Benchmarking: Bond - Boddington - Revision history

Alex Doll: /* Sources, SAG 2011 conference */

2016-04-18T16:01:54Z

Sources, SAG 2011 conference

← Older revision		Revision as of 16:01, 18 April 2016
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	* secondary crusher specific energy consumption 0.5 kWh/t with product size 38 mm		* secondary crusher specific energy consumption 0.5 kWh/t with product size 38 mm
	** power draw of secondary crushers = 460 + 554 + 583 + 581 = 2178 kW, assumed to be at motor input		** power draw of secondary crushers = 460 + 554 + 583 + 581 = 2178 kW, assumed to be at motor input
	** secondary crushing throughput 4560 t/h		** secondary crushing throughput 4560 t/h; not clear if this is fresh feed or includes a circulating load.
	* throughput 1100 t/h per grinding line × 4 lines = 4400 t/h		* throughput 1100 t/h per grinding line × 4 lines = 4400 t/h
	* HPGR specific energy consumption, E<sub>HPGR</sub> = 1.40 kWh/t		* HPGR specific energy consumption, E<sub>HPGR</sub> = 1.40 kWh/t

Alex Doll: /* Sources, SAG 2011 conference */

2016-04-18T15:30:40Z

Sources, SAG 2011 conference

← Older revision		Revision as of 15:30, 18 April 2016
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	Plant operating parameters:		Plant operating parameters:
			* primary crusher product (circuit F<sub>80</sub>) = 160 mm
⚫	* throughput 1100 t/h per line × 4 lines = 4400 t/h
	* secondary crusher specific energy consumption 0.5 kWh/t with product size 38 mm		* secondary crusher specific energy consumption 0.5 kWh/t with product size 38 mm
			** power draw of secondary crushers = 460 + 554 + 583 + 581 = 2178 kW, assumed to be at motor input
⚫	* HPGR specific energy consumption 1.40 kWh/t
			** secondary crushing throughput 4560 t/h
⚫	* overall E<sub>crush</sub> 1.90 kWh/t
		⚫	* throughput 1100 t/h per grinding line × 4 lines = 4400 t/h
		⚫	* HPGR specific energy consumption, E<sub>HPGR</sub> = 1.40 kWh/t
		⚫	* overall E<sub>crush</sub> = 1.90 kWh/t
	* HPGR circuit product size (T<sub>80</sub>) 6 mm		* HPGR circuit product size (T<sub>80</sub>) 6 mm
	* ball mills drawing about 14 MW (assumed DCS, works out to 13.0 MW at mill shell)		* ball mills drawing about 14 MW (assumed DCS, works out to 13.0 MW at mill shell)

Alex Doll at 22:31, 29 May 2014

2014-05-29T22:31:19Z

Alex Doll at 19:32, 27 May 2014

2014-05-27T19:32:32Z

← Older revision		Revision as of 19:32, 27 May 2014
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			[[category: Benchmarking]]
			[[category: HPGR]]
			[[category: Bibliography]]
	==Benchmarking: Bond/Rowland SSBM model - Boddington HPGR circuit==		==Benchmarking: Bond/Rowland SSBM model - Boddington HPGR circuit==

Alex Doll: /* Microcracking/phantom cyclone/ball mill performance */

2014-05-27T05:49:06Z

Microcracking/phantom cyclone/ball mill performance

← Older revision		Revision as of 05:49, 27 May 2014
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	==Discussion==		==Discussion==

			===Essbm calibration factor versus Etotal displayed===
			The '''Essbm calibration factor''' in the Bond/Rowland SSBM Circuit Model is not the same as the "-19%" displayed on the "E<sub>total</sub>" line of the flowsheet. The calibration factor that is input in the circuit settings relates to a hypothetical "perfect" cone-crushing circuit with slightly different inter-stage transfer sizes than is simulated in the actual circuit.

