon concentrate scrapper

Overflow water

Blower Surge Bin

Figure 2.26: Cone filter

MC reduced up to 6%

DRY MILL MINING & MINERAL PROCESSING

Plant is designed to separate Rutile, leucoxene, Zircon and crude Monazite

Non magnetic product of wet magnetic separation plant is polished and upgraded in spiral plant is fed to dry mill to separate individual minerals.

There are mainly HTEDS, ESPS, IRMS, HTESS

Three driers Lots of elevators and conveyers equipped

The material to be separated should be free from moisture and hot and dry feed is usually ideal for proper separation results on high tension separator.

DRY MILLMINING & MINERAL

PROCESSING

C

M NC

C

C

NC

C C NC

NC

NM

Wet mill spiral plant production

Dryer

Rough HTEDS

First Cleaner HTEDS

Second Cleaner HTEDS

Vibrating screen

HIIRMS HIIRMS

ESPS

Dryer

ESPS

NC

M

M

M

Figure 2.27: Flow sheet of Rutile and Leucoxene separation

MAG MAG

Leucoxene Leucoxene

Rutile

Over size

FEED RATE IS 3ton/hr

feed have 40-45% mags,13-15% Rutile, quartz 10%

In rutile mags 4-7%, zircon 1-1.5%

In lecoxene mags over 95%

NC

Rough HTEDS non conductor

Scavenger HTEDS

First Cleaner HTEDS

Second Cleaner HTEDS

Third Cleaner HTEDS

Fourth Cleaner HTEDS

ESPS

M

M

Crude zircon (FNC)

NC

C

NC

NC

M

NC

NC

C

C

C

C

Dryer

HTEDS

HTESS HTEDS

HIIRMS

NC C

NC

C 3rd cleaner

C NC

Rough HTEDS

Figure 2.28: Flow sheet of Zircon and crude monazite separation

MAG NM

M

M

M

M

Zircon Crude monazite

Zircon upgrading


PROCESSING

FNC 20-25% quartz after upgrading quartz 1%

Zircon magnetic <1%, rutile 1-0.5% quartz <1%

Crude monazite 45% magnetics


PROCESSING

Electrode

Conductors

Feed

Non conductors

Brush

Carpco manufactured high tension electro dynamic separator are mount on this plant

pinning effect

mineral particles (zircon, monazite), having received a surface charge from the electrode, retain this charge and are pinned to the oppositely charged separator surface by positive-negative attraction.


PROCESSING

Carpco manufactured electro static plate separators

Electro static plate separators are mounted on two stage of mineral separation for a specific reason

One set of ESPS are mount at final stage of rutile circuit. In HTEDS oversize non conductor may not pin the rotor due to high centrifugal force so it will throw to conductor fracture so the ESPSs are installed to remove these non conductor over size material from rutile.

Other set is installed on non conductor purification circuit. In HTEDS very fine conductors may be pinned the rotor and go to non conductor fracture. So ESPS is mounted to separate these fine conductors from non conductor


PROCESSING

Figure 2.31: Induced roll magnetic separation

Magnetic nose piece

Brush Non magnetic magnetic

There are three induced roll magnetic separators are mount to separate magnetic minerals from non magnetic minerals. When the feed passes through a high intensity magnetic field generated between a feed rotor and an adjacent pole piece, the magnetic particles are attracted to the rotor while non magnetic particles throw away. The attracted particles are removed by a tension brush.

Quality control MINING & MINERAL PROCESSING

QUALITY CONTROL IS DONE BY LABORATORY

BLOCK ADaily sample taken for HMS,HM% in concentrate > 95%, in tailing < 5%

Block BDaily sample are taken for high flux test to find out % of magnetic presentIn magnetic > 95% and in non-magnetic < 14% but it’s nearly 30%

Dry millDaily Dry mill feed taken for lift up magnetic separationHourly sample taken from final rutile, zircon & FNC.

in Rutile zircon %< 2%HI –TI %< 5%

in Zirconrutile %< 5%monazite % < 5%

Desire end product qualityTiO2 % in Rutile > 95%TiO2 % in ilmenite > 50%ZrO2% in Zircon > 63%

