Refinery
1. 0 I NTRODUCTI ON
Rio Tinto Zimbabwe Limited (RioZim) operates the Empress Nickel Refinery
(E.N.R) at Eiffel Flats, Kadoma, Zimbabwe [1]. It was built in 1968 to refine
nickel-copper matte from the Empress nickel mine using the Outokumpu
atmospheric leaching process. The mine and its associated concentrator and
smelter were closed down in 1982 after the economic mineral reserves had
been depleted. The refinery has been operating successfully as a toll refinery
since then, treating mainly matte from the Bamangwato Concession Limited
(B.C.L) operations in Botswana. This matte contains about 45-50% nickel, 40-
45% copper and 5-7% sulphur with the remainder made up of cobalt, iron and
arsenic. The refinery aims to maximize copper and nickel recoveries and to
produce nickel and copper cathodes that are satisfactory to the customers’
thickener 4 from the cementation and copper 1 leach circuit at E.N.R., the
of the crucial roles slag plays, is the removal of impurities from the matte.
After a heat of the smelting process upon tapping, two different layers of
the slag and matte should ideally be formed due to differences in densities
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
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of the slag and matte, whereupon the matte is tapped onto the granulation
pit and the slag tapped into chill moulds. The matte being tapped should
ideally be free of any slag and the slag should also ideally be free of any
heat, some of the matte gets entrained in the slag, while some matte is
oxidised due to the highly oxidising conditions that prevail in the furnace.
The oxidised matte reports to the slag. These occurrences are referred to
(i.e. total of Ni + Cu) should not exceed 1% upon assaying any sample of
metal-to-slag losses have been experienced, exceeding 1%. This has lead
to a lot of metal being lost with the slag being dumped at the slag dump at
E.N.R. To date the total of metal lost exceeds 250 tons (see appendix 1),
background the aim of this project is to design a suitable and cost effective
The method considered for this project involves mineral processing since
the alloy from slag to acceptable recoveries. This can be achieved through
values and the gangue such as specific gravity, size, shape, colour, and
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
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these tests will lead to design of a plant/pilot plant scale flow, diagram for
the milling of, and separation of the alloy from the slag.
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2. 0 LI TERATURE SURVEY
nature of the entrained alloy particles in the slag and their association with other
components in the slag [2]. This when accomplished can help in establishing the
nickel and compositional variations within the slag stockpile. The dissemination
of the entrapped metal of interest within the slag matrix has a strong bearing on
effective liberation of values from the gangue and effectiveness of the separation
The first stage in the characterization of the slag would involve chemical analysis
of the slag samples. Chemical analysis at Empress Nickel Refinery is carried out
for every slag-tap conducted after every heat of the Sirosmelt furnace. As the
slag is being tapped into chill moulds, a sample is taken and sent for analysis to
assay for different elements and other components in the slag and their relative
composition. X-rays are bombarded on the sample, and a detector measures the
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Particle size analyses can also be carried out on slag samples. These are a
range of tests performed with the aim of determining the amount of crushing to
metal values from the gangue. These include sieve analysis and recovery versus
particle size analysis on the separation equipment of choice [3]. Sieve analyses
provide information on the size fractions to which the greatest proportion of metal
values report, leading to predictions of the optimum mesh of grind for effective
liberation of metal values from the gangue. A metal distribution curve will be
plotted for various size fractions to which the slag would have been ground [4].
Recovery versus particle size analysis shows the particle size for which the
gravity separation.
comminution needed and the beneficiation methods necessary. It also shows the
necessary.
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the value metal alloy from the gangue at various particle sizes. In the separation
stage, size analysis of the products will be used to determine the optimum size of
the feed to the process for maximum efficiency and to determine the size range
at which any losses are occurring in the process, so that they may be reduced
[3].
