Wills' mineral processing technology : an introduction to the practical aspects of ore treatment and mineral recovery / Barry A. Wills, Senior Partner, MEI, UK, James A. Finch, FRSC, FCIM, P.Eng.

Format:

Book

Author/Creator:

Wills, B. A. (Barry Alan), author.

Finch, James A., author.

Language:

English

Subjects (All):

Ore-dressing.

Minerals.

Physical Description:

1 online resource (1 volume) : illustrations

Edition:

Eighth edition.

Place of Publication:

Amsterdam, [Netherlands] : Butterworth-Heinemann, 2016.

System Details:

text file

Summary:

Wills' Mineral Processing Technology: An Introduction to the Practical Aspects of Ore Treatment and Mineral Recovery has been the definitive reference for the mineral processing industry for over thirty years. This industry standard reference provides practicing engineers and students of mineral processing, metallurgy, and mining with practical information on all the common techniques used in modern processing installations. Each chapter is dedicated to a major processing procedure—from underlying principles and technologies to the latest developments in strategies and equipment for processing increasingly complex refractory ores. The eighth edition of this classic reference enhances coverage of practical applications via the inclusion of new material focused on meeting the pressing demand for ever greater operational efficiency, while addressing the pivotal challenges of waste disposal and environmental remediation. Advances in automated mineralogy and analysis and high-pressure grinding rolls are given dedicated coverage. The new edition also contains more detailed discussions of comminution efficiency, classification, modeling, flocculation, reagents, liquid-solid separations, and beneficiation of phosphate, and industrial materials. Finally, the addition of new examples and solved problems further facilitates the book’s pedagogical role in the classroom. Connects fundamentals with practical applications to benefit students and practitioners alike Ensures relevance internationally with new material and updates from renowned authorities in the UK, Australia, and Canada Introduces the latest technologies and incorporates environmental issues to place the subject of mineral processing in a contemporary context, addressing concerns of sustainability and cost effectiveness Provides new case studies, examples, and figures to bring a fresh perspective to the field

Contents:

Front Cover

Wills' Mineral Processing Technology

Copyright Page

Contents

Preface

Acknowledgments

1 Introduction

1.1 Minerals

1.2 Abundance of Minerals

1.3 Deposits And Ores

1.4 Metallic and Nonmetallic Ores

1.5 The Need for Mineral Processing

1.6 Liberation

1.7 Concentration

1.8 Representing Mineral Processing Systems: The Flowsheet

1.9 Measures of Separation

1.9.1 Grade

1.9.2 Recovery

1.9.3 Grade-Recovery Relationship

1.9.4 A Measure of Technical Separation Efficiency

1.10 Economic Considerations

1.10.1 Contained Value

1.10.2 Processing Costs

1.10.3 Milling Costs

1.10.4 Tailings Reprocessing and Recycling

1.10.5 Net Smelter Return and Economic Efficiency

1.10.6 Case Study: Economics of Tin Processing

1.10.7 Case Study: Economics of Copper Processing

1.10.8 Economic Efficiency

1.11 Sustainability

References

2 Ore Handling

2.1 Introduction

2.2 The Removal of Harmful Materials

2.3 Ore Transportation

2.4 Ore Storage

2.5 Feeding

2.6 Self-Heating of Sulfide Minerals

3 Sampling, Control, and Mass Balancing

3.1 Introduction

3.2 Sampling

3.2.1 Sampling Basics: What the Metallurgist Needs to Know

Composition Variance

Distribution Variance

Preparation Variance and Analysis Variance

3.2.2 Gy's Equation and Its Use to Estimate the Minimum Sample Size

3.2.3 Sampling Surveys

Rules of Thumb

3.2.4 Sampling Equipment

Probabilistic Samplers

Non-Probabilistic Samplers

3.3 On-line Analysis

3.3.1 On-line Element Analysis

On-stream Analysis

On-belt Analysis

3.3.2 On-stream Mineral Phase Analysis

3.3.3 On-stream Ash Analysis

3.3.4 On-line Particle Size Analysis

3.3.5 Weighing the Ore

3.3.6 Mass Flowrate

Magnetic Flowmeter

Ultrasonic Flowmeters

Array-based Flowmeters.

