DMS2 REPORT

INDUSTRIAL REPORT ON THE DMS2 PLANT.

Institution Zimbabwe school of mines

Period of engagement in a Section 4 weeks

Report Distribution Mr. G. Chipepera

Mr. E. Mutandiro
Mr. T. Mufumi
Mrs. M. Musarurwa

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Table of Contents
1.0 Background...........................................................................................................................................3
2.0 Sectional SHE aspects...........................................................................................................................3
2.1 Safety.................................................................................................................................................3
2.2Health.................................................................................................................................................4
3.0 DMS2 Process flow diagram.............................................................................................................5
3.1 DMS2 Process flow description.........................................................................................................5
3.2 Media cycle.......................................................................................................................................6
3.4Media Quality.....................................................................................................................................6
4.0 Major equipment used for separation at Bikita Minerals.......................................................................9
4.1 Screens.............................................................................................................................................10
4.1.1 Operating principle...................................................................................................................10
4.1.2 Technical specifications and considerations..............................................................................10
4.2 Cyclones..........................................................................................................................................11
4.2.1 Operating principle...................................................................................................................11
4.2.2 Technical specifications and considerations..............................................................................12
4.3Drum Magnets..................................................................................................................................12
4.3.1 Operating principle...................................................................................................................12
4.3.2Technical specifications and considerations...............................................................................13
4.4 Demagnetizing coil..........................................................................................................................13
5.0 TECHNICAL SPECIFICATIONS OF EQUIPMENT.........................................................................13
6.0 RECOMMENDATIONS.....................................................................................................................13
7.0 REFERENCE......................................................................................................................................14

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Acronyms:
DMS- Dense Medium Separator
HMS-Heavy Medium Separator
CVB- Conveyor belt
S.G- Specific Gravity

1.0 Background
Dense medium separation (DMS) also called heavy medium separation (HMS), sorts’ particles on the
basis of their apparent density relative to that of a carrying medium. There are two DMS plants at Bikita
Minerals. At first, there was only one DMS plant (DMS1) which processed feed of particles ranging from
size 2mm to 28mm. After a series of test works, it was discovered that there are a lot of fines generated
during the comminution process and these fines have a high grade of lithium therefore it was necessary to
set up a new DMS plant (DMS2) which bases on fines (2mm-6mm) since separation should be due to
density differences not differences in particle size. This report deliberates on the DMS2 plant which
receives its feed from the -2mm fines dumps.

2.0 Sectional SHE aspects

2.1 Safety
Risk Effect Mitigation
Working at heights  Falling from heights  Inspection of walk ways and
 Dropping tools onto passerby hand rails
 Wear hard hat

Stored Energy (Tensioned  Unexpected energy release.  Ensure Engineering

conveyor belt snapping) department releases energy
sources before commencing
maintenance.

Flying particles and  Eye irritation  Wear safety goggles

objects(produced by the nozzle  Damaging of the cornea and the  Annual medical fitness
sprays) conjunctiva of the eye. examination.
Uneven surfaces  Tripping and falling leading to  Clear spillage as quickly as
(spillages on conveyor injury. possible.
belt3)

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2.2Health
Risk Effect Mitigation
Heavy material Lifting and  Back injuries.  Follow correct working
Handling (pushing the swinging procedure.
conveyor belt)

Noise (Noise generated  Diseases such as hypertension  Wear hearing protection (ear
by vibrating screens in and ischemic heart disease plug or muffs).
operation)  Eardrum damages  Monitor noise levels around
the plant

3.0 DMS2 Process flow diagram

FIG: 1.0 showing the flowsheet diagram of DMS2

3.1 DMS2 Process flow description

Sinks are ferried from the past sink dumbs to the stock pad by the reduction plant using dampers. From
the stock pad, the sinks are then drawn by a vibro chute onto the tunnel conveyor belt, which then passes
the ore onto the overhead conveyor belt. The overhead conveyor belt then introduces the feed onto a 6mm
apertured screen where it is conjoined with the feed preparation screen undersize. The oversize falls freely

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onto the ground where it is later on removed by a front end loader whilst the undersize is pumped to the
de-slimming cyclone and is fed at a pressure of 136Kpa. In the cyclones, the slimes are separated from
the fines. Cyclone underflow reports to the de-slimming screen with 0.8mm apertures for further de-
slimming while the cyclone overflow (slimes slurry) is pumped to the thickener along with the de-sliming
screen undersize for water reclamation. The screen submits the oversize to the mixing box, where the ore
is mixed with the media from the dense medium sump and pumped to the severing cyclones.

