FLOWSHEETS Zinc Plant Flowsheet (SOMINCOR) .

FLOWSHEETS Zinc Plant Flowsheet (SOMINCOR)

http://www.sec.gov/Archives/edgar/containers/fix270/1377085/000120445907001642/lundintechrep.htm

Analysis of flowsheets

1

2 3

F e e d

ta ilin g Oc o n c e n tra te C 1

s e m ip ro d u c t P 1 s e m ip ro d u c t P 2

c o n c e n tra te C 2 c o n c e n tra te C 3

SIMPLE CASE

final concentrate final tailing

Balance of each node

input parameters: α, , Input data

c o n c e n tra te C 1

s e m ip ro d u c t P 1

c o n c e n tra te C 2 c o n c e n tra te C 3

αfe e d

c o n c e tra te ta il in g calculated parameteres: , , r, a…

– content of a component in feed %, – content of a component in concentrate, %, – content of a component in combined products, %, – content of a component in tailing, %

GRADE

– yield of a product , % – recovery of a considered component in a product, %r – recovery of other than considered components in another product, %

Grade Concentrate * Tail*Selectivity feed concentrate tailing yield recovery recovery

α l ν γ ε εr aNode # % % % % % % -

1 1.421 15.25 0.2185 8.00 85.85 93.122 101.2322 15.250 29.00 7.0000 37.50 71.31 68.584 122.5913 0.219 0.60 0.1500 15.22 41.80 84.836 133.133

*, and r calculated from α, ,

EQUATIONS

)/()(100

/)( (%)

(%)

)100/()100(100 r (%)

)100/( rrra (-)

a = 100 ideal separation , a ~ 1000 no separation

Flowsheet with balances of nodes (local balances)

1

2 3

product grade ,%

yield,% recov., %

C1 29.0037.50 71.31

feed

tailing Tconcentrate C1 concentrate C2 concentrate C3

F 1.421100.0 100.0

P2 0.218592.00 14.15

P1 15.258.00 85.85

C2 7.00062.50 28.69

C3 0.6015.22 41.80

T 0.15084.84 58.20

Upgrading curves for nodes using local balances

conclusion: separation is best in node 1 (a=101.30 and worse in nodes 2 and 3, a=~125)

Best flotation results upgrading curve

EQUATIONS

for instance for products C1+C2

2211)( CCCC

21 CC

Product l b g Sg e S e er Ser

0.00 100.00 0.00 100.00 100.00C1 29.00 29.00 3.00 3.00 61.22 61.22 97.84 97.84C2 7.00 15.25 5.00 8.00 24.63 85.86 95.28 93.12C3 0.60 5.93 14.00 22.00 5.91 91.77 85.88 79.01T 0.15 1.42 78.00 100.00 8.23 100.00 20.99 0.00F 1.42

weighted average

Global balance of flowsheet

1

G = 1 -2 ,c= 1 ,c2 ,c /1 0 0

α

lo c a l

ta ilin g

2

α

, ,

ta ilin g

c o n c e tra te

c o n c e tra te

G = 1 -2 ,T = 1 ,T2 ,T /1 0 0

G = 1 -2 ,c= 1 ,c 2 ,c /1 0 0 G = 1 -2 ,T = 1 ,T 2 ,T /1 0 0

2 ,c , 2 ,T , 2 ,c , 2 ,T

g lo b a l

Global balance of flowsheet

Options of industrial flowsheet

C f=C 1

O pt io n 1 r

C 1 2 9 .0 0 3 .0 0 3 .0 0 2 9 .0 0 6 1 .2 2 6 1 .2 2 9 7 .8 4C f 2 9 .0 0 3 .0 0 3 .0 0 2 9 .0 0 6 1 .2 2 6 1 .2 2 9 7 .8 4