Slurry Density

3.4 Slurry Streams: Some Typical Calculations

Volumetric Flowrate

Slurry Density and % Solids

3.5 Automatic Control in Mineral Processing

3.5.1 Hierarchical Multilayer Control System

3.5.2 Instrumentation Layer

3.5.3 Regulatory Control Layer

3.5.4 Advanced Process Control Layer

Expert Systems

3.5.5 Optimization Layer

3.5.6 The Control Room

3.6 Mass Balancing Methods

3.6.1 The n-product Formula

Sensitivity Analysis

Error Propagation

Excess of Data

More than One Process Unit

No Correction of Measurement Errors

3.6.2 Node Imbalance Minimization

Limitations

3.6.3 Two-step Least Squares Minimization

3.6.4 Generalized Least Squares Minimization

3.6.5 Mass Balance Models

3.6.6 Error Models

3.6.7 Sensitivity Analysis

3.6.8 Estimability and Redundancy Analysis

3.6.9 Mass Balancing Computer Programs

3.6.10 Metallurgical Balance Statement

3.7 Example Mass Balance Calculations

3.7.1 Use of Particle Size

3.7.2 Use of Percent Solids

3.7.3 Illustration of Sensitivity of Recovery Calculation

4 Particle Size Analysis

4.1 Introduction

4.2 Particle Size and Shape

4.3 Sieve Analysis

4.3.1 Test Sieves

4.3.2 Choice of Sieve Sizes

4.3.3 Testing Methods

4.3.4 Presentation of Results

4.4 Sub-sieve Techniques

4.4.1 Stokes' Equivalent Diameter

4.4.2 Sedimentation Methods

4.4.3 Elutriation Techniques

4.4.4 Microscopic Sizing and Image Analysis

4.4.5 Electrical Impedance Method

4.4.6 Laser Diffraction Instruments

4.5 On-line Particle Size Analysis

4.5.1 Slurry Systems

4.5.2 On-belt Systems

5 Comminution

5.1 Introduction

5.2 Principles of Comminution

5.3 Comminution Modeling

5.3.1 Energy-based Comminution Models

5.3.2 Breakage Characterization

Bond Tests.

Drop Weight Tests

MacPherson Test

SPI and SGI Tests

SAGDesign Test

Bond-based AG/SAG Models

5.3.3 Population Balance Models

Linking to Energy

Simplified Grinding Model

5.3.4 Fundamental Models

5.4 Comminution Efficiency

Possible Standards

Operating Work Index WiO

Functional Performance Analysis

6 Crushers

6.1 Introduction

6.2 Primary Crushers

6.2.1 Jaw Crushers

Jaw-crusher Construction

6.2.2 Gyratory Crushers

Gyratory Crusher Construction

6.2.3 Crusher Capacity

6.2.4 Selection of a Jaw or Gyratory Crusher

6.3 Secondary/tertiary Crushers

6.3.1 Cone Crushers

Wet Crushing

Wear

6.3.2 The Gyradisc® Crusher

6.3.3 The Rhodax® Crusher

6.3.4 A Development in Fine Crushing

6.3.5 Roll Crushers

6.4 High Pressure Grinding Rolls

6.5 Impact Crushers

6.5.1 Hammer Mills

6.5.2 Impact Mills

6.5.3 Vertical Shaft Impact (VSI) Crushers

Barmac Vertical Shaft Impact Crusher

Canica Vertical Shaft Impact Crusher

6.6 Rotary Breakers

6.7 Crushing Circuits and Control

7 Grinding Mills

7.1 Introduction

7.2 Tumbling Mills

7.2.1 Motion of the Charge

7.2.2 Power Draw

7.2.3 Construction of Mills

Shell

Mill Ends

Trunnions and Bearings

Drive

Liners

Mill Feeders

7.2.4 Types of Tumbling Mill

Rod Mills

Ball Mills

Autogenous/Semi-autogenous Mills

7.2.5 Motor Selection for Tumbling Mills

Gearless

Synchronous

Wound-rotor Induction

7.2.6 Sizing Tumbling Mills

Rod and Ball Mills

AG/SAG Mills

7.3 Stirred Mills

7.3.1 Power Draw and Stress Intensity

Power Draw

Stress Intensity

7.3.2 Sizing Stirred Mills

Levin Test

Metso Jar Ball Mill Test

Signature Plot Technique

7.3.3 Mill Types

TowerMill®/Vertimill®

Stirred Media Detritor (SMD®)

IsaMill®

VXPMill®.

