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> M i n e r a l P r o c e s s i n g > E n g i n e e r i n g D e s i g n > T r a i n i n g > S p e c i a l i s t S e r v i c e s

Perth | Brisbane | Melbourne |Newcastle|Noosa

Midas Engineering Group Pty Ltd

ABN 72 159 772 675

W: www.midasengineering.com.auE: [email protected]

5th Annual FeTech Conference 2014

Criteria for Selecting a Jig or DMS process

Presented by John Visser

Mineral Engineering Technical Services


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> DISCLAIMERWith respect to all the information contained herein, neither Mineral Engineering Technical Services Pty Ltd, nor

any officer, servant, employee, agent or consultant thereof make any representations or give any warranties,

expressed or implied, as to the accuracy, reliability or completeness of the information contained herein, including

but not limited to opinions, information or advice which may be provided to users of the document. No

responsibility is accepted to users of this document for any consequence of relying on the contents hereof.

> COPYRIGHT Passing of this document to a third party, duplication or re-use of this document, in whole or part, electronically or

otherwise, is not permitted without the expressed written consent of Mineral Engineering Technical Services Pty

Ltd.

> ACKNOWLEDGEMENTSThis document is a dynamic record of the knowledge and experience of personnel at Mineral Engineering

Technical Services. As such it has been built upon over the years and is a collaborative effort by all those

involved. We are thankful for the material supplied by and referenced from various equipment manufacturers,

vendors, industry research and project partners.


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Key Attributes

Working globally since 1988

Dynamic and innovative niche consultancy

Dedicated team providing customised service

Specialist in Mineral Processing & Engineering Projects

Unique solution finder

Pragmatic, efficient, complete engineering through

quality, personalised & exceptional service delivery


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Overview

Introduction

Criteria for selection

Jig Setup

DMS Setup

Case studies

Capex and Opex


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Introduction


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Introduction

Both machines upgrade material

Significant difference in particle sgbetween discard and product

Size distribution < 40mm nominally

Wet processes

The processes can be complementary


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Criteria For Selection


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Criteria for selection

Criteria Jigs DMS

Particle size Narrower sizing Broader sizing

Density cut No restriction Max limit of 3.8

Density difference between float andsinks

> 1.0 0.5 to 0.8

Efficiency (partition curve) Less sharp Sharper

Efficiency (relative to particle size) Much less dependant Dependant on small size

Near density material(Influence onproductgrade)

Varying grade Achieve grade moreeffectively

Yield and recovery Less optimisation Better optimisation

Tailings grades Higher Lower

Separation Density Density

Capex Higher Lower

Opex Lower Higher


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Efficiency Comparison

0

10

20

30

40

50

60

70

80

90

100

F 2.7 2.85 - 3 3.15 - 3.3 3.45 - 3.6 3.75 - 3.9 4.05 - 4.2

Recov

ery(%)

Size Fraction (mm)

DMS & Jig Partition Curves

DMS

Jig (Interpolated)


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JIG SETUP


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Gravity Separation Performance

> Concentration Criterion =SG of heavy mineralSG of fluidSG of light mineralSG of fluid

Concentration Criterion (CC) Gravity Separation

CC>2.5 Easy down to 75 m

1.75


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Jigging Action


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Jig Variations

Fixed screen and moving screen (less common) variations

Different variations suit different feed stock

Variation Type (all fixed) Pulse Mechanism

Richards Water pulse

Harz Mechanical piston pulse

Russian MOBK Pneumatic piston pulse

Denver Diaphragm pulse

Bendelari Diaphragm pulse

Yuba Diaphragm pulse

Pan-American Moving hutchBaum (side pulse) Air pulse

Batac (under bed pulse) Air pulse Smartdogmining.com


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Under bed (Batac) pulsed machines

