Mineral Processing Design and Operations
An Introduction
- 3rd Edition -
- Latest edition
- Authors: Denis S. Yan, Janine Beazley
- Language: English
Mineral Processing Design and Operations: An Introduction, Third Edition outlines the various methods commonly used in mineral beneficiation and concentration processes. It provid… Read more
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Description
Description
Mineral Processing Design and Operations: An Introduction, Third Edition outlines the various methods commonly used in mineral beneficiation and concentration processes. It provides a balance of fundamental theoretical operational principles and practical explanations of the design and operation of apparatus and equipment. The basics of process controls for efficient and economic modes of separation are also introduced. This fully updated third edition features updates on key areas within the field such as the properties of slurries and tailings waste management, as well as the increasing importance of sensor-based ore sorting options to improve efficiency and sustainability. The book covers the theory and formulae for unit capacities and power requirements to help the designer develop the necessary equipment and flowsheets to economically attain maximum yield and grade. Application of the theory to practice is explained at each stage, helping operators understand associated implications in each unit process. It aims to help students, practicing engineers and operators who are interested in processing minerals to economically liberate and concentrate them for down-stream extraction processes. To understand the unit as well as the integrated processes, the subject has been treated with a mathematical emphasis to help in applying the theory in actual process design and operations. Data provided in the appendix is intended to aid in the calculations of designing and plant operations, whilst solutions to simple and common plant problems are also provided. Mineral Processing Design and Operations: An Introduction, Third Edition is written primarily for undergraduate, graduate and postdoc level students in metallurgy, chemical engineering and process engineering who are engaged in the beneficiation of minerals. It also remains a valuable text for professional engineers working in industry given the breadth of coverage.
Key features
Key features
- Outlines the theory and practice involved in the design of flow sheets and the operation of an integrated mineral processing plant
- Describes automation in mineral processing plants allowing maximum yields and consistent high concentrate grades
- Examines common problems and offers solutions in the form of various examples
Readership
Readership
For metallurgists and process engineers as well as primarily graduate and postgraduate level students in the disciplines of metallurgy, chemical engineering, process engineering) requiring an introductory guide to large scale industrial operations to liberate and recover commercially valuable minerals from ores both in operation and research
Table of contents
Table of contents
1. Introduction
1.1 Mineral Sampling
1.1.1 Introduction
1.1.2 Statistical Terminology
1.1.3 Mineral Particles Differing in Size – Gy’s Method
1.1.4 Mineral Particles of Different Density
1.1.5 Incremental Sampling
1.1.6 Continuous Sampling of Streams
1.1.7 Sampling Ores of Precious Metals
1.1.8 Sampling Nomographs
1.1.9 Problems
2. Particle Size Estimation and Distributions
2.1 Introduction
2.2 Methods of Size Estimation
2.3 Particle Size Distribution
2.4 Combining Size Distributions
2.5 Problems
3. Size Reduction and Energy Requirement
3.1 Introduction
3.2 Design of Size Reduction Processes
3.3 Energy for Size Reduction – Work Index
3.4 Estimation of Work Index for Crushers and Grinding Mills
3.5 Factors Affecting the Work Index
3.6 Approximation Methods for Work Index
3.7 Work Index and Abrasion
3.8 Problems
4. Jaw Crusher
4.1 Introduction
4.2 Design of Jaw Crushers
4.3 Jaw Crusher Operation
4.4 Jaw Crusher Capacity Estimation
