Slide 1 / 241

Mining & Mineral Refining Field Instrumentation Solutions

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 2 / 241

Your robust and reliable choice for the Mining industry

Offering cost reduction solutions

- to save energy and raw material

- to reduce downtime

- to reduce maintenance

Environmental protection using e.g. pH analysis systems

for emission reduction and process water treatment

Wireless solutions optimizing bulk storage and supply

processes

Increasing productivity and quality

Maintenance reduced to a minimum due to equipment

with non contact or no moving parts

Time and cost saving due to uniform operating

philosophy

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Demographic Change

Need for Energy

Need for Water

MEGATRENDS influencing Primaries

Environmental protection

Slide 3

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Mass balance of Energy and Raw Materials Getting more from your ore boosts the value of your company

Global Trend

Worldwide demand for resources such as crude oil, coal,

natural gas, water, iron ore and copper is rising, driven by

population growth and greater purchasing power. Resources

are limited and extraction is getting more expensive. Efficient

and effective use of resources is an overriding challenge for

future growth.

See comments from leading Metals and mining companies

Arcelor Mittal and BHP Billiton

SOURCE :

http://www.sika.com/en/group/sustainability/megatrends/energy_and_raw_materials.html

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Urbanization and industrialization driving current and future Chinese commodity demand

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Rising urbanization in developing countries Comment from Arcelor Mittal

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Mass balance of Energy and Raw Materials Getting more from your ore boosts the value of your company

There are still vast reserves of most resources to explore, but they

are becoming more and more expensive to mine and unearth.

The stock market value of a company is not only linked to current

and future reserves and output (exploration & production) but also

to the valuation of precious metals caught up in the individual

processes.

Internal process auditing (metal accounting)

and optimization increase stock values and has

become an economic necessity.

SOURCE :

http://www.amira.com.au/

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Groupcon 2011 Primaries & Metal

Primaries & Metal industry segments Customers in EVERY country have common topics

SAVING of ENERGY

W.A.G.E.S & PRIMARY FUEL

as well as

RAW MATERIAL

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Mass balance of Energy and Raw Materials Getting more from your ore boosts the value of your company

Worldwide demand for resources such as crude oil, coal, natural gas,

water, iron ore and copper is rising, driven by population growth

and greater purchasing power. Resources are limited and extraction

is getting more expensive. Efficient and effective use of resources is

an overriding challenge for future growth.

Production levels cannot cope with demand. There are still vast

reserves of most resources to explore, but they are becoming more

and more expensive to mine and unearth. The stock market value of

a company is not only linked to current and future reserves and

output (exploration & production) but also to the valuation of precious

metals caught up in the individual processes. Internal process auditing

and optimization has become an economic necessity.

Rising energy and raw material prices in Europe and USA have

propelled investment in energy and resource efficiency and renewable

energy technologies like wind and solar power.

http://www.amira.com.au/

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Summary of trends in Primaries & Metal The driving forces behind process automation

Process optimization taking safety aspects into account e.g. Mine ventilation or cooling water leakage detection e.g LDS solutions

Urban Mining - a new term which stands for the re-use of urban waste in order to extract useful materials.

Manufacturing, Optimization, use of alternative fuels and raw material (AFR) – e.g. bunker fuel oil flow and stock value

Waste Heat Recovery Power Generation

Environmental protection e.g. - emission reduction with SNCR treatment for exhaust gas or methane monitoring in coal plant e.g. Clean Development Mechanism (CDM) - process and waste water treatment

Optimizing bulk and liquid storage and supply processes based on Inventory Management

Wireless sensors are anticipated to continue to make inroads in a number of end-user applications

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 11 / 241

Measurement Technology by process

Click blue for an application example

Product proven in use for this application

Click green for utilities examples

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 12 / 241

Endress+Hauser products & services

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

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Typical field instruments in mining processes

Free space

Level radar

Ceraphire®

Pressure

Guages

Guided

Microwave

Level

Ultrasonic

Level

Temperature transmitters

Gas flow

meters

Slurry flow meters

Web servers/

Wireless

Gateways

Heavy duty level

switches

Density Sensors

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Environmental protection

Wastewater treatment and disinfection

• Sludge levels

• Chlorine control

• Suspended solids

Effluent analysis + water sampling

• TOC

• BOD

• Static or portable

Heavy metals analysis

• Copper

• Iron

• Aluminium

• Chromate

• ….

Sensors, panels, stations

or containers

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 15 / 241

Open System integration/Field Communication

W@M

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 16 / 241

Common Mining Processes

W@M

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 17 / 241

Typical Mining Processes

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Barrick Gold Operations Dominican Republic

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Xstrata Nickel– Falcando operations Dominican Republic

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

E+H & Xstrata Process Support Current Position

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 21 / 241

Mining and Minerals Processing Automation solutions

Recovery

• Flotation

• Gravity separation

• Magnetic separation

Materials Handling

• Loading

• Conveying

• Stocking

• Pumping

• Filtering

• De-watering

• Waste/overburden handling

• Drying/Pyro processing

Rock Size Reduction

• Drilling

• Blasting

• Crushing

• Screening

• Grinding

• Cyclones

®

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 22 / 241

Crushing, Grinding & Screening

Extraction & Ore storage

Flotation & Thickening

Roasting & Autoclaving

Smelting

Refining

Environmental Issues

Common Mining Processes

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 23 / 241

Slurry pumping with a Promag S Meter

Problem

Pumps cavitate or dry run if drills are not working efficiently

Drill speed & pump rate optimized against slurry volume output

Medium : Bentonite slurry and stones

Features

Soft rubber pipe liner, Screw in wire brush electrodes

4-20mA slurry volume output to pump or drill drives

Benefits

Pumps and drills speed up or slow down in direct proportion to their output

Instrument Insensitive to high slurry solids content (even for large stones) and abrasive media

Brush electrodes give 50% longer life in abrasive media

Measurement in slurries with 30% solids

Flow

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Leach pad design

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Heap Leaching Measurement considerations

Pregnant solution production

rate analysis

Acid consumption & metering

and pipe line distribution / time

Leakage detection of leachate

collection pipes

Pressure monitoring of under

floor airlines - agitation

Level control of ore heaps

(7-10 meters) during stacking

and reclaiming

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 26 / 241

Mobile leaching pipeline stations Sulphuric acid leach control

Monitoring of pressure and flow in a leaching field

Location of station in the field after 150 day leach cycle

Wireless network

44 Adapters SWA70 non-Ex and 2 Fieldgates SWG70 (prototypes), i.e.

2 networks with about 22 adapters each

All adapters are arranged in one line

Budget USD 75.000 for wireless;

in addition SC-US sold site survey

and installation

Installation: Week 4/2009

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 27 / 241

Mobile leaching pipeline stations Sulphuric acid leach control

2 WirelessHART

networks along line

One of the network nodes with

2 adapters:

one for flow, one for pressure

6000 feet

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 28 / 241

Wireless Monitors Mobile Operations

Benefits to the customer

• The use of robust wireless field network

reduces costs in implementation and

relocation

• The availability of reliable flow and

pressure information allows leach field

operators to optimize operation resulting

in a ROI of about 2 months

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 31 / 241

Stockpile inventory monitoring Ore storage, stacking and reclaiming

Problem

Planning your ore deliveries & extraction process against real ROM inventory levels

Features

Sensors range from 5m to 80m

Volumetric stock pile calculations based on 10 level readings possible

Remote stock visualization with FieldGate® and P View software package

Benefits

Accurate monitoring and delivery of raw material inventory

Makes ore delivery to process plant smoother e.g. no stock outs

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 32 / 241

Bulk Logistics optimization Fieldgate® data access via ethernet, telephone lines or GSM

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 33 / 241

Typical Mining Process Copper, Nickel, Zinc, Gold…

W@M

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 34 / 241

Typical Gold Mining Process Circuits

Crushing & Milling /

Grinding

Acidulation

Autoclaving

Neutralization

CIL Carbon in leach circuit

Carbon strip circuit

Refinery

W@M

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 35 / 241

Crushing, Grinding & Screening

Extraction & Ore storage

Flotation & Thickening

Roasting & Autoclaving

Smelting

Refining

Environmental Issues

Common Mining Processes Key Stages

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 36 / 241

Milling & Crushing circuits

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 37 / 241

Common crusher units include :

Vertical shaft impactors (Impact)

Hammer (shear + attrition)

Gyratories and cone crushers (compression + attrition)

Jaw crushers (compression)

Mobile plant

Crushing circuit process

Mechanical reduction methods

Impact

Attrition

Shear

Compression

Metso crushers

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 38 / 241

Key Crushing, screen & feed requirements

Considerations in crusher circuit design

What is the crusher power demand per ton per hour of crushed product?

What is its capacity? Optimum speeds of belt feeders? Screen size?

Will it accept the largest input size expected?

How much supervision of the unit is necessary?

