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Developed by Moly-Cop Grinding Systems

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Podremos moler mas Podremos moler mas
Toneladas Toneladas
Si alimentamos Si alimentamos
mas fino...? mas fino...?
Podremos aumentar Podremos aumentar
La potencia del La potencia del
Molino Molino
Necesitaremos ciclones Necesitaremos ciclones
Mas Grandes....? Mas Grandes....?
Necesitare cambiar de Necesitare cambiar de
Bombas..? Bombas..?
Deberiamos aadir Deberiamos aadir
Mas agua..? Mas agua..?
Como Afectara el nuevo Como Afectara el nuevo
Mineral a los molinos..? Mineral a los molinos..?
Necesitaremos um Necesitaremos um
Molino mas...? Molino mas...?
Cual sera la configuracin Cual sera la configuracin
Ideal del cicuito.? SAG o sin SAG..? Ideal del cicuito.? SAG o sin SAG..?
En la mente de un estudioso Ingeniero de procesos
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Moly Moly--Cop Tools Cop Tools Moly Moly--Cop Tools Cop Tools
Moly-Cop Tools es un conjunto de planillas EXCEL2000

Moly-Cop Tools es un conjunto de planillas EXCEL2000


diseadas para ayudar al Ingeniero de Procesos a
caracterizar la eficiencia operacional de un determinado
circuito de molienda, en base a metodologas y criterios de
amplia aceptacin prctica.
Moly-Cop Tools comprende una amplia gama de simuladores
para la molienda convencional y semiautgena bajo las
configuraciones ms usuales; ms algunas planillas
complementarias referentes a la Ley de Bond, el algebra de
las cargas de bolas y otras de utilidad general.
Moly-Cop Tools est disponible, bajo licencia sin cargo, a
travs de la organizacin Moly-Cop.
Moly Moly--Cop Tools Cop Tools
DE QU SE TRATA ? DE QU SE TRATA ?
Moly Moly--Cop Tools Cop Tools
DE QU SE TRATA ? DE QU SE TRATA ?
Moly-Cop Tools est diseado para operar en

Moly-Cop Tools est diseado para operar en


ambiente EXCEL 2000 y por lo tanto, es fcilmente
accesible para cualquier Ingeniero de Procesos con
conocimientos bsicos de planillas de clculo.
A diferencia de otros desarrollos anteriores, Moly -
Cop Tools tiene compatibilidad con otras
aplicaciones de Office 2000 y equipos perifricos.
Moly-Cop Tools imprime los resultados en formatos
flexibles, fcilmente adaptables a las necesidades
de cada ususario.
Moly Moly--Cop Tools Cop Tools
LA VENTAJA LA VENTAJA
Moly Moly--Cop Tools Cop Tools
LA VENTAJA LA VENTAJA
Moly-Cop Tools
TM
: Theoretical Framework
Proceso de Molienda y Clasificacin
Introduccin.
La liberacin de las especies minerales valiosas es sin lugar a dudas
el proceso unitario de mayor importancia en todo circuito de
procesamiento de minerales.
A pesar de su reiterada y reconocida ineficiencia energtica, los
molinos de bolas, operando en circuito cerrado o inverso con
clasificadores hidrulicos, son la alternativa tecnolgica
tradicionalmente seleccionada para la molienda de minerales.
En los ltimos aos se ha avanzado notoriamente en la
caracterizacin matemtica de la molienda de minerales en molinos de
bolas; particularmente en cuanto a la cintica con que tal fenmeno
ocurre, afectado por distintas condiciones operacionales
Moly-Cop Tools
TM
: Theoretical Framework
Tamao de Particula Tamao de Particula
d = (d
1
* d
2
)
0.5
Moly-Cop Tools
TM
: Theoretical Framework
DISTRIBUCION DE TAMAOS DISTRIBUCION DE TAMAOS
% Retained
% Passing
D80 D80
80 80
10
100
10 100 1000 10000
Particle Size, m
%
Moly-Cop Tools
TM
: Theoretical Framework
10
100
10 100 1000 10000
Particle Size, m
%

P
a
s
s
i
n
g
P80 P80 F80 F80
80 80
TAREA DE MOLIENDA TAREA DE MOLIENDA
Product
Feed
DISTRIBUCION DE TAMAOS DISTRIBUCION DE TAMAOS
Moly-Cop Tools
TM
Test ID :
TOTAL SAMPLE WEIGHT, grs 400.00 (Dry)
Mesh Mesh Cumm.
i # Opening Passing
grs % %
1 1.05 25400 0.00 100.00
2 0.742 19050 21.02 5.26 94.75
3 0.525 12700 13.24 3.31 91.44
4 0.371 9500 31.86 7.97 83.47
5 3 6700 62.72 15.68 67.79
6 4 4750 61.77 15.44 52.35
7 6 3350 46.39 11.60 40.75
8 8 2360 30.20 7.55 33.20
9 10 1700 18.25 4.56 28.64
10 14 1180 13.71 3.43 25.21
11 20 850 9.04 2.26 22.95
12 28 600 7.76 1.94 21.01
13 35 425 6.62 1.66 19.36
14 48 300 6.03 1.51 17.85
15 65 212 5.54 1.39 16.46
16 100 150 5.16 1.29 15.17
17 150 106 4.85 1.21 13.96
18 200 75 4.53 1.13 12.83
19 270 53 4.25 1.06 11.77
20 400 38 3.81 0.95 10.81
21 -400 0 43.25 10.81
TOTAL 400.00 100.00 D80 = 8847 m D50 = 4456 m
Retained
Weight
PARTICLE SIZE DISTRIBUTION
Sample 1
1
10
100
10 100 1000 10000 100000
Particle Size, microns
%

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Moly-Cop Tools
TM
Test ID :
TOTAL SAMPLE WEIGHT, grs 400.00 (Dry)
Mesh Mesh Cumm.
i # Opening Passing
grs % %
1 1.05 25400 0.00 100.00
2 0.742 19050 21.02 5.26 94.75
3 0.525 12700 13.24 3.31 91.44
4 0.371 9500 31.86 7.97 83.47
5 3 6700 62.72 15.68 67.79
6 4 4750 61.77 15.44 52.35
7 6 3350 46.39 11.60 40.75
8 8 2360 30.20 7.55 33.20
9 10 1700 18.25 4.56 28.64
10 14 1180 13.71 3.43 25.21
11 20 850 9.04 2.26 22.95
12 28 600 7.76 1.94 21.01
13 35 425 6.62 1.66 19.36
14 48 300 6.03 1.51 17.85
15 65 212 5.54 1.39 16.46
16 100 150 5.16 1.29 15.17
17 150 106 4.85 1.21 13.96
18 200 75 4.53 1.13 12.83
19 270 53 4.25 1.06 11.77
20 400 38 3.81 0.95 10.81
21 -400 0 43.25 10.81
TOTAL 400.00 100.00 D80 = 8847 m D50 = 4456 m
Retained
Weight
PARTICLE SIZE DISTRIBUTION
Sample 1
1
10
100
10 100 1000 10000 100000
Particle Size, microns
%

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Utilities_Size Distribution
Moly-Cop Tools
TM
: Theoretical Framework
El consumo especifico de energa
El consumo especifico de energa es el parmetro controlante del proceso,
conocido como la cantidad de energa mecnica aplicada a cada masa
unitaria de partculas la que determina en gran medida la fineza de los
fragmentos resultantes.
Existe una relacion entre el Existe una relacion entre el
Consumo Especifico de Energia Consumo Especifico de Energia
y el y el
Resultante.......... Resultante..........
Es decir: Es decir:
Existe una relacion entre el Existe una relacion entre el
Consumo Especifico de Energia Consumo Especifico de Energia
y el y el tamao de producto tamao de producto
Resultante.......... Resultante..........
Es decir: Es decir:
A mas A mas kWh/ton kWh/ton, menor , menor P80 P80 !!
Moly-Cop Tools
TM
: Theoretical Framework
Leyes de la Molienda
" La energa consumida para reducir el tamao 80% de un material es inversamente
proporcional a la raz cuadrada del tamao 80%; siendo este ultimo igual a la abertura del
tamiz que deja pasar el 80% en peso de las partculas"
|
.
|

\
|
=
80
1
80
1
* * 10
F P
Wi E
Ley de
Bond

Moly-Cop Tools
TM
: Theoretical Framework
En la expresin anterior el par F80 y P80 se les denomina tarea de molienda; as mismo
permite estimar la energa (Kwhr) requerida para moler cada unidad (ton) de mineral.
Resulta Obvio que un aumento en la potencia (P), debiera traducirse en un aumento de
la capacidad (M)
M
P
E =
Leyes de la Molienda
Ley de
Bond
Moly-Cop Tools
TM
: Theoretical Framework
4
5
6
7
8
9
10
11
12
80 100 120 140 160 180 200 220 240 260
Product Size, m
S
p
e
c

f
i
c

E
n
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y
,

k
W
h
/
t
o
n
Feed Size
4000 m
2000 m
1000 m
The Bonds Lawhelps quantify the
relationship between the Specific
Energy Consumption, the original
Feed Size (F80) and the resulting
Product Size (P80).
Efecto del tamao de Alimentacin Efecto del tamao de Alimentacin
Ley de Bond Ley de Bond
Moly-Cop Tools
TM
: Theoretical Framework
Limitaciones y deficiencias de las teoras
clsicas de la conminucin
Primero, el procedimiento de Bond utiliza un solo tamiz de
separacin para simular la malla de corte, es decir se realiza una
clasificacin ideal, lo cual es imposible de alcanzar a nivel
industrial.
Segundo, las condiciones de equilibrio alcanzadas en un test de
laboratorio corresponden a estado estacionario alcanzado en un
molino plug flow de flujo piston. Es decir en el metodo de Bond
no considera que los molinos no actuan como mezcladores de
pulpa ademas de moler las particulas de mineral. Las
caracteristicas dinmicas de transporte de pulpa en el molino
normalmente se situan entre los casos extremos de mezcla
perfecta y flujo piston.
Moly-Cop Tools
TM
: Theoretical Framework
Limitaciones y deficiencias de las teoras
clsicas de la conminucin
Tercero, se supone tambin en forma implcita que todos los
materiales se fracturan de una manera similar, es decir de acuerdo
a las caractersticas tpicas de un material ideal dicho material se
caracteriza por tener una distribucin RR, con una pendiente igual
a 0.5.
Cuarto, en el mtodo de Bond se utilizan solo 3 parmetros para
calcular el consumo de energa en la molienda, ellos son el WI, F(0
y P80, el concepto de Wi, engloba todo el proceso de fractura, es
por ello que se ha debido incluir una serie de factores de
correccin a fin de tomar en cuenta el efecto de diversas variables
de operacin.
Moly-Cop Tools
TM
: Theoretical Framework
Corresponde a la velocidad de rotacion N del molino;
normalmente expresado como la fracccin N
c
de la
velocidad critica del molino N
crit

