Mineral Processing Foundations of theory and practice of minerallurgy 1st English edition JAN DRZYMALA, C. Eng., Ph.D., D.Sc. Member of the Polish Mineral Processing Society Wroclaw University of Technology 2007 Translation: J. Drzymala, A. Swatek Reviewer: A. Luszczkiewicz Published as supplied by the author ©Copyright by Jan Drzymala, Wroclaw 2007 Computer typesetting: Danuta Szyszka Cover design: Danuta Szyszka Cover photo: Sebastian Bożek Oficyna Wydawnicza Politechniki Wrocławskiej Wybrzeze Wyspianskiego 27 50-370 Wroclaw Any part of this publication can be used in any form by any means provided that the usage is acknowledged by the citation: Drzymala, J., Mineral Processing, Foundations of theory and practice of minerallurgy, Oficyna Wydawnicza PWr., 2007, www.ig.pwr.wroc.pl/minproc ISBN 978-83-7493-362-9 Contents Introduction ....................................................................................................................9 Part I Introduction to mineral processing .....................................................................13 1. From the Big Bang to mineral processing................................................................14 1.1. The formation of matter ...................................................................................14 1.2. Elementary particles.........................................................................................16 1.3. Molecules .........................................................................................................18 1.4. Solids................................................................................................................19 1.5. Minerals............................................................................................................22 1.6. Deposits, mining and mineral processing.........................................................27 Literature .................................................................................................................29 Part II Characterization of mineralurgical processes....................................................31 2. Delineation, analysis, and evaluation of separation..................................................32 2.1. Principles of separation ....................................................................................32 2.2. Analysis and assessment of separation process................................................42 2.2.1. Division of feed into products (SP)..........................................................42 2.2.2. Upgrading (UP)........................................................................................44 2.2.2.1. Quantitative and qualitative analysis of upgrading .........................44 2.2.2.2. Upgrading curves.............................................................................49 2.2.2.2.1. The Henry curve .......................................................................51 2.2.2.2.2. The Mayer curve.......................................................................54 2.2.2.2.3. The Dell curve...........................................................................58 2.2.2.2.4. The Halbich curve.....................................................................59 2.2.2.2.5. Equal basis upgrading curves....................................................61 2.2.2.2.5.1. The Fuerstenau curve .........................................................61 2.2.2.2.5.2. The Mayer-Drzymala-Tyson-Wheelock curve...................65 2.2.2.2.5.3. Other upgrading curves ......................................................70 2.2.2.3. Upgradeability .................................................................................71 2.2.2.4. Upgrading indices and evaluation of separation treated as upgrading .....................................................................................................74 2.2.2.5. Summary..........................................................................................77 2.2.3. Classification (CF) ...................................................................................78 2.2.3.1. Analysis of separation process as classification..............................78 2.2.3.2. Classification curves........................................................................82 2.2.3.2.1. Frequency curves ......................................................................82 2.2.3.2.2. Distribution curve .....................................................................85 2.2.3.2.3. Partition curve...........................................................................89 4 2.2.3.2.4. Modified classification curves ..................................................91 2.2.3.2.5. Other classification curves........................................................93 2.2.3.3. The assessment of separation considered from classification point of view.........................................................................................94 2.2.3.4. Classificability and ideal classification ...........................................96 2.2.3.4.1. The particle size analysis ..........................................................97 2.2.3.4.2. Densimetric analysis ...............................................................101 2.2.3.5. Summary........................................................................................101 2.2.4. Other approaches to separation ..............................................................102 2.3. Delineation of separation................................................................................102 2.3.1. Role of material and separator................................................................102 2.3.2. Ordering .................................................................................................104 2.3.2.1. Mechanics of ordering...................................................................105 2.3.2.2. Thermodynamics of ordering ........................................................108 2.3.2.3. Probability of ordering...................................................................110 2.3.3. Stratification...........................................................................................110 2.3.4. Splitting..................................................................................................111 2.3.5. Total physical delineation of separation.................................................114 2.3.6. Time aspects of separation .....................................................................115 2.3.7. Summary ................................................................................................116 Literature ...............................................................................................................117 Part III Separation processes ......................................................................................121 3. Comminution..........................................................................................................122 3.1. Principles of size reduction ............................................................................122 3.2. Physicomechanical description of particle disintegration ..............................127 3.3. Empirical evaluation of size reduction...........................................................130 3.4. Other descriptions of grinding........................................................................135 3.5. Kinetics of grinding........................................................................................136 3.6. Analysis of grinding process ..........................................................................136 3.6.1. Grinding as classification process ..........................................................139 3.6.2. Grinding as upgrading process...............................................................141 3.7. Devices used for grinding...............................................................................144 Literature ...............................................................................................................147 4. Screening ................................................................................................................149 4.1. Principles........................................................................................................149 4.2. Particle size and shape....................................................................................150 4.3. Description of screening process....................................................................153 4.3.1. Mechanics of screening..........................................................................153 4.3.2. Probability of screening .........................................................................157 4.4. Kinetics of screening......................................................................................160 4.5. Other parameters of screening........................................................................166 4.6. Analysis and evaluation of screening.............................................................166 5 Literature ...............................................................................................................166 5. Hydraulic and air separation...................................................................................167 5.1. Principles........................................................................................................167 5.2. Classification by sedimentation......................................................................172