Question

A complex open pit ore contains economic quantities of ferrous minerals, Hematite and
Magnetite, base minerals, Galena and Sphalerite, and industrial minerals, K-Feldspar, Zircon,
Corundum, and Kaolin. The ore also contains a significant proportion of slimy Talc and
Carbonaceous Shale gangue which is washed and discarded to the tailings dam.
Description of flowsheet:
Primary crushed Run-of-Mine ore is washed on grizzley bar screens. Screen oversize proceeds
to secondary crushing while undersize is further screened and classified in small cyclones. Most
of the Talc and Carbonaceous Shale reports to cyclone overflow and is discarded to the tailings
dam. Secondary crusher product is subjected to heavy medium separation (HMS) in ferrosilicon
medium of SG 2.3. Galena, Sphalerite, Hematite, and Magnetite report to the “Sink” fraction and
K-Feldspar, Zircon, Corundum, and Kaolinite report to the “Float” fraction. From this stage, the
“Sink” and “Float” streams are treated in adjacent but dedicated plants.
The “Float” stream undergoes tertiary crushing and grinding followed by silica flotation to
produce high grade K-Feldspar for glass manufacture. Tailings of silica flotation are subjected to
electrostatic separation to produce industrial grade concentrate containing Zircon, Corundum,
and Kaolin. Reject from electrostatic separation is discarded to the tailings dam.
The “Sink” stream is subjected to magnetic separation where magnetic minerals, Hematite and
Magnetite, are concentrated and fed to the blast furnace. The non-magnetics, Galena and
Sphalerite, are treated by differential flotation to produce separate lead and zinc concentrates.
Tailings from lead and Zn flotation are discarded to the tailings dam.
Draw a block diagram of the flowsheet.

Answer 1

Ko

Raw-complex unden size) eper pixe Segen Crusher Crusher lunder Small Acyclones Washed on Grizzley bar und Screens Loversized Tale and ' Carbonaceous Shale Secondary Crusher Discarded Dam Heavy Modium 1. Seperation - HMS terrosilicen med. of SG 2.3 (Sink ) ( Float Galena, Spralenite,' il Hematite, Magnetite K-Feldspar, Corurdum Kaolinite Tertiary crushing) Magnet ersation) (Silica Floatatim) Non Magnetic materials Hematite & - Magnetite (concentrated) High magnetic minerals Galena Sphalerite Grade R-feldspar Electrostatic Seperation Differential ! Blast Furnate) Floatim Tailing (Dam) Rejected tailing Dam Corundum . Kaoline · Rih Concentrated Concentrated Pb Zine