Chapter 23

DESIGN CRITERIA: THE FORMAL BASIS OF DESIGN

JOHN W. SCOTT
WRIGHT ENGINEERS LTD.
VANCOUVER, CANADA
INTRODUCTION
The design cri t eri a for a particular
concentration and dewatering project
will provide t he formal basis for design
of t he process, equipment and facilities.
These cri t eri a will specify t he required
capacities and operating schedules for
t he equipment, as well as t he quantity
and quality of t he feed t o be processed
and products obtained. The general
climatic and geographical conditions a t
t he site, specific information on soil or
rock conditions; and applicable design
standards and codes will also be
included.
The design cri t eri a will generally be
based on an interpretation of testwork
carried out on t he particular ore and
site, and will thus parallel in detail and
completeness this testwork. As t he
project moves from t he early conceptual
phases through t o final detailed design,
t he design cri t eri a will be developed and
become more detailed as information is
generat ed and made available f or use.
The design cri t eri a a r e critical t o t he
design ef f or t as t he formal specification
t o t he designer of what and how much is
t o be processed, what and how much is
t o be produced, and where and under
what conditions.
The act ual design cri t eri a will be a
formal tabulation of t he design basis
information developed f or t he project in
question. For a preliminary study, this
may consist of a single page of data; f or
a feasibility study several pages and for
a detailed design up t o several hundred
pages and multiple volumes. Depending
on t h e complexity of t he process and t he
level of detail included, each project will
be unique t o some degree.
The design process for a project
normally progresses from preliminary
conceptual phases through t o a final
detailed design. The cri t eri a used for t he
initial concepts ar e generally developed
from rough dat a and preliminary
testwork on t he or e in question.
Regardless, t he plant throughput and
products a r e defined, thus giving a scope
and definition t o t he study phase. In
some studies a range of throughputs may
be analyzed in order t o arri ve a t t he
most economically at t r act i ve size for
t he proposed operation. This optimum
size is then used as t he design
throughput for t he more detailed design
phases. Similarly as more testwork
results ar e available and t he ore
characteristics and process become more
well defined a continuous updating of t he
design cri t eri a is undertaken.
CONCENTRATION AND DEW ATERING CIRCUITS
At t he completion of t he preliminary
design phase or basic engineering,
sufficient information will be available
t o prepare a formal design cri t eri a
document which will form t he basis for
detailed design work. It is important t hat
a t each phase of the development of the
project when cost est i mat es or studies
ar e prepared, t he design cri t eri a used t o
form t he basis of design and estimation
for this phase are carefully and fully
documented.
DEVELOPMENT OF DESIGN CRITERIA
Conceptual Designs
At the outset of ' t he conceptual
design phase for a concentration and
dewatering plant t here will normally be
little information available. The fi rst
task of the conceptual design group is t o
gather what information is available and
then develop t est programs t o provide
t he essential dat a t hat is missing. During
this phase, t he metallurgical response of
t he ore is t he most important a s i t will
define the flowsheet and equipment
requirements. The or e will be
characterized mineralogically and a
bench scale t est program will be
developed and carried out on the
available samples (normally split drill
cores) t o provide basic information for
flowsheet development. If t he ore is
widely variable, t he flowsheet will be
designed accordingly and a further more
detailed metallurgical t est program
planned.
The basic document produced will be
a metallurgical and material balance t o
provide flows and tonnages for
equipment sizing and selection. If
sufficient material is available, batch
thickening and filtering t est s will be run
t o give preliminary unit area
requirements, however these may be
adjusted by experience factors a t this
st age if abnormal ar eas or sizes ar e
indicated. Further testing would be
planned and carried out for t he next
st age of project development.
The design criteria for t he other
disciplines required a t this phase are
minimal, with t he cri t eri a used general
in nat ure and based on similar projects in
similar climatic areas t o give a
reasonable and sound basis t o t he
preliminary estimate.
Feasibility Studies
A feasibility study is normally
undertaken af t er an order of magnitude
or preliminary est i mat e has indicated
t hat t he project (or expansion or
renovation) is financially at t ract i ve
enough t o merit furt her work. During t he
preliminary study scoping t est s would
have been completed on t he
metallurgical response of t he ore and a
generally suitable flowsheet selected.
Any problem ar eas requiring resolution
with further testwork would have been
identified and suitable laboratory and
pilot plant programs initiated. The pilot
work, in particular, would be aimed a t
verifying t he flowsheet and also
providing a n opportunity for thickening,
filtration, drying and other ancillary
t est s on samples produced from more or
less continous operation on
representative bulk samples. The ef f ect s
of recycle wat er st reams on t he
metallurgy will have been noted, with
provision made for wat er t reat ment or
possibly even a once-through system. For
physical separations, unwanted slimes
buildups, t he need for settling ponds or
unusual drying requirements, etc. will
have been noted. Unusually abrasive or
slimy characteristics will have been
observed and noted. The small flows
typical in pilot plants exaggerate t he
rheological problems encountered in
certain ores and these also will be
studied a t this phase; particulary for
extremely fine grinds and high pulp
densities -characteristics perhaps more
common in present day ores. The
feasibility study will have considered any
alternative processing schemes in depth
and rejected all except t he most logical
and profitable via a series of technical-
economic studies. Metallurgically, t he
ore will have been studied thoroughly on
t he basis of pilot plant t est s on
DESIGN CRITERIA: FORMAL BASIS OF DESIGN
representative bulk samples, thus
providing a valid design basis.