Typical problems in a crusher circuit

Feed hopper over fill and chute choking and plugging

Material characteristic change e.g. bulk density, moisture, temperature, hardness

Crusher circuit optimization e.g. re-circulating load measurement

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 39 / 241

Crushing and screening controls

Overfill control

in feed bins Emergency Blockage

microwave detector

High level indicator

Surge pocket minimum

volume, 2 truck loads

Low level indicator

Blockage detection

of Grizzlies or screens

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 40 / 241

FMU 90 Continuous Ultrasonic Controller

Features and benefits

1 / 2 & 10 level sensor input (10 from April 2005)

6 Relays give you 6 freely programmable alarms

Rugged Field or compact panel mount options

24VDc version for mounting on mobile crushers

IP66 (NEMA4X) housing means no dust or water ingress

3 DIN rail sizes means “ready to fit” in crusher control panels

Prosonic S crusher level control package Rock solid around the clock

FDU 90 Series Level Sensors

Features and Benefits

Extremely tough IP68/NEMA6P sensor housing

ATEX Dust approved (ATEX II 2G; 1/2D, FM, CSA)

Level

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 41 / 241

Application

The level in the crusher feed bowl is measured using an

ultrasonic sensor

The continuous level value is transmitted via the 4-20mA

output to the Variable Speed Drive on the feeder

The crusher feeder slows down or speeds up the feed to the

crusher.

A second sensor measures levels on the feeder under the

crusher to detect blockages

Automation of the Crusher feeder Using a level control to optimize crusher feed

TOP TIP ! Make your process visible.

Use bright backlit RIA displays for

added safety

Level

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 42 / 241

Ultrasonic Measurement in Primary Crusher

Unloading into primary crusher

Bright RIA 141 Field Display

FDU sensor plus Prosonic S

transmitter

Level

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 43 / 241

Ultrasonic Measurement in primary crusher

Continuous level measurement

Non contact

Mounted away from any possibility

of mechanical damage.

Correct alignment to product

surface

Sun cover to protect sensor from

the elements

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 44 / 241

Primary crusher in the quarry (1) level control of feeder

contact free ultrasonic measurement pre-feed

bin of the crusher

reduced crusher liner wear due to better feed control

feed bin over spill protection, no observer necessary

level system can link to a traffic light to automate the

crusher truck loading

electronics can be mounted up to 300m ( 915 ft) away

from the sensor

grain size /surface > 4 mm – 0.16 inches

up to 6 free programmable relays

Rail mount Prosonic S

transmitter with FDU

ultrasonic sensor

Level

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 45 / 241

Primary crusher in the quarry (2) Level control of feed bin

continuous level control with contact free

ultrasonics

reduction in crusher liner wear due to controlled

material feed

identification of material clogging in feed bin

recognition of material bridging in feed bin

(combination of signal “max. level” with “min. current

consumption”)

easy installation on a swinging boom or arm

stone sizes > 4 mm – (0.29”)

ultrasonic measuring unit Prosonic S

with sensor FDU

Level

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 46 / 241

Primary crusher in the quarry (3) Direct level control of Jaw Crushers

Jaw crusher control

Use compact 4 wire Prosonic M unit

which is quicker than 2 wire sensors

Select a remote mount FHX40 display and

electronics to allow programming and

monitoring away from the crush zone

Mount the sensor on a movable arm for

ease of crusher maintenance

Level and low power consumption

= blocked crusher

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 47 / 241

Primary crusher in the quarry (4) Level control of feed bin

control with Prosonic S FDU sensor :

(sensor is protected by a cover plate against flying

stones)

control with Prosonic S FDU sensor :

- sensor is mounted on a mobile arm

for protection against vibration and

ease of access

additional application

Level

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 48 / 241

detection of blockages in the discharge chute of

crusher with contact free radiometric

measurement

protection of crusher in discharge zone avoiding

down times

reduction of energy costs due to efficient

material feed control

no contact with the product thus no wear

independent of grain size and grain surface

high reliability with self checking functionality

retrofit installation possible

Crusher discharge Level control

Gammapilot M with source container and

scintillation sensor Radiometrics

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 49 / 241

Crusher discharge Level control

• Gammapilot with source container and scintillation sensor in

protecting housing replacement with compact Gammapilot M

Flow

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 50 / 241

continuous and contact free measurement of

conveyor loads

measuring of conveyor load to control the

upstream feeders

over spill protection of feed bin

no contact with the product thus no wear

display and electronic unit can be mounted

separately up to 300 m (984 ft) away

Discharge conveyor Material flow control

Prosonic S rail mount integrator with FDU Sensor

Level

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 51 / 241

Discharge belt conveyor Loading control

limit detection with Prosonic T

control of material height on the belt with an

ultrasonic probe

prevents over spill avoiding shut downs

belt load monitoring allows control of the

upstream feeders

no contact with the product so no sensor wear &

tear

simple installation with screw connection

two wire version with 4-20 mA output

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 52 / 241

Secondary crusher (1) Level control of feed bin

Solicap M limit detection switch

over spill detection of crusher feed bowl with

a capacitance probe

reduced energy costs due to controlled constant

material feed (ON/OFF – operation of feeder)

simple mounting means lower installation costs

no calibration required

display and electronics can be mounted

separately

Level

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 53 / 241

Capacitance probe on a lignite coal mining site

Level

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 54 / 241

Capacitance probe at bucket wheel reclaimer Avoid collision with pile

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 55 / 241

Conveyor transfer points Over spill detection

over spill protection of conveyor transfer points

with a capacitance probe

increased safety of operation

reduction in energy costs by preventing

overloading

simple mounting means lower installation costs

no moving parts

display and electronic unit can be mounted

separately

Solicap M sensor

Level

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 56 / 241

Raw material storage Continuous level control

continuous level control of silos with ultrasonics

continuous monitoring ensures uninterrupted

material flow

self cleaning sensor

display and electronics can be mounted

separately up to 300 m (984ft) apart

arrangement with Fieldgate module for remote

transmission of data via Ethernet/Internet,

WLAN, modem or GSM for direct inventory

control

measuring range up to 70 m – (230ft)

Prosonic S wall mount integrator

with FDU sensor and alignment device

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 57 / 241

Blocked chute detectors Soliwave M

Problems

The chute under the impactor blocks and the crusher hammers or liners are damaged

Features

Added safety for primary crushing rigs

Two microwave point level sensors

Integrated SPDT relay or 4-20mA

TOP TIP ! A Prosonic T above

screens & belt transfer

points detects material

blockages

Benefits

No contact with media, outside crushing process

Small compact device requires minimal installation space

Robust yet light weight design

Level

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 58 / 241

Benefits

Raw material density is the quality parameter used to optimize the

speed & temp. of the mills

Mass flow control on conveyor belts Raw material density and load measurement

Top TIP ! Add a speed sensor + Memo Graph S.

You get an alternative to a Multi Idler

Belt Scale. (Kg / Hr )

Features

FMG60 Detector is mounted over the belt near the FMU sensor

The source container is mounted under the conveyer

Combined Density & level on the belt gives the meal bulk density

Add a shear gate and you get a fixed material height on the belt

Radiometrics

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 59 / 241

Typical Grinding and Milling Controls

Types of mine mill

Vertical Ball mills for lime stone

grinding

Autogenous mills (SAG) for milling

stone directly from primary crushers

Conical ball mills for wet grinding

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 60 / 241

Problems

Air, ore and grinder ball mix optimisation

Ore feed to mill speed ratio control

Pressure control of the mill hydraulics

Overheating

Getting optimum material dispersion rates

Solutions

DP measurement across the mill

Pneumatic feeder air flow monitoring

Temperature measurement at outlet

Vertical roller ball mills Common problems

Top Tip : Temperature in

Temperature out

The tough TAF 12T ceramic thermocouple for abrasive

media

Nickel coated stainless steel probe

Utilities

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 61 / 241

Mill air pressure package RMA422, Cerabar T/M/S, RIA displays

Cerabar S

Continuous

Differential pressure

Analogue output 2

Incoming pressure

Analogue output 1

Analogue input 1 Analogue input 2

minimum pressure

Limit switch

Ceraphant T

Switch

Pressure

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 62 / 241

Mill air pressure & temperature package ECOGRAPH T & RIA 141 displays

Cerabar S

Differential pressure

with Deltabar S

Analogue output 2

Incoming pressure

& temperature

Analogue output 1

Analogue input 1 Analogue input 2

3 Limit switches

Ceraphant T

Analogue input 3 Analogue input 4

Omnigrad TC10-15 Omnigrad TAF 11-16

Temperature

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 63 / 241

Problems

Mill outlet Chute or screen plugs or buffer tank overfilling

Solutions

High or low level tank alarms, mill pipe outlet flow detectors

Features

Top, side or angle mounting

Self cleaning forks or single rod

Extended rod or fork up to 4m(12ft) or fork 20m (60ft) on a rope

Overfill & blockage of mill buffer tanks Good Vibrations with a Soliphant Fork or Monorod

Benefits

Buffer bin after the mill with temperatures up to150°C (302°F)

Vibration fork FTM 30 measures grain sizes to 10mm (3/8”).

