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1、 Sorting
sorting is a mineral processing method to separate useful minerals and gangue minerals by using the physical properties of ore, such as surface characteristics, optical properties, electrical properties, magnetic properties, radioactivity and the absorption and reflection ability of ore to rays. Sorting is mainly used for the separation of massive and granular materials, such as removing large waste rock or picking out large rich ore. The upper limit of separation particle size is 250-300 mm, and the lower limit is 10 mm. For some precious minerals (such as diamond), the lower limit is 0.5-1 mm. For the separation of non-metallic minerals, sorting can be used to preconcentrate or obtain final procts. It has the following advantages: it can partly replace the selective mining method with low efficiency and high cost; Large pieces of waste rock are removed in advance to save the transportation, crushing, grinding and mineral processing costs of waste rock; Improve the grade of ore and the content of useful minerals; The waste rock can be used for backfilling and building materials to rece its environmental pollution
sorting can be divided into three ways: flow sorting (continuous sorting), partial sorting (heap sorting) and block sorting. Flow separation is to make a certain thickness of material layer continuously pass through the detection area; Partial separation and block separation means that one ore or one ore passes through the detection area alone. The quality of block selection or partial selection is better. At present, block selection is the main method in instry. There are two types of block picking: manual picking and mechanical picking
Manual sortingaccording to the appearance characteristics (color, luster, shape, etc.) between ore and waste rock, ore or waste rock can be sorted out by hand, and can be divided into forehand sorting (picking useful minerals from ore) and backhand sorting (picking waste rock from ore). It is mainly used for the separation of some ores which are difficult to be sorted by mechanical methods or whose quality can not be guaranteed. For example, asbestos with long fiber and massive mica are selected from ore; Large gangue is picked out from kaolinite of coal measures. Hand picking is the simplest way of picking, but it has high labor intensity and low efficiency
2. Mechanical sorting γ According to the difference reflected by radiation or the difference of natural radiation ability of ore, the separation of ore and gangue is realized by means of instrument. For example:
radioactive sorting: associated ores containing uranium and thorium elements
ray absorption sorting: coal, iron and chromium ores
luminescent sorting: diamond, fluorite, scheelite and asbestos
photoelectric sorting: gypsum, talc, asbestos, marble, limestone, magnesite, wolframite, diamond
electromagnetic sorting: metal sulfide ore and oxide ore
With the development of modern science and technology, especially the application of electronic computer, the mechanical sorting is becoming more and more perfect, the efficiency is greatly improved, and the application field is graally expanded. At present, photoelectric sorting is more commonly used in the non-metallic ore instry with mature equipment
Fig. 2-1 mechanical picking principle diagram
Mechanical picking principle is shown in Fig. 2-1. The ore to be selected falls into the radiation area proced by the radioactive body evenly through the vibrating chute. Different physical signals will be generated after the ores of different properties are irradiated. The detector will send the detected signals to the information processing system, which will amplify and identify the signals, and finally send the command signal to the actuator, The actuator can divide the material into useful ore and waste rock. Generally, the high-speed air valve with up to 300 times per second is used in the actuator, which greatly improves the proction efficiency. The modern electronic technology is used as the control system with high degree of automation. The modern sorting machine has become a high-tech mineral processing equipment with camera, computer and so on