Examples

Alljig from Allmineral

Batac from Humboldt Wedag

Apic jigs from Bateman


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AlljigSide Pulsed


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MBE Batak Jigs


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DMS SETUP


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DMS Medium

Heavy Liquids

Response of a given feed to a DMS process and be accurately

established in a laboratory by testing with various heavy liquids

Name Specific Gravity, 25oC

Methylene iodide 3.33

Tetrabromoethane 2.96

Bromoform 2.86

Tribromoethane 2.61

Methylene bromide 2.48

Ethylene dibromide 2.17

Methylene chlorobromide 1.92

Pentachlorethane 1.67

Carbon tetrachloride 1.59

Trichloroethylene 1.46

Ethylene dichloride 1.26

Liquids Used to Test Feeds


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DMS Medium

Heavy Liquids

Aim is to separate the ore samples into a series of fractions according

to density

May be used to assess the efficiency of an existing dense mediumcircuit

Heavy liquids give off toxic fumes and must be used with properventilation

The use of pure liquids has not been found to be practicable on acommercial scale

Industrial processes employ finely ground solids suspended in water


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DMS Medium

FeSi SG: 6.7-6.9

Milled FeSi produced in different size ranges

30-95% 45m

Coarser, low viscosity grades achieve medium densities of up to 3.3

Atomised FeSi

More spherical particles

Medium is of lower viscosity

Used to achieve densities as high as 4


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Gravity DMS Drum Separator

Drum Separator

Side view


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Drum Separator

End view



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Gravity DMS Drum SeparatorSinks Launder

WEMCO Heavy Media Drum Separator


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C t if l DMS DSM C l


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Centrifugal DMS DSM Cyclone

Dutch State Mines (DSM)Cyclone Separator

Used for finer feeds, 0.04 to0.0005 m

Separation is made by the actionof centrifugal and centripetal

forces.

The heavier portion of the feedleaves the cyclone at the apexopening (5), and the lighterportion leaves at the overflow top

orifice

C t if l DMS DSM C l


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Centrifugal DMS DSM Cyclone


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T i l DMS Fl h t


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Typical DMS Flowsheet

DMS PFD


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DMS PFD


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Case Studies

DMS results: Operation A


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DMS results: Operation A

The operations product grades are > 65% Fe

Density cut point for achieving grade is considered to be 4.2 So, no chance

Description Weight (g) Weight (%) Fe (%)

+3.8sg 7.3 3.8 61.54

-3.8+3.6sg 28.6 15.0 57.11

-3.6+3.3sg 146.0 76.9 55.95

-3.3sg 4.0 2.1 52.19

Total (+1.18mm) 185.9 97.8 56.27

-1.18mm 4.1 2.2 46.47

Calculated Head 190.0 100.0 56.05

Head Assay 55.67

Jig results: Operation A


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Jig results: Operation A

Notice grade is achieved

Notice also the mass yield

Lump product Pilot plantresults for 11 test runs

Product(32-62mm) Weight (%) % Fe Grade Fe Recovery (%)

Feed Run 1 100 60.1 101.2

Conc. Run 1 85 65.4 92.5Reject Run 1 15 34.6 8.6

Feed Run 4 100 62.1 99.3

Conc Run 4 86.8 66.5 93

Reject Run 4 13.2 29.7 6.3

Feed Run 7 100 59.7 99.9

Conc. Run 7 85.4 65.3 93.4

Reject Run 14.6 26.4 6.5

Jigging Test Runs


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Costing

Capex and Opex


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Capex and Opex


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Capex and Opex

Capex

Opex

Direct Costs EquipmentInstalled

BulkEarthworks &Civils

Platework,Structural &Piping

Electrical &Instrumentation

Buildings DesignContingency

Freight TotalCosts

DMS $16,01M $3,13M $3,65M $2,55M $0.58M $2,59M $1.00M $27.0M

Jigs $16,71M $3,27M $3,81M $2,66M $0.61M $2,71M $1,04M $30.8M

Area Fixed Variable Misc. Total % Total

Labour Power Reagents &Consumables

Maintenance $/tonne Costs

DMS plant $0.56 $0.73 $4.41 $0.34 $0.04 $6.08 35.5%

Jig plant $0.56 $1.04 $0.75 $0.35 $0.00 $2.70 12.5%

References


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References

Mills, Chapter 18, Mineral Processing Plant Design Mular, BhappuEditors, SME, 1980


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