Presentation for IMMT

Post on 12-Apr-2017

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Beneficiation Plant

Scrubbing(Scrubber)

Comminution(Crusher, Rod Mill & Ball Mill)

Gravity Separation(Coarse & Fines Jig)

Magnetic Separation(MIMS, Coarse & Fines WHIMS)

Magnetic Separation(MIMS, Coarse & Fines WHIMS)

Classification (Screw Classifier, Hydrocyclone)

Dewatering(Thickeners, Vaccum Belt Filter & Press Filter)

Methods Of Beneficiation Process

Beneficiation Plant Process Flow Sheet

SBR

DD S

SD S

S CLR

C J

L O S

CRS

SD S

RM

BM

IT

CT

B F

CW

FW

- 30

- 30 + 5

- 5 + 1

- 1

- 0.15 - 1 + 0.15

- 0.15

- 0.15

- 30 + 10

- 10 + 5

- 5 + 1

- 1 + 0.5

- 0.5 +0.15 - 0.15

- 0.5

- 10

- 0.15

B F Product

Pellet Fines Product

Tailing Pond

- 1

- 1- 1

- 5 + 1

+ 5

+ 1

+ 0.15

Modified Beneficiation Plant Process Flow Sheet With Longi

WHIMS

SBR

DD S

SD S

S CLR

C J

L O S

CRS

SD S

RM

BM

IT

CT

PF

B F

CW

FW LW 1

- 30

- 30 + 5

- 5 + 1

- 1

- 0.15 - 1 + 0.15

- 0.15

- 0.15

- 30 + 10

- 10 + 5

- 5 + 1

- 1 + 0.5

- 0.5 +0.15 - 0.15

- 0.5

- 10

- 0.15

B F Product

Pellet Fines Product

Tailing

+ 30

+ 5

+ 0.15

- 1

- 5 + 1

Month wise quality report (2013-14)

Apr-13 May-13 June-13 July-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14

58.9959.54

60.5059.62

60.17 60.3459.77

60.6559.97 59.91

59.48

64.20 63.9964.43

62.98 63.33

64.4363.55

64.07 63.96 63.77 63.94

62.22 62.3362.93

61.94 62.34 62.42 62.4063.24

62.38 62.72 62.79

51.2752.30

54.08

52.86 53.1152.44

50.50

49.43 49.36

47.23

45.87

Feed BF Fines Tails

After Longi WHIMS

Month wise tailing Fe% (2013-14)

Apr-13 May-13

June-13

July-13 Aug-13 Sep-13 Oct-13 Nov-13 Dec-13 Jan-14 Feb-14

51.2752.30

54.08

52.86 53.1152.44

50.5049.43 49.36

47.23

45.87

Feed Constituents

• Fe – 58.5-60.0 %• SiO2 – 3.5 – 3.0 %• Al2O3 – 5.5 – 5.5 %• LOI – 6.5– 4.5 %• Size – (-30mm)

BF Product Constituents

• Fe – 63.5-64.5 %• SiO2 – 1.32-1.25 %• Al2O3 – 1.98-1.90 %• LOI – 3.39-3.2• Size- (-30+10mm)• Recovery by Wt% - 8-11%

Pellet Fines Product Constituents

• Fe – 62.5-63.5 %• SiO2 – 1.76-1.65 %• Al2O3 – 2.66-2.50 %• LOI – 4.22-4.0 %• Size- (-10mm to 0 mm )• Recovery by Wt% – 62-64%

Tailing Constituents

• Fe – 46-48.5 %• SiO2 – 12.0-10.20 %• Al2O3 – 11.5-10.5 %• LOI – 8.5-8.0 %• Size- (-150 micron to 0 micron)• By wt% - 30-25 %

Mass Balance

Average Mass Balance of plant Sl. No Equipment Avg TPH Avg Wt %

1 Main Feed 716 1002 Coarse jig feed 248 353 Coarse Jig Prod 174 244 Coarse jig reject 74 105 Fines Jig Feed 239 336 Fines Jig Prod 143 207 Fine Jig Reject 96 138 Classfier o/flow 72 109 Coarse Whims Feed 157 22.0

