Ph

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Planning and Design of a Process for PGM Ore
Dressing
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• Presentation topics Presented by
• Introduction A.Chandan
• Process Units
• Size reduction Ramakrishna
• Froth flotation Padala
• Pyrometallurgy Tariq
• Hydrometallurgy Kumar
• Water Treatment Selva
• Plant Layout B.Ravikumar
• Environmental Regulation and Safety Yozi Bastian
• Cost Estimation Amar

Planning and Design of a Process for PGM ore
Dressing
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Planning and Design of a Process for PGM ore
Dressing
Merensky-Reef 600 t/h
TASK
PGMs 50-90
PGMs 5.5 g/t
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Planning and Design of a Process for PGM ore
Dressing
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Planning and Design of a Process for PGM ore
Dressing
TOPICS
INTRODUCTION
INDIVIDUAL UNITS
PLANT LAYOUT
COST
CONCLUSION
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Planning and Design of a Process for PGM ore
Dressing

• Platinum Group Metals
• Pt Platinum
• Pd Palladium
• Rh Rhodium
• Ir Iridium
• Ru Ruthenium
• Os Osmium

INTRODUCTION By A.CHANDAN
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Planning and Design of a Process for PGM ore
Dressing
APPLICATIONS
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Planning and Design of a Process for PGM ore
Dressing
Off gas treatment
(Fe, Cu, Ni) sulphates for recovery
Froth Flotation
Crushing and Grinding
Roasting and Smelting
Atmospheric and Pressure Leaching
PROCESS BLOCK DIAGRAM
Water treatment
PGMs to refinery
Block diagram of the PGM ore concentration process
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Planning and Design of a Process for PGM ore
Dressing
Size Reduction By Ramakrishna
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Planning and Design of a Process for PGM ore
Dressing
(Fe, Cu, Ni) sulphates for recovery
Off gas treatment
Froth Flotation
Crushing and Grinding
Roasting and Smelting
Atmospheric and Pressure leaching
Water treatment
PGMs to refinarey
Block diagram of the PGM ore concentration process
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Planning and Design of a Process for PGM ore
Dressing
Contents

• Process Options and Selection
• Equipment Selection
• Crushing
• Grinding
• Solid-Liquid Separator
• Process Flow Diagram
• Design Parameters

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Planning and Design of a Process for PGM ore
Dressing
Process Options and Selection

• Purpose of size reduction
• To liberate individual minerals trapped in rock
  crystals (ores) and thereby open up for a
  subsequent enrichment in the form of separation
• To produce fines from mineral fractions by
  increasing specific surface

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Planning and Design of a Process for PGM ore
Dressing
Process Steps

• Process steps
• Stationary Screening
• Primary Crushing
• Secondary Crushing
• Tertiary Crushing
• Screening
• Grinding (wet grinding)
• Solid-Liquid Seperation

• Selection Parameters
• Particle size
• Reduction ratio
• Power requirement
• Hardness of the ore

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Planning and Design of a Process for PGM ore
Dressing
Equipment Selection
Selection of crushers grinding equipment
depends on

• Hardness of the ore
• Throughput
• Operating conditions
• Feed size
• Capacity
• Cost effective alternative
• Capital maintainance
• Power

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Planning and Design of a Process for PGM ore
Dressing
Equipment Selection

• Selection of Crushers
• Roll, hammer, Impact crushers are suitable for
  soft ore and for low capacities
• For harder feed there is a choice between a
  gyratory and a jaw crusher
• Compared to other crushers the cone crusher has
  some advantages
• Making them very suitable for size reduction and
  shaping downstream a crushing circuit.
• Possibilities to change feed and discharge
  openings during operation

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Planning and Design of a Process for PGM ore
Dressing
Equipment Selection
Selection of Grinding Equipment

• Rod mills usually run open circuit
• The selection is in between AG/SAG and ball
  mill.
• Advantages of Ball mill
• It can be used for wet or dry, wet grinding
  facilitates the removal of the product
• Installation and power costs are low and the
  grinding medium is cheap and suitable for hard
  materials
• It can be used for batch or continuous operation
  and also in open or closed circuit grinding