The plant si t e will now have been
selected and t he buildings and facilities
laid out. The si t e will have been drilled
for geotechnical information and
carefully surveyed t o provide surface
contours and an est i mat e of cut and fill
quantities. An effort will have been
made t o find local materials suitable for
compacted fill, and for concret e
aggregate in t he case of r emot e
locations. The bearing strength of t he
soil and underlying bedrock will be
t est ed and cri t eri a for foundation design
prepared. Architecturally t he climatic
conditions will be carefully noted, and a
program to develop wind and snow
loadings under taken if necessary,
otherwise local/regional records will be
used. Prevailing winds and severe
cl i mat i c conditions will be considered t o
ensure t he best orientation of buildings
and openings in t he buildings, subject t o
si t e constraints.
Power supply will have been studied,
with power fact or correction allowed
for. If there ar e high energy costs self-
generated power or high efficiency
motors (with accompanying higher
capital costs) will be considered.
Water supply and tailings disposal
will have been carefully studied, with
hydrological and geotechnical studies
commissioned as required.
At t he end of t he feasibility study,
t he metallurgical response of t he ore,
general si t e conditions, climatic
constraints and power, wat er and wast e
disposal systems will have been
identified, studied and resolved.
Basic Engineering and Detailed
Design
Following a positive feasibility study,
t he next phase of a project involves
basic engineering followed by detailed
design. The basic engineering for a
project involves developing t he
feasibility study t o a point where t he
major equipment has been tendered, a
supplier recommended and design
advanced t o a point where detailed
engineering can commence. The end
product is t he detailed design cri t eri a
document, serving as a specification t o
t he detailing engineer and a basis for t he
project budget estimate.
At t he commencement of t he basic
engineering, a draft design cri t eri a
document will be prepared, based on a
format used by t he particular
engineering company doing t he design
work. The preparation of this draft will
normally bring t o light a number of areas
where specific design criteria ar e
missing, so t hat relevant t est work can
be carried out or t he necessary
information obtained. As t he engineering
progresses and major pieces of
equipment ar e committed t o purchase,
actual weights and dimensions of t he
equipment in question will be available
for inclusion in t he appropriate sections
of t he criteria. At t he same time, t he
flowsheets and general arrangement
drawings will be updated t o show t he
recommended equipment. The
mechanical, structural and civil groups
will work very closely with each other
during this period t o ensure t hat t he
basic cri t eri a ar e available for such
problem areas in t he design as large
rotating equipment or severe vibration.
At t he completion of t he basic
engineering, t he formal design cri t eri a
will be issued t o serve as t he basic
document for detailed engineering
Use of Cri t eri a during Design
The design cri t eri a are used
throughout all st ages of a design as t he
primary wri t t en source of information
for t he engineers carrying out t he design
work, and t he source document for
further work.
Conceptual desiqn. I n the i ni t i al
conceptual stage, the general cri t eri a
wi t h respect t o plant capacity, ore
characteristics and preliminary
metallurgical results are used t o develop
a flowsheet and preliminary plant layout.
The metallurgical and mechanical
engineer wi l l rel y on the cri t eri a t o
prepare the flowsheet and size and
select the major process equipment.
Based on this work and any site
constraints a plant layout wi l l be
developed t o f or m a basis for cost
estimation. The areas where the cri t eri a
are poorly defined or missing wi l l be
covered by past experience at thi s stage,
and testwork or si te investigations
planned t o obtain the missing
information. The cr i t er i a used, including
the assumptions made wi l l be formalized
i n a short summary and included i n the
study report. (See Table 1).
TABLE 1. CONCEPTUAL DESIGN -
OUTLINE OF DESIGN
CRITERIA
1. GENERAL CRITERIA
2. METALLURGICAL BALANCE
3. OPERATING SCHEDULE AND
THROUGHPUT
4. PROCESS CRITERIA
5. ASSUMPTIONS
6. RECOMMENDED TESTWORK
Detai l ed feasibility Study. For the
detailed feasibility study phase of a
project, the general operating and
metal l urgi cal design cr i t er i a wi l l have
been refined and augmented by further
laboratory and pi l ot plant testing.