N = N
c
N
crit
Corresponde a la velocidad de rotacion N del molino;
normalmente expresado como la fracccin N
c
de la
velocidad critica del molino N
crit

N = N
c
N
crit
N
crit
VELOCIDAD DE ROTACION DEL MOLINO VELOCIDAD DE ROTACION DEL MOLINO
N
crit
= ( 76.6 / D
0.5
)
donde D en ft y N en rpm.
Moly-Cop Tools
TM
: Theoretical Framework
Modelo Hogg & Fuerstenau Modelo Hogg & Fuerstenau
ECUACION DE LA POTENCIA ECUACION DE LA POTENCIA

oo
W sin W sinoo
WW
NN
P
net
= c W sino N
Torque
with :
W =
ap
J (tD
2
/4) L
c/D ~ 0.447 - 0.476 J
PP
net net
= 0.238 D = 0.238 D
3.5 3.5
(L/D) N (L/D) N
cc

ap ap
( J ( J -- 1.065 J 1.065 J
2 2
) s ) siin n oo
oo
0.0000
0.0100
0.0200
0.0300
0.0400
0.0500
0 5 10 15 20 25 30 35 40 45
Effective Mill Diameter, ft
(
k
W
h
/
t
o
n
)
/
r
e
v












.
Conventional
SAG
J = 26 %
o = 40
J = 38 %
o = 32
Modelo Hogg & Fuerstenau Modelo Hogg & Fuerstenau
VALIDACION DE LA ECUACION DE LA POTENCIA VALIDACION DE LA ECUACION DE LA POTENCIA
Modelo Hogg & Fuerstenau Modelo Hogg & Fuerstenau
VALIDACION DE LA ECUACION DE LA POTENCIA VALIDACION DE LA ECUACION DE LA POTENCIA
No basta con tener
Potencia disponible,
tambin hay que saber
Usarla con Eficiencia !
Moly-Cop Tools
TM
: Theoretical Framework
AREA ESPECIFICA DE LA CARGA DE BOLAS AREA ESPECIFICA DE LA CARGA DE BOLAS
Se ha demostrado que la variable nica y controlante del
efecto de la carga de bolas sobre los parmetros cinticos
es su rea rea especfica especfica a, a, definida como la superficie
expuesta al impacto (m2) por unidad de volumen aparente
de carga (m3)
a
f
d
v
B
R
=
8000 1 *( )
La expresin anterior destaca la relacin
lineal inversa entre el tamao de recarga y el
rea especfica generada.
De esta manera, cuando se recarga bolas
ms grandes, el rea expuesta ser menor
que cuando se recarga bolas ms pequeas.
0
20
40
60
80
100
1 10 100
F80 Fresh Feed Ore, mm
C
h
a
r
g
e

A
r
e
a
,

m
2
/
m
3
Conventional Grinding
SAG Grinding
Current Technology Limit
2
2
3
4

5
6
8
AREA ESPECIFICA DE LA CARGA DE BOLAS AREA ESPECIFICA DE LA CARGA DE BOLAS
Planilla Planilla Media Charge_Level Media Charge_Level ... ...
Moly-Cop Tools
TM
Remarks :
Effective Mill Diameter 12.00
Average Measurements of
Free Height (h) : 7.32
Angle |, degrees 154.66
Charge Level, % 36.15
by Measuring Free Height Above the Charge
DETERMINATION OF CHARGE LEVEL IN A MILL
Molino 1
0
10
20
30
40
50
60
0.50 0.60 0.70 0.80 0.90 1.00
h/D Ratio
%

F
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l
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g
Moly-Cop Tools
TM
Remarks :
Effective Mill Diameter 12.00
Average Measurements of
Free Height (h) : 7.32
Angle |, degrees 154.66
Charge Level, % 36.15
by Measuring Free Height Above the Charge
DETERMINATION OF CHARGE LEVEL IN A MILL
Molino 1
0
10
20
30
40
50
60
0.50 0.60 0.70 0.80 0.90 1.00
h/D Ratio
%

F
i
l
l
i
n
g
hh
|
Media Charge Level
Planilla Planilla Mill Power_Ball Mills Mill Power_Ball Mills ... ...
Moly-Cop Tools
TM
Remarks Molino 1.

Mill
Power, kW
Mill Dimensions and Operating Conditions 804 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 129 Slurry
12.00 15.50 72.00 36.00 36.00 100.00 36.00 933 Net Total
rpm 15.92 10.00 % Losses
1036 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 17.91 83.26 13.33 0.00 5.395
Mill Charge Weight, tons
CONVENTIONAL BALL MILL POWER ESTIMATION
Slurry
Hogg & Fuerstenau Model
Moly-Cop Tools
TM
Remarks Molino 1.

Mill
Power, kW
Mill Dimensions and Operating Conditions 804 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 129 Slurry
12.00 15.50 72.00 36.00 36.00 100.00 36.00 933 Net Total
rpm 15.92 10.00 % Losses
1036 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 17.91 83.26 13.33 0.00 5.395
Mill Charge Weight, tons
CONVENTIONAL BALL MILL POWER ESTIMATION
Slurry
Hogg & Fuerstenau Model
Mill
Power, kW
Mill Dimensions and Operating Conditions 831 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 133 Slurry
12.00 15.50 72.00 40.00 40.00 100.00 36.00 965 Net Total
rpm 15.92 10.00 % Losses
1072 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 19.89 92.51 14.82 0.00 5.395
Mill Charge Weight, tons
Slurry
3.4 % Mayor Potencia 3.4 % Mayor Potencia
M
i
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P
o
w
e
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_
B
a
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l

M
i
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s
Planilla Planilla Bond_Op. Work Index Bond_Op. Work Index .. ..Caso Base Caso Base..
Moly-Cop Tools
TM
Remarks Molino 1.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 13.03 Specific Energy, kWh/ton 9.33
Feed Size, F80, microns 9795 Net Power Available, kW 933
Product Size, P80, microns 150.0 Number of Mills for the Task 1
Total Plant Throughput, ton/hr 100.00 Net kW / Mill 933
Mill
MILL DIMENSIONS AND OPERATING CONDITIONS : Power, kW
804 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 129 Slurry
12.00 15.50 72.00 36.00 36.00 100.00 36.00 933 Net Total
L/D rpm 10.0 % Losses
1.29 15.92 1036 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 17.91 83.26 13.33 0.00 5.395
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Estimation of the Operating Work Index from Plant Data
Moly-Cop Tools
TM
Remarks Molino 1.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 13.03 Specific Energy, kWh/ton 9.33
Feed Size, F80, microns 9795 Net Power Available, kW 933
Product Size, P80, microns 150.0 Number of Mills for the Task 1
Total Plant Throughput, ton/hr 100.00 Net kW / Mill 933
Mill
MILL DIMENSIONS AND OPERATING CONDITIONS : Power, kW
804 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 129 Slurry
12.00 15.50 72.00 36.00 36.00 100.00 36.00 933 Net Total
L/D rpm 10.0 % Losses
1.29 15.92 1036 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 17.91 83.26 13.33 0.00 5.395
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Estimation of the Operating Work Index from Plant Data
Planilla Planilla Bond_Mill Throughput Bond_Mill Throughput ... ...
Moly-Cop Tools
TM
Remarks Molino 1.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 13.03 Specific Energy, kWh/ton 9.33
Feed Size, F80, microns 9795 Net Power Available, kW 965
Product Size, P80, microns 150.0 Number of Mills for the Task 1
Total Plant Throughput, ton/hr 103.43 Net kW / Mill 965
Mill
MILL DIMENSIONS AND OPERATING CONDITIONS : Power, kW
831 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 133 Slurry
12.00 15.50 72.00 40.00 40.00 100.00 36.00 965 Net Total
L/D rpm 10.0 % Losses
1.29 15.92 1072 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 19.89 92.51 14.82 0.00 5.395
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Estimation of a Conventional Ball Mill Grinding Capacity
Moly-Cop Tools
TM
Remarks Molino 1.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 13.03 Specific Energy, kWh/ton 9.33
Feed Size, F80, microns 9795 Net Power Available, kW 965
Product Size, P80, microns 150.0 Number of Mills for the Task 1
Total Plant Throughput, ton/hr 103.43 Net kW / Mill 965
Mill
MILL DIMENSIONS AND OPERATING CONDITIONS : Power, kW
831 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 133 Slurry
12.00 15.50 72.00 40.00 40.00 100.00 36.00 965 Net Total
L/D rpm 10.0 % Losses
1.29 15.92 1072 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 19.89 92.51 14.82 0.00 5.395
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Estimation of a Conventional Ball Mill Grinding Capacity
3.4 % Mayor Capacidad 3.4 % Mayor Capacidad
Las Odiosas Las Odiosas
Limitantes Operacionales Limitantes Operacionales
Debemos cuidar de no exceder la Debemos cuidar de no exceder la
potencia mxima del motor. potencia mxima del motor.
Adems, e Adems, es preciso reconocer que, por s preciso reconocer que, por
su su geometra y diseo, no todos los geometra y diseo, no todos los
molinos molinos industriales aceptan los mismos industriales aceptan los mismos
niveles niveles mximos mximos de llenado de llenado.. EEn particular n particular,,
los del tipo overflow, de gran dimetro, los del tipo overflow, de gran dimetro,
normalmente limitados a llenados normalmente limitados a llenados
inferiores al 40%. inferiores al 40%.
En general, niveles superiores al 42% de En general, niveles superiores al 42% de
llenado slo incrementan los consumos llenado slo incrementan los consumos
de bolas, sin lograr a cambio un de bolas, sin lograr a cambio un
correspondiente incremento en la tasa de correspondiente incremento en la tasa de
tratamiento. tratamiento.
Mandamiento #1 Mandamiento #1 Mandamiento #1 Mandamiento #1
Moly-Cop Tools
TM
Remarks Base Case Example