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Planning and Design of a Process for PGM ore
Dressing
Equipment Selection
Selection of Solid-Liquid seperator

• Advantages of hydrocyclones over centrifuges
• Simple construction cheaper than centrifuge
• Low maintenance
• Less space required
• Control of speed is easier
• Low energy consumption
• Higher efficiency with low cost can be obtained
• Higher capacity can be handled by operating
  multiple
• hydrocyclones (hydrocyclone battery)

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Planning and Design of a Process for PGM ore
Dressing
Process Flow Diagram
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Planning and Design of a Process for PGM ore
Dressing
Design Results

• Crushers Results

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Planning and Design of a Process for PGM ore
Dressing
Results

• Hydrocyclone
• Number of hydrocyclones 11
• Cone angle 20
• D50C 92.5µ

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Froth FlotationbyPadala Subrahmanyeswara Reddy
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Planning and Design of a Process for PGM ore
Dressing
(Fe, Cu, Ni) sulphates for recovery
Off gas treatment
Froth Flotation
Crushing and Grinding
Roasting and Smelting
Atmospheric and Pressure leaching
Water treatment
PGMs to refinarey
Block diagram of the PGM ore concentration process
23
Planning and Design of a Process for PGM ore
Dressing
Froth Flotation

• Process Selection
• Purpose
• Flotation Reagents And Amounts
• Flotation Machines - Selection
• Flotation Circuit
• Flotation Process Flow Sheet
• Results

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Planning and Design of a Process for PGM ore
Dressing
Froth Flotation

• Processes
• Gravity Separation or Flotation
• Selection
• Froth Flotation
• Purpose
• Minerals 3
• Metal Oxides 2
• Gangue(Sand) 95
• Concentrating minerals

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Planning and Design of a Process for PGM ore
Dressing
Froth Flotation
Flotation Reagents And Amounts
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Planning and Design of a Process for PGM ore
Dressing
Froth Flotation

• Flotation Machines
• Outokumpu Flotation Machines
• Basic Inventory is 20 lower than in a
  conventional plant
• Low space requirements
• A simple design with low maintenance cost
• Low power requirements
• Easy performance control
• Fast froth removal

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Planning and Design of a Process for PGM ore
Dressing
Froth Flotation
Flotation Circuit
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Planning and Design of a Process for PGM ore
Dressing
Froth Flotation
Flotation Tanks Details
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Planning and Design of a Process for PGM ore
Dressing
Froth Flotation
Process Flow Sheet
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Planning and Design of a Process for PGM ore
Dressing
Froth Flotation
Results PGMs in feed 3.28 kg/hr PGMs in
Concentrate 2.94 kg/hr PGMs in Tailings 0.34
kg/hr Percentage of Extraction 89.5 Percentage
Purity 90
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• Pyrometallurgy
• By
• Tariq Anwar

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Planning and Design of a Process for PGM ore
Dressing
(Fe, Cu, Ni) sulphates for recovery
Off gas treatment
Froth Flotation
Crushing and Grinding
Roasting and Smelting
Atmospheric and Pressure leaching
Waste water treatment
PGMs to refinarey
Block diagram of the PGM ore concentration process
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Planning and Design of a Process for PGM ore
Dressing
Pyrometallurgy

• Contents
• Roasting
• Smelting
• Atomization
• Process flow diagram
• Results

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Roasting

• Roasting
• Converts sulphides to oxides or sulphates
• Why ?
• Ore is rich in sulphides
• Eliminates fugitive SO2 emissions from smelter
• Produces SO2 of high concentration for Sulphuric
  acid production
• Reduced energy consumption for smelting
• Roasting eliminates drying

Planning and Design of a Process for PGM ore
Dressing
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Planning and Design of a Process for PGM ore
Dressing
Roasting

• Reactions
•   2FeS2 11 O2 Fe2O3
  4SO2 
• 2FeS 3O2
  2FeO 2SO2 
• 2CuFeS2 13/2O2 2CuO 4SO2
  Fe2O3
• Feed size 74 microns
• Operating temperature pressure 1000 C
  1bar
• Considerations
• Involves gas-solid reactions
• Reactions begin at the outer layer of the solid
  particle
• Outer layers are converted into new compounds
• Ash layer diffusion controls reaction