data about the size distribution of particles in the material [5]. However, the exact
size of an irregular particle cannot be measured. For a spherical particle, the size
is uniquely defined by its diameter, while for irregular particles the “equivalent
diameter” is often used. Recorded data from any size analysis should, where
short list of some of the more common methods of size analysis, together with
Test sieving is the most widely used method for particle size analysis. It covers a
very wide range of particle size; and will thus be used in this project for any
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
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weight of sample material, successively through finer sieves, and weighing the
amount collected on each sieve to determine the percentage weight in each size
fraction. Sieving is carried out with wet or dry materials and the sieves are
Elutriation 40-5
In each of the standard series of sieves the apertures of consecutive sieves bear
a constant relationship to each other. It has been realized that a useful sieve
scale is one in which the ratio of the aperture widths of adjacent sieves is the
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There are several ways in which the results of a sieve test can be tabulated. The
assess their full significance. There are many different ways of recording results,
the most common being that of plotting cumulative undersize (or oversize)
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Milling is carried out in order to prepare the slag from the slag dump, for
extraction of the valuable metal [5]. Apart from regulating the size of the slag, it is
a process of physically separating the grains of valuable metal from the gangue
objective is the liberation, or release, of the valuable mineral, and in this case,
alloy, from the associated gangue minerals by size reduction of the slag size to
the coarsest possible particle size. Comminution in its earliest stages is carried
out in order to make the freshly excavated material easy to handle by scrappers,
conveyors, and slag carriers [5]. Comminution in the mill takes place as a
of run-of-dump slag to such a level that grinding can be effected until the metal
alloy and the gangue are substantially produced as separate particles. Crushing
is usually a dry process, and is performed in several stages with small reduction
ratios ranging from three to six in each stage. The reduction ratio in crushing can
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2. 3. 1 Crushing Equipment
Crushing is the first mechanical stage in the process of comminution of the slag
material in which the main objective is the liberation of the valuable alloy from the
gangue [5]. The nature of machinery for a given crushing operation is influenced
by the nature of the product required and the quantity and size of material to be
handled. Lumps of slag to be fed can be as large as 50cm and these have to be
open-circuit crushing, undersize material from the screen is combined with the
crusher product and is routed to the next operation. If the crusher is producing
undersize from the screen is the finished product. Closed-circuit crushing has the
crushing of slag lumps from the slag stockpile, heavy-duty machines are used to
reduce the slag lumps to a size suitable for transport by conveyors and for
feeding the secondary crushers. Two suitable primary crushers are the jaw and
gyratory crushers, as illustrated in figs. 2.2 and 2.3 [5]. Jaw crushers range in
size up to1680mm gape by 2130mm width. This size of machine can handle slag
with a 203mm set. However, at crushing rates above 545t/h the economic
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
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advantage of the jaw crusher over the gyratory diminishes; and above 725t/h jaw
Jaw crushers may be divided into three main groups; the Blake, with a movable
jaw pivoted at the top, giving greatest movement to the smallest lumps, the
Dodge, with the movable jaw pivoted at the bottom, giving greatest movement to
the largest lumps, and the overhead eccentric, which is hinged at the top similarly
to the Blake, with the movable jaw suspended on the eccentric shaft. Jaw
crushers are applied to the primary crushing of hard materials and are usually
followed by other types of crushers. In smaller sizes they are used as single-
stage machines.
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cone-shaped mortar or bowl. The angles of the cone are such that the width of
the passage decreases towards the bottom of the working faces. The pestle
consists of a mantle, which is free to turn on its spindle. The spindle is driven
from an eccentric bearing below. Differential motion causing attrition can occur
only when pieces are caught simultaneously at the top and bottom of the
passage owing to different radii at these points. Crushing occurs through the full
cycle in a gyratory crusher, and this produces a higher crushing capacity than a
similar sized jaw crusher, which crushes only in the shuttling half of the cycle. For
this reason gyratories are often operated in parallel with a scalping grizzly
screen, provided the added cost of the screen is less than the cost of increased
crusher capacity.
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Secondary crushers are much lighter than the heavy-duty, rugged primary
machines. Since they take the primary crushed ore as feed, the maximum feed
size of slag material it can take will be ideally less than 15cm in diameter.