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 13.03 Specific Energy, kWh/ton 9.33
Feed Size, F80, microns 9795 Net Power Available, kW 1018
Product Size, P80, microns 150.0 Number of Mills for the Task 1
Total Plant Throughput, ton/hr 109.18 Net kW / Mill 1018
Mill
MILL DIMENSIONS AND OPERATING CONDITIONS : Power, kW
878 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 141 Slurry
12.00 15.50 76.00 40.00 40.00 100.00 36.00 1018 Net Total
L/D rpm 10.0 % Losses
1.29 16.81 1131 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 19.89 92.51 14.82 0.00 5.395
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Estimation of a Conventional Ball Mill Grinding Capacity
Planilla Planilla Bond_Mill Throughput Bond_Mill Throughput ... ...
5.6 % Mayor Capacidad 5.6 % Mayor Capacidad
Las Odiosas Las Odiosas
Limitantes Operacionales Limitantes Operacionales
Debemos cuidar de no exceder la Debemos cuidar de no exceder la
potencia mxima del motor. potencia mxima del motor.
AAumentan los riesgos de impactos bola umentan los riesgos de impactos bola //
revestimiento revestimientoss y los resultantes daos a y los resultantes daos a
estos ltimos, afectando negativamente la estos ltimos, afectando negativamente la
disponibilidad operacional del equipo. disponibilidad operacional del equipo.
En el extremo, la carga de bolas puede En el extremo, la carga de bolas puede
llegar a impactar preferentemente a las llegar a impactar preferentemente a las
barras levantadoras del extremo opuesto, barras levantadoras del extremo opuesto,
imperando una condicin de volante de imperando una condicin de volante de
inercia, caracterizada por una inercia, caracterizada por una
disminucin de la potencia demandada. disminucin de la potencia demandada.
Mandamiento #2 Mandamiento #2 Mandamiento #2 Mandamiento #2
Moly-Cop Tools
TM
Remarks Molino 1.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 13.03 Specific Energy, kWh/ton 9.08
Feed Size, F80, microns 7000 Net Power Available, kW 965
Product Size, P80, microns 150.0 Number of Mills for the Task 1
Total Plant Throughput, ton/hr 106.18 Net kW / Mill 965
Mill
MILL DIMENSIONS AND OPERATING CONDITIONS : Power, kW
831 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 133 Slurry
12.00 15.50 72.00 40.00 40.00 100.00 36.00 965 Net Total
L/D rpm 10.0 % Losses
1.29 15.92 1072 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 19.89 92.51 14.82 0.00 5.395
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Estimation of a Conventional Ball Mill Grinding Capacity
Moly-Cop Tools
TM
Remarks Molino 1.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 13.03 Specific Energy, kWh/ton 9.08
Feed Size, F80, microns 7000 Net Power Available, kW 965
Product Size, P80, microns 150.0 Number of Mills for the Task 1
Total Plant Throughput, ton/hr 106.18 Net kW / Mill 965
Mill
MILL DIMENSIONS AND OPERATING CONDITIONS : Power, kW
831 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 133 Slurry
12.00 15.50 72.00 40.00 40.00 100.00 36.00 965 Net Total
L/D rpm 10.0 % Losses
1.29 15.92 1072 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 19.89 92.51 14.82 0.00 5.395
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Estimation of a Conventional Ball Mill Grinding Capacity
Planilla Planilla Bond_Mill Throughput Bond_Mill Throughput ... ...
2.7 % Mayor Capacidad 2.7 % Mayor Capacidad
Las Odiosas Las Odiosas
Limitantes Operacionales Limitantes Operacionales
Debemos disponer de capacidad ociosa Debemos disponer de capacidad ociosa
en la etapa previa de chancado. en la etapa previa de chancado.
La tecnologa actual permite chancar a La tecnologa actual permite chancar a
tamaos tan finos como 1/4, pero tamaos tan finos como 1/4, pero
difcilmente menores. difcilmente menores.
Mandamiento #3 Mandamiento #3 Mandamiento #3 Mandamiento #3
Moly-Cop Tools
TM
Remarks Molino 1.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 13.03 Specific Energy, kWh/ton 8.44
Feed Size, F80, microns 7000 Net Power Available, kW 965
Product Size, P80, microns 170.0 Number of Mills for the Task 1
Total Plant Throughput, ton/hr 114.30 Net kW / Mill 965
Mill
MILL DIMENSIONS AND OPERATING CONDITIONS : Power, kW
831 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 133 Slurry
12.00 15.50 72.00 40.00 40.00 100.00 36.00 965 Net Total
L/D rpm 10.0 % Losses
1.29 15.92 1072 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 19.89 92.51 14.82 0.00 5.395
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Estimation of a Conventional Ball Mill Grinding Capacity
Moly-Cop Tools
TM
Remarks Molino 1.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 13.03 Specific Energy, kWh/ton 8.44
Feed Size, F80, microns 7000 Net Power Available, kW 965
Product Size, P80, microns 170.0 Number of Mills for the Task 1
Total Plant Throughput, ton/hr 114.30 Net kW / Mill 965
Mill
MILL DIMENSIONS AND OPERATING CONDITIONS : Power, kW
831 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 133 Slurry
12.00 15.50 72.00 40.00 40.00 100.00 36.00 965 Net Total
L/D rpm 10.0 % Losses
1.29 15.92 1072 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 19.89 92.51 14.82 0.00 5.395
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Estimation of a Conventional Ball Mill Grinding Capacity
Planilla Planilla Bond_Mill Throughput Bond_Mill Throughput ... ...
7.7 % Mayor Capacidad 7.7 % Mayor Capacidad
Las Odiosas Las Odiosas
Limitantes Operacionales Limitantes Operacionales
Debemos analizar los posibles impactos Debemos analizar los posibles impactos
sobre la eficiencia de las etapas sobre la eficiencia de las etapas
siguientes en la cadena de procesamiento. siguientes en la cadena de procesamiento.
Mandamiento #4 Mandamiento #4 Mandamiento #4 Mandamiento #4
Planilla Planilla Media Charge_Optimal Ball Size Media Charge_Optimal Ball Size ... ...
Moly-Cop Tools
TM
Remarks :
Mill Dimensions and Operating Conditions :
Eff. Diameter, ft 12.00 Eff. Diameter, m 3.66
Eff. Length, ft 15.50 Eff. Length, m 4.73
% Critical Speed 72.00 Mill Speed, rpm 15.92
Ball Dens., ton/m
3
(app) 4.65 Mill Volume, m
3
49.74
Ball Filling, % (app) 40.00 Charge Weight, tons 92.43
Scrap Size, in 0.50
Ore Properties :
Ore Density Work Index Feed Size, F80
ton/m
3
kWh/ton (metric) microns
2.80 13.03 7000
RECOMMENDED OPTIMAL BALL SIZE :
AZZARONI's Formula :
Optimal Ball Size, in 2.77 String Area, m
2
/m
3
67.80
ALLIS CHALMERS' Formula :
Optimal Ball Size, in 2.35 String Area, m
2
/m
3
79.83
OPTIMAL MAKE-UP BALL SIZE
Molino 1.

Moly-Cop Tools
TM
Remarks :
Mill Dimensions and Operating Conditions :
Eff. Diameter, ft 12.00 Eff. Diameter, m 3.66
Eff. Length, ft 15.50 Eff. Length, m 4.73
% Critical Speed 72.00 Mill Speed, rpm 15.92
Ball Dens., ton/m
3
(app) 4.65 Mill Volume, m
3
49.74
Ball Filling, % (app) 40.00 Charge Weight, tons 92.43
Scrap Size, in 0.50
Ore Properties :
Ore Density Work Index Feed Size, F80
ton/m
3
kWh/ton (metric) microns
2.80 13.03 7000
RECOMMENDED OPTIMAL BALL SIZE :
AZZARONI's Formula :
Optimal Ball Size, in 2.77 String Area, m
2
/m
3
67.80
ALLIS CHALMERS' Formula :
Optimal Ball Size, in 2.35 String Area, m
2
/m
3
79.83
OPTIMAL MAKE-UP BALL SIZE
Molino 1.

Planilla Planilla
Media Charge_ Media Charge_
Optimal Ball Size Optimal Ball Size ... ...
(Mixed Strings) (Mixed Strings)
Moly-Cop Tools
TM
Remarks :
Mill Dimensions and Operating Conditions :
Eff. Diameter, ft 12.00 Eff. Diameter, m 3.66
Eff. Length, ft 15.50 Eff. Length, m 4.73
% Critical Speed 72.00 Mill Speed, rpm 15.92
Ball Dens., ton/m
3
(app) 4.65 Mill Volume, m
3
49.74
Ball Filling, % (app) 40.00 Charge Weight, tons 92.43
Scrap Size, in 0.50
Balanced Charge : Overall
String 1 String 2 Charge Area
Top Size, in 2.50 2.00 Current Mix
Specific Area, m2/m3 75.11 93.38 75.11
Recharge Policy, % 100.00 0.00 Target Value
Mill Charge Content, % 100.00 0.00 67.80
Excess Area 7.31
Balanced Charge,
Ball Size, in % Passing % Passing % Retained
2.5 100.00 100.00 36.06
2.0 40.87 100.00 41.03
1.5 12.82 31.37 17.31
1.0 2.40 5.88 5.13
0.5 0.00 0.00 0.48
0.5 0.00 0.00 0.00
0.5 0.00 0.00 0.00
0.5 0.00 0.00 0.00
Weight, tons 92.43 0.00 92.43
Volume, m3 (app) 19.89 0.00 19.89
Area, m2 1494 0 1494
# Balls per ton 3087 5666 3087
BALL CHARGE COMPOSITION AT EQUILIBRIUM
Molino 1.