The set point is not fixed. Determination of the density is depended upon the type of ore being fed. If the
ore type from the pits contains a lot of feldspar (the near density of petalite) then the set point is lowered a
bit to allow it to sink at the same time if petalite seems to be appearing in the sinks stream the set point is
raised for it to report to the floats stream. The feed medium is mostly at a density of 2 130kg/ �3 with the
differentials between the sinks and the floats ranging from 0.7 to 1.1. The medium and ore mixture is then
fed into the cyclones at a pressure of 136 Kpa enhanced by force of gravity. Separation occurs in the
cyclones such that minerals with S.G greater than set point are discharged from the cyclone at the sink
side as underflow and the lighter mineral, which is the wanted product (petalite), exits the cyclone from
the float side as overflow. The floats and sinks are introduced onto a drain and rinse screen where they are
washed off media before they form stockpiles after being conveyed. Both conveyor belts are mounted
with weightometer to account for the tonnage from the system. After averaging computations revealed a
yield of petalite of about 20%. As is in DMS1 this yield also differs depending on the source of ore being
fed into the system.

3.2 Media cycle

At the DMS2 plant fine magnetite is used in conjunction with ferrosilicon .The circulating media right
from the dense medium sump mixes with feed at the mixing box situated right after the de-sliming screen
before being pumped to the separating cyclones .In the cyclones, media is then partitioned into two
categories that is the overflow and the underflow. The lighter media exits with the overflow whilst heavier
media exits with the underflow. The underflow goes to the sinks screen and the overflow to the floats
screen. These screens are fitted with 0.8mm apertured screens to allow media to pass through. On the
drain side, that is the screens’ undersize just before the water sprays, media is collected into the dense
sump since it is still concentrated and the density of the media is still high. The dense medium sump is
also called the correct medium sump since it contains the required density. Media which passes through
the floats screen and the sinks screen after the water sprays is collected into the dilute sump. These sumps
are continuously agitated to prevent the settling and solidifying of ferrosilicon. Water is then added in the
dilute sump for easy pumping of the solution to the wet drum magnet for media recovery. The recovered
media is then passed through a demagnetizing coil before reporting to the correct media sump. The reason
why the correct media sump always contains the required density, it is mounted with a Densometer a
(sensor device) which detects the S.G and directs a signal to a motorized valve which opens and closes
depending on the value of the S.G sensed and therefore sends a signal to a computerized read-out output
device for the operators to know the medium density. Media is charged regularly via the floor sump to
replace the one lost during the operation .In this circuit there are three main points at which media can be
lost that is, on the double screens given that there is inadequate washing, with the magnet effluent and
media contained in the fines since all of it cannot be washed away.

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3.4Media Quality.
During circulation, a lot of corrosion and abrasion takes place. When exposed to air (oxygen) magnetite
slowly oxidizes under an encircling ambient temperature and pressure to produce mag-Haematite.
Moisture content affects the rate of oxidation of magnetite. Oxidized iron is more brittle and softer (5.5
hardness) and magnetite is less brittle and harder (6.5 hardness). These property changes impairs the
quality of the media. Fine magnetite corrodes faster that coarse magnetite due to the differences in surface
area and dispersion rates. The Mag–Hematite and Haematite tend to clot on the body of magnetite
forming a coating, therefore reducing the media recovered by the magnet since Haematite is
paramagnetic. Haematite has an increased radius due to oxidation therefore it has a lower S.G (4.85) as
compared to magnetite (5.2), this affects the efficiency of separation.

4.0 CONTROL PHILOSOPHY AND PLANT OPTIMIZATION

4.1 Process start-up procedure, shutdown procedure and interlock mechanism

All the conveyor belts in the DMS section have a startup sequence interlock system. Belts and equipment
downstream will not start if the equipment and belts up stream have not started. This is done so as to
avoid overloading of the machinery hence spillages. The interlock is controlled automatically. The
conveyor belts at Bikita are fitted with pull wires to allow for emergency belt stoppage. The screens also
have an emergency stop button.

The following is the sequence used when starting up the section and in vice versa is the shutdown
procedure: Water pumpFloats conveyor beltSinks conveyor beltDe-sliming discharge
pumpEffluent pumpDrum magnet separatorMagnetic separator feed pumpDouble screenDe-
sliming screenCyclone feed pump 5Mixing box feed pumpDensifier feed pumpFines
pumpFines screen Fines conveyor beltOverhead conveyor beltVibro feeder.

4.2 Troubleshooting

Troubleshooting problems becomes second nature to good plant operators. This section deals with the
basic troubleshooting process and gives some examples of how to apply these processes. The following
process flow gives a troubleshooting methodology:

 Identify a problem by assessing what impact it has on the plant’s performance and production
targets. Identify the possible causes of the problem.

