Mineral Beneficiation: Pamphlet 84 APRIL, 1949
Mineral Beneficiation: Pamphlet 84 APRIL, 1949
Mineral Beneficiation: Pamphlet 84 APRIL, 1949
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PAMPHLET NO. 84 r cc -:..;.,. lgr?..d--& APRIL, 1949
Mineral Beneficiation
Gravity Concentration
A Fundamental Study
April, 1949
SCHOOL
OF MINES, UNIVERSITY OF IDAHO
in cooperation zoith
IDAHO
BUREAUO F MINESAND GEOLOGY
INTRODUCTION
The increasing demand for metals and mineral products, coupled
with the critical depletion of known deposits of high grade ore,
has led to the development and mining of low grade ore deposits.
Before these low grade ores can be of value in a manufacturing or
refining process i t is necessary that their mineral or metal content
be increased by some method of beneficiation. This need for the
concentration of low grade ores has led to the development of new
processes such as flotation and heavy-media separation and to the
improvement of other processes such as magnetic separation.
Gravity processes of mineral beneficiation are the earliest on
record. They include panning, sluicing, blanket-covered strakes,
vanners, bumping tables, and jigs. All such processes primarily
take advantage of a difference in the specific gravity of the min-
erals to be separated. Other factors, less significant than specific
gravity yet having a strong bearing on the efficiency of the
gravity process, are shape and size of the particles to be separated.
One of the practical shortcomings of all gravity processes is in
the matter of capacity-capacity falling off rapidly ( a ) as the
specific gravities of the minerals to be separated approach a com-
mon value, and (b) as the particle size comprising the feed de-
creases. Obviously all gravity processes fail completely when the
specific gravity spread vanishes. Also, gravity processes fail or
become impotent when the particles are so small that viscosity
tends to overcome the force of gravity.
PURPOSE
The study herewith reported was an investigation of the cap-
acity factor in gravity concentration processes-in particular
those processes in which mineral beneficiation is effected in
washed, flowing pulp films on inclined surfaces.
ORES
The ores used for this study were an artificial ore composed of
magnetite and magnesite, and a naturally occurring ore contain-
ing cobalt and copper.
The artificial ore was chosen for the following reasons:
1. The mineral constituents could be separated readily by gravity
concentration.
(3)
4 SCHOOL OF MINES, UNIVERSITY OF IDAHO
INVESTIGATIONS
TEST PROCEDURE
PREPARATION OF THE ORE
The artificial ore was prepared by separately crushing the I
magnetite and magnesite through a 10-mesh screen. The minus
10-mesh crusher products were again screened separately with
screens whose apertures had been calculated from the equal settling
!
ratios of the two minerals. For example, the maximum magnesite
particle passing through a 28-mesh screen is equal settling with I
the maximum magnetite particle passing through a 48-mesh screen
(5) .* Tyler sieves were used.
The oversize from the second screening operation was stage
ground in a 2000-gram laboratory ball mill. The ball mill was oper- I
I
ated in closed circuit with the same screen that was used in the
second screening operation ( 1 ) . The undersize products from both
* Referencesare at the end of the paper.
MINERAL BENEFICIATION BY GRAVITY CONCENTRATION 5
the second screening operation ancl the ball mill circuit were then
combined in the proper proportions to produce a mixture of 10
per cent magnetite and 90 per cent magnesite. The mixture was
classified in a four-inch by four-foot hydraulic classifier of local
design. The spigot products from the hydraulic classifier con-
stituted the feed used in subsequent gravity concentration tests.
Normally, two spigot products were made with each lot of ground
ore and designated a s spigot product No. 1. and spigot product No.
2. The maximum sized particle in each spigot product was con-
trolled by varying the velocity of the water in the classifier. Table
2 is a typical screen analysis of the spigot products produced in the
classification of the artificial ore.
