213/24, 25 PM Mineral Processing Plot Plant Equipment
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Mineral Processing Pilot Plant Equipment
The testing of tonnage lots of ores and industrial materials by continuous Mineral Processing Pilot
Plant operation is in many instances advisable before a full scale milling plant is installed. The
treatment of complex ores by new processes or by the use of new or unusual reagents in flotation
may involve problems the effect of which should be studied under small scale continuous operating
conditions.
The milling of ores by fine grinding and flotation requires the establishment of closed circuits where
middling or unfinished products are returned to various points in the flowsheet for additional
treatment. Where unusual flotation reagents are used, or when an intricate flowsheet is required, the
effect on the operation is not satisfactorily determined from batch laboratory tests.
Commercial operation of the cyanidation process for the treatment of gold and silver ores involves the
continuous re-use of much of the cyanide solution after removal of the dissolved gold or silver by
precipitation, This introduces the problem of the dissolution of undesirable base metal salts especially
when complex or partially oxidized ores are treated. These salts may build up in the solution and act
as cyanicides to affect the rate of dissolution of the gold or silver by cyanide and also affect the
efficiency of prescription methods.
The milling of complex ores may require the use of combined methods of treatment such as gravity
concentration and flotation, or coarse flotation followed by slime flotation, or gravity and
amalgamation followed by cyanidation,
The continuous Metallurgical Processing Pilot Plant test offers ample opportunity for the study of
all such problems under the same conditions as would exist in a large milling plant. The results thus
secured will eliminate the need for costly experimentation with large tonnages of ore when the
commercial plant is placed in operation, and assures selection of the proper size and type of
equipment. It also affords an excellent opportunity for the operating personnel of the proposed milling
plant to become familiar with the various problems which are presented by the ore treatment. The
determination of the best method of feeding certain reagents, the effect of various pulp densities upon
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911metallurgist.com has maintained a complete continuous Pilot Plant Equipment for several years.
The operation of this plant on numerous classes of ores, both metallic and non-metallic has provided
much information on the various functions of pilot plant operation. Besides offering its facilities to
many operators for continuous pilot plant tests, it has served as a practical demonstrator for those
who desire to plan their own pilot plants.
On the basis of the experience obtained in our own testing plant, and in supplying equipment for
hundreds of ore testing laboratories, the following information is submitted to aid in planning the
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installation of a pilot plant.
TYPICAL LAYOUTS OF TEST PLANT INSTALLATIONS
Hurgist
Types of Pilot Plant Installations
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3123224,325 PM Minera Processing Pit Plat Eaupmont
1. Pilot plants for the use of schools of mines, mining bureaus and private companies where
extreme flexibility is required for testing numerous ores by different flowsheets.
2. Larger tonnage pilot plants for mining and milling operations where extensive testing of
ores of the same general character is to be conducted. Equipment of such pilot plants is
available in several different size ranges, a general list of which is shown on the final page
of this article.
Selection and Arrangement of Pilot Plant Equipment
The equipment for the proposed pilot plant should be selected to secure operating conditions which
will be the same as in a regular milling plant. The arrangement of the equipment should allow
maximum flexibility for changing the flowsheet
Pilot Plant Crushing and Sampling Equipment
The crushing equipment should be in a separate room to eliminate dust in the main ore dressing
section. The type and size of crushing equipment selected depends upon the type of product required
for subsequent treatment. In general crushing to minus 1/8" for the 12" diameter ball mill and minus
¥%' for the 16" diameter ball mill are desirable. Larger size ball mills may take feed crushed to minus
3/8" or minus %4"
Secondary crushing by means of rolls is generally preferred in this type of plant because of the high
capacity, less head room required, and simplicity of cleaning, The Vibrating Screen is highly
recommended for the screening operation because of its portability, large capacity and efficiency. It
can be furnished as a totally enclosed unit to minimize the dust nuisance.
