PROCEEDINGS OF 14 th INTERNATIONAL MINERAL PROCESSING SYMPOSIUM October 15-17, 2014 Kuşadası Turkey Mineral Processing in Everything! Editors Üner İPEKOĞLU, Vedat ARSLAN and Sezai ŞEN Dokuz Eylül University, Department of Mining Engineering Turkish Mining Development Foundation
Kuşadası - Turkey October 15-17, 2014 Website: www.imps2014.org The proceedings are also available in USB flash memory. Publisher : Turkish Mining Development Foundation ISBN : 978-975-441-436-3 Edited by Printing Layout Published by : Üner İPEKOĞLU, Vedat ARSLAN, Sezai ŞEN : Sezai ŞEN, Baran TUFAN : Üç Adım Matbaa-Reklam Ltd. Şti. Izmir/Turkey The Proceedings of 14 th International Mineral Symposium was printed by the contribution of TUBITAK. ii
ORGANIZING COMMITTEE Symposium Presidents Dr. Nevzat KAVAKLI Mustafa AKTAŞ Symposium Chair Prof. Dr.Üner İPEKOĞLU Deputy Undersecretary, Ministry of Energy & Natural Resources General Director of The Turkish Coal Enterprises Dokuz Eylül University Institutional Advisory Committee (in alphabetical order) Ayhan YÜKSEL President, Chamber of Mining Engineers of Turkey Burhan İNAN G. Director of The Turkish Hard Coal Enterprises Prof. Dr. Ercüment YALÇIN Dean, Faculty of Eng., Dokuz Eylül University Prof. Dr. Güven ÖNAL President, Turkish Mining Development Foundation Prof. Dr. Mehmet FÜZÜN Rector, Dokuz Eylül University Mehmet Hamdi YILDIRIM G. Director of The Mining Affairs M. Ümit AKDUR Turkish Gold Miners Association Mehmet ÜZER G. Director, Mineral Res. & Expl. Dr. Orhan YILMAZ General Manager, Eti Mine Works Prof. Dr. Turan BATAR President, Mineral Processing Society of Turkey Industrial Advisory Committee (in alphabetical order) Ahmet TEZCAN Eti Copper Inc. Alp GÜRKAN Soma Coal Inc. Arif KURTEL İmbat Mining Inc Bülent TÜFEKÇİOĞLU Tüfekçioğlu Rubber, Mac. and Min. Ind. Co. David A. BICKFORD Tüprag Metal Mining Industry & Trade Ergun TUNCER Bilfer Mining Inc. İsmet SİVRİOĞLU Koza Gold Operations Company Jeremy SHORT Anagold Mining Inc. Murat Zekeriya AYDIN Kolin Construction Oktay Rıfat KUŞOĞLU Coal Enterprises Inc. Özlem ÖNAL Dedeman Mining Sabri KARAHAN DAMA Engineering Co. Savaş ŞAHIN Demir Export Inc. Serdar NİŞLİ Aksa Enerji Şeyda ÇAĞLAYAN Türk Maadin Inc. v
STEERING COMMITTEE Prof. Dr. A. Üner İPEKOĞLU Prof. Dr. Hüseyin ÖZDAĞ Prof. Dr. Güven ÖNAL Prof. Dr. Ümit ATALAY Prof. Dr. Gülhan ÖZBAYOĞLU Prof. Dr. Özcan GÜLSOY Prof. Dr. Çetin HOŞTEN Prof. Dr. Levent ERGÜN Prof. Dr. A. İhsan AROL Prof. Dr. Volkan BOZKURT Prof. Dr. Gündüz ATEŞOK Prof. Dr. Neşet ACARKAN HONORARY MEMBERS Prof. Dr. M. Zeki DOĞAN Prof. Dr. Ali AKAR Dr. H. Avni YAZAN Prof. Dr. Yaşar ÇILINGIR Prof. Dr. Suna ATAK Prof. Dr. Halim DEMIREL Prof. Dr. Erdoğan YIĞIT Prof. Dr. İrfan BAYRAKTAR Prof. Dr. Mevlüt KEMAL Prof. Dr. Mehmet CANBAZOĞLU Sabri KARAHAN LOCAL COMMITTEE (Dokuz Eylül University) Prof. Dr. Vedat ARSLAN Prof. Dr. İlknur CÖCEN Prof. Dr. Erol KAYA Prof. Dr. Mehmet TANRIVERDİ Assoc. Prof. Dr. Tayfun ÇİÇEK Assoc. Prof. Dr. Abdullah SEYRANKAYA Assoc. Prof. Dr. Ufuk MALAYOĞLU Assoc. Prof. Dr. Sezai ŞEN Assist. Prof. Dr. Hatice YILMAZ Lecturer Dr. Özge GÖK Lecturer Dr. Baran TUFAN Resc. Assist. Dr. Erkan GÜLER Resc. Assist. Dr. Gül Akar ŞEN Resc. Assist. Dr. Vedat Taylan ENGİN Resc. Assist. Ebru TUFAN Resc. Assist. Çağrı ÇERİK Resc. Assist. Ümit HORASAN vi
Proceedings of 14 th International Mineral Processing Symposium Kuşadası, Turkey, 2014 DESIGNING OF AGGREGATE PLANT FLOWSHEET BY SIMULATION METHOD Erkan Yersel 1, Turan Batar 2, Baran Tufan 3, a and Necmettin Erdoğan 4 1. Çanakkale Onsekiz Mart University, Department of Mining Engineering, Çanakkale, Turkey 2. Gediz University, Department of Mechanical Engineering, Izmir, Turkey 3. Dokuz Eylül University, Department of Mining Engineering, Izmir, Turkey 4. Aksaray University, Department of Mining Engineering Aksaray, Turkey a. Corresponding author (baran.tufan@deu.edu.tr) ABSTRACT: The aim of this study is the use of simulation program in