HIGMill®

7.3.4 Some Operational Points

Media

Media Loading

Slurry Percent Solids

7.4 Other Grinding Mill Types

Vibratory Mills

Centrifugal Mills

Roller Mills

Table and Roller Mills

Pendulum Roller Mills

7.5 Grinding Circuits

7.5.1 Circuit Types

7.5.2 Circuit Operation

7.5.3 Control of the Grinding Circuit

Instrumentation

Control Objectives/strategies

8 Industrial Screening

8.1 Introduction

8.2 Screen Performance

Efficiency Formulae

Efficiency and Circulating Load

Efficiency or Partition Curve

Separation Efficiency

8.3 Factors Affecting Screen Performance

Particle Size

Feed Rate

Screen Angle

Particle Shape

Open Area

Vibration

Moisture

8.4 Mathematical Models of Screens

Phenomenological Models

Empirical Models

Numerical Models

8.5 Screen Types

8.5.1 Vibrating Screens

Inclined or Circular Motion Screens

Grizzly Screens

Horizontal, Low-Head, or Linear Vibrating Screens

Resonance Screens

Dewatering Screens

Banana or Multislope Screens

Modular Screens

Mogensen Sizer

High-Frequency Screens

Derrick Stack Sizer®

8.5.2 Vibration Modes

Circular Motion (Single-Shaft) Screens

Linear-Vibration (Double-Shaft) Screens

Oval Motion (Triple-Shaft) Screens

8.5.3 Other Screen Types

Static Grizzlies

Mogensen Divergators

Trommels

Rotaspiral

Bradford Breaker

Roller Screens

Flip-Flow Screen

Circular, Gyratory, or Tumbler Screens

Sieve Bends

Linear Screen

Pansep Screen

8.5.4 Screening Surfaces

Bolt-In Screening Surfaces

Tensioned Screening Surfaces

Woven-Wire Cloth

"Self-Cleaning" Wire

Tensioned Rubber and Polyurethane Mats

Modular Wire and Wedge Wire Panels

9 Classification

9.1 Introduction

9.2 Principles of Classification.

9.2.1 Force Balance

9.2.2 Free Settling

9.2.3 Hindered Settling

9.2.4 Effect of Density on Separation Efficiency

9.2.5 Effect of Classifier Operation on Grinding Circuit Behavior

9.3 Types of Classifiers

9.4 Centrifugal Classifiers-The Hydrocyclone

9.4.1 Basic Design and Operation

9.4.2 Characterization of Cyclone Efficiency

The Partition Curve

Sharpness of Cut

Multidensity Feeds

Unusual Partition Curves

Cyclone Overflow Size Distribution

9.4.3 Hydrocyclones Versus Screens

9.4.4 Mathematical Models of Hydrocyclone Performance

Bradley model

Computational Models

9.4.5 Operating and Geometric Factors Affecting Cyclone Performance

9.4.6 Sizing and Scale-Up of Hydrocyclones

Scale-Up of Hydrocyclones

Sizing of Hydrocyclones-Arterburn Technique

Sizing of Hydrocyclones-Mular-Jull Model

Sizing of Hydrocyclones-Simulation Packages

9.5 Gravitational Classifiers

9.5.1 Sedimentation Classifiers

Nonmechanical Sedimentation Classifiers

Mechanical Sedimentation Classifiers

9.5.2 Hydraulic Classifiers

10 Gravity Concentration

10.1 Introduction

10.2 Principles of Gravity Concentration

10.3 Gravitational Concentrators

10.3.1 Jigs

Jigging Action

Types of Jig

10.3.2 Spirals

10.3.3 Shaking Tables

Duplex Concentrator

Mozley Laboratory Separator

10.4 Centrifugal Concentrators

Kelsey Centrifugal Jig

Knelson Concentrator

Falcon Concentrator

Multi-Gravity Separator

Testing for Gravity Recoverable Gold

10.5 Sluices and Cones

Sluices

Reichert Cone

10.6 Fluidized Bed Separators

CrossFlow™ Separator

Reflux Classifier™

10.7 Dry Processing

Pneumatic Tables

Air Jigs

Other Pneumatic-Based Devices

10.8 Single-Stage Units and Circuits

Single Versus Two Stages of Spirals.

Parallel Circuits.

Notes:

Includes bibliographical references at the end of each chapters and index.

Description based on online resource; title from PDF title page (ebrary, viewed November 12, 2015).

ISBN:

9780080970547

0080970540

OCLC:

958956169