Table 2
Screen analysis of magnetite-magnesite spigot prodilcts
Figure 1
Photograph of Rotary Pan Concentrator
8 SCHOOL OF MINES, UNIVERSITY OF IDAHO
surface of the desired slope was obtained. Then the concrete sur-
face was covered with damp burlap sacks and allowed to set for
twenty-four hours. Next, a coating of waterproof cement was ap-
plied to the concrete base with a trowel. The waterproof cement
surface was finished with either a trowel or a damp brush, de-
pending on the type of surface desired. After finishing, the surface
was covered with damp sacks and allowed to set until hard. Figure
2 illustrates the construction and gives the details of the pans used.
t+ I I in. -1
Figure Z
Pan Construction
DISCUSSION OF RESULTS
Since the rotary pan concentrator presented a new approach
to the study of gravity concentration, the first phase of the prob-
lem was a determination of the factors affecting the operation of
the machine. The factors thus studied were type of surface, speed
of rotation, rate of feed, pulp density of feed, particle size of feed,
and slope of surface. Preliminary studies of all the factors except
surface slope were made with the artificial magnetite-magnesite
ore on a n arbitrarily chosen slope of two inches per foot. The
cobalt-copper ore was used in the study of surface slope a s a factor
of operation.
The second phase of the problem was a comparison of the cap-
acity and efficiency of the rotary pan concentrator with a com-
mercially proved gravity concentrating machine. The standard
Wilfley laboratory table was chosen for this comparison.
TYPES OF SURFACES
Three types of surfaces; smooth, rough, and riffled, were in-
vestigated. As defined here, a smooth surface has a roughness
approximately equivalent to that of unvarnished linoleum, and the
rough surface has a roughness approximately equivalent to t h a t
of heavy canvas. The riffled surface consisted of a smooth surface
on which were superimposed two concentric riffles one thirty-
second of a n inch in height. The riffles were located a t distances
of six inches and nine inches from the discharge hole.
Table 4 compares the results obtained on a smooth surface with
the results obtained on a rough surface. The feed rate for both
tests was 400 grams per minute. From Table 4 it is seen that the
rough surface increases the recovery of magnetite 13.3 per cent
with a reduction of 2.4 per cent in the gracle of concentrate.
Only a few tests were made with a riffled surface, a s i t was
immediately apparent that riffles dicl not improve the efficiency
of the rotary pan concentrator. A large portion of the gangue
minerals was retained on the surface of the concentrator by the
riffles, and a s the surface rotated these minerals were washed into
10 SCHOOL OF MINES, UNIVERSITY O F IDAHO
Table 4
Comparison of recoveries on a smooth surface with recoveries
obtained on a rough surface
Concentrate
Surface % y,
Rec.
Smooth 42.5
Rough 55.8
SPEED OF ROTATION
The effect of varying the speeci of rotation on recovery ancl grade
of concentrate was studied with minus 28-mesh feed, minus 48-
mesh feed, and minus 100-mesh feed. Table 5 is a summary .of the
results obtained a t various speeds of rotation. The feed rate in
all tests was 450 grams per minule. I t is seen that the per cent
recovery of magnetite varies directly with the speecl of rotation.
A t speeds above five revolutions per minute the incerase in re-
covery is overshadowed by the decrease in the grade of concentrate.
The optimum speed of rotation seems to be from four and one half
to five revolutions per minute.
Table 5
Recovers of magnetite in concentrate a t various speeds of rotation
RATE OF FEED
Table G shows the effect of increasing the feed rate on the
recovery and the grade of products produced by the rotary pan
concentrator. The tests were conducted on minus forty-eight mesh
feed, and the speed of rotation was constant a t five revolutions per
minute. As the feed rate increases, the total recovery, which in-
cludes recovery in the concentrate plus recovery in the middling,
MINERAL BENEFICIATION BY GRAVITY CONCENTRATION 11
Conc. Middling
Feed
Rate % %, ?C 70 Total
gms/min. FesOi Rec. Fe:,Ol Rec. Rec.
Concentrate Middling
Feed % % % % T
Size Fe.,O, Recovery Fe:,O, Recovery Rec
PesoI Fe30,
-28 mesh 63.6 55.8 11.2 42.3 98.1
-48 mesh 88.7 69.3 10.6 28.8 98.1
-100 mesh 61.5 78.4 5.4 15.1 93.5
1st Spigot 6.00 48.3 2.72 36.6 84.9 5.40 52.7 1.96 15.6 68.3 8.96 26.4 3.75 43.0 69.4
2nd Spigot 5.49 51.0 1.66 31.9 82.9 3.51 60.1 0:59 10.1 70.2 7.38 20.9 3.52 30.5 51.4
14 SCHOOL O F MINES, UNIVERSITY O F IDAHO
COMCENTRATOR
Conc. *
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T o woste
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Cleaning Circuit
Figure 3
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Final
Conc.