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Planning and Design of a Process for PGM ore
Dressing
Roasting

• Options
• Multiple hearth roaster
• Fluidized bed roaster
• Fluidized bed advantages
• Easy handling and transport of solids
•  Large throughput possible        
• Uniform temperature distribution
• Large solid gas exchange area
• Suitable for handling smaller particles

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Planning and Design of a Process for PGM ore
Dressing
Smelting

• Reduction with carbon, forming, two layers
  metallic layer slag layer
• Reductant fluxes are added to reduce metal
  oxides to metals
• Why ?
• PGMs are conveniently collected in iron based
  alloy
• PGM losses are very low
• Base metals of high purity are formed
• High reaction rates
• Well established process

      
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Planning and Design of a Process for PGM ore
Dressing
Smelting

• Options
• A.C. (alternating current) arc furnace
• D.C. (direct current) plasma arc furnace
• D.C. Plasma arc furnace advantages
• Can handle fines
•  Dc arc is more stable than ac arc      
• Simple construction (single electrode) - easy
  gas sealing
• Very high temperatures can be attained  
• Little off gas volume - less losses
• Can process chromite bearing PGM ore(UG2 ore)

39
Planning and Design of a Process for PGM ore
Dressing
Smelting

• Temperatures
• Off gases 1100 C
• Metal slag 1600 C
• Plasma column 20000 C
• Arc attachment zone 2500C
• Roof walls are water cooled !
• Reactions
• FeO C Fe CO
• NiO C Ni CO
• CuO C Cu CO
• Fe2O3 C 2Fe 3CO

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Planning and Design of a Process for PGM ore
Dressing
Atomization

• Convert the hot molten metal coming from DC
  arc furnace into solid particles
• of appropriate size for subsequent leaching
  step
• Options
• Water atomizer
• Gas atomizer
• Water atomizer advantages
• Widely used for powders of Au, Pd, Pt, Co, Cu,
  Ni, Fe
• Particle size from 10 microns to few millimeters
  
• The particles are irregular in shape
• Cost effective as compared to granulation
  milling

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Planning and Design of a Process for PGM ore
Dressing
Process flow diagram

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Planning and Design of a Process for PGM ore
Dressing
Results
Roaster Height 12.6
m Diameter 8.2 m Fluidization velocity 0.8
m/s Smelter Power consumption 15.2
MW Operating current 33.6 kA Electrode
diameter 473 mm Capacity 45 tonnes
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Planning and Design of a Process for PGM ore
Dressing
Results
Atomizer Height 3 m Diameter 1.2 m Water
flow rate 16.6 Kg/s Product size 14 microns
0.016 PGMs
0.03 PGMs
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Planning and Design of a Process for PGM ore
Dressing
Hydrometallurgy
by Kumar
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Planning and Design of a Process for PGM ore
Dressing
(Fe, Cu, Ni) sulphates for recovery
Off gas treatment
Froth Flotation
Crushing and Grinding
Roasting and Smelting
Atmospheric and Pressure leaching
Waste water treatment
PGMs to refinarey
Block diagram of the PGM ore concentration process
46
Planning and Design of a Process for PGM ore
Dressing
Contents

• Leaching
• Process classification
• Selection of process
• Block diagram
• Considerations
• Reactions
• Equipment selection
• Process flow diagram
• Design parameters

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Planning and Design of a Process for PGM ore
Dressing
Leaching

• Two main steps are involved is
• Contact of liquid solvent with the solid to
  effect transfer of solute from the solid to the
  solvent.
• Separation of resulting solution from the
  residual solid.