A series of alternative flowsheets
may be developed at thi s stage, wi t h the
technically and economically "best" one
selected for further development. Once
again, the cri t eri a available wi l l be
checked wi t h the selected flowsheet and
any deficiencies covered by further
testwork. At this stage the plant si te
wi l l have been carefully surveyed and
soils investigations carried out t o
provide site specific design cri t eri a t o
the structural and ci vi l engineering
groups. The information developed wi l l
again be collected and included i n the
feasibility report as a separate 'IDesign
Cri teri a" section (See Table 2). Based on
the design cri t eri a an d the selected
flowsheet, the mechanical equipment
wi l l have been specified and quotations
solicited from suppliers t o obtain
suffi ci entl y accurate cost data f or the
report. The plant layout wi l l have been
refi ned and developed t o provide a good
basis f or ci vi l and structural takeoffs
and preliminary design work. The power
supply and el ectri cal requirements wi l l
be defined by the equipment selection,
and yard and building lighting, heating
requirements, etc. The archi tectural
finishes wi l l be selected on the basis of
the duty, weather and plant areas. The
cr i t er i a used for this selection wi l l be
experience i n similar installations and
any specific chemical resistance
required.
TABLE 2. FEASIBILITY STUDY -
OUTLINE OF DESIGN
CRITERIA
SECTION I 1.- INTRODUCTION
2.- GENERAL CRITERIA
3.- OPERATING
SCHEDULE AND
CAPACITY
4.- METALLURGICAL
BALANCE
SECTION I1 PROCESS
DESCRIPTION
EQUIPMENT
DESCRIPTION
. FLOTATION /
MAGNETICSEPN/
ETC.
. THICKENING AND
FILTERING
. DRYING AND
PACKING
3.- FACILITIES
DESCRIPTION
. BUILDINGS
. SERVICES
. SITE AND ACCESS
4.- REQUIRED
TESTWORK
DESIGN CRITERIA: FORMAL BASIS OF DESIGN
Detai l ed desiqn. Detai l ed engineering
wi l l be cri t i cal l y dependent on design
criteria, and i n f act the f i rst phase of
detailed design or basic engineering is
carri ed out t o provide a detailed design
cri t eri a t o be used as the basis f or f i nal
detailing.
During the basic engineering the
equipment tendered on wi l l be selected,
and the flowsheet, equipment l i st and
general arrangement drawings up dated
t o t hei r f i nal form. The design cri t eri a
developed f or the detailed feasibility
study wi l l also be updated, and any
f urt her i nformati on included as i t is
made available. At this stage, actual
equipment loads wi l l be available so
structural and foundation design may be
advanced. Normally, the f i r st detailed
process and instrumentation diagrams
are developed and wi l l f or m the basis f or
piping design i n conjunction wi t h the
flowsheet. Final selection of such
equipment as filters, dryers and
thickeners wi l l enable a detailed water
balance t o be prepared, providing the
flows of fresh and recl ai m water as the
design cr i t er i a for the water system. The
heating and venti l ati on requiremerts wi l l
have been defined by the cl i mat i c
conditions and by any l ocal codes and
ordinances. Similarly codes governing
noise levels and personnel protecti on wi l l
be incorporated i nt o the cri t eri a t o
ensure compliance.
As the basic engineering proceeds,
areas wi l l t ur n up which require further
specific tests for design t o proceed.
These would be carri ed out and the
cri t eri a updated i n those areas. The f i nal
document produced at this stage i s
known by various names: design criteria,
design basis memorandum, etc. However
i t wi l l consist of a f ormal document
including al l design cri t eri a used, a
description of the process and the set of
basic engineering drawings. These
documents then f orm the basis f or the
detailed engineering design. A
generalized table of contents f or such a
document is given i n Table 3.
TABLE 3. INDEX FOR A DESIGN
CRITERIA
I.- General Cri t eri a
1.0 Introduction
2.0 Scope of Work
3.0Criteria Summary
4.0 Mechanical Design Cr i t er i a
4.1 Conveyors
4.2. Chutes
4.3 Fabricated Items
4.4 Process Pumps
4.5 Piping
4.6 Linings
4.7. Codes and Standards
5.0 El ectri cal Design Cri t eri a
5.1 General
5.2 Codes and Standards
5.3 PowerSupplySystem
5.4 Mai n Substation
5.5 System Voltages
5.6 Emergency Power
5.7 Meteri ng
5.8 Di stri buti on Switchgear
5.9 600 Volt Power
5.10 Motors
5.11 Power Factor Correcti on
5.12 Motor Controllers
5.13 Controls and Pi l ot Devices
5.14 Lightning and Surge
Protecti on
5.15 Grounding
5.16 Overhead Transmission
Line
5.17 Lightning and Receptacles
5.18 Wiring Methods
5.17 Wire and Cable
5.20 Conduit
5.21 Enclosures
5.22 Cable Tray
5.23 Special Equipment
5.24 Communications
6.0 Structural Design Cri t eri a
6.1 General
6.2 Design Loads
6.3 Uni t Stresses andLi mi ti ng
Deflections
6.4 Load Factors
6.5 Load Combinations
7.0 Mechanical Services Criteria
7.2 Design and Drafting
Standards
7.3 Materials
7.4 Design Conditions
7.5 HVAC
7.6 Building System
7.7 Plumbing
7.8 Fire Protection
8.0 Air Pollution Control Criteria
8.1 Codes and Standards
8.2 Materials
8.3 Design
9.0 Architectural Design Criteria
9.1 General
9.2 Washrooms
9.3 Change Rooms
