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On my point of view LMSL. CONTENTS 1.INTRODUCTION 2.MINING & MINERAL PROCESSING 3.RENOVATION OF WET MILL SPIRAL UPGRADING PLANT.

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Presentation on theme: "On my point of view LMSL. CONTENTS 1.INTRODUCTION 2.MINING & MINERAL PROCESSING 3.RENOVATION OF WET MILL SPIRAL UPGRADING PLANT."— Presentation transcript:

1 On my point of view LMSL

2 CONTENTS 1.INTRODUCTION 2.MINING & MINERAL PROCESSING 3.RENOVATION OF WET MILL SPIRAL UPGRADING PLANT

3 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

4 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

5 The formation of deposit Resouces estimation –Infered Production per annum –My calculation Organization structure –Employer amount –Engineers –t/a INTRODUCTION

6 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

7 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

8 Financial performance INTRODUCTION Rs.’000s

9 Financial position INTRODUCTION Rs.’000s

10 CONTENTS 1.INTRODUCTION 2.MINING & MINERAL PROCESSING 3.RENOVATION OF WET MILL SPIRAL UPGRADING PLANT

11  SIMPLIFIED SEPERATION FLOWSHEET  MINING AND WASHING  WET GRAVITY UPGRADING PLANT  WET MAGNETIC SEPERATION PLANT  ILMENITE DRIER PLANT  WET MILL  SPIRAL UPGRADING  TABLE ZIRCON UPGRADING  DRY MILL  MINERAL PROCESSING LABORATORY  WORKSHOPS MINING & MINERAL PROCESSING

12 PROCESS FLOW CHART

13 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

14 MINING & MINERAL PROCESSING Mechanized loading of beach sand Mechanized unloading of beach sand in processing plant

15 MINING & MINERAL PROCESSING This dragline can be kept for show

16 MINING & MINERAL PROCESSING

17 Sand 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

18 Wet Gravity upgrading plant MINING & 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.

19 Wet Gravity upgrading plant MINING & MINERAL PROCESSING ASSAY IS %OF HEAVY MINERAL FEED 50-70%, CON OVER 90%, TAILING 1-6%

20 Wet Gravity upgrading plant MINING & MINERAL PROCESSING

21 Wet Gravity upgrading plant MINING & MINERAL PROCESSING

22 Wet Gravity upgrading plant MINING & 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’

23 MINING & MINERAL PROCESSING

24 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.

25 Wet Magnetic Separation plant MINING & MINERAL PROCESSING Assay is % of magnatic Feed 60% Mags 90-95% Non mags 30-40

26 Wet Magnetic Separation plant MINING & MINERAL PROCESSING

27 Wet Magnetic Separation plant MINING & MINERAL PROCESSING

28 Ilmenite 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%

29 MINING & MINERAL PROCESSING Ilmenite Dewatering Go-Down & Drier 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

30 MINING & MINERAL PROCESSING Ilmenite Dewatering Go-Down & Drier Plant

31 WET MILL MINING & MINERAL PROCESSING Wilfley Tabling Plant Plant concept The plant comprises twelve wilfley tables to upgrade the dry mill final non conductions (crude zircon). Final non conductions are treated on two stage of wilfley table bank. The final conductions contain zircon, monazite, quartz, rutile and some amount of ilmenite. Monazite and zircon have higher specific gravity than other minerals so they are separate easily by wilfley table. 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.

32 WET MILL MINING & MINERAL PROCESSING 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 `

33 WET MILL MINING & MINERAL PROCESSING Wilfley Tabling Plant Assay isQuartz% 20-25% in feed % in cone filter % in tailing

34 WET MILL Wilfley Tabling Plant MINING & MINERAL PROCESSING

35 WET MILL MINING & MINERAL PROCESSING MC reduced up to 6%

36 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.

37 DRY MILL MINING & MINERAL PROCESSING 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%

38 DRY MILL MINING & MINERAL PROCESSING FNC 20-25% quartz after upgrading quartz 1% Zircon magnetic <1%, rutile 1-0.5% quartz <1% Crude monazite 45% magnetics

39 DRY MILL MINING & MINERAL PROCESSING 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.

40 DRY MILL MINING & MINERAL 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

41 DRY MILL MINING & MINERAL PROCESSING Induced roll magnetic separator 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.

42 Quality control MINING & MINERAL PROCESSING QUALITY CONTROL IS DONE BY LABORATORY BLOCK A Daily sample taken for HMS,HM% in concentrate > 95%, in tailing < 5% Block B Daily sample are taken for high flux test to find out % of magnetic present In magnetic > 95% and in non-magnetic < 14% but it’s nearly 30% Dry mill Daily Dry mill feed taken for lift up magnetic separation Hourly sample taken from final rutile, zircon & FNC. in Rutile zircon %< 2% HI –TI %< 5% in Zircon rutile %< 5% monazite % < 5% Desire end product quality TiO2 % in Rutile > 95% TiO2 % in ilmenite > 50% ZrO2% in Zircon > 63%

43 CONTENTS 1.INTRODUCTION 2.MINING & MINERAL PROCESSING 3.RENOVATION OF WET MILL SPIRAL UPGRADING PLANT

44 Wet mill RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Cover this Concept of plant Reason for renovation Pump selection New holman table instalation New multotec spiral instalation Other works Pump selection My first design for wet mill FNC upgrading

45 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Plant processing sequence before the renovation

46 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 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

47 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT After renovation work Sample Date 05/oct/2013 Feed rate 10 Ton/hr Assay % heavy mineral 82.66% 61.18% 93.24% 93.99% 99.19% 97.79% 99.24% 25.5%

48 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 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.

49 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 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 % range to achieve better polishing. Rotation direction of impellers in the adjacent cell is opposite new launder fabricated and fixed Attritioner Attritioner is the main equipment. 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 % range to achieve better polishing. In the cell one impeller rotates right hand side and next impeller rotates left hand side.

50 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 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 micron micron

51 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT

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53 Spiral table 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 – litre/min, min 5m head pressure  Feed hose detail- minimum 50mm ID  Feed density % by solids by weight  Pulley speed rev/min, not exceeding 290 rev/min  Stoke length – 8 -16mm

54 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Spiral table Holman Wilfley-Table 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

55 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Spiral table Holman Wilfley-Table 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

56 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Spiral Multotec spiral concentrator Spiral concentrator SC 20/ 5/ B/ 3

57 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Spiral Multotec spiral concentrator 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 down The specially slopes trough profile forces these slow, heavy particles to move down the shorter inner edge

58 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Spiral Multotec spiral concentrator Spiral concentrator SC 20/ 5/ B/ 3 Feed hose diameter- 50mm Particle size range- 0-3mm Solid- 0-50% solid w/w Volume/ outlet – 3-5m^ 3 Operating slurry head – 460mm Spiral trough

59 Plant model Play the video

60 RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Pump

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

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66 5S ACCIDENT THEORY


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