Sensors not affected by heavy build-up.

No calibration necessary.

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 64 / 241

Application Example

FTE Paddle switches are mounted as high alarms

A Prosonic FMU electronics + FDU sensor provide

a reliable level measurement of the crushed raw slurry

The ultrasonic sensor is mounted using the “easy aimer”

or top target positioner FAU40

Pictures: Lafarge Aluminates, China

Continuous or switch level protection Overfill protection in holding bins with paddle switches

Level

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 65 / 241

Features

High or low level alarm

Grain size up to 50mm (2”), ATEX II 1/3D

Bulk density as low as 100g/l

Compact, extended and cable versions

Benefits

Easy installation through 1¼” process hole

No calibration required

Pictures: Lafarge Aluminates, China

Dry running protection Paddle with the current with a Soliswitch FTE30

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 66 / 241

Mill circuit optimization Promag S Slurry meter

Problems

Optimum mill speed rotation

Application:

Flow meter installed vertically on mill discharge and input.

Line size: 450 mm.

Flow rate: 1300 m3/h. (Velocity 2.2 m/s)

Features

Liner : Natural rubber

Electrodes: 316 SS Brush Electrodes.

Benefits

Long electrode/ liner life

Helps optimize mill efficiency

Flow

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 67 / 241

Alluvial Diamond Project mobile recovery + DMS plant

Flow measurement with Promag S

Industry Trend: jet line system with water as a carrier including IPJ (Inline

pressure Jig) and DMS (Dense Medium Separation) with FeSi (Ferrous Silicone)

to make water denser

Flow

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 68 / 241

Alluvial Diamond Projects mobile recovery + DMS plant

Pressure measurement with a Cerabar M with ceramic membrane

on an IPJ (Inline pressure Jig)

and at the slurry pump

Pressure

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 69 / 241

Alluvial Diamond Projects mobile recovery + DMS plant

Detection of solids under water

with Soliphant

installed from the side

and from the top

Level

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 70 / 241

Crushing, Grinding & Screening

Extraction & Ore storage

Flotation & Thickening

Roasting & Autoclaving

Smelting

Refining

Environmental Issues

Common Mining Processes Key Stages

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 71 / 241

Flotation

Froth Flotation is a selective process for separating

minerals from gangue by using surfactants and wetting

agents. The flotation process is used for the separation

of a large range of sulfides, carbonates and oxides prior

to further refinement

Other commonly used separation processes include

crystallisation, distillation, electrostatic methods and

gravity separation

The process was first successfully operated on a

commercial scale in Australia in the early 1900’s

Today it is the most widely separation process in the

base and precious metal processes

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 72 / 241

Flotation process

After the ore has been

ground to a fine paste it is

mixed with water and

stirred to form a

homogenous mixture

Upon entering the first

flotation cells the mineral

content of the mixture can

be as low as 1/10th of a

percent

By the time the concentrate

emerges from the flotation

circuit it is 95 percent pure

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 73 / 241

Flotation process

Particles are made Hydrophobic

through the addition of reagents

Air is bubbled through the mixture

Metals attach to the air bubbles and

are floated to the top of the vessel

and are harvested

Gangue settles to the bottom of the

vessel and are discarded

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 74 / 241

Flotation

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 77 / 241

Brush electrodes

and thick natural rubber

lining

Primary slurry in grinding

processes, tunnel digging

machines, dredging

Rocky slurry, grain size

> 0.02 in (0.5 mm)

Typical flow speed over

3…13 ft/s (1…4 m/s)

Extremely high abrasion

resistance due to softness of

the lining and the

electrodes

Linatex avail. as special

Solution for Rocky slurry

sensor robustness for extended

lifetime of measuring point

high signal stability in noisy

application

increased process reliability

increased operational reliability

cost reduction

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 80 / 241

TOP TIP : View tank levels from your PC?

Schedule tank refill orders automatically?

Install FieldGate® and PC Java Applets

Flotation Cell Solutions

Cell Control parameters include :

Level & Interface

Dosing of xanthate frothers

PH

Air Flow

Frothing chemicals “frothers” are made of

glycol and aliphatic alcohols and their waste

should be disposed of responsibly

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Waste treatment and analysis From sensor, to analyser panel to drop in container

Tailor made mobile effluent control

solutions

Analysers for every environmental

concern

Limit value monitoring in mine

wastewater inflow and outflow

River toxicity monitoring

Internal monitoring of wastewater

Monitoring of cooling water and

steam e.g. boilers

Production loss monitoring

Analysis

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 82 / 241

Levels of foam and slurry in flotation tanks Ultrasonics with ball & float system

Prosonic Ultrasonic

sensor measures top level of foam

Metal target & ball float gives level

of the slurry

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Safety first

Picture courtesy of Phil Thwaites of Xstrata XPS, Sudbury, Ontario

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 84 / 241

Levels of foam and slurry in flotation tanks

Mechanical plate & ball solution up close

Top TIP ! Measure injected air

for agitation using a

Prowirl 72 Vortex mass

flow meter

Level

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Xstrata float innovation

The XPSFloat™

Less prone to build up

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Install to maintain

Float and rod should be easy

to remove from the process

Simple remove and clean

installation means sound

measurment

Build up on the rod means

inaccurate measurement

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 87 / 241

Compact ultrasonic sensor Separate instrumentation

Prosonic T Prosonic (S)

Flotation cell level & interface controls

Rio Tinto’s Palabora mine, South Africa

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 88 / 241

Level of slurries with ultrasonic Prosonic S

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 89 / 241

Flotation cells

Slurry level & foam interface measurement

Features:

Prosonic M FMU ultrasonic level device, optional without display

2-Wire, Hart® programmable

Compact IP68 aluminum housing

Benefits:

Simple operation / setup without manual

Excellent 2mm accuracy

Robust non plastic housing

Measures from 25cm (10”) to 15m (50 ft)

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 90 / 241

Dosing of flotation cell flocculants Flow metering with worlds smallest mass meter - CUBEMASS

precise online metering of xanthates with

a coriolis mass flow meter

• Measurment output links digitally to spray head

& dosing controller

• measurement accuracy not affected by pipe

vibrations

• standard industry outputs such as Ethernet,

4-20 mA HART®,PROFIBUS® or Foundation

Fieldbus™

Digital Wall mount

or compact display

& electronics

In line coriolis mass Meter and dosing

panel

Utilities

Slide 91 / 241

BHP Billiton Cannington

Silver & Lead Mine, Queensland Australia

Flotation Cell Project

Slide 91

09.07.2004

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 92 / 241

Cannington Project Charter

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 93 / 241

Flotation Tank control philosophy

Switch room cabinet

PLC rack and ALL I/O

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 94 / 241

Control Panel Segments

PROFIgate

(Ethernet – PROFIbus DP

Link modules / Siemens

Segment couplers

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 95 / 241

Instrumentation setup using E+H PC

Tools & Software

PROFIgate

(Ethernet – PROFIbus DP

Link modules / Segment

couplers

Endress+Hauser Instrument

setup on the ProfiBus network

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 96 / 241

Allen Bradley

PLC 5

SST PROFIbus DP

Scanner

Cannington Flotation Cell PLC System

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 97 / 241

Lead concentrate metering to flotation cells

• Lead Concentrate

• High solids content

• Very abrasive media

• Low conductivity

• Promag 55S Magnetic

Flow Meter

• Natural Rubber lining

• Brush electrode

•

Flow Provides solids content, mass flow

and slurry density when linked to a

radiometric gamma meter

r

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 98 / 241

Valve control using E+H Flow Meters

Flow

Promass 80 Mass Flow

Meter dosing acids and

xanthates

Promag 55S magnetic slurry

meter

Samson 3785 valve

positioners

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 99 / 241

Flow control using a Promass 80 Coriolis Flow Meter

• Remote Promass Flow Meter

Transmitter with display

• Note ProfiBus T box

Flow

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 100 / 241

Acid Flow Control to the Flotation Tanks

• Acid valve installation with

Samson 3785 positioner

• Note Profibus T box

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 101 / 241

Profibus instrument network cabling

• T box couplers

• High and safe

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 102 / 241

PH Control in the tanks using the TopClean System

• TopClean pH system with

full PROFIbus integration

• Remote cleaning actuation

• Remote control of measuring

system

Analytical

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 103 / 241

Level control of foam and slurry in the flotation tanks

using Ultrasonic sensors and ball & float system

• Prosonic T Compact Ultrasonic

sensor measures level of foam

• Metal target for level device

• Ball float in the tank

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 104 / 241

Flotation tank level control up close

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 106 / 241

Dosing of additives for flotation process

Mass flow measurement with Promass A coriolis meter

Flow

Slide 107 / 241

Optimising Tailings Thickener Control Begins with Optimised Process Measurement

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 108 / 241

Thickening

The production of a concentrated slurry from a dilute suspension of

solid particles in a liquid

In practices thickeners are also used to produce clear liquids therefore

clarification is a concurrent process

Both thickening and clarification are outcomes of sedimentation

(mechanical separation)

