1. Teknologi Pengolahan Material
Sungging Pintowantoro
Department of Materials and Metallurgical Engineering,Faculty of Industrial Technology (FTI),
Sepuluh Nopember Institute of Technology Surabaya (ITS), Kampus ITS, Keputih Sukolilo, Surabaya 60111,
Telp/Fax :
Department of Materials and Metallurgical Engineering, FTI-ITS
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2. Department of Materials and Metallurgical Engineering, FTI-ITS
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3. PETA PERSEBARAN SDA INDONESIA
Department of Materials and Metallurgical Engineering, FTI-ITS
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4. PETA PERSEBARAN SDA INDONESIA
Department of Materials and Metallurgical Engineering, FTI-ITS
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5. Mineral Processing Overview
Mineral Processing Terminology, Economics
Comminution and Classification
Physical processing methods
Chemical processing methods
Waste products treatment and disposal
Process plant flow sheets: uranium and potash

6. Importance of Mineral Processing
“No substance has been as important as metal in the story of man's control of his environment. Advances in agriculture, warfare, transport, even cookery are impossible without metal. So is the entire Industrial Revolution, from steam to electricity.” Read more:

7. Importance of Mineral Processing
Bronze Age- Bronze is in use in Sumer, at Ur, in around 2800 BC
Iron Age - from the 11th century BC onwards, steel replaces bronze weapons. It becomes essential, from now on, to have a good steel blade rather than a soft and indifferent one.

8. Lecture 8 Mineral Processing Overview:
Geology-Mining-Processing Relationship
Mineral Processing Terms
Definitions
Mineral Economics review
Project Stages

9. Lecture 9 Comminution & classification circuits Comminution Methods
Principles
Crushing
Grinding
Classification Methods
Hydrocyclone
Screening
Assignment

10. Lecture # 10 Physical Processing Methods Gravity Magnetic
Electrostatic
Radiometric
Froth Flotation
Solid/liquid separation
Assignment

11. Lecture 11 Chemical Processing Basic Circuits Leaching
Solvent Extraction
Precipitation
Drying
Downstream – Purified Product
Electrowinning
Smelting
Assignment

12. Lecture #12 Waste Stream Management: Tailings Disposal Surface
Underground
Effluent Treatment
Chemical Precipitation
Membrane Technology
Assignment

13. Lecture # 13 Saskatchewan Mill Process Flowsheets Uranium Potash
Assignment

14. Geology – Mining – Processing
All 3 aspects must be favorable to make a deposit economically viable
Geology: Find it. Is it big enough to be economic?
Mining: Dig it. Is it economically recoverable from the ground?
Processing: Extract it. Is it economically separable from the host rock?

15. Prevalence of mineral processing
In Saskatchewan as of 2009 there were:
3 uranium mills
8 potash mine/mills
1 gold mine/mill
coal mines (thermal)
Salt mine
An identified diamond deposit (Fort a la Corne)
An identified rare earth element deposit (Hoidas Lake)

16. Prevalence of mineral processing
Mining is all around us!
In Alberta there are:
Oil sands process plants (uses mining and mineral processing techniques)
Coal plants
Industrial minerals (limestone)
Nickel/cobalt metallurgical complex
In Manitoba there are:
Many copper/zinc mines and mills, feeding the Flin Flon metallurgical complex
Nickel mines nearby Thompson smelter
In the Northwest Territories there are:
3 operating diamond mines
Gold mines

17. Introduction to Mineral Processing
Scope of mineral processing
Definitions
Economics
Project Stages

18. Mining Terminology - Review
Miners send their products to their customer – the mill.
Ore : Rock that contains a mineral or minerals in sufficient quantities as to make commercial extraction (mining – milling) profitable.
Grade : A measure of concentration of a mineral/metal contained in rock (or ore). Gold and other precious metals – g/t or oz/t, base metals - %, uranium – kg/tonne, rare earth elements – ppm…
Cut off Grade : The minimum concentration or grade of mineral that is required for rock to be considered ore.
Waste : Not Ore.
Ore Body: A mineralized deposit (resource) whose characteristics have been examined and found to be commercially viable. The extents of the ore body are determined by the cut-off grade.
Host Rock: The rock containing an ore deposit. Typically composed of 2 or more minerals.
Gangue: Minerals in the ore body that are not of economic interest

19. Mineral Processing Is the recovery of valuable minerals from ore
Takes place in a mill, aka concentrator - because it concentrates valuable minerals by removing unwanted material.
The two main products are the concentrate streams (valuable minerals) and the tailings streams (rejects).