Friction ore washing is a kind of technology to treat the ore which is stuck with clay or contains more mud, including crushing and separation. For non-metallic minerals such as quartz and feldspar, after long-term weathering, the primary ore deposits exposed on the surface are wrapped by the decomposition procts of clay minerals or rocks, forming cemented or argillaceous bodies. In this case, the method of friction washing and disintegration, which is different from ore crushing, is often used to separate mineral monomers before separation, which can not only remove the surface adhesion of mineral particles, but also prevent unnecessary crushing or over crushing. Usually, minerals are soaked and washed in water medium, supplemented by mechanical agitation (adding dispersant if necessary). With the help of friction between minerals, mineral particles adhered by slime are separated from clay impurities, which is called friction washing. The surface of some weathered or primary fine-grained non-metallic minerals can be purified by friction washing to expose the surface which can reflect the properties of the ore itself. After the impurities are removed, not only the mineral particles themselves can be purified, but also the conditions for the subsequent purification operation (such as flotation) can be improved. Scrubbing (ore scrubbing) can not only be used as the preparation for other purification operations, but also complete the purification of minerals separately
Fig. 2-2 friction ore washing machines are mainly friction ore washing machines, cylinder ore washing machines, trough ore washing machines, etc. In addition, the double screw scrubbing machine is often used in the scrubbing and purification of some non-metallic minerals such as quartz and diatomite. The structure of friction washer is shown in Figure 2-2
Ore washing and screening
ore washing is the separation of ore and slime by hydraulic washing or additional mechanical scrubbing. Commonly used equipment are washing screen, cylinder washing machine and trough washing machine
ore washing is often accompanied by screening, such as washing directly on the vibrating screen or sending the ore (clean ore) from the ore washing machine to the vibrating screen for screening. Screening can be used as an independent operation to separate procts with different particle sizes and grades for different purposes< Gravity separation
at present, gravity separation is only used to separate manganese ores with simple structure and coarse grain size, especially for manganese oxide ores with high density. The common methods are dense medium dressing, jigging dressing and shaking table dressing
at present, the technological process of manganese oxide ore treatment in China is to crush the ore to 6-0 mm or 10-0 mm, then divide it into groups, carry out jigging in coarse grade, and send it to shaker in fine grade. Most of the equipments are Hartz type reciprocating jig and 6-s type shaker
3. High intensity magnetic separation
manganese minerals belong to weak magnetic minerals [specific magnetic coefficient X = 10] × 10-6～600 × It can be recovered in the high intensity magnetic separator with magnetic field intensity ho = 800-1600ka / M (10000-20000oe), and the grade of manganese can be increased by 4% - 10%
because of its simple operation, easy control and strong adaptability, magnetic separation can be used for the separation of all kinds of manganese ores, and has been playing a leading role in manganese ore dressing in recent years. Various new types of high intensity magnetic machines for coarse, medium and fine particles have been developed. At present, the most common application of domestic manganese ore is medium grain high intensity magnetic separator, coarse and fine grain high intensity magnetic separators are also graally applied, and fine grain high intensity magnetic separators are still in the experimental stage< At present, the newly built and rebuilt gravity magnetic separation plants in China include Liancheng, Fujian, Longtou, Jingxi and Xialei manganese mines in Guangxi. For example, Liancheng Manganese Mine gravity magnetic separation plant mainly deals with leaching manganese oxide ore, and uses am-30 jig to treat 30-3mm washed ore, which can obtain high-quality manganese concentrate with more than 40% manganese. After manual separation, it can be used as raw material for battery manganese powder. The grade of manganese concentrate should be increased by 24% ～ 25% to 36% ～ 40% after jigging tailings and washed ore less than 3mm are grinded to less than 1m and separated by high intensity magnetic separator
5. High intensity magnetic flotation
at present, only Zunyi Manganese ore is used in high intensity magnetic flotation process. The ore is a low manganese, low phosphorus and high iron manganese ore mainly composed of manganese carbonate ore
according to the instrial test, the grinding process is rod mill ball mill, and the equipment scale is 100% φ 2100mm × 3000mm wet grinding machine. Shp-2000 high intensity magnetic separator is used for high intensity magnetic separation, and CHF air flotation machine is mainly used for flotation. After many years of proction test, the performance is good, it is very suitable for Zunyi Manganese ore dressing application. The successful test of high intensity magnetic flotation process and its application in proction indicate that the deep separation of manganese ore in China has made a big step forward
