Mineral Processing Design and Operations

Mineral Processing Design and Operations

An Introduction

2nd Edition - May 2, 2016

Write a review

  • Authors: Ashok Gupta, Dennis Yan
  • eBook ISBN: 9780444635921
  • Hardcover ISBN: 9780444635891

Purchase options

Purchase options
DRM-free (EPub, PDF, Mobi)
Sales tax will be calculated at check-out

Institutional Subscription

Free Global Shipping
No minimum order


Mineral Processing Design and Operations: An Introduction, Second Edition, helps further understanding of the various methods commonly used in mineral beneficiation and concentration processes. Application of theory to practice is explained at each stage, helping operators understand associated implications in each unit process. Covers the theory and formulae for unit capacities and power requirements to help the designer develop the necessary equipment and flow-sheets to economically attain maximum yield and grade. This second edition describes theories and practices of design and operation of apparatus and equipment, including an additional chapter on magnetic, electrostatic, and conductivity modes of mineral separation. Basics of process controls for efficient and economic modes of separation are introduced.

Key Features

  • Outlines the theory and practice in the design of flow sheets and operation of an integrated mineral processing plant
  • Introduces the basic magnetism, electrostatic, conductivity, and dielectrophoresis properties of minerals and related separation techniques
  • Describes automation in mineral processing plants allowing maximum yields and consistent high concentrate grades
  • Outlines problems and offers solutions in the form of various examples


Metallurgists and process engineers as well as university students as an introductory guide to large scale industrial operations to liberate and recover commercially minerals from ores. Students and engineers interested in the disciplines of metallurgy, chemical engineering, mechanical and electrical engineering (including electronic engineering), both in operation and research are expected to benefit

Table of Contents

  • Chapter 1: Mineral Sampling

    1.1 Introduction

    1.2 Statistical Terminology

    1.3 Mineral Particles Differing in Size – Gy’s Method

    1.4 Mineral Particles of Different Density

    1.5 Incremental Sampling

    1.6 Continuous Sampling of Streams

    1.7 Sampling Ores of Precious Metals

    1.8 Sampling Nomographs

    1.9 Problems


    Chapter 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


    Chapter 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


    Chapter 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


    Chapter 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


    Chapter 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

    Chapter 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


    Chapter 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


    Chapter 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


    Chapter 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


    Chapter 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


    Chapter 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


    Chapter 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 Problems


    Chapter 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


    Chapter 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


    Chapter 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

    6.6 Flowing Film Concentrators

    16.7 Dense (or Heavy) Media Separation

    16.8 Gravity Separation Performance

    16.9 Problems


    Chapter 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

    Chapter 18: Flotation

    18.1 Introduction

    18.2 Flotation Reagents

    18.3 Flotation Equipment

    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


    Chapter 19: Metallurgical Process Assessment

    19.1 Introduction

    19.2 Analyses of Constituents

    19.3 Definition of Terms

    19.4 Material Balance

    19.5 Circulating Load

    19.6 Problems


    Chapter 20: Process Control

    20.1 Introduction

    20.2 Controller Modes

    20.3 Signals and Responses

    20.4 Input and Output Signals of Controllers

    20.5 Integration of Processes and Block Diagrams

    20.6 Setting and Tuning Controls

    20.7 Complex Advanced Controllers

    20.8 Dead Time Compensation

    20.9 Instrumentation and Hardware

    20.10 Controls of Selected Mineral-Processing Circuits

    20.11 Advances in Process Control Systems 801

    20.12 Expert Systems

    20.13 Mechanics of Digital Process Control Systems

Product details

  • No. of pages: 882
  • Language: English
  • Copyright: © Elsevier 2016
  • Published: May 2, 2016
  • Imprint: Elsevier
  • eBook ISBN: 9780444635921
  • Hardcover ISBN: 9780444635891

About the Authors

Ashok Gupta

Ashok Gupta
25 years in Managerial Position in industry involved in operation, production and research and 18 years in academia (Teaching Undergrad, & Post Graduate courses and conducting Research). Retirement followed by work as Consultant

Affiliations and Expertise

Carine-Perth, Australia

Dennis Yan

Dennis 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, Australia

Ratings and Reviews

Write a review

There are currently no reviews for "Mineral Processing Design and Operations"