C 2 7 .0 0 5 .0 0 8 .0 0 1 5 .2 5 2 4 .6 3 8 5 .8 6 9 3 .1 2C 3 0 .6 0 1 4 .0 0 2 2 .0 0 5 .9 3 5 .9 1 9 1 .7 7 7 9 .0 1T 0 .1 5 7 8 .0 0 1 0 0 .0 0 1 .4 2 8 .2 3 1 0 0 .0 0 0 .0 0T f 0 .5 7 9 7 .0 0 1 0 0 .0 0 0 .5 7 3 8 .7 8 1 0 0 .0 0 0 .0 0

F 1.42 100.00 100.00 1.42 100.00 100.00 0.00

Fina l c o nc e nt ra t e , C f

Fina l t a iling , T f

Fe e d, F

1

2 3

Feed

tailing T

final concentrate Cf

semiproduct P1 semiproduct P2

concentrate C2

concentrate C3

final tailing Tf

concentrate C1

4

=

1

2 3

Feed

tailing T



concentrate C2

concentrate C3

final tailing T f

concentrate C1

45

1

2 3

Feed



final tailing T f

C f=C 1+C 2

O pt io n 2 r

C 1 2 9 .0 0 3 .0 0 3 .0 0 2 9 .0 0 6 1 .2 2 6 1 .2 2 9 7 .8 4C 2 7 .0 0 5 .0 0 8 .0 0 1 5 .2 5 2 4 .6 3 8 5 .8 6 9 3 .1 2C f 1 5 .2 5 8 .0 0 8 .0 0 1 5 .2 5 8 5 .8 6 8 5 .8 6 9 3 .1 2

C 3 0 .6 0 1 4 .0 0 2 2 .0 0 5 .9 3 5 .9 1 9 1 .7 7 7 9 .0 1T 0 .1 5 7 8 .0 0 1 0 0 .0 0 1 .4 2 8 .2 3 1 0 0 .0 0 0 .0 0T f 0 .2 2 9 2 .0 0 1 0 0 .0 0 0 .2 2 1 4 .1 4 1 0 0 .0 0 0 .0 0

F 1.421 100.00 100.00 1.42 100.00 100.00 0.00



Fe e d, F

=

1

2 3

Feed

tailing T



concentrate C2

concentrate C3

final tailing Tf

concentrate C1

4

O pt io n 4 r

C 1 2 9 .0 0 3 .0 0 3 .0 0 2 9 .0 0 6 1 .2 2 6 1 .2 2 9 7 .8 4C 2 7 .0 0 5 .0 0 8 .0 0 1 5 .2 5 2 4 .6 3 8 5 .8 6 9 3 .1 2C 3 0 .6 0 1 4 .0 0 2 2 .0 0 5 .9 3 5 .9 1 9 1 .7 7 7 9 .0 1C f 5 .9 3 2 2 .0 0 2 2 .0 0 5 .9 3 9 1 .7 7 9 1 .7 7 7 9 .0 1

T 0 .1 5 7 8 .0 0 7 8 .0 0 1 .4 2 8 .2 3 8 .2 3 0 .0 0T f 0 .1 5 7 8 .0 0 1 0 0 .0 0 0 .1 5 8 .2 3 1 0 0 .0 0 0 .0 0

F 1.421 100.00 78.00 1.42 100.00 100.00 0.00



C f=C 1+C 2+C 3

Fe e d, F

1

2 3

Feed

tailing T



concentrate C2

concentrate C3

final tailing T f

concentrate C1

45

C f=C 1+C 3

O pt io n 3 r

C 1 2 9 .0 0 3 .0 0 3 .0 0 2 9 .0 0 6 1 .2 2 6 1 .2 2 9 7 .8 4C 3 0 .6 0 1 4 .0 0 1 7 .0 0 5 .6 1 5 .9 1 6 7 .1 4 8 3 .7 2C f 5 .6 1 1 7 .0 0 1 7 .0 0 5 .6 1 6 7 .1 4 6 7 .1 4 8 3 .7 2

C 2 7 .0 0 5 .0 0 2 2 .0 0 5 .9 3 2 4 .6 3 9 1 .7 7 7 9 .0 1T 0 .1 5 7 8 .0 0 1 0 0 .0 0 1 .4 2 8 .2 3 1 0 0 .0 0 0 .0 0T f 0 .5 6 8 3 .0 0 1 0 0 .0 0 0 .5 6 3 2 .8 6 1 0 0 .0 0 0 .0 0

