Difference between revisions of "Benchmarking: Specific Energy Consumption Models"

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(→‎Benchmarking: Bond/Barratt - Cadia)
(→‎Benchmarking: Bond/Barratt - Cadia)
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[[Benchmarking: Bond - Cadia East|Show details of benchmarking]]
  
[[Benchmarking: Bond - Cadia East|Show details of benchmarking]]
   
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==Benchmarking: Bond/Barratt - Cadia==
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==Benchmarking: Amelunxen SGI - Agnico Eagle==
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''Dunne, R., Morrell, S., Lane, G., Valery, W. and Hart, S.'', '''Design of the 40 foot diameter SAG mill installed at the Cadia gold copper mine'''. Proceedings of SAG 2001, pages I-43 to I-58.
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''Starkey, J., Robitaille, J., Cousin, P., Jordan, J. and Kosick, G.'', '''Design of the Agnico Eagle Laronde Division SAG Mill'''. Proceedings of SAG 2001, pages III-165 to III-178.
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''Lane, G., Foggiatto, B. and Bueno, M'', '''Power-based comminution calculations using Ausgrind'''. Proceedings of Procemin 2013, Chapter 2, paper 2.
  
   
 
* Survey conducted shortly after start-up
  
* Survey conducted shortly after start-up
   
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Result for default Optimized Bond/Barratt SABC model conditions:
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Result for default Amelunxen SGI SAB model conditions:
 
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[[Benchmarking: Bond - Cadia|Show details of benchmarking]]
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[[Benchmarking: SGI - Agnico Eagle|Show details of benchmarking]]
   
 
==Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Copper Mountain==
  
==Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Copper Mountain==

Revision as of 19:27, 19 May 2015

Benchmarking: Bond/Barratt - Cadia East (underground)

Engelhardt, D., Robertson, J., Lane, G., Powwel, M.S. and Griffin, P., Cadia Expansion - From open pit to block cave and beyond. Proceedings of MetSoc 2012.

  • Design criteria and plant trial of underground Cadia East ore
  • Ore was blasted underground and had F80 = 80 mm on surface

Result for default Optimized Bond/Barratt SABC model conditions:

ESAG Eball Etotal
Model 12.2 kWh/t 15.1 kWh/t 27.7 kWh/t 1294 t/h
Measured 10.6 kWh/t 13.2 kWh/t 23.8 kWh/t 1482 t/h
Difference 1.6 kWh/t 1.9 kWh/t 3.9 kWh/t -188 t/h
Difference 15% 14% 16% -13%

Show details of benchmarking

Benchmarking: Amelunxen SGI - Agnico Eagle

Starkey, J., Robitaille, J., Cousin, P., Jordan, J. and Kosick, G., Design of the Agnico Eagle Laronde Division SAG Mill. Proceedings of SAG 2001, pages III-165 to III-178.

  • Survey conducted shortly after start-up

Result for default Amelunxen SGI SAB model conditions:

Esag Epeb Ebm Etotal t/h
Predicted - 167
Survey 8.6 - 8 16.6 2065
Difference -
Difference -

Show details of benchmarking

Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Copper Mountain

  • Morrison, R., Current Plant Conditions at Copper Mountain. Presentation to the BC/Yukon Branch Canadian Mineral Processors, November 29, 2012; Vancouver, Canada.

Result for default Optimized Bond/Barratt model conditions:

Tonnage
Model 1455 t/h
Measured 1600 t/h
Difference 145 t/h
Difference 9.5%


Show details of benchmarking

Benchmarking: Bond/Barratt SAG Mill Specific Energy Consumption - Esperanza

  • Villanueva, F. and Soto, L., SEC and the impact on a mills selection for DMC project. Proceedings of the XXVII International Mineral Processing Congress, October 2014, Santiago, Chile. C14-23.

Paper describes modelling of two expansion cases (Esperanza Sur and Encuentro). Some operating data for the current Esperanza pit & plant are provided as they were used to tune the comminution models used for the expansion cases.

Average ore
Measured SAG specific energy consumption, kWh/t 5.5
Predicted SAG specific energy consumption, kWh/t 5.9
Difference, kWh/t 0.4
Difference, % model predicts 7% high

Show details of benchmarking

Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Fort Knox

  • Magnuson, R.; Hallow, J.; Mosher, J.; Major, K., The Fort Knox Mill: Design, Commissioning and Operation. Proceedings of the SAG 2001 Conference, Vancouver, Canada.

