The modular concentrating plant

I.Brief description of a plant
The plant consists of dismountable frames on which the following equipment is set: receiving bin with a feeder, an AG mill DxL=4,0×1,5, a planetary mill, jigs, a screen, centrifugal concentrators (hydro-cyclones), dewatering and water recycling systems, final recovery section (planetary mill, vibrosieve, drying kiln), pumps with slurry pipelines, central control panel etc

II. Basic performance values of the plant

    • Ore throughput rate, t/hr — 10,0
    • Maximum size of feed, mm — 350
    • Gold recovery from +40 mcm size fraction, % — min 90
    • Gold content in final concentrate, % — min 30
    • Installed power, kW — 300-350
    • Electric power requirement per 1 t, kW-hr/t — 28,0-32,0
    • Raw water requirement per 1 t, m3/t — 2,3-2,8
    • Building dimensions LxBxH, m — 12х12х10

Approximate weigh of main units, t

  1. crushing-grinding section — 29,0
  2. regrinding section — 12,0
  3. primary concentration section — 4,2
  4. final recovery section — 2,1
  5. tailings dewatering — 9,5
  6. bearing frames — 12,0
  7. dismountable columns — 8,0
  8. dismountable ceilings — 9,0
  9. pump section — 1,9
  10. unit for feeding ore into mills — 1,9
III. General consumable material and items
Item name
Unit measure
Consumption
1
Mill lining
kg/tonne
0,25-0,3
2
Mill lining
2/year
24
3
Rubber pipelines
m/year
200
4
Pump body and impeller (5 pumps)
un./year
5х5
5
Apexes
un./year
60

IV. Production time and time of shipment of equipment and materials

6-7 months

V. Period of installation, start-up and putting into operation

1- 2 months

VI. The plant is provided with

spare parts for the warranty period (6 months)

VII. The plant is served by

a group of 5 workers per shift

VIII. The process flow-sheet description

1. Bin; 2. Apron feeder 3. Charging car; 4. AG mill of cantilever design; 5, 11, 15, 21. sumps with slurry pumps; 6. Screen. 7. Akins classifiers; 8, 10. Jigs; 12, 13,16, 17, 22, 23. Hydro-cyclones; 14. Planetary mill; 18. Apron thickener; 19. Peristaltic pump; 20. Centrifuge; 24, 25. Concentrators; 26. Water pump.

The ore is fed to a 15 m3 receiving bin (1) by means of a truck ore or auto-loaders. The volume of the bin is chosen on the basis of the volume of the body dump-truck (12 m3) and ore accumulation for 2,0-2,5 work hours of a plant.
      The bin is equipped with 350 mm openings. The grid is designed not to pass oversize large ore lumps of more than 350-400 mm into a main AG or SAG mill. If lumpy ore does not pass through a grid it is crushed by hand by means of a wedge and a sledge hammer.
Ore passing through the screen is fed by an oscillating feeder (2) to receiving bin (3) which is installed on rollers in order to remove it for inspection of the receiving mouth.

Ore concentration

      Primary crushing and grinding take place in the AG mill of cantilever design MMSK (4). Its internal dimensions and the rotation speed of the mill are chosen to ensure throughput rate of about 7,0-7,5 t/hr.
Ground ore with a maximum particle size of 12-15 mm discharged and fed by gravity into the sump and pumped to a sieving surface of the screen (6). Screen is equipped with rubber sieves with an opening size of 5 mm (upper sieve) and 1 mm (bottom sieve). The rubber sieves guarantee use of the screen without any repair work for 12-18 months.
      The product of screening of +5 mm runs by gravity to the MMSK (4) for further recrushing, the product of -5+1 mm is fed to the planetary ball grinding mill (14) for regrinding it up to 70 (40) microns, the product -1 mm flows to the Akins classifier (7) to prepare it for further concentration in a jig (8). The quantitative relationship of the mentioned products, fed into the MMSK and the planetary mill, and their size will be varied during a startup process to attain the maximum number (99,9%) of the product -70 microns. At this size of grinding it is possible to recover gold up to 20 microns in full.

Concentration of course, medium-size and small gold grains

      The thickened product of the Akins classifier (7) is fed by gravity to a jig (8), which is equipped with rubber sieves. Due to rubber sieves their service life increases by 10-12 times in comparison with metallic ones. The tailings from the jig is charged to a scavenger jig (10) through a dewatering unit (9). Concentrate from the jigging machine (8) is sent to a concentrator (25), concentrate from the scavenger jig (10) comes back to the screen (6).

Concentration of fine and ultra-fine gold grains

      Fine gold grains of the classification process and tailings of jigging are fed into the section of short-cone hydro-cyclones (12, 13). Slurry of the first hydro-cyclone (12) is conducted to the planetary mill (14) for further fine-grained gold recovery, slurry of the second one (13) comes back to the first one. The product after the hydro-cyclone (12) is sent to the hydro-cyclone (13). After this process the product becomes dump and goes to the section of thickeners (18). The reground product (after the planetary mill) is conducted to another group of short-cone hydro-cyclones (16, 17), working out the same operations as the hydro-cyclones (12, 13) do.
Slurry of the hydro-cyclone (16) runs to be separated in the hydro-cyclones (22, 23). The product after this group (23) flows to the second separation in the group of hydro-cyclones (16, 17), but slurry is to the concentrator (24) for gold recovery. The tailings of the concentrators (24, 25) are in the cycle: grinding-separation.

Circulating water formation

      The apron thickeners (18) are used to thick the tailings, entered a tailing dam, and to receive clarified water for the technological process. At the present time they are the most effective equipment for this purpose.
There are 7 package-type thickeners with the total sedimentation area of 4,5 m2. Such a quantity of thickeners allows to receive enough clarifier technological water and thickened product with water content more than 20-30%. In this case it is possible to support water balance at a plant pumping only 2,3-2,8 m3/hr instead of 30-40 м3/час without using of thickeners. Ii is also possible reduce water feed up to 0,3-0,5 m3/hr using a centrifuge (20).

1. Sump with a slurry pump; 2. Hydro-cyclone; 3. Akins classifier; 4. Gate valve; 5. Planetary mill; 6, 8. Vibrosieves; 9. Drying kiln.

Concentrates produced on concentration tables (24, 25) are fed to final upgrading. After dewatering (2, 3) they are sent to a planetary mill (5) for selective grinding. Overflow from the mill is discharged onto a vibrosieve (6), where some fractions are formed. Whereas product -70+40 microns fraction is the poorest (gold content attains only 1% after the first selective grinding), then it is sent to additional grinding into a laboratory planetary mill (7). Overflow of this mill is discharged onto a small vibrosieve (8). After the second grinding product -70+40 microns fraction contains more than 15% of gold. All the ground and washed fractions are fed into a drying kiln of periodic action (9). Some products of this flow-sheet, i.e. overflow from a sump and the undersize (-40 microns) of vibrosieves, are sent back to the main flow-sheet.

      So, classic flow-sheet of consistent extraction and recovery of coarse, small, fine and ultra-fine gold grains is realized in this technology. Also output to waste dump of product of size of less than 30 microns allows to accumulate in intraplant flows gold of size of more than 70 and 30 microns, which will be recovered in cycles of concentration of small and fine gold grains. According to gold of size of less than 30 microns, there are ways to extract it at the level of 40-60%.

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