MP Lecture Notes
MP Lecture Notes
MP Lecture Notes
TECHNOLOGY
(MME-203)
4th Semester B. Tech
Dept. of Metallurgical and Materials Engineering
V.S.S.university of Technology , Burla
Sambalpur , odisha
MODULE -I
Introduction to mineral and mineral Engineering
Mineral- a substance from which we get metal non metals or
any valuables.
Mineral Engineering ( branch of mme which deals with study
of minerals and its processing )where the minerals is being
processed to get a concentrate from which metals are
extracted .
Flow chat to showw the relationship of mineralal engineering
with mining and extr
xtractive metallurgy engineering
ing
Subject covers
Minerals definition
MINERAL : Natural occur inorganic aggregate of metals
and non metals .
Or Inorganic compound having a definite chemical
composition and crystal structure (atomic structure). Or
minerals are the forms in which metals are found in the
earth crust and as sea bed deposit depend on their
reactivity with their environment, particular with oxygen ,
sulphur, and co2.
Anything of economical value which is extracted from the
earth.
Characteristic of mineral
1-Minerals are homogeneous in physical and chemical
composition.
2-Minerals shows isomorphism (atomic structure do not
change )(with the same atomic structure but different
chemical formulas)
ustal structure remains same) Example- olivine (Mg,Fe)2
SiO4 in different olivines the ratio of Mg /Fe atoms varies
3-Mineral also shows polymorphism (different crustal
structure) same chemical composition but different physical
properties.
Example – graphite and diamond
quartz, tridymite, cristobalite, stishovite and coesite--SiO2---
quartz forms at low temperature and forms in the hexagonal
system,
cristobalite forms at a high temperature and forms in the
tetragonal system,
tridymite is an intermediate temperature form which is
orthorhombic---
coesite is stable at high pressures and is associated with
meteor impact and is a monoclinic mineral---
stishovite is tetragonal and is thought to be associated with
rocks from Mars
a. calcite and aragonite--CaCO3---calcite is hexagonal and
aragonite, orthorhombic
b. pyrite and marcasite--FeS2---pyrite forms at a high
temperature and is isometric
Rock vs mineral
1-Chalk, clay, granite(igneous rock),coal are rocks there are
not come under definition of minerals because they are not
physically and chemically homogeneous.
2- rocks generally consists of variety of minerals.
Mineral Vs Ore:
ORE definition - natural aggregates of minerals from which a
metal or metallic compound can be extracted economically
and profitable.
All ores can be minerals but all mineral cannot be an ore.
Ore: is mixture of extractable mineral and extraneous rocky
materials described as gangue
Physical properties of mineral
1-transperency
2-luster
3-color
4-specific gravity
5-hardness
6-cleavage
7-fracture
8-magnetic property
9-electric property
10-radiactive
11- optical property
Uses of some mineral.
1-diamond is used as an abrasive and cutting material.
2-garnet sand is used to make sand paper.
3-soft mineral like talk is used to make cosmetics powders.
Principal operatio
tion in mineral processing:
Four kind of princ
incipal operation are there :
1-Comminution- size reduction process whichh in
involves
crushing and grind
inding operation
2-sizing-Sizing is the separation of material orr product
p into
various fractionss ccharacterised by difference in size.
s Sizing
can be performed
ed by screening or classification.on. The latter
depends on the set
settling velocity of particles inn a fluid (air or
water).
3-concentration-CConcentration may be regardeded as
collection of valua
luable minerals in a small bulk.
k. It
I is carried
out by various means which mainly depend upon the
mineral types and it characteristic
4-dewatering- after concentration the concentrate is in
moist form or in a liquid pulp so it first dewatered before
sending it to smelter or for shipment.
Two fundamental operation of mineral processing:
1-the release or liberation of the valuable mineral from the
gangue minerals
2-concentration – separation of these valuable minerals
from the gangue.
Release or liberation is accomplished by comminution
process . this process involves
Crushing and grinding .
In comminution process we get a product which is a
mixture of relatively clean particles of mineral and gangue.
• Maximum energy is consumed in grinding process which
accounts 50 per of the concentrator energy consumption.
• Key to good mineral processing : grinding is the key to
good mineral processing because it provides efficient
separation of valuables mineral from gangue.
• Production of very fine untreatable smile particles which
may be lost into the tailing
Disadvantage of fine grinding is :
• Energy cost increases
• In order to produce clean concentrate with less
contamination of gangue mineral, fine grinding is
essential.