4.5 Critical Operating Speed
4.6 Power Consumption Estimation
4.7 Problems
5. Gyratory and Cone Crusher
5.1 Introduction
5.2 Design of Gyratory Crushers
5.3 Gyratory Crusher Circuit Design
5.4 Gyratory Crusher Operation
5.5 Capacity of Gyratory and Cone Crushers
5.6 Power Consumption of Gyratory and Cone Crushers
5.7 Problems
6. Roll Crushers
6.1 Introduction
6.2 Design of Roll Crushers
6.3 Operation of Roll Crushers
6.4 Capacity of Roll Crushers
6.5 Power Consumption of Roll Crushers
6.6 High Pressure Grinding Rolls (HPGR)
6.7 Operation of HPGR
6.8 Capacity of HPGR
6.9 Power Consumption of HPGR
6.10 Problems
7. Tubular Ball Mills
7.1 Introduction
7.2 Design of Tubular Mills
7.3 Operation of Tubular Ball Mills
7.4 Estimation of Mill Capacity
7.5 Mill Power Draw-Mechanical Methods
7.6 Problems
8. Tubular Rod Mills
8.1 Introduction
8.2 Design of Rod Mills
8.3 Operation of Rod Mills
8.4 Rod Mill Capacity
8.5 Rod Mill Power Draft
8.6 Rod Mill Drive
8.7 Problems
9. Autogenous and Semi-Autogenous Mills
9.1 Introduction
9.2 Design of AG/SAG Mills
9.3 Operation of AG/SAG Mills
9.4 AG/SAG Mill Power
9.5 Choice of Options between AG and SAG Mills
9.6 Problems
References
10. Stirred Mills – Ultrafine Grinding
10.1 Introduction
10.2 Vertical Mills
10.3 Horizontal Disc Mill – IsaMill
10.4 Design Testwork
10.5 Problems
11. Mathematical Modelling of Comminution Processes
11.1 Introduction
11.2 Basis for Modelling Comminution Systems
11.3 Mathematical Models of Comminution Processes
11.4 Modelling Crushing and Grinding Systems
11.5 Problems
12. Screening
12.1 Introduction
12.2 Basic Design Features of Screens
12.3 Operation of Straight Screens
12.4 Capacity and Screen Selection of Straight Screens
12.5 Operation of Curved Screens
12.6 Modelling of the Screening Process
12.7 Screening and Crushing Circuits
12.8 Problems
13. Classification
13.1 Introduction
13.2 Design Features of Mechanical Classifiers
13.3 Designing the Pool Area of Mechanical Classifiers
13.4 Design Features of Centrifugal Classifiers
13.5 Operation of Mechanical Classifiers
13.6 Capacity of Mechanical Classifiers
13.7 Operation of Centrifugal Classifiers
13.8 Hydrocyclone Models
13.9 Hydrocyclone Capacity
13.10 Hydrocyclone Circuits
13.11 Reflux Classifiers
13.12 Problems
14. Solid – Liquid Separation – Thickening
14.1 Introduction
14.2 Design Features of Thickeners
14.3 Thickener Design-Batch Process
14.4 Thickener Design-Continuous Thickeners
14.5 Operation of Thickeners
14.6 Thickeners in Circuits
14.7 Problems
15. Solid Liquid Separation – Filtration
15.1 Introduction
15.2 Design Features of Filters
15.3 Operation of Filters
15.4 Capacity of Continuous Vacuum Filters
15.5 Washing of Deposited Cake
15.6 Drying of Deposited Cake
15.7 Optimum Thickness of Cake
15.8 Filtering Media
15.9 Filtering Aids
15.10 Filtration in Mineral Processing Circuits
15.11 Problems
16. Gravity Separation
16.1 Introduction
16.2 Particle Settling Rates
16.3 Gravity Separation Operations
16.4 Jigs
16.5 Differential Motion Table Separators
16.6 Flowing Film Concentrators
16.7 Dense (or Heavy) Media Separation
16.8 Gravity Separation Performance
16.9 Problems
17. Magnetic and Electrostatic Separation
17.1 Introduction
17.2 Atomic Theory of Magnetism
17.3 Types of Magnetism in Minerals
17.4 Magnetic Properties of Some Selected Commercial Minerals
17.5 Industrial Roll Design and Methods of Magnetic Separation of Minerals
17.6 Electrical Conductivity of Minerals
17.7 Electrostatic Forces and Mineral Separation
17.8 Practical Separation Units
18. Flotation
18.1 Introduction
18.2 Flotation Reagents
18.3 Flotation Equipment (add Hydrofloat cells)
18.4 Flotation Circuits
18.5 Flotation Kinetics
18.6 Factors Affecting the Rate of Flotation
18.7 Application of Kinetic Equations
18.8 Other Flotation Models
18.9 Problems
19. Ore Sorting
19.1 Introduction
19.2 Principles of Ore Sorting
19.3 Types of Ore Sorters
20. Tailings Disposal
20.1 Introduction
20.2 Disposal Options
20.3 Dam Wall Construction
21. Properties of Slurries
21.1 Introduction
