Lyntas/mining_domain_knowledge_reference_dataset huggingface dataset:
Area: Minning Projects 
Ore beneficiation plant
In the mining industry beneficiation or benefication in extractive metallurgy, is any process that improves (benefits) the economic value of the ore by removing the gangue minerals, which results in a higher grade product (concentrate) and a waste stream (tailings). Exemplary beneficiation processes are froth flotation and gravity separation.
Area: Minning Projects 
Flotation Cells
The froth flotation process is commonly employed for the selective separation of a mineral species from a liquid solid suspension of both valuable and unwanted gangue mineral particles

A mechanical flotation cell essentially consists of a vessel or a tank fitted with an impeller or rotor. The impeller agitates the slurry to keep particles in suspension, disperses air into fine bubbles and provides an environment in the cell tank for interaction of bubbles and hydrophobic particles and their subsequent attachment and therefore separation of valuable mineral particles from the undesired gangue mineral particles. The bubble particle aggregates move up in the cell by buoyancy and are removed from the cell lip into an inclined drainage box called a launder.
Area: Minning Projects 
Size Control
Size control is the tool for improvement of the size fractions in the process stages and in the final products. For the coarser part of the process, screens are used (in practise above 1-2 mm). In the finer part we have to use classification with spiral classifiers, see section 4.
Area: Minning Projects 
Secondary crusher  Type
In a rock crushing circuit, the second stage normally starts to be of importance for control of size and shape. Because of this the jaw crusher, in most cases, is disqualified as secondary crusher.
Instead the cone crusher is used more frequently. Also in comminution (crushing and grinding) circuits for ore and minerals the cone crusher is frequently used as the secondary stage, see 3:4. Using a secondary HSI means as always a restriction in feed hardness and abrasiveness.
Area: Minning Projects 
Final crushing stage  More than just crushing
For many rock and gravel crushing circuits the final crushing stage is of special interest. The final sizing and shaping will take place in this stage influencing the value of the final product.
For hard, abrasive rock circuits Cone crushers, Vertical Shaft Impactors (VSI) or High Pressure Grinding Rolls (HPGRs) can be used
Area: Minning Projects 
VSI  A rock on rock autogeneous crushing impactor
Horizontal impactors normally use rock to metal impaction. This means a restriction in crushing circuits with hard feed material, when wear can be dramatically high.
The VSI Impactor of Barmac type is using a rock-to-rock impaction technology where most of the design is protected by rock, see below. This means that we can use the advantages of the impaction techniques also in hard, abrasive rock operations.
The crushing action takes place in the rock cloud in the crushing chamber, not against the rock protection
Area: Minning Projects 
High Pressure Grinding Rolls (HPGRs) - HRC
HPGRs utilize two counter-rotating tires  one fixed and one floating  in order to effectively crush ore. Hydraulic cylinders apply very high pressure to the system, causing inter-particle comminution as the feed travels between the two tires.
The basic operating principle behind HPGRs makes them very energy efficient
Area: Minning Projects 
rinding  Introduction
Size reduction by crushing has a size limitation for the final products. If we require further reduction, say below 5-20 mm, we have to use the processes of grinding. Grinding is a powdering or pulverizing process using the rock mechanical forces of impaction, compression, shearing and attrition
Grinding  Tumbling mills

 Wet or dry  Primary, coarse grinding (up to 400 mm feed size)  Grinding media is grinding feed  High capacity (short retention time)  Sensitive to feed composition (critical size material),
Area: Minning Projects 
Semi  Autogenous (SAG) mill

 Wet or dry  Higher capacity than A-G mill grinding  Primary, coarse grinding (up to 400 mm feed size)  Grinding media is grinding feed plus 4-18% ball charge (ball dia.100-125 mm)  High capacity (short retention time)  Less sensitive to feed composition (critical size material), see data sheet 3:44
Area: Minning Projects 
Size Control
In mineral processing practices we have two methods dominating size control processes:
Screening using a geometrical pattern for size control
Classification using particle motion for size control
There are many types of screens, but they can be reduced to the four types shown below.