9.4 Lunch Rooms
9.5 Offices and Labs
9.6 Building Enclosures
10.0 Instrumentation Design Criteria
10.1 Purpose
10.2 References
10.3 General
10.4 Instruments
10.5 Control Panels
11.- Process Area Cri t eri a
11.0 Operating Schedule and Capacity
11.1 General
11.2 Schedules and capacity
12.0 Process Metallurgy
12.1 Ore Characteristics
12.2 Metallurgical balance
12.3 Material balance
44.0 Water Supply
44.1 Operating Criteria
44.2 Process Description
44.3 Equipment
47.0 Tailing Disposal
47.1 Operating Criteria
47.2 Process Description
47.3 Equipment
51.0 Ancillary Buildings
51.1 Offices
51.2 Change House
51.3 Laboratory
51.4 Shop & Warehouse
92.0 Conditioning and Flotation
92.1 Operating Criteria
92.2 Process Description
92.3 Equipment
93.0 Reagents
93.1 Operating Data Summary
93.2 Reagent Preparation and
Equipment Description
93.3 Reagent Fume and Dust
Control
94.0 Hydrosizing & Tabling
94.1 Operating Criteria
94.2 Process Description
94.3 Equipment
95.0 Filtration and Drying
95.1 Operating Criteria
95.2 Process Description
95.3 Equipment
97.0 Concentrate Packing & Storage
97.1 Operating Criteria
97.2 Process Description
97.3 Equipment
REQUIREMENTS FOR DESIGN CRITERIA
The requirements for design criteria
for a specific concentration and
dewatering circuit are naturally
dependent on the particular ore, the
flowsheet chosen and t he si t e
constraints. Normally, t he design
criteria will be developed in two
complementary sections; t he first
generally including a description of t he
ore, process, plant si t e and geographical
location along with t he general design
criteria developed by each engineering
discipline. The second section will
present design cri t eri a for each ar ea of
t he plant and process including an
operating dat a summary and detailed
process and equipment descriptions. The
general arrangement drawings,
flowsheets and process and instrument
diagrams form an integral part of t he
design cri t eri a documentation and a r e
included and referenced extensively for
clarity and convenience.
General
The general design cri t eri a consist of
t he basic project description plus t he
general cri t eri a for each engineering
discipline. The outline for a complete
design cri t eri a manual a s required for
detailed design is provided by t he index
referenced in Table 3.
The summary of basic design cri t eri a
will include:
Description of t he project
Scope of work
Location
Meteorlogical dat a
Site and soils description
Utilities
Transportation
Applicable Laws and Codes.
Operating Schedule and Capacity
The heart of any design is t he
required plant capacity and t he
operating schedule. These define t he si ze
of t he equipment and t he operating duty.
The operating schedule is normally
twenty-four hours per day, t hr ee shifts
per day, 365 days per year for a typical
concentrator. In some cases t he plant
may be designed t o operat e fewer days
per week but continuous twenty-four
hour operation is usual. In some
dewatering sections filters may be
operated on a single shift basis, this will
be clearly set out in t he design cri t eri a
for t he area. In addition t o t he operatinq
-
schedule and throughput, some
estimation of t he availability of t he
function of t he maintenance
requirements of each individual piece of
equipment and also t he operating
st rat egy of t he plant. For instance, a
weekly maintenance shift may be
planned f or certain areas due t o required
preventive maintenance on cert ai n
critical i t ems of equipment. These i t ems
in t he design cri t eri a a r e normally
tabulated in a format as shown in Table
4.
TABLE 4 - TYPICAL OPERATING
SCHEDULE
PLANT AREA
PERIOD FLOTATION
Availability (%I) 94
Process Metallurgy
The design cri t eri a for process
metallurgy will include a description of
t he or e treated, t he products t o be
made, t he physical and chemical
characteristics of t he ore which af f ect
t he process, an estimated metallurgical
balance, reagent additions, nominal
aquipment residence t i mes and product
specifications. The metallurgical cri t eri a
f or each ar ea of t he plant or unit process
ar e normally summarized in an
Operating dat a summary f or t hese areas
and a r e utilized with a n accompanying
process and equipment description t o
provide a compl et e cri t eri a for detailed
design.
plant is used f or setting t he act ual
hourly throughput. This availability i s a
CONCENTRATION AND DEWATERING CIRCUITS
Typical design cri t eri a requirements
for t he normal unit operations
encountered in concentration and
dewatering circuits ar e summarized in
t he following tables. The testwork
required t o obtain t he required design
cri t eri a values is beyond t he scope of
this paper, and is more t han adequately
covered in t he other chapters of this
book. The process metallurgist normally
requires sufficient testwork t o prepare
metallurgical and material balances for
a selected flowsheet and size and sel ect
t he major process equipment for t he
flowsheet. The selected flowsheet and
equipment then provide derived design
cri t eri a for laying out t he plant and t he
subsequent detailed design in all areas.