21.2 Slurry Viscosity
21.3 Viscosity - Effects on Mineral Processing
22. Metallurgical Process Assessment
22.1 Introduction
22.2 Analyses of Constituents
22.3 Definition of Terms
22.4 Material Balance
22.5 Circulating Load
22.6 Problems
23. Process Control
23.1 Introduction
23.2 Controller Modes
23.3 Signals and Responses
23.4 Input and Output Signals of Controllers
23.5 Integration of Processes and Block Diagrams
23.6 Setting and Tuning Controls
23.7 Complex Advanced Controllers
23.8 Dead Time Compensation
23.9 Instrumentation and Hardware
23.10 Controls of Selected Mineral-Processing Circuits
23.11 Advances in Process Control Systems
23.12 Expert Systems
23.13 Mechanics of Digital Process Control Systems
1.1 Mineral Sampling
1.1.1 Introduction
1.1.2 Statistical Terminology
1.1.3 Mineral Particles Differing in Size – Gy’s Method
1.1.4 Mineral Particles of Different Density
1.1.5 Incremental Sampling
1.1.6 Continuous Sampling of Streams
1.1.7 Sampling Ores of Precious Metals
1.1.8 Sampling Nomographs
1.1.9 Problems
2. Particle Size Estimation and Distributions
2.1 Introduction
2.2 Methods of Size Estimation
2.3 Particle Size Distribution
2.4 Combining Size Distributions
2.5 Problems
3. Size Reduction and Energy Requirement
3.1 Introduction
3.2 Design of Size Reduction Processes
3.3 Energy for Size Reduction – Work Index
3.4 Estimation of Work Index for Crushers and Grinding Mills
3.5 Factors Affecting the Work Index
3.6 Approximation Methods for Work Index
3.7 Work Index and Abrasion
3.8 Problems
4. Jaw Crusher
4.1 Introduction
4.2 Design of Jaw Crushers
4.3 Jaw Crusher Operation
4.4 Jaw Crusher Capacity Estimation
4.5 Critical Operating Speed
4.6 Power Consumption Estimation
4.7 Problems
5. Gyratory and Cone Crusher
5.1 Introduction
5.2 Design of Gyratory Crushers
5.3 Gyratory Crusher Circuit Design
5.4 Gyratory Crusher Operation
5.5 Capacity of Gyratory and Cone Crushers
5.6 Power Consumption of Gyratory and Cone Crushers
5.7 Problems
6. Roll Crushers
6.1 Introduction
6.2 Design of Roll Crushers
6.3 Operation of Roll Crushers
6.4 Capacity of Roll Crushers
6.5 Power Consumption of Roll Crushers
6.6 High Pressure Grinding Rolls (HPGR)
6.7 Operation of HPGR
6.8 Capacity of HPGR
6.9 Power Consumption of HPGR
6.10 Problems
7. Tubular Ball Mills
7.1 Introduction
7.2 Design of Tubular Mills
7.3 Operation of Tubular Ball Mills
7.4 Estimation of Mill Capacity
7.5 Mill Power Draw-Mechanical Methods
7.6 Problems
8. Tubular Rod Mills
8.1 Introduction
8.2 Design of Rod Mills
8.3 Operation of Rod Mills
8.4 Rod Mill Capacity
8.5 Rod Mill Power Draft
8.6 Rod Mill Drive
8.7 Problems
9. Autogenous and Semi-Autogenous Mills
9.1 Introduction
9.2 Design of AG/SAG Mills
9.3 Operation of AG/SAG Mills
9.4 AG/SAG Mill Power
9.5 Choice of Options between AG and SAG Mills
9.6 Problems
References
10. Stirred Mills – Ultrafine Grinding
10.1 Introduction
10.2 Vertical Mills
10.3 Horizontal Disc Mill – IsaMill
10.4 Design Testwork
10.5 Problems
11. Mathematical Modelling of Comminution Processes
11.1 Introduction
11.2 Basis for Modelling Comminution Systems
11.3 Mathematical Models of Comminution Processes
11.4 Modelling Crushing and Grinding Systems
11.5 Problems
12. Screening
12.1 Introduction
12.2 Basic Design Features of Screens
12.3 Operation of Straight Screens
12.4 Capacity and Screen Selection of Straight Screens
12.5 Operation of Curved Screens
12.6 Modelling of the Screening Process
12.7 Screening and Crushing Circuits
12.8 Problems
13. Classification
13.1 Introduction
13.2 Design Features of Mechanical Classifiers
13.3 Designing the Pool Area of Mechanical Classifiers
13.4 Design Features of Centrifugal Classifiers
13.5 Operation of Mechanical Classifiers
13.6 Capacity of Mechanical Classifiers
13.7 Operation of Centrifugal Classifiers
13.8 Hydrocyclone Models
13.9 Hydrocyclone Capacity
13.10 Hydrocyclone Circuits
13.11 Reflux Classifiers
13.12 Problems
14. Solid – Liquid Separation – Thickening
14.1 Introduction
14.2 Design Features of Thickeners
14.3 Thickener Design-Batch Process