Product of comminution
Here region A represent valuable mineral
Where as AA represents rich in valuable mineral but is
higly intergrown with the gangue mineral . During
comminution a range of fragments are produced ranging
from fully liberated mineral and gangue particles.Here from
the figure we can see
Type 1- is rich in mineral and are classified as concentrate
since as they have an acceptable degree of locking with the
gangue , which limits the concentrate grade.
Type 4- is tailing since small amount of mineral presents
reduces the recovery of mineral into the concentrate.
Types 2, 3- are middling's degree of regrinding needed to
promote economic liberation of mineral from particle 3
would be greater than in 2.
Functional diagram
ram of blake jaw crusher
Gyratory crusher
1-The name gyratory crusher comes from the fact that
while the spindle is revolving around the axis of the frame
generating a conical surface, at the same time it rotates
about own axis due to frictional drag.
2-a gyratory crusher may be looked upon as a jaw crusher
with circular jaws between which material is being crushed
at same point at all times
3-A conical crushing head gyrates inside a funnel –shaped
casing , open at the top of the machine .
4-an eccentric drives the bottom end of the shaft .
At any point on the periphery of the casing ,therefore the
bottom of the crushing head moved towards and then away
from the stationary wall
5-side caught in the V shaped space between the head and
the casing are broken and rebroken until they pass out the
bottom.
6- the crushing head is free to rotate on the shaft and turns
slowly because of friction with the material being crushed .
Gyratory crusher
Functional dig of gyratory crusher
Foundation Rugged
Roll crusher
1- roll crushers are now a days replaced by cone crushers in
many mills but still some mills used it.
2-they are mostly used for sticky , friable , frozen and less
abrasive feed as lime stone, coal, chalk, gypsum, phosphate,
and soft iron ore .
3- advantage over gyratory and jaw crusher is that it will not
choke near the discharge end when crushing friable rock with
a large proportion of maximum size pieces in the feed.
4- function of roll crusher is very simple .
Construction and working :
1-it consist of two rolls(horizontal cylinders which revolved
toward each other
2- the set is determined by shims which cause the spring
loaded roll to be held back from the solidly mounted roll .
3-the crushing process in roll crusher is one of single pressure
where as in jaw and gyratory it is a repeated pressure.
4- some roll crushers are made up of one rotating cylinder
which revolved towards a fixed plate others use 3, 4, 6,
cylinders
5- diameter and speed of the roll varies from crusher to
crusher
6- the rolls may be grear driven , but this limits the distance
adjustment between the rolls , but where as Modern rolls are
driven by v belt from separate motors
Multi roll machine may use rolls in pair or in set of three .
Disadvantages of roll crusher:
In order for reasonable reduction ratios to be archived very
large rolls are required in relation to the size of the feed
particle they there fore have the highest capital cost of all
crusher
Force on a particle in a crushing roll
1- feeding arrangement
2-partciles size of the feed
3-gridning media -material , size ,quality
4-mill size , its speed and power consumption
5- solid liquid ratio and circulating load in a close circuit .
Phenomenon inside ball mill
Working of ball mill
1-When the ball mill is rotated the ball are picked up by the
mill wall and carried nearly to the top(this is due to
centrifugal force which keep the ball in contact with the
wall and with each other during upward moment), where
they break contact with the wall and fall to the bottom to be
picked up again.
2- while in contact with the wall the ball do some grinding
by sleeping and rolling over each other. But most of the
grinding occurs at the zone impact , where the free falling
balls strike the bottom of the mill.
3-if the speed is too high , how ever the ball are carried
over and the mill is said to be centrifuging . The speed at
which centrifuging occurs is called the critical speed.
During centrifuging no grinding or very little grinding
occurs , so operating speed must be less than the critical .
The critical speed of ball mill is given by
Sieving process
Concept of mesh
The mesh number system is a measure of how many
openings there are per linear inch in a screen. Sizes vary by
a factor of √2. This can easily be determined as screens are
made from wires of standard diameters, however, opening
sizes can vary slightly due to wear and distortion.
As the mesh number increases the no of opening increases
per liner inch , where as the size of the opening decreases.
Screening
Screen are attached with all types of crushing units at
feed and discharge end
• Screening: it is carried out by passing the comminution
products over a surface provided with opening of desired
size.
