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FundamentalsPressure and Pressure Drops
Definition of Force, Area, and PressureEngineering Units of Force and Pressure
Pressure in a Container
Molecular View of Pressure
Measuring Pressure with a Manometer
Effect of the Liquid Density of Manometer ReadingsPressure Caused by GravityStatic Head
Gauge, Absolute Pressures, and Pressure DropTemperature, Heat Flow, and Heat Exchangers
Definition of Temperature and Thermometers
Temperature as Kinetic Energy of MoleculesThe Absolute Temperature Scale
Relationship Between Temperature and Pressure
Definition of Heat and Heat CapacityEngineering Units of HeatIntroduction to Heat Exchangers
Heat Exchanger Types: Shell and Tube and Plate and Frame
Acids, Bases, and pHDefinition of Ions
Definition and Examples of the pH Scale
Hydrochloric Acid as an ExampleSlurries and Slurry Density
Typical Metallurgical Plant SlurriesExamples of Typical Slurries with Photographs
How to Calculate Slurry Percent Solids
Definition of Slurry Specific GravityIntroduction to Slurry Pumps
Sampling and Measuring Slurry Specific Gravity
Measuring Size Distribution with Standard Sieves
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Solutions and Solution ConcentrationDefinition of a Solution
Solids that Form Ions in a Water Solution
Solids that Do Not Form Ions in a Water Solution
Definition of Solvents and SolutesDefinition of Solution Concentration
Saturate Solutions
Ore, Metal Values, Gangue, and TailingsDefinitions of Terms
Sulphide and Oxide OresHost Rock
Mineral Liberation
Example Types of OresTailings Disposal and Impoundments
Tailings Dam and Beach
Atypical Means of Disposal Such as UndergroundRecovery and Concentrate Grade
Recovery as a Function of Feed, Concentrate, and Tails Grade
Definition of Recovery
Effect of Recovery on Concentrate GradeDistribution of Gangue Components in Concentrate and Tails
Simple Calculations
Inverse Grade/Recovery Relationship
AgitationRetention Time
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Plant Safety
IntroductionGeneral Safety
Personal Protective EquipmentEmergencies and General Rules
Housekeeping
Maintenance WorkGeneral Housekeeping
Safe Lifting Technique
Conveyors and Belt Feeders
Bins and HoppersV-Belt Drives
High-Pressure Air
Radiation Devices
Safety Showers and Eyewash StationsReagents
Sulfuric AcidFire
Classifications
Fire Extinguishers
Job Safety Analysis
Hazard TypesConducting the Analysis
Safe Job Procedures
Material Safety Data Sheets (MSDS)
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Crushing and Conveying
Gyratory Crushers, Hydroset, and Lubrication
Objective of Primary CrushingRun of Mine Ore and Truck Dumping
Gyratory Crusher Components
Gyrating Action of a Gyratory Crusher
Gyrator Crusher LubricationComponents of the Main Shaft
Eccentric Bushing
Oil Heating and CoolingOil Filters
Spider Assembly and Lubrication
Hydraulic Adjustment SystemRaising and Lowering the Mantle
Shock Absorbing
Clearing the Crusher
Symons Cone CrushersPrinciples of Operation and Description of Components
Animation
Gap adjustmentHydraulic System Controls
Tramp Metal Release MechanismHydraulic release MechanismLubrication System
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Jaw Crushers
Principle of Operation Including and Animation
Description of Crushing Action
ComponentsSingle Toggle
Hydraulic Rock Breaker
Principle of Operation, Description, and OperatingMethodology
Apron FeederPrinciple of Operation
Components
AnimationStockpiles and Reclaim Belt Feeders
Crushed Ore Stockpiles
Live and Dead StorageDraw Holes
Angle of Repose
Effects of Reclaim on Size Classification
Belt Feeder Components and Safety FeaturesDefinitions and Examples of Feeder Components
Belt Scales
Belt Cleaners and Scrapers
Safety Concerns and Emergency Pull CordsConveyor Belts
Manufacture of Conveyor Belting IncludingBelt Conveyor Components and Safety Features
Definitions and Examples of Conveyor Components
Different Types of Idlers, Including Return and Training
Idlers, Belt Scales, Belt Cleaners, and ScrapersSafety Concerns and Emergency Pull Cords
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Belt Scales, Magnets, and Metal DetectorsBelt Sale Components and Principles
How the Scale Computes Weight Over the Belt