F 1.421 100.00 100.00 1.42 100.00 100.00 0.00


Fe e d, F


1

2 3

Feed

tailing T



concentrate C2

concentrate C3

final tailing T f

concentrate C1

4

C f=C 2

O pt io n 8 r

C 2 7 .0 0 5 .0 0 5 .0 0 7 .0 0 2 4 .6 3 2 4 .6 3 9 5 .2 8C f 7 .0 0 5 .0 0 5 .0 0 7 .0 0 2 4 .6 3 2 4 .6 3 9 5 .2 8

C 1 2 9 .0 0 3 .0 0 8 .0 0 1 5 .2 5 6 1 .2 2 8 5 .8 6 9 3 .1 2C 3 0 .6 0 1 4 .0 0 2 2 .0 0 5 .9 3 5 .9 1 9 1 .7 7 7 9 .0 1T 0 .1 5 7 8 .0 0 1 0 0 .0 0 1 .4 2 8 .2 3 1 0 0 .0 0 0 .0 0T f 1 .1 3 9 5 .0 0 1 0 0 .0 0 1 .1 3 7 5 .3 7 1 0 0 .0 0 0 .0 0

F 1.421 100.00 100.00 1.42 100.00 100.00 0.00

Fe e d, F



0 10 20 30 40 50 60 70 80 90 1000

10

20

30

40

50

60

70

80

90

100

useful component recovery in concentrate, , %

oth

er t

han

use

ful

com

p.r

eco

very

in

tai

lin

g ,

er,

%

no upgrading

ideal upgrading

ide

al r

em

ixin

g

a=101.3

C1+C2+C3

C1+C3

C1C1+C2

C2

C2+C3

C1+C2+O

Selectivity of separation for different options of composition of final flotation products

=

1

3

F e e d

ta ilin g T

f in a l c o n c e n tra te C f



f in a l ta il in g T f

4


1

2

F e e d

fin a l c o n c e n tra te C f



f in a l ta il in g T f


4

Selection of optimum point of process

0 10 20 30 40 50 60 70 80 90 1000

10

20

30

40

50

60

70

80

90

100


oth

er t

han

use

ful

com

p.r

eco

very

in

tai

lin

g ,

er,

%

no upgrading

ideal upgrading

ide

al r

em

ixin

g

a=101.3

C1+C2+C3

C1+C3

C1C1+C2

C2

C2+C3

C1+C2+O

common sense optimum point of separation

example of point of optimum separation based on

economics

Final decision: Cf=C1+C2 + something depending on criterion of upgrading optimal point

Transformation of the Fuerstenau(recovery-recovery or -) upgrading curve into Halbich (grade-recovery or β- ) upgrading curve

0 10 20 30 40 50 60 70 80 90 1000

10

20

30

40

50

60

70

80

90

100


othe

r th

an u

sefu

l com

p.re

cove

ry in

ta

iling

, er

, %

ideal upgrading

idea

l rem

ixin

g

a=101.3

C1+C2+C3

C1+C3

C1C1+C2C2

C2+C3

C1+C2+O

)(

)100(

r

r

aa

a

a

100)100(100

)(1002

the Fuerstenau (- ) is alfa -insensitive equivalent of the Halbich ( β- ) upgrading curve