10 From R/mill 96 1311 From Crusher 74 1012 Total Coarse whims feed 327 4613 Coarse whims product 98 1414 Coarse whims Tails 229 3215 Intermediate thickener o/flow 80 1116 Intermediate thickener feed 301 4217 Fines whims feed 221 3118 Fines whims recovery 77 1119 Fines whims tails 144 2020 Longi whims feed 144 2021 Longi whims product 43 622 Longi whims tailing 100 1423 Total Tailings 180 25

Plant Major Modifications

• Installation of 2 No’s Additional Longi whims

• Scope-To reduce the Fe in tailing to 43% and • Increase the plant Recovery to 85%

• To reduce the ultra-fines(-10micron) in Ball mill by Maintaining

• Constant and consistent feed density to Hydrocyclone through the Buffer tank.

Buffer Tank

Plant Major Modifications

• Medium Intensity Magnetic Separator (MIMS)

• Improve the recovery of fine whims from 35% to 40% ,as well as to avoid layer formation of Ferro-Magnetic Material in the Fine whims Matrix.

MIMS

Plant Major Modifications

Modified Beneficiation Plant Process Flow Sheet With Longi

WHIMS Phase 2

SBR

DD S

SD S

S CLR

C J

L O S

CRS

SD S

RM

BM

IT

CT

TT

PF

B F

CW

MMS

FW LW 1 LW 2

LW 2

- 30

- 30 + 5

- 5 + 1

- 1

- 0.15 - 1 + 0.15

- 0.15

- 0.15

- 30 + 10

- 10 + 5

- 5 + 1

- 1 + 0.5

- 0.5 +0.15 - 0.15

- 0.5 - 10

- 0.15

B F Product

Pellet Fines Product

Tailing

+ 5

+ 1

- 1

- 5 + 1

+ 0.15

Recovery & Tailing Comparison

Sl.NO Details Plant Tailing (Fe in %)

Product (Recovery)(%)

Tailing(%)

1 Before Longi WHIMS 53.58 67.66 32.34

3 After Longi WHIMS 48.50 75 25

4 After Longi Phase 2 & MIMS

with Buffer tank43.00 85 15

21

DESCRIPTION UNIT PARAMETER

WHIMS

Capacity M3 200T/H

Diameter of rotor MM 3600

Magnetic Induction Gauss Max 12000

Water Cunsumption M3 300M3/H

Quantity Nos 4

COARSE JIGS

Capacity TPH 125

Effective Jigging Area M2 6.6

Width of Air Chamber MM 800

Quantity No's 6

FINES JIGS

Capacity TPH 125

Effective Jigging AreaQuantity

M2No’s

7.25

Equipment Details

22

DESCRIPTION UNIT PARAMETER

CRUSHER

Capacity TPH 200

Feed Size mm 5 - 30Output size mm 1 - 5

ROD MILL

Capacity TPH 200TPH+Recycle load Bulk Density T/M3 2.2

Feed Size mm 0 - 5

Output size < 1mm

BALL MILL

Capacity TPH 220TPH+Recycle load Bulk Density T/M3 2.2

Feed Size mm 0 - 1

Output size < 0.1mm

23

DESCRIPTION UNIT PARAMETER

HYDRO CYCLONE

Capacity TPH 300TPH

Specific Gravity T/M3 3.5

Feed Size mm 0 - 1

VACUUM FILTER

Capacity TPH 200TPH

Specific Gravity T/M3 4

Feed Size mm 0 - 1

% weight solid in feed Approx. 60%

INTERMEDIATE THICKENER

Capacity TPH 450TPH

Feed Size mm 0 - 0.1

% weight solid in feed Approx. 9%

24

DESCRIPTION UNIT PARAMETER

CONCENTRATE THICKENER

Capacity TPH 200TPH

Specific Gravity 4

Feed Size mm 0 - 0.1

% weight solid in feed Approx. 18%

Quantity Nos 1

TAILLING THICKENER

Capacity TPH 300TPH

Specific Gravity 2.5

Feed Size mm 0 - 0.5

% weight solid in feed Approx. 6.9%

Quantity Nos 1

Thank You !!!