 Get as much information about the problem from the process. This could be tonnages, sample
results or downtime.

 Using the information you have gathered, set up verifications for each cause.

 Once the cause has been verified, put corrective actions in place to provide a solution to the
problem.

The following parameters are monitored because they give an indication of the performance of the
section.

4.3 Cyclone underflow monitoring

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The plant attendant visually monitors the skirting that is being produce the cyclone underflow. The angle
at which the cyclone underflow discharges is indicative of the pressure in the cyclone and can indicate the
efficiency of the classification process going on. Ideally the cyclone underflow should be a mirror image
angle of the cone of the cyclones slope. Below is a diagram of the various shapes that can be produced by
the cyclone underflow.

FIG.1.1 Diagram show the discharge of a cyclone

4.4 Broken or Damaged Panels

When panels are broken or damaged, the openings are too large and oversize material will report to the
undersize. This causes chokes in the upstream process (thickening and classification)

4.5 Density control system

As part of system performance monitoring Bikita uses density monitoring as a critical performance
indicator. If density is off specifications then following can be experienced

1. Poor classifications.

2. Poor grinding for the dry grinding mills.

3. Cyclone chocking.

There might be errors that can result from malfunctioning of the measuring devises so to eliminate any
possibilities of errors in the values of density that is recorded by the instruments, manual checks are done
The densities are checked after every hour by the Attendants stationed in the plant. The density checks are
done manually using specific density or pulp density scales which incorporate the use of 1 liter containers
and the specific density of water .These hourly density checks are logged in and are a means of monitored
for deviations. Manual densities of the sinks and floats stream are also determined to assess the
differentials for quality assurance.

4.6 Cyclone spigot and components thickness maintenance

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From time to time the lining on the spigots and other components wear out due to abrasion caused by high
density slurry. To that effect there is need to constant monitor the extent of wear in order to repair the
spigots or vortex finders before the effects can be felt in the process. The met services department does
the inspections during a weekly scheduled shutdown. They then forward their finding and
recommendations to the engineering department which will then do all the maintenance required. If the
component is worn out beyond repair then the met services can press on order to the stores.

4.7 Other key maintenance areas

 Changing of the worn out component of the pumps. The pump consumables are Impellers, frame
plates, shaft sleeve, staffing box, volute casing, volute finding.
 Greasing of gear systems
 Oil fill ups in gearboxes
 Greasing of pulley bearings
 Inspection of the conveyor belts

Major Downtime
11.60%
1st Qtr
2nd Qtr
6.63% 3rd Qtr
2.21%
45.30% 4th Qtr
5th Qtr

34.25%

4.8 Downtime

Fig1.2.Showing the distribution of downtime

Major downtime causes

1st Qtr (45%): Scheduled shut down for maintenance.

2ndQtr (34%): Pipe choke-up (impaired pressure due to pipe bends/ high percentage solids)

3rdQtr (2%): Inadequate water supply (water reporting to slimes dam at the thickener/ steel tank overflow)

4thQtr (7%): Media correction (power cut)

5thQtr (12%): Unplanned maintenance (machinery breakdown)

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5.0 Major equipment used for separation at Bikita Minerals

The following are the major equipment used at Bikita minerals for separation, screens, magnetic
separators and dense medium cyclones.

5.1 Screens

FIG: 1.3 Showing the de-sliming screen discharging into the mixing box

5.1.1 Operating principle

The screen has a surface that has many apertures with uniform dimensions. Particles presented to the
surface will either pass through or be retained, according to whether the particles are larger or smaller
than the apertures. Particles bigger than the apertures of the screens are retained, and constitute the
oversize. Those that are smaller pass through the screening surface, forming the undersize (this process
can be dry or wet). There are water spray nozzles which provide pressurized water. The water’s role is to
wash the ore before it is transported to the mixing boxes in the plant since slimes cannot be easily washed
off media which impairs the grade of the final product. The spay water is also used to rinse away the
media on the drain and rinse screen. Factors which affect screen efficiency are the vibration speed, angle
of inclination of the screen and the length of the screen among others. The efficiency of screening is
determined by the degree of perfection of the separation of the material into size fractions above or below
the aperture size. There is a motion head which is mounted on top and joined to the body of the screen.
The weights in the motion head are eccentric resulting in vibrations when the head is in motion.
Vibrations are transferred to the screen. There are springs joined to the screen which return an equal but
opposite force to the screen thereby enhancing vibration.