Thickening can be carried out either batch wise or continuously but

the more common method utilised in industry is continuous

The product produced is either rejected (tailings) or used as an input

for the next stage of processing (concentrate)

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 109 / 241

Thickening control loop

Slide 110 / 241

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 112 / 241

Tailings thickener operation, conventional

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 113 / 241

Tailings thickener operation, conventional

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 114 / 241

Tailings thickener operation, High Compression/ Paste

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 115 / 241

Tailings thickener operation, High Compression/ Paste

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 116 / 241

Time (hrs)

Underf

low

% s

olids

Tailings thickener operation, Control Strategy

Without appropriate sensing technology

With appropriate sensing technology

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 118 / 241

Process Measurement in Tailings Thickeners

PT

LT

LT

PT

DT

FT

FT

DT

AT

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 119 / 241

PT

Process Measurement in Tailings Thickeners Rake torque control with Cerabar pressure sensors

Rake Torque

Hydraulic lift control

Protect damage to drives

Initiate rake lift

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 120 / 241

Process Measurement in Tailings Thickeners

Cerabar PMC51 or 71 Pressure sensor

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 121 / 241

Commodity item YES – Stock item at most vendors

Operating Principle Strain gauge semiconductor bridge

Sizing required YES – Consider pressure peaks

Life cycle maintenance None - if sized correctly

On site calibration None

Vendor assistance Not needed

Process Measurement in Tailings Thickeners

[Pa] P = [N]

[m²] F A

A

F

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 122 / 241

PT

Process Measurement in Tailings Thickeners

Prosonic Ultrasonic level sensor

Rake Torque

To control rake lift and actual rake depth

LT Rake Lift

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 123 / 241

Process Measurement in Tailings Thickeners

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 124 / 241

Process Measurement in Tailings Thickeners

Commodity item YES – Stock item at most vendors

Operating Principle Non contact Ultrasonic

Sizing required No – base entry model is enough

Life cycle maintenance None

On site calibration Zeroing for reference and lift span

Vendor assistance Not needed

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 125 / 241

PT

Process Measurement in Tailings Thickeners

Rake Torque

Position of compressed bed (fluidised bed)

LT Rake Lift

LT Bed Level

Feedback flocculant dosing effect

Early warning for solids carry over to overflow

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 126 / 241

Process Measurement in Tailings Thickeners

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 127 / 241

Process Measurement in Tailings Thickeners

Commodity item No – Only specific vendors

Operating Principle Submersible Sonar

Sizing required No – one model cover all ranges

Life cycle maintenance YES – Periodical cleaning

On site calibration YES - In situ, after installation

Vendor assistance YES

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 128 / 241

CUS 70: Rinsing Pump for Sensor cleaning

Option

mounting bracket

pump

sensor

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 129 / 241

Process Measurement in Tailings Thickeners

Analytical

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 130 / 241

Process Measurement in Tailings Thickeners

Commodity item No – Only specific vendors

Operating Principle Infrared Light Adsorption

Sizing required No – one model cover all ranges

Life cycle maintenance YES – Periodical cleaning

On site calibration YES – In site, After installation

Vendor assistance YES

Analytical

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 131 / 241

Process Measurement in Tailings Thickeners

Fill the float with 3Kg of bottom slurry

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 132 / 241

Process Measurement in Tailings Thickeners

Commodity item No – Only specific vendors

Operating Principle Electromechanical Displacement

Sizing required No – one model cover all ranges

Life cycle maintenance No

On site calibration YES – Fill sensing body with slurry

Vendor assistance No

Careful Tape cleaning

Microprocessor controlled

with English text menus

Electronically controlled

Powerful motor Tape wipers Separate tape compartment

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 133 / 241

PT

Process Measurement in Tailings Thickeners

Rake Torque

Solids inventory

LT Rake Lift

LT Bed Height

Feed forward to underflow pump PT

Bed Mass

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 134 / 241

Process Measurement in Tailings Thickeners

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 135 / 241

Hot tap insertion with water purge

Process Measurement in Tailings Thickeners

Commodity item No – Special connection required

Operating Principle Ceramic capacitance bridge

Sizing required YES – Consider height and Bed SG

Life cycle maintenance YES – Flushing against blockage

On site calibration No

Vendor assistance No

atmospheric pressure

pressure

substrate

diaphragm

gauge pressure cell

Conventional PT with separate valve

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 136 / 241

PT

Process Measurement in Tailings Thickeners

Rake Torque

Dry solids flow discharge

LT Rake Lift

LT Bed Height

PT

Bed Mass

DT Underflow Density

FT

Volumetric flow

Control underflow slurry pump

Total slurry volume discharge

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 137 / 241

Process Measurement in Tailings Thickeners

Flow

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 138 / 241

Process Measurement in Tailings Thickeners

Commodity item No – Only specific vendors

Operating Principle Nucleonic Gamma Ray Attenuation

Sizing required YES – Vendor to advise

Life cycle maintenance None – Except legislation directives

On site calibration YES – Vendor to advise

Vendor assistance YES

r

µSv/h

mCi

X-ray in Medicare

• Dental 0.01 mSv

• Head 0.1 mSv

• Mammogram 0.5 mSv

• Spinal column 1 mSv

• Stomach 10 mSv

High sensitivity 0,1 µSv/h gamma scintillator detector

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 139 / 241

Process Measurement in Tailings Thickeners

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 140 / 241

Process Measurement in Tailings Thickeners

Commodity item YES – Select liner & electrodes with care

Operating Principle Magnetic Inductive in line flow meter

Sizing required YES – Diameter dependant

Life cycle maintenance None

On site calibration No

Vendor assistance No

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 141 / 241

PT

Process Measurement in Tailings Thickeners

Rake Torque

Dry solids feed

LT Rake Lift

LT Bed Height

PT

Bed Mass

DT Underflow Density

FT

Volumetric flow

Feed forward to flocculant dosing

FT

Volumetric flow

DT Underflow Density

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 142 / 241

PT

Process Measurement in Tailings Thickeners

Rake Torque

Quality assurance of clarified water in ppm

LT Rake Lift

LT Bed Height

PT

Bed Mass

DT Underflow Density

FT

Volumetric flow

Register excess carry over of solids

FT

Volumetric flow

DT Underflow Density

AT Clarity

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 143 / 241

Process Measurement in Tailings Thickeners

Analytical

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 144 / 241

Process Measurement in Tailings Thickeners

Commodity item No – Certain vendors only

Operating Principle 90 degree scattered infrared light

Sizing required No – Same sensor fits all

Life cycle maintenance Periodical cleaning

On site calibration YES

Vendor assistance YES

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 145 / 241

Process Measurement in Tailings Thickeners

Analytical

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

John Immelman

Slide 146 / 241

Process Measurement in Tailings Thickeners

PT

LT

LT

PT

DT

FT

FT

DT

AT

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 147 / 241

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 148 / 241

Jindal Steel Vijaynagar Ltd. India Ore sludge package solution

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 149 / 241

Density measurement of ore slurry with a compact Gammapilot M

Abrasive slurry, flowing

with high velocity

Field housing FHX40

with display VU331

Use of NaJ crystal due to

high stability of

+/-0,1%.

Integrated detector and

transmitter plus

source container

Radiometric

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 150 / 241

Slurry measurement at final concentrator

Process Specification:

Fluid: Platinum Slurry, 60%, fine particles

Pressure: 7 bar

Temperature: Ambient

Instrument:

Model: Promag 35S

Size/Lining: DN 300 DIN PN 10

Company: Lonmin Platinum Ref:

Location: Rustenburg, South Africa

PHOTO

Process:

Platinum slurry density measurement

Process problems included :

Slurry has a high settling velocity

Solution:

Vertical installation, as long a straight runs as

possible

Pitfalls to avoid: Don’t forget back pressure!

Key Success Factors:

High accuracy, abrasive resistant liner Flow

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 152 / 241

Density measurement in thickeners and clarifiers pumping the sludge dependent on density/sludge level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 153 / 241

Sludge level in thickening tanks Is the slurry thick enough?