• Screening equipment may be stationary or moving bar
punched metal plate or woven wire mess.
1-grizzels (non vib
vibrating )stationary screen
• -Screening larg
rge size particles more than 255 m
mm (used
for primary scre
creening).
• -consists of sim
imple parallel heavy wear resista
istance
manganese steeteel bars or rails separated by required
req
space at the ends
end
• -these bar may
ay be laid horizontally or inclined
ned
• -usually crosss section
s of the bar is trapezoidal
dal with wide
base upward to prevent clogging or weedingg of o particles
2-vibrating screen
en:
• -used for treatin
ting large tonnage of material
• -vibrating motin
oting(shaking motion) is imparte
rted by means
of cam , eccentr
ntric unbalanced fly wheel, or
electromagnetic
etic mass.
• -it may be singl
ngle doubled, or triple decked to obtain
different size of particle from single feed
• - these screens
ns can
c be used upto 35 mess
• - amplitude iss usually
u 6-8mm
• - angle is aroun
und 20-30 degree for dry and 5--10 degree
for wet
• -rpm is varied below 1200 -1800.
4-oscillating screen :
• a-these are characterized by relatively low speed in the
range of 300- 400 rpm in plane ,essentially parallel to
screen
b-the riddle is a screen driven in a oscillating path by an
eccentric or other mechanism attached to it
5-Reciprocating screen :
• a-these are driven by an eccentric under the screen at the
feed end
• b-the motion varies from gyratory (up to 50 mm dia ) at
feed end to a reciprocating motion at the discharge end
the inclination is about 5 degree
6-trommels ( vibrating screen)
• a-there are revolving screen or drum separator type
consist of a screen in the form cylindrical or conical in
shape rotated about its axis
• b-the material is feed at one end of the screen , the
undersized materials falls through the screening surface
while the oversize is conveyed by rotating motion down
the incline to the discharge end .
• c-it can handle both dry or wet feed
• d- it can separate several size feed by using a series of
screen from coarset t finest.
• e- cheap and most suitable for washing of coal and iron
ore
7-gyratory screen :
• a-contains removable and replicable circular decks or
trays for different size products .
• b- it works both gyratory and vertical motion to the
screen decks
grizzle Tromme
Consider a sphe
pherical particle of dia d and denensity Ds
falling under gr
gravity in a viscous fluid of density
den Df
under free settli
ttling conditions, ideally in a fluid
flui of infinite
extent. The par
particle is acted by three force
1- a gravitational force acting acting downwards
2-an upward buoyant force due to the displaced fluid
3-a drag force d acting upwards
d- diameter of spherical particle
Ds- density of solid
Df- density of fluid
M’-mass of the displaced liquid
M- mass of the particle
X- partial velocity
Equation of motion of particle is given by
Gravitational force – buoyant force – drag force = m
dx/dt
mg - m’g – D = M dx/dt
At terminal velocity that is when upward force is equal to
downward (x tend to 0)
That is dx/dt = 0
g(m-m’) – D = m . Zero
g(m-m) – D = 0
D = g (m – m’)
We know that density = mass/volume
So mass is equal to density x volume
D = g (Ds.v – Df .v)
D = gv (Ds – Df )
= g [ 4/3 π (d/2)3 ] ( Ds – Df )
= g1/6 π d3 ( Ds – Df )
Stocks assumed that the drag force on the a sphere
particle to be entirely due to viscous resistance and
deduced the expression.
D= 3 π d η V
Here
η = fluid velocity
V= terminal velocity
3 π d η V = π/6 g d3 (Ds – Df)
V = g d 2 (Ds – Df) / 18 η
This expression is called stokes law
Newton assumed that the drag force was entirely due to
turbulent resistance and deduced
D= 0.55 π d 2 v 2 Df
0.55 π d 2 v 2 Df = π/6 g d3 (Ds – Df)
V = (3gd (Ds-Df)/Df)1/2
This is newton's law of turbulent resistance
Stokes' law makes the following assumptions for the
behaviour of a particle in a fluid:
1-Laminar Flow
2-Spherical particles
3-Homogeneous (uniform in composition) material
4-Smooth surfaces
5-Particles do not interfere with each other.
Stokes law vs newton's law
Stockes law is valid for particles of size below about
50micrometer in dia.
The upper size limit is determined by dimensionless
reylond number .
Newtons law is valid for particles of size greater than 0.5
cm in dia
MODULE-II
Concentration
Concentration means enrichment of ore.
