Benchmarking: Specific Energy Consumption Models
Contents
- 1 Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Copper Mountain
- 2 Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Fort Knox
- 3 Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Kanowna Belle
- 4 Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Meadowbank
- 5 Benchmarking: Bond/Barratt SABC Circuit Specific Energy Consumption - Macraes
- 6 Benchmarking: Bond/Barratt ABC Circuit Specific Energy Consumption - Santa Rita
- 7 Benchmarking: Bond/Rowland SSBM Circuit Specific Energy Consumption - Boddington
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 model conditions:
| Tonnage | |
|---|---|
| Model | 1455 t/h |
| Measured | 1600 t/h |
| Difference | 145 t/h |
| Difference | 9.5% |
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.
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 | Raw Model | Difference | |
|---|---|---|---|---|---|
| ESAG | 12.55 kWh/t | 13.27 kWh/t | +5.7% | 15.70 kWh/t | +25.1% |
| Eball | 9.70 kWh/t | 10.24 kWh/t | +5.6% | 12.12 kWh/t | +24.9% |
| Epeb | 0.99 kWh/t | 1.04 kWh/t | +5.2% | 1.23 kWh/t | +24.5% |
| Etotal | 23.24 kWh/t | 24.55 kWh/t | +5.6% | 29.05 kWh/t | +25.0% |
The Optimized Bond/Barratt SABC model better matches the survey than the Raw Bond/Barratt model.
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% |
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% |
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% |
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).
