SMART DOG MINING

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An Introduction to Jigs
Using jigs to concentrate coal and minerals has been around for a long time, the use of
jigs for concentrating ores was reported in De Re Metallic by Agricola published in
1556. And he referenced earlier work going back to Egypt almost 3000 years ago.
Early ore jigs used a basket, loaded with ore, that was moved up and down (jigged) in a
tank of water. This jigging allowed the particles to become rearranged in layers of
increasing density from bottom to top. The same principle is used in modern jigs to
stratify and separate the particles of differing density. For more information on how jigs
work see SDM an Introduction to the Principles of Jigging.

Jig circuits can be one of the simplest mineral processing circuits, primarily as jigs are
rather forgiving in operation. Jigs come in different sizes and shapes, but in general, a
jig plant is essentially a materials handling system that is designed to supply ore in a
specified physical state to the jigs and to carry away the products.

TYPICAL CIRCUIT
The most basis example is a placer jig circuit (Figure 1). It consists of a feed hopper
and conveyor (sometimes not included), a trommel to remove large oversize rocks, the
jig, a water circuit, and a tails handling method.
Figure 1: Basic Placer Jig Circuit

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An Introduction to Jigs
The other is a coal cleaning circuit (Figure 2) which consists of a Baum jig usually fed
directly from plant feed, producing a final reject from the first compartments, a recycled
middlings (usually crushed) from the second, and a clean coal. The clean coal is often
screened for fines processing, due to inefficiency of the primary jig cleaning fines.

Figure 2: Coal (Baum Jig) Circuit

Jigs use a large amount of water so reclamation of water with recycling is standard
practice. Clean water is not necessary as clay and fully suspended slimes do not
appreciably affect results up to an apparent density of 1.05. However, provision must be
made to clarify enough water to stay below this level. In some cases chemical additions
may help.

EQUIPMENT DESCRIPTION
The fundamental principles jigging are essentially the same for all jigs, the basic
differences between the various types of jigs are a matter of practical engineering to
optimize the operating performance, materials handling, maintenance and control.

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An Introduction to Jigs
The earliest jig was a moving bed jig (see De Re Metallic by Agricola). The screen
containing the bed is jigged up and down in water to create the liquid pulse. There are
some significant advantages to moving bed jigs both in performance and water
consumption. But since they are not commonly found, this discussion will be returned
to in another paper. Currently, the majority of jigs found are of the fixed bed type in
which the liquid pulse passes up and down through the jig bed which is retained on a
stationary screen. The different types of fixed bed jigs are given shown in Figure 4.

Figure 4: Fixed Bed Jig Types

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An Introduction to Jigs
Type
Baum
Richards
Harz
Denver
Bendelari
Yuba
Pan-American
Russian MOBK

Pulsating Mechanism
Air
Water
Mechanical Piston
Mechanical Diaphragm
Mechanical Diaphragm (internal)
Mechanical Diaphragm (side)
Moving Hutch
Pneumatic piston

Stroke Modification
Air discharge control
Water valve control
Differential piston action
Water valve
none
Hydraulic or mechanical
Mechanical
Air discharge control

For coal cleaning, the Baum (Figure 5) and Batac jigs are the most common type. For
other minerals, the Pan-American (mechanical or diaphragm) jig is the most commonly
used type. This difference has more to do with through put capacity, especially float
capacity. Baum and Batac jigs of 1500 tons/hour capacity exist. A small Baum jig
would have a capacity of 50 tons/hour. A jig of 100 tons/hour capacity is large for a
mineral jig. Large mineral jigs, and small Baum jigs can be found. But the above
pertains to most common capacities.

Figure 5: Typical Baum Jig

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An Introduction to Jigs
Batac jigs are Baum style jigs, with the air chest under the deck screen (usually on the
divider wall between cells). Other than this they are similar in operation and capacity to
Baum style with improved performance reported for fine sizes. Having the air chests
under the screen requires less floor space. They also tend to have improved
instrumentation giving better control. Sizing is similar to a Baum jig.

Baum style jigs usually have two compartments, a primary and a secondary (figure 5).
Coal is normally fed to the primary where the main reject is produced. Coal from the
primary feeds the secondary which produces the clean coal. The secondary reject may
be a second or middlings product (market depending), recleaned in another jig,
combined with the primary reject, or recycled (partly) to the feed.