Basic Metallurqical Cri t eri a
Ore mineralogy
Metallurgical balance
Material balance
Feed r at e (and variations)
Particle Size Distributions (Feed and
Products)
Specific gravity (Feed and Products)
Supplementary Criteria
Froth
Flotation: Flotation r at e dat a
Air requirements
Conditioning t i me
Reagent additions
Gravity
Separation: Heavy liquid separation
t est results
Laboratory and/or pilot
plant results for:
Jigging, Tabling, Spirals
or Cones.
Extended Mineralogical
Analysis.
Classification
characteristics
Magnetic
Separation: Magnetic susceptibilities
Laboratory t est results
Magnetic field strength
required
Electrostatic
Separation:
Electrical properties
Laboratory t est results
Field strength
Dryness and t emperat ure
requirements
Thickening: Unit ar ea requirements
(Laboratory or pilot plant)
Flocculant mixing
requirements
Flocculant r at es
Underflow densities
Overflow clarities
Slurry rheology (if
underflow is non
newtonian)
Filtering: Unit ar ea requirements
Cloth permeability
Vacuum requirements
Form t i me
Dry t i me
Cake thickness
Slurry rheology
Filter Aid requirements
Cloth washing
requirements
Air blow requirements
Altitude ef f ect s
Drying: Feed moisture
Product moisture
Dusting characteristics
Off gas volumes and dust
loadings
Operatings schedule
Heat capaclty of solids
Relative humidity
Engineering Disciplines
The engineering disciplines involved
in a concentrator design will include:
Metallurgical
Mechanical
Electrical
Civil / Structural
Mechanical Services
Architectural
Instrumentation and Control
The design cri t eri a required by each
of these disciplines is outlined in t he
typical index given in Table 3. As can be
seen each discipline requires a general
compilation of design codes and
standards as well a s specific cri t eri a for
t he various ar eas covered by t he
discipline. The full details of t he general
cri t eri a would require more space than is
available in this book, however a typical
excerpt from t he general design cri t eri a
for each discipline is presented in
Appendix I. The references t o codes and
standards normally refer t o Canadian
Standards, f or plants built in ot her
countries t he applicable national, s t a t e
and local codes would apply.
For each discipline involved in t he
detailed design t here ar e a number of
basic cri t eri a based on fundamental
design pract i ce for t hat discipline and
ot her points which ar e specifically
rel at ed t o concentrator design. These
have been developed through experience
and ar e particularly required when t he
detailed design is being carried out by a
firm less involved in t he mineral
industry, perhaps off-shore in an under
developed country or in a country with
few mineral resources.
Metallurgical. The metallurgical
cri t eri a normally required for each of
t he unit processes ar e listed in a
previous section. In addition t o t he
process criteria, an operating philosophy
for t he plant is normally developed
which refl ect s t he plant location and t he
human resources available t o operat e it.
This operating cri t eri a should be
carefully thought out and wri t t en down
in order t o be of use t o t he design t eam
and for t he training of operating
personnel.
Mechanical. The mechanical
engineering for a concentrator, once t he
major equipment has been selected, is
mostly involved with material handling,
pumping and design f or minimum spillage
and easy maintenance of t he eqipment.
In this respect, t he design cri t eri a ar e
particularly specific t o concentrator,
with such points a s launder slopes, pipe
connection details, wear liners, conveyor
skirting and pump selection being
critically important. With t he use of
finer grinds in some flotation plants, t he
behavior of thickened slurries and ot her
pulp st r eams has become Less
predictable, t herefore slurry viscosity
testwork for pump and piping selection
has become more common.
Electrical. The electrical design
criteria for a plant normally involve an
extremely wide scope possibly from si t e
power generation t o wiring details.
Particular emphasis must be given t o
energy conservation through such
methods as power f act or correction, high
efficiency motors and lights and correct
cable sizing.
Civil / Structural. The st ruct ural
design requires particular emphasis on
rotating equipment, vibration analysis,
and recognition of plug loads in such
vessels as flotation tanks and
conditioners. In addition, careful
investigations of t he underlying soil or
rock characteristics a r e required f or
successful foundation design. Car e
should be taken a t t he earliest
opportunity t o obtain as much
information a s possible over t he ent i re
mill site, a s buildings may be relocated
several t i mes during t he progress of t he
design.
Mechanical Services. The services
required in a modern concentrator
complex for heating, ventilation, fire
protection, plumbing, sewer and wat er
supply, et c. can be a major design area.
It is essential t o develop t he design
cri t eri a for t hese ar eas in accordance
with local codes and regulations and also
bearing in mind t he number of workers in
t he plant. Sanitary services must also
consider t he provision of separat e
facilities for men and women as well as
for supervision and labour. This s et of
cri t eri a must be carefully discussed with
t he operations personnel who ar e
involved a t t he design stage.
