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Design project

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by

Hashani Abeygunasekara

on 17 March 2014

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Transcript of Design project

Project overview
Problem statement
Design objectives
Statement of significance
Scope of the project
“With the rapid growth of the technology in the world, mineral sands have earned high demand levels.
That is due to their wide-spread applications in number of industries.
Adequate supply of mineral sands, is required to meet the market needs.
Current Sri Lankan production is not enough when compared to other mineral sand producing countries even though Sri Lanka has a plenty of rich deposits of mineral sands.”

This project will be carried out to design a mineral processing plant in order to increase the production capacity of the country.
In the process of designing the plant, all the factors including technological, economic and social have been taken in to consideration.
In this project the value addition processes namely manufacture of synthetic rutile and pigment production are not discussed.
The timely requirement of the industry is to first increase the production capacity, then only it is possible to go for such value addition techniques after having a steady position in the world mineral sands market.

Mineral sands production is a strategic industry for future economic development.
The installation of a new mineral processing plant will contribute to long-term supply of mineral sands to the local, European and international markets to meet growing demand for titanium and rare earth materials.
Diversification of the export products and export to the global market will be more flexible and reliable.
It will bridge up knowledge and expertise in the field of mineral processing industry to the country and will maintain the production capacity in a considerable level compared to the other countries.
Flow-sheet design
Deposit parameter
Energy consumption estimates
Diesel
Electricity
Project feasibility study
EIA
SWOT
Social Impact Assessment
Financial feasibility
Deposits in Sri Lanka
Mineral sands industry
Pulmoddai deposit
Present Mining and Processing operations in SL
World production of Mineral sands
Pre-feasibility study
SWOT Analysis
Environment Impact Assessment
Social and Economic Impact Assessment
Financial feasibility analysis
Investment Appraisal
NPV
IRR
Pay-back period
Cost estimates
Revenue estimates
Capital costs
Operating costs
Conclusion and Recommendation
Plant design
Gravity upgrading plant
Wet magnetic separation plant
Ilmenite Dewatering Plant
Spiral upgrading plant
Desalination plant
Dry mill
Wet tabling plant
Zircon powdering plant
Packing plant
Strengths
Weaknesses
Opportunities
Threats
Large reserve position within the country
High level knowledge and industrial experience available
Availability of man-power
Availability of land for expansion
High percentage of assay
Composition of the deposit
Deposits above ground
Government incentives
End of war
Lack of continuous and reliable source of supply
Trend in losing out buyers
Demand exceeding the capacity
Increase the level of employment
High profit potential
Economic development of the country
Emergence of new industries
FDI opportunities
Ever increasing demand
Monopolistic position of LMS
Large scale initial capital requirement
Government policy changes
Rivalry
Positives
Lower the level of unemployment
Standard of living get increased
Increased investment on infrastructure
Negatives
Adverse effects on tourism industry
Adverse effects on fishery industry
Radio-activity of Monazite
Dust emissions
Increased temperature
Noise pollution
Polluted air emissions
Decisions
Sequence of processing
Hours of operation
Equipment selection
Plant capacity
Raw sand requirement
Raw sand transportation
Feed capacity
Pre-concentrating plant
Separate the heavies from gangue
Remove oversize material
Feed of ~60 t/h to produce heavies of ~50t/h
Final concentrate of 98-99% heavies
Separates Magnetite and Ilmenite from the Wet gravity upgrading plant concentrate
Low intensity Magnetic Drum separators for Magnetite separation
High intensity Wet Magnetic separators for Ilmenite separation
Dewatering and dry Ilmenite
MC down to 4-5% using drainage slots on the floor
Further reduction down to 2% using a thermal dryer
Dryer accepts 30t/h of Ilmenite concentrate with a maximum MC of 6%
Feed comprises of non magnetic product of Wet Magnetic Separation plant
Prepare the feed for high tension separation at dry mill
Removal of clay coatings, slimes and fines, remaining quartz
Polishes the grain surface
Separates Rutile, Leucoxene and Zircon from the feed
Use both magnetic separators and electrical conductivity based separators
Accessory plant for the dry mill
Upgrades the dry mill final non conductives
HOLMAN tables were chosen
Zircon with Monazite get separated
Tailings are disposed
Value-added product from crude sand
Wider market and higher selling price
$2000-$2500 per MT

Wide applications:
Metallurgical
Ceramic
Chemical and Refractory
The conversion of salt or brackish water into usable fresh water
To address the substantial amounts of fresh water requirement
To make use of highly available sea water
Desalination through Reverse Osmosis
Mostly practiced in America
RO is a technique which forces the water through a series of membranes, leaving the salts behind.
Proposed reverse osmosis desalination system for Melbourne, Australia.
Source: Seawater Desalination Feasability Study, 2007
Enclosing the final products for storage distribution, protection and sales.
Acquiring modern technology to minimize the unit packing time
Only mining and processing
No value additions
SL Production serves only up to 0.9% of the world production
Mineral sand mining, only at Pulmoddai
Pulmoddai deposit
West coast deposits
Southern coast deposits
Baddeleyite deposits
Net Cash-flows
@CoC 0f 12%
=
LKR 8,046,569,920.44

(assuming a 50 year project)
32%
4 years
Design of a mineral sand processing plant for the Pulmoddai mineral sand deposit
Supervised by : Dr. D. M. D. O. K. Dissanayake
Thank you...
This plant is considered as the first stage of developing mineral sand industry. Next stage should be production of diversified and value added products after having a steady and increased production
The byproduct brine can be used for salt production
Desalination plant can also be used for making drinking water
Tailing should not be dumped back to beach as it dilute the ore and affect replenishment process
Plant equipment should be purchased from one manufacturer. There are number of companies who offer complete plant according to clients requirements such as flow sheet, production etc.
Foreign assistance is encouraged for possible technology transferring to the country
Types of packaging:
Bag packing (between 25 and 50-kg bags)
Big Bag-Filling – filling into flexible large packaging
Bulk loading – Container vehicles
Full transcript