Area: Minning Projects 
Classification  Introduction
For size control of particles finer than 1 mm, we are moving out of the practical range of conventional screens. Classification is the process of separating particles by size into two or more products according to their behaviour in air or water (liquids).
Classification methods
 Wet classification with hydrocyclones using separation by centrifugal force covering the size range of 100 10 micron (typical)
 Wet classification with spiral classifiers using separation by gravity covering the size range of 100  1000 micron (typical)
 Dry classification using separation by centrifugal force covering the range of 150  5 micron (typical).
Area: Minning Projects 
Hydrocyclone
Centrifugal forces classify solids by size (mass). High mass particles closer to outer wall reporting to underflow. Low mass particles closer to the centre reporting to overflow.
Hydrocyclone design 
1. Vortex finder 2. Inlet head 3. Spigots (apex) 4. Overflow elbow 5. Feed inlet 6. Barrel 7. Cones 8. Cone extension
Area: Minning Projects 
Spiral classifier
By combining a gravity settler of rectangular section with a sloped transport spiral for the sediment  we have a spiral classifier
Area: Minning Projects 
Enrichment  Washing
 Washing, mainly used in the enrichment process of industrial minerals, coal, aggregates, sand and gravel, normally with the products in solid form (size = 1 mm and coarser)
 Separation, mainly used in the enrichment processes of metallic minerals and high value industrial minerals, normally with the products in liberated particle form (size = 1mm and smaller)
Washing is the simplest method of enrichment used to improve the value of rock and mineral fractions from sand size and upwards. Removing of surface impurities like clay, dust, organics or salts is often a must for a saleable product.
Different techniques are used depending on how hard these impurities are attached to the rock or mineral surface, see section 5
Area: Minning Projects 
Tumbling scrubber
If solids of rock, gravel or minerals contain a high and sticky content of clay and dirt that has to be removed, wet screening is normally not effective enough. A medium speed washing drum for scrubbing solids against solids is then the option. The drum is relatively short in relation to its diameter. Water requirements per ton is the same as for wet screening. Typical capacities 8 120 t/h.
Area: Minning Projects 
Attrition scrubber
These scrubbers are mainly used for washing of material below 10 mm in size. Very high energy inputs are possibly used for washing of silica sand for glass making and cleaning of foundry sand. The machine is also suitable for clay blunging and lime slaking,
Area: Minning Projects 
Wash water treatment  closed system
After recovery of coarser material the fines can be treated in a closed system recovering all process water and bringing the fine solids into a transportable form.
Area: Minning Projects 
Enrichment  Separation
Most value minerals (both metallic and industrial) are priced by their purity. After liberation by size reduction and size control all minerals are free to be separated from each other.
Depending on the properties of the individual minerals they can be recovered by different methods of separation
Area: Minning Projects 
Upgrading
After the enrichment operation we end up with a value product (concentrate) and a non-value product (tailings). These products are probably not sellable nor disposable due to the content of process water, particle size, or chemical composition.
By upgrading we mean the methods of increasing the value of these products by sedimentation, mechanical dewatering, drying, calcining or sintering and recovering the process water from the tailings, making them disposable, see section 6.
Area: Minning Projects 
Separation by shaking tables
A cross stream of water transports material over the table to riffles running perpendicular to the direction of feed. Particles build up behind each riffle and stratification occurs with heavier particles sinking to the bottom. The light particles are carried over each riffle to the tailings zone. The shaking action of the tables carries the heavy particles along the back of each riffle to the concentrate discharge.