Problem :

Slurry solids content needs to be increased and excess water pumped off to save heating

costs

Solution :

Ultrasonic CUM750 transmitter with CUS70 sensor

Features

Multi channel version for parallel measurement in 4 tanks

Sensor cable run length up to 100m

Temperature to 153°C (307°F)

Benefits

No moving parts

Insensitive to floating sludge

Analytical

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 154 / 241

Sludge level measurement example East Driefontein Gold Mine

Analytical

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 155 / 241

Rate control and dosage of flocculent in wet processes

Photos: Ciba Spezialitätenchemie Lampertheim GmbH, Lampertheim

Analytical

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 156 / 241

Density monitoring in thickeners

Optoelectronic solid content measurement

Analytical

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 157 / 241

Guided radar measurement in thickeners

Benefits:

Plain language display -time and cost saving due to uniform operating philosophy

Reduced stocking costs by modularity : highest flexibility even for different silo

Pre-calibration of device minimises the effort for set-up: mount and measure

High reliability of rod probe, not influenced by large nozzle or changes in density

Features:

Rod probe modular and exchangeable

Single rod probe with highest sensitivity, no danger of bridge formation

Measuring range up to 4 m (12ft) maximum with rod probe

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 158 / 241

Acidulation circuit control

Slurry thickness & concentration measurement

Problem :

Sludge level Blanket measure

Solution :

CUC101 see SI 026C

Features

Opto-electrical turbidity sensor

Sludge level to 11m

Measuring range 0..12g/l

Accuracy at 1% of measured value

Repeatability 0.5%

2 x 4-20mA output, level and concentration

Benefits

Direct continuous concentration level measurement

Sensor replaceable without re-calibration

Concentration & level for slurry profile evaluation

Analytical

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 159 / 241

Application :

Sulphuric acid addition to gold slurry.

Level Solution :

FMR 245 radar plus low level silo alarm

Features

suitable for use in a safety instrumented system to SIL2 for

overspill protection according to IEC61511-1

Benefits

2 Wire instruments for easy installation

Non contact level technology

DIN or ANSI flange process connection options for highest

degree of chemical protection

Acidulation circuit control parameters Level in sulphuric acid tanks

TOP TIP : View tank levels from your PC?

Schedule tank refill orders automatically?

Install FieldGate® and PC Java Applets

W@M

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 160 / 241

Acidulation circuit acid control parameters Sulphuric acid concentration of ore slurry

Problem :

Sulphuric acid concentration of the carbonate rich slurry

needs to be measured

Conductivity solution :

Liquiline CM42 with CLS50D PFA Inductive sensor ,

compact field transmitter and built in Pt 100 temperature

sensor

Features

Pre set H2S04 concentration curves

Self monitoring safety function; ageing, moisture ingress, short circuit

Smallest most compact transmitter available

Benefits

Self checking extends the sensor life

Measures concentration and temperature

Analytical

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 161 / 241

Acidulation circuit flow control parameters

Sulphuric acid mass flow / dosing control

Problems :

Accurate metering of concentrated acids

Application :

Sulphuric Acid Metering

Flow solution :

In Line Promass 80F Coriolis mass flow meter

TOP TIP !

Make your process visible.

Use bright backlit displays

for added safety

Features

Mass flow, temperature and density parameters

Hart®, Profibus PA and FF protocols

Benefits

Three in one measurement solution

High process temperatures to 210°C/410°F

Accurate to 0.15% of flow range, 1000 : 1 turndown

Flow

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 162 / 241

Acidulation circuit control parameters From acid surge tanks into the Autoclave circuit

Locations :

Rouyn-Noranda, PQ, Canada

Application :

Mass flow and density control. Gold Slurry 5%

solids, bulk density 2 t/m3, particle size @

50…250 mesh, 40 PSIG, Ambient Temperature.

Flow Solution :

Promass 80F with remote display and transmitter.

Features

Accuracy 0.15% of flow span

Turndown 1000 to 1

Benefits

3 in 1 solution : Mass flow, temperature & density

Compact device means simple installation

Process Temperatures from -60 to +210°C

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 163 / 241

Typical flow sheet mineral separation

continuous level metering in agitator bin 1.2 & 3.0

density metering with pressure differential device in bin 1.2 & 3.0

volume control in transfer piping

plus

level measurement bin 1.0 & 1.1 either with ultrasonic

or limit vibration limit switches

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 164 / 241

Solid-liquid separation by sedimentation

Analytical

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 165 / 241

Material discharge dependent on sludge density with 2 pressure measurements PMC with flush mounted membrane

Pressure

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 166 / 241

Solid content + differential pressure measurement in thickeners in wet processes

Pressure

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 167 / 241

Optical turbidity measurement for rate control and dosage of flocculent

Analytical

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 168 / 241

Optical turbidity measurement for rate control and dosage of flocculent

Installation of the sensor CUS 41

in inlet of thickener in pipe filled

with process water

Promag 53H

volumetric flocculent

dosing of Fe3Chlorid

Analytical

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 169 / 241

Flow measurement of water with 50W in closed circuits in wet process

Flow

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 170 / 241

Pressure measurements with Cerabar S und Deltapilot S

Measuring of the conveying

pressure with Cerabar S

PMC 71

Hydrostatic level

measurement in tank with

Deltapilot S DB 50

Pressure

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 171 / 241

for friction bearing lubrication with 4 x Promass F in total

predictive maintenance purpose

in combination with temperature

measurement at bearing

Mass flow measurement of lubricating oil

Installation point

of the mass flow

meter

Flow

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 172 / 241

Recognising solids under water

Soliphant T/M

Both Soliphant families can recognise

solids under water. I.e. they do not

switch when the probe is covered by

liquid but when the probe is covered

by sand or sludge.

Sludge level needs to be recognised in

alumina sedimentation tanks.

Customers can set this in Soliphant M

using the sensitivity.

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 173 / 241

Pressure measurement of lubricating oil

Cerabar S installed at various points using manometer connection

Pressure

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 174 / 241

Crushing, Grinding & Screening

Extraction & Ore storage

Flotation & Thickening

Roasting & Autoclaving

Smelting

Refining

Environmental Issues

Common Mining Processes Key Stages

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Schematic courtesy of Phil Thwaites, Xstrata Sudbury

Roaster automation Promass coriolis meters for slurry handling

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Roaster Feed - Multivariable metering Digital output control with Ethernet

Roaster Feed – Coriolis combined

Mass Flow, temperature and

Density Meter

Four 4” Promass 83F installed, one

on each feed line

Controls mass feed rate and density

to 2 roasters

Measurements required for

regulatory compliance (sulphur

balance) and mass balance

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Promass 83I straight tube coriolis

required due to poor screening of

slurry

Diagnostics with a FieldXpert HHC

Roaster feed preparation Simple Profibus control philosophy + Bluetooth

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 178 / 241

Refractory Ore Processing Autoclaving circuits, pressure oxidisation

Sulphide Ore slurry is oxidized at

high pressure and temperatures

Important parameters in the

oxidation of refractory gold ores

under oxygen pressure are the

fineness of grinding; the pressure,

temperature, density and pH of the

slurry in the autoclave; and the

total retention time.

autoclave at Barrick's Goldstrike Plant, USA

Radiometrics

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 179 / 241

Refractory Ore Processing Acid Matte Copper Leaching Process

TOP TIP ! Always make a backup?

Install a MEMOGRAPH S

Secure your process data.

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 180 / 241

Refractory Ore Processing Copper leaching process description

Locations :

Murrin Murrin Nickel Cobalt Plant Leonora, Australia

Application :

The PAL area receives slurried feed, heats it to 225oC

and mixes it with hot concentrated sulphuric acid

inside four titanium-lined autoclaves.

Nickel and cobalt are leached into solution.

Precipitated iron and aluminum tailings are washed

and stored in the tailings dam.

The autoclaves discharge leached slurry to the counter-

current decantation (CCD) washing area, where it is

mixed with flush-steam heated water, producing a

clear solution of nickel and cobalt in preparation for

hydrogen sulphide precipitation of mixed nickel/cobalt

Process circuit :

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 181 / 241

Level measurement in the autoclave Radiometric measurement with Gammapilot M

Application

Level measurement and limit detection

in flush tanks in autoclaves

Features

Functional safety to IEC 61508 (SIL2)

Level, interface or density functionality

Hart®, Profibus PA & FF output protocols

Benefits

Non-invasive measurement through

the tank wall and thick brick lining

High temperatures and high pressure

have no influence on measurement

Thick brick

lining

Detector

Murrin Murrin / Australia

Source

container

Radiometrics

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 182 / 241

Gammapilot M Product line Radiometric level and density transmitter

Radiometric system components :

Source

Source container

Compact transmitter / detector

Remote display

More details:

Radiometrics

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 183 / 241

Autoclave & Neutralization circuits Oxygen or air metering package

Application

Air is pumped in the circuit tanks to speed up the lime

acid mixing

Flow solution

Promass 80 Coriolis Mass Flow Meter

Features

Mass flow and temperature measurement

Benefits

Quick on-site setup via a plain language display

- time and cost saving due to uniform operating

philosophy

Compact multivariable device may reduce the number of

measuring points

Maintenance reduced to a minimum due to no moving

parts

Flow

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 184 / 241

Oxygen or air control Differential pressure transmitter used for gas flow measurement

• Deltatop is an all in one device,

differential pressure transmitter,

valve block and orifice plate in one

order code!