			The "E<sub>total</sub>: E<sub>ssbm</sub>" factor shown at the bottom of the flowsheet refers to the actual E<sub>total</sub> of this simulated flowsheet (E<sub>secondary</sub> + E<sub>HPGR</sub> + E<sub>ball</sub>) versus the hypothetical "perfect" cone-crusher SSBM circuit described by Rowland.

	===Microcracking/phantom cyclone/ball mill performance===		===Microcracking/phantom cyclone/ball mill performance===

Alex Doll: /* Modelling */

2014-05-27T05:43:43Z

Modelling

← Older revision		Revision as of 05:43, 27 May 2014
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	Use the '''Bond/Rowland single stage ball mill''' circuit model with the '''HPGR-BM''' flowsheet.		Use the '''Bond/Rowland single stage ball mill''' circuit model with the '''HPGR-BM''' flowsheet.

			[[File:Benchmarking-BoddingtonBM.png\|thumb]]
	Ball mill model:		'''Ball mill model:'''
	* Use the '''Nordberg wet overflow ball mill''' model		* Use the '''Nordberg wet overflow ball mill''' model
	* Quantity 4		* Quantity 4
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	* To achieve 14 MW at DCS, assume speed is 73% of critical and load is 23 % v/v (mills are fixed speed, unable to find speed in literature; load is low, but probably kept low due to problems getting throughput in HPGR circuit).		* To achieve 14 MW at DCS, assume speed is 73% of critical and load is 23 % v/v (mills are fixed speed, unable to find speed in literature; load is low, but probably kept low due to problems getting throughput in HPGR circuit).

	Secondary crusher model:		'''Secondary crusher model:'''
	* Quantity 4.		* Quantity 4.
	* MP 1000 crushers, use 1000 HP motor.		* MP 1000 crushers, use 1000 HP motor.
	* set mechanical efficiency to 0.60.		* set mechanical efficiency to 0.60.

			[[File:Benchmarking-BoddingtonHPGR.png\|thumb]]
	HPGR model:		'''HPGR model:'''
	* Quantity 4.		* Quantity 4.
	* HPGR motor 5600 kW (actually 2 × 2800 kW)		* HPGR motor 5600 kW (actually 2 × 2800 kW)
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	** results is mechanical efficiency of 0.28.		** results is mechanical efficiency of 0.28.

			[[File:BenchmarkingModel-Boddington.png\|thumb]]
	Circuit model:
			'''Bond/Rowland SSBM Circuit model:'''
	* Set the crusher product size to 6000 µ		* Set the crusher product size to 6000 µ
	* Circuit feed size 160 000 µm and product size 100 µm		* Circuit feed size 160 000 µm and product size 100 µm

Alex Doll at 05:37, 27 May 2014

2014-05-27T05:37:24Z

@@ Line 22: / Line 22: @@
 Plant operating parameters:
 * throughput 1100 t/h per line &times; 4 lines = 4400 t/h
-* secondary crusher specific energy consumption 0.50 kWh/t with product size about 60-66 mm
+* secondary crusher specific energy consumption 0.5 kWh/t with product size 38 mm
-* HPGR specific energy consumption 1.60 kWh/t
+* HPGR specific energy consumption 1.40 kWh/t
-* overall E<sub>crush</sub> 2.10 kWh/t
+* overall E<sub>crush</sub> 1.90 kWh/t
 * HPGR circuit product size (T<sub>80</sub>) 6 mm
 * ball mills drawing about 14 MW (assumed DCS, works out to 13.0 MW at mill shell)
@@ Line 38: / Line 38: @@
 [http://www.citic-censa.com/LinkClick.aspx?fileticket=Gqz1uLIuNqU%3d&tabid=124 CITIC Censa installation list]
-* mill shell is 44.5 ft long (F:F, use 44.0 ft EGL)
+* mill shell is 44.5 ft long (F:F), use 44.0 ft EGL
 ==Modelling==
 Use the '''Bond/Rowland single stage ball mill''' circuit model with the '''HPGR-BM''' flowsheet.
 Circuit model:
 * Set the crusher product size to 6000 &micro;
 * Circuit feed size 160&nbsp;000 &micro;m and product size 100 &micro;m

Alex Doll: Created page with "==Benchmarking: Bond/Rowland SSBM model - Boddington HPGR circuit== ===Sources, SAG 2011 conference=== ''Steven Hart, S., Parker, B., Rees, T., Manesh, A. and McGaffin, I.'' ..."