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Planning and Design of a Process for PGM ore
Dressing
Process Classification

• Insoluble PGM residue
• The base metal is dissolved leaving the PGMs in a
  highly concentrated residue suitable for refining
• Dissolved PGM
• The base metal and PGMs are dissolved together,
  and then subsequent separation of each metals in
  a sequence of hydrometallurgical operations

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Planning and Design of a Process for PGM ore
Dressing
Selection of process

• Atmospheric leach
• simpler to operate
• cheaper
• most reliable to leach the bulk
• Pressure leach
• To speed the dissolution of all values into the
  leach solution
• improve the solubility rate of solids that are
  at best only slowly soluble at atmospheric
  leach.
• Atmospheric leach - Iron and Nickel
• Pressure oxidative leach - Copper

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Planning and Design of a Process for PGM ore
Dressing
Considerations

• Physical characterstics of the solids
• Process and operating conditions
• Choice of solvent
• Temperature
• Leaching cycle and contact method
• Type of reactor

51
Planning and Design of a Process for PGM ore
Dressing
Block diagram
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Planning and Design of a Process for PGM ore
Dressing
Reactions
First step leaching
Fe(s) H2SO4 (aq)
FeSO4(sol) H2 (g)
Second step leaching
Cu(s) H2SO4(aq) 0.5O2(g)
CuSO4 (sol) H2O (l)
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Planning and Design of a Process for PGM ore
Dressing
Equipment Selection

• Selection Basis
• Good solid-liquid mixing
• High conversion
• Easy to install and control
• Atmospheric leach
• Continous stirred tank reactor
• Pressure leach
• Autoclave reactor

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Planning and Design of a Process for PGM ore
Dressing
Process flow diagram
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Planning and Design of a Process for PGM ore
Dressing
Design parameters

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Water treatment

• By
• Selva kumar
  

Planning and Design of a Process for PGM ore
Dressing
57
Planning and Design of a Process for PGM ore
Dressing
(Fe, Cu, Ni) sulphates for recovery
Off gas treatment
Froth Flotation
Crushing and Grinding
Roasting and Smelting
Atmospheric and Pressure leaching
Water treatment
PGMs to refinarey
Block diagram of the PGM ore concentration process
58
Planning and Design of a Process for PGM ore
Dressing
Contents

• Process selection
• Block diagram
• Screening
• Sedimentation
• Ion exchange
• Process Flow Diagram

59
Water Treatment

• Purpose of water treatment
• Water conservation
• reuse water
• control water pollution

Purification of water
Planning and Design of a Process for PGM ore
Dressing
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Planning and Design of a Process for PGM ore
Dressing
Process selection

• Preliminary treatment includes screening,
  comminution, grit
• removal, oil and grease removal etc.
• Primary treatment includes gravity separation,
  flotation, filtration,
• thickener etc
• Secondary treatment includes ion exchange,
  reverse osmosis,
• adsorption etc
• Tertiary treatment includes biological
  treatment, chemical treatment

61
Planning and Design of a Process for PGM ore
Dressing
Block diagram
62
Chair of Mechanical Process Engineering
Screening

• Removing the floatable solids
• Vibration screen is preferred, because

• It can handle high capacity per unit area
• increased accuracy of sizing low maintenance
  cost

Sedimentation

• Solid-liquid separation - utilizes gravity (size
  and specific weight) to
• remove suspended solid
• Here most of gangue materials from froth
  tailings are removed
• Sedimentation Processes - Thickening and
  clarification

Planning and Design of a Process for PGM ore
Dressing
63
Chair of Mechanical Process Engineering
Clarification

• Process to remove relative amount of fine
  suspended particles and
• produce clear effluent
• For better separation of colloidal particles by
  gravity, it is necessary to
• agglomerate them by addition of coagulants and
  flocculants.

• Coagulants and flocculants

• Coagulants- destabilization of colloidal
  suspension
• Flocculants- agglomeration of the neutralized
  colloids

Planning and Design of a Process for PGM ore
Dressing
64
Planning and Design of a Process for PGM ore
Dressing
Water Treatment

• Inorganic coagulants
• increases coagulation
• But modifies the physical-chemical
  characteristic of the water
• (conductivity, pH) and increases sludge volume.
• Organic Coagulant
• Polyelectrolyte is used because it reduces
  sludge volume and does not alter pH.