6. Pyrometallurgical enrichment
pyrometallurgical enrichment of manganese ore is a kind of separation method for treating refractory poor manganese ore with high phosphorus and high iron, which is generally called manganese rich slag method. Its essence is a high temperature separation method of selective separation of manganese, phosphorus and iron by controlling the rection temperature of manganese, phosphorus and iron in blast furnace or electric furnace
pyrometallurgical enrichment has been used for nearly 40 years in China. In 1959, experiments were carried out on a 9.4m3 small blast furnace in Zijiang iron works, Shaoyang, Hunan Province, and preliminary results were obtained. Then, in 1962, Shanghai ferroalloy plant and Shijingshan iron and steel plant smelted manganese rich slag in blast furnace respectively. In 1975, the blast furnace of Manaoshan manganese mine in Hunan Province not only smelted manganese rich slag, but also recovered lead, silver and pig iron (commonly known as semi steel) from the bottom of the furnace, providing a basis for comprehensive utilization. Since the 1980s, the proction of manganese rich slag has developed rapidly, and the proction of manganese rich slag has been developed successively in Hunan, Hubei, Guangdong, Guangxi, Jiangxi, Liaoning, Jilin and other places
pyrometallurgical enrichment process is simple and stable, which can effectively separate iron and phosphorus from ore, and obtain manganese rich, low iron and low phosphorus manganese rich slag, which generally contains 35% - 45% Mn, Mn / Fe? 12～38，P/Mn< 002, is a kind of high-quality manganese alloy raw materials, but also the general natural rich manganese ore is difficult to achieve the above three indicators of artificial rich ore. Therefore, pyrometallurgical enrichment is a promising method for refractory mineral processing with high phosphorus, high iron and low manganese in China< There are a lot of researches on chemical separation of manganese in China, among which there are many experiments, and the most promising ones are bisulfite method, black manganese ore method and bacterial leaching method. At present, it has not been put into instrial proction< At present, sintering method is widely used in China. Only when the manganese concentrate or fine ore is very fine and - 200 mesh is more than 80% and no resial carbon is allowed in the proct, pelletizing or briquetting is adopted
in the early 1950s, the sintering pot and local method were used to sinter manganese ore powder in China. With the development of iron and steel proction, indigenous sintering can not meet the requirements, so one after another to build sintering machine or other efficient briquetting equipment. In 1970, China's first fine manganese ore sintering machine (18m2) was built and put into operation in Xiangtan Manganese Mine. In 1972, Jiangxi Xinyu Iron and steel plant built two 24m2 sintering machines. In 1977, China's first manganese concentrate pelletizing equipment 80m2 belt roaster was built and put into operation in Zunyi Manganese Mine. In the 1980s, Xiangtan Manganese Mine, Bayi manganese mine and Xiangxiang ferroalloy plant have successively built more than 18-24m2 sintering machines, and Shanghai ferroalloy plant has imported ball pressing equipment as fine ore briquetting
the development of briquetting technology has brought greater economic benefits to the smelting of manganese alloys. Taking Jiangxi Xinyu Iron and steel works as an example, the technical indexes of blast furnace smelting can be greatly improved by increasing the clinker ratio and replacing hot sinter with cold sinter< (3) smelting of manganese ore
manganese ore mainly includes high carbon ferromanganese, medium and low carbon ferromanganese, manganese silicon alloy and metallic manganese, which are commonly known as
high carbon ferromanganese. Blast furnace is mainly used in China. In the 1950s, there was no special factory to proce blast furnace ferromanganese (high carbon ferromanganese), but some iron and steel plants smelted and sold by themselves, and the proction volume was very small. Since 1958, Xiangtan Manganese Mine has built 6.5m3 and 33m3 blast furnaces for smelting ferromanganese. After 1960s, Xinyu, Yangquan, No.3 plant of Masteel and No.4 plant of Chongqing Iron and Steel Co., Ltd. have transformed into blast furnace ferromanganese. In 1980s, the development of blast furnace ferromanganese is faster. The output of ferromanganese increased from 200000 tons in 1981 to 400000 tons in 1995