MINERAL BENEFICIATION BY GRAVITY CONCENTRATION 15
Table 10
Distribution of cobalt in screen fractions of test products
T.able 11
Summary of cycle test on cobalt-copper ore
70 % %
Pr~duct Wt. co. Rec.
Co.
Total Cleaner Conc. 10.0 7.22 49.6
4th Cycle Cleaner Midd. 5.9 5.13 20.7
Total Cleaner Tails 8.4 1.24 7.1
Total Rougher Tails 75.7 0.44 22.6
Total 100.0 1.46 100.0
SUMMARY
This study represents only lsreliminary work on the nossibility
of using the rotary pan concentrator as a machine for utilizing the
~ r i n c i p l e sof flowing-film gravity concentration. The tests out-
lined here are encouraging. With the laboratorr size machine the
metallurgical results have been superior to those obtained with the
laboratory Wilfley table. The high capacity of the machine has
been surprising, although i t has been shown that this will dron off
rapidly as the size of the feed becomes finer-a characteristic of
all gravity concentrating machines.
The diameter of the concentrator is a variable which has not
been studied. On the small machine tested, the time of residence
of the pulp on the concentrating surface is relatively short. It is
apparent that as the diameter is increased, the time of residence
of the pulp on the machine will be increased and the capacity per
unit of area will be lowered. If the necessary separation can be
made in a trils down a short incline, no advantage is gained in wash-
ing beyond the distance required to make this separation.
More study would be required to analyze the fundamental dif-
ferences between the rotary pan concentrator and the round tables
that are now largely obsolete. I n the rotary pan the thickness and
velocity of the flowing film both increase toward the discharge
at the apex. This is the reverse of the round table discharging on
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16 S C H O O L OF M I N E S , U N I V E R S I T Y OF I D A H O
the periphery. Also the centrifugal force with the rotary pan tends
to holcl the particles against the concave deck. On a round table
having a convex surface the opposite is true. I t is believed that
these fundamental differences are sufficient to warrant further
investigation.
ACKNOWLEDGMENTS
The writer wishes to thank Mr. A. W. Fahrenwald, Dean of the
School of Mines, University of Idaho, for suggesting this problem
and giving generously of his time in the discussion of the research
procedure. The advice and criticisms of Mr. Joseph Newton, Pro-
fessor of Metallurgy, have been of immeasurable assistance. The
writer is also indebted to Mr. Lewis S. Prater, Metallurgist, Idaho
Bureau of Mines and Geology, for his assistance in the laboratory
and to Mr. C. R. Kurtak, Chemist, Idaho Bureau of Mines and
Geology for his many ore analyses.
BIBLIOGRAPHY
1. B o n d , Fred C . , and M a x o n , W a l t e r L., " S t a n d a r d G r i n d a b i l i t y T e s t s and Cal-
culations." T r a n s a c t i o n s A m e r i c a n I n s t i t u t e of M i n i n g a n d Metalltirgical
Engineers. 153: 362-372. 1943.
2. F i n k e y , J o s e f , " S c i e n t i f i c F u n d a m e n t a l s o f G r a v i t y Concentration," t r a n s -
lated b y C . 0 . A n d e r s o n and M . H . G r i f f i t t s . U n i v e r s i t y of Missouri
S c h o o l of M i n e s a n d M e t a l l t ~ r g yB u l l e t i n N o . 1, T e c h n i c a l S e r i e s No. 11.
1930.
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G r a w - H i l l B o o k C o m p a n y , Inc. 1939. 554 pp.
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Flotation Cells." Engineering a n d M i n i n g J o u r n a l 146: 82-84. M a r c h 1945. >
5. T a g g a r t , A r t h u r F., H a n d b o o k o f Mineral Dressing. 1st edition. N e w Yorlc:
J o h n W i l e y and S o n s , Inc., 1945. 1926 pp.
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M e t h o d s of O r e A n a l y s i s . 11th edition. N e w Y o r k : J o h n W i l e y a n d S o n s ,
Inc., 1939. 325 pp.
IDAHONIAN, MOSCOW