Sedimentation Unit

• Tank, Drive unit, Lifting device, Rake mechanism
• and Overflow and underflow arrangements

65
Planning and Design of a Process for PGM ore
Dressing
Water Treatment
Ion Exchange

• Ion exchange is a reversible chemical reaction
  wherein an ion from solution is exchanged for a
  similarly charged ion attached to an immobile
  solid particle

Structure of Ion Exchange resins

• Ion exchange resins are made of synthetic
  polymer matrix
• Styrene-divinylbenzene (DVB) is used as base
  polymer because it has well defined structure and
  are fully ionized over entire pH range
• The organic -swellable copolymer is converted to
  water swellable material by the introduction of
  functional ionic sites

66
Planning and Design of a Process for PGM ore
Dressing
Water Treatment
Classification of ion exchange resin

• Cation exchange resins
• Strong-acid exchange resins (SAC)
• Weak-acid exchange resins (WAC)
• Anion exchange resins
• Strong-base exchange resins (SBA)
• Weak-acid exchange resins (WBA)
• Strong-acid cation exchange resins are prepared
  by sulfonating the benzene ring in the
  polymer
• Strong -base resins are produced by amination
  or by
• chloromethylation

67
Planning and Design of a Process for PGM ore
Dressing
Water Treatment
Operating mode

• Fixed-bed countercurrent ion exchange is
  preferred over co-current because,
• lower leakage of ions during service
• lower consumption of regenerants
• decreased quantity of regenerant wastes
• lower consumption of water for rinsing and
  backwash

68
Planning and Design of a Process for PGM ore
Dressing
Water Treatment

• System Operation

• Service-exchange reaction occurs, the
  hardness-producing ions are equally exchanged by
  ions,until operating capacity is reached
• Back washing-prepare resin for regeneration
• Regeneration-displaces exchanged ions during
  service run and returns the resin to desired
  capacity
• Rinsing-ion exchange resin is rinsed free of
  excess regenerate before being put back into
  operation

69
Process flow diagram
Planning and Design of a Process for PGM ore
Dressing
70
Planning and Design of a Process for PGM ore
Dressing

Process Flow Diagram Plant Layout By

Bolishetti
71
Planning and Design of a Process for PGM ore
Dressing

Process Flow Diagram Plant Layout By

Bolishetti
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Process Flow Diagram
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Planning and Design of a Process for PGM ore
Dressing
 
Plant Layout

• The basis for 3D Layout design is
• Process flow diagram
• Pipe lists
• Drafts of process and instrumentation diagrams
• Data sheets of the main equipment
• Dimensions of the construction site

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Planning and Design of a Process for PGM ore
Dressing
Plant Layout

• Factors influencing arrangement of equipment
• Process demands
• safety
• Pipe routing
• Operability
• Access to the equipment
• Maintenance
• Cost

75
Planning and Design of a Process for PGM ore
Dressing
Plant Layout
Iterative sequence of plant layout
76
Planning and Design of a Process for PGM ore
Dressing
2D Layout
77
Planning and Design of a Process for PGM ore
Dressing
Flotation section 3D design
78
Planning and Design of a Process for PGM ore
Dressing
Leaching section 3D design

79
Planning and Design of a Process for PGM ore
Dressing
Environment Safety By Yozi Bastian
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Planning and Design of a Process for PGM ore
Dressing
Chair of Mechanical Process Engineering
Contents

• Environmental Regulations
• Off - Gas Treatment
• Safety
• Results

81
Planning and Design of a Process for PGM ore
Dressing
Chair of Mechanical Process Engineering
Environmental Regulations

• BImSchG
• Principles
• remove any damage caused by air polution
• any harm must be avoid
• Aims
• Protection against harmful effects to the
  environment
• Licensible installation
• Prevention

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Planning and Design of a Process for PGM ore
Dressing
Environment Regulations

• Pollution Types
• Air Pollutants
• SO2
• CO
• Particulates Matter
• Noise Pollution
• Water Pollution

83
Planning and Design of a Process for PGM ore
Dressing
Environmental Regulations
MAK-Value
84
Planning and Design of a Process for PGM ore
Dressing
Gas Treatment
SO2 Treatment
85
Planning and Design of a Process for PGM ore
Dressing
Chair of Mechanical Process Engineering
Gas Treatment
CO Treatment
86
Planning and Design of a Process for PGM ore
Dressing
Environmental Regulations

• Sources of noise and vibration
• Furnaces
• Electric motors
• Belt conveyors
• Pumps
• Compressors
• Crushers and mills
• Fan

• Regulation of noise
• By constructing the equipment in a closed
  buildings
• Making insulation
• Maintenance
• Grinders are arranged in a special building.

Typical Sound Levels at the Workplace limit 85 dB
87
Planning and Design of a Process for PGM ore
Dressing
Safety

• Introduction
• Chemical plants contain a large variety of
  hazards
• Safety layer

88
Planning and Design of a Process for PGM ore
Dressing
Safety
C.S.T.R
89
Planning and Design of a Process for PGM ore
Dressing
Gas Treatment Results
Baghouse Filter
ESP
90
Planning and Design of a Process for PGM ore
Dressing
Cost Estimation and Overall Review
By Amarnath Reddy
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Planning and Design of a Process for PGM ore
Dressing
Cost Estimation

• Contents
• Estimating Fixed capital cost
• Estimating Total production cost/annum
• Income incurred per year
• Pay back period
• Analysis

92
Planning and Design of a Process for PGM ore
Dressing
Cost Estimation

93
Planning and Design of a Process for PGM ore
Dressing
Total capital investment
Total capital investmentFixed Capital
investmentTotal production costs

• Fixed capital investment P.E.CO.D.CI.D.CConti
  ngencies
• P.E.CPurchases Equipment Cost
• O.D.COther Direct Costs
• I.D.CIndirect Cost

94
Planning and Design of a Process for PGM ore
Dressing
Purchased Equipment cost
95
Planning and Design of a Process for PGM ore
Dressing
Other Direct costs
6PEC
45 PEC
30PEC
15 PEC
9PEC
13PEC
47PEC
31PEC
13PEC
O.D.C118million
96
Production Costs

• Manufacturing Costs Direct Production Costs
  Fixed Charges
• Plant Overhead Costs
• Total Product Cost Manufacturing Cost General
  Expenses

97
Production Costs
98
Planning and Design of a Process for PGM ore
Dressing
Working capital/annum
58.4
5.7
21.5
6.5
7.9
Total Production cost 305million
99
Planning and Design of a Process for PGM ore
Dressing
SUMMARY
Details Costs in millions
Purchased Equipment cost 35.8
Other Direct Costs 118.1
Indirect Costs 29.3
Fixed capital investment 163
Manufacturing costs 287.8
General Expenses 17.2
Total Production Costs 305
100
Planning and Design of a Process for PGM ore
Dressing
Income incurred /year
Number of kgs Produced/year
22817 kg/year Selling price
Per Kg
17000 per kg Gross Earnings Total Income
Total Product Cost 82.6 million Net
Profit Gross Earnings Taxes
61,9 million/year

• Cost analysis
• maintenance cost increases every year by 5
• 50 of the initial investment is from banks
• 30 from the share holders

101
Planning and Design of a Process for PGM ore
Dressing
Analysis

102
Planning and Design of a Process for PGM ore
Dressing
Analysis

103
Planning and Design of a Process for PGM ore
Dressing
Analysis

• The Pgms Price is expected to be 2005
• The pay back period
  
• The pay back period for share holder
• Bank installment clearence
  

• 25000 per kg
• 3 years for the owners
• 4 years
• 5 years

104
Planning and Design of a Process for PGM ore
Dressing

Overall Review
105
Planning and Design of a Process for PGM ore
Dressing
Overall review

Final Concentration of PGM is
57
106
Planning and Design of a Process for PGM ore
Dressing
Thankyou very much
Tutors Dr.-Ing. Helmut Wiggers Dipl.-Ing.
Frank Landwehr Dipl.-Ing. Daniel
Feggeler Dipl.-Ing. Sascha Groom

Reference Prof. Dr. techn. Peter
Walzel Co-reference Prof. Dr. Gabriele Sadowski

107
Planning and Design of a Process for PGM ore
Dressing

• Thank You
• Very Much