14.4 Thickener Design-Continuous Thickeners
14.5 Operation of Thickeners
14.6 Thickeners in Circuits
14.7 Problems
15. Solid Liquid Separation – Filtration
15.1 Introduction
15.2 Design Features of Filters
15.3 Operation of Filters
15.4 Capacity of Continuous Vacuum Filters
15.5 Washing of Deposited Cake
15.6 Drying of Deposited Cake
15.7 Optimum Thickness of Cake
15.8 Filtering Media
15.9 Filtering Aids
15.10 Filtration in Mineral Processing Circuits
15.11 Problems
16. Gravity Separation
16.1 Introduction
16.2 Particle Settling Rates
16.3 Gravity Separation Operations
16.4 Jigs
16.5 Differential Motion Table Separators
16.6 Flowing Film Concentrators
16.7 Dense (or Heavy) Media Separation
16.8 Gravity Separation Performance
16.9 Problems
17. Magnetic and Electrostatic Separation
17.1 Introduction
17.2 Atomic Theory of Magnetism
17.3 Types of Magnetism in Minerals
17.4 Magnetic Properties of Some Selected Commercial Minerals
17.5 Industrial Roll Design and Methods of Magnetic Separation of Minerals
17.6 Electrical Conductivity of Minerals
17.7 Electrostatic Forces and Mineral Separation
17.8 Practical Separation Units
18. Flotation
18.1 Introduction
18.2 Flotation Reagents
18.3 Flotation Equipment (add Hydrofloat cells)
18.4 Flotation Circuits
18.5 Flotation Kinetics
18.6 Factors Affecting the Rate of Flotation
18.7 Application of Kinetic Equations
18.8 Other Flotation Models
18.9 Problems
19. Ore Sorting
19.1 Introduction
19.2 Principles of Ore Sorting
19.3 Types of Ore Sorters
20. Tailings Disposal
20.1 Introduction
20.2 Disposal Options
20.3 Dam Wall Construction
21. Properties of Slurries
21.1 Introduction
21.2 Slurry Viscosity
21.3 Viscosity - Effects on Mineral Processing
22. Metallurgical Process Assessment
22.1 Introduction
22.2 Analyses of Constituents
22.3 Definition of Terms
22.4 Material Balance
22.5 Circulating Load
22.6 Problems
23. Process Control
23.1 Introduction
23.2 Controller Modes
23.3 Signals and Responses
23.4 Input and Output Signals of Controllers
23.5 Integration of Processes and Block Diagrams
23.6 Setting and Tuning Controls
23.7 Complex Advanced Controllers
23.8 Dead Time Compensation
23.9 Instrumentation and Hardware
23.10 Controls of Selected Mineral-Processing Circuits
23.11 Advances in Process Control Systems
23.12 Expert Systems
23.13 Mechanics of Digital Process Control Systems
Product details
Product details
- Edition: 3
- Latest edition
- Published: October 1, 2026
- Language: English
About the authors
About the authors
DY
Denis S. Yan
6 years Consultant Metallurgist, Mineral Engineering Technical Services, Perth, Western Australia; and 22 years in academia, research and lecturing on Mineral Processing, W.A School of Mines, Kalgoorlie, Western Australia.
Affiliations and expertise
Minerals Engineering and Extractive Metallurgy, Curtin University of Technology, Kalgoorlie, AustraliaJB
Janine Beazley
Janine Beazley has more than thirty years’ experience as a metallurgist in the minerals industry following her graduation from the University of New South Wales with a Bachelor of Science (Hons) in Pure and Applied Chemistry. She has held production and management roles across numerous processing environments. Her experience involves comminution, flotation, hydrometallurgy including heap and in-place leaching, agglomeration techniques, solvent extraction and electrowinning. Her expertise covers plant optimisation, commissioning of unit processes, managing and planning of plant shutdowns and pilot plants. Janine’s role as senior tutor at the WA School of Mines made her the first female educator lecturing in a mining school in Australia where she gained her passion for STEM education, encouraging and supporting students, particularly women, to embark on careers in the minerals industry. Janine has worked on numerous projects at various study levels. She is currently working as a consultant metallurgist in the engineering design company METS.
Affiliations and expertise
Consultant Metallurgist with Minerals Engineering Technical Services, Perth, Western Australia, Australia