Here after seizing the particles are sent for concentration
where the gangue (tailings) are separated from the valuable
minerals, producing a concentrate and tailings.
• Uses of jigs :
1. Used for cleaning coal
2. Heavy media separation including alluvial gold
• While treating coal and mineral the lighter particle is
concentrate for coal and heavy fraction is concentrate for
mineral
• For this very reason gravity separation is product is
called light or heavy rather than concentrate or tailings.
Differential motion table separator:
• Here an ore of bed experience a horizontal shaking
motion which lead to the segregation of particles
according to either size of density.
• If the particles are of same density then the particle’s will
segregates according to size with the fine particles
sinking and the coarse particles rising to the top. And if
the particles with different density exist then particles
with higher density will sink to a lower level then lighter.
• Shaking tables:
• Here a differential motion(shaking where forward and
backward moment accours) and a riffled deck with cross
flowing water is used to create a particle separation.
• The shaking motion is asymmetrical, being slow in
forward direction and being rapid in backward direction.
Due to differential motion a conveying motion is
imparted on the particle which are in contact with the
table deck in the direction of motion due to friction.
• Wilfley table :
1. It consist of slightly inclined flat surface or deck with a
series of parallel ridges and riffles along the direction of
motion .
2. The riffles are
re tapered towards the opposite
te end
e of the
reciprocating drive.
dr
3. Feed is introduc
duced at the corner of the tablee at
a about 25
per cent solid (b
(by mass)and with the shakingg motion , the
particles spread
ad out over the table
4. 4- Water is intro
ntroduced along the top edge off tthe deck to
assist segregatin
ating and transport of particles on the table.
5. Due to this the
he pparticles moves diagonally across
acr the
deck from thee feed
f end.
6. As the feed mat aterial spreads out over the tabl
able the
particles stratifi
tified in layers behinds the riffle.
fle.
7. The riffles help
elp to transmit the shaking motio
tion to the
particle and prevent
pre the particle washing direc
irectly off the
table.
8. Here if the table
ble operates in a correct manner
er then the
middling’s frac
raction discharge at the diagonal
nally opposite
corner of the tab
table to the feed.
9. Size separation
on will be very difficult it theree iis range of
size increases
Operating parameters
1. Particles size , shape
2. particles density
3. deck shape
4. riffle design
5. water and feed flow
6. stroke and speed of the table and deck slope
The lower size limit for an effective separation on a table
is about 50 micro meter even if the density difference is
high
• For optimum table operation the feed flow of solids and
water onto the table must be uniform and constant
1- collectors
2- frothers
3- modifiers
Collectors : main function of collector is it makes the selected
minerals hydrophobic by forming a continuous film of
heteropolar at molecular level.
Due to this these minerals get adhere to air preferentially and
start floating .
Collectors classification :
1- cationic- if the part which impart water repellancy to the
mineral surface carries a negative charge
2- anionic - if the part which impart water repellancy to the
mineral surface carries a positive charge
Collectors are heteropolar that means one portion is polar and
other is non polar.
Examples of collectors :
Anionic collectors : potassium or sodium ethyl xanthate,
dithio phosphate, fatty acids
Cationic collectors: fatty amines aceates
Frother :
main function is to form a stable and particular size of froth
on which collector coated mineral get attached and floated up.
These are heteropolar in nature having one of more water
repellent and water loving polar group.
The froth must be stable and strong enough to support the
weight of the desired mineral attached to it and permits it
separation from the pulp.
Most important point is these froth must breakdown when
they are removed from the flotation cell.
Examples : pine oil, aliphatic alcohol, cresylic acids
Modifiers or regulator :
They modifies the action of collector either by enhancing or
by reducing its water repellent effect on the mineral surface .
They make collector action more selective towards certain
mineral
1- activator – it help
lp in reactivate or increase the
susceptibility to flota
lotation of some mineral that hasas been
depressed ex- cuso4o4 is a standard activator for sph
phalerite
2- ph regulator: optim
ptimum result only in a particular
lar range of
ph value of the pulplp .for this reason proper ph cont
ontrol of the
pulp is of greater importance.
imp
ex- ,soda ash, and h2
h2so4
3- depressant : some
me times we want differential floflotability for
which it is desirable
le to prevent or supress the flota
otation of one
mineral over another
her . Ex= cyanide,lime acts both th as ph
regulator and depres
ressant
4- dispersant :sometietimes the gangue may be of such
suc nature
that it flocculates to such an extent which may intenterfere with
effieient flotation of the desired mineral . It is esseential to use
a dispersant .
