Mineral process design and modelling is the second of two core technical modules for the Professional PG Dip / MSc Minerals Processing. The module would cover the selection, design and operation of unit operations and circuits in mineral processing and extractive metallurgy. It will include preliminary testing, data analysis and simulation of processing circuits up to the creation of process flow diagrams. It will not cover further stages of design such as process and instrument drawings/design (e.g. CAD drawing, valve and pipe sizing) or construction of processing plants.

The module will include laboratory and pilot scales tests typically used to characterise material behaviour in a process as well as the models and software used to predict performance. Areas discussed will include comminution, flotation, physical separation, materials handling, dewatering, waste management and aspects of hydrometallurgy, pyrometallurgy and electrometallurgy. The latest innovations and current practices will be discussed alongside the Importance of variability in mineralogy across a deposit on the success of processing.

The health and safety implications related to industrial practices will be discussed. This will include discussion of the dangers of working with different mineral types, controlling and handling of chemicals, safety aspects of industrial processes and safe lab practices.

Prerequiste modules: CSMM177, CSMM178, CSMM179, CSMM180

The module aims to advance your understanding of the basic minerals processing principles taught in the Year One ‘Mining Life-Cycle’, and the detailed understanding of the fundamental principles of extraction in the year 2 ‘Principles of minerals process engineering’ module, by providing you with the technical skills required for a career in minerals process engineering.

Practical, hands-on activities using case studies, industry standard software and data from process plants will improve your key skills in selecting equipment, designing circuits and modelling and optimising processes using software. The module will cover comminution, flotation, physical separation, materials handling, dewatering, waste management and aspects of hydrometallurgy, pyrometallurgy and electrometallurgy. Modelling will focus on comminution circuits which represent a significant portion of capital and operating costs in mining operations.

On successful completion of this module you should be able to:

Module Specific Skills and Knowledge

Discipline Specific Skills and Knowledge

Personal and Key Transferable / Employment Skills and Knowledge

Unit 1 Comminution, flotation and physical separation topics

1. Introduction to the link between mineralogy of an ore and the selection of a mineral processing circuit.

2. Typical comminution circuits and innovative approaches for different minerals and commodities will be discussed. Standard laboratory and pilot scale testing for prediction of plant behaviour will also be covered alongside testing of grinding media, and methods of comminution circuit process control.

3. The selection of screening surfaces and determination of correct equipment size for fixed and vibrating screens will be covered alongside discussion of typical and innovative classification equipment and the methods to select and size these for processing plants.

4.The design, selection and sizing of mechanical and pneumatic flotation cells as well as flotation circuits will be covered. Methods of modelling flotation behaviour in plants and control strategies for flotation circuits will be included as well as current research and innovations in flotation plant design.

5. The selection of physical separation equipment using standard laboratory tests and models will be covered.

Unit 2 Extractive metallurgy topics

1. An overview of hydrometallurgy, biohydrometallurgy, pyrometallurgy and electrometallurgy in the context of the extractive minerals industry. The basic methods for the selection, design and operation of metallurgical operations for a variety of minerals of economic interest will be covered.

2. The effects of mineralogy and upstream mineral processing options on extractive metallurgy will be discussed, as well as typical preparatory techniques such as agglomeration, pelletising and briquetting.

Unit 3 Materials handling, dewatering and waste management topics

1. Introduction to the techniques used to store and move material when dry and wet.

2. The use of dewatering (solid-liquid separation) equipment in the extractive minerals industry will be covered. This will include discussion of the selection, design and operation of thickeners, filters and dryers and the latest developments in dewatering technology.

3. Overview of the various methods used to dispose of material streams designated as having no economic value. This will include the use of tailings ponds and backfill including paste backfill as well as re-processing options.

Unit 4 Geometallurgy topics

1. Overview of the role of geometallurgy in the mineral extraction industry. Including the general principles and techniques associated with geometallurgy and the links to process mineralogy.

2. Introduction to geostatistical techniques used to model the spatial distribution of key processing properties in a geometallurgical framework.

3. Discussion of the latest innovations and trends in geometallurgy, including critical interaction with relevant research manuscripts and conference proceedings.

Unit 5 Process modelling and optimisation topics

1. An overview of circuit modelling and reconciliationapproaches will be given. Different software used for modelling will be compared alongside expected future trends in this field.

2. Introduction to the JKSimMet software package with JKSimMet supported exercises including optimization of a grinding and classification circuit.

3. Process control: introduction to the basics of process control and how this can be adopted to improve stability in a processing plant.

Unit 6 Sampling practice and data analysis topics

1. Practical sampling techniques for field, drill core, stockpile and conveyor belt sampling will be included.

2. Methods of analysing laboratory test and plant data will be discussed.

All referral marks are capped at 50%.

Basic reading:

ELE: http://vle.exeter.ac.uk/

Web based and Electronic Resources:

www.knovel.com

https://app.knovel.com/web/toc.v/cid:kpMSMPSE02/viewerType:toc/root_slug:modeling-and-simulation-of-mineral-processing-systems-2nd-edition/url_slug:simulation-continuous

https://app.knovel.com/hotlink/pdf/id:kt008LYW71/mineral-processing-plant/guiding-process-introduction

Other Resources:

Reading list for this module: