COURSE UNIT TITLE

: MINERAL PROCESSING PLANT DESIGN

DEGREE PROGRAMMES

Description of Individual Course Units

Course Unit Code Course Unit Title Type Of Course D U L ECTS
MIN 5002 MINERAL PROCESSING PLANT DESIGN ELECTIVE 2 2 0 6

Offered By

Graduate School of Natural and Applied Sciences

Level of Course Unit

Second Cycle Programmes (Master's Degree)

Course Coordinator

PROFESSOR DOCTOR ABDULLAH SEYRANKAYA

Offered to

Mineral Processing
Mineral Processing
Mineral Processing

Course Objective

The primary objective of this course is to present the current state of the art knowledge in mineral processing plant design and practice. The course will mostly cover the sizing of unit operations, sampling, ore characterization, laboratory testing, evaluation of comminution and concentration tests, equipment selection, flow sheet design, basic circuits, sizing and selection of auxiliary equipment, capital and operating costs in Mineral Processing to process different ores. The design philosophy of process planning and plant practice has been an important factor that will tend to stand out; namely the requirement to decrease costs in all phases of plant design and practice.

Learning Outcomes of the Course Unit

1   perform the engineering design and mass balance calculations related with mineral processes and hydrometallurgical processes
2   develop conceptual process flow sheets for comminution and concentration circuits
3   select and size the major equipment in mineral processing plant
4   apply the fundamental knowledge of mathematics, science, and engineering for the selection and design of mineral processes, and gain an ability to function on multi-disciplinary teams
5   gain an ability to identify, formulate, and solve engineering problems and use the modern engineering tools necessary for engineering practice
6   develop analytical thinking skills and capability to perform the basic engineering calculations, and provide the ability to evaluate the results of the experiments and improve writing and communication skills
7   be aware of developments related to mineral processing plant design and planning, and provide the ability to recognize the need for, and to engage in lifelong learning
8   consider occupational health and safety, environmental issues and ethical values

Mode of Delivery

Face -to- Face

Prerequisites and Co-requisites

None

Recomended Optional Programme Components

None

Course Contents

Week Subject Description
1 Introduction to mineral processing plant design, Feasibility study
2 Sampling and its importance, Ore/mineral characterization tests, Ore Mineralogy and its importance, Mineral processing laboratory tests and interpretation of test results
3 Crushing and screening tests and evaluation of test results, Crushing and screening circuits, Size reduction circuit design and equipment selection, Sizing crushers and screens, Developments in modeling and simulation of comminution circuits
4 Grinding and classification circuits, Mass balance calculations, Properties of mills and grinding media, Critical speed and its importance, Selection criteria and sizing of various types of mills (ball, rod, autogenous mills etc.).
5 Classification equipments. Evaluation of the performance of classificators, Selection and sizing of hydrocyclones and Mechanical Classifiers, Sizing and selection of pumps
6 Development of process flow sheet for comminution and classification units
7 Concentration circuits, Selection and sizing of concentration equipments (gravity, magnetic, electrostatic separators), Separation efficiency
8 Flotation circuits, Cell/column design, Selection of flotation reagents,
9 Equipments for solid-liquid separation and their properties, Sizing and selection of dewatering equipments (thickener, filters etc.), On-line analysis and automation in mineral processing plants
10 Investment and operating cost calculations, Methods for estimation of major equipment cost, Feasibility report
11 Auxiliary equipment selection and design, selection and sizing of pump, transportation of pulp, Tailing ponds and reclamation, Dust collecting systems and dust collectors
12 Midterm Exam
13 Modern mineral processing planning, Problems and uncertainties in mineral processing plant design, Future of mineral processing planning
14 Environmental Impact Assessment, Occupational health and safety; and Examples of some mineral processing plant in Turkey, Project presentation

Recomended or Required Reading

Mineral Processing Plant Design, Practice and Control. Eds.: A. L. Mular, D. N. Halbe and D. J. Barratt,vol:1-2, SME, Littleton, Colorado, 2002, ISBN:0-87335-223-8.
Gupta, A.and Yan, D.S. (2006). Mineral Processing Design and Operation-An Introduction. Elsevier, Radarweg 29, PO Box 211, 1000 AE Amsterdam, The Netherlands, ISBN-13: 978-0-444-51636-7
King, R.P. Modeling and Simulation of Mineral Processing Systems. Butterworth-Heinemann, ISBN-10: 0-7506-4884-8. 2001.
Napier-Munn, T. J., Morrell, S., Morrison, R. D., and Kojovic, T. (1996) Mineral Comminution Circuits: Their Operation and Optimization, Julius Kruttschnitt Mineral Research Centre, Indooroopilly, Queensland, Australia.
Advances in Gravity Concentration. Eds.: Honaker, R.Q. and Forrest. W.R., SME (Society for Mining, Metallurgy, and Exploration, Inc.), Littleton, Colorado, (2003), ISBN-10: 0-87335-227-0

Planned Learning Activities and Teaching Methods

Assessment Methods

SORTING NUMBER SHORT CODE LONG CODE FORMULA
1 MTE MIDTERM EXAM
2 ASG ASSIGNMENT
3 FIN FINAL EXAM
4 FCG FINAL COURSE GRADE MTE * 0.25 + ASG *0.25 +FIN *0.50
5 RST RESIT
6 FCGR FINAL COURSE GRADE (RESIT) MTE * 0.25 + ASG *0.25 +RST *0.50


*** Resit Exam is Not Administered in Institutions Where Resit is not Applicable.

Further Notes About Assessment Methods

None

Assessment Criteria

1-6: Mid-term exam, Laboratory and Reports, Project presentation
7-8: Final exam

Language of Instruction

Turkish

Course Policies and Rules

To be announced.

Contact Details for the Lecturer(s)

Doç. Dr. Abdullah SEYRANKAYA: a.seyrankaya@deu.edu.tr Tel: +90 232 3017519
Prof. Dr. Erol KAYA: erol.kaya@deu.edu.tr Tel:+90 232 3017514

Office Hours

To be announced.

Work Placement(s)

None

Workload Calculation

Activities Number Time (hours) Total Work Load (hours)
Lectures 13 2 26
Tutorials 10 2 20
Preparations before/after weekly lectures 13 1 13
Preparation for midterm exam 1 10 10
Preparation for final exam 1 10 10
Preparing assignments 3 10 30
Preparing presentations 3 10 30
Final 1 3 3
Midterm 1 3 3
Quiz etc. 3 2 6
TOTAL WORKLOAD (hours) 151

Contribution of Learning Outcomes to Programme Outcomes

PO/LOPO.1PO.2PO.3PO.4PO.5PO.6PO.7PO.8PO.9PO.10PO.11
LO.154442122131
LO.252335122131
LO.354332112131
LO.455555334151
LO.554335454133
LO.621335555333
LO.731112324235
LO.821111111511

CONTACT INFORMATION
Dokuz Eylül Üniversitesi Cumhuriyet Bulvarı No: 144 35210 Alsancak / İZMİR
Phone: +90(232) 412 12 12 - Fax: +90 (232) 464 81 35

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