A dispersant or a dispersing
di agent or a plasticizer
zer or a
superplasticizer is either
ei a non-surface active polym
lymer or a
surface-active substa
stance added to a suspension, ususually a
colloid, to improvee the
t separation of particles andd to prevent
settling or clumping.
ng.
Ex- starch and gluee
Selective attachment
ent of the air bubbles to hydroph
phobic
particle .the buoyanc
ancy of the bubble then carriess th
these
particles to the surfa
rface , leaving the hydrophilic particles
pa
behind
Magnetic separation
on
Magnetic separation
on :
Principle : difference
nce in the magnetic properties between
be
different minerals or between minerals and gangue
gue
Used to separate : va
valuable minerals from non mag
agnetic
gangue
Eg- magnetite(magn
gnetic) from quartz (non magnet
netic )
Magnetic gangue or contaminants from non magne
gnetic values
Eg- tin ore that is cas
cassiterite (non magnetic ) is separated
sep from
traces of magnetitee ,wolframite
,w (gangue)
classification of mate
aterial on basis of whether thyy are
a attracted
or repelled by the magnet
ma :
diamagnetic: thesee m
material get repelled in the mag
agnetic lines
of force where the fi
field intensity is smaller .
ex- quartz
Diamagnetic material cannot be separated by magnetic
concentration process because force involved are very small.
Paramagnetic: these material get attracted along the line of
magnetic force to a point of greater field intensity .
Paramagnetic materials can be concentrated in high intensity
magnetic separator
Examples of paramagnetic minerals : ilmenite (FeTiO3) ,
rutile (TiO2),
wolframite ((Fe Mn)WO4), monazite
(Ce,La,Nd,Th)PO4
, siderite (Feco3), Pyrrohotite (FeS), Chromite (FeCr2O4),
hematite (Fe2O3) and manganese material.
If we see elements such as Ni co, Mn Cr , Ce, Ti , O and Pt
are paramagnetic in nature but in most cases the paramagnetic
properties of mineral is are due to presence of iron in some
ferro magnetic form .
Ferromagnetism is a special case of paramagnetism where
very high force is involved .
If we see ferromagnetic materials they retain magnetism even
after removal from the field called remanence. They can be
concentrated using low intensity magnetic separator.
Ex- magnetite ,
Magnetic separator design :
Prime requirement of magnetic separator is a provision of a
high intensity field in which there is a steep field strength
gradient
From this figure (a)we can see there is field of uniform flux
(lines are straight ), magnetic particle will orient themselves
but not move along the lines of force since there is not field
gradient here.
But to produce a non uniform flux(conversing flux)(we have
to change the shape of the pole by making one pole tapered
which concentrate the magnetic flux into a very small area
giving high intensity and other pole is flat due to which the
same total magnetic flux distributed over a large area. Due
which a steep field gradient across the gap by virtue of
different intensity field. Can seen from fig (b)
Wet
Dry
Dry Wet
feed
feed
feed feed
MODULE-III
Agglomeration
What is agglomera
eration: agglomeration is a techn
chnique by
which the fine iron ores are converted into lump
mps.
Why agglomeratio
ation is required :
1- use of fine iron
on ore in iron making , since during
dur
communiation of iron i ore some of the ores aree cconverted
into fines. So thesese fines cannot be feed into furnace
fur
directly so it is first
firs converted into lumps .
Why we cannott ch
charge fines into blast furnacee :
1- if we charge fin
fines into furnace it get converte
rted into
lumps inside thee bblast furnace and it will reduce
ces
permenabilty forr gases
g and slag and metals .
2- heavy dust loss
oss occurs from the top in the b/f gas.
Agglomeration techniques
tec
1-briquetting
2-
nodulising[rotar
y kiln sintering
3-vacuum
extrusion
4-sintering
5-pelletising.
Sintering techniqu
ique
Sintering princi
nciple
Process variable
ble
Equipment for
or sintering
s
Mechanism of ssintering
Raw materials
ls requirement’
r
Sinter types
SINTERING PRIN
RINCIPLE:
here the iron oree ffines or iron bearing fines aree mixed
m with
solid fuel(coke ) aand put on a permeable grate.