Secondary crushers also operate with dry feeds, and their purpose can be to
reduce the slag material to a size suitable for grinding. The bulk of secondary
This class is called impact crushers [6]. The moving parts are beaters, which
transfer some of their kinetic energy to the ore particles on contacting them. The
internal stresses created in the particles are often large enough to cause them to
shatter. These forces are increased by causing the particles to impact upon an
anvil or breaker plate. Examples of impact crushers include the hammer mill, the
The Tidco Barmac crusher combines impact crushing, high-intensity grinding and
size of over 50mm is shown in fig. 2.4. The basic comminution principle
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revolving at a high speed. Grinding will commence when rock enters the rotor,
second. The rotor continuously discharges into a highly turbulent particle cloud
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2. 3. 2 Grinding Mills
Grinding is normally the last stage in the process of comminution. In this stage
tumbling mills [5]. These contain a charge of loose crushing bodies-the grinding
medium-which is free to move inside the mill, thus comminuting the slag
particles.
It is the purpose of the grinding section to exercise close control of the product
mesh of grind in order to exercise close control of the product from any slag
grinding section. The optimum mesh of grind will depend on many factors,
including the extent to which the values are dispersed in the gangue, and the
slag form E.N.R. is envisaged to be on tailings from the first stage of gravity
continuous process with material being fed at a controlled rat from storage bins
into one end of the mill and overflowing at the other end after a suitable dwell
time.
Tumbling mills are of three basic types: rod, rod and autogenous [6]. At Empress
Nickel refinery, ball mills (see fig. 2.5) are extensively used on the cementation
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leach circuit and on the siroleach circuit [1]. Thus a ball mill would be suitable for
grinding purposes on crushed slag from secondary crushers since such a mill
would be readily available and provisions for its use on slag recovery can be
made. A ball mill uses steel balls as the grinding medium. Closed circuit grinding
with high circulating loads would be preferable to open circuit grinding since the
former produces a closely sized end product and a high output per unit volume
compared with open circuit grinding. Grinding in a ball mill is effected by point
contact of balls and slag particles and given time, a desired degree of fineness
can be achieved.
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products on the basis of the velocity with which the grains fall through a fluid
medium [5]. This fluid is usually water, and wet classification is generally applied
screening. Since the velocity of particles in fluid medium is dependent not only on
the size, but also on the specific gravity and shape of the particles, the principles
is rising at a uniform rate. Particles introduced into the sorting column either sink
or rise according to whether their terminal velocities are greater or less than the
upward velocity of the fluid. The sorting column therefore separates the feed into
than the velocity of the fluid and an underflow consisting of particles with terminal
velocities less than the velocity of the fluid and an underflow or spigot product of
Many different types of classifiers have been designed and built which include
the settling cone (fig. 2.6), which is sometimes used as a dewatering unit in
them to dip into the settled material and to move it up the incline to the discharge.
Spiral Classifiers (fig. 2.7) use a continuously revolving spiral to move the sands
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
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up the slope. They can be operated at steeper slopes than the rake classifiers, in
which the sands tend to slip back when the rakes are removed.
utilises centrifugal force to accelerate the settling rate of particles. It is one of the
most important devices in the minerals industry [9], its main use in mineral
separation sizes. It is widely used in closed circuit grinding operations but has
found many other uses such as de-sliming, de-gritting, and thickening. In the
recovery of alloy from E.N.R. slag, classification can be used before gravity
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
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slimes, which increase viscosity of the slurry and hence reduce the sharpness of
separation, and obscure visual cut-off points [5]. Settling cones preceding the
gravity device can be used to control pulp density within the circuit. For a
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
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their relative movement in response to gravity and one or more other forces, the
latter often being the resistance to motion offered by a viscous fluid such as
water or air [5]. It is essential for effective separation of alloy particles from
gangue, that a marked density difference exists between the minerals and the
When the quotient is greater than 2.5, whether positive or negative, then gravity
only on its specific gravity, but also on its size. Large particles will be affected
more than smaller ones. The efficiency of gravity processes therefore increases
with particle size, and the particles should be sufficiently coarse. In practice,
close size control of feeds to gravity processes is required in order to reduce the
size effect and make the relative motion of the particles specific gravity
dependant.