Belt MagnetsTypes and PrinciplesMetal DetectorsTypes and Principles
Screw Conveyors
Construction, Components, and PrinciplesSafety Concerns
Dust Control and Bag-Type Dust Collectors
Introduction to Methods of Dust ControlBaghouse Components and Principles
Simple Dust Collection Ductwork and Hood Example
Description of Bags and Bag CagesViews and Descriptions of Baghouse Internals
Methods for Removing Collected Dust from the Bags
Setting Pulse Times Based on Pressure DropRotary Valves to Maintain the Dust Seal
Types of Dust Collector Fans
Dust Suppression Sprays and Techniques
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Pumping
Horizontal Centrifugal PumpsIntroduction
Pump Components and PrinciplesPacking and Packing Gland Including Gland Seal Water
Variables to Consider in Pumping Applications
Total Head, Flowrate, and Power RelationshipsStatic, Friction, and Velocity Head
Typical Pumping System
Effect of Piping System and Fittings on Friction HeadFlowrate and Total Head RelationshipSimple Curve
Flowrate and Power RelationshipSimple Curve
Cavitation
Pumping Slurries
Vertical Centrifugal PumpsDry and Wet Pit Pumps
Pump Stages or BowlsPositive Displacement Pumps
Introduction to Positive Displacement Pumps
Differences Between Positive Displacement and CentrifugalPumps
Progressive Cavity Pumps, Components, and Principles
Reciprocating Pumps, Components, and PrinciplesDiaphragm Pumps, Components, and PrinciplesThree-Way Air Valve to Control Reciprocating Pumps
Reagent Metering Pumps
IntroductionPeristaltic Metering Pumps, Components, and Principles
Diaphragm Metering Pumps, Components, and Principles
Cam Drives
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Grinding
Introduction to Grinding Technology
Introduction to Grinding
How Particles are Broken
Grinding ParametersTypes of Grinding Mills
Types of Grinding Circuits
SAG and Ball Mills
Introduction and General Description of CircuitsSAG Mills, Components, and Principles
SAG Mill Volumetric Loading of Charge Components
Cataracting Action in the Rotating SAG MillSAG Mill Liner Components
Semi-Autogenous Grinding MillsDrive Gears and Motors
Mill Lubrication SystemsGear Teeth, Pinions, and Trun-nion BearingsMill ClutchesTypes, Function, and Objectives
Operating Considerations
Ball Mill Description, Objectives, and PrinciplesBall Mill Grinding
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Classification
Cyclones
Introduction to Screening Technology
Zones and MotionEfficiency Factors
Components, Function, and Principles; Clusters
Variables Affecting PerformanceCyclone Operation Troubleshooting
Heavy Media Drums
Principles and DescriptionAnimation
Heavy Media Hydrocyclones
Principles and Description
SpiralsPrinciples and Description
Vibrating Screens
Introduction to Screening
Screen Function and PrinciplesVibration Techniques
Screen Slopes
Screening efficiencyMaterials of Construction
Grizzlies, Components, and Principles
Double- and Triple-Deck Screens
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Flotation
Introduction to Flotation Technology
Introduction
Phases, Reagent Classes, and FunctionsBubble Formation and Dynamics
Froth Dynamics and Management
Conventional and Tank Flotation CellsIntroduction and Brief Explanation of the Flotation Process
Introduction to Hydrophilic and HydrophobicAgitation and Air Introduction to Flotation Cells
Introduction to Simple Flow Diagrams Showing Feed,
Concentrate, and TailsExplanation of Flotation StagesRougher, Scavenger,
Cleaner Cells and Various Combinations
Construction, Components, and Principles of Tank CellsConstruction, Components, and Principles of Conventional
Banks of Cells Connected by Transition Boxes
Key Variables and Their Control
Dart ValvesDefinition of Froth and Slurry Levels
Mixing Zones and Flotation Cells
Column Flotation Cells
IntroductionColumn Flotation Cells Construction, Components, and
Principles of Column CellsWhere Column Cells are Typically Used in Circuits and
Why
Control of Froth Depth on Column Cells
Column Cell Air InjectionWash Water and Air Dispersion
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Flocculants
Introduction to Flocculants and Long-Chain Molecules
Principles of How Flocculants Work
Effect of pH and Types of FlocculantsEffects of Dilution and Why it is Important