Planilla Planilla Bond_Op. Work Index Bond_Op. Work Index ... ...
Moly-Cop Tools
TM
Remarks Molino 1, con bolas de 2.5"

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 12.12 Specific Energy, kWh/ton 7.85
Feed Size, F80, microns 7000 Net Power Available, kW 965
Product Size, P80, microns 170.0 Number of Mills for the Task 1
Total Plant Throughput, ton/hr 122.92 Net kW / Mill 965
Mill
MILL DIMENSIONS AND OPERATING CONDITIONS : Power, kW
831 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 133 Slurry
12.00 15.50 72.00 40.00 40.00 100.00 36.00 965 Net Total
L/D rpm 10.0 % Losses
1.29 15.92 1072 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 19.89 92.51 14.82 0.00 5.395
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Estimation of the Operating Work Index from Plant Data
Moly-Cop Tools
TM
Remarks Molino 1, con bolas de 2.5"

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 12.12 Specific Energy, kWh/ton 7.85
Feed Size, F80, microns 7000 Net Power Available, kW 965
Product Size, P80, microns 170.0 Number of Mills for the Task 1
Total Plant Throughput, ton/hr 122.92 Net kW / Mill 965
Mill
MILL DIMENSIONS AND OPERATING CONDITIONS : Power, kW
831 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 133 Slurry
12.00 15.50 72.00 40.00 40.00 100.00 36.00 965 Net Total
L/D rpm 10.0 % Losses
1.29 15.92 1072 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 19.89 92.51 14.82 0.00 5.395
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Estimation of the Operating Work Index from Plant Data
7.5 % Mayor Capacidad 7.5 % Mayor Capacidad
Planilla Planilla Bond_Mill Sizing Bond_Mill Sizing ... ...
Moly-Cop Tools
TM
Remarks Dimensionamiento del Nuevo Molino.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 12.12 Specific Energy, kWh/ton 7.85
Feed Size, F80, microns 7000 Net Power Requirement, kW 3923
Product Size, P80, microns 170.0 Number of Mills for the Task 1
Design Throughput, ton/hr 500.00 Net kW / Mill 3923
MILL DESIGN PARAMETERS AND OPERATING CONDITIONS : Power, kW
2782 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 445 Slurry
17.50 21.00 72.00 38.00 38.00 100.00 35.00 3227 Net Total
L/D rpm 10.0 % Losses
1.20 13.18 3586 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 54.46 253.23 40.55 0.00 5.395
Power Oversize, % (18)
HYDROCYCLONES CLUSTER : (Preliminary Sizing)
# Cyclones Cyclone Feed Circulating ton/hr m3/hr Pressure
per Mill Diameter, in % Solids Load, % per Cyclone per Cyclone Loss, psi
4 26.00 62.00 250.0 437.5 424.4 17.93
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Conventional Ball Mill Sizing
Moly-Cop Tools
TM
Remarks Dimensionamiento del Nuevo Molino.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 12.12 Specific Energy, kWh/ton 7.85
Feed Size, F80, microns 7000 Net Power Requirement, kW 3923
Product Size, P80, microns 170.0 Number of Mills for the Task 1
Design Throughput, ton/hr 500.00 Net kW / Mill 3923
MILL DESIGN PARAMETERS AND OPERATING CONDITIONS : Power, kW
2782 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 445 Slurry
17.50 21.00 72.00 38.00 38.00 100.00 35.00 3227 Net Total
L/D rpm 10.0 % Losses
1.20 13.18 3586 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 54.46 253.23 40.55 0.00 5.395
Power Oversize, % (18)
HYDROCYCLONES CLUSTER : (Preliminary Sizing)
# Cyclones Cyclone Feed Circulating ton/hr m3/hr Pressure
per Mill Diameter, in % Solids Load, % per Cyclone per Cyclone Loss, psi
4 26.00 62.00 250.0 437.5 424.4 17.93
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Conventional Ball Mill Sizing
May be set to any May be set to any May be set to any May be set to any
desired value, desired value,
using Tools / Goal using Tools / Goal
Seek, changing Seek, changing
Cell C19 Cell C19 or or Cell Cell
D21 D21..
Planilla Planilla Bond_Mill Sizing Bond_Mill Sizing ... ...
Planilla Planilla Bond_Mill Sizing Bond_Mill Sizing ... ...
Planilla Planilla Bond_Mill Sizing Bond_Mill Sizing ... ...
Moly-Cop Tools
TM
Remarks Dimensionamiento del Nuevo Molino.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 12.12 Specific Energy, kWh/ton 7.85
Feed Size, F80, microns 7000 Net Power Requirement, kW 3923
Product Size, P80, microns 170.0 Number of Mills for the Task 1
Design Throughput, ton/hr 500.00 Net kW / Mill 3923
MILL DESIGN PARAMETERS AND OPERATING CONDITIONS : Power, kW
3382 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 542 Slurry
18.50 22.21 72.00 38.00 38.00 100.00 35.00 3923 Net Total
L/D rpm 10.0 % Losses
1.20 12.82 4359 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 64.39 299.41 47.95 0.00 5.395
Power Oversize, % (0)
HYDROCYCLONES CLUSTER : (Preliminary Sizing)
# Cyclones Cyclone Feed Circulating ton/hr m3/hr Pressure
per Mill Diameter, in % Solids Load, % per Cyclone per Cyclone Loss, psi
6 26.00 62.00 250.0 291.7 282.9 7.64
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Conventional Ball Mill Sizing
Moly-Cop Tools
TM
Remarks Dimensionamiento del Nuevo Molino.

GRINDING TASK :
Ore Work Index, kWh/ton (metric) 12.12 Specific Energy, kWh/ton 7.85
Feed Size, F80, microns 7000 Net Power Requirement, kW 3923
Product Size, P80, microns 170.0 Number of Mills for the Task 1
Design Throughput, ton/hr 500.00 Net kW / Mill 3923
MILL DESIGN PARAMETERS AND OPERATING CONDITIONS : Power, kW
3382 Balls
Diameter Length Mill Speed Charge Balls Interstitial Lift 0 Overfilling
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, () 542 Slurry
18.50 22.21 72.00 38.00 38.00 100.00 35.00 3923 Net Total
L/D rpm 10.0 % Losses
1.20 12.82 4359 Gross Total
% Solids in the Mill 72.00 Charge Apparent
Ore Density, ton/m3 2.80 Volume, Ball Density
Slurry Density, ton/m3 1.86 m3 Charge Interstitial above Balls ton/m3
Balls Density, ton/m3 7.75 64.39 299.41 47.95 0.00 5.395
Power Oversize, % (0)
HYDROCYCLONES CLUSTER : (Preliminary Sizing)
# Cyclones Cyclone Feed Circulating ton/hr m3/hr Pressure
per Mill Diameter, in % Solids Load, % per Cyclone per Cyclone Loss, psi
6 26.00 62.00 250.0 291.7 282.9 7.64
Mill Charge Weight, tons
BOND'S LAW APPLICATION
Slurry
Conventional Ball Mill Sizing
Developed by Moly-Cop Grinding Systems
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Water ?
La Ley de Bond La Ley de Bond
Es suficiente?? Es suficiente??
170 tph
Apex ?
# of Cyclones ?
P80 = 150 m
Vortex ?
Carga
Circulante
1833 kW
F80 = 10500 m
Distribucin de producto
Moly-Cop Tools
TM
: Theoretical Framework
Water
Configuraciones Tpicas Configuraciones Tpicas
CIRCUITO DIRECTO CIRCUITO DIRECTO
Fresh Feed
Underflow
Cyclone
Feed
Overflow
4
3
2
5
7
6
1
5
Moly-Cop Tools
TM
: Theoretical Framework
Water
Fresh
Feed
Underflow
Cyclone
Feed
Overflow
4
3
2
5
7
6
1
5
Configuraciones Tpicas Configuraciones Tpicas
CIRCUITO INVERSO CIRCUITO INVERSO
Moly-Cop Tools
TM
: Theoretical Framework
Moly-Cop Tools
TM
: Theoretical Framework
El Proceso de Clasificacin
Se denomina clasificacin a la operacin de separacin de los
componentes de una mezcla de partculas en dos o mas fracciones
de acuerdo a su tamao.
La clasificacin en algunos casos es una operacin primordial,
especialmente cuando se requieren especificaciones estrictas de
tamao. En otros casos es una operacin auxiliar de la molienda,
donde sus objetivos son asegurar el tamao de partcula este bajo
un determinado tamao.
El hidrocicln es sin lugar a dudas el tipo de clasificador mas
ampliamente usado en los circuitos industriales de molienda.
Moly-Cop Tools
TM
: Theoretical Framework
Modelos de Clasificacin con Hidrociclones
Eficiencia de Clasificacin,
se denomina como la
fraccin de tamao en la
alimentacin que es
recuperada en la descarga.
Se espera que alcance su
mas alto valor para las
partculas gruesas en la
alimentacin y que el
contenido de partculas
finas sea mnimo

Moly-Cop Tools
TM
: Theoretical Framework
Modelos de Clasificacin con Hidrociclones
Solo una fraccin de la
pulpa de alimentacin
realmente participa del
proceso de clasificacin en
un cicln, mientras que la
fraccin restante sufre un
By-pass directo al flujo
de descarga

Moly-Cop Tools
TM
: Theoretical Framework
Es definida como el ratio de
tonelaje seco que es retornado
al molino a traves del
underflowde los ciclones
Es conveniente pensar que
la carga circulante es una
propiedad de los ciclones en
lugar deI curcuito o del molino
Es definida como el ratio de
tonelaje seco que es retornado
al molino a traves del
underflowde los ciclones
Es conveniente pensar que
la carga circulante es una
propiedad de los ciclones en
lugar deI curcuito o del molino
CARGA CIRCULANTE CARGA CIRCULANTE
Oflow Oflow
Uflow Uflow
Moly-Cop Tools
TM
: Theoretical Framework
Modelos empricos de clasificacin
Hasta este momento, el desarrollo en el rea de
modelaje matemtico ha provenido fundamentalmente de
dos grupos de investigadores encabezados por Lynch y
Plitt y mas recientemente estudios llevados a cabo por J.
L. Bouso y el CIMM de Chile.
Por su parte el CIMM de Chile, desarrollo a partir del
modelo de Plitt ensayos adicionales (77 en total), que
permitieron obtener un modelo de clasificacin muy
cercano en su forma al propuesto por Plitt, por lo cual se le
escogi como base para realizar las simulaciones en el
presente trabajo
Moly-Cop Tools
TM
: Theoretical Framework
Modelos empricos de clasificacin
Modelo de Plitt
Ecuacin de la presin de alimentacin
87 . 0 2 2 94 28 37
78
1
) (
* 0055 . 0 exp * *
DO
DU .
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h
.
DC
psv ( Q a
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1.
+
Ecuacin del tamao de corte
corregido
) 1 - .( Q .
h
.
DU
PSV) (
DO DI DC
*
a
=
50
d
0.5 0.4
0.3 0.
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2
c
o
5
8 71
2 60 . 6
* 063 . 0 exp * * *
Ecuacin de la particin de pulpa.
DC
.
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) DO (DU ) (DU/DO
h
*
a
=
Q
Q
= S
0.
0.
3
o
u
11 . 1 24
36 . 0 2 2 31 . 3
54
* * +
E B
- (1 +
B
=
E
c
i pw pw i
)
i
c
c
m
E
= 1 - [-0.693.(
di
d
50
) ] exp
15 . 0
*
* * exp 1 ]
Q
h
Dc
[ ]
R
1.58 -
a
[ = m
2
v 4

R
- 1
R
. - Rv
=
B
sc
sc
pw
* |
|
1 + S
S
= Rv
sc i=1
n
i
c
R
= fi.
E
Ecuacin de la eficiencia de Clasificacin
Moly-Cop Tools
TM
: Theoretical Framework
Modelos empricos de clasificacin
Modelo del CIMM
i pf pf i
c
E
=
B
+(1-
B
.
E
)
i
c
c
m
E
= 1 - [-0.693.(
di
d
50
) ] exp
m= [
a
- 1.58.
R
].[
Dc
.h
Q
]0.15
4 v
2
exp
pf pw B
= .
B

