flowsheets zinc plant flowsheet (somincor)
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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
final concentrate Cf
semiproduct P1 semiproduct P2
concentrate C2
concentrate C3
final tailing T f
concentrate C1
45
1
2 3
Feed
final concentrate Cf
semiproduct P1 semiproduct P2
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
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
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
Fina l c o nc e nt ra t e , C f
Fina l t a iling , T f
C f=C 1+C 2+C 3
Fe e d, F
1
2 3
Feed
tailing T
final concentrate Cf
semiproduct P1 semiproduct P2
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
Fina l t a iling , T f
Fe e d, F
Fina l c o nc e nt ra t e , C f
1
2 3
Feed
tailing T
final concentrate Cf
semiproduct P1 semiproduct P2
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
Fina l t a iling , T f
Fina l c o nc e nt ra t e , C 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
s e m ip ro d u c t P 2
c o n c e n tra te C 3
f in a l ta il in g T f
4
s e m ip ro d u c t P 1
1
2
F e e d
fin a l c o n c e n tra te C f
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
f in a l ta il in g T f
c o n c e n tra te C 1
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
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
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
useful component recovery in concentrate, , %
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
f in a l c o n c e n tra te C f
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
fin a l ta ilin g T f
c o n c e n tra te C 1
1
4
s e m ip ro d u c t P 3
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
f in a l c o n c e n tra te C f
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 3
fin a l ta ilin g T f
1
fe e d 2
2
5
fe e d 1
ta ilin g T
f in a l c o n c e n tra te C f
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 3
fin a l ta ilin g T f
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
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
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