FLOWSHEET WITH A RECYCLE STREAM

23

5

fe e d 1

ta ilin g T





fin a l ta ilin g T f


1

4


fe e d 2

Flowsheet with balance of nodes (local balances) input parameters: α, ,

P ro duc t , %

Fe e d 1 , % , %

F1 1 .4 22 1 .9 5 3 9 .9 6

C 3 0 .6 07 8 .0 5 6 0 .0 4

F2 0 .7 81 0 0 .0 0 1 0 0 .0 0

P 1 2 5 .0 0 P 2 0 .5 70 .8 9 2 8 .4 0 9 9 .1 1 7 1 .6 0

P 1 2 5 .0 0C 2 3 .0 0 1 1 .7 7 1 1 .7 7

8 8 .2 3 8 8 .2 3

P 3 5 .5 9 P 2 0 .5 71 0 0 .0 0 1 0 0 .0 0 1 0 0 .0 0 1 0 0 .0 0

C 1 2 5 .0 0 C 2 3 .0 0 C 3 0 .6 0 T 0 .4 41 1 .7 6 5 2 .6 3 8 8 .2 4 4 7 .3 7 7 8 .4 8 8 3 .3 0 2 1 .5 2 1 6 .7 0

C o nc e nt ra t e 1 = P 1 T a iling

1

2

3

4 5

EQUATIONS

)/()(100

/)( (%)

(%)

)100/()100(100 r (%)

)100/( rrra (-)

a = 100 ideal separation , a ~ 1000 no separation

Recycle node (1)

Separating nodes

2

111 100 F

FFF

31112 )100(100 CFFFF

node

2 l g Sg e S e e r

0,00 0,00 100,0025,00 0,89 0,89 28,40 28,40 99,330,57 99,11 100,00 71,60 100,00 0,000,78

4 l g Sg e S e e r

0,00 0,00 100,0025,00 11,76 11,76 52,63 52,63 90,653,00 88,24 100,00 47,37 100,00 0,005,59

5 l g Sg e S e e r

0,00 0,00 100,000,60 78,48 78,48 83,30 83,30 21,550,44 21,52 100,00 16,70 100,00 0,000,57

Upgrading curves for nodes using local balances

node 5 is not efficient

2

5

fe e d 1

ta ilin g T





1

fe e d 2

2

5

fe e d 1

ta ilin g T





1

fe e d 2

F E E D 1F 1 1 .4 2

1 0 0 .0 0 1 0 0 .0 0C 3 0 .6 0

3 5 0 .0 0 1 4 7 .7 8F 2 0 .7 8

4 5 0 .0 0 2 4 7 .7 8

P 1 2 5 .0 0 P 2 0 .5 74 .0 0 7 0 .3 7 4 4 6 .0 0 1 7 7 .4 1

C 2 3 .0 03 0 .0 0 6 3 .3 4

P 3 5 .5 93 4 .0 0 1 3 3 .7 1

C 1 2 5 .0 0 C 2 3 .0 0 C 3 0 .6 0 T 0 .4 44 .0 0 7 0 .3 7 3 0 .0 0 6 3 .3 4 3 5 0 .0 0 1 4 7 .7 8 9 6 .0 0 2 9 .6 3

C o n c e n tr a te T a ilin g

1

2

3

4 5

Global balance of flowsheet (feed F2 is 100%)

Eqs for recycling nodes

known parameters: α, ,

132 FCF 132 FCF

1

2

β

n

Calculations

Feed 1: grades are known, G and G are equal to 100%

Node 1Grades are known, local and for F1 are known (=21.95%) (for C3 is 100- 21.95 =78.05%) or can be calculated from grades of products

Calculation of global for F2

Q) How large is for C3 when for F1 is 100%? A) When F1=100%, C3 =(100/21.95)x 78.05= 350%. Then F2= F1+ C3 = 100+350=450%

2111 )100(100

1

33 100

F

CGC

F 1

C 3

F 2

1

%1001 GF

31112 )100(100 CFFFF

Calculation of for recycling node (here F2):

F 1

C 3

F 2

1

1

33

100

F

CGC

1

22

100

F

FGF

%1001 GF

%10032 GC

GF

5

T

P 2

C 3

P 2

TC 3100

323

CPGC

Calculation for (normal) separation nodes

10032

3CPG

C

Graphical representation of separation data (not very useful, recoveries greater than 100%)

Grade –recovery curve for Pb, Cu and Zn circuits within the Eureka Concentrator (based on Ch. Greet, Spectrum Series, 2010)