)]
R
- .(1 - .[1 - 1
R
. - Rv
=
B
sc
sc
pw
|
|
Rv =
S
S+1
sc i=1
n
i
c
R
= fi.
E
Ecuacin de la eficiencia de Clasificacin
Ecuacin de la presin de alimentacin
H=
a
*
Q . (-7.63. .+10.79.
DC
.
h
.
DI
.
DO
.
DU
1
1.46 2
0.20 0.15 0.51 1.65 0.53
exp | |
Ecuacin del tamao de corte corregido
d
50
=
a
*
DC
.
DI
.
DO
. (11.12, )
DU
.
h
.Q .( - 1 )
c
2
0.44 0.58 1.91
0.80 0.37
0.44 0.5
exp u
o
S =
Q
Q
=
a
*
h
.(DU / DO) . (-4.33. +8.77. )
H
.
DC
u
o
3
0.19
2.64 2
0.54 0.38
exp | |
Ecuacin de la particin de pulpa.
Moly-Cop Tools
TM
: Theoretical Framework
INTERACCIONES MOLIENDA INTERACCIONES MOLIENDA--CLASIFICACION CLASIFICACION
Cual es el ptimo contenido
de Slidos...
... En la alimentacin a los
ciclones...?
... En el underflow de los
ciclones....?
... En el Overflowde los
ciclones....?
Existe una Carga Circulante
ptima... ?
Moly-Cop Tools
TM
: Theoretical Framework
LA CUARTA LEY DE LA MOLIENDA/CLASIFICACION LA CUARTA LEY DE LA MOLIENDA/CLASIFICACION
Para una ptima eficiencia energtica del proceso de
Molienda, se requiere que el contenido de particulas finas en el
molino sea lo mas baja posible............para una tarea de
molienda dada
Este Objetivo se consigue operando con el mnimo % de
solidos en el overflow y el maximo % solidos posible en el
underflow.
El % de solidos en la alimentacin y la carga circulante
optima seran obtenidas como una expresin del balance de
masa.
Para una ptima eficiencia energtica del proceso de
Molienda, se requiere que el contenido de particulas finas en el
molino sea lo mas baja posible............para una tarea de
molienda dada
Este Objetivo se consigue operando con el mnimo % de
solidos en el overflow y el maximo % solidos posible en el
underflow.
El % de solidos en la alimentacin y la carga circulante
optima seran obtenidas como una expresin del balance de
masa.
(f
s5
)
opt
=
(1 + CC
opt
)
1/(f
s7
)
min
+ CC
opt
/(f
s6
)
max
Moly-Cop Tools
TM
: Theoretical Framework
Contenido de finos en la descarga del Molino Contenido de finos en la descarga del Molino
0.10
0.12
0.14
0.16
0.18
0.20
0.22
0.24
0.26
0.28
30 32 34 36 38 40 42 44 46 48
% Solids Overflow
%

F
i
n
e
s

i
n

M
i
l
l

D
i
s
c
h
a
r
g
e
F
3
=
(1/f
s7
- 1) + CL (1/f
s6
- 1)
(1/f
s7
- 1) + (1 - )CL (1/f
s6
- 1)
F
7
(1 + CL)
% Solids
Underflow
72
76
80
72
76
80
CL
2
5
alcanzada en equilibrio.
La forma de alcanzar el objetivo de, minimizar el % de Finos en la descarga del
Molino - es operando el circuito al minimo % Solids posible en el Overflow,
al maximo % Solidos en el Underflow y con la carga circulante alcanzada en equilibrio.
Water
Mass Balance Mass Balance
BallBal_Direct BallBal_Direct
504 tph
Apex 4.5
# of Cyclones= 6
P80 = 168 m
Vortex= 9.1
Circulating
Load 279
4316 kW
F80 = 6912 m
Product Size Distribution
Moly-Cop Tools
TM
: Theoretical Framework
BallBal_Direct
Theoretical Framework Theoretical Framework
BATCH PROCEDURE BATCH PROCEDURE
S
e
t
t
i
n
g

N
e
w

S
t
a
n
d
a
r
d

M
e
t
h
o
d
o
l
o
g
i
e
s

i
n
S
e
t
t
i
n
g

N
e
w

S
t
a
n
d
a
r
d

M
e
t
h
o
d
o
l
o
g
i
e
s

i
n
G
r
i
n
d
i
n
g

P
r
o
c
e
s
s

A
n
a
l
y
s
i
s
G
r
i
n
d
i
n
g

P
r
o
c
e
s
s

A
n
a
l
y
s
i
s
Developed by Moly-Cop Grinding Systems
Moly-Cop Tools
TM
: Theoretical Framework
Descripcin y Muestreos a Nivel Industrial
Condiciones Iniciales
Molino 16 x 20
Nc : 38%
Vc : 73%
Hp : 2600
Bolas 3.5:2,5 (75:25)
Ciclones D26 (5)
Tm/hr : 290
CC : 360%
D50 : 190 micrones
By pass : 23%
Moly-Cop Tools
TM
: Theoretical Framework
Ensayos experimentales de Molienda batch
El equipo Necesario es el siguiente:
Molino de torque de 15x 12
Trasductor de potencia o medidor de
Kw en lnea
Medidor y regulador de velocidad
variable (60- 90% de Vc)
Timer o registrador digital de tiempo,
incluido temporizador
Bolas de Acero forjado (representar
reas superficiales m2/m3)
Juego de mallas
Rop Tap
Software para estimacin de
parmetros (Moly-Cop Tools)
Las etapas de la metodologa son:
Homogeneizacin, cuarteo y
secado de la muestra en evaluacin.
Separacin granulomtrica inicial
por mono-tamaos, si es que fuera
necesario.
Establecer condiciones de molienda
lo mas similares posibles a la
instalacin industrial, ver tabla 2
Determinar la variable de
investigacin, en este caso la
variable principal de estudio ser la
distribucin de cuerpos moledores al
interior del molino (rea superficial de
la carga, m2/m3)
Moly-Cop Tools
TM
: Theoretical Framework
Metodologa de experimentacin
Condiciones de Molienda
Variable Unidad Valor
Tamao de Alimentacin (% -1/2) 83
% de slidos % 75
Nivel de llenado de carga % 38
Llenado intersticial % 40
Velocidad del molino Rpm 50
Velocidad crtica % 73
Tiempos de molienda Min 2,4
Alimentacin a molino Kg 7.5
Carga de bolas Kg 21.0

Moly-Cop Tools
TM
: Theoretical Framework
Metodologa de experimentacin
Condiciones de Molienda
Monofraccin Collar Evaluado Tiempo de Mol.
+ 3/8" 3.5", 3.0" 2 y 4 min
-3/8", + 6" 3.5", 3.0",2.5' "
-6, + 20 2.0", 2.5" "
Alimentacin Collar Evaluado
Area
Superficial
m
2
/m
3
Tiempo de
Molienda
Representativa 3.5" 49.0 2 y 4 min
" 3.0" 58.0 "
" 2.5" 70.0 "
" 2.0" 86.0 "
Theoretical Framework Theoretical Framework
MODELO GENERAL DE LA MOLIENDA MODELO GENERAL DE LA MOLIENDA
S
e
t
t
i
n
g

N
e
w

S
t
a
n
d
a
r
d

M
e
t
h
o
d
o
l
o
g
i
e
s

i
n
S
e
t
t
i
n
g

N
e
w

S
t
a
n
d
a
r
d

M
e
t
h
o
d
o
l
o
g
i
e
s

i
n
G
r
i
n
d
i
n
g

P
r
o
c
e
s
s

A
n
a
l
y
s
i
s
G
r
i
n
d
i
n
g

P
r
o
c
e
s
s

A
n
a
l
y
s
i
s
Developed by Moly-Cop Grinding Systems
Moly-Cop Tools
TM
: Theoretical Framework
(1-S
1
At) f
1
S
1
At f
1
b
21
S
1
At f
1
b
i1
S
1
At f
1
b
n1
S
1
At f
1
(1-S
2
At) f
2
S
2
At f
2
b
i2
S
2
At f
2
b
n2
S
2
At f
2
t = t
f
1
f
2
f
i
f
n
2
3
i + 1
n + 1

t = t + At
2
3
i + 1
n + 1

Caracterizacin Cinetica de la Molienda Caracterizacin Cinetica de la Molienda


Moly-Cop Tools
TM
: Theoretical Framework
FUNCION SELECCION, S FUNCION SELECCION, S
i i
, min , min
--11
Por ejemplo, S
2
= 0.10
min
-1
, significa que el
10% de las particulas
retenidas en el tamao
de la fraccion 2 seran
fracturadas durante el
siguiente minuto
Por ejemplo, S
2
= 0.10
min
-1
, significa que el
10% de las particulas
retenidas en el tamao
de la fraccion 2 seran
fracturadas durante el
siguiente minuto
La velocidad fraccional de fracturacin (moliendabilidad); es
decir, la fraccin de las partculas en el rango de tamaos [d
i
, d
i
]
que se fracturan por unidad de tiempo
0.001
0.01
0.1
1
10
1 10 100 1000 10000 100000
Particle Size, m
S
e
l
e
c
t
i
o
n

