Optimization of Comminution Circuit Throughput and Product Size Distribution by Simulation and Control. Quarterly Technical Process Report for July 1, 2002 to September 30, 2002.
The goal of this project is to improve energy efficiency of industrial crushing and grinding operations (comminution). Mathematical models of the comminution process are being used to study methods for optimizing he product size distribution, so that the amount of excessively fine material produced can be minimized. This will save energy by reducing the amount of material that is ground below the target size, and will also reduce the quantity of materials wasted as 'slimes' that are too fine to be useful. This will be accomplished by: (1) modeling alternative circuit arrangements to determine methods for minimizing overgrinding, and (2) determining whether new technologies, such as high-pressure roll crushing, can be used to alter particle breakage behavior to minimize fines production. In the seventh quarter of this project, analysis of the plant operation identified sources of overgrinding in the circuit. Overgrinding was primarily caused by two effects: (1) The hydrocyclones used to close the circuit and remove fully-ground particles from the circuit were preferentially returning high-density ore particles to the secondary mills for regrinding even after they were already ground to pass the desired product size, and (2) The primary grinding mills were operating at less than full capacity, suggesting that a shift of grinding load to the primary mills could liberate more material before it reached the secondary mills, allowing more complete liberation with a coarser grind. Circuit modeling is underway to determine how best to modify the circuit to reduce these effects.
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