Endress+Hauser

is the second biggest supplier of

pressure transmitters world-wide.

Measuring ranges from

0.5 mbar to 400 bar

• Absolute, relative or differential

pressure, all available with Hart as

standard, Profibus PA or Fieldbus

Foundation as option. Flow

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 185 / 241

Deltatop / Deltaset

• Deltatop = compact device • Deltaset = modular solution

Without impulse pipes With impulse pipes

from DN 10 to DN 2000

Complete pre-mounted measuring unit

Optimized and ready to be installed

Flow measurement with differential pressure

Flow

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 186 / 241

Deltatop / Deltaset Pressure flow kits just for the mine

• Complete solution for every measuring point

• Pitot tubes from DN 50 to DN 12000

• Quick commissioning with the new Quick Setup

menu

• Diagnostics functions

• Orifice plate versions from DN 10 to DN 1000

• Functional safety up to SIL 2

• Customized pre-mounting and configuration

Flow

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 187 / 241

Deltatop

Tough flow kits for the mine environment

Flow

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 188 / 241

Deltaset In mine waste water recycling

Electrically

heated

Deltaset Pitot tube DN 800

with heated

impulse piping

Flow measurement in a bio filter

chimney

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 189 / 241

Steam recycling from the autoclave Mass flow of steam with Deltatop

Steam calculation is done via

energy manager

Software specific for steam

Flow

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 190 / 241

Energy Manager RMC 621 Compact solution for steam in the autoclave circuit

Error handling (I)

DP measurement in RMS 621 according to DIN EN ISO 5167-1

Online calculation of all parameters of the flow equation

Discharge coefficient

Velocity of approach factor

Expansion coefficient

Input signals

DP

Temperature

Pressure

Utilities

Mining overview

Extraction & Ore

storage

Crushing, Grinding

& Screening

Flotation

Roasting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 191 / 241

Neutralization Circuit Process overview

The slurry on discharge from the

autoclave has 15 to 20 grams per

liter of sulphuric acid. The acid is

neutralized with milk of lime.

Slurry changed from pH 1.5 to 10.5

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 192 / 241

Acid Neutralization Circuit

Avoid exposure to acid . Install automatic pH Controllers

Problems :

Repeated contact with low concentrations may cause dermatitis.

Lime milk addition increases slurry pH from 1.5 to 10.5

PH Control solution

Liquisys M CPM 253 with CPS11 or CPF81 electrode

Features

Compact IP65 / NEMA4X field housing

Measures pH -2 to 16 ; Hart®, Profibus PA and DP outputs

Benefits

Memosens sensor calibration is done in the lab meaning a safer process

Manual pH sampling can dangerous. This is now removed.

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 193 / 241

Carbon adsorption recovery processes Cyanidation & Carbon in Pulp (CIP)

Ore is crushed to 200

mesh/75µM

2lb of sodium cyanide is added

per ton of Ore & water

Lime is added to keep pH level

at 11

Slurry at 50% solids is pumped

through 4 or 5 air agitated tanks

Granular carbon is added and

gold is adsorbed

Screens between the tanks trap

the carbon and gold

Gold is washed from carbon and

recovered by electrolysis

Analytical

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 194 / 241

Carbon adsorption recovery

Air addition for agitation in CIP tanks using a Prowirl Vortex Meter

Features:

Large turndown of 40 to 1 for gas flows to 75 m/s

DN15 to 150 process connection to PN 160

Accuracy across flow range of better than 1%

Benefits:

Compact device which is easy to install in compressed air line

Reduces the use of compressed air on site by optimizing the compressors

Increased safety with self-monitoring functions

Cost effective – short return on investment

Tek Cominco

Williams Mine,

Ontario, Canada

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 195 / 241

Problems

Blowing any powder around a mine can be a nightmare. Pipe blocks and tank over

filling can cause explosions and dust clouds and gas can attract environmentalists or worse.

Solutions

The Soliphant vibration switch for solids with grain sizes up to 10mm (3\8”) is fitted in

many mines as an over spill alarm.

The Cerabar S pressure gauge will warn against powder or gas build up & plugs in

pneumatic conveyer lines

Pneumatic conveying of coal or lime powder Dust cloud and explosion concerns ?

Features

Long term pressure stability at 0.1% deviation/ year

Over pressure resistant ceramic cell

Benefits

Bins protected from overfilling and potential explosions from over

pressurization

Barakov miner in Luhansk

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 196 / 241

Crushing, Grinding & Screening

Extraction & Ore storage

Flotation & Thickening

Roasting & Autoclaving

Smelting

Refining

Environmental Issues

Common Mining Processes Key Stages

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 197 / 241

Chemical or refractory processes Tanks, silos, bins and vessels on the plant

Acid Wash Vessels

Agitators

Boilers

Carbon Columns

Carbon Conditioning

Tanks

Carbon Sizing Screens

Carbon Stripping

Vessels

Cathode Wash Boxes

Chemical Mixing Tanks

Chemical Storage Tanks

Dart Valves

De-aeration Vessels

Drying Ovens

Electro winning Cells,

Polypropylene

Electro winning Cells,

Stainless Steel

Carbon Regeneration Kilns

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 198 / 241

Air & steam flow metering using Prowirl 72 Vortex Meters to 400°C

SO2 Gas pressure monitoring with Deltabar S

H2S04 concentration control in the boiler’s venturi circuit with ConduMax W

CLS 13

Roasting Circuits Sulphuric dioxide converted in to sulphuric acid

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 199 / 241

Typical Refining Process Copper, Nickel, Zinc, Gold Mine

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 200 / 241

Electro winning Processes

Commercially available systems

Electro winning involves placing an anode and cathode

into a bath of slowly circulating electrolyte.

Metal ions move to the cathode to be plated.

EMEW®, the electrolyte is circulated rapidly past the

anode and cathode at a higher flow rate, allowing for

improvements in efficiency and recovery.

The ANODE runs through the centre of the cell. The

Inside surface of the pipe is the CATHODE.

There are two types of EMEW® cell. One produces metal

plate, the other produces metal powder

Electrolyte is pumped through the cell from the bottom.

Power is applied. Metal begins to plate, or powders on the

CATHODE.

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 201 / 241

Electrolytic Copper Process Crushing, stockpiling and rinsing

• The first Step will always be to have

the mineral ore in an appropriated size

for either, Floatation, or extraction by

solvents, therefore, the rocks are

brought from the pit to the crushers by

truck.

• Right after the rocks are properly sized

they are dumped into the acid bath

area, using mechanical conveyors.

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 202 / 241

• Lubricant Oil flow to mills.

• Oil Pressure for mills and belt clutch systems.

• Lubricant Oil temperature.

• Chute overflow detection.

• Water flow measurement for milling and dilution.

• Mill discharge flow measurement.

• Cyclone separation pressure measurement.

• pH Measurement.

• Reactive high level detection.

• Air flow to flotation tanks.

• Interface measurement in flotation baths.

Electrolytic Copper Process

Analytical

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 203 / 241

Electrolytic Copper Process Copper ore rinsing

• The rock piles are now being washed by a constant flow of sulphuric acid and a mixture of an extracting compound.

• This weak acid solution washes stones all the way down, diluting the copper and bringing it to the lagoons where the solution now called “head” is concentrated for further pumping to the electrowinning plant.

Analytical

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 204 / 241

• Extractant solution flow measurement

going to irrigation area.

• Level measurement in lagoons.

• Flow measurement of head return to

the transfer process.

• Pressure measurement in the pumping

stations.

Electrolytic Copper Process Copper ore rinsing

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 205 / 241

• Once the head reaches the plant, it is filtered, to remove solids and then mixed with kerosene and “LIX®”. (ion exchange reagent). The copper is transferred then from the acidic solution to the organic one.

• Separation by density is then carried out with very large static separators.

• After that, the organic solution is mixed again, but now with the electrolyte that is going to form the copper plates as it takes place at refinery in the previous process.

Electrolytic Copper Process Copper recovery and extraction

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 206 / 241

• Kerosene flow measurement.

• Conductivity measurement in agitation

bath.

• Temperature in heat exchanger inlet

and oulet.

• Electrolyte flow measurement.

• Concentrated acid flow measurement.

Electrolytic Copper Process Copper recovery and extraction

Flow

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 207 / 241

• Copper is now diluted into the

electrolite.A DC current is applied

between SS anode and cathode.

• Current means that only copper ions

travel in the direction of the cathode.

• Copper is now 99.99 to 99.999 % pure,

and the main contaminant up to this

point is just Oxygen.

Electrolytic Copper Process Copper recovery and extraction

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 208 / 241

• H2SO4 Level Measurement (20% by weight, 60ºC )

• Water flow measurement for all the plant services.