F
u
n
c
t
i
o
n
,

t
o
n
/
k
W
h


.
S
i
E
= o
0
(d
i
)
o
1 / [ 1 + (d
i
/d
crit
)
o
2] S
i
E
= o
0
(d
i
)
o
1 / [ 1 + (d
i
/d
crit
)
o
2]
o
0
o
1
d
crit
(o
2
- o
1
)
Moly-Cop Tools
TM
: Theoretical Framework
FUNCION FRACTURA, b FUNCION FRACTURA, b
ij ij
Fraccin, en peso, de los fragmentos resultantes de la fractura de
Partculas de tamao original j, que reportan a la fraccin i inferior.
Por ejemplo, b
significa que el 10% de todos
los fragmentos de partculas
originalmente retenidas en la
fraccin 2 resultan retenidos
en la fraccin 5 inferior, como
consecuencia de un evento
primario de fractura
Por ejemplo, b
52
= 0.10 ,
significa que el 10% de todos
los fragmentos de partculas
originalmente retenidas en la
fraccin 2 resultan retenidos
en la fraccin 5 inferior, como
consecuencia de un evento
primario de fractura.
1
10
100
0.01 0.1 1
Relative Particle Size, d
i
/ d
j+1
B
i
j
Fraction 10x14 #
Fraction 14x20 #
Fraction 20x28 #
B
ij
= |
0
(d
i
/d
j+1
)
|
1 + (1 - |
0
) (d
i
/d
j+1
)
|
2] B
ij
= |
0
(d
i
/d
j+1
)
|
1 + (1 - |
0
) (d
i
/d
j+1
)
|
2]
|
0
|
1
Parmetros Caractersticos Parmetros Caractersticos
FUNCION FRACTURA, b FUNCION FRACTURA, b
Parmetros Caractersticos Parmetros Caractersticos
FUNCION FRACTURA, b FUNCION FRACTURA, b
ij ij
Moly-Cop Tools
TM
: Theoretical Framework
EL CICLO OPTIMIZANTE EL CICLO OPTIMIZANTE
Balance
De Materiales
Balance
De Materiales
BallBal
SAGBal
Estimation
De Parametros
Estimation
De Parametros
BallParam
SAGParam
Escalamiento y Escalamiento y
Simulacin
BallSim
SAGSim
Nuevas Cond.
De operacin
Nuevas Cond.
De operacin
Nuevos
Proyectos
Pruebas Piloto
o de Laboratorio
Pruebas Piloto
o de Laboratorio
Instalaciones
Existentes
Muestreo en
Planta
Muestreo en
Planta
Implementacion Implementacion Recomendaciones Recomendaciones
Moly-Cop Tools
TM
: Theoretical Framework
Ajuste del Modelo Ajuste del Modelo
Alcanzar su minimo valor.
Para este proposito se usan NON-LINEAR
REGRESSION ALGORITHMS, como la subrutina
SOLVER del EXCEL2000.
min | = e
i
(F
i
- F
i
*)
2
Encontrar un set de parametros os y |s, que
Cumplan la funcion objetivo:
Mass Balance Mass Balance
BallParam_Direct BallParam_Direct
Moly-Cop Tools
TM
: Theoretical Framework
Moly-Cop Tools
TM
Simulation N 1
Remarks
40.00 % Solids
59.97 % - Size 18
psi 7.98 151.0 P80
# of Cyclones 10
Vortex 7.50 Circ. Load 305.79
Apex 3.67 0.382 Bpf m
3
/hr 1542
0.392 Bpw
% Solids 76.00
Water,
m
3
/hr 356.9
ton/hr 400.0 Water, 222.1
F80 9795 m
3
/hr
Gross kW 4316.1
kWh/ton (Gross) 10.79 % Balls 38.00
Wio (metric) 15.14 % Critical 72.00
% Solids 72.00
% Solids 62.20
Base Case Example

Planilla Planilla BallParam_Direct BallParam_Direct ... ... (Data_File) (Data_File)
Moly-Cop Tools
TM
Circuit Type DIRECT Sample N 1
Remarks
Mill Dimensions and Operating Conditions 3348 Balls Charge Apparent
Diameter Length Speed Charge Balls Lift 0 Overfilling Volume, Ball Density
ft ft % Critical Filling,% Filling,% Angle, () 536 Slurry m3 Charge Interstitial Excess ton/m3
16.0 24.0 72.0 38.00 38.00 49.1 3885 Net Power 52.03 241.92 38.74 0.00 5.395
rpm 13.79 10.0 % Losses
4316 Gross kW Feedrate, ton/hr (dry) 400.0
Cyclone Dimensions (inches) and Operating Pressure (psi)
Number Diameter Height Inlet Vortex Apex psi Ore Density, ton/m3 2.80
10 20.0 75.0 3.50 7.50 3.67 7.98 Balls Density, ton/m3 7.75
i Mesh Opening Mid-Size ton/hr % Retained % Passing ton/hr % Retained % Passing ton/hr % Retained % Passing ton/hr % Retained % Passing ton/hr % Retained % Passing
1 1.05 25400 100.00 100.00 100.00 100.00 100.00
2 0.742 19050 21997 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00
3 0.525 12700 15554 20.00 5.00 95.00 13.70 1.12 98.88 18.18 1.12 98.88 18.18 1.49 98.51 0.00 0.00 100.00
4 0.371 9500 10984 66.40 16.60 78.40 31.27 2.56 96.32 41.50 2.56 96.32 41.50 3.39 95.12 0.00 0.00 100.00
5 3 6700 7978 56.28 14.07 64.33 30.72 2.51 93.81 40.76 2.51 93.81 40.77 3.33 91.79 0.00 0.00 100.00
6 4 4750 5641 41.32 10.33 54.00 27.89 2.28 91.53 37.01 2.28 91.53 37.02 3.03 88.76 0.00 0.00 100.00
7 6 3350 3989 33.36 8.34 45.66 29.04 2.37 89.16 38.54 2.37 89.16 38.54 3.15 85.61 0.00 0.00 100.00
8 8 2360 2812 27.36 6.84 38.82 33.26 2.72 86.44 44.14 2.72 86.44 44.15 3.61 82.00 0.00 0.00 100.00
9 10 1700 2003 21.64 5.41 33.41 38.60 3.16 83.28 51.22 3.16 83.28 51.22 4.19 77.81 0.00 0.00 100.00
10 14 1180 1416 20.40 5.10 28.31 50.48 4.13 79.16 66.99 4.13 79.16 66.99 5.48 72.34 0.00 0.00 100.00
11 20 850 1001 15.60 3.90 24.41 59.41 4.86 74.30 78.84 4.86 74.30 78.85 6.45 65.89 0.00 0.00 100.00
12 28 600 714 14.16 3.54 20.87 75.83 6.20 68.10 100.62 6.20 68.10 100.53 8.22 57.67 0.10 0.02 99.97
13 35 425 505 12.04 3.01 17.86 92.60 7.57 60.53 122.88 7.57 60.53 120.95 9.89 47.78 1.94 0.49 99.49
14 48 300 357 10.36 2.59 15.27 107.11 8.76 51.77 142.13 8.76 51.77 131.23 10.73 37.05 10.90 2.73 96.76
15 65 212 252 8.84 2.21 13.06 108.25 8.85 42.92 143.65 8.85 42.92 116.42 9.52 27.54 27.23 6.81 89.96
16 100 150 178 7.52 1.88 11.18 94.67 7.74 35.18 125.63 7.74 35.18 85.81 7.02 20.52 39.81 9.95 80.00
17 150 106 126 6.48 1.62 9.56 74.59 6.10 29.08 98.98 6.10 29.08 56.91 4.65 15.87 42.06 10.52 69.49
18 200 75 89 5.52 1.38 8.18 55.21 4.51 24.57 73.26 4.51 24.57 36.45 2.98 12.89 36.81 9.20 60.29
19 270 53 63 4.72 1.18 7.00 40.69 3.33 21.24 54.00 3.33 21.24 24.14 1.97 10.91 29.86 7.46 52.82
20 400 38 45 3.40 0.85 6.15 29.38 2.40 18.84 38.99 2.40 18.84 16.24 1.33 9.59 22.75 5.69 47.13
21 -400 0 19 24.60 6.15 0.00 230.45 18.84 0.00 305.81 18.84 0.00 117.25 9.59 0.00 188.54 47.13 0.00
Totals 400.00 100.00 1223.14 100.00 1623.14 100.00 1223.14 100.00 400.00 100.00
% Solids 95.00 72.00 62.20 76.00 40.00
Slurry Density, ton/m3 2.569 1.862 1.666 1.955 1.346
Weighting Factor 1.000 1.000 1.000 1.000
Fresh Feed Mill Discharge Cyclone U'flow Cyclone O'flow Cyclone Feed
BALLPARAM_Direct : Simultaneous Mass Balance Closure and Grinding Parameters Estimation.
EXPERIMENTAL SIZE DISTRIBUTIONS
Base Case Example

Mill Charge Weight, tons
Slurry Interstitial
Slurry Filling,%
100.00
Planilla Planilla BallParam_Direct BallParam_Direct ... ... (Control_Panel) (Control_Panel)
BallParam_Direct
Moly-Cop Tools
TM
Sample N 1
Weighting Factors :
Streams :
Mill Discharge 1
Cyclone U'flow 1
Cyclone O'flow 1
Size Distributions 1
% Solids 1
Grinding Parameter Guesses :
alpha0 alpha1 alpha2 dcrit
0.00910 0.651 2.50 6514 4
alpha02 alpha12
0 1
0 1 Default Values
beta0 beta1 beta2
0.200 0.249 4.02
beta01
0
0 Default Value
Classifiers Parameter Guesses :
Bpf Bpc d50c m
0.382 0.000 183.2 1.660
Circulating Load : 3.058 Delta 0.062
Obj. Function : 0.011 Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.
BallParam_Direct : SIMULTANEOUS MASS BALANCE CLOSURE AND GRINDING PARAMETERS ESTIMATION
1
10
100
10 100 1000 10000
Particle Size, microns
%

P
a
s
s
i
n
g
Mill Discharge
Cyclone U'flow
Cyclone O'flow
Fresh Feed
Planilla Planilla
BallParam_Direct BallParam_Direct
... ... (Reports) (Reports)
Moly-Cop Tools
TM
Simulation N 1
Remarks : Base Case Example

Fresh Mill Mill Sump Cyclone Cyclone Cyclone
Feed Feed Discharge Water Feed U'flow O'flow
Ore, ton/hr 400.0 1598.5 1598.5 0.0 1598.5 1198.5 400.0
Water, m3/hr 21.1 399.6 621.6 356.9 971.3 378.5 600.0
Slurry, ton/hr 421.1 1998.0 2220.1 356.9 2569.8 1577.0 1000.0
Slurry, m3/hr 163.9 970.4 1192.5 356.9 1542.2 806.5 742.9
Slurry Dens., ton/m3 2.569 2.059 1.862 1.000 1.666 1.955 1.346
% Solids (by volume) 87.2 58.8 47.9 0.0 37.0 53.1 19.2
% Solids (by weight) 95.00 80.00 72.00 0.00 62.20 76.00 40.00
Mesh Opening
1.05 25400 100.00 100.00 100.00 0.00 100.00 100.00 100.00
0.742 19050 100.00 100.00 100.00 0.00 100.00 100.00 100.00
0.525 12700 95.00 97.70 98.95 0.00 98.95 98.60 100.00
0.371 9500 78.40 91.21 96.61 0.00 96.61 95.48 100.00
3 6700 64.33 85.37 94.30 0.00 94.30 92.39 100.00
4 4750 54.00 80.66 92.17 0.00 92.17 89.56 100.00
6 3350 45.66 76.33 89.93 0.00 89.93 86.57 100.00
8 2360 38.82 72.01 87.32 0.00 87.32 83.09 100.00
10 1700 33.41 67.59 84.26 0.00 84.26 79.00 99.99
14 1180 28.31 62.26 80.20 0.00 80.20 73.60 99.99
20 850 24.41 56.47 75.38 0.00 75.38 67.16 99.99
28 600 20.87 49.39 69.18 0.00 69.18 58.91 99.97
35 425 17.86 41.13 61.56 0.00 61.56 48.90 99.52
48 300 15.27 32.27 52.68 0.00 52.68 37.94 96.82
65 212 13.06 24.39 43.62 0.00 43.62 28.17 89.94
100 150 11.18 18.50 35.68 0.00 35.68 20.95 79.82
150 106 9.56 14.51 29.43 0.00 29.43 16.16 69.19
200 75 8.18 11.87 24.83 0.00 24.83 13.10 59.97
270 53 7.00 10.05 21.44 0.00 21.44 11.06 52.55
400 38 6.15 8.80 19.01 0.00 19.01 9.69 46.92
D80, microns 9795 4510 1164 0 1164 1844 151.0
Specific Energy Consumption : 10.79 kWh/ton (Gross)
Operational Work Index : 15.14 kWh/ton (metric)
BALLPARAM_ DIRECT
Conventional Closed Circuit Grinding Simulator
CIRCUIT MASS BALANCE
Configuration : DIRECT
Particle Size Distributions (Cummulative % Passing)
Planilla Planilla
BallParam_Direct BallParam_Direct
... ... (Reports) (Reports)
Moly-Cop Tools
TM
Simulation N 1
Remarks : Base Case Example