Flocculant Makeup Systems
Filters Introduction to Filters and Characteristics Common to All
FiltersDefinitions: Feed, Filtrate, Filter Cake, Filter Media
Filer Media Pressure Drop
Types of Filter MediaMethods of Forcing Feed Through Filter Media
Pressure and Vacuum Filters
Methods of Filter Cake RemovalMethods of Cleaning or Replacing the Filter Media
Types of Filters: Drum, Disc, Belt, Plate and Frame, and
Vertical
Larox Filters
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Gold and SilverCyanide Leaching
Introduction and Objectives
ChemistryLeach Tanks
Carbon In Pulp
ChemistryCIP TanksCarbon Advance
Screens
Counter-Current DecantationIntroduction and Objectives
Concept of Washing
Example Three-Stage Circuit
Factors Affecting RecoveryElution and Acid Wash
Introduction and ObjectivesChemistry
Typical Circuits
Carbon Reactivation
Introduction and ObjectivesKilns and Combustion Controls
ChemistryTypical Circuits
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Merrill Crowe Precipitation
Introduction and Objectives
Clarification Filters
ChemistryDeaeration and Zinc Addition
Precipitation Filters
Mercury RetortRetort Oven
CondensersCarbon Adsorption
Vacuum Pump
Gold ElectrowinningIntroduction and Objectives
Electro-Chemistry
Rectifiers and ControlsMaterial Handling
Typical Circuits
Dor Smelting
FluxingSmelting Furnace
Casting
Tailings Detoxification
Introduction and ObjectivesChemistry
Typical Circuits
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Reagents and Sampling
Flotation Reagents MakeupTypical Flotation Reagent Makeup Circuit
Flocculant Makeup
Typical Flocculant Reagent Makeup Circuit
Lime and Lime Slaking
Introduction to Limestone, Quick Lime, and Slaked LimeQuick Lime Production Methods
Safety ConcernsLime Slaking and Slakers
Lime Bin Activators
Slaking System ScrubbersTypical Lime Slaking Circuit
Sampling Theory and Automatic Samplers
Introduction to SamplingWhy Obtaining a Representative Sample is DifficultObjectives of Sampling
Metallurgical Accounting
Process ControlProduct Quality Measurement
Sampling MethodsPrimary and Secondary Samplers
Manual Sampling
Types of Automatic Samplers:
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Air Compressors
Air CompressorsIntroduction and Typical Plant Air Compressors
Operation of a Pneumatic CylinderBasic Types:
Reciprocating Compressors Rotary CompressorsReciprocating Compressors, Components, and PrinciplesRotary Compressors, Components, and Principles
Air ReceiversLubrication and Cooling
Air Filters
Air Dryers
Air Blowers
Introduction to Air Blowers and FansUses
Centrifugal Fans, Components, and PrinciplesAxial Fans and Dampers
Engineering Units Used for Fans and Blowers
Typical Fan Performance CurvesPressure, Flow, and Power Relationships
Types of Centrifugal FansAdvantages and Disadvan-
tages:
Backward Curved/Airfoil Blades Radial Blades Forward Curved BladesPositive Displacement Blowers, Components, and Princi-ples
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Combustion and Offgas Handling
Burners, Combustion, and Heaters
Types of Fuels
Fuel Air MixtureStoichiometry
Flue Gas Products and Excess OxygenGas, Oil, and Pulverized Coal Burners
Combustion Air and Atomizing Air
Primary air and Secondary AirTypical Burner Safety Interlocks
Gas Handling Cyclone
IntroductionPrinciples
Components
Flues Cross Section
Dust Handling
Draft
Dew Point of Air, Water, and SO2 MixturesDew Point as a Function of SO2 Content
Chemistry
Corrosive Problems
Drag Chain ConveyorIntroduction
Principles
ComponentsEductor
Principles
Components
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Boilers and Steam Generation
Steam Characteristics
Saturated and superheated steam
Heat of vaporizationWater Tube Boiler Construction
Steam drumTubes
Thermal circulation
Burner assemblyInsulation
Blowdown
Steam Transmission
SafetySteam leaks
Safety relief valves
Energy conservationInsulation
Pressure drops through fittings
Valve usageGate valveGlobe valve
Ball valve
Check valveCondensate removal and steam traps
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Electrostatic Precipitators
Introduction
Principles
ComponentsElectrodes, Collecting Plates, and Insulators
Hoppers and Dust CollectionIsolating Units
Rappers
Stack EffectIntroduction
Effect of Heat