recovery enhancement of mineral processing plants and exemplifying. The simulation method has been found in early 1960 s in the world and progressed till today. The simulation methods become widespread with rapid developments in this field. The AggFlow Simulation Packaged Software (ASPS) is used to apply what-if scenarios in mineral processing plants such as iron, boron ores, and aggregates, etc. Different criterion and parameters are applied on different flowsheets of processing plants to collect and evaluate performance data. Simulation is a technique to create realistic modeling of systems and observing the changes. In other words, the term simulation can be described as the working model of a real system. The application of ASPS in aggregates are given in this study and evaluated due to the related processing plant model. 1. INTRODUCTION Simulation and modeling are described as designing flowsheets and optimization in mineral processing technologies. The main purpose of simulation and modeling is to reduce the unit cost by enhancing the recovery and/or grade. Today, designs of mineral processing plants are more complicated and difficult due to increasing cost of construction and operation. Thus, this problem can be overcome by simulation as straight and as cheap as possible [King, 2001]. Experts of simulation comprehend the strength and weaknesses of the model to give early responses when necessary during design studies. The first step is to determine the flowsheets to be used in AggFlow Simulation Package Program (ASPP). Selection of machinery and equipment should be accomplished following the selection of flowsheet. The operating parameters of this machinery such as power and capacity can be accessed from the database of ASPP. The design of flowsheet not only involves machinery and equipment selection, it also consists of initial investment and operating cost feasibility [AggFlow, 2009]. In most of the cases, the entrepreneurs establish the processing plant without being aware of how much product is going to be fabricated of what is the maximum production capacity in reality. Therefore, many processing plant operates with under or over capacities and/or with low efficiencies. The optimization of plant efficiency should be applied by comparing the real data and data gathered from simulation software to reach an optimum resultant potential of the plant [Hartge et al., 2006]. Simulation is not a miracle. The practical use of software interfaces with many different adoptable parameters would bring in the success in simulation. In addition, technical abilities of specialists, error and deviation estimations, application of several different what-if scenarios, brain storming sessions among 17
engineers and essentially rapid and flawless execution of these aspects are the main reasons for a successful simulation in a mineral processing plant. In this study, an application of ASPP on aggregate production was focused on for flowsheet modeling. The operating parameters of the production plant were discussed with several what-if scenarios. The outputs of these simulations were analyzed and evaluated separately. 2. METHOD AND APPLICATIONS The flowsheet designed by benefiting from studies by Drew and Roberts, 2002; Köse, 2010 is illustrated in Figure 1. To summarize, coarse aggregates (<200 mm) were fed to jaw crusher via vibrating scalper and sent to a single deck screen together with underflow. The overflow of the screen was fed to hammer crusher and the product was fed to a triple deck screen with the underflow of the single deck screen. The coarse particles were triaged and sent to hammer crusher as closed circuit. The product of <30 mm particles were stockpiled. In addition, two different product stockpiles of -30+10 and -10+5 mm aggregates were gathered. The fine particles (>5 mm) were gathered in a different product silo as fine aggregates. The feed specifications used in Figure 1 and 2 were labeled as Reference (R) conditions. These four different products fabricated in an aggregate production plant are all economically valuable. The ballast production industry represents a significant opportunity for mining industry [Köse, 2010]. Figure 1. Reference conditions for aggregate production simulation. 18