Number of Cyclones : 10 Operating Conditions :
Cyclone Dimensions, in : Feed Flowrate, m3/hr 1542.2
Diameter 20.00 Pressure, psi 7.98
Height 75.00 D50 (corr.), microns 183.2
Inlet 3.50 Water By-Pass, % 39.2
Vortex 7.50 Solids By-Pass, % 38.2
Apex 3.67 Plitt's Parameter 1.66
Ore Density, ton/m3 2.80 Circulating Load, % 305.8
Mesh Opening Mid-Size Feed U'flow O'flow Actual Corrected
1.05 25400 21997 100.00 100.00 100.00 1.000 1.000
0.742 19050 15554 100.00 100.00 100.00 1.000 1.000
0.525 12700 10984 98.95 98.60 100.00 1.000 1.000
0.371 9500 7978 96.61 95.48 100.00 1.000 1.000
3 6700 5641 94.30 92.39 100.00 1.000 1.000
4 4750 3989 92.17 89.56 100.00 1.000 1.000
6 3350 2812 89.93 86.57 100.00 1.000 1.000
8 2360 2003 87.32 83.09 100.00 1.000 1.000
10 1700 1416 84.26 79.00 99.99 1.000 1.000
14 1180 1001 80.20 73.60 99.99 1.000 1.000
20 850 714 75.38 67.16 99.99 0.999 0.999
28 600 505 69.18 58.91 99.97 0.985 0.976
35 425 357 61.56 48.90 99.52 0.924 0.877
48 300 252 52.68 37.94 96.82 0.810 0.692
65 212 178 43.62 28.17 89.94 0.681 0.484
100 150 126 35.68 20.95 79.82 0.574 0.311
150 106 89 29.43 16.16 69.19 0.499 0.189
200 75 63 24.83 13.10 59.97 0.451 0.111
270 53 45 21.44 11.06 52.55 0.422 0.065
400 38 19 19.01 9.69 46.92 0.382 0.016
Ore, ton/hr 1598.5 1198.5 400.0
Water, m3/hr 971.3 378.5 600.0
Slurry, ton/hr 2569.8 1577.0 1000.0 a1 9.677
Slurry, m3/hr 1542.2 806.5 742.9 a2 1.428
Slurry Dens., ton/m3 1.666 1.955 1.346 a3 54.957
% Solids (by volume) 37.0 53.1 19.2 a4 0.549
% Solids (by weight) 62.2 76.0 40.0 H 0.976
Size Distributions, % Passing
BALLPARAM_ DIRECT
Conventional Closed Circuit Grinding Simulator
CLASSIFIERS PERFORMANCE
Mass Balance around the Classifiers
Classifier Constants
Classifier Efficiency
Planilla Planilla
BallParam_Direct BallParam_Direct
... ... (Reports) (Reports)
Moly-Cop Tools
TM
Simulation N 1
Remarks : Base Case Example

