Benchmarking: Morrell Mih - Tropicana - Revision history

Alex Doll: /* Modelling */

2026-01-30T11:32:00Z

Modelling

← Older revision		Revision as of 11:32, 30 January 2026
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	* (optional) Set the conveyor lift height to 30 m		* (optional) Set the conveyor lift height to 30 m
	* Result is 745 t/h circuit throughput with E<sub>total</sub> of 20.5 kWh/t (excluding auxiliary equipment)		* Result is 745 t/h circuit throughput with E<sub>total</sub> of 20.5 kWh/t (excluding auxiliary equipment)
	* Predicts 1% increase in ball mill operating work index (17.75) versus laboratory Wi (17.5).		* Predicts 6% increase in ball mill operating work index (18.7) versus laboratory Wi (17.5).

	==Discussion==		==Discussion==

Alex Doll: /* Discussion */

2018-06-14T15:05:11Z

Discussion

← Older revision		Revision as of 15:05, 14 June 2018
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	\| E<sub>secCr</sub> \|\| 0.52 kWh/t \|\| 0.40 kWh/t \|\| model 30% high		\| E<sub>secCr</sub> \|\| 0.52 kWh/t \|\| 0.40 kWh/t \|\| model 30% high
	\|-		\|-
	\| E<sub>hpgr</sub> \|\| 2.83 kWh/t \|\| 2.60 kWh/t \|\| model 9% high		\| E<sub>hpgr</sub> \|\| 2.81 kWh/t \|\| 2.60 kWh/t \|\| model 8% high
	\|-		\|-
	\| E<sub>ball</sub> \|\| 18.36 kWh/t \|\| 16.77 kWh/t \|\| model 9% high		\| E<sub>ball</sub> \|\| 18.41 kWh/t \|\| 16.77 kWh/t \|\| model 10% high
	\|-		\|-
	\| E<sub>total</sub> \|\| 21.70 kWh/t \|\| 19.77 kWh/t \|\| model 10% high		\| E<sub>total</sub> \|\| 21.74 kWh/t \|\| 19.77 kWh/t \|\| model 10% high
	\|}		\|}

	The Morrell model results using SMC and ball mill laboratory tests is about 10% conservative versus the survey results. This is not a bad result considering the variation in laboratory result (A×b) observed and how neither the SMC test nor the ball mill test were originally created to deal with HPGR technology.		The Morrell model results using SMC and ball mill laboratory tests is about 10% conservative versus the survey results. This is not a bad result considering the variation in laboratory result (A×b) observed and how neither the SMC test nor the ball mill test were originally created to deal with HPGR technology.

	The throughput determined by the ball mill treatment rate is ~~710~~ t/h, versus observed 734 t/h (model is 3% conservative, an excellent prediction).		The throughput determined by the ball mill treatment rate is 708 t/h, versus observed 734 t/h (model is 4% conservative, an excellent prediction).

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

Alex Doll: /* Modelling */

2018-06-14T15:02:35Z

Modelling

← Older revision		Revision as of 15:02, 14 June 2018
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	'''HPGR model:'''		'''HPGR model:'''
	* Quantity 1		* Quantity 1.
	* HPGR motor 4400 kW (actually 2 × 2200 kW)		* HPGR motor 4400 kW (actually 2 × 2200 kW).
	* set mechanical efficiency to 0.50 to avoid limiting the throughput		* set mechanical efficiency to 0.50 to avoid limiting the throughput (would be 0.45 to match plant kW draw).