Some flowsheets can be complex

100.000 0.010t /h % C u 0.851 1.180 0.011

L % bb % B I % B II % 100.000 100.0000.01786

281.466 0.011100.000 100.000 2.928 0.610

0.129 0.022 3.779 0.740 0.028 0.028 1.595 2.9280.851 2.928 0.851 2.928 0.006 1.595 1.595 0.010 177.8650.005 0.002 0.007 62.712 100.000 177.865 62.712 215.770 0.8240.006 0.092 9.840 0.335 2.550 3.352 0.310 1.595

0.010 2.435 0.021 0.071 8.865 0.075 0.260 88.701 0.755 2.597 178.0040.0091 100.0783 20.3013 69.8499 0.0085 19.1569 65.9125 0.0104 23.3027 80.1767

0.551 6.680 0.0020 0.0070 0.0019 0.0066 0.0138 0.0023 0.0081 0.0280 23.3030.075 0.260 0.216 0.011 0.003 32.372 57.579 0.113 0.002 0.004 0.004 0.004 0.003 37.158 66.092 37.158 100.078 1 7 8 .0 0 4

366.536 50.184 172.665 143.687 0.075 0.260 30.548 54.333 2.994 0.20045.655 81.281 143.687 62.920 111.912 0.358 1.230 89.320 0.674 2.320

19.636 0.005 158.795 0.643 7.130 0.643 62.842 0.920 10.680 0.081 0.277 21.413 13.428 46.2030.096 0.331 0.216 0.476 15.745 9.874 33.974 38.086

0.007 50.017 68.274 234.909 153.367 0.609 6.050 28.006 2.177 0.23070.319 0.007 62.842 111.912 281.655 94.788 0.091 0.314 0.205 72.727 0.490 1.687 1.595

1.836 54.913 188.937 11.231 38.642 178.42750.543 90.011 226.535 17.909 31.854 100.000

91.577 68.274 2.608 13.428 2.177242.515 1.067 0.967 4.260 118.017 49.873 100.000

1.836 68.274 0.172 0.591 0.205 0.967 49.763 100.00066.289 72.865 250.703 86.857 2.928

201.923 0.246 13.090 0.751 1.720 178.585100.000 22.339 0.038 0.132 0.046 77.661 0.751 0.751

50.017 172.093 59.622 0.216 0.133 0.459 0.159 0.751282.018 45.503 81.011 155.503 22.847 78.610 27.235 128.554

0.910 0.471 0.910 20.785 37.005 71.032 70.76312.298 21.901 55.120 89.320 72.865

90.639 0.034 26.770 2.598 0.817 0.120 3.504 6.232 0.002735.212 0.005 0.017 0.011 27.273 0.184 0.633 9.736

0.034 82.091 0.817 9.75889.347 13.361 45.972 30.014 0.850 10.653 9.758 2.197 7.560

9.758

H y d ro c y k lo n

F lo ta c ja G łó w n a c

F lo t. C zy szc zą c a I

F lo ta c ja G łó w n a a b

F lo t. C zy szc zą c a I I

1

2

3

4 a

5

6

7

8

B a la s t I

B a la s t I I4 b

3 a

5 a

1 a

1

2

3

4

5

67

8

9

The Eureka Mine – An Example of How to Identify and Solve Problems in a Flotation PlantChristopher Greet

Publications : Spectrum Series

Flotation Plant Optimisation: A Metallurgical Guide to Identifying and Solving Problems in Flotation Plants

Spectrum Series 16

Published in 2010

The Eureka Mine – An Example of How to Identify and Solve Problems in a Flotation PlantChristopher Greet

Useful literature

http://www.ausimm.com.au/productcatalog/productlisting.aspx?ID=13

http://www.ausimm.com.au/productcatalog/productlisting.aspx?ID=16

Homework

Create your own flowsheet and calculate local and global balanses as well as plot graphs which will help you to evaluate the plant performance

FLOWSHEETS Zinc Plant Flowsheet (SOMINCOR) .

Documents

Transcript of FLOWSHEETS Zinc Plant Flowsheet (SOMINCOR) .