Top layer of this
is ssinter bed is heated to the sinte
ntering
temperature (12-11300 ) by a gas or oil burner andan air is
drawn downwards rds, through the grate , with thee hhelp of
exhaust blower coconnected. From underneath to the t grate. A
narrow combustiotion zone is formed on the top an and this
combustion travel
vels downwards layer by layer up upto sintering
level
The cold blast drawn through the bed cools the already
sintered layer and thereby gets itself heated. The heat
contained in the blast is utilized in the drying and
preheating the lower layers in the bed that is in advance of
combustion of each layer.
In the combustion zone bonding of grains takes place and a
strong and porous aggregate is formed. The process is over
when the combustion zone has reached the lowest layer of
the bed.
The sinter formed is droped after partial cooling it is then
broken , screened , and cooled to produce desired fraction.
The undersized is recycled and over is send to b/f .
Up draught sintering{for ferrous ore) here the air is suck
downards through the ore bed , or grate
Down draught sintering[for non ferrous ore] here the air is
suck upward through the ore bed, grate.
Process variables in sintering
bonding theory
ry
Moisture is very
ery much essential for pelletisati
sation process
and it must bee in
i less quantity.
Excess moisture
ture is also determintal .
How this moisture helps in binding the particles ?
Surface tension of the moisture present in between the
particles help in binding.
Rolling of moist particles lead to formation of high
density balls .
Easy with which the particles are rolled into balls depend
upon the grain finess that is surface area. More surface
more will be tendency of balling.
Three water particle system
1-pendular state:[ in this type of water particle system
water is present at the point of conatct between the
particles and the surface tension hold the particles.
2-funnicular state:[ in this type of system all the pores are
fully occupied by water in an aggregate system.
3-capillary state:[in this system akl the pores are fully
occupied by water but there in no coherent film of water
covering the entire surface of particle.
So strength of the ball depends upon the surface tension
and mechanical interlocking.
Diagram of water particle system
Example showing the strength of green ball with critical
amount of water:
When we go to sea beach for dry sand to wet sand which
is just attached with the sea . We find a region in
between these two which contains less water . So if we
determine the strength the strength is maxium for the
sand from middle region.
Mechanism of ball formation
Mechanism behind this ball formation is the nucleation
and growth mechanism .
1-So first stage is nucleation of ball
2-Then growth of this ball
But the entire process depend upon the critical amount of
moisture (water) present in the feed.
Suppose the amount of water is les then critical amount
then there is non unifom water distribution in the system
, the major amount or water will be present in granulate
material leaving non granulated material dry. And if the
amount is more then critical amount then growth will be
more where as strength will be reduced due to increase in
plastic behavior.
• Nucleation formation region:-
• A bond is formed immediately between particles when
one wet particle comes in contact with another dry or
wet particle .in this way other particles are also attached
with it and a highly porous loosely held aggregate is
formed. And due to rearrangement and partial packing in
short duration to from a small spherical stable nuclei.
• Transition period : after nuclei are formed they pass
through a transition period . In this period rearrangement
of particles occurs which lead to removal of pores and
voids. System goes from pendular –funnicular- to
capillary.
• this wet granulates grows if they are favorable oriented.
In this process some granules may even break because of
impacts, abrasion etc. growth occurs by two alternative
methods.
A- growth by assimilation: is possible when balling
proceeds with out the addition of fresh feed
material.[during rolling some small particles breaks due
to rolling action and these particles attached with bigger
one and bigger will grow more big. Here thee is no
addition of fresh materials.
B- growth by layering : growth occurs by addition of
fresh materials. [here the ball pick up new materials
while rolling the amount of materials picked up by the
balls is directly proportional to its exposed surface.
Equipment or industrial practice
• Two type of pelletiser are there :
• 1- disc
• 2-drum
Disc pelletiser: it consist of a disc with outward sloping
perpheral wall .resemble like flying saucers. Which
rotates around its own center , in an inclined position to
horizontal .
Dia of disc -3.6-5.6 m .
Inclination is 45 degree to the horizontal.
The material to be pelletized is generally fed directly
onto the disc and moisture level is made up with the help
of moist material on the disc. It can also control the
material flow pattern on the disc. In the reason where
water is added seeds are easily formed . With the growth
of these seeds their fractional drag against the disc
decreases and the centerifugal force acquired by them
increases and consequently they move out of nucleation
zone. They also tends to rise on the inclined surface of
the pelletiser in the direction of rotation and fall down
against the toe section of the disc. The height and the
width of trajectory of the ball movement increases with
the size of the ball until eventually the balls are deflector
downwards by the scraper. During this movements the
ball encounter fresh feed and growth takes place more by
layering while compaction assimilation plays a relatively
minor role.
