How to design a new circuit

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How to design a new circuit

This How-To explains how to design a brand new circuit for a new mining project where grindability testing exists, but there is presently no existing grinding circuit. This is commonly described as a "greenfield design".

A SAG-mill and ball mill circuit is assumed for the purpose of this description. Other types of circuits follow the same overall work flow.


  1. Create a new project in your work area (your Administrator must do this).
    1. Make sure that the appropriate users have been given access to the project
  2. Load the project's testwork into the database.
  3. Create a new circuit model and select an appropriate Specific Energy model for the testing that has been done on this project.
    1. If the program has the three work index values, choose a Bond/Barratt SAB or SABC model
    2. If the program has results of an SMC™ test and the full details of a Ball mill work index test, choose a SMC model
    3. If the program has results of an SGI or SPI™ test and a Ball mill work index test, choose a SGI model
  4. Enter the default circuit configuration: the flowsheet type, feed size, product size, etc.
  5. When presented with the flowsheet page, the circuit will display an error because no mills are assigned to the circuit yet.
    1. Click the green + Primary Mills(s) button and add a SAG or AG mill to the circuit
    2. Click the green + Secondary Mills(s) button and add a ball mill to the circuit
    3. (optional) Click the green + Crushers(s) button and add a pebble crusher to the circuit

That's it. The circuit simulation should now show a simulation result for the first sample (that satisfies the circuit model testwork requirements). Click the View result of this circuit for all samples to run a batch simulation of this circuit for all the available samples.