Maximize the results of processes like flotation and thickening thanks to precise instrumentation
Declining ore grades pose a special challenge for mining operations. Of course there are various processing techniques to get the most out of the raw materials like leaching, thickening and flotation. But naturally they consume energy, chemicals and water. Which means that, to balance out the yield and the costs, the extraction processes must run at an optimum level. Especially in times of volatile markets and prices.
35%
productivity loss in mining
That is the result of a study done by the international consulting group McKinsey. They state that mines worldwide lost roughly one third of their productivity in the years 2004-2014.
Leaching, flotation and thickening are fundamental steps in modern mining separation processes. Achieving an optimal separation however is a complex task due to the many interconnected variables. All three processes use chemicals which are one of the main cost drivers. And they consume also a lot of water, which in some mining regions can be a very scarce resource, which the plants first have to produce through processes like desalination of salt water for example.
Leaching
Froth flotation
Thickening
Applications
Leaching
Leaching is an extraction method that uses acid solutions that are sprayed on crushed ore to generate a pregnant solution with the desired metal. The acids used depend on the type of ore to be leached.
Our expertise in the field
It has been shown that the concentration and the irrigation flow rate of the acid solution has a significant impact on the yield and the acid consumption. Endress+Hauser can offer measuring instruments for parameters that can withstand the aggressive nature of the acids and deliver reliable data.
Our digital analytical sensors feature non-contact digital data transmission and simple sensor exchange using pre-calibrated sensors reduces process downtime and regular regeneration extends sensor lifetime.
Flotation is used in various mining processes, such as gold and copper mining, to recover mineral particles which are finer than 500 micron or 35 mesh. Various parameters influence this process and by that your yield. The most important parameters for process efficiency are: flow and density measurement of feedstock, froth height, precise determination of the froth and liquid slurry interface, liquid pH and Eh, dosing and quality of chemical reagents and air flow.
Our expertise in the field
Endress+Hauser not only has instruments for all these tasks but also offers a variety of measuring technologies to ensure you can use the optimum instrument for your process – all from a single source.
For the measurement of the feedstock, we recommend using an electromagnetic flowmeter with integrated solids content calculation.
To determine froth height and froth/slurry interface the ideal solution is using two ultrasonic sensors. One measures the distance to the froth, the second sensor measures the distance to a target plate connected to a rod and a conical float..
Our digital analytical sensors for pH and Eh measure reliably even in harsh environments.
The dry solids content, the feed rate and the froth height can be used as a feed forward signal for the xanthate, frother and pH modification chemical dosing control loop. Our Coriolis flowmeter can input these parameters and enable accurate dosing.
Air is used in flotation for agitation. By measuring the air flow the costs for creating compressed air can be optimized. Our vortex flowmeter is not affected by plant vibration or air hammers, and offers high accuracy and a wide measuring range.
Thickening is a mineral concentration process based on gravity settling. Solids settle on the tank bottom, a process which is accelerated by the addition of flocculent.
Our expertise in the field
Important indicators are bed level, bed mass, underflow density and flow to calculate the total slurry volume, and overflow clarity for final quality assurance. By measuring all these parameters, operators can make the whole process more efficient and safer by reducing the risk of tank overflow.
Measuring the bed level is one o f the most important parameters for this process. It is ideally measured using submersible sonar technology. Depending on the bed level, the dosing of the flocculent - measured with a flowmeter - can be optimized.
"The biggest challenge that I see when I visit customers is that they do not use the full potential of their data which they can gather from their sensors. 97% of the data is untapped."
Benefits
Whatever challenges you face with your extraction processes - be it low yields, high OPEX or expensive maintenance routines - thanks to the in-depth industry expertise of our consultants they know exactly how to improve your processes. Together with our customers they have achieved remarkable results during the past 60 years - thanks also to our industry-optimized instrumentation portfolio.
Memosens pH sensors reduced the time spent on calibrations and field repairs by up to 90% at Agnico Eagle's gold mine in Kittilä, the largest primary gold producer in Europe.
The measurement of interface in thickeners is done manually, while the turbidity measurement is done by obtaining samples sent to the laboratory. With Endress+Hauser there is an automated solution.
Water, beverages, dairy products, chemicals or pharmaceuticals have to be analyzed every day. Choose the device best suited to your process needs from our comprehensive product portfolio.
Flowmeter
Flowmeter
Water, natural gas, steam, mineral oil, chemicals are some of the fluids that have to be measured day in, day out. Select the flowmeter best suited to your process needs.
Level
Level
Continuous level measurement and point level detection in liquids and bulk solids
Pressure
Pressure
Powerful instruments for process pressure, differential pressure, level and flow.
Software
Software
Apart from all relevant measuring and system technologies, we also offer appropriate software for all branches of industry that provide to run your operating processes at its full potential.
System products
System products
Applicator
Temperature measurement
Temperature measurement
Thermometers and transmitters for the process industry
Instrumentation Services
Instrumentation Services
Maximize plant performance, minimize OPEX, increase uptime, all with compliance. Partner with Endress+Hauser instrumentation services.
Endress+Hauser is dedicated to helping you meet your operating targets throughout the water cycle by combining an innovative portfolio of measuring instruments, expert services and industry expertise.
Food & Beverage: Trust in quality
Food & Beverage: Trust in quality
Your partner to meet global hygiene regulations, ensure consistent product quality and plant availability while conserving resources and lowering costs.
Life Sciences: Innovative technology for process excellence
Life Sciences: Innovative technology for process excellence
Partner with us to accelerate your journey from bench-top to production, minimizing risk at every step
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