The rate of production of balls on a disc is a function of
the following variables
1- diameter of the disc
2-height of the peripheral wall
3- angle of inclination of disc
4-place on the disc where mix is fed
5-speeed of rotation
6-place where water is sprayed
7-rate of feed
8-rate of moisture addition
9-rate of withdrawl of the product
10-nature of size of feed.
11-desired size range of pellets and percentage recycled
12- binders and flux.
Drum pelletiser
This type of pelletiser is a steel drum which is having both
end open with a length to diameter ratio of 2.5-3.5 rotating
around its own axis in a slightly inclined position to the
horizontal .
Length-6-9 m
Dia-2-3m
Angle of inclina
lination-2-10 degree
Rotate at (Rpm)
m)-10-15 rpm
Here the charge
rge is fed from that side of the dr
drum which
is at higher leve
evel.water is also sprayed theree the
th material
rolls over the su
surface of the rotating drum and slides
downward due ue to inclination of the drum inn a cascading
motion. And finally
fin it comes out at other end.
nd.
Disc vs drum
Testing of agglo
glomerate
Determine thee Room
R temperature physical properties:
pr
such as resistan
tance to abrasion and impact duri
uring handling
and charging ar
are :
A-Shatter test,(i
t,(impact test)
b- tumbling test (abrasion test)
C-Porosity test
st
D-Compression
ion test
Shatter test:
It is done to determine the impact strength of the raw
materials as raw materials are charge from a big height
into the blast furnace and during handling also its suffers
.
In this test a standard amount of material is taken and it
is dropped for a certain no of drops from a standard
height on a standard floor. And then the amount of
material retained on or passed through the certain sieve
expressed as percentage of the original weight is
indicated as the shatter index.
Shatter test in u.k:
Developed in U.K and test in U.k : 20 kg sample is taken
with size +10mm dropped 4 times from height of 2 m.
the material is then screened and shatter index is
expressed as the percentage materials greater than 10mm
surviving.
Tumbling test and abrasion test
This test is used to determine the strength and abrasion
resistance of sample.
Also called micum test .
Here a standard weight of material is tumbled in a
standar size drum for fixed number of revolution which
is carried out at a standard speed . The percentage
material passing through or retained on a certain seive is
the index.
According to these test pellets are high quality products
then sinter and natural ore.
In case of micum test :sample weight : 50kg
Drum dia x length 1x1 m
Speed(rpm)=25
No of revolution = 100
Compression test
• Compression test: we cannot measure the compression
strength of the raw material as there are not in regular
size. But pallets we can measure as it is regular in size.
• Standard weight of material is taken (2kg) with standard
size 10-15 mm size is dried and placed in a cylinder of
200mm dia and a load of 100 t is applied on it via piston
. the + 5mm materials surviving the test is the
compression strength index.
Porosity:
Porosity : expressed as the volume of pores as a
percentage of total volume of the material tested. Two
types of porosity are there open and closed . open pores
are those pore which is accessible to fluids.
Reducibility test:
This test determines the rate of reduction of raw
materials under blast furnace condition. Since condition
inside the b.f is different in different region from top to
bottom. So a special apparatus is designed to carry out
this test. Here we use a special apparatus with tempeartur
of 900- 1000 degree centigrade and reducing gas of co2
or co+N2 of constant composition for study. Here the
sample of know weight of certain fixed size and is placed
in the furnace in the form of static bed of fixed
dimension .
MODULE-1V
Primary energy resources of the World
80 58.75
60
40 17.39
20 8.91 12.32
0 0.52 2.08
Coal
• A combustible black/brownish-black sedimentary or
metamorphic rock primarily composed of carbon along
with other elements such as hydrogen, sulfur, oxygen and
nitrogen.
• Rank of a coal is the maturity of the coal.
• Peat lignite bituminous anthracite
• Peat has lowest rank as it is most immature where as
anthracite has highest rank
Some important terms
• Coalification or metamorphism is the process of
conversion of lignite to anthracite.
• Carbonization of coal is the heating of coal in absence of
air at high temperature to produce a residue coke, tar and
gas.