Area: Minning Projects 
Separation by flotation
Flotation is a mineral separation process, which takes place in a water-mineral slurry. The surfaces of selected minerals are made hydrophobic (water-repellent) by conditioning with selective reagents. The hydrophobic particles become attached to air bubbles that are introduced into the pulp and are carried to a froth layer above the slurry thereby being separated from the hydrophilic (wetted) particles. In addition to the reagents added, the flotation process depends on two main parameters.
 Retention time needed for the separation process to occur determines the volume and number of flotation cells required.
 Agitation and aeration needed for optimum flotation conditions, determine the type of flotation mechanism and the power input required.
Area: Minning Projects 
Flotation circuit layout
Flotation circuit designs vary in complexity depending primarily on the type of mineral, degree of liberation of valuable minerals, grade (purity) of the product and the value of the product.
Area: Minning Projects 
Reactor cell flotation system (RCS)
The RCSTM (Reactor Cell System) flotation machine utilizes the patent protected DVTM (Deep Vane) mechanism. Flow pattern characteristics are
Area: Minning Projects 
DR Flotation cell system
The Reactor Cell System Flotation Machine is the preferred choice for many mineral flotation applications. The DR design may be specified for certain applications, particularly where de-slimed coarse particles have to be handled such as in glass and potash processing. Features of the DR design are as follows.
Area: Minning Projects 
Column flotation cells
Column flotation cells, like mechanical cells, are used to perform mineral separations. Column cells do not use mechanical agitation (impellers). Instead, mixing is achieved by the turbulence provided by the rising bubbles. Columns are mostly used to produce final grade concentrates because they are capable of high selectivity. Other features which distinguish them from mechanical cells are their shape, bubble generation system and the use of wash water. An optimum flotation circuit is a combination of mechanical cells and column cells
Applications for flotation columns include:
 Sulfides  Iron ore  Phosphate  Coal  Industrial minerals  Potash
With upgrading we understand, the further processing of the final products from the enrichment stages in a process.
This is valid both concerning the valuable minerals (the concentrate) and the waste minerals (the tailings). In the first case upgrading means improving the product value by bringing the concentrate to transportability or into a completely dry form. Processing can also go further to calcining and sintering. On the tailing side upgrading means that waste material (wash water, process effluents etc.) is properly taken care of in order to protect the environment, to recover process water and to turn certain portions into valuables.
Area: Minning Projects 
Sedimentation
Sedimentation is a continuous solid-liquid separation process with settling of solids by gravity. 
Clarification is the process for removal of solids from a dilute solid/liquid suspension. 
Thickening is the process for concentrating particles in a supension by gravity compression
Area: Minning Projects 
Flocculation
All sedimentation technologies are related to particle size. One way of improving the settling speed generally is therefore to increase the size of the particles. Fine particles can be connected together by coagulation or flocculation. The settling rate of the combined particles will be higher than that of each individual particle. This can also be applied prior to mechanical dewatering.
Area: Minning Projects 
Flocculation system
A handling system is needed for flocculent utilisation. This comprises provision to mix, store and dilute the polymer. The dilute polymer is then mixed with the feed slurry and allowed to condition (or age) before a sedimentation or dewatering process.
Area: Minning Projects 
Conventional clarifier
Clarification is achieved when the liquid upstream velocity VL (rise rate) is lower than the sedimentation velocity of the solids VS
Area: Minning Projects 
Conventional clarifier  sizing
Clarifier diameter is selected to give a suitable upstream velocity (m/h). Sizing is usally done using Surface Load, meaning the volume of slurry m3/h fed per m2 of clarifier surface. Typical surface loads are given below.
Area: Minning Projects 
Conventional thickener
Continuous thickening to give the required solids concentration in the underflow depends on balancing the volumetric solids flow rate at a critical concentration with the diameter of the thickener.
Area: Minning Projects 
Conventional clarifier/thickener  Design
Bridge type
For smaller thickeners, up to 30  40 m diameter, the rakes and drive mechanism are supported on a bridge superstructure, which straddles the tank as shown.Centre pier type
For tanks over 30  40 m diameter a bridge structure will be impractical. The mechanism and rakes are therefore supported from a centre pier and the bridge is only used for access and to support feed pipe and launder.
