On my point of view LMSL

MINING & MINERAL PROCESSING INTRODUCTION MINING & MINERAL PROCESSING RENOVATION OF WET MILL SPIRAL UPGRADING PLANT CONTENTS

LMSL is a heavy mineral mining and beneficiation company INTRODUCTION 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 First of all I wish to state the purpose of my presentation is not to tell you anything new . It is to show what I understand about LMSL We all heard the human has notify the time (past time era , eon) as stone age, iron age and etc, on that point of view, what is the current age……….. We are at the age of wonder metal. We have to proud we are a company support for the production of wonder metal. I know u all know about wonder metal.

Business encompasses mining, mineral concentration & separation 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 First of all I wish to state the purpose of my presentation is not teach you anything . It is to show what I understand about LMSL We all heard the human has notify the time (past time era , eon) as stone age, iron age and etc, on that point of view, what is the current age……….. We are at the age of wonder metal. We have to proud we are a company support for the production of wonder metal. I know u all know about wonder metal.

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

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 World is 4.54 billion years old

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 Slope of the beach is a factor influence the grade of deposit. α

INTRODUCTION Financial performance Rs.’000s Financial perfomance of company depicted by income statement. Annual profit of company is 238 million in 2009 and 428 million in 2010

INTRODUCTION Financial position Rs.’000s Financial position of company is depicted by balance sheet

MINING & MINERAL PROCESSING INTRODUCTION MINING & MINERAL PROCESSING RENOVATION OF WET MILL SPIRAL UPGRADING PLANT CONTENTS

MINING & MINERAL PROCESSING 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 Financial position of company is depicted by balance sheet

MINING & MINERAL PROCESSING PROCESS FLOW CHART Above flowsheet shows diagrammatically the sequence of operations of all plants. Here onward I am tring to explain each plant.

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

MINING & MINERAL PROCESSING This dragline can be kept for show WE CAN PAINT AND KEEP THIS A MONOMENT

MINING & MINERAL PROCESSING

MINING & MINERAL PROCESSING 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

MINING & MINERAL PROCESSING Wet Gravity upgrading plant 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. I most like to be in this plant during my training because I could see the repairing works everyday and by learn And here I learn about warman pumps and could identify parts of it, Humbry spiral is a envirnmental friendly and most effective seperation technique in the mineral processing industry Fully function in see water

MINING & MINERAL PROCESSING Wet Gravity upgrading plant MINING & MINERAL PROCESSING ASSAY IS %OF HEAVY MINERAL FEED 50-70%, CON OVER 90%, TAILING 1-6% Concentrates are pumped and stockpile near wet magnetic seperation plant for desalinating and to operate both plant somewhat independently. For this pumping high abrasive resistance alkathean pipes are used with tapercore gee bolt coupling. Say something about tapercore.

MINING & MINERAL PROCESSING Wet Gravity upgrading plant MINING & MINERAL PROCESSING Power failure causes to dump the bins. it tend to wastage and time taken to restart the plant as well as causes time to function the sea water pump again. So if we can negotiate with CEB and if we get the power failure time in advance we can make arrangement to operate power generator and transfer the suppy within few minutes.

MINING & MINERAL PROCESSING Wet Gravity upgrading plant MINING & MINERAL PROCESSING Power failure causes to dump the bins. it tend to wastage and time taken to restart the plant as well as causes time to function the sea water pump again. So if we can negotiate with CEB and if we get the power failure time in advance we can make arrangement to operate power generator and transfer the suppy within few minutes.

MINING & MINERAL PROCESSING Wet Gravity upgrading plant 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’

MINING & MINERAL PROCESSING Humbry spiral is a environmental friendly and most effective separation technique in the mineral processing industry Fully function in see water

MINING & MINERAL PROCESSING Wet Magnetic Separation plant 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. READINGS manufactured 16 POLE WHIMS are used.