Proceedings of 14 th International Mineral Processing Symposium Kuşadası, Turkey, 2014 Figure 2. Interface of ASPP showing feed specifications for 100 tph capacity 3. CASE STUDIES, DISCUSSIONS AND EVALUATIONS Several different case studies were formed and operating parameters were evaluated on designed aggregate production flowsheet by ASPP. The errors encountered were evaluated separately for each what-if scenario [Yersel, 2012]. In the first scenario; the reference flowsheet with 100 tph capacity was simulated without errors (Figure 1). The amount and particle sizes of products were determined. In the second scenario; a total feed of 300 tph was simulated on the existing processing plant. It was revealed that the capacity of jaw crusher was inadequate for this feed amount as 16.1%. The error report formed by ASPP is given in Figure 3. In the third scenario; the aperture of vibrating sculpture was set to 300 mm which revealed a problem in the maximum feed size for hammer mill (Figure 4). The feed for hammer mill with a maximum feed size of 300 mm exceeded the already existing hammer mill s maximum feed size of 250 mm. In the fourth scenario; the screen aperture of single deck screen was set to 100 mm. The existing production plant worked properly with this setup with changes is P 80 and amounts of products. 19
Figure 3. Error report of jaw crusher formed by ASPP when the feed amount of existing plant was raised to 300 tph. Figure 4. Error report of hammer mill formed by ASPP when the vibrating scalper open side setting was adjusted to 300 mm. 4. CONCLUSIONS In conclusion, ASPP provides optimum solutions in machinery and equipment selection for changing feed amounts, particle sizes, etc. by modeling and simulation. It was revealed that, enhancing the existing processing plants and/or designing a whole new plant is possible by simulation. Modeling of such systems provides early estimations of design cost, duration, new application possibilities and product specifications. The ability to create rapid optimization solutions and/or alternatives by simulation and modeling is a significant advantage in those days of global competition. The necessity of integrating simulation package programs which brings discipline and positive perspective to system analysis in design and optimization of processing plants is revealed and highly recommended for extensive usage [Yersel, 2012]. 20
Proceedings of 14 th International Mineral Processing Symposium Kuşadası, Turkey, 2014 REFERENCES Aggflow BedRock Software, 2009. Welcome to Aggflow the industry standard program for optimizing plant production. April 25, 2011. http://aggflow.com/help/getting_started.html. Drew, A.and Roberts, N. (Eds.), 2002. Optimizing the efficiency of primary aggregate production. UK: Minerals industry sustainable technology. Hartge, E.U., Pogodda, M., Reimers, C., Schwier, D., Gruhn, G. and Werther, J., 2006. Flowsheet simulation of solids processes, Institute of Solids Process Engineering and Particle Technology, Technical University Hamburg, Germany.,146-158. King, R.P., 2001. Modelling and Simulation of Mineral Processing Systems. USA: Department of Metallurgical Engineering University of Utah. Köse, S., 2010. Bir agrega-kırmataş işletmesinde kırma-eleme tesisindeki enerjitüketimlerinin formasyonlara bağlı olarak incelenmesi. İstanbul: İÜ, Mühendislik Fakültesi, Maden Mühendisliği Bölümü, Bitirme Ödevi. Yersel, Ş.E., 2012. Cevher Hazırlama ve zenginleştirme Tesislerinin Simülasyon Yöntemiyle Verimliliğinin Arttırılması. İzmir: Dokuz Eylül Universitesi, Fen Bilimleri Enstitüsü, Doktora Tezi. 21