Optimized Bond/Barratt SABC circuit (10% Essbm calibration factor).

Result for default model conditions:

Etotal WiO Tonnage
Model 11.43 15.90 kWh/t 1,607 t/h
Measured 10.50 14.61 kWh/t 1,733 t/h
Difference 0.93 1.29 kWh/t 126 t/h
Difference 8.9% 8.8% 7.3%

Model predicts 8.9% harder than survey resulting in predicted throughput 7.3% lower than survey.

Show details of benchmarking

Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Kanowna Belle

Lunt, D.J., Thompson, A. and Ritchie, I. The Design and Operation of the Kanowna Belle Milling Circuit, SAG 1996, Pages 81-96.

Survey Optimized
Model		 Difference
ESAG 12.55 kWh/t 13.27 kWh/t +5.7%
Eball 9.70 kWh/t 10.24 kWh/t +5.6%
Epeb 0.99 kWh/t 1.04 kWh/t +5.2%
Etotal 23.24 kWh/t 24.55 kWh/t +5.6%

Two possible circuit models were tested, and the Optimized Bond/Barratt SABC model better matches the survey than the Raw Bond/Barratt model.

Show details of benchmarking

Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Meadowbank

  • Muteb, P. & Allaire, J., Meadowbank Mine Process Plant Throughput Increase, Proceedings of the Canadian Mineral Processors Annual General Meeting, Ottawa, Canada, January 2013.

Paper describes a "sick" SAG mill and the changes made to "bring it to health". The "healthy" mill conditions benchmark as follows:

  • Actual SAG/ball motor powers (at shell): 3,168 kW / 4,105 kW
  • Actual daily average throughput: 500 tonnes/hour
  • Predicted SAG/ball motor powers (at shell): 3,096 kW / 4,182 kW
  • Predicted nominal throughput: 500 tonnes/hour (0% difference)
SAG Ball Mill total
Measured specific energy consumption, kWh/t 6.34 8.21 14.55
Predicted specific energy consumption, kWh/t 6.19 8.36 14.55
Difference, kWh/t -0.15 0.15 0.00
Difference, % -2.3% 1.8% 0.0%

Show details of benchmarking

Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Macraes

Barns, K., Lane, G., Osten, K. & Scagliotta, N., Benchmarking Energy Efficiency - A Case Study at Macraes Gold Mine, Proceedings of the AusIMM MetPlant conference, Perth, Australia, September 2004.

Difference between model results and plant surveys:

Survey 5 Survey 4 Survey 3 Survey 2 Survey 1 Overall
Average
SAG specific power -5.3% -5.0% 6.3% 0.5% 2.2% -0.2%
ball mill specific power -6.3% -4.7% 3.6% 1.9% 3.2% -0.5%
total specific power -6.8% -3.8% 5.4% 1.4% 2.9% -0.2%

Show details of benchmarking


Benchmarking: Bond/Barratt ABC Circuit Specific Energy Consumption - Santa Rita

Latchireddi, S. & Faria, E., Achievement of High Energy Efficiency in Grinding Mills at Santa Rita, Proceedings of the Canadian Mineral Processors Annual General Meeting, Ottawa, Canada, January 2013.

Faria, E. & Latchireddi, S., Commissioning and Operation of Milling Circuit at Santa Rita Nickel Operation, Paper #137: Proceedings of the International Autogenous Grinding, Semiautogenous Grinding and High Pressure Grinding Roll Technology Conference, Vancouver, Canada, September 2011.

FAG BM Pebble
Crusher		 total
Measured specific energy consumption, kWh/t 9.55 7.28 0.34 17.18
Predicted specific energy consumption, kWh/t 9.78 8.33 0.39 18.50
Difference, kWh/t 0.23 1.05 0.05 1.32
Difference, % 2.4% 14.4% 14.7% 7.7%

Show details of benchmarking

Benchmarking: Bond/Rowland SSBM Circuit Specific Energy Consumption - Boddington

The Bond/Rowland SSBM model was fit to the observed operation of the Boddington HPGR circuit. The fitting parameters are:

  • Essbm calibration factor: (-0.13)
  • Mechanical efficiency of HPGR crushers: 0.28.

Because the model is specifically fit to the Boddington data, it doesn't make any meaningful throughput predictions, but the following predictions are available:

  • Ball mill operating work index reduction versus laboratory: 5% (microcracking/phantom cyclone effect)
  • Secondary crusher WiO is 18.1 kWh/tonne (versus laboratory determination 27.7 kWh/t).

Show details of benchmarking

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