Simple Equation for Calculating Pressure DifferentialInduced vs. Natural Draft
Overcoming System Resistance
Stack Opacity DetectorPrinciples
Components
Pneumatic Conveying
TypesPrinciple of Dense-Phase and Dilute-Phase Systems
Advantages and Disadvantages of each Type
Principle of Pod-Type Dense-Phase Systems
Fuller Kinyon PumpsIntroduction
PrinciplesContinuous Dense-Phase Operation
Air Slide
Introduction
PrinciplesComponents
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ElectricityIntroduction
Atomic Nature of Electricity, Ions, Free Electrons
Conductors and Insulators
Voltage, Electric Current, and ResistanceEngineering Units for Voltage and Analogies
Definition and Units for Current and Resistance
Analogies for Resistance
Simple Direct Current CircuitsSimple Electrical Relationships
Electrical Safety IssuesPower
Engineering Units; Power Relationship to Current and
VoltagePower Analogies
InsulationApplications and Potential Problems and Abuse
Direct CurrentAlternating Current
Simple AC GeneratorFactors that Affect Voltage Generated by a Generator
Concept of a Conductor Cutting Magnetic Field Flux Lines
More Complex AC Generators and Simple Animation
Simple AnimationsMultiple Pole AC Generators
Industrial Revolving Field Generators, Components, and
Principles
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TransformersIntroduction and Objectives
Transformer Definitions, Components, and Principles
Simple Equations for Determining Primary and SecondaryVoltage and Affect on Power.
AC Motors
Induction Motors, Components, and PrinciplesAction of an Induction Motor.
Squirrel Cage Motors and AssemblySynchronous Motors, Components, and Principles
Characteristics of Synchronous Motors
Formula to Calculate Synchronous Motor SpeedVariable Frequency Motors
Multiple Phase AC Power
Single-Phase Revolving Field Generator
Two-Phase AC Generator
Electrical Distribution SystemsHigh, Low, and Medium Voltage
Substations and Load Centres
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Process Controllers
Introduction to Process Controllers
Introduction and Examples
TermsAutomatic Control
Advantages of Automatic ControlIntroduction to a Simple Control Loop
Functions of Sensors, Transmitters, and Controllers
Example of a Controller Face PlateExplanations of Automatic and Manual
Definitions of Process Variable, Set Point, and Output
Definition of Direct and Reverse ControlSimple Examples
Illustrations of Control Loops Using Symbols or Block
DiagramsManual Control
Descriptions and Examples of Manual Control
Example of Manual Level Control
Block Diagram Illustrating Pure Manual ControlControl Modes
Introduction to the Various Control Modes:
Binary Proportional Proportional Plus Integral Proportional Plus Integral Plus DerivativeBinary Control and Factors to Consider
Proportional Control and Factors to ConsiderDefinition of Proportional Gain and Error
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Control Modes
Definition of Proportional Band
Affect of Proportional Gain on System Response
Example of a Control Loop Using Proportional ControlExplanation of Offset and its Affect on a Control Loop
Proportional Plus Integral Control (PI) and How itRemoves Offset
PI Control and Factors to Consider
Example PI Loop and How Offset is RemovedProportional Plus Integral Plus Derivative Control (PID)
Advantages of PID Control and Factors to Consider
Example PID Loop and its Response
Types of Automatic ControlLocal Automatic (Local Set Point)
Cascade (Automatic Remote Set Point)Dead BandControl Loop Tuning
Interlocks
Introduction to Interlocks
Definitions
Examples
SensorsIntroduction to SensorsPressure Sensors
Flow Sensors
Level SensorsTemperature Sensors
Density Sensors
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Control Devices
Introduction to Control DevicesControl Valves
Gate Valve
Globe ValveButterfly Valve
Plug ValveBall ValveDiaphragm
Vanes
Troubleshooting
Troubleshooting Controllers and Control Devices
Methodologies
Process Problems
Distinction Between Process Control Problems and Process
ProblemsRealistic Examples
Introduction to P&IDs
Identify Various Types of instruments
Identify Various Types of signal linesRead P&IDs.
Read P&ID Legends
Instrument SymbolsMeanings of Letters
Line Symbols
P&ID ExamplesReading the Legend