2014-05-27T04:36:49Z

Created page with "==Benchmarking: Bond/Rowland SSBM model - Boddington HPGR circuit== ===Sources, SAG 2011 conference=== ''Steven Hart, S., Parker, B., Rees, T., Manesh, A. and McGaffin, I.'' ..."

New page

==Benchmarking: Bond/Rowland SSBM model - Boddington HPGR circuit==

===Sources, SAG 2011 conference===
''Steven Hart, S., Parker, B., Rees, T., Manesh, A. and McGaffin, I.'' '''COMMISSIONING AND RAMP UP OF THE HPGR CIRCUIT AT NEWMONT BODDINGTON GOLD''', SAG 2011 paper number 41.

''Hart, S., Rees T., Tavani, S., Valery W. and Jankovic, A.'' '''PROCESS INTEGRATION AND OPTIMISATION OF THE BODDINGTON HPGR CIRCUIT''', SAG 2011 paper number 126

* Primary crusher product (model F80) approximately 160 mm
* Secondary crushing circuit 4×MP1000 crushers, typically using about 60% of power draw
* Tertiary crushing circuit 4×2.4 m by 1.65 m HPGR, each with two 2.8 MW drives
* Fine screen aperture 10 mm
* Ball mill 26 ft diam by 44 ft long with twin-pinion 8 MW drives

Plant survey conducted April 2010. Ore sample was sent to local laboratory (assumed to be ALS Ammtec) gave following determinations:
* UCS 135 MPa
* WiC 27.7 (metric)
* WiRM 20.0 (metric)
* WiBM 14.4 (metric)
* DWi 9.3; A×b 30
* Bond Ai 0.52

Plant operating parameters:
* throughput 1100 t/h per line × 4 lines = 4400 t/h
* secondary crusher specific energy consumption 0.50 kWh/t with product size about 60-66 mm
* HPGR specific energy consumption 1.60 kWh/t
* overall Ecrush 2.10 kWh/t
* HPGR circuit product size (T80) 6 mm
* ball mills drawing about 14 MW (assumed DCS, works out to 13.0 MW at mill shell)
* Eball = 13000 kW / 1100 t/h = 11.82 kWh/t (at shell)
* circuit P80 ranged from 92 to 128 µm (use 100 µm)

===Sources, other===
[http://www.straits.com.au/files/Boddington%20Gold%20Mine%20Milling%20Area%20(MR003).pdf AGC AusGroup project fact sheet].
Photo of the ball mill bay indicates:
* Mills are trunnion mounted. Simulate with Nordberg wet overflow model.
* Motors are induction, use 0.96 as motor efficiency.
* Mechanical drives include gearboxes, use 0.97 motor efficiency to shell.

[http://www.citic-censa.com/LinkClick.aspx?fileticket=Gqz1uLIuNqU%3d&tabid=124 CITIC Censa installation list]
* mill shell is 44.5 ft long (F:F, use 44.0 ft EGL)

==Modelling==
Use the '''Bond/Rowland single stage ball mill''' circuit model with the '''HPGR-BM''' flowsheet.