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It is essential for the efficient operation of all gravity separators that the feed is
desliming and screening. One of the most important aspects of gravity circuit
control is therefore essential, and this is most important on the raw feed [5]. This
can be achieved through the use of settling cones and such other thickeners,
separators, which are best suited for purposes of recovering alloy form ground
2. 5. 1. 1 Spirals
introduced at the top of the spiral and, as it flows spirally downwards, the
particles stratify due to the combined effect of centrifugal force, the differential
settling rates of the particles and the effect of interstitial trickling through the
flowing particle bed. These mechanisms are complex being much influenced by
the slurry density and particle size. It is believed in some academic quarters that
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
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the main separation effect is due to hindered settling, with the largest densest
Ports for the removal of the higher specific gravity particles are located at the
lowest points in the cross-section. Wash-water added at the inner edge of the
stream, flows outwardly across the concentrate band. The width of the
tailings being discharged from the lower end of the spiral conduit. Spirals are
made with shapes of varying steepness, the angle affecting the specific gravity of
separation, but having little effect on the concentrate grade and recovery.
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2. 5. 1. 2 Shaking Tables
The principle behind the shaking table is that when a flowing film of water flows
over a flat, inclined surface the water closest to the surface is retarded by the
friction of the water absorbed on the surface; the velocity increases towards the
water surface [5]. If mineral particles are introduced into the film, small particles
will not move as rapidly as large particles, since they will be submerged in
slower-moving portion of the film. Particles of high specific gravity move more
slowly than lighter particles, and so a lateral displacement of the material will be
produced (fig. 2.10). The flowing film effectively separates coarse light particles
from small dense particles, and this mechanism is utilised to some extent in the
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feed at about 25% solids by weight, is introduced at the feed box and is
distributed along C; wash water is distributed along the balance of the feed side
slow forward stroke and a rapid return, which causes the mineral particles to
‘crawl’ along the deck parallel to the direction of the motion. The minerals are
thus subjected to two forces-that due to the table motion and that at right angles
to it due to the flowing film of water. The net effect is that the particles move
diagonally across the deck from the feed end and, since the effect of the flowing
film depends on the size and density of the particles, they will fan out on the
table, the smaller, denser particles riding highest towards the concentrate
launder, which runs along the length of the table. Fig. 2.12 shows an idealized
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concentrate end is often used to separate this product into two fractions: a high-
Particle size plays a very important role in table separations; as the range of
feed is made up of a wide range of particle sizes, some of these sizes will be
cleaned inefficiently. Thus since the shaking table effectively separates coarse
light from fine dense particles, it is common practice to classify the feed since
classifiers put such particles into the same product, on the basis of their equal
settling rates. This classification can be effected through use of classifiers such
The capacity of a table varies according to size of feed particles and the
concentration criteria. Tables can handle up to 2 tonnes per hour of 1.5mm sand
The quantity of water used in the feed pulp varies but for ore tables normal feed
dilution is 20-25% solids by weight. In addition to the water in the feed pulp, clear
water flows over the table for final concentrate cleaning. This varies from a few
litres to almost 100 litres/min according to the nature of the feed material.
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Tables slope from the feed to the tailings discharge end and the correct angle of
incline is obtained by means of a hand wheel. The table is slightly elevated along
the line of motion from the feed end to the concentrate end. The correct amount
of end elevation varies with feed size and is greatest for the coarsest and highest
gravity feeds. Normal end elevations in ore tabling range from a maximum of
90mm for a very heavy coarse sand to as little as 6mm for an extremely fine
feed.
This flowing film device (fig. 2.14), which uses orbital shear, is now used in heavy
ore) [11]. The separator consists of a v-shaped stainless steel tray measuring
128cm in length, 72cm in width, 91cm in height and weighing 150kg. Below the
tray is the shaking mechanism, which causes the tray to vibrate longitudinally at
oscillation is at 60 to 120 rpm. At one end of the tray is the feed cone and
concentrate wash water pipe, while an ‘irrigation’ water pipe runs along the
length of the tray with holes perforated on the pipe at equal separations, from
which jets of water impinge on the sample. At the other end of the tray is the
tailings launder for collection of tails. The tray is sloped at 1-50 to the horizontal
from the feed end. This laboratory piece of equipment has the advantage that its
‘V” profile tray with ‘end knock’, when treating closely sized material, is capable
not only of duplicating heavy liquid analysis results, but of giving additional data
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in the higher specific gravity ranges. It is also able to predict shaking table
therefore useful in carrying out release analysis and for prediction of reaction of
particles, are available for the gravity separation of a mixture of ground alloy and
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this section.
