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2009 Issue25 Sampling

Continuous sampling provides high reliability and accuracy while saving time and money compared to manual sampling methods. To obtain a truly representative sample, all particles in the slurry must have an equal chance of being sampled. Factors like velocity, pressure differences, and particle size can bias the sample if not properly accounted for. Choosing the right sampler type and location is important for process monitoring and metallurgical accounting.

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64 views3 pages

2009 Issue25 Sampling

Continuous sampling provides high reliability and accuracy while saving time and money compared to manual sampling methods. To obtain a truly representative sample, all particles in the slurry must have an equal chance of being sampled. Factors like velocity, pressure differences, and particle size can bias the sample if not properly accounted for. Choosing the right sampler type and location is important for process monitoring and metallurgical accounting.

Uploaded by

Sreedhar Bellary
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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Output Australia | December 2009 | Page 5

Sampling in concentrators
Author: Brian McPherson
In order to manage and optimize your plant, it is critical to truly understand how the plant operates. This understanding will come through accurate and efficient measurement of key performance parameters. One vital performance parameter is, of course, the metallurgical performance, and measurements of this can be carried out via sampling and analysis This article will focus on analysis. continuous sampling, which not only saves time and money but also provides a high degree of reliability and accuracy, and is not subject to human error.

Key sampling principle


An important principle of correct sampling is the concept that all materials in a process flow must have the same probability of being part of the sample, therefore all particles must be in suspension and well mixed. If slurry velocity is greater than 1.5m/second, turbulence keeps fine particles in suspension and well mixed horizontally. The finer and lighter the solids in slurry, the more ideal the mixing. The effects of gravity will come into play when the particle size rises above 100um and/or the SG of the material is high. To achieve true representation of all particle sizes the velocity of the slurry should be equal both inside the sample nozzle /cutter and outside around the nozzle/cutter. For example, if the pressure inside the nozzle/cutter is lower (suction in the sample line) the sample will be biased with fine material as these smaller lighter particles are drawn preferentially into the sample nozzle/cutter.

Equal pressure inside and around the cutter/nozzle, normal operation

Lower pressure inside the sample line, finer particles are drawn into the cutter

Key considerations before choosing a sampler


There are some important issues to discuss when choosing a sampler; Is this sample for metallurgical accounting or process control? What is the destination of the process stream and sample stream? Are there any future changes expected in the process e.g. increased flow, process variations? Are there any contaminants e.g. trash, rocks, grinding media What is the best location for the sampler?

Output Australia | December 2009 | Page 6 Gravity samplers


For example, if you wish to have a metallurgical quality sample it is recommended that a gravity type sampler be used. The sample volume achieved in a given time period will vary according to plant flow. Thi i critical t obtaining fl This is iti l to bt i i samples suitable for metallurgical accounting. A gravity sampler will give true representation of both process flow and solids content. Ideal location for these types of samplers would be at the start of the process feed; final product and final tails The cutters on gravity tails. samplers take an equal cut of all horizontal layers which may have different contents due to segregation.

Launder Box Sampler, Gravity type

With gravity samplers it is important to ensure the line from the samplers to the pump has an atmospheric break if using pumps to deliver the sample stream to the analyser or composite point. If there is none, the sample will be compromised, i.e. the pump will dictate how much sample is to be p p p p p taken. If the process flow is low, then the pump will cause lower pressure inside the cutter and so more smaller particles will be drawn into the cutter, thus biasing the sample.

Pressure samplers
Pressure type samplers are best suited to monitor process control and if positioned correctly do not require any other pumping assistance to deliver sample to the t th analyser or composite point. Th rate of sample l it i t The t f l flow is best controlled by the diameter and length of the sample line. During installation it is important that the sample flow must not go higher than the process pipe, otherwise there is the possibility that the sample stream will not flow. At one particular site, for example, this is exactly what was installed, and shown in the following photo. One option to remedy the situation was to install a pumping stage which had substantial cost stage, implications. Outotec, however, suggested raising the sampler to a greater height, a solution which took just two days work and saved thousands in the process. The sampler was raised, thereby increasing the process stream height, equaling the sample discharge point which resulted in continuous sample flow.

Pressure Pipe Sampler

Output Australia | December 2009 | Page 7

Sample stream lines

Process stream lines

Problem - sample stream is above process stream lines Solution - sampler subsequently raised above sample discharge point
In summary, it is important to remember that, although the sampling cost of a project is typically low, sampling correctly i th k t successfully monitoring th metallurgical performance of th l li tl is the key to f ll it i the t ll i l f f the plant and achieving the best economical return. If the sampling is not of a high quality, it can have an adverse effect on the life and direction of a project. It is highly recommended that major consideration and careful planning be made when choosing sampler type, location and layout - as this small outlay in time and money will quickly reap rewards. _______________________________________________________________________________________________

Brian McPherson is currently Applications Engineer- Automation for Outotec in Perth, Australia, with y pp g over 20 years experience in minerals processing. Previously, Brian worked in the Service Department in mills, thickeners, flotation, automation and training. In this current role he helps customers in Australia optimise automation and sampling installations in both new projects and brown field operations.

If you would like more information, click here to contact information [email protected]

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