Alex Doll: /* Modelling */

2018-06-14T15:02:00Z

Modelling

← Older revision		Revision as of 15:02, 14 June 2018
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	* Secondary crushing, '''E<sub>secCr</sub>''' = 0.63 × MiEquation(Mic = 7.75, F80 = 35000 µm, P80 = 3500 µm) × 1.0 = '''0.52 kWh/t'''		* Secondary crushing, '''E<sub>secCr</sub>''' = 0.63 × MiEquation(Mic = 7.75, F80 = 35000 µm, P80 = 3500 µm) × 1.0 = '''0.52 kWh/t'''
	* HPGR, '''E<sub>hpgr</sub>''' = 0.84 × MiEquation(Mih = 14.89, F80 = 35000 µm, P80 = 6000 µm) × 1.0 = '''2.81 kWh/t'''		* HPGR, '''E<sub>hpgr</sub>''' = 0.84 × MiEquation(Mih = 14.89, F80 = 35000 µm, P80 = 6000 µm) × 1.0 = '''2.81 kWh/t'''
	* Ball mill, '''E<sub>ball</sub>''' = MiEquation(20.21, 750.0, 3500.0) × 1.000 + MiEquation(25.390, 75.0, 750.0) = '''22.58 kWh/t'''		* Ball mill, '''E<sub>ball</sub>''' = MiEquation(20.21, 750.0, 3500.0) × 1.000 + MiEquation(25.390, 75.0, 750.0) = '''18.41 kWh/t'''

	'''Ball mill model:'''		'''Ball mill model:'''
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	* Quantity 1.		* Quantity 1.
	* XL900 crushers, use 900 HP motor.		* XL900 crushers, use 900 HP motor.
	* set mechanical efficiency to 0.55 so that sec crushing isn't limiting the throughput (would be 0.45 to match plant kW draw).		* set mechanical efficiency to 0.6 so that sec crushing isn't limiting the throughput (would be 0.45 to match plant kW draw).


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	* Quantity 1		* Quantity 1
	* HPGR motor 4400 kW (actually 2 × 2200 kW)		* HPGR motor 4400 kW (actually 2 × 2200 kW)
			* set mechanical efficiency to 0.50 to avoid limiting the throughput

Alex Doll: /* Modelling */

2018-06-14T14:59:37Z

Modelling

← Older revision		Revision as of 14:59, 14 June 2018
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	Using the average A×b = 38.75 for the Primary-Average ore type gives '''Mia = 20.21 kWh/t, Mic = 7.75 kWh/t''' and '''Mih = 14.89 kWh/t'''.		Using the average A×b = 38.75 for the Primary-Average ore type gives '''Mia = 20.21 kWh/t, Mic = 7.75 kWh/t''' and '''Mih = 14.89 kWh/t'''.
	(using an arithmetic average of A×b values is not recommended generally, but won't make a difference to the precision of this survey data).		(using an arithmetic average of A×b values is not recommended generally, but won't make a difference to the precision of this survey data).

			Convert the ball mill work index to an Mib value of 25.39 kWh/t by assuming the test conditions suitable for a Wi of 17.6 metric units:
			* BM test F80: 2300 µm
			* BM test P80: 75 µm (assume same as the circuit design)
			* BM test grams per revolution: 1.01 (calculated based on above)

	The model predictions are:		The model predictions are:
	* Secondary crushing, '''E<sub>secCr</sub>''' = 0.63 × MiEquation(Mic = 7.75, F80 = 35000 µm, P80 = 3500 µm) × 1.0 = '''0.52 kWh/t'''		* Secondary crushing, '''E<sub>secCr</sub>''' = 0.63 × MiEquation(Mic = 7.75, F80 = 35000 µm, P80 = 3500 µm) × 1.0 = '''0.52 kWh/t'''
	* HPGR, '''E<sub>hpgr</sub>''' = 0.84 × MiEquation(Mih = 14.89, F80 = 35000 µm, P80 = 6000 µm) × 1.0 = '''2.81 kWh/t'''		* HPGR, '''E<sub>hpgr</sub>''' = 0.84 × MiEquation(Mih = 14.89, F80 = 35000 µm, P80 = 6000 µm) × 1.0 = '''2.81 kWh/t'''
	* Ball mill, '''E<sub>ball</sub>''' = MiEquation(19.~~982~~, 750.0, 3500.0) × 1.000 + MiEquation(25.390, 75.0, 750.0) = '''18.36 kWh/t'''		* Ball mill, '''E<sub>ball</sub>''' = MiEquation(20.21, 750.0, 3500.0) × 1.000 + MiEquation(25.390, 75.0, 750.0) = '''22.58 kWh/t'''

	'''Ball mill model:'''		'''Ball mill model:'''
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	* Quantity 1.		* Quantity 1.
	* XL900 crushers, use 900 HP motor.		* XL900 crushers, use 900 HP motor.
	* set mechanical efficiency to 0.45 to match plant kW draw.		* set mechanical efficiency to 0.55 so that sec crushing isn't limiting the throughput (would be 0.45 to match plant kW draw).