The principle of the MGS can be visualized as rolling the horizontal surface of a
conventional shaking table into a drum, then rotating it so that many times the
normal gravitational pull can be exerted on the mineral particles as they flow in
the water layer across the surface [12]. Fig. 2.15 shows a cross-section of the
superimposed on the motion of the drum; the shake imparted to one drum being
balanced by the shake imparted to the other, thus balancing the whole machine.
driven slightly faster than the drum but in the same direction. This scrapes the
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settled solids up the slope of the drum, during which time they are subjected to
outer, narrow end of the drum. The lower density minerals, along with the
majority of the wash water, flow downstream to discharge as tailings via slots at
In the concentration of alloy in the Sirosmelt slag, the recovery is defined as the
percentage of the total metal contained in the slag that is recovered in the
concentrate. Thus a recovery of 90% will mean that 90% of the alloy in the slag is
recovered in the concentrate and 10% lost to the tailings. Recovery is usually
expressed in terms of the valuable end product. The ratio of concentration is the
ratio of the weight of the feed to the weight of the concentrates. It is a measure of
the efficiency of the concentration process and it is closely related to the grade or
assay of the concentrate. The value of the ratio of concentration will generally
increase with the grade of concentrate. The grade, or assay, usually refers to the
The enrichment ratio is the ratio of the grade of concentrate to the grade of the
feed and again is related to the efficiency of the process. Ratio of concentration
and recovery are essentially independent of each other, and in order to evaluate
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tailings assays will be higher and the recovery low. If a high recovery of metal is
aimed for, there will be more gangue in the concentrate and grade of concentrate
and ratio of concentration will both decrease. It is impossible to give figures for
Since concentrate grade and recovery are metallurgical factors, the metallurgical
the recovery attainable for any value of concentrate grade. A typical recovery-
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Concentrate grade and recovery, used simultaneously, are the most widely
gravity separation processes to recover alloy from slag. These two measures can
separation:
S .E. = Rm − Rg
Cc × 100%
Rm =
Ff
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Rg = 100C (m − c ) m − f
100Cc
Rm − Rg =
Therefore, f − {100C (m − c ) (m − f )}
100Cm(c − f )
Rm − Rg =
(m − f ) f
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3. 1 Met hodology
It was hoped that this exercise would also offer an opportunity to investigate
the degree of grinding required for effective liberation of the values from the
and nickel [13]. Information from the mineralogical analysis will then be used
such techniques. Laboratory scale separation will be carried out. Results from
these tests will lead to design of a plant/pilot plant scale flow diagram for the
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3. 2 Chemical Analysis
Chemical Analysis was done to establish the elements in the slag and their
E.N.R. Sirosmelt plant assay record sheets for the period from 01/09/2002 to
25/09/2002 from the daily product accounting samples and the average assays
for different components from the slag-tap were calculated. The results are given
in §4.1.
Two polished sections were prepared from slag samples by being first ground to
flat surfaces, then being successively ground and polished until a mirror finish
was obtained for each surface. The sections were studied using a Zeiss reflected
light microscope and photographs were taken. Results obtained which are meant
A 4.5kg sample of the slag was crushed in a laboratory jaw crusher then ground
to passing 1mm. A sieve analysis was carried out in the size range plus 1000µm
to minus 53µm. The sieves used were the following: 1000µm, 850µm, 500µm,
425µm, 355µm, 212µm, 125µm, 75µm, 53µm aperture sieves. Each of the 9 size
fractions was assayed for copper and nickel content and the metal distribution
was computed. The results of the metal distribution are given in section §4.3.
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were crushed for different size fractions in the range minus 1000 to plus
53microns and collected using sieves. The sieves used were the following:
1000µm, 850µm, 500µm, 425µm, 355µm, 212µm, 125µm, 75µm, 53µm aperture
sieves. The 100g sample of slag crushed to a particular size was placed on a
Mozley Multi-gravity Laboratory Separator and wetted. The cyclic motion of the
tray mobilised the slag particles enabling stratification to take place. The heavy
metal particles sank to the tray surface and were ‘thrown’ upstream by the ‘end-
knock’ action. The lighter (gangue) mineral particles were carried downstream by
Interpretation of the data was carried out by assay analysis of the separator
products. For each particle size fraction, concentrates were collected and sent for
assaying for Cu and Ni. The assay results were used to calculate the recovery
(see appendix 3) for each particle size fraction and recovery versus particle size
Samples were collected from different parts of the slag dump in varying amounts.