• Gasification of coal is the heating of coal with
insufficiently less quantity of air in addition to steam to
produce a gas rich in CO and H2.
• Caking and coking coal: when powdered coal is
carbonized, it forms an expanded lumpy mass. Such
coals are called caking coal and the phenomena called
caking of coal.
• However in cases where the residue is very hard and
strong it is called coke and the process called coking of
coal.
• All coking coal are caking in nature but not all caking
coals are coking in nature.
• Caking corresponds to a slower heating rate and coking
to a faster rate of heating.
• Bituminous coal is used essentially as coking coals.
Non caking/coking are those bituminous coals which
have high percentage of moisture and oxygen and do not
form gel on heating
Basis for reporting the analysis of coal
• Run of mine coal: The crude coal as obtained from the
mine is called as run of mine coal. There is no treatment
of coal like size reduction, moisture elimination etc.
• As received coal: from mines to costumer end
transportation involves size reduction, washing,
weathering etc. thus coal received at the customer end is
reported as received coal for the analysis.
• Air dried: during transportation and storage there may be
change in the moisture content depending upon the
atmospheric temperature and humidity.
• Dry coal: when study has to be done without the effect of
moisture, then coal analysis is reported as DRY basis.
• Dry-ash free(d.a.f.) : By eliminating both ash and
moisture content , data reported is Dry-ash free. This is
suitable for coal with low ash content (<10%)
• Dry-mineral matter free( d.m.m.f.) analysis is suited for
high ash content (>10%)
• Proximate analysis: finding out the weight percentages of
moisture, volatile matter, fixed carbon and ash in coal. It
gives an approximate composition of the coal to decide
its utility for a purpose.
• Ultimate analysis: finding out the percentage of carbon,
hydrogen, oxygen, nitrogen and sulfur of the pure coal
free from moisture and inorganic constituents. Used by
the designer of coal burning equipments.
• Combustion is an exothermic chemical reaction of a fuel
with oxygen or air at high temperature to liberate heat.
• Calorific value is the quantity of heat in kcal liberated by
the combustion of unit quantity of fuel.
• For solid and liquid fuel it is expressed in kcal/kg and for
gas it is kcal/Nm3 N means normal temperature and
pressure (0°C and 760 mmHg)
• Gross and net calorific value: gross calorific value
includes the latent heat during condensation of water
vapor formed during combustion and thus is higher than
net calorific value.
• Peat: It is the first stage product in the formation of coal
from wood under the action of temperature, pressure and
bacteria.
• Calorific value is around 4500kcal/kg.
• Light brown in color lots of fibers are present with
around 90% moisture.
• Mainly used as a domestic fuel after sun drying for 40-50
days.
Classification of coal
• Lignite: It is the second stage in the formation of coal. It
occurs in thick seam up to 30 meters of thickness.
• Having moisture content about 60% calorific value
reaches around 5000kcal/kg(on 10% moisture basis)
• On exposure to atmosphere, the brown color of lignite
darkens and the moisture content reduces to equilibrium
value of 10 to 20%.
• Major deposits are found close to the earth surface.
• Bituminous coal: It is the most common variety of coal.
Moisture content is less than 10% and carbon content
varies 75-90%.
• Calorific value on mineral matter free basis goes up to
9000 kcal/kg.
• Most of the coking coals are bituminous coal.
2-producer gas
as-
Different meani
aning in uk and usa
Usa: it is a gene
eneric name refers to wood gass , syngas ,
town gas
This gas is very
ery poisonous because it contain
in large
amount of carbo
rbon monoxide in it.
In uk it is alsoo ccalled suction gas
Here air is pass
assed over red hot carbon (coal) l) w
which
produce co . The
Th nitrogen in air remains unch changed and
dilute the gass , s it has a low calorific value .
3-blast furnace
ce gas- also called top gas
The gas is prod
oduced as a by product from the
he blast
furnace due to rreduction of ore
Composition : C
Co, 18-20%Co2, 60%N2, mois
oisture,
It has moderate
ate calorific value due to presenc
ence of Co in
it .
Its is used to drive
dri turbines and for reheating
ng purpose .
Gas is poisonou
ous due to presence of Co
Reference books
1- Mineral processing technology by Berry A Willis
2-principle of mineral dressing by A.MA .GAUDIN
Note pictures and diagram are taken from Mineral
processing technology by Berry A Willis books and from
internet .