A common way of describing a Baum jig is by giving the width, number of primary cells,
and then the number of secondary cells. A 734 jig would be seven (7) foot wide, with
three (3) primary, and four (4) secondary cells. For most jigs the normal cell is 3 foot
wide. Jig bed area would be calculated as follows:

Sq. ft. = No. of cells x jig width x 3 or for the 734 jig;
7 foot wide jig = 7 x 7 x 3 = 147 sq. ft2

A few three compartment Baum jigs have been used, adding a tertiary stage. This
would be used for a coal having a large amount of near gravity material.

The most common mineral jig in use today is the Pan-American style, although some
Yuba and Denver jigs can be found.

Circular jigs tend to fall into two groupings, single hutch round jigs and ones made of
individual cells like segments in an orange. In both cases improved performance is
gained by allowing the bed to spread, allowing finer particles to separate better. But at

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An Introduction to Jigs
a space penalty and in more complicated feed and concentrate systems. General
sizing is similar to other mineral jigs.

Figure 6: Typical Pan-American Mineral Jig

The typical Pan-American (often just Pan-Am) jig as shown in Figure 6, is normally built
as a duplex jig (a pair of balanced jig cells). Each cell is consists of an upper hutch
(usually rectangular), a lower hutch (usually conical), joined by an annular diaphragm of
flexible rubber to allow up-and down movement of the lower hutch.

The typical Pan-Am consists of the following:

two cells each 42 x 42 (1 m x 1 m);

common drive (energy savings);

amount of ragging typically 425lbs (193 kilos) per cell;

type of ragging typically 3/16 inch (4.75mm) steel shot;

stroke length inch to 1 inch (19 to 38mm);

stroke frequency 120 to 200 cycles per minute.

Pan-Am duplex jigs are popular in many regions, and can be seen in action in Alaska,
Yukon, South America, and Africa, much of this is due to their inherent simplicity and
relative ease of maintenance.
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An Introduction to Jigs
EQUIPMENT SIZING
Jigs are sized on the feed tonnage per unit of jig area. Different types of feed will
require different sizing criteria. Specifically coal jigs have different sizing criteria than
mineral jigs.

Coal Jigs (Baum & Batac) capacity depends on the amount of fine feed. The greater
the amount of fines, the lower the basic jig capacity. If the amount of fines is above
30% by weight, the fines may size the jig. While a portion of the fines may be removed
by classification ahead of the jig, some fines are needed. If a classified (screened) feed
is used capacity will decrease or greater amounts of water will be needed. In this case
fines being the material that is of the average particle size. Part of this is due to
normally larger particle size being feed in coal. Feed sizes of over 6 top size are
common. Since a large portion of the work in separation is done processing marterial
near the gravity of separation, for coal feeds that have a high amounts of material near
the gravity of separation, the jigs capacity maybe limited by its refuse handling capacity.

For coal jigs, normal water use is 7 to 8 gal/min of water per ton/hour of dry solids. This
water is split 30% to the feed, and the remainder to cells. A more precise way of calculating water requirements is in gal/min per square foot of jig area allowing for the
dilution of the fines. Fine particles are needed to create a semi- suspensoid (heavy
medium). Typical coal jig capacities are shown in Table 1 and Figure 7.
Table 1 Baum Jig Capacity

Baum Jig Capacity

T/Hr per Foot2 Jig Area

% < 6.35 mm

Jig Capacity

(-1/4")

(T/Hr/Foot2)

< 25 %
25% - 30%
>30 %
100%

4-5
3-4
2-3
1 - 1.5

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An Introduction to Jigs

Figure 7: Baum Jig Capacity

Baum and some Batac jigs use bucket elevators to drain and discharge the refuse. The
physical ability to extract the refuse may be the sizing criteria. A check is also made of
the sink (refuse) handling capacity (figure 8).