the procts proced by electric furnace include carbon ferromanganese, medium and low carbon ferromanganese, manganese silicon alloy and manganese metal. Jilin Ferroalloy Plant was the first one to proce EAF in China. It was built and put into operation in 1956. The maximum capacity of EAF is 12500kVA; In the early 1960s, Hunan, Zunyi and Shanghai ferroalloy plants were built and put into operation one after another. These plants can proce carbon ferromanganese, medium and low carbon ferromanganese and manganese silicon alloys; Zunyi ferroalloy plant also uses silicothermic method to proce manganese metal. According to the Ministry of metallurgical instry's main technical and economic indicators of national ferroalloy in 1995, 11 of the 15 major ferroalloy plants in China proced manganese series alloy procts in 1994. Through continuous development and expansion, these key ferroalloy plants have made important contributions to the proction of iron and steel instry
since the 1980s, local small and medium-sized ferroalloy enterprises have developed rapidly. According to statistics, the proportion of ferroalloy proction of local small and medium-sized enterprises in the whole country increased from 32.39% in 1980 to 54.01% in 1989, and reached 69.85% in 1996, with more than 1000 enterprises. Most of these small and medium-sized enterprises use 1800kVA small electric furnace, with backward equipment and poor proct quality
the equipment used in the proction of ferromanganese and silicomanganese alloy is basically the same, both of them are submerged arc furnace, and the transformer capacity of the furnace is generally 1800-12500kva. Hunan and Zunyi ferroalloy plants have imported 3000kva and 31500kVA Mn Si electric furnaces from Germany respectively, which have been put into operation
flux process is generally used in the proction of high carbon ferromanganese in electric furnace in China. The proction of manganese silicon alloy generally adopts slag method
the proction of medium and low carbon ferromanganese mainly includes electric furnace method, oxygen blowing method and shaking ladle method. Shaking ladle process includes direct proction of medium low carbon ferromanganese in shaking ladle and shaking ladle electric furnace process. The process of shaking ladle electric furnace is advanced, the proction is stable, and the technical and economic effect is good< There are pyrometallurgical and Hydrometallurgical methods for manganese proction. Pyrometallurgy of manganese began in 1959 in China. It was first successfully trial proced by Zunyi ferroalloy plant with silicothermic method, and has been exclusively proced up to now. The first step is to refine manganese ore into manganese rich slag; In the second step, manganese rich slag is used to refine high silicon silicon manganese alloy. In the third step, manganese rich slag is used as raw material, high silicon silicon manganese is used as recing agent and lime is used as flux. Hydrometallurgy is mainly electrolytic method, often called electrolytic manganese metal. In 1956, the first electrolytic manganese plant was built in Shanghai 901 plant. By the early 1990s, there were more than 50 large and small electrolytic manganese plants, with an annual total proction capacity of more than 40000 tons. The proction process is roughly divided into three proction processes: preparation of manganese sulfate solution, electrolysis and post-treatment. After treatment is the completion of electrolysis, including proct purification, washing, drying, stripping, packaging and other series of operations. Finally, the qualified EMM procts with Mn content of 99.70% ～ 99.95% were obtained
the beneficiation process of Belgian Magic Star Diamond generally includes preparation, roughing and cleaning. The preparation operations before beneficiation of Belgian Magic Star Diamond generally include crushing, screening, ore washing, grinding, hydraulic classification, etc. The purpose is to create good conditions for beneficiation in advance, so that the beneficiation can be carried out smoothly and obtain good results< Crushing
1.1. Crushing is the main preparation operation before the separation of Belgian magic star diamond primary ore. in the crushing stage, on the one hand, the coarse-grained ore should be fully dissociated, on the other hand, the crushing of Belgian Magic Star Diamond crystal should be reced as far as possible. In the process of ore crushing, the requirement of protecting crystal is more strict than crushing other ores. The crushing equipment is mainly jaw crusher, There are also gyratory crushers, hydro crushers, etc.