Area: Minning Projects 
Inclined Plate Settler  IPS
The inclined plate settler consists of two main components, the upper tank containing the lamella plates inclined at 55° and the lower conical or cylindrical sludge container.
The feed for the inclined plate settler enters through vertical chambers on either side of the lamella packs and passes into each plate gap through slotted feed ports.
Clarification takes place above the suspension inlet so there is no mixing of the clarified fluid with the incoming feed.
Above each pack is a full-length overflow launder fitted with throttling holes to create a slight hydraulic back pressure on the incoming feed stream. This method of feed control guarantees equal distribution to all lamella chambers with minimum turbulence at the entry points.
The solids settle onto and slide down each lamella plate to the sludge container where the solids are further thickened and compressed with the assistance of the raking system
Area: Minning Projects 
Mechanical dewatering  Introduction
Mechanical dewatering means mechanical removal of liquids from a slurry to obtain the solids in a suitable form and/or recovery of a valueable liquid for:
 Further processing  Transportation  Agglomeration  Disposal  Recovery of valuable liquids
Area: Minning Projects 
Gravimetric dewatering
When the particles in a slurry are too coarse for the capillary forces to trap the water, the use of gravity is enough to remove the water and give at least transportable solids.
Area: Minning Projects 
Al Jalamid Beneficiation Plant  12Mtpy
Dec 17, 2007
RIYADH, Saudi Arabia, 17 DEC 07: Ma'aden has today signed the final two major plant contracts for its mega phosphate project. The contracts are for the power & desalination plant as well as the beneficiation plant of what will be the worlds largest fully integrated phosphate fertilizer complex.
The power and desalination plant which will be located at the phosphate processing complex at Ras Az Zawr will be undertaken by Hanwha Engineering and Construction Corporation (Hanwah) of Korea. The value of the contract is US$280 million.
The beneficiation plant will be located at the phosphate mine site in Al Jalamid in the north of the Kingdom. The US$350 million contract was won by Guizhou Hongfu Industry and Commerce Development Co. Ltd. (Hongfu) of China.
Speaking at the signing ceremony for the two contracts, Ma'aden President and CEO, Dr Abdallah Dabbagh said, As with the other major contracts for the phosphate project, we have scoured the globe for the right partners with the right experience and expertise. Both Hanwah and Hongfu have met our specific criteria and I am very pleased to welcome them both to this monumental project.
The signing of these two contracts means now that all major plant contracts have been agreed. Work at the Ras Az Zawr site has already begun with the driving of piles for the sulphuric acid plant and started basic construction of foundations. This project is now very much a reality and on track to deliver the first phosphate fertilizer to waiting markets to feed the world in the last quarter of 2010.
Area: Minning Projects 
Power & Desalination Plant
Site mobilisation for the power and desalination plant will commence in January 2008 with construction stating in May of that year. The plant is expected to be completed and fully operational by the middle of 2010.The power plant consists of 2 x 66% Siemens Condensing Steam Turbines & Generators, with an output of 126.76MW base load and 146.53MW peak load. The phosphate project is expected to be a net exporter to the grid of approximately 10MW, depending on final load examination.
The desalination plant will utilise Entropie Multi Effect Distillation (MED) and can process up to 40,000 cubic metres per day. The plant will also include storage facilities for desalinated, process and potable water.
Area: Minning Projects 
Beneficiation Plant
Construction on the beneficiation plant at Al Jalamid will commence in April 2008, with completion expected by May 2010.
The beneficiation plant is required to remove calcium and magnesium carbonates from the phosphate deposit run-of-mine ore to produce 4.63 MTPY dry phosphate concentrate suitable for use in the manufacture of phosphoric acid.