• Condensate recovery system flow measurement, level measurement, Conductivity

• Level in various containers with reactive for electrolyte conditioning.

• Electrolite flow to the separation cells.

Electrolytic Copper Process Copper recovery and extraction

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 209 / 241

Mineral refinery processes Electrolyte Flow Controls

Application

Electrolyte flow control through a 2” plastic pipe

Solution :

Prosonic 90/93W clamp on pipe ultrasonic flow meter

Valleyfield Zinc Refinery,

Canada

Features

Flow range 0...15m/s (49 ft/sec) with 150 to 1 turndown

Typical repeatability of ±0.3% for flows > 0.3m/s (

Benefits :

Simple to install and retro- fit with direct clamp-on-pipe fitting

High accuracy electrolyte pump flow controL

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 210 / 241

Mineral refinery processes Valve control of electrolyte flow to electro winning tanks

Open and close valves against

specific flow set points with a

Promag Magnetic Flow Meter

Remote transmitter for convenient

programming and visualization

Meters have a wide range of ANSI

or DIN flange connections to fit

your existing pipes

You can link the meter to existing

PLC or SCADA using standard

industry connectivity such as 4-

20mA Hart, Profibus PA and

Fieldbus Foundation

Flow

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 211 / 241

Control the flow thru the filters

with a Promag Flow Meter

Valve, meter and piping is usually

separate from the filter tank on a

skid to ease transport

Mineral refinery processes Electrolyte filter tank measurement

Flow

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 212 / 241

Mineral refinery processes Electrolyte storage tank level monitoring

Monitor tank levels and prevent

over spills with a Prosonic M

compact Ultrasonic Level sensor

Separate display for easier setup

and programming

Install on a moving boom or arm for

ease of maintenance or

programming

Relay outputs to switch pumps on

or off

Level

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 213 / 241

Mineral Extraction from natural brine deposits

Evaporation ponds

Salar Brine

Salar de Atacama's process diagram

Carnallite deposits

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 214 / 241

Flow product

Promass 83F

Features

Density measurement

Temperature

Mass and volumetric flow

Customer: SQM Salar, Chile

Material : Lithium brine solution

Uses : Ceramics, aluminium, battery

Mineral Extraction from natural brine deposits Density and Flow Measurement

Benefits

Brine is pumped from ponds to tanks and for further refining only when set

density is confirmed

Actual brine densities match stipulated quality standards

Brine quality consistency better than with just lab density testing

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 215 / 241

Fertilizer production process Ammonium phosphate

beneficiation plant

phosphoric acid plant

ammonia plant

granulation plant

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 216 / 241

Ammonium Phosphate Granulation pH value as a mix controller

Phosphoric acid mixed with ammonia

Topclean S, Topcal S auto clean, auto

calibrating pH meter

Features

Auto retractable pH sensors

Calibration buffer solutions

MemoSens® means initial lab calibration

Benefits

Automated maintenance

No need for manual dipping meaning a

much safer work environment

Calibration data saved in sensor

Analytical

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 217 / 241

Phosphoric Acid Plant Bi Products Selling off gypsum to concrete or plaster board producers

Opportunity

Deliver gypsum against your customer’s production requirements

Solution

Offer your customer a just in time delivery based on his actual silo levels.

Install a FieldGate, remote silo visualization and level control system

Features

View your own gypsum stock levels and match these with levels in customer tanks

Benefits

Offer your customer a just in time delivery based on his actual silo levels.

Install a FieldGate, remote silo visualization and level control system

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 218 / 241

Phosphoric Acid Plant Bi -Products Selling off gypsum to concrete or plaster board producers

Opportunity

Deliver gypsum against your customer’s production requirements

Solution

Offer your customer a just in time delivery based on his actual silo levels.

Install a FieldGate, remote silo visualisation and level control system

Features

View your own gypsum stock levels and match these with levels in customer tanks

Benefits

Offer your customer a just in time delivery based on his actual silo levels.

Install a FieldGate, remote silo visualization and level control system

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 219 / 241

Crushing, Grinding & Screening

Extraction & Ore storage

Flotation & Thickening

Roasting & Autoclaving

Smelting

Refining

Environmental Issues

Common Mining Processes Key Stages

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 220 / 241

The mine life cycle Impacts on the water environment

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 221 / 241

Features:

Silo Guard consists of a continuous guided level radar Levelflex M, Cerabar T

pressure sensor, remote displays with integral alarm relays

Optional Remote data access and control with Fieldgate® inside, sends you

an SMS message or E-Mail in an overfill emergency

Visual and audible high level & pressure overfill alarms in pneumatically

filled powder bins

Environmental Protection Packages Silo Guard Overfill Protection System

Benefits:

Eliminate the prospect of silo damage

Meet requirements of local Health and Safety for over filling

Prevent environmental emission issues

Assist you in preventative maintenance

Air & Powder

Inlet Valve

% Level

High Relays

mBar, relays

Over & under

Relays close inlet valve

when in alarm state

W@M

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 223 / 241

Measurement in tailings dam overflow wells

Waterpilot FMX with remote data transmission

RIA45 + TMT181

Temperature

RIA46

Level

RMA422

Monitoring

Power

Display

Monitoring

Transmitting

Controlling

FMX21

Level, Pressure +

Temperature

Pressure

HAW

Surge Arrestor

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 228 / 241

Remote monitoring of effluent water Analytical parameters and flow

Remote data transfer in case of heavy

rain

measuring

- conductivity

- pH

- turbidity

plus

flow across a v-notch weir with

ultrasonics

Pressure

Mining overview

Extraction, leaching

& ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaving

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 231 / 241

Quarrying Process Solution Kaolin clay settling ponds

Ammonia measurement in effluent using a

CA 70AM and a CA 50 and CA 30

CA 70AM-Stamolys ammonia analyzer

CA 30-submersible sampling system

CA 50-sedimentation unit

China clay pools are natural or fabricated holding tanks where,

the ammonia solution is allowed to slowly dissipate to

atmosphere and the pH of the resulting wastewater is allowed

to stabilize to a range of 6.0 - 10.5 standard pH units

Analytical

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 233 / 241

Recycled process water quality How dirty is your water?

Problem :

If you drain your waste water to land or river then it must meet local environmental

standards for cleanliness and chemical content e.g. EU IPPC law,

Solution :

Measure the turbidity of your treated water with a Turbimax CUS 41

Features :

Integrated sensor cleaner wiper for lime build up

Benefits :

Measure the solid content of your treated water and

BOD

Comply with local discharge legislation

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 234 / 241

Effluent water quality How safe is the water?

Problem :

Waste water from your plant may meet local emission limit values for certain chemicals

but will your effluent affect river oxygen levels

Solution :

Simple dissolved oxygen sensor at the point of discharge will check oxygen levels

Features :

Flow through, retractable and immersion assembly options

Measuring ranges from 0.001 to 60 mg/l of 02

Benefits :

Factory calibrated system means fit and forget

Ensures survival of river live stock

Analytical

Mining overview

Extraction, Leaching

& Ore storage

Crushing, Grinding

& Screening

Flotation

Smelting &

Autoclaves

Refining

Enviromental

Issues

Thickening

Milling & Grinding

Slide 236 / 241

Silo Guard Systems Remote viewing and multi silo monitoring

The “Remote Guard” with FieldGate® inside will send your maintenance crew a mobile

SMS or E-Mail in an emergency situation.

A “Multi Guard” Silo protection system will link all your silos in to one control panel and

record every fill as it happens

Local guidance information for the Mining and Quarrying Industry states a requirement for

:

Prevention against over-filling of silos with a high level device

Silo operating conditions must not exceed manufacturers specifications

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“Silo Guard” Panel & Component Examples

SILO GUARD

Levelflex FMP51 Continuous Level

Soliphant FTM / Minicap FTC High Level Alarm

Cerabar T PMC 131 Pressure switch

RIA 250/450 Pressure display

RIA 250/450 Level display

SILO GUARD - Multi

ECOGRAPH /Memograph S

Prosonic S Ultrasonic transmitter

SILO GUARD - Remote

Field Gate Unit (Ethernet/GSM/Analogue)

Java Applets

P View

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Problem :

Environmental Laws require that extraction systems are

monitored to ensure certain levels of dust emissions are

not exceeded.

Solutions :

The Soliwave M is mounted on the filter outlet pipe. The

microwaves detect any dust particles passing through the

wave from a torn filter. Buildup on the pipe walls can also be

monitored

DCE

Filter

System

Exhaust

D to 100m

Dust build up & blockage detector in an air filter system Soliwave M

FAN

Soliwave M

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Filter dust in collecting box Soliphant T Monorod Switch

Pump

Application

FTM20-AA42A

• Filter dust from cleaning

dry (500 g/l) in the

collecting tank

• Controls box discharge as

max alarm to start up a

pneumatic pump

Problems

• Strong external vibration

from pneumatic system

• Build up on sensor

Alternative solutions

• Minicap

• Soliswitch

• Soliphant M

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Technology Tip Common Dust Filter Modules

Filter envelopes

with shake clean

motor & gear

mechanism

Filter types :

Envelope

Cartridge

Dust collection

box or silo

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Problem :

Dust from the plant filter system is collected and recycled. A level system that can

measure through thick dust clouds is required

Solution :

Levelflex FMP50 guided radar

Dust Levels in the bag house Measuring through dust clouds?