The samples were crushed in a laboratory jaw crusher and ground in a cone
crusher to pass the 850µm screen. The grinding product was mixed
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Multi-gravity Separator Table was used for gravity separation (see §2.4.1.3). A
flow sheet was first designed for the gravity separation program to be followed.
This was done in order to achieve the maximum recoveries possible taking into
process runs through the Mozley Gravity Separator Table. Thus a rougher-
into account its efficiency in achieving high recoveries without compromising the
A 3kg sample of crushed slag was fed dry into the feed cone at one end of the
form a pulp of about 25% solids. The MMGS table was turned on and
simultaneously the water through the ‘irrigation’ and ‘concentrate’ pipes was
turned on. The feed cone was unscrewed to let the feed flow as a pulp onto the
table. The pulp was sprayed with a stream of water from the ‘irrigation’ and
concentrate wash pipes to enhance flow. The table was sloping towards the
tailings end at approximately 5o. The sample was subjected to the gravity
separation action for one minute after which the machine was switched off. The
slag ground to passing 850µm and was fed to the MMGS table. The concentrate
from the rougher separation run, MZT1, was collected, dried and weighed and
was subjected to another run which is the cleaner separation run, MZT2 (after a
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small measured amount was taken for assaying purposes). The concentrate from
MZT2 was taken for the recleaner separation run, MZT4 to give separate products
MZT1 together with fresh feed, while the concentrates were treated as the final
concentrate, dried and weighed and taken for assaying. The tailings from MZT1
separation run on the MMGS, MZT3 under the same conditions as described
above. The tailings from MZT3 were collected as the final tailings, dried and
weighed and taken for assaying while the concentrate was collected, to be re-fed
to MZT1 together with fresh feed. Two products were obtained for each run with
the lighter gangue minerals being collected at the tailings end while the heavier
value metal was obtained at the concentrate end. The products were decanted
and oven dried at 105oC for 2hours. A sample was extracted from each product
and taken for assaying. The results for the above test work are shown in §4.5.
D. Muchena 2003
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
Slag Feed
850µm
MZT 1
concentrate tailings
MZT 4 MZT 3
tailings concentrate
Final
Final tailing
concentrate
Fig 3.1: Schematic experimental flow sheet for the concentration of alloy from slag
D. Muchena 2003
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
A 20kg sample of crushed Sirosmelt slag was mixed with water to form a pulp of
density 40% solids and was pumped into a spiral concentrator, at the top. As the
occurred. Two separate products were obtained at the concentrates and tailings
ports. The products were dried and weighed and taken to assay for copper and
D. Muchena 2003
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
%Ni %Cu %S %Fe %FeO %Co %CaO %SiO2 %Al2O3 %MgO %Cr2O3
0.97 1.12 0.10 10.06 12.06 0.36 28.80 26.70 11.74 5.70 1.84
The results above show that the average assays for Cu and Ni are above
The results of metallographic analysis of slag samples are shown in figs. 4.1a
and 4.1b.
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
Slag samples showing different phases present in the slag. [Magnification: 50x]
After careful study and analysis of the phases shown above, the following
i. Most of the copper and Nickel in the slag occurs as an alloy within matte
(Cu2S), cuprite (Cu2O), tenorite (CuO), bunsenite (NiO) and covellite (CuS),
ii. Generally, Au, Pd, and Pt correlate with Cu and Ni. This indicates that the
three are associated with Cu and Ni in the alloy. This could be confirmed by
microbe analysis.
iii. Slag fragments make up the ultimate majority of the samples. The slag
oxide, mainly magnetite. Fine matte particles (< 75µm) occur as rounded
iv. Majorities of the entrained matte particles have clear margins and only rare
cases of coating were observed. The coatings are broken rims of cuprite
and/or magnetite. The rest of the magnetite occurs mainly as spherical and
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
free of oxidation rims. Majority range in size from 600 to 1000µm, average
size 300µm. Patches of cuprite were visible inside slag. Finer particles of
vi. The specific gravities of the Ni-Cu alloy and the slag are 8.8 and 2.3
The results of the metal distribution (see appendix 4) are showed below.
