Mineral Processing

Comminution consumes the largest share of mine-site energy — Bond work index W_i sizes mill power from feed and product P80. Reduction ratio RR tracks crusher stages from ROM to mill feed.

Screening separates by size aperture; efficiency E measures mass reporting to correct fraction. Hydrocyclones classify fines by centrifugal field — cut size d50 set by spigot, vortex finder, and feed pressure in closed grinding circuits.

Gravity separation exploits density differences — Stokes settling for fines, heavy medium baths for coal and iron ore, spirals and tables for minerals. Concentration ratio CR = feed grade/concentrate grade measures enrichment.

Flotation separates valuable minerals by selective attachment to air bubbles — recovery R and grade trade off through reagent suite (collector, frother, modifier) and circuit layout (rougher-scavenger-cleaner).

Thickeners concentrate slurry by gravity settling — area sized from flux Q×C/(ρ_s v_s). Filters further reduce cake moisture before tailings stacking or transport; flocculant dose critical for ultra-fines.