Circuit model:
* Set the '''Essbm calibration factor''' to 0
* Set the crusher product size to 6000 µ
* Circuit feed size 160 000 µm and product size 100 µm

Ball mill model:
* Use the '''Full Morrell C-model'''
* Mill dimensions, diameter 26 ft, EGL 43.5 ft
* motor mechanical efficiency 0.97; motor efficiency to DCS 0.96
* Assume 6 inch liner thickness, 1.26 k-factor, 7.80 t/m3 ball density.
* To achieve 14 MW at DCS, assume speed is 73% of critical and load is 27 % v/v

← Older revision		Revision as of 22:31, 29 May 2014
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	* MP 1000 crushers, use 1000 HP motor.		* MP 1000 crushers, use 1000 HP motor.
	* set mechanical efficiency to 0.60.		* set mechanical efficiency to 0.60.
			* contribute E<sub>secondary</sub> of 0.50 kWh/t to E<sub>crush</sub>

	[[File:Benchmarking-BoddingtonHPGR.png\|thumb]]		[[File:Benchmarking-BoddingtonHPGR.png\|thumb]]
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	* HPGR motor 5600 kW (actually 2 × 2800 kW)		* HPGR motor 5600 kW (actually 2 × 2800 kW)
	* Adjust the mechanical efficiency to get E<sub>crush</sub> of 1.9 kWh/t (E<sub>HPGR</sub> of 1.4 kWh/t),		* Adjust the mechanical efficiency to get E<sub>crush</sub> of 1.9 kWh/t (E<sub>HPGR</sub> of 1.4 kWh/t),
	** results is mechanical efficiency of 0.28.		** results is mechanical efficiency of 0.30.

	[[File:BenchmarkingModel-Boddington.png\|thumb]]		[[File:BenchmarkingModel-Boddington.png\|thumb]]
	'''Bond/Rowland SSBM Circuit model:'''		'''Bond/Rowland SSBM Circuit model:'''
	* Set the crusher product size to 6000 µ		* Set the crusher product size to 6000 µm
	* Circuit feed size 160 000 µm and product size 100 µm		* Circuit feed size 160 000 µm and product size 100 µm
	* Adjust the '''Essbm calibration factor''' to get E<sub>ball</sub> of 11.8		* Adjust the '''Essbm calibration factor''' to get E<sub>ball</sub> of 11.8
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	** Gives a throughput of 4400 t/h.		** Gives a throughput of 4400 t/h.
	** gives 5% reduction in ball mill operating work index (13.6) versus laboratory Wi (14.4).		** gives 5% reduction in ball mill operating work index (13.6) versus laboratory Wi (14.4).
	* Result is ~~4400~~ t/h circuit throughput with E<sub>total</sub> of 13.78 kWh/t		* Result is 4431 t/h circuit throughput with E<sub>total</sub> of 13.78 kWh/t (close enough)

	==Discussion==		==Discussion==
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	The Bond (impact) crushing work index is given as 27.7 based on a laboratory determination. Use the circuit survey data to compare the operating work index to this laboratory determination.		The Bond (impact) crushing work index is given as 27.7 based on a laboratory determination. Use the circuit survey data to compare the operating work index to this laboratory determination.

	The reported power draws of these MP 1000 crushers were 460+554+583+581 for a total of 2178 kW at the DCS. Use a conversion 0.96 for DCS to "shell" power gives 2090 kW. The secondary crushers are reported to ~~receive~~ a 160 mm primary crushed feed to a 38 mm secondary crushed product. Back-calculating the operating work index of the crusher gives:		The reported power draws of these MP 1000 crushers were 460+554+583+581 for a total of 2178 kW at the DCS. Use a conversion 0.96 for DCS to "shell" power gives 2090 kW. The secondary crushers are reported to process a 160 mm primary crushed feed into a 38 mm secondary crushed product. Back-calculating the operating work index of the crusher gives:

	<math>\frac{2090 kW}{4400 t/h} = 0.475 kWh/t = Wi_{O} \left(\frac{10}{\sqrt{38000}} - \frac{10}{\sqrt{160000}} \right)</math>		<math>\frac{2090 kW}{4400 t/h} = 0.475 kWh/t = Wi_{O} \left(\frac{10}{\sqrt{38000}} - \frac{10}{\sqrt{160000}} \right)</math>