CONCENTRATION AND DEWATERING CIRCUITS
Architectural. The architectural
cri t eri a generally refl ect t he style of
building exterior and interior finishes
desired for t he plant. In addition, t he
provision of specific cri t eri a for heavy
use areas, particular chemical resistance
requirements, and climatic
considerations ar e important. The
development of cri t eri a for offices,
washrooms, drys and laboratories
requires a detailed description of t he
proposed work force and operating
schedules for t he various areas.
Instrumentation. The instrumentation
desiqn cri t eri a ar e normally developed in
conj kct i on with t he -process. and
mechanical engineering groups, and in
accordance with t he proposed operating
criteria. The specific instruments chosen
for each application will reflect an
overall control philosophy for t he plant
whether i t is computer based, distributed
control or simply local start-stop
switches for simple circuits.
The particular design cri t eri a
referred t o in Appendix I refer t o a
tungsten concentrator incorporating both
flotation and gravity concentration. The
criteria developed for a large base
met al s flotation concentrator or an iron
ore concentrator utilizing spirals or
magnetic separation would be similar in
nature but refl ect t he specific ore and
process under consideration.
Plant/Process Area
For each ar ea of t he plant and stand
alone unit processes, such a s flotation,
t he design cri t eri a will specify t he
operating criteria, a process description
and a detailed equipment description.
The operating cri t eri a include t he
operating schedule for t he particular
area along with t he availability
predicted for t he equipment, and t he
nominal flowsheet and design
throughputs. The relationship between
nominal and design flows is oft en
misunderstood and should be clearly
explained and specified in t he design
cri t eri a, and if possible noted on t he
flowsheets a s well.
In t he initial operation of t he plant
this may not be a major point, but a t t he
st age where debottlenecking, production
limiting fact ors and possibly expansion
become a f act of life, t here is a critical
need for such information t o be well
defined and available.
Onceagain,spacelimitationsprevent
including a complete design criteria for
al l process ar eas of a typical
concentrator, however excerpt s from a
s et of process ar ea cri t eri a developed
for a tungsten concentrator ar e given in
Appendix 11. The areas covered ar e
generally applicable t o most
concentration/dewatering plants but
naturally would be augmented and
modified specifically for t he plant and
process being designed.
The equipment descriptions in this
particular design cri t eri a are not
specific a s t o supplier, a s t he equipment
has not yet been purchased. In a fully
detailed design cri t eri a for a project in
detailed engineering, t he major
equipment would be committed t o and
would be described specifically. As this
equipment is purchased, t he design
cri t eri a document will be updated t o
refl ect t he particular machine t o be
installed.
DESIGN CRITERIA: FORMAL BASIS OF DESIGN
SUMMARY AND CONCLUSIONS
The compilation and use of a formal
design cri teri a document is essential to
the engineering design of concentration
and dewatering circuits. Careful
preparation of this document prior t o
commencing detailed design along wi th
continuous updating ensure a consistent
basis for design i n al l areas and for al l
disciplines involved i n the design.
LIST OF APPENDICES
APPENDIX I Examplesof General Design
Data
APPENDIX I1 Examples of Process Area
Cri teri a
ACKNOWLEDGEMENT
The assistance of my colleagues at
Wright Engineers Lt d , particularly Brian
Montpellier, Project Manager and
management permission to prepare this
paper are gratefully acknowledged.
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6.0 STRUCNWY DESIW CRITERIA
6.1.1 Lildirw Code Standards
All buildings and their structural melbffs shall be designed
to r s i s t safely and effectively all lmds and al l effects of
loads and influences that may reasonably be expected, and
shall in all cases satisfy the r wu i r mt s af Section 4.1 of
the National Building Code of Canada 1960 and standards set
fwth by eight Engineets Limited.
Except as set f a t h in Article 4.1.1.4 Subsectim 2.6.2. of
the National kildinq Code of Canada 1WO the followin shall
apply:
Fmdations, excavations, soil and rock retaining
structures shall confar to Subsection 4.2.4 of the
National Building Code. ht wi al s to be used in
fmdatiuns (Subsection 4.2.3)
kildings and their structural d w s .a& of wood
shall mf wa to CSA Standard Can. 3-DEHW 'Code for
Engineering Design in Ycodm.
( i i i ) hmv Structures
Buildings and their structural u*bers made of plain and
reinfmed masonry shall cmf ar to CSR Standard
~- 530( - H78 ' ksmry Design and Cmskwtim for
Buildingsn.
(iv) Concrete Structures
Wlildings and their structural &err ude of plain,
rei nhced and prestressed c ~ c r e t e shall cmform to
CCYad23.3-Kn 'Code for the Design of C m t e
Structures fw Buildings:. For establishing 'design
load factas*. the tabulation in Section 6.4 of t hu
criteria shall be used. I t i s based on the N.B.C. 1080
factors but expanded for special loads and effects
acting on rinins projects.
(vl Steel Structures
(a) hildinss and their structural &ers made of
structural steel shall confag to C% Standards
516-1969 'Steel Structures fw hildings".
