Mines to Mill integration for improving overall recovery

Improve the recovery of ore from the mine through the process of size reduction, grinding or crushing, milling, and size separation generally results in increased production.

The major concern in Rampura Agucha Mill recovery is Galena liberation as well as low Sphalerite liberation. The typical Lead concentrate sample contains 64.2% lead, 13.2% sulphur, 5.6% iron, 4.8% SiO2 and 6.4% carbon and Silver grade in the concentrate is 881 ppm. Most of the galena losses are due to unrecovered galena grains in the 20 micron particle size, where they occur as tiny inclusions within silicates and sphalerite. Nearly 85% of the mass of lead concentrate is distributed in less than 20 micron size fraction. Silver is mainly distributed in Argentotennantite, Pyrargyrite, and Diaphorite.

Mines with Mill capacity of at least 6.5 mpta ore processing and recovery from the mill is less than 90% on Zn or 60% on Pb.

Functional Requirements of the End-User

  • To remove well liberated graphite prior to lead floatation stage and increase the silver recovery at concentrate.
  • To minimise the generation of unwanted fine particles and dust.

Functional & Operational Capabilities

  • To understand liberation dynamics, size-by-size behaviour of partially liberated minerals, hydrodynamic conditions in the flotation cell, grain size reactions and its dynamics.

Operational constraints

  • To be retrofittable into existing machinery and should have near zero maintenance.
  • This should be easy to use without any special product training required and avoid any changes to existing process.

Expected Tangible Benefits and Measurable Gains

  • Increase in recovery from the mill

Performance Metrics or Outcomes

  • Mill Recovery - MIC / MIO ratio