MINING & MINERAL PROCESSING Wet Magnetic Separation plant Assay is % of magnatic Feed 60% Mags 90-95% Non mags 30-40 Low intensity magnetic separator is to remove ferro magnetic particles magnetite 40.19 Ilmenite, monazte and HI TI ilmenite are paramagnetics ilmenine(11.67)>hi ti ilmenite>monazite(4.1) Magnetic susceptibility in bracket

MINING & MINERAL PROCESSING Wet Magnetic Separation plant MINING & MINERAL PROCESSING

MINING & MINERAL PROCESSING Wet Magnetic Separation plant

MINING & MINERAL PROCESSING 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% 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 3o and the rotational speed of drying drum is 7rpm

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

MINING & MINERAL PROCESSING Ilmenite Dewatering Go-Down & Drier Plant There is a pentulam flap to prevent the false air entering the air cyclone

MINING & MINERAL PROCESSING 2.7.2. Wilfley Tabling Plant 2.7.2.1. 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. MINING & MINERAL PROCESSING WET MILL 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. We will see this in detail in next chapter

MINING & MINERAL PROCESSING WET MILL 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 ` Contain 20% quartz

MINING & MINERAL PROCESSING WET MILL Wilfley Tabling Plant Assay isQuartz% 20-25% in feed 0.7-1.7% in cone filter 30-40 % in tailing Quartz% 20-25% in feed/ 0.7-1.7% in cone filter/ 30-40 % in tailing

MINING & MINERAL PROCESSING WET MILL Wilfley Tabling Plant

MINING & MINERAL PROCESSING WET MILL Cone filter is used to filter the moisture in the final zircon concentrate. Moisture content is reduced up to 6% in cone filter then it allows feed to dryer at dry mill. MC reduced up to 6%

MINING & MINERAL PROCESSING DRY MILL 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.

MINING & MINERAL PROCESSING DRY MILL 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%

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

MINING & MINERAL PROCESSING DRY MILL 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.

MINING & MINERAL PROCESSING DRY MILL 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

MINING & MINERAL PROCESSING 2.8.2.3. 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. MINING & MINERAL PROCESSING DRY MILL 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.

MINING & MINERAL PROCESSING 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% LNL

MINING & MINERAL PROCESSING INTRODUCTION MINING & MINERAL PROCESSING RENOVATION OF WET MILL SPIRAL UPGRADING PLANT CONTENTS

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 My first design for wet mill FNC upgrading

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Plant processing sequence before the renovation RENOVATION OF WET MILL SPIRAL UPGRADING PLANT The fine separation fully abandon Wilfley table tailing contain reasonable amount of heavy minerals

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Reasons for Renovation on my view point RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 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 The fine separation fully abandon Wilfley table tailing contain reasonable amount of heavy minerals

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

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.

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 2.7.1.3.2. 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 70-80 % range to achieve better polishing. In the cell one impeller rotates right hand side and next impeller rotates left hand side. 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 In my view point, it is a washing machine in mineral processing industry

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 - 106 micron + 106 micron

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Hydro-sizer (hydro classifier) Terminal velocity calculation Stoke law 𝑉= 𝑔 𝑑 2 (𝐷𝑠−𝐷𝑓) 18ƞ Stoke assumed the drag force on a spherical particles is to be entirely due to viscous But here it is entirely due to turbulent Here 𝐷𝑠 – density of solid 𝐷𝑓−density of fluid (water) d – diameter ƞ−viscosity of fluid 𝑉= 𝑔 𝑑 2 (𝐷𝑠−𝐷𝑓) 18ƞ Viscous resistance – effectively all resistance to motion is due to viscosity of fluid Turbulent resistance- at high velocities the main resistance is due to the displacement of fluid by the body

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 𝑉= 3𝑔𝑑(𝐷𝑠−𝐷𝑓) 𝐷𝑓 Terminal velocity calculation Newton’s law 𝑉= 3𝑔𝑑(𝐷𝑠−𝐷𝑓) 𝐷𝑓 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 𝑉= 3𝑔𝑑(𝐷𝑠−𝐷𝑝) 𝐷𝑝 Here 𝐷𝑠 – density of solid 𝐷𝑓−density of fluid (water) Dp – density of pulp d – diameter 𝑉= 𝑔 𝑑 2 (𝐷𝑠−𝐷𝑓) 18ƞ Viscous resistance – effectively all resistance to motion is due to viscosity of fluid Turbulent resistance- at high velocities the main resistance is due to the displacement of fluid by the body

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 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 Spiral table

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 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 Spiral table

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 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 Spiral table

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

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 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 Spiral

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT 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 Spiral Each spiral 126kg, 500kg each housing frame

Plant model Play the video

RENOVATION OF WET MILL SPIRAL UPGRADING PLANT Pump

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

5S ACCIDENT THEORY