Minerals and coal : process calculations

The aim of process calculations is to evaluate the performance of minerals and coal processing operations in terms of efficiency of the operation, grade of the final products and recovery of the required constituents. To meet these requirements, in-depth detailed calculations are illustrated in this book. This book is designed to cover all the process calculations. The method and/or steps in process calculations have been described by taking numerical examples. Process calculations illustrated in a simple and self explanatory manner based on two basic material balance equations will allow the reader to understand the contents thoroughly. Inclusion of elaborate process calculations in every chapter is the highlight of this book. This book is unique and devoted entirely to the process calculations with sufficient explanation of the nature of the calculations. This book will prove useful to all: from student to teacher, operator to engineer, researcher to designer, and process personnel to plant auditors concerned with minerals and coal processing. Content: 1. Minerals and coal 1.1 Types of minerals 1.2 Mineral processing 1.3 Coal 1.4 Varieties of coal 1.5 Coal processing 1.6 Problems for practice 2. Material Balance 3. Sampling 4. Size analysis 4.1 Sieve analysis 4.2 Testing method 4.3 Presentation of particle size distribution data 4.4 Particle size distribution equations 4.5 Size assay analysis 4.6 Problems for practice 5. Screening 5.1 Purpose of screening 5.2 Screen 5.3 Screen action 5.4 Material (mass) balance 5.5 Screen efficiency 5.6 Tromp curve 5.7 Problems for practice 6. Density 6.1 Solids and pulp 6.2 Retention time 6.3 Miscible liquids 6.4 Problems for practice 7. Liberation 8. Comminution 8.1 Objectives of comminution 8.2 Laws of comminution 8.3 Types of comminution operations 8.4 Problems for practice 9. Crushing 9.1 Types of crushers 9.2 Crushing operation 9.3 Open circuit and closed circuit operations 9.4 Problems for practice 10. Grinding 10.1 Grinding action 10.2 Wet and dry grinding 10.3 Grinding circuits 10.4 Problems for practice 11. Principles of settling 11.1 Laminar and turbulent flows 11.2 Fluid resistance 11.3 Terminal velocity 11.4 Free settling 11.5 Hindered settling 11.6 Equal settling particles 11.7 Settling ratio 11.8 Settling of large spheres in a suspension of fine spheres 11.9 Problems for practice 12. Classification 12.1 Classifiers 12.2 Efficiency of separation in hydrocyclone 12.3 Problems for practice 13. Beneficiation operations 13.1 Gravity concentration 13.2 Froth flotation 13.3 Magnetic separation 13.4 Electrical separation 14. Sink and float 15. Float and sink 15.1 Float and sink test 15.2 Near gravity materials 15.3 Yield reduction factor 15.4 Washability index 15.5 Optimum degree of washability (ODW) 15.6 Washability number 15.7 Effect of sizing on washability characteristics of coal 15.8 Mayer curve 15.9 Problems for practice 16. Metallurgical accounting 16.1 Two products beneficiation operations 16.2 Three products beneficiation operations 16.3 Separation efficiency 16.4 Economic efficiency 16.5 Problems for practice 17. Coal washing efficiency 17.1 Dependent criteria 17.2 Independent criteria 17.3 Problems for practice 18. Process plant circuits 18.1 Water requirements 18.2 Flotation contact time 18.3 Coal analysis and washability 18.4 Additional problems for practice Cover -- Half Title -- Title Page -- Copyright Page -- Dedication -- Table of Contents -- Preface -- Acknowledgements -- List of tables -- List of figures -- 1 Minerals and coal -- 1.1 Types of minerals -- 1.2 Mineral processing -- 1.3 Coal -- 1.3.1 Proximate analysis -- 1.3.1.1 Determination of moisture -- 1.3.1.2 Determination of volatile matter -- 1.3.1.3 Determination of ash -- 1.3.1.4 Determination of fixed carbon -- 1.3.2 Expression of analytical results on different bases -- 1.3.2.1 As received or As sampled -- 1.3.2.2 Air-dried -- 1.3.2.3 Dry or moisture free -- 1.3.2.4 Dry, ash free (d.a.f) -- 1.3.2.5 Dry, mineral matter free (d.m.m.f) -- 1.3.3 Calculations on different bases -- 1.3.3.1 As received or As sampled basis -- 1.3.3.2 Air-dried basis -- 1.3.3.3 Dry or moisture free basis -- 1.3.3.4 Dry, ash free (d.a.f) basis -- 1.3.3.5 Dry, mineral matter free (d.m.m.f) basis -- 1.4 Varieties of coal -- 1.5 Coal processing -- 1.6 Problems for practice -- 2 Material (mass) balance -- 3 Sampling -- 4 Size analysis -- 4.1 Sieve analysis -- 4.2 Testing method -- 4.3 Presentation of particle size distribution data -- 4.4 Particle size distribution equations -- 4.5 Size assay analysis -- 4.6 Problems for practice -- 5 Screening -- 5.1 Purpose of screening -- 5.2 Screen -- 5.3 Screen action -- 5.3.1 Factors affecting the rate of screening -- 5.4 Material balance -- 5.5 Screen efficiency -- 5.6 Tromp curve -- 5.7 Problems for practice -- 6 Density -- 6.1 Solids and pulp -- 6.2 Retention time -- 6.3 Miscible liquids -- 6.4 Problems for practice -- 7 Liberation -- 8 Comminution -- 8.1 Objectives of comminution -- 8.2 Laws of comminution -- 8.3 Types of comminution operations -- 8.4 Problems for practice -- 9 Crushing -- 9.1 Types of crushers -- 9.2 Crushing operation -- 9.3 Open and closed circuit crushing operations