Ove Bin
Vibeoting
Screen
Jaw Crusher Crushing Rolls
steet
‘Sompling Sheet
Recommended arrangement of the equipment in a crushing
section which is to be set up for manual handling of ore
Manually Operated Equipment
In pilot plants designed to treat small quantities of different ores it is usually considered best to leave
the crushing section arranged for manual handling of ore, with all of the equipment on one level. This
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The disadvantage is that of requiring considerable hand labor shovelling the crude ore into the
crusher, the crushed ore onto the vibrating screen, the screen oversize into the rolls and the rolls
product back onto the screen. In addition, the sampling must be done by hand, the finished product
carried to the ore feeder in the grinding section. The floor should be made of cement into which
anchor bolts for the machines may be grouted
The finished product is most conveniently sampled by placing every Sth or 10th shovel of product
onto a coned pile on a steel sampling plate as the material is being transferred to the fine ore bins.
The sample thus produced is thoroughly mixed and again fifth shoveled, and the final sample further
reduced by means of the Jones Sample Splitter.
Mechanically Operated Equipment
In cases where a considerable quantity of ore is to be tested and if it is desired to reduce hand labor
toa minimum, the crushing section can be equipped with ore bins, elevators and samplers, the same
as ina large milling plant.
Pilot Plant Grinding Circuit
Elevation of Grinding Section
The ore feeder should be placed high enough to permit feeding by gravity to the ball mill or to any
machines which may be used for pretreatment ahead of the grinding circuit.
The ball mill and classifier are installed on an elevated platform to obtain gravity flow of the ball mill
discharge to the Jig or Unit Cell, which is placed on the main floor level.
Closed Circuit Piloting
In order to obtain maximum flexibility for test plant purposes the ball mill classifier circuit should be
closed by using a Vertical Sand Pump. The ball mill discharge is pumped to the classifier, which
permits placing the classifier high enough to give gravity flow of the classifier sands to the ball mill. An
important advantage of this arrangement is that the classifier slope can be changed as desired
without interfering with the flow of return sands to the ball mill. A drum type feeder is recommended
for the ball mill to eliminate the splash and waste which usually occur when using a scoop feeder and
feed box
Pilot Ball Mill Capacity
In pilot plants which test various types of ores it is frequently necessary to obtain an extremely fine
grind. The added capacity of the grinding circuit necessary to produce a finely ground ore pulp is most
conveniently secured by mounting the grinding mill on an adjustable steel frame to allow for an
increase in the length of the mill. Extra shell sections can be added to most Ball Mills, so that when a
fine grinding problem is encountered the mill can be doubled in length without expensive changes in
foundations and, within the limits of the power of the driving motor, without change of drive.
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Processing Plot Plant Equipment
In most pilot plants, particularly those treating just one type of ore, the Hopper Type Ore Feeder is
considered very satisfactory. This unit has an adjustable gate to regulate the amount of ore fed onto
the belt which travels under the hopper.
Suggested layout of the equipment in 2 crushing section
when it Is desired to have mechanical handii
Elevator
Dillon Screen
rushing _Rolle\
ncersite Te
Ore Sampler
ELEVATION
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A Reversible Ore Feeder areatly simplifies the operation of a test
plant when pretreatment of an ore is required ahead of grinding
However, a uniform rate of feed on small tonnage can best be obtained with a belt feeder. The belt
feeder is particularly desirable if damp, sticky ore is to be handled or if the plant is to be used for
testing a wide variety of ores.
The first step in ore treatment generally consists of grinding and classification of the ore preparatory
to various concentration or chemical treatment processes. However, it is sometimes desired to
subject the crushed ore to gravity concentration, blunging, log washing or desliming before grinding.
In these cases the operation is greatly simplified if the travel of the feeder belt can be reversed, to
permit feeding the ore direct to any desired pretreatment equipment. The Belt Ore Feeder for pilot
plants can be equipped with a reversible drive. The Hopper Ore Feeder is a small unit which can be
easily turned around to reverse the direction of feed.
Controlling the Rate of Feed
Mechanical feeders are easily installed for delivering a large tonnage of ore to a belt feeder from the
fine ore bin of a mechanically operated crushing and sampling plant.
Where a manually operated crushing and sampling plant is installed, the feeding of the ore must be
by hand. If a hopper type feeder is used the rate of feed is regulated by the adjustable hopper gate.
The desired feed rate can easily be obtained by feeding weighed amounts of ore at various openings
of the gate until the correct setting is secured.