( b) Buildinss and their structural &ws mde of
light gauge steel &all cmfam to CSA Standards
5136-1074 "Cold Formed Steel Structural tlelrbas".
Standards
Before structural design or detailing conrences m any
sectian of the woject, reference shall be made to
Kisht Enginems Limited desi.gn and d-afting standards
to ensure that al l item c ml y with these standards.
6.2 Desiqn Loads
bcund snar load 2.9 Mlsq U. Snar load coefficients to be
deterained frm coaentary H of the wppleeent to the NBC.
7.0 tEMW SERVICES CRITERIA
7.3 kterials
7.1 k i a Codes and Standards
All desiv shall be in accordance with the following codes and
regulations:
- The Ltional Wlildinq Code of Canada - latest edition
- The Canadian Heating, Ventilating and Air Conditioning
Code - latest editim
- Cli~tic Information for Building Design in Canada -
latest edit ion
- The Federal Ministry of Energy, nines and Petroleua
Reswces, ninwal Resarrces 8ranchr invirormental
Reulations - latest edition
- Underuritwls Reconmendations
- The lbtional Fire Code of Canada 1977 - latest edition
- Ontario Plumbing Code -latest edition
- Pressure Vessels and Piping Regulations as issued by the
Euvanaent of the N.W.T.
- Canadian Standard Association
- kplicable local Codes.
HWlC systens shall be designed and constructed in accordance with
established engineering principles using the publications of the
following associations:
- The bride and Data Boaks of the lkrican Society of
Heating, Refrigeration and Air Conditioning Enqinews
(W).
- Sect lletal and Air Conditioning Contractor's National
Assaiatim Inc. (SMM) Duct Constructim Standards.
7.2 Desiw and Draf tins Standards
Drafting Ball confwm to Yight Engineers Limited Drafting
Standards and Syabols. Drawings shall be prepared using the Guide
f m the Canadian Mining and htallur.qica1 Industries, by the nining
Association of Canada. &i@t Engineers Limited's Design Standards
shall be used throughout unless otherwise specifically noted.
kterials used in the MHU: pluobing and fire protection s y s t w rill
ccwly with the applicable standards referenced in the National
Building Code of Canada and other avplicable c&. Haterial not
covered by these standards a materials f w special conditions will
cmply to such other standards as are approved f a the particular
ap~lication.
WCLC E w i p m t will be selected for heavy duty industrial service.
Comercia1 duty w u i p m t will be restricted to use in ancillary
bui ldings.
Ventilation ductwk will c w l y to the applicable SIYWJA pressure -
velocity classification except that in process buildings and
elswhere exposed to possible M e the a i n i m Pressure
classification will be 2' ffi.
7.4 ksiqn Conditims
The heating systeas will be k i g n e d f a an outdoor winter
teweratute of -5 deg C except &en the systems are to be designed
to prevent freezing only, in which case an o u t d m t w w a t u r e of
-20 deq C will be used.
The ventilating and air conditioning systeK will be desiped for
cutdwr s w cmditims of 35 deg C.C.D.B. and 31 deg C.W.B.
Indmr temperature and relative humidity will be as noted f a each
area.
7.5 Heatinq, Ventilatinq a d Air Conditioning
8.0 AIR POULIIIW (ItNlmDESIGI( CRITERIA
8.1 Codes and Standards
Pollution control shall be provided to k e s the
concentrafian of contaminants belor acceptable
threshold limits nithin occupied work areas.
kight Ensines Liaited's design and draftins
stanbrds +all-be used throughout un!eis
otheruise ~eci i i cal l y noted.
All vor k shall be carried out in accordance with
the Clean Air Actl and all othw acplicable Lmal.
and Natianal Standards and Codes. The systems
shall be designed and constructed in accordance
with stablished enqinewing principles usins the
foilwinq p~ublications as an accwtable standard:
industrial Veiitilation by the kerican Conference
of 5overnrental Industrial Svgienistr.
Shest Hetal and Air Ibditioning Cmtractor7s
Ltimal Association Inc. (SMCCW hct
Construction Standards.
Plant and P~OCESS Ventilalion by Y.C.L. Heaeon.
Design Guidelines for Oust Ccntrol at Nine Shafts
and Surface Gperatians by the bt i mal kthority.
Fume ductwak and equipment shall be constructed
of corrosion-resistant material applicable to the
fumes being handled. Oust hmds. enclosures and
Qctmk shall be constructed of galvanized a
black steel to Might Ensinws Linited Qsign
standards.
Equipment shall be selected for heavy Ctv
industrial service. Fans gmwally shall be Class
I1 constructim and dust c o l l ~ t a s shall Ce
constructed of relced steel plate.
8.3.1 Fume Crntrol
In working areas threshold liraits for
abmphwic contaminants shall not exceed
the values published in the llp~eitdix to
"Industrial Vmtilatim*.
