Wear Reduction and Media Density Optimization for the Single Stage Pipe Densifier at Sishen Iron Ore’s Beneficiation Plants
Date
0202-02
Authors
Journal Title
Journal ISSN
Volume Title
Publisher
University of the Witwatersrand, Johannesburg
Abstract
The depleting high-grade iron ore mining supply at Sishen Mine in the Northern Cape, South Africa, has given rise to its beneficiation plants operating at higher media densities to upgrade lower-grade ore. In this study, densification was numerically modelled using an MPPIC model and experimentally tested using a 200-mm diameter centrifugal densifier from two local suppliers – Multotec and HMA. Shear stress, wear rate, separation efficiency and media losses were measured at increasing operating densities and differing vortex finder sizes. Optimum operating conditions were established. It was found that a feed density of 3.60 t/m3 and a shear stress of 9.70 e-3 N/m3 at the inlet using a vortex finder diameter size of 30 mm exhibited favourable performance in terms of media densification and downstream recovery. The practical significance of this is proven in terms of wear rate and its predictability to provide a consistent overflow of below 1.20 t/m3 media to the recovery circuit. Furthermore, information about ideal operating conditions in terms of inlet pressure and controls to identify premature failures were established.
Description
Master of Science in Engineering by advanced coursework and research: A research report submitted to the Faculty of Engineering and the Built Environment, University of the Witwatersrand, Johannesburg, in partial fulfilment of the requirements for the degree of Master of Science in Engineering, School of Chemical and Metallurgical Engineering, in 2024.
Keywords
Dense Media Seperation (DMS), Ferrosilicon (Fesi), Centrifugal densifier, Pipe denisfier, Vortex finder, Drum plant, UCTD
Citation
Both, Simone. (2024). Wear Reduction and Media Density Optimization for the Single Stage Pipe Densifier at Sishen Iron Ore’s Beneficiation Plants. [Master's dissertation, University of the Witwatersrand, Johannesburg]. WIReDSpace. https://hdl.handle.net/10539/38879