Alex Doll: /* Modelling */

2018-06-14T14:52:14Z

Modelling

← Older revision		Revision as of 14:52, 14 June 2018
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	==Modelling==		==Modelling==
	Use the '''Morrell SMC HPGR and ball mill''' circuit model with the '''HPGR-BM''' flowsheet. The relationship between a drop weight test A×b and the Mia, Mic and Mih factors (fitted to published information) is:		Use the '''Morrell SMC HPGR and ball mill''' circuit model with the '''HPGR-BM''' flowsheet. The relationship between a drop weight test A×b and the Mia, Mic and Mih factors (fitted to Doll, 2016 published information) is:
	* Mia = ~~392~~.~~18 ×~~ (A×b)<sup>-0.~~814~~</sup>		* Mia = 390.89× (A×b)<sup>-0.81</sup>
	* Mih = ~~580~~.6 × (A×b)<sup>-1.~~000~~</sup>		* Mih = 577.0 × (A×b)<sup>-1.00</sup>
	* Mic = ~~305~~.78 × (A×b)<sup>-1.~~005~~</sup>		* Mic = 303.48 × (A×b)<sup>-1.00</sup>

	[[File:Benchmarking-Tropicana-Mih.png\|thumb\|alt=Screenshot showing model output screen\|Model screenshot]]		[[File:Benchmarking-Tropicana-Mih.png\|thumb\|alt=Screenshot showing model output screen\|Model screenshot]]

	Using the average A×b = 38.75 for the Primary-Average ore type gives '''Mia = 19.98 kWh/t, Mic = 7.75 kWh/t''' and '''Mih = 14.98 kWh/t'''.		Using the average A×b = 38.75 for the Primary-Average ore type gives '''Mia = 20.21 kWh/t, Mic = 7.75 kWh/t''' and '''Mih = 14.89 kWh/t'''.
	(using an arithmetic average of A×b values is not recommended generally, but won't make a difference to the precision of this survey data).		(using an arithmetic average of A×b values is not recommended generally, but won't make a difference to the precision of this survey data).

	The model predictions are:		The model predictions are:
	* Secondary crushing, '''E<sub>secCr</sub>''' = 0.63 × MiEquation(Mic = 7.75, F80 = 35000 µm, P80 = 3500 µm) × 1.0 = '''0.52 kWh/t'''		* Secondary crushing, '''E<sub>secCr</sub>''' = 0.63 × MiEquation(Mic = 7.75, F80 = 35000 µm, P80 = 3500 µm) × 1.0 = '''0.52 kWh/t'''
	* HPGR, '''E<sub>hpgr</sub>''' = 0.84 × MiEquation(~~Mic~~ = 7.75, F80 = 35000 µm, P80 = 6000 µm) × 1.0 = '''2.83 kWh/t'''		* HPGR, '''E<sub>hpgr</sub>''' = 0.84 × MiEquation(Mih = 14.89, F80 = 35000 µm, P80 = 6000 µm) × 1.0 = '''2.81 kWh/t'''
	* Ball mill, '''E<sub>ball</sub>''' = MiEquation(19.982, 750.0, 3500.0) × 1.000 + MiEquation(25.390, 75.0, 750.0) = '''18.36 kWh/t'''		* Ball mill, '''E<sub>ball</sub>''' = MiEquation(19.982, 750.0, 3500.0) × 1.000 + MiEquation(25.390, 75.0, 750.0) = '''18.36 kWh/t'''