120.00
100.00
Cummulative Distribution (%)
80.00
Copper
60.00
Nickel
40.00
20.00
0.00
1000 850 500 425 355 212 125 75 53 53-
size (microns)
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
From the results shown, it was observed that metal distribution in the various size
ranges shows that 92.77% of the copper and 91.09% of the nickel is contained in
the size fraction minus 1000 to plus 125microns. This can be seen from the
graph in fig. 4.2 where the size range is the steepest part of the graph. The
Particles greater than 1000microns constitute 49.62% of the copper and 37.45%
of the nickel respectively, while particles less than 125microns constitute 7.23%
of the copper and 8.91% of the nickel. Therefore to effectively liberate the
particles and still save on comminution costs the particles should be ground in
90
80
70
Recovery (%), Grade (%)
60
50
grade
recovery
40
30
20
10
0
1000 850 500 355 212 125 75 53 53-
size (microns)
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
90
80
70
recovery (%), grade (%)
60
50 grade
recovery
40
30
20
10
0
1000 850 500 355 212 125 75 53 53-
size (micro n s)
The performance of the separator varied with the feed size as shown on the
graph in fig. 4.3 and fig 4.4. Recoveries of copper and nickel by size show that
plus 60% recoveries occur between minus 850microns to plus 125microns. The
125microns due to loss of values in fines at fine sizes. The fall at 500microns is
probably due to loss of values with gangue due to little unlocking at that size for
metal particles entrained in the slag at sizes lower than 850microns. This shows
that in a circuit to be designed for the recovery of metal values from E.N.R. slag,
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
passing 850microns, whereupon the tailings from this run would be further
The results are summarised in the experimental flow sheet in fig. 4.5
Generally high recoveries in the concentrate were obtained for each of the
stages above. The final separation stage MZT4 gave the highest recoveries of
enough recoveries were obtained. A high grade of the alloy, totalling 85.62% was
also obtained. Thus it can be safely concluded that further concentration beyond
The concentrate of the alloy obtained from gravity separation can be recharged
together with pellets into the Sirosmelt furnace or added to the granulated matte,
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
wt % 100.00
Feed % Cu, %Ni 1.12, 0.97
Rec (Ni, Cu) 100.00, 100.00
concentrate tailing
MZT1
Grind
wt % 29.63 wt % 70.36 80%,
13.27, 2.35 125µm
% Cu, %Ni 36.00, 6.02 % Cu, %Ni
Rec (Ni, Cu) 51.85, 53.33 Rec (Ni, Cu) 48.15, 46.67
tailing concentrate
MZT2
wt % 49.64
22.41, 5.81 wt % 50.36
% Cu, %Ni
47.88, 30.90 % Cu, %Ni 49.40, 6.23
Rec (Ni, Cu)
Rec (Ni, Cu) 52.12, 69.11
wt % 93.89 wt % 6.11
% Cu, %Ni 1.83, 1.75 % Cu, %Ni 37.40, 32.86
Rec (Ni, Cu) 44.99, 42.87 Rec (Ni, Cu) 55.01, 57.13
D. Muchena 2003
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
The concentration grade is low, at 6.74% for Cu and 6.13% for Ni. However the
recoveries are high at 92.86% and 97.51% for copper and Nickel respectively.
Thus although little metal is lost to tailings, the resultant grade after spiral
concentration is low.
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
5. 0 CONCLUSI ONS
1. The average assays for Cu and Ni are above the expected limits of a total
processing technique.
2. Since metallic species in the slag occur in the size range from <15µm to
matte particles coarser than 200µm. For particles less than 15µm, very
3. The large difference in specific gravities between the Ni-Cu alloy and the
the Cu-Ni alloy. The appropriate technique chosen was gravity separation,
separating them.