1.2. Screening
there are many places that need to use screening operation in Belgium Magic Star Diamond beneficiation. On the one hand, screening can timely separate the ore with appropriate particle size in the crushing stage, avoid excessive crushing of ore, rece power consumption and improve efficiency, It is also good for crystal protection: on the other hand, it can prepare for the next mineral processing operation. The screening equipment is the screening machine, the most commonly used is the vibrating screen, followed by the shaking screen.
1.3. Ore washing
the Belgian Magic Star Diamond placer and some primary ores contain a lot of clay minerals, It must be removed before mineral processing. Ore washing is the process of removing clay material from ore, including two stages of dispersing clay and separating the dispersed clay material from granular material. Commonly used ore washing equipment include high-pressure water gun, cylindrical ore washing machine, trough ore washing machine, etc.
1.4, The main purpose of grinding Belgian Magic Star Diamond ore is to dissociate all or most of the monomers of the fine Belgian magic star diamond in the ore, so that it can be recovered in the next step of mineral processing, Selective grinding can grind most ores to the required size, discard tailings and improve efficiency. Grinding operation is usually carried out in a rotating cylindrical mill. The mills include ball mill, rod mill and autogenous mill, The basic principle is that the medium (or ore itself) is used to grind the ore with impact phase.
1.5. Hydraulic classification
when the particle size of fine materials is separated, it is difficult to use the screening method, The basic principle of hydraulic classification is based on the difference of settling velocity in fluid e to the difference of particle size (or density). The main equipment for hydraulic classification is spiral classifier and hydrocyclone
the mineral processing flow of diamonds generally includes preparation, roughing and cleaning. The preparation operations before mineral processing generally include crushing, screening, ore washing, grinding, hydraulic classification, etc. The purpose is to create good conditions for mineral processing in advance, so that the separation operation can be carried out smoothly and obtain good results< In the crushing stage, on the one hand, the coarse-grained ore should be fully dissociated, on the other hand, the crushing of diamond crystal should be reced as much as possible. In the process of ore crushing, the requirement of crystal protection is more strict than that of crushing other ores. The crushing equipment is mainly jaw crusher, but also rotary crusher On the one hand, screening can timely separate out the ore with appropriate particle size in the crushing stage, avoid excessive crushing of ore, rece power consumption, improve efficiency, and also have benefits for crystal protection; on the other hand, it can prepare for the next step of mineral processing. The screening equipment is screening machine, The most commonly used is vibrating screen, followed by shaker screen.
1.3. Ore washing
diamond placer and some primary ores contain a large number of clay minerals, which must be removed before beneficiation. Ore washing is the process of removing clay materials from ores, including two stages of dispersing clay and separating the dispersed clay materials from granular materials Grinding
grinding is the continuation of the crushing process, which means that in mechanical equipment, the particle size of the ore is further reced by the impact and grinding of the medium and the ore itself, In addition, according to the difference of wear resistance between diamond and gangue minerals, selective grinding can grind most of the ore to the required size and discard tailings to improve efficiency. Grinding operation is usually carried out in a rotating cylindrical mill. The mills include ball mill, rod mill and autogenous mill, The basic principle is that the medium (or ore itself) is used to grind the ore with impact phase.
1.5. Hydraulic classification
when the particle size of fine materials is separated, it is difficult to use the screening method, The basic principle of hydraulic classification is based on the difference of settling velocity in fluid e to the difference of particle size (or density). The main equipment for hydraulic classification is spiral classifier and hydrocyclone
Ore washing machine is a large-scale equipment used to clean ore in black and non-ferrous metallurgical mines, iron and steel, metallurgy, chemical instry and building materials. It is divided into spiral ore washing machine and cylinder ore washing machine