Alex Doll: /* Modelling */

2016-04-22T18:26:49Z

Modelling

← Older revision		Revision as of 18:26, 22 April 2016
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	* Mih = 580.6 × (A×b)<sup>-1.000</sup>		* Mih = 580.6 × (A×b)<sup>-1.000</sup>
	* Mic = 305.78 × (A×b)<sup>-1.005</sup>		* Mic = 305.78 × (A×b)<sup>-1.005</sup>

			[[File:Benchmarking-Tropicana-Mih.png\|thumb\|alt=Screenshot showing model output screen\|Model screenshot]]

	Using the average A×b = 38.75 for the Primary-Average ore type gives '''Mia = 19.98 kWh/t, Mic = 7.75 kWh/t''' and '''Mih = 14.98 kWh/t'''.		Using the average A×b = 38.75 for the Primary-Average ore type gives '''Mia = 19.98 kWh/t, Mic = 7.75 kWh/t''' and '''Mih = 14.98 kWh/t'''.

Alex Doll: /* Discussion */

2016-04-22T18:15:36Z

Discussion

← Older revision		Revision as of 18:15, 22 April 2016
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	\|}		\|}

	The Morrell model using SMC and ball mill laboratory ~~test results~~ is about 10% conservative versus the survey results. This is not a bad result considering the variation in laboratory result (A×b) observed and how neither the SMC test nor the ball mill test were originally created to deal with HPGR technology.		The Morrell model results using SMC and ball mill laboratory tests is about 10% conservative versus the survey results. This is not a bad result considering the variation in laboratory result (A×b) observed and how neither the SMC test nor the ball mill test were originally created to deal with HPGR technology.

	The throughput determined by the ball mill treatment rate is 710 t/h, versus observed 734 t/h (model is 3% conservative, an excellent prediction).		The throughput determined by the ball mill treatment rate is 710 t/h, versus observed 734 t/h (model is 3% conservative, an excellent prediction).

Alex Doll: /* Modelling */

2016-04-22T18:14:16Z

Modelling

← Older revision		Revision as of 18:14, 22 April 2016
Line 42:		Line 42:

	==Modelling==		==Modelling==
	Use the '''Morrell SMC and ball mill ~~HPGR~~''' circuit model with the '''HPGR-BM''' flowsheet. The relationship between a drop weight test A×b and the Mia, Mic and Mih factors (fitted to published information) is:		Use the '''Morrell SMC HPGR and ball mill''' circuit model with the '''HPGR-BM''' flowsheet. The relationship between a drop weight test A×b and the Mia, Mic and Mih factors (fitted to published information) is:
	* Mia = 392.18 × (A×b)<sup>-0.814</sup>		* Mia = 392.18 × (A×b)<sup>-0.814</sup>
	* Mih = 580.6 × (A×b)<sup>-1.000</sup>		* Mih = 580.6 × (A×b)<sup>-1.000</sup>

Alex Doll: /* Sources, SAG 2015 conference */

2016-04-22T18:13:38Z

Sources, SAG 2015 conference

← Older revision		Revision as of 18:13, 22 April 2016
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	* ball mill throughput 734 t/h (use this as overall throughput at 91.2% availability)		* ball mill throughput 734 t/h (use this as overall throughput at 91.2% availability)
	* HPGR specific energy consumption, E<sub>HPGR</sub> = 2.60 kWh/t		* HPGR specific energy consumption, E<sub>HPGR</sub> = 2.60 kWh/t
			** power draw back-calculates to 763 t/h × 2.60 = 1984 kW (45% of available power)
	* energy associated to auxiliary equipment in sec crushing & HPGR = 0.70 + 1.08 = 1.78 kWh/t		* energy associated to auxiliary equipment in sec crushing & HPGR = 0.70 + 1.08 = 1.78 kWh/t
	* HPGR circuit product size assumed (T<sub>80</sub>) 3.5 mm		* HPGR circuit product size assumed (T<sub>80</sub>) 3.5 mm