20. Disciplines related to mineral processing

21. Fields of Metallurgical Engineering
Description
Example of topics
Mineral Processing
Beneficiation or
Mineral Dressing
Theory and practice of liberation of minerals from ores and their separation by physical methods at ambient conditions
Crushing and grinding, magnetic and electrical methods, flotation, etc.
Extractive metallurgy
Chemical methods sometimes at high temperature and pressure for treating ores to recover their metal values in a pure form
Leaching, precipitation, electrolysis, oxidation, reduction, etc.
Metal Processing
Physical metallurgy
Study of physical properties of metals and alloys, preparation of alloys
Crystal structure, effect of impurities, metallography, heat treatment, etc.
Engineering metallurgy
Processing of metals in the molten state
Casting, welding, etc.
Mechanical metallurgy
Processing of metals in the solid state
Forging, rolling, extrusion, piercing
Powder metallurgy
Processing of metal powders into finished products
Preparation of metals in powder form, hot pressing, etc.

22. Engineering Terminology in Mineral Processing
Circuit: The path that the ore that is being processed takes as it proceeds from one processing point to another.
Flow Sheet - Drawing that indicates the path that the mineral takes within a process. Several circuits are often contained within a flow sheet
Recovery Rate – The percentage of valuable metal/mineral, by mass, in the concentrate from the feed

23. Mineral Processing The goals of mineral processing are to:
separate economic mineral particles from waste or gangue
subject minerals to processes in order to concentrate them or to extract metals from them

24. Many forms of mineral processing
Depends on feed material and desired product

25. Mineral Processing Terminology
Concentration: Another word for grade
Heads: A term that is used to denote the mineral found in the FEED to a circuit.
Head Grade: aka feed concentration
Concentrate: a purified mineral. May require further downstream processing to convert for end uses. Examples: Copper and nickel sulfides
Tailings - Material rejected from a mill after the recoverable valuable minerals have been extracted.
Industrial mineral: is used for end purpose without chemical alteration. Examples: gravel, coal
Mineralogy: Description of mineral contents

26. What is mineral processing?
a)A solid naturally-occurring compound having a definite chemical composition.
b) Inorganic substance that are extracted from the earth for use by man.
c) A naturally occurring inorganic element or compound having an orderly internal structure and characteristic chemical composition, crystal form, and physical properties.

27. Mineral classification
Nonmetallic processing has some commonalities
with metal processing, but lots of differences

28. Examples of minerals

29. Examples of minerals

30. Mineralogy determines recoverability

31. Impact of mineralogy We mine rocks but we concentrate minerals.
Gangue minerals also important
Understanding mineralogy allows design of processes
Important for feasibility studies
This is an overhead photo of the surface operations of Kidd Mine and shows the key ventilation infrastructure for the mine. Greater detail is given in the following slides.
Kidd Mine employs the use of a predominantly exhaust-only type of ventilation system whereby the primary flows through the mine are enabled through the operation of a surface exhaust fan system. The two exhaust shafts are as follows:
NVS (North Vent Shaft): The primary exhaust route for the mine air.
SVR (South Vent Raise): The secondary route of mine exhaust air.
The fresh air is drawn into the mine through four main routes:
#2 Shaft: Primary intake. Note that the air is heated during the winter to prevent freeze-up of the shaft conveyances.
#1 Shaft: Main fresh air supply for Mine D. This air is refrigerated in the summer using the Refrigeration Plant and BAC (Bulk Air Cooler)
Portal: Fresh air for upper part of the mine. Air is heated during winter to prevent icing of the ramp.
Open Pit: Air is drawn through the bottom of the pit for the Cold Stope.

32. What is mineral processing?
Extract values, reject waste
Conversion of mined ore into usable product
More expensive/challenging with lower grade ores
Numerous processing methods

33. Mineral Processing Methods = beneficiation + extractive metallurgy
Beneficiation aka Mineral Dressing
Overlap of physical and chemical methods, depending on product
Where extractive metallurgy leaves off, metal processing begins

34. Mineral Processing Terminology
Beneficiation: enrichment of ores and separation of unwanted gangue minerals
subsequent metals extraction more efficient.
Can be divided into two distinct steps:
Liberation: the rock is broken down by mechanical means, mineral components become independent of each other, detached Separation: valuable minerals are separated by means of physical and physico-chemical methods making use of differences in specific gravity, magnetic properties, etc.
Extractive metallurgy:
Chemical reactions of the processes
equipment where reactions take place
Flowsheets – combinations of processes

35. Typical Beneficiation Steps

36. Beneficiation Terminology
Comminution: Reduction of particle size
Starts at mine with blasting
Two basic types of equipment used:
Crushing – breakage by compression
Grinding – breakage by abrasion and impact

37. Comminution Equipment
Shaft

38. Comminution Equipment
Shaft

39. Beneficiation Terminology
Classification : Separation based mainly on particle size
Behavior affected by size, shape, and density of the particles
Two common types of classifiers:
Screens – dry method, coarser particles
Hydrocyclones – wet method, finer particles

