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Mineral processing unit operation and examples

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UNIT OPERATIONS In mineralprocessing plant , Numerous steps, called unit operations, are involved in achieving the goal of extracting minerals and metals from ores in their purest possible form. These steps include Size reduction . The process of crushing and grinding ores is known as comminution. The purpose of the comminution process is threefold: (1) to liberate valuable minerals from the ore matrix, (2) to increase surface area for high reactivity, and (3) to facilitate the transport of ore particles between unit operations. Size separation. Crushed and ground products generally require classification by particle size. Sizing can be accomplished by using classifiers, screens, or water elutriators. Screens are used for coarse particulate sizing; cyclones are used with fine particulates. Concentration . Physicochemical properties of minerals and other solids are used in concentration operations. Froth flotation, gravity concentration, and magnetic and electrostatic co...
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METALLURGICAL EFFICIENCY

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One of the most important and basic concepts in beneficiation plant is metallurgical efficiency. Two  terms are commonly used to describe the efficiency of metallurgical processes: recovery and grade . These phenomena are illustrated in the generalized process presented in Figure 1. In above example, 100 tph of ore are being fed into a concentration operation that produces 4.5 tph of concentrate and 95.5 tph of tailings. In upgrading this process, then, 1.0 tph of the desired material, A, is introduced into the unit operation and 0.9 tph (4.5 × 0.2) of this material reports to the concentrate, resulting in 90% recovery (0.9/1.0 × 100). The grade of the mineral, A, has been improved from 1% to 20%. The term percent recovery refers to the percentage of the valuable material reporting to the concentrate with reference to the amount of this material in the feed. Note that obtaining the highest possible recovery is not necessarily the best approach in a concentration process. High...
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