CO

NTE

NT

S


UPGRADING PLANT

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT

Figure 2.19: simplified Flow sheet of wet mill spiral Plant

Spiral

Wet magnetic separation plant tailing

Spiral classifier

Attritioner

Hydrosizer

Scavenger spiral C

GO-DOWN

Slimes & fines

fines

coarse

T T

Wilfley Table T

C

C

Assay

Heavy Mineral %

75%

40-50%

80%

10-20%

30-40%

90%

85-90%

Plant processing sequence before the renovation


Figure 2.19: simplified Flow sheet of wet mill spiral Plant

Spiral


Spiral classifier

Attritioner

Hydrosizer

Scavenger spiral C

GO-DOWN

Slimes & fines

fines

coarse

T T

Wilfley Table T

C

C

Assay

Heavy Mineral %

75%

40-50%

80%

10-20%

30-40%

90%

85-90%

Reasons for Renovation on my view point

Hydro-sizer fines separation fully abandon

Spiral concentrators and tables are out-dated model in the processing industry

Bins are corroded and it’s the time for re-fabrication

Plant steal structure need to be stabilise

All pumps out of efficiency


T

M

T

Rougher Spiral


Spiral classifier

Attritioner

Hydrosizer

Scavenger spiral

C

GO-DOWN

Slimes & fines

fines coarse

T

Wilfley Table T

C

C

M

M

Rougher Spiral

Scavenger spiral

Wilfley Table

GO-DOWN

TAILING

M

M C

C C

T

T

M

After renovation work

Sample Date 05/oct/2013Feed rate 10 Ton/hr

Assay % heavy mineral

82.66%

61.18%93.24%

93.99%

99.19% 97.79%

99.24%

25.5%


Spiral classifier

Denver manufactured spiral classifier use on this plant to remove clay and slit and to control the underflow solid in pulp w/w% above 80

When the feed is introduced to spiral classifier,

particle of lower settling velocity is carried away in a liquid overflow

particles of higher settling velocity is deposited on bottom and dragged upward against the flow of liquid by spiral like rotating shaft

Double pitch spiral newly fabricated and wearing shoes attached and mounded

We have to maintain the underflow solid in pulp w/w% above 80

we can’t use hydro-cyclone instead of spiral classifier.


Renovation

Attritioner

It remove clay coat and polish the sand.

The attritioner is having seven cells. There are three impellers inside the shell fixed to cartridge. There are separate seven motors for seven cells.

Feed material pulp density should be in 70-80 % range to achieve better polishing.

Rotation direction of impellers in the adjacent cell is opposite

new launder fabricated and fixed

7 6 5 4 3 2 1

Figure. 2.21: Attritioner and the impeller


Hydro-sizer (hydro classifier)

In hydrosizer, a fluid is rising at a uniform rate, feed (particles) introduced into a hydrosizer either sink or rise according to whether their terminal velocities are greater or less than the upward velocity of fluid

Inspection glass

Drain hole

Teeter plate

Fines

Figure. 2.22: Hydrosizer

Underflow Particle with terminal velocity >V

Particle with terminal velocity <V

Overflow

Fluid velocity

V

+ 106 micron

- 106 micron


Hydro-sizer (hydro classifier)

Terminal velocity calculation

Stoke law

Stoke assumed the drag force on a spherical particles is to be entirely due to viscousBut here it is entirely due to turbulent

Here

– density of soliddensity of fluid (water) d – diameter viscosity of fluid


Terminal velocity calculation

Newton’s law

Newton assumed the drag force on a spherical particles is to be entirely due to turbulent resistance This equation valid for free settling, actual situation is hindered settling

So the equation

Here – density of soliddensity of fluid (water)Dp – density of pulp d – diameter

Underflow Particle with terminal velocity >V

Particle with terminal velocity <V

Overflow

Fluid velocity

V


Spiraltable

Holman Wilfley-Table

Manufactured from Holman Wilfley Ltd, UK

Model- Holman 8000 shaking Table

Deck riffle material – LDPE

Riffle pattern- mineral sands w191

Design Parameters

Feed rate – 1 Ton/hr Design feed< 250 micron Wash water flow rate & pressure – 18- 30

litre/min, min 5m head pressure Feed hose detail- minimum 50mm ID Feed density- 25-30% by solids by weight Pulley speed- 270-280 rev/min, not exceeding

290 rev/min Stoke length – 8 -16mm

LH

RH

RH

LH


Spiraltable


general preventive maintenance

Avoid sharp or hot object impacting the deck Avoid welding or grinding near deck Avoid walking on deck If the plant is to be shutdown for a period, deck

should be washed off

LH

RH

RH

LH



Fix the Holman table

First the existing table and concrete bearing of old foundation were removed

New table base has been decided to fix with concrete foundation by anchor bolt resin grouting (resin R-KEX 400, Rs 4460)

