Size classification

Processing costs include those for size reduction, size classification, minerals concentration and separations, soHd—Hquid separation (dewatering), materials handling and transportation, and tailings disposal. Size reduction, one of the most expensive unit operations in minerals processing, could account for as much as 50% of the total energy consumed. This cost varies considerably from deposit to deposit and quite often from one area of a deposit to another. Ore bodies are extremely heterogeneous and the associated minerals Hberation, complex. 

Clays (qv) are aluminosihcate minerals, some of which have definite chemical compositions. In regard to tar sands, however, clay is only a size classification and is usually deterrnined by a sedimentation method. According to the previous definition of fines, the fines fraction equals the sum of the silt and clay fractions. The clay fraction over a wide range of fines contents is a relatively constant 30% of the fines. 

Size Reduction Combined with Size Classification. 20-16... 

Size Reduction Combined with Size Classification Grinding systems are batch or continuous in operation (Fig. 20-11). Most large-scale operations are continuous batch ball or pebble mills are used... 

Internal size classification plays an essential role in the funclion-ing of machines for dry grinding in the fine-size range particles are retained in the grinding zone until they are as small as required in the finished product then they are aUowed to discharge. 

Ball mills or tube mills can be operated in closed circuit with external air classifiers with or without air sweeping being employed. If air sweeping is employed, a cyclone separator may Be placed between mill and classifier. (The principles of size reduction combined with size classification are discussea under Characteristics of Size Classifiers. ) Likewise other types of grinding mill can be operated in closed circmt with external size classifiers (Fig. 20-12), as will be described at appropriate places on succeeding pages. However, many types of grinders are air-swept and are so closely coupled with their classifiers mat the latter are termed internal classifiers. 

The collection technique involves the removal of particles from the air stream. The two principal methods are filtration and impaction. Filtrahon consists of collecting particles on a filter surface by three processes—direct interception, inertial impaction, and diffusion (5). Filtration attempts to remove a very high percentage of the mass and number of particles by these three processes. Any size classification is done by a preclassifier, such as an impactor, before the particle stream reaches the surface of the filter. 

Mass concentration units for ambient measurements are mass (/xg) per unit volume (m ). Size classification involves the use of specially designed inlet configurations, e.g., PMjq sampling. To determine mass concentration, all the particles are removed from a known volume of air and their total mass is measured. This removal is accomplished by two techniques, filtration and impaction, described in Chapter 13. Mass measurements are made by pre-and postweighing of filters or impaction surfaces. To account for the absorption of water vapor, the filters are generally equilibrated at standard conditions T = 20°C and 50% relative humidity). 

The production of aluminum begins with the mining and beneficiation of bauxite. At the mine (usually of the surface type), bauxite ore is removed to a crusher. The crushed ore is then screened and stockpiled, ready for delivery to an alumina plant. In some cases, ore is upgraded by beneficiation (washing, size classification, and separation of liquids and solids) to remove unwanted materials such as clay and silica. 

A theoretical analysis of an idealized seeded batch crystallization by McCabe (1929a) lead to what is now known as the AL law . The analysis was based on the following assumptions (a) all crystals have the same shape (b) they grown invariantly, i.e. the growth rate is independent of crystal size (c) supersaturation is constant throughout the crystallizer (d) no nucleation occurs (e) no size classification occurs and (f) the relative velocity between crystals and liquor remains constant. 

R.L. Augsburger J.K. Lee, Hydraulic Size Classification Facility for Bali Propellants , Rept No TD-128, Olin Corp, New Haven (1974)... 

Closed circuit grinding employs external size classification and return of oversize for regrinding. The rules of pneumatic conveying are applied to design of air classifiers. Closed circuit is most common with ball and roller mills. 

Keough, B.K. "Influence of Additives and Particle-Size Classification on the Continuous Crystallization of Calcium Sulfite Hemihydrate," M.S. Thesis, University of Arizona, Tucson (1983). 

The number of inputs which are available for controlling crystallisation processes is limited. Possible Inputs for a continuous evaporative crystallisation process are, crystalliser temperature, residence time and rate of evaporation. These Inputs affect the crystal size distribution (CSD) through overall changes in the nucleatlon rate, the number of new crystals per unit time, and the growth rate, the increase in linear size per unit time, and therefore do not discriminate directly with respect to size. Moreover, it has been observed that, for a 970 litre continuous crystalliser, the effect of the residence time and the production rate is limited. Size classification, on the other hand, does allow direct manipulation of the CSD. 

There is a clear need for other size classifiers which combine a high separation efficiency with flexibility and compactness. Hydrocyclones have a small volume, are simple in operation and are standard size classification equipment, for example in closed circuit grinding applications. The recent development of the flat-bottom hydrocyclone, which permits classification in the coarse size range, creates an additional motive to study the use of hydrocyclones for Crystal Size Distribution (CSD) control. Furthermore, throttling of a flat botom hydrocyclone does not necessarily provoke blockage but allows continuous control of its cut size when a controlled throttling valve is used. There is a clear incentive for its use in this application since it may provide an additional process input. 

Most of the published composition/size distribution data have been obtained by analyzing cascade impactor samples. Some of these data suffer from poor size classification as a result of particle bounce or reentrainment, seriously limiting size resolution. Even when this problem is overcome, the data obtained with conventional cascade impactors are not capable of resolving many details of the distribution of submicron particles. These instruments typically classify only those particles larger than 0.3-0.5 tam aerodynamic diameter. All smaller particles are collected on a filter downstream of the impactor. Some measurements of the variation of composition with size below this limit have been attempted by aerodynamically classifying resuspended ash ( ). These data suffer from incomplete disapregation as well as poor classification of the smaller particles. 

Another application of tumblers is to the manufacture of mixed fertilizers, in which solid ammonium nitrate, liquid ammonia, liquid phosphoric acid, and liquid sulfuric acid are charged separately and reacted. The incidental agglomeration is excessive, however, and the process must be followed by appropriate crushing and size classification. 

Size, Classification Size, Particle. See under Particle Size Measurements of Solid Propellants, Explosives, and Pyrotechnics in Vol 8, P18-R to P59-L... 

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