40. Classification Equipment

41. Beneficiation Terminology
Separation Techniques take advantage of the differences in characteristics between minerals:
Flotation: Attachment of minerals to air bubbles - hydrophibicity
Magnetic Separation: Apply magnetic field
Gravity Separation: differences in specific gravity of materials
Electrostatic Separation: Apply electrostatic polarity
Particle size distribution has large influence on results

42. Separation Equipment
Flotation cell

43. Separation Equipment
Magnetic separator

44. Separation Equipment
Gravity separation - jig

45. Separation Equipment
Electrostatic separator

46. Beneficiation Terminology
Dewatering: To remove water from a substance. Also refers to the circuit where this takes place.
Dewatering Techniques:
Thickener: Allow gravity settling
Filter: Apply air pressure to draw water out
Centrifuge: Apply centrifugal force
Dryer: Apply heat to evaporate
Slurry Density: The amount of solids in a slurry, expressed as a percentage by weight.

47. Dewatering Equipment
Thickener

48. Dewatering Equipment
Disc filter

49. Dewatering Equipment
Rotary kiln dryer

50. Beneficiation Terminology
Waste Disposal - "Mining is waste management ..."
The majority of tonnage mined must be disposed of as tailings
Water used must be treated and released
Tailings Dam: Built from ground waste rock discharged after processing from the mill
Acid Mine Drainage: produced by exposing sulfide minerals to air and water, resulting in oxidation that generates acid.
Waste Rock: Unprocessed non-mineralized / low grade mined material
Water Balance: Accounting of water inputs and outputs from a mine/mill site.
Water Treatment: The removal of harmful contaminants from water

51. Waste Disposal
Tailings Dam

52. Waste Disposal
Waste Rock Pile

53. Waste Disposal
Acid Mine Drainage

54. Waste Disposal
Water Balance

55. Mineral Processing Methods = beneficiation + extractive metallurgy
Beneficiation aka Mineral Dressing
Overlap of physical and chemical methods, depending on product
Where extractive metallurgy leaves off, metal processing begins

56. Extractive Metallurgy Terminology
Hydrometallurgy
Leaching - the process of extracting a soluble constituent from a solid by means of a (water based) solvent
Water changes solubility, by making it acidic or basic, oxidizing or reducing
Solvent Extraction – transfer between immiscible fluids
Ion Exchange – solid resins that adsorb/desorb dissolved chemical species
Precipitation – convert dissolved into solid
Crystallization via evaporation
Ionic precipitation - addition of a reagent to a solution creates a metal compound whose solubility is so low that precipitation takes place immediately

57. Hydrometallurgy Equipment
Tank leach circuit

58. Hydrometallurgy Equipment
Solvent extraction mixer-settlers

59. Hydrometallurgy Equipment
Ion Exchange

60. Hydrometallurgy Equipment
Vacuum crystallizer

61. Extractive Metallurgy Terminology
Pyrometallurgy – use of heat to induce a chemical transformation
Roasting – convert to oxide form. Example: 2 CuS2 + 5 O2 → 2 CuO + 4 SO2
Smelting - uses reducing substances that will combine with those oxidized elements to free the metal. Example:
2 Fe2O3 + 3 C → 4 Fe + 3 CO2

62. Pyrometallurgy Equipment
Smelter

63. Extractive Metallurgy Terminology
Electrometallurgy – use of electrical energy to induce a chemical transformation
Electrowinning – to precipitate a metal from solution using electric potential
Electrorefining – to purify a metal by dissolving it, then re-precipitating it

64. Electrometallurgy Equipment
Alternating anodes and cathodes in a tankhouse for electrowinning

65. Flowsheet examples
Aluminum: from bauxite
Copper: from chalcopyrite
Iron: from hematite
Gold – Placer, sulphide and oxide
Oil Sands – Fort McMurray

66. Aluminum

67. Copper

68. Iron

69. Gold

70. Oil Sands

71. Mineral Processing Recovery
Recovery : Potential for loss every step of the way, in each circuit!
Tonnage vs. Recovery: A processing circuit pushed beyond its capacity will induce recovery loss
Feed Grade vs. Recovery : A higher feed grade tends to have higher processing recovery
Concentrate Grade vs. Recovery: A higher concentrate grade tends to result in lower processing recovery (= rejection of lower quality minerals to tailings)
Concentrate Grade vs. Price: A higher quality concentrate will fetch a higher price (have lower impurity penalties)
Revenue = Production (tonnes) x grade x recovery x price

72. Milling Operating Costs
Typical relative cost of beneficiating an ore
Operation %
Crushing
5 - 20
Grinding
Flotation
25 -45
Dewatering and drying
10 -20
Other operations
5 - 10