Where a belt type feeder is used a constant and accurate rate of feed may be secured by the
following method. The speed of the belt, which should be adjustable, is set at a slow speed of about
18 lineal feet per hour. Two adjustable skirt boards made of 1" x 4” or 1” x 6" lumber are placed over
the belt and fastened to supports, allowing just a small clearance between the belt and the lower edge
of the board, These prevent ore spillage and provide guides for a spreader.
Assume it is desired to treat 200 pounds of ore per hour. Make a spreader out of wood to fit between
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spreader of proper depth to distribute 66 2/3 pounds of the crushed ore over six feet of the belt. This
will give an accurate feed rate of 200 pounds per hour.
A flagged marker riding on the ore can be used to show the position of the ore on the belt without
close inspection.
Recovery of Minerals in the Grinding Circuit
One of the basic principles followed in any milling plant is to “Remove the mineral as soon as it is
free.” For this reason almost all pilot plants are equipped with a Mineral Jig and a Unit Flotation Cell to
investigate the possibility of making a high grade concentrate from the partially ground ore in the
grinding cirouit.
Pilot Mineral Jig
The Mineral Jig was developed to recover a high grade gravity concentrate from a partially ground
and unclassified ball mill discharge before the mineral had been ground to a slime. Heavy gravity
minerals and metals such as galena, wolframite, scheelite, cassiterite, cerussite, and metallic gold or
silver will circulate through the classifier and ball mill until ground to very fine particles unless
removed from this circuit. The Jig accomplishes this removal and the importance of this method of
concentration cannot be over-emphasized.
Any ore containing high gravity mineral should be tested by a Mineral Jig. Gold ores being treated by
flotation or cyanidation generally contain gold particles which are easily removed from the grinding
circuit by the Mineral Jig with a high ratio of concentration. This concentrate may be subjected to
barrel amalgamation and the recovered gold produced in bullion form.
Mineral Jigs suitable for treating ball mill discharge in pilot plants are available in the 1-M laboratory
size for treating 50 to 150 pounds per hour, the 4" x 6" for treating 200 to 500 pounds per hour, and
the 8" x 12” for semi-commercial size plants.
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Skirt Boards on feeder prevent spillage of ore. A spread-
er is used to distribute ore evenly on the feeder Belt
Belt Strip
The Mineral Jig may also be used as a cleaner jig where it is desired to produce a small amount of
final concentrate with unusually high ratio of concentration. For instance, it may be used to retreat
rough concentrates produced by the 4” x 6" Mineral Jig with the cleaner tailing product being returned
to the rougher circuit for retreatment.
Laboratory Jaw Crusher
Pilot Flash Flotation Cell
Unit Cell Flotation is an operation which has been developed by Equipment Company to secure a
yield of rich concentrate from ores as they are being ground for final treatment. The Unit Cell is
constructed to withstand the abrasive action of the partially ground pulp in the ball mill discharge.
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Leboratory Ball-Red Mill
Operation of the Unit Cell is one of the easiest and most productive processes in flotation, The
necessary flotation reagents are generally fed with the ore to the ball mill. The ball mill discharge, with
some dilution water added, passes through the Unit Cell. A scalping screen through which the ball mill
discharge passes is recommended to prevent tramp oversize from collecting in the cell. Special sand
relief openings are provided in the cell to allow the discharge of the ordinary coarse sand in the pulp.
Laboratory Crushing Rolls
The size of Unit Cell recommended for pilot plants is generally the same as that of one of the cells of
the flotation machine in the regular flotation section,
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Hydroclassifier with
Suction-Pressure Pump
Mineral Jig and Flash Flotation Cell
There are some cases where both the Jig and Unit Cell may be used to good advantage in the
grinding circuit. For example, the Jig and Unit Cell have been used for treating complex lead-zinc
ores, producing lead concentrates with a lower zinc content than was obtainable by flotation alone,
Many gold ores contain a fraction of the gold present as a free mineral and the balance associated
with oxide minerals or partially oxidized or tarnished sulphides. In such cases the Jig can be used to
remove the free gold, and the Unit Cell to recover the sulphides at a coarse mesh.