2” concrete slap has been erected on existing foundation Foundation marked for drilling Drill the bore holes to correct diameter (24mm) and

depth(200mm) Clean the hole and inject the resin At once the threaded bar was inserted slowly and with

twisting motion. The base is set into the thread and fixed Then the table is lay over the base and fitted correctly Then the gear unit, motor, launder, wash water line and all

other accessories fitted

LH

RH

RH

LH


Multotec spiral concentrator

Spiral concentrator SC 20/ 5/ B/ 3

LH

RH

RH

LH



THEORY Spiral Trough separate material by means of centrifugal and gravitational force

The lighter particles stay suspend in the water and are forced to outer edge of trough by the centrifugal force created by circular motion

The heavier particles sink to the bottom of the trough where drag created by friction , slow them downThe specially slopes trough profile forces these slow , heavy particles to move down the shorter inner edge



Spiral concentrator SC 20/ 5/ B/ 3

Feed hose diameter- 50mmParticle size range- 0-3mmSolid- 0-50% solid w/wVolume/ outlet – 3-5m^3Operating slurry head – 460mm

Spiral trough

LH

RH

RH

LH

Plant model

Play the video


Pump

TROMMEL

FINE SIZE FRACTION WET CONCENTRATE

ATTRITIONER AT 302

SPIRAL CLASSIFIER CL 301

HYDRO CLASSIFIER CL 302

COARSE SIZE FRACTION WET CONCENTRATE

CO

AR

SE

FINE

DUMP BIN

TRASH

P305

B307

B305

B310 B309 B308 B314 B313 B312 B311

P307 P308 P310 P309 P311 P312 P313

SH 304

P318

P314

`3” Line 3

B318 B317 B316 B315

P317 P316 P315

DI 301

DI 305

DI 302 DI 303

SCAVENGER CONCENTRATE

UPGRADING TABLES

TA 301 TA 302

SCAVENGER SPIRALS

ROUGHER SPIRALS

ROUGHER SPIRALS

SCAVENGER SPIRALS

SCAVENGER CONCENTRATE UPGRADING TABLES

Line 2

3” Line 5

Line 4

Line 1

4”

3”

3”

NON-MAGS

C T C C C T

T M M

M C C C C T M T

T

TA 303 TA 304

CYCLONE CY 301

CYCLONE CY 302

DI 306

DI 304

FRE

SH W

AT

ER

CY 303 CY 304

CY 306 CY 305

FINE SPIRAL CONCENTRATE

COARSE SPIRAL CONCENTRATE

STOCKPILING

TROMMEL

FINE SIZE FRACTION WET CONCENTRATE

ATTRITIONER AT 302

SPIRAL CLASSIFIER CL 301

HYDRO CLASSIFIER CL 302

COARSE SIZE FRACTION WET CONCENTRATE

CO

AR

SE

FINE

DUMP BIN

TRASH

P305

B307

B305

B310 B309 B308 B314 B313 B312 B311

P307 P308 P310 P309 P311 P312 P313

SH 304

P318

P314

`3” Line 3

B318 B317 B316 B315

P317 P316 P315

DI 301

DI 305

DI 302 DI 303


TA 301 TA 302

SCAVENGER SPIRALS

ROUGHER SPIRALS

ROUGHER SPIRALS

SCAVENGER SPIRALS


Line 2

3” Line 5

Line 4

Line 1

4”

3”

3”

NON-MAGS

C T C C C T

T M M

M C C C C T M T

T

TA 303 TA 304

CYCLONE CY 301

CYCLONE CY 302

DI 306

DI 304

FR

ES

H W

AT

ER

CY 303 CY 304

CY 306 CY 305

FINE SPIRAL CONCENTRATE

COARSE SPIRAL CONCENTRATE

STOCKPILING

THANK YOUQUESTIONS ?

Argument always try to prove who is right rather than what is right,So we will discuss the matter

on my point of view lmsl. contents 1.introduction 2.mining & mineral processing 3.renovation of...

Documents

processing plant slide

heavy mineral sand mining

heavy mineral mining

spiral upgrading plant

washing slide

s slide

crawling introduction

sand tippers