(111 horizmtal duct runs shall be slaped
fat. proper lfainage and flushing. Drop-out
boxes shall be incaporated at the top of
verticzl risers !rm vessles, hhere
neceswy. Air ba!ancing shall be achieved
bv dwws and tram air inlet s t ~hs Mere
necessary. Ductmk shall be flanged at
strategic locatims for ease of
installatim rr diwntlins *here
neceswy. Fuoe collectors, Jlere
rquired, shall be selected to maintain
fuw emission at u below levels
established by the Governrent in the Clean
Air Act and kctic Hining Eaissiclns fict.
In genera11 all f w control stacks shall
exhaust wtdwrs above rwf level.
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92.2.2 Upqrack Flotatim
92.0 Sulphide Cmditiminq and Flotation
92.1 Cueratins Criteria
9.1.1 Primary Flotation
- Solids F!ow 33 mtph
- %lids S.6. 3.4
- hl p Censity 322 Solids nlw
- Tic2 5 min.
42.1.1 S~ccindarv F!otation (U~qpqrade Plant)
- Eolids Flow Batch !4.3
tlbatchi
- Salids S.G. 5.4
- F~lp Densitv = . =QL
bl i ds nlw
- Tine IS
ninlstase
92.2.1 Primarv Flotation
Depmding on the Sulphide content of the ore zone being
mined, rod mill screen underflow will go directlv to
lar intensity net mayetic separatim or be by-passed
ta sulphide flotation. Pulp will be conditioned in
sulphuric acid and flotation reagents to bring the pH
to 4, and floated for 5 minutes in a bank of 8 50 cu.
ft. cells (Denver DR 24 or yuivaleit) to produce a
The upgrade circuit has 2 batch flotatiai systems, cne
for ccarse concentrate ( 4 cells) and one for fine
concentrat= (2 cells). Cells are al! 54 cu. ft . barse
batch flotation i s sized at 4.8 tmn~slbatch for 50
minutes. Fine batch flotation i s 2.64 tonneslbatch h?
40 rinutes.Throuawav flotatim concentrate will
overflu t o a decision tank beiwe being vmed to the
tailings thickener to ensure the sch~el i t e cmtent is
acceptably lm.
??.:.I kcid C~ndltionw Tanks
Trc ! . : a .: 2.11hi?h riid stcei rthber
line2 conditicrlin~ tank receivins slirrry
from the rod nil1 scr'ew. t!uhsnical
asitation i s prcvided by a sos~.ntkd
i.wellw nounted on an overhead frane.
The agitators are driven by ar. eleitric
aotm thr~uqh a V-belt &ive and rilht
an?le seat. box. Flsw thrwsh i s by
gravity..
The tanks contains vertical b a f f l ~ to
ninioize urirling and 0.5 in minim
freeboard to prevent splashing over the
sides. The tanks have XI ovwf low pipe
to channel eergmcy overflor product to
the floor drain and suq.
thrcw away sulphik cmentrate. Cell tailing will be
neutralised with l i w and passed over LIHS befwe
deslimins, hydrosizinq h tabling.
92.3.2 Lime Cmditimer Tanks
The l i re cmdi timing -1s consist of
two 1.5 a did. x 2 a high tanks. The
tanks are cmstructed of rubber lined
mild steel. V-drives and right angles
yearbaxes m t e d an werhead frsmes
power the suspended impellers.
Flow t h r q h each staqe i s by gravity.
The tanks cmtain vertical anti-cwirl
bafiles and have a sininurn of 0.5 e
Ir~ebcard.
02.3.3 Flotation Cells
l3e numbers and sizes oi the flotatian
cells are tabulated be1ou:-
at Ripary circuit 8 % 50 cu f t .
b) Coarse Upgrade 4 x 50 cu ft .
C) Fine lbgrade 2 r 50 cu ft .
The cells are fabricated f r w aild steel
plate and areas subject to abrasion are
covered with rubber. 1111 cells are acid
proof. Cells are single or duuble
overflow froth discharge type, supplied
with feed, junction and discharge bcxes.
Fulp Wt h level i s adjusted by neir bars
at junction and discharge boxes.
The spindle bearing housing and drive
notor i s tank minted. Drive i s via, vee
beits and sheaves, and sized with a 1.15
ssr-vice factor.
Froth collection l a u n k are Prwirkd at
each bank of cells. Construction and
slope of laundrss canforn to WEL Standard
56-540.
92.4 Reaqent Preparatian
Reasent Ccnsuwt im
CWPW Sul~hate
Sulphuric k i d
Frothw
Xanthate
Lime
kqlt
kqlt
&It
kq/t
kglt
92.4.2 Reasent Re~ar at i ai and Eaui~lnent Oescri~tion
Nost reagents have a two tank rix/stwe svstm. All
vessels are PVC where practical.
92.4.2.2 bppw Sulphate
This reagent i s received in bags. I t i s
dissolved in an agitated nix tank and
stored in an agitated hcldinq tank.
42.4.2.4 Sul~huric Acid
WI1k rulphuric acid frt u a stacaqe tank
i s pumped to a dilutionlholdin~ tank in
the si l l .