4. Metal distribution in the various size ranges shows that 92.77% of the
copper and 91.09% of the nickel is contained in the size fraction minus
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
5. Recoveries of copper and nickel by size show that plus 60% recoveries
of the gravity separation process falls for particles below 125microns due
6. The Mozley multi gravity separator table produced high recoveries for both
recleaner gravity concentration circuit. The grades for copper and nickel
were 51.40% and 34.22 for the same process. Thus it can be concluded
that shaking tables can be used in the concentration of the alloy in the
slag.
7. The spiral concentrator produced very low grades of the alloy although
recovery was high. This shows that little separation between the gangue
and the alloy was effected. Thus their use in concentrating the alloy was
less effective.
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
6. 0 RECOMMENDATI ONS
crushing the slag using a jaw crusher and using a Barmac crusher
shaking table. But due to the gradual phasing out of the James
Separator Drum are highly recommended for alloy from slag (AFS)
applications.
improvement in grade.
spiral concentration.
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
6.5 The product from gravity separation can be fed into the Sirosmelt
granulated matte.
6.6 The recommended plant flow diagram for the whole process of
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
7. 0 BI BLI OGRAPHY
3. Bernhardt, C., Particle Size Analysis, Chapman and Hall, London, 1994,
pp8-26
4. Anon. Test Sieving, British Standard 1796, London Press, London, 1976,
pp9-11
pp213-215
1988, pp106
10. Mills, C., Mineral Processing Plant Design, AIMME, 1978, pp38-39
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
12. Mozley R. et al., The Mozley Mineral Separating Systems, 2000, pp2
14. Craig, J.R., Vaughan, J.D., Ore Microscopy and Petrography, John
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
8. 0 APPENDI CES
Total amount on Nickel lost to slag = 1.12% of 11958.3 tons = 133.93296 tons
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
Cc × 100% Tt × 100%
Re cov ery = or Re cov ery =
Ff Ff
Where C = wt % of concentrate,
c = grade of concentrate,
T = wt % of tailing
t = grade of tailing
F = wt % of Feed,
F = grade of feed
Size Mass Wt
Assa Assa Distributio Distributio Cumulative Cumulative
y y n n
(Micron g (%) Cu Ni Cu (%) Ni (%) Distribution Cu Distribution
s) (%) (%) (%) Ni (%)
1000 1219. 27.05 2.11 3.44 49.62 37.45 49.62 37.45
5
850 292.3 6.48 0.67 1.91 3.78 4.98 53.39 42.43
500 669.9 14.86 1.37 2.61 17.72 15.61 71.11 58.04
425 381.1 8.45 0.97 2.25 7.16 7.65 78.27 65.69
355 243.6 5.40 0.76 2.49 3.55 5.41 81.82 71.11
212 657.5 14.59 0.69 2.69 8.75 15.79 90.57 86.90
125 299.3 6.64 0.38 1.57 2.19 4.19 92.77 91.09
75 354.1 7.86 0.50 1.13 3.40 3.57 96.16 94.66
53 210 4.66 0.39 1.45 1.60 2.72 97.76 97.38
-53 180.3 4.00 0.65 1.63 2.24 2.62 100.00 100.00
Total 4507. 100.00 1.12 0.97 100.00 100.00 100.00 100
6
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
Size Concentrate
(Microns) mass wt Assay Assay Recover Recover Recover
y y y
g % Cu % Ni % Cu % Ni % (Cu+Ni)
%
1000 8.8 4.4 20.4 14.44 5.31753 18.4697 7.54409
6 7 4
850 17.4 8.7 39 13.32 63.4205 60.6722 62.6975
6 5 2
500 19.2 9.6 37.4 14.02 33 51.5678 36.5924
2 4
355 19.7 9.85 30.8 14.86 50.1454 58.7835 52.6640
5 3 5
212 27.4 13.7 25.2 15.14 63.8151 77.1070 68.2293
6 6 8
125 14.3 7.15 35.8 14.72 84.4785 67.0369 78.5256
5 4 5
75 8.5 4.25 34.4 14.72 36.7336 55.3628 40.8532
7 3 3
53 2.3 1.15 43.4 14.58 15.8444 11.5634 14.495
4 5
53- 1.7 0.85 42.2 7.15 6.97859 3.72852 6.19608
9 8 6
Total 119.3 59.65
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Designing a process for the recovery of Nickel-Copper alloy from Sirosmelt slag at Empress Nickel
Refinery
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