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Beneficiation Plant
| Date post: | 12-Apr-2017 |
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| Upload: | mukesh-ranjan-behera |
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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
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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
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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
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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%
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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 !!!