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An Introduction to Jigs

Figure 8 Baum Jig Elevator Capacity

Normal water use is 7 to 8 gal/min of water per ton/hour of dry solids. This water is split
30% to the feed, and the remainder to cells. A more precise way of calculating water
requirements is in gal/min per square foot of jig area allowing for the dilution of the fines.
Fine coal particles (minus 6.35 mm (1/4")) are needed to create a semi- suspensoid
(heavy medium). Table 2 gives general requirements for Baum jigs.
Table 2: Baum Jig Water Requirements

Baum Jig Water Requirements

G/min per Foot2 Jig Area

% - 6.35 mm Maximum Minimum Average

< 25%
45
30
37.5
25 to 30 %
30
17.5
23.5
> 30%
15
5
10
Average conditions = 32.7 g/min
Average cell is 3' x 8' or 24 ft2 = 785 G/m/cell

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An Introduction to Jigs
For mineral jigs, capacity is heavily dependent on the average specific gravity of the
feed. This determines the volume of material (dry basis) that is fed to the jig. Jig design
also affects capacity, as circular jig have a higher unit capacity then rectangular jigs.
This comes from the spreading of jig be towards the overflow weir, allowing for a less
dense bed improving fines separation. For any particular operation there is a "best"
combination of the jig adjustment factors. Their selection is often is based on
experience and operator preference, and is open to much debate as to what is "best".
The following are some of the major adjustment factors:

Stroke Speed and length. Balancing the stroke speed and length are two
important aspects, and can lead to good or poor performance. Jigs have a
natural period of motion which results in an optimum speed for any given type
and size of jig. The Material characteristics also impact this.

Water Flow. The jig stroke is modulated by the water upflow. Too much hutch
water can cause losing fine values to the tails. Too little hutch water can can
cause the reporting of tails to the concentrate.

Ragging. Determining the proper type and size of ragging is important in the final
specific gravity cut point. The tails will in general be lighter than the ragging,
while the concentrate will be heavier. Ragging size also limits the size of the
coarse material that will pass.

Jig Slope. The bed must be sloped across large jig machines to provide bed
movement. Jig design must allow for adjustment of this slope in the installation.

Jig area. The area of the jig is what determines the feed capacity.

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An Introduction to Jigs
Table 3: General Mineral Jig Capacity

Mineral Jig
Capacity
2
T/Hr per Foot Jig
Area

Average Feed
Sp Gr

Low
End

Average

High
End

2.35
2.50
2.75
3.00
3.50

1.5
1.6
1.7
1.9
2.2

1.5
1.6
1.8
2.0
2.3

1.6
1.7
1.9
2.0
2.4

Jig configuration and particle size will have some impact

but an average of 1.8 Tons/hr/ft2 of jig area is common

Figure 9: General Mineral Jig Capacity

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An Introduction to Jigs
EXAMPLE
The following is an example of sizing and selecting a coal (Baum style) jig. It is included
for reference only. In actual practice many different factors can cause the specific
selection to change.

Conditions:
500 ton/hour of raw coal
6" top size
25% minus 1/4"
85% (at 1.65 Sp.Gr.) reporting to clean coal.
With 25 % minus 1/4", from table 1 and figure 7, the average design capacity would be
3.5 tons/hour/foot2. 500 tons/hour of raw coal requires:
500 T/hr
= 142.8 Ft2 or 143 Ft2
3.5 T/Hr/Ft2
From above, a 734 jig (7 foot wide, 7 cells) has a jig area of 147 Ft2.

Checking refuse handling capacity gives:

100 - 85 x 500 T/Hr = 75 T/hr
100
Of this, normally 75 to 80 % reports to the primary elevator, or design for 60 T/hr in the
primary. From figure 8, this would require a 22 inch wide elevator as a minimum.
Water requirements based on size (Table 2) are 23 G/min/ Ft2 or:
147 Ft2 x 23 G/min/ Ft2 = 3381 g/min
For a feed rate of 500 T/hr the average water requirement would be 3500 to 4000 g/min.
As the amount of minus 1/4" material is low, using 3400 G/min is probably adequate as
a starting point. Of this, 30 % (1020 G/min) would be added to the feed and the
remainder to the cells (340 g/min each).
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An Introduction to Jigs
In general a mineral jig is sized in a similar manner.
Conditions:
50 ton/hour of placer feed to trommel
1/2" top size
Average feed density 2.75 gm/cc (~2.75 Sp. Gr)
Concentrate - > 5 gm/cc
Assuming some reject of material by the trammel (~10%), would give a projected jig
feed of 45 tons/hour. From Table 3 and figure 9 the average capacity would be 1.8
tons/hour/foot2. 45 tons/hour of feed requires:
50 T/hr
= 25 Ft2
1.8 T/Hr/Ft2
A standard duplex Pan-Am jig (42 x 42 x 2) has ~24.5 Ft2, of area and would be a
good choice,

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