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Continuous Test Plant with
Belt-Hopper Type Ore Feeder
Pilot Flotation Circui
The flotation section of the pilot plant comprises the conditioners, rougher flotation machines, cleaner
flotation machines, reagent feeders, sand pumps, concentrate thickeners, and filters.
Gravity flow of the ground ore pulp from the grinding section through the flotation section is possible
when the ball mill and classifier are elevated as described under Grinding Section, Elevation.
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Laboratory Minerel Jig
Unit Flotation Colls
Flotation Conditioners
Conditioning of the pulp before flotation is an important operation as it provides an even feed to the
flotation circuit and premixes the various reagents. The more nearly even the feed to flotation, the
better the results obtained. The Conditioner is provided with outlet pipes at different levels so that the
capacity can be varied to secure different conditioning times. Conditioners may be selected from a
variety of sizes to best fill the requirements of the flotation section. A conditioner should be provided
for each bank of flotation cells. The conditioner, being a self-contained motor driven unit, is portable
and can be used in any place in the plant as a mixer or repulper.
Loboratory Conditioner
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The number of banks of rougher cells needed will depend upon the nature of problems to be
encountered, Two banks of cells with six or eight cells to each bank can be used to produce separate
concentrate in differential flotation work. A third bank of cells, to be used as standby cells for extra
cleaning or for occasional need to produce a third concentrate, will be found very useful
No. 7. “Sub-A’
Flotation Machine
Vertical Sand Pump
“Sub-A’ Flotation Machines for test plants are available in three cell sizes. The No. 5 machine
contains a pulp volume of 0.29 cu. ft. per cell when filled to operating pulp level without the machine
running. The No. 7 cell measured under the same conditions has a volume of 1.11 cu. ft. and the No.
8 a volume of 2.75 cu. ft. The actual pulp volume in the machines where the pulp is agitated with
frother is considerably less because of the displacement by air bubbles. Capacity varies with the
flotation time required for different ores.
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Reagent Feeders
Mineral Processing Plot Plant Equipment
N
“
\
|
\
U
Wiltley Teble with
Centrifugal Feeder-Classitier
Laboratory Thickener with
Suction-Pressure Diaphragm Pump
Flotation reagent feeders for pilot plants have been developed by Equipment Company which are
capable of accurately feeding small quantities of reagents. Wherever possible in the pilot plant it is
desirable to feed all reagents in liquid form which allows closer control than feeding solids.
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1523213/24, 25 PM Mineral Processing Plot Plant Equipment
Bolt bry Reagent Feeger
i 2
PL)
mi
The feeding of most reagents which are required in quantities more than a few drops per minute is
accurately performed by the Portable Wet Reagent Feeder with micrometer control. Reagents
required in quantities as low as one drop per minute are most accurately fed by the bent tube
attachment which has been perfected in the Equipment Company Test Plant. This attachment can be
operated by any of the Equipment Company disc type feeder mechanisms by removal of the cup disc
and attaching the dipper tube to the shaft.
Pon Filter and Vac. Eqpt.
Insoluble dry reagents may be fed by either the cone type or belt type dry reagent feeder. Dry
reagents used in very small quantities are usually most conveniently and accurately fed by the belt
tune feeder. This arranaement is similar to that described for the ore feeder in the arindina section.
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Pilot Plant Thickeners
Thickeners and Filters for pilot plants are built in small units that embody the same principles as those
in the commercial size units. Thickeners having various diameters from 3 feet up to those of
commercial size units are available. Two convenient sizes for small pilot plants are the 3 ft. diameter
by 3 ft. depth and the 6 ft. diameter by 3 ft. depth. These units have the regular Equipment Company
spiral rakes and %4" Suction-Pressure Pump for removal of the thickened pulp. They are motor driven
self-contained units which are easily portable and can be set up at any desired point in the plant.
Special shallow tray thickeners for handling extremely frothy materials can also be supplied
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‘Typical Continuous Test Plant installation showing closed grinding circuit with jig and unit cell
and gravity flow from classifier to flotation circuit
Pilot Test Filters
Filtration for pilot plants is generally handled by the Rotary Drum Filter. This filter is available in sizes
ranging from 18" diameter x 6” face up to commercial size units. For pilot plants having a capacity up
to 500 pounds per hour the 18” x 6", 18" x 12", or 36" x 12" are ordinarily used. The size to be used is
of course dependent upon filtration rate of concentrate and quantity to be filtered.