Features :

Reliable level measurement in powder and dust to 45 meters (115ft)

Approved for use in potential dust explosion areas e.g. ATEX II 1/3D

Benefits :

Fit and forget in the silo.

Remote programming and data visualization

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Fuel supply Storage and handling

Each type of fuel has be stored and

controlled with different measurement

systems.

Depending on the fuel type, gaseous,

liquid or solid and whether it is the

primary or secondary fuel the following

measurement systems will be used:

• level control

• pressure control

• control of volume

• control of waste oil viscosity (for example waste oil - measurement

installed to save energy in heating)

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Fuel supply (1) Level control of tank for heavy oils

level control of tanks with pressure

measurement devices

• easy setup reduces installation costs

• extra safe due to metallic measuring cell

• second process barrier for highest safety

• direct mounting at discharge point

• standard industry outputs such as 4-20 mA

HART®, PROFIBUS® or Foundation

Fieldbus™

Cerabar S pressure measurement Pressure

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Fuel supply (2) Level control of oil tank

continuous level control of oil tanks with free space

time of flight radar

• helps optimise the fuel supply and materials

logistics process

• no contact with media – measurement

independent of product properties

• change the product in the tank and there is no

need to recalibrate the radar

• easy setup via display or PC-program ToF-Tool

• For all materials with DK-value 1.4

radar measurement

Micropilot M Level

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Fuel supply (3) Level control in tank

Over spill or empty detection of oil tanks with

a vibrating sensor

• sensor is self monitoring and will check for

malfunction; safe and reliable

• operation of limit switch not affected by flow,

turbulence, air bubbles, foam, vibration, solid

constituents or built-up

• no mechanical moving parts

• no adjustment: rapid and economical

commissioning

Liquiphant FTL vibration fork limit switch

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Fuel supply (4) Waste oil

Promass F mass flow measurement system

online mass metering of waste oil at the

feeding station

• precise metering of delivered oil

• not affected by pipe vibrations

• no mechanical moving parts

• maintenance free in comparison to mechanical

flow meters

• standard industry outputs such as 4-20 mA

HART®, PROFIBUS® or Foundation Fieldbus™

Flow

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Fuel supply (5) Mass flow- and density measurement of waste oil

online mass metering with density measure-

ment of waste oil of fuel supply for rotary kiln

• optimised control of burning process and

reduction of discharge gas emissions

• not affected by pipe vibrations

• maintenance free in comparison to mechanical

flow meters,

• three in one solution of mass flow, density and

temperature

• standard industry outputs such as 4-20 mA

HART®, PROFIBUS® or Foundation Fieldbus™

Promass F mass flow measurement system

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Fuel supply (6) Viscosity control of waste oil

online measurement of viscosity for changing

qualities of waste oil

• control improvement of burning process

• slashes the cost of utility bills by saving energy

in heating up the waste oil

• measurement accuracy not affected by pipe

vibrations

• standard industry outputs such as 4-20 mA

HART®, PROFIBUS® or Foundation Fieldbus™

Promass I

the 4 in 1 Mass Flow Solution

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Fuel supply with coal dust Level control of silos

Levelflex M radar measurement unit

continuous level control with guided radar

measurement in coal dust silos

• continuous level measurement ensures

uninterrupted material flow

• minimum process down time due to radar’s

quick setup procedure

• reliable measurement, even during pneumatic

filling when thick dust clouds are common

• measurement principle independent of moisture

content or product changes

• recommended installation for powder and

products with a grain size up to max.

20 mm – 0.79 inches

• measuring range up to 45 m/147 ft - please

consider pulling forces -

Level

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Fuel supply with coal dust Level control in silos

point level detection in coal dust silo for max.

detection with a capacitance probe

• no calibration required, fit and forget

• simple mounting means lower installation costs

• integrated active compensation of built-up

• maintenance free – no moving parts

• long expected life time

• temperature range up to 60 °C – 140 °F

• grain size up to 50 mm – (2”)

Minicap measurement unit

Level

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Coal mill Pressure control

monitoring material flow by air pressure

control of coal mill

• fully configurable calibration and easy setup due

to modular concept reduces commissioning

costs

• extra safe due to ceramic measuring cell

• high overload protection up to a factor of 40

• second process barrier for highest safety

• quick an comfortable commissioning with PC-

program Commuwin II

• standard industry outputs such as 4-20 mA

HART®, PROFIBUS® or Foundation Fieldbus™

Cerabar S pressure sensor

ATEX

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Levelflex M with rod probe to 4 m /13ft

continuous level control with guided radar

measurement in sampler vessel with agitator

• Level devices when mounting space is at a

premium

• operation not affected by turbulence and foam

build up

• pre-adjusted setup: rapid and economical

commissioning

• measurement principle independent of density

or product change

• rod probe for for small liquid tanks

• coaxial probe for low DK liquids

• cable probe for solids to 35m / 115ft

• for materials with DK-value 1.6

ATEX

Secondary fuel supply with solvent (1) Continuous level control in sampler vessels

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point level measurement with vibration fork in

sampler vessel with agitator

• sensor has function monitoring to check for

damage; safe and reliable

• operation of limit switch not affected by flow,

turbulence, air bubbles, foam, vibration, solid

particles or build-up

• reliable long term operation due to integrated

corrosion protection

• suitable for mounting in restricted spaces

• product temperature up to +150 °C –

(302 °F)

• solid particles up to max. 5 mm – (0.2”)

Liquiphant FTL measurement unit

Secondary fuel supply with solvent (2) Limit detection in sampler vessel

ATEX

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Secondary fuel supply with solvent (3) Pressure control in conveyor piping -

pressure control in conveyor piping

• extra safe due to metallic measuring cell

• start and end of measuring range freely

adjustable

• easy setup via push buttons or digital interface to

PC

• long term stability of 0.1 % drift/year

• standard industry outputs such as 4-20 mA

HART®, PROFIBUS® or Foundation Fieldbus™

additional temperature measurement TER at

sample vessel

Cerabar M pressure sensor

ATEX

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Secondary fuel supply with waste tyres Level control of pre-burning chamber

maintenance and contact free level control

with radiometric measurement

• density profiling for otherwise difficult products

• no contact with the product thus no wear

• high reliability with self checking functionality

• low radiation due to scintillator sensor

• standard industry outputs such as 4-20 mA

HART®, PROFIBUS® or Foundation Fieldbus™

Gammapilot M with source container

and scintillation sensor Radiometrics

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Secondary fuel supply with waste plastic Level control of storage bin

maintenance and contact free point level

control with microwave measurement

• no contact, independent to media, there-fore

recommended for burning paper, plastic and

wood chips

• no maintenance costs caused by wear

• robust design – long expected life time

• sealed construction, dust and water tight

• Integrated 4-20mA or relay output

• max. range 100m – (300 ft)

• ambient temperature up to 70 °C – (129 °F)

Soliwave M FQR/FDR

Microwave measurement unit

Level

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Secondary fuel supply with waste plastic Continuous level control

Prosonic Sensor S / FDU measurement unit

continuous level measurement with ultrasonic

probe to control of screw conveyor

• no contact with media means low maintenance

costs

• low installation costs

• self cleaning sensor

• 6 free programmable relays

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overspill protection with electromechanical

paddle switch at bucket elevator feed

• ready to operate without calibration

• easy setup

• high operational safety due to internal non slip

coupling

• optional integrated switch signal light

Secondary fuel supply with waste plastic Limit detection at bucket elevator

Soliswitch FTE paddle switch

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Fuel supply using animal carcasses and bone meal(1) Limit detection at conveyors

Minicap capacitance probe

overspill protection of conveyors using point

level capacitance measurement

• simple mounting means lower installation costs

• no calibration required

• maintenance free – no moving parts

• available in compact or with cable probe to 6m

– 20ft

• grain sizes up to 30 mm – (1.8”)

Level

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Air line controls

Cerabar T pressure transmitter

pressure and temperature control of pneumatic

conveyors

• increase in site safety by monitoring potentially

hazardous fuel / air flow conditions

• overload protected and designed for vacuum

operation (pressure sensor)

• tough housing completely made of stainless steel

• reliable and long term stable

• small and compact means easy to install

• long term stability < 0.15 % drift/year (pressure

sensor)

• measuring range adjustable with PC program

compact Easytemp TSM thermometer

Pressure