PROGRAM : BACHELOR OF ENGINEERING TECHNOLOGY:
EXTRACTION METALLURGY
SUBJECT : METALLURGICAL ACCOUNTING A2
CODE : MEAMTA2
DATE : ASSIGNMENT 2
17/05/ 2021
DURATION : (X-PAPER) 16H.
WEIGHT : 20: 80
TOTAL MARKS : 40
FULL MARKS : 40
EXAMINER : MR. Craig NSAKABWEBWE
MODERATOR : MS M. MADIBA (INTERNAL)
NUMBER OF PAGES: 5PAGES
INSTRUCTIONS TO CANDIDATES:
1. PLEASE ANSWER ALL THE 3 QUESTIONS
2. THE ASSIGNMENT IS DUE THE 20/05/2024.
3. QUESTION ONE REFERS TO THE COMPLEX FLOTATION CIRCUIT DESCRIBED
BELOW.
4. THE QUESTIONS TWO AND THREE REFER TO THE TWO-STAGE GRINDING
CIRCUIT DESCRIBED BELOW.
DESCRIPTION OF A COMPLEX COPPER FLOTATION CIRCUIT
The circuit shown in Figure 1 is sampled, and the results in Table 1 are obtained:
Table 1: Assays of flotation streams
Stream Assay (%) metal
1 1.5
2 Not sampled
3 0.51
4 0.12
5 16.1
6 25.0
7 2.1
8 4.2
9 Not sampled
Figure 1: Flotation Circuit in Node Form
DESCRIPTION OF A TWO-STAGE GRINDING CIRCUIT
A two-stage grinding circuit using a rod mill in an open circuit with a ball mill in a closed circuit
with a rake classifier is used to grind 50 tonnes per hour of ore (SG 3.0). The circuit layout is
shown in Figure 2. Assume that the circuit was sampled, and the results were as shown in Table
2.
Table 2: Streams analysis results of a two-stage grinding circuit
Stream % solids by weight %-200 mesh
Circuit (Rod Mill) Feed 80 5
Rod Mill Discharge 80 20
Classifier sands (Ball Mill Feed) 75 20
Classifier Overflow 33.3 75
Ball Mill Discharge 75 47.5
The final product of the milling circuit is sent to the froth flotation circuit consisting of flotation
cell banks as shown in Figure 3. The chemical compositions of the froth flotation streams are
shown in Table 3. The mass flow rate of the concentrate produced at the concentration circuit is
found to be dependent on the frother dosage.
Figure 2. A two-stage grinding circuit
Figure 3: Flotation Circuit
Table 3: Assays of Froth Concentration products
component Actual Assays
Feed Conc Tails
Sn 11.6 9.1 17.4
Fe 10.9 10.6 11.2
SiO2 9.8 8.8 11.3
S 14.8 12.4 15.3
TiO2 33.5 30.3 33.9
Question 1
Confirm using the connection matrix that sufficient data has been obtained to calculate all the
mass flow rates and use the connection matrix to calculate the flows.
Question 2
Using data in Table 1 carry out a material balance and calculate the following:
2.1. The tonnes/ hour of solids in the classifier overflow.
2.2. Percentage circulating load in the ball mill circuit.
2.3. The tonnes/hour of dilution water added to the rake classifier.
2.4. The specific gravity of the ball mill discharge slurry.
2.5. Solids percentage of the rake classifier feed.
2.6. The (%-200 μm) in the rake classifier feed.
2.7. Determine the adjusted assays of elements in the various products of the flotation
concentration circuit. The adjusted assays are consistent with the calculated best-fit flow rates of
the flotation circuit.
2.8. From the adjusted data, calculate the recovery of tin at the flotation circuit.
2.9. The plant has installed an on-stream assaying system on all the process streams. Determine
the uncertainty in the tin recovery. The assaying accuracy is shown in Table 4.
Table 4: Relative Standard deviation as a function of grades
% Cu Relative Standard Deviation (RSD)
0.05-2.0 9
2.0-10 7
>10 4
2.10. Based on the adjusted grades of tin obtained at the flotation circuit; determine the monthly
performance of the plant by completing the Table 5. Assuming that it is a February production and
the concentration circuit is fed at a flowrate of 50tph.
Table 5. Monthly Performance of the Plant
Item Weight (t) Assay (%) Weight Metal Distribution
(t) Metal (%)
Feed
Concentrate
Tails
QUESTION 3
3.1. Neatly draw a block diagram of the circuit shown in Figure 3 with a simple feedback control
loop controlling the flowrate of concentrate at the flotation circuit. Carefully label all the
components making your neat diagram.
3.2. Show possible disturbances and explain how they can affect the controlled variable.