In addition to the drum type fiter, there is also available the Pan Filter which is a very desirable unit
for filtering large samples of pulp or for filtering tailing product when desired. A duplex unit, with two
pans which can be alternately filled and discharged, can be made to serve as a continuous filter for
the smaller pilot plant installations.
Vacuum pumps, receiver tanks, filtrate removal pump, and pressure pump for cake discharge from
the continuous filters are necessary auxiliary equipment for filtration section.
Gravity Concentration Pilot Circuit
The equipment for gravity concentration in the present day pilot plant is generally confined to those
units which are used in conjunction with flotation or cyanidation. The two units which may be
considered indispensable for the up-to-date pilot plant are the Mineral Jig and the Wilfley
concentration table.
Mineral Jig
The Mineral Jia is generally used in closed circuit with the ball mill and classifier as discussed under
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or when fine crushing, without grinding, is employed.
Wilfley Concentrating Tables
Gravity table concentration is often used in pilot plants to recover non-floatable mineral from flotation
tailing. Tables may also be used as primary concentrators in which case they are generally used in
conjunction with the hydraulic sizing classifier. The equipment available for gravity table concentration
in pilot plants includes the No. 13A table having deck dimensions 40" x 18", the No. 13B Table having
deck dimensions of 50" x 24” and the No. 12 table which has a deck dimension of 7'8" x 3°11".
Table feed may be hydraulically sized in the Laboratory Hydraulic Classifier which has classifying
chambers 4" x 4”
Cyanide Leaching Pilot Testing
The operation of the continuous pilot testing plants for treatment of ores by the cyanidation process is
not so commonly practiced as is that of testing by flotation. However, the pilot plant built for flotation
testing can readily be converted into a cyanide treatment plant since equipment for crushing and
grinding the ore would be the same. Laboratory agitators and thickeners similar in design and
operation to standard machines are available. The agitators are built in various sizes to fit the capacity
requirements of pilot plants.
Another satisfactory method of pilot plant testing by cyanidation is by use of the Batch Cyanide Plant
which is built for cyanidation of small lots of ore or concentrate. This plant which consists of a
combined agitator and thickener tank and storage tanks for solutions and precipitation apparatus is
necessarily intermittent in operation but the results secured from re-use of the solutions is comparable
with those from a continuously operated plant.
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Special bent tube dip attachment developed in Lab. for accurately feeding a very small quantity of
reagent. The end of the tube fills with reagent through a small hole made in the glass. The quantify of
reagent fed depends upon the distance between the hole and the bottom of the tube.
Auxiliary Pilot Plant Equipment
One of the most important pieces of auxiliary equipment is the Vertical Sand Pump. This pump is a
motor driven self-contained unit which is easily portable and requires no floor foundation. It pumps
frothy concentrate as well as coarse sand products and will operate upon fluctuating flows of pulp.
This pump is available in size ranges from three-fourths-inch to large commercial plant size units
tank for constant head water supply is advisable since the small flows of pulp require accurate
control of the water supply, The Bolted Steel Tank has proven to be very satisfactory for this purpose.
It can be easily assembled in any location and is free from leakage.