The beneficiation plant physical limits are comprehensive, starting with the primary crusher located in the mine area, an overland conveyor, run of mill (ROM) storage, crushing and milling circuit, de-sliming, conditioning, flotation, dewatering, filtration, wet concentrate storage, concentrate drying, and rail car load-out, pumping plant tailings to the tailings dam, as well as a central control building and fuel & chemical reagent storage tanks.
The Scope of Work includes the provision of all professional and technical services, labour, equipment, facilities and materials and all other functional services necessary and required to engineer, procure, construct, commission and performance test the beneficiation plant facilities on a lump sum turn key basis, as defined in the contract.
Area: Minning Projects 
About Maaden
Ma'aden was established as a Saudi Arabian joint stock company in March 1997 to facilitate the development of Saudi Arabias non-petroleum mineral resources and to diversify the Kingdoms economy away from the petroleum and petrochemical sectors. Maaden is engaged in the development, advancement and improvement of all aspects of the mineral industry, mineral products and by-products and related industries in Saudi Arabia. In July 2008 Maaden offered 50% of the companys shares for subscription in a successful SR 9.25 billion IPO. Maaden has progressed towards realizing its vision of building a world class mineral enterprise and its mission of being a profitable, publicly owned, international mining company, while maintaining the utmost concern for human resources, health and safety, environmental and social issues.
Area: Minning Projects 
Involved in Projects management in varying capacity, prepare close out reports for Al Jalamid
projects, involve in reviewing the design of the new assets water treatment plant, new 2 impact
crushers, rod mill and belt filter. Supervision of assets construction. Prepare scope of work for all modification to plant, prepare commissioning procedures, witness the performance tests, etc.
Area: Minning Projects 

 Involved with PMC team in pre-commissioning and commissioning of the 3 GE/GTG and main
substation building, this included review method statements, the walk down, generate punch list, test
packages and witnessing the hydro tests
 Involved in field checking equipment installations against P&ID, liasing with beneficiation Contractor with respect to construction schedule, developing and categorizing of punch list to achieve mechanical
completion.
Area: Minning Projects 
XXX has assisted as a technical expert with Pre-commissioning and commissioning of the beneficiation plant including the following sub-systems: Primary crusher, secondary crusher, stacker and reclaimer, milling and desliming systems, reverse flotation, 
wet concentrate storage, drying and tailings disposal.
 Monitored and supervised the beneficiation plant reliability and preliminary performance tests.
 During reliability and performance tests a number of problems were identified that needed to be
attended to before the handover of the plant. These are summarised as:  Water shortage - The basic design of the beneficiation plant was assumed that the fresh water required to run the plant at 100% designed capacity is 801m3/hr, in addition to 726 m3/hour as a make-up water used from filtrate and tailings thickener overflow water recycled directly into grinding and Desliming circuit. During
plant operation and due to collector residual in the recycled water which resulted in failure of grinding-
Desliming system performance. The contractor was obliged to use a 726m3/hr of raw water to compensate the contaminated recycled water. The maximum water available from the 7 water wells at AJ is 1050m3/hr
Accordingly, the shortage in water required to run the plant at maximum capacity is 726 m3/hr. The
contractor is working on solution to resolve this problem
 Excessive foaming - This problem is preventing the plant to operate over 70% of the designed capacity
 Lower grade- The average grade obtained during preliminary performance test is 31.5% P2O5 versus the designed grade 32.5% P2O5
 Action: The contractor Wengfu has worked on several modifications to the tailings thickener in order to improve the thickener performance. After the modification the overflow process water quality has been
improved and the foaming was less. A further modification will be carried out on thickener feeding pipes and installing a new pipeline from overflow tank to process water tank in milling and Desliming area. The
contractor has submitted a technical and financial proposal to MPC to resolve the water shortage problem. A
detailed laboratory tests were carried out by Wengfu in China to determine the ultimate design for the required water treatment facility.