5.1.2 Technical specifications and considerations

The first screen is the fines screen. The screen is a 1.8×3m single deck vibrating screen mounted with
10mm screen panels. It receives feed from the -2mm dump reserves. The undersize (-10mm) along with
the feed prep screen undersize (-2mm) becomes the feed for the DMS2 plant whilst the oversize is
discarded. The second screen (DMS2) is a de-slimming screen which allows the feed to mix with the
media (magnetite) free of slimes that are (-0.8mm). The screen is a 1.3×4.3m single deck vibrating screen

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fitted with 0.8mm screen panels. The oversize is discharged into the mixing box whist the undersize is
discarded to the thickener for water reclamation. Then finally are the drain and rinse screens which are for
media recycle and product cleaning. These screens are fitted with 0.8mm aperture size screen panels.

 The fines enhanced by the moisture are agglomerating hence beds of undersize constituents are
passing to the oversize stream. I suggest that another pipeline of nozzles be added for efficient
wash down.

Fig1.4 showing a bed of undersize material reporting to the oversize stream

5.2 Cyclones

FIG: 1.5 Showing the de-sliming cyclone in operation

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5.2.1 Operating principle

At the DMS2 plant, cyclone feed is pumped from the wing tank to the DMS cyclone under pressure as a
result of a VSD controlled pump. The feed then enters the cyclone at tangential angle, it starts rotating
due to the circular inlet design. As the solid particles start rotating, they are subjected to a centrifugal
action, which cause the heavier particles to move to the outside of the cyclone in a downward moving
spiral. This coarse fraction leaves the cyclone through the spigot (underflow). A secondary upward
moving spiral is simultaneously established which exits the cyclone via the vortex finder (overflow). The
lighter particles, which are not subject to high centrifugal forces join this upward moving spiral and leave
the cyclone via the overflow.

5.2.2 Technical specifications and considerations

DMS 2 was mounted with CL350 dense medium cyclones which separate at a pressure of 136Kpa. Given
they are new the spigots at the DMS2 have a diameter of 120mm. Spigots are changed as they wear out
due to abrasion. There is a de-sliming cyclone which removes very fine material from DMS2 feed before
the feed is further de-slimed at the de-sliming screen. It processes up to 70tpd at an approximate pressure
of 136Kpa. The internal surface of the cyclones is made up of cast steel. This is a very hard material
which is resistant to abrasion.

 I suggest that the separating pressure of the cyclones in DMS2 be maintained between 1.7 and 2.2
Bars for more efficient separation.

5.3Drum Magnets

FIG: 1.6 showing the wet drum in operation in the DMS2 plant

5.3.1 Operating principle

The feed consisting of water, slimes, and media is introduced to the magnet and flows in a direction
which is opposite the rotating direction of the drum. Media is attracted to the drum surface as the drum

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rolls. This media is then scrapped by a rubber scraper which is situated directly opposite the point of feed
entrance.

5.3.2Technical specifications and considerations

In the DMS2 plant, there is one wet drum magnet mounted with magnetic assembly inside which snares
the magnetite hence grasps it to the drum’s stainless steel surface. The DMS2 magnet is of size
1015×1220mm and 1500rpm capacity and is coupled with a 1.5kw motor. Test works proved that the
magnet is 96% efficient.

5.4 Demagnetizing coil

The Magnetized magnetite particles tend to aggregate, forming a non-uniform suspension in water hence
blockage of pipes and fluctuating medium density. Therefore to form a perfect mixture this magnetization
effect has to be removed by the demagnetizing coil to produce a non-flocculated suspension in the
separating vessel. The demagnetizing coil is ring shaped and it is located on a pipe which transports
media reclaimed at magnets to the dense medium sump.

6.0 TECHNICAL SPECIFICATIONS OF EQUIPMENT

7.0 RECOMMENDATIONS
1. The weight meters should oftenly be calibrated to give correct tonnages particularly the one on
the product conveyor belt .
2. I suggest that the DMS2 pipeline system be dug deeper into the ground to avoid interaction by
earth-moving machines.
3. I suggest that the pipes be installed and coupled with less bends to avoid impairment of the
pressure thus choke ups.
4. I suggest that a scalping screen be installed right after the overhead conveyor belt for appropriate
feed carriage.
5. I recommend that a bigger transformer be installed to capacitate the increment of plants since the
current one tends to cut from time to time which results in malfunctioning of equipment
therefore, loss of material (magnetite) and operational downtime.
6. As is in DMS1, the conveyor belts in DMS2 should be covered to avoid backing away of the
product on the belts due to rain.

7.0 REFERENCE
1. B. Wills, mineral processing Technology, 2006.

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2. J. Correa, "www.sciencedirect.com," April 2006.[ONLINE].

3. G.K. Batcher, Introduction to Fluid Dynamics, 1967, Cambridge University Press.
4. C. R. M. Schwertmann, "The Iron Oxides," 1996.

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