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Mine
5 Processing Plt Plant Equipment
EQUIPMENT COMPANY CONTINUOUS PILOT PLANT TESTING EQUIPMENT
Required Capacity—Pounds Per Hour
50 t0 150 200 to 500 1500 to 2500
a TP Ship Wi| Sin_| HP [hip Wi] Sime | HP [in We
ame of Machine Mite BEaN loeisc| alter [Pins |oagssin] wate [ Binds
Goarse Ore Bin = | 950 | tot0n [ — | 350 | aston | — | 2300
Belt Ore Feeder % | 350 | Se") Z| ‘soo | “ts” | 1 | too
Jaw Crusher S| uso | stxer |S | 1130 | sxto" | 10 | s120
Bucket Blevator uy | 2200 | or | aye | 2300 | 6” | as | 2400
Screen, Double Deck | 27s | rz"soe | “9 | “275 | sa"sa6"| 94 | “400
Crushing Rolle torx6” | 174 | 130 | rorxsr | 194 | 1530 | x2x12"| 3 | 2350
Ore Sampler, Snyder ar | v4 | aa | oor | | aes | ae | 1 | “oes
Fine Ore Bin Ston | = | 950 | 10%0n 1350 | 25%0n | — | 2300
Fine Ore Feeder, Belt | 4 | 380 | a" 00 | ie" | 7 | i400
” Bel Hoppée orxisr | 4 | 365 | oreiar ass | orxser | 4 | ‘550
Ball Mill szraiz"| 1 | s000 | se"xi6"| 136 | 1850 | sorxa6"| 734 | so00
Cross-Flow Classifier & | % | ao fos |v | las |e | 2 | “950
Hydro-Classifier with Diaphragm Pumps sor | % | 400] sor | 34 | f00 | ae | 2 | 550
Mineral Jig im | t/6| 120 | axe | 176 | 200 | s’xizr | 34 | 500
Unit Blotation Cell Nos | % | 260 | No? | % | 300 | Noe | 3% | 700
szrais| % | 200 | rsrx2e| 1% | 360 |2a-es6r| 34 | 560
© (1), 6 Cell No.5 | % | 260 | No7 | % | 500 | Nos | % | 700
Concentrate Thickener with Diaphragm Pumps | | coo | MS? | 2 | aso | Se | | 1600
Concentrate Filter (2), Drum awe’ | 15% | 910 | sermi2"| 1% | S10 | s'x2" | 344 | S010
on Pan Sea | 1 | eas | ana" | 132 | 1000
Wet Reagent Feeder Portable| 1/20| 130 |Portable| 1/20 | 130 |Portable| 1/20] 130
Dry Reagent Feeder, Cone o. | % | a30 |e | 9g | a0 | ten | 4g’ | 175
or Belt ox | % | 460 | 460 | xe | 4 | 460
Vertical Sand Pump se | Tt | 380 2 | ais | OPP | 2 | ans
Cyanide Agitators ©) so"eao"| 34 | 500 % | 650 | exe | 1 | 1400
Cyanide Thickeners with Diaphragm Pumps a | | 380 1 | 1600 | 1x4 | 2 | 2000
Gyanide Filter ©) sat’ | 244 | 1685, 3% | s010 | sxe | 754 | 6200
Precipitation Equipment No.1] 2) | 1200 | 1200 | No.2 | 254 | S000
Pulp Sampler taba" | /iz | “50 wiz] "30 | Noi | 4 | 200
Willey Laboratory Table ase |'4'| ato xa | ato | “3! | | 650
1. Multiple banks to be used depending on problem
2. Includes necessary vacuum equipment
3. At least two preferably three. Includes steel tank. Sizes shown in this table are for
estimating only. Exact requirements will depend on many factors including grindability of
ore, fineness required, flotation time and densities, settling and filtering characteristics.
Following is a list of instruments and small equipment necessary in producing the desired data from
the testing operation:
we [me | we
1. Pulp Density Seale 7 , Platform Scale—500 Iba. capacity, 180
2) Shaker ‘Sereen v6 | 140 9. Laboratory Pan Balance 10
3. Set Tyler Standard Screen Sieves 23 10. Reagent solution tanks, carboys, and pails 500
4 Electric pH Meter 20 11, Vanning ‘plaques, 1
5, Binocular Microscope 10 12, Hand pulp samplers 4
6. Mineralight 10 413, Sample pans and pails, 50
7 Jones Sample Splitter 70. 14. Volumetric measuring cylinders 10
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21123213/24, 25 PM Mineral Processing Plot Plant Equipment
TYPICAL LAYOUTS OF TEST PLANT INSTALLATIONS
Source: This article is a reproduction of an excerpt of “In the Public Domain” documents held in
911Metallurgy Corp's private library.
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by David Michaud | June 10,2016| fm Equipment, Laboratory Procedures | @ Metallurgical Laboratory Testing, Metallurgical
‘Testwork Program, mineral processing engineering, Pilot Plant, Pilot Plant Equipment
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