Diameter, ft 16.0 Mill Power, kW (Gross) 4316
Length, ft 24.0 Mill Power, kW (Net) 3885
Speed, % Critical 72.0 Throughput, ton/hr 1598.5
App. Density, ton/m3 5.39 % Solids (by weight) 72.0
Charge Level, % 38.0 Sp. Energy, kWh/ton 2.70
Balls Filling, % 38.0 Reduction Ratio 3.87
Lift Angle, () 49.1
Mill Mill
i Mesh Opening Mid-Size Feed Discharge
1 1.05 25400 21997 100.00 100.00
2 0.742 19050 15554 100.00 100.00
3 0.525 12700 10984 97.70 98.95
4 0.371 9500 7978 91.21 96.61
5 3 6700 5641 85.37 94.30
6 4 4750 3989 80.66 92.17
7 6 3350 2812 76.33 89.93
8 8 2360 2003 72.01 87.32
9 10 1700 1416 67.59 84.26
10 14 1180 1001 62.26 80.20
11 20 850 714 56.47 75.38
12 28 600 505 49.39 69.18
13 35 425 357 41.13 61.56
14 48 300 252 32.27 52.68
15 65 212 178 24.39 43.62
16 100 150 126 18.50 35.68
17 150 106 89 14.51 29.43
18 200 75 63 11.87 24.83
19 270 53 45 10.05 21.44
20 400 38 19 8.80 19.01
D80, microns 4510 1164
alpha01 alpha02 alpha11 alpha12 alpha2 Dcrit Beta00 Beta01 Beta1 Beta2
0.00910 0.0000000 0.651 1.000 2.50 6514 0.200 0.000 0.25 4.02
Breakage Function Parameters Selection Function Parameters
Size Distributions
BALL MILL PERFORMANCE
BALLPARAM_ DIRECT
Conventional Closed Circuit Grinding Simulator
Theoretical Framework Theoretical Framework
SIMULACION DE CIRCUITOS DE SIMULACION DE CIRCUITOS DE
MOLIENDA / CLASIFICACION MOLIENDA / CLASIFICACION
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Developed by Moly-Cop Grinding Systems
Moly-Cop Tools
TM
: Theoretical Framework
MILL :
Dimensions : 18.5| x 22.0 (eff.)
Rotational Speed : 72 % Critical
Charge Level : 38 % balls
MILL :
Dimensions : 18.5| x 22.0 (eff.)
Rotational Speed : 72 % Critical
Charge Level : 38 % balls
CLASSIFIERS :
6 Cyclones @ 26|
CLASSIFIERS :
6 Cyclones @ 26|
Feed :
Throughput : 500 ton/hr
Feed Size : 92% - 1/2
Feed :
Throughput : 500 ton/hr
Feed Size : 92% - 1/2
PRODUCT : 76% - 100 # PRODUCT : 76% - 100 #
Datos Operacionales Datos Operacionales
POWER : < 4500 KW POWER : < 4500 KW
CYCLONES : max. 10 CYCLONES : max. 10
F80 : > 4.8 mm F80 : > 4.8 mm
P80 : < 0.18 mm P80 : < 0.18 mm
WATER : < 1050 m
3
/hr WATER : < 1050 m
3
/hr
PUMP : < 3000 m
3
/hr PUMP : < 3000 m
3
/hr
% Sol. : < 80 % Sol. : < 80
Psi : < 13 Psi : < 13
Moly-Cop Tools
Planilla Planilla BallSim_Direct BallSim_Direct ... ... (Data_File) (Data_File)
i Mesh Opening Mid-Size ton/hr % Retained % Passing
1 1.05 25400 100.00
2 0.742 19050 21997 28.06 5.57 94.43
3 0.525 12700 15554 12.50 2.48 91.95
4 0.371 9500 10984 20.80 4.13 87.83
5 3 6700 7978 43.13 8.56 79.27
6 4 4750 5641 67.01 13.30 65.97
7 6 3350 3989 56.20 11.15 54.82
8 8 2360 2812 55.98 11.11 43.71
9 10 1700 2003 29.14 5.78 37.93
10 14 1180 1416 24.66 4.89 33.04
11 20 850 1001 22.35 4.43 28.60
12 28 600 714 10.38 2.06 26.54
13 35 425 505 17.67 3.51 23.04
14 48 300 357 14.52 2.88 20.16
15 65 212 252 10.82 2.15 18.01
16 100 150 178 11.24 2.23 15.78
17 150 106 126 8.39 1.66 14.12
18 200 75 89 7.45 1.48 12.64
19 270 53 63 6.68 1.32 11.31
20 400 38 45 7.74 1.54 9.78
21 -400 0 19 49.28 9.78 0.00
Selection Function Parameters : Expanded Form :
alpha0 alpha1 alpha2 dcrit alpha02 alpha12
0.009686 0.659 2.5 7093 0 1
0 1 Suggested Default Values
Breakage Function Parameters : Expanded Form :
beta0 beta1 beta2 beta01
0.4 0.65 4 0
0 Suggested Default Value
Classifier Constants :
a1 a2 a3 a4
7.596 1.109 53.836 0.324 0.931
9.932 1.361 52.968 0.441 0.950 Suggested Default Values
Feed Size Distribution
i Mesh Opening Mid-Size ton/hr % Retained % Passing
1 1.05 25400 100.00
2 0.742 19050 21997 28.06 5.57 94.43
3 0.525 12700 15554 12.50 2.48 91.95
4 0.371 9500 10984 20.80 4.13 87.83
5 3 6700 7978 43.13 8.56 79.27
6 4 4750 5641 67.01 13.30 65.97
7 6 3350 3989 56.20 11.15 54.82
8 8 2360 2812 55.98 11.11 43.71
9 10 1700 2003 29.14 5.78 37.93
10 14 1180 1416 24.66 4.89 33.04
11 20 850 1001 22.35 4.43 28.60
12 28 600 714 10.38 2.06 26.54
13 35 425 505 17.67 3.51 23.04
14 48 300 357 14.52 2.88 20.16
15 65 212 252 10.82 2.15 18.01
16 100 150 178 11.24 2.23 15.78
17 150 106 126 8.39 1.66 14.12
18 200 75 89 7.45 1.48 12.64
19 270 53 63 6.68 1.32 11.31
20 400 38 45 7.74 1.54 9.78
21 -400 0 19 49.28 9.78 0.00
Selection Function Parameters : Expanded Form :
alpha0 alpha1 alpha2 dcrit alpha02 alpha12
0.009686 0.659 2.5 7093 0 1
0 1 Suggested Default Values
Breakage Function Parameters : Expanded Form :
beta0 beta1 beta2 beta01
0.4 0.65 4 0
0 Suggested Default Value
Classifier Constants :
a1 a2 a3 a4
7.596 1.109 53.836 0.324 0.931
9.932 1.361 52.968 0.441 0.950 Suggested Default Values
Feed Size Distribution
Planilla Planilla BallSim_Direct BallSim_Direct ... ... (Data_File) (Data_File)
Planilla Planilla BallSim_Direct BallSim_Direct ... ... (Data_File) (Data_File)
Planilla Planilla
BallSim_Direct BallSim_Direct
... ... (Reports) (Reports)
Fresh Mill Mill Sump Cyclone Cyclone Cyclone
Feed Feed Discharge Water Feed U'flow O'flow
Ore, ton/hr 504.0 1902.5 1902.5 0.0 1902.5 1398.5 504.0
Water, m3/hr 26.5 477.9 739.8 464.4 1204.2 451.4 752.9
Slurry, ton/hr 530.5 2380.3 2642.3 464.4 3106.7 1849.8 1256.9
Slurry, m3/hr 206.5 1157.3 1419.3 464.4 1883.7 950.8 932.9
Slurry Dens., ton/m3 2.569 2.057 1.862 1.000 1.649 1.946 1.347
% Solids (by volume) 87.2 58.7 47.9 0.0 36.1 52.5 19.3
% Solids (by weight) 95.00 79.92 72.00 0.00 61.24 75.60 40.10
Mesh Opening
1.05 25400 100.00 100.00 100.00 0.00 100.00 100.00 100.00
0.742 19050 94.43 96.49 97.96 0.00 97.96 97.23 100.00
0.525 12700 91.95 94.64 96.77 0.00 96.77 95.61 100.00
0.371 9500 87.83 92.59 95.81 0.00 95.81 94.30 100.00
3 6700 79.27 89.05 94.54 0.00 94.54 92.57 100.00
4 4750 65.97 83.83 92.84 0.00 92.84 90.26 100.00
6 3350 54.82 78.85 90.82 0.00 90.82 87.51 100.00
8 2360 43.71 73.24 88.15 0.00 88.15 83.88 100.00
10 1700 37.93 68.67 85.11 0.00 85.11 79.75 100.00
14 1180 33.04 63.34 81.08 0.00 81.08 74.26 100.00
20 850 28.60 57.27 76.18 0.00 76.18 67.60 99.99
28 600 26.54 50.71 70.11 0.00 70.11 59.42 99.78
35 425 23.04 42.43 62.43 0.00 62.43 49.42 98.52
48 300 20.16 33.87 53.57 0.00 53.57 38.81 94.53
65 212 18.01 26.34 44.60 0.00 44.60 29.35 86.92
100 150 15.78 20.24 36.32 0.00 36.32 21.85 76.48
150 106 14.12 15.83 29.38 0.00 29.38 16.45 65.27
200 75 12.64 12.66 23.82 0.00 23.82 12.67 54.76
270 53 11.31 10.33 19.41 0.00 19.41 9.98 45.57
400 38 9.78 8.47 15.90 0.00 15.90 8.00 37.80
D80, microns 6913 3638 1099 0 1099 1735 169.4
Specific Energy Consumption : 8.56 kWh/ton (Gross)
Operational Work Index : 13.21 kWh/ton
CIRCUIT MASS BALANCE
Configuration : DIRECT
Particle Size Distributions (Cummulative % Passing)
Fresh Mill Mill Sump Cyclone Cyclone Cyclone
Feed Feed Discharge Water Feed U'flow O'flow
Ore, ton/hr 504.0 1902.5 1902.5 0.0 1902.5 1398.5 504.0
Water, m3/hr 26.5 477.9 739.8 464.4 1204.2 451.4 752.9
Slurry, ton/hr 530.5 2380.3 2642.3 464.4 3106.7 1849.8 1256.9
Slurry, m3/hr 206.5 1157.3 1419.3 464.4 1883.7 950.8 932.9
Slurry Dens., ton/m3 2.569 2.057 1.862 1.000 1.649 1.946 1.347
% Solids (by volume) 87.2 58.7 47.9 0.0 36.1 52.5 19.3
% Solids (by weight) 95.00 79.92 72.00 0.00 61.24 75.60 40.10
Mesh Opening
1.05 25400 100.00 100.00 100.00 0.00 100.00 100.00 100.00
0.742 19050 94.43 96.49 97.96 0.00 97.96 97.23 100.00
0.525 12700 91.95 94.64 96.77 0.00 96.77 95.61 100.00
0.371 9500 87.83 92.59 95.81 0.00 95.81 94.30 100.00
3 6700 79.27 89.05 94.54 0.00 94.54 92.57 100.00
4 4750 65.97 83.83 92.84 0.00 92.84 90.26 100.00
6 3350 54.82 78.85 90.82 0.00 90.82 87.51 100.00
8 2360 43.71 73.24 88.15 0.00 88.15 83.88 100.00
10 1700 37.93 68.67 85.11 0.00 85.11 79.75 100.00
14 1180 33.04 63.34 81.08 0.00 81.08 74.26 100.00
20 850 28.60 57.27 76.18 0.00 76.18 67.60 99.99
28 600 26.54 50.71 70.11 0.00 70.11 59.42 99.78
35 425 23.04 42.43 62.43 0.00 62.43 49.42 98.52
48 300 20.16 33.87 53.57 0.00 53.57 38.81 94.53
65 212 18.01 26.34 44.60 0.00 44.60 29.35 86.92
100 150 15.78 20.24 36.32 0.00 36.32 21.85 76.48
150 106 14.12 15.83 29.38 0.00 29.38 16.45 65.27
200 75 12.64 12.66 23.82 0.00 23.82 12.67 54.76
270 53 11.31 10.33 19.41 0.00 19.41 9.98 45.57
400 38 9.78 8.47 15.90 0.00 15.90 8.00 37.80
D80, microns 6913 3638 1099 0 1099 1735 169.4
Specific Energy Consumption : 8.56 kWh/ton (Gross)
Operational Work Index : 13.21 kWh/ton
CIRCUIT MASS BALANCE
Configuration : DIRECT
Particle Size Distributions (Cummulative % Passing)
Planilla Planilla
BallSim_Direct BallSim_Direct
... ... (Reports) (Reports)
Number of Cyclones : 6 Operating Conditions :
Cyclone Dimensions, in : Feed Flowrate, m3/hr 1883.7
Diameter 26.00 Pressure, psi 7.7
Height 78.00 D50 (corr.), microns 183.3
Inlet 6.50 Water By-Pass, % 37.5
Vortex 9.10 Solids By-Pass, % 34.9
Apex 4.51 Plitt's Parameter 1.34
Ore Density, ton/m3 2.80 Circulating Load, % 277
Mesh Opening Mid-Size Feed U'flow O'flow Actual Corrected
1.05 25400 21997 100.00 100.00 100.00 1.000 1.000
0.742 19050 15554 97.96 97.23 100.00 1.000 1.000
0.525 12700 10984 96.77 95.61 100.00 1.000 1.000
0.371 9500 7978 95.81 94.30 100.00 1.000 1.000
3 6700 5641 94.54 92.57 100.00 1.000 1.000
4 4750 3989 92.84 90.26 100.00 1.000 1.000
6 3350 2812 90.82 87.51 100.00 1.000 1.000
8 2360 2003 88.15 83.88 100.00 1.000 1.000
10 1700 1416 85.11 79.75 100.00 1.000 1.000
14 1180 1001 81.08 74.26 100.00 0.999 0.999
20 850 714 76.18 67.60 99.99 0.991 0.986
28 600 505 70.11 59.42 99.78 0.956 0.933
35 425 357 62.43 49.42 98.52 0.881 0.817
48 300 252 53.57 38.81 94.53 0.775 0.655
65 212 178 44.60 29.35 86.92 0.666 0.487
100 150 126 36.32 21.85 76.48 0.572 0.342
150 106 89 29.38 16.45 65.27 0.500 0.231
200 75 63 23.82 12.67 54.76 0.448 0.152
270 53 45 19.41 9.98 45.57 0.414 0.099
400 38 19 15.90 8.00 37.80 0.370 0.032
Ore, ton/hr 1902.5 1398.5 504.0
Water, m3/hr 1204.2 451.4 752.9
Slurry, ton/hr 3106.7 1849.8 1256.9 a1 7.596
Slurry, m3/hr 1883.7 950.8 932.9 a2 1.109
Slurry Dens., ton/m3 1.649 1.946 1.347 a3 53.836
% Solids (by volume) 36.1 52.5 19.3 a4 0.324
% Solids (by weight) 61.2 75.6 40.1 0.931
CLASSIFIERS PERFORMANCE
Mass Balance around the Classifiers
Classifier Constants
Classifier Efficiency Size Distributions, % Passing
Number of Cyclones : 6 Operating Conditions :
Cyclone Dimensions, in : Feed Flowrate, m3/hr 1883.7
Diameter 26.00 Pressure, psi 7.7
Height 78.00 D50 (corr.), microns 183.3
Inlet 6.50 Water By-Pass, % 37.5
Vortex 9.10 Solids By-Pass, % 34.9
Apex 4.51 Plitt's Parameter 1.34
Ore Density, ton/m3 2.80 Circulating Load, % 277
Mesh Opening Mid-Size Feed U'flow O'flow Actual Corrected
1.05 25400 21997 100.00 100.00 100.00 1.000 1.000
0.742 19050 15554 97.96 97.23 100.00 1.000 1.000
0.525 12700 10984 96.77 95.61 100.00 1.000 1.000
0.371 9500 7978 95.81 94.30 100.00 1.000 1.000
3 6700 5641 94.54 92.57 100.00 1.000 1.000
4 4750 3989 92.84 90.26 100.00 1.000 1.000
6 3350 2812 90.82 87.51 100.00 1.000 1.000
8 2360 2003 88.15 83.88 100.00 1.000 1.000
10 1700 1416 85.11 79.75 100.00 1.000 1.000
14 1180 1001 81.08 74.26 100.00 0.999 0.999
20 850 714 76.18 67.60 99.99 0.991 0.986
28 600 505 70.11 59.42 99.78 0.956 0.933
35 425 357 62.43 49.42 98.52 0.881 0.817
48 300 252 53.57 38.81 94.53 0.775 0.655
65 212 178 44.60 29.35 86.92 0.666 0.487
100 150 126 36.32 21.85 76.48 0.572 0.342
150 106 89 29.38 16.45 65.27 0.500 0.231
200 75 63 23.82 12.67 54.76 0.448 0.152
270 53 45 19.41 9.98 45.57 0.414 0.099
400 38 19 15.90 8.00 37.80 0.370 0.032
Ore, ton/hr 1902.5 1398.5 504.0
Water, m3/hr 1204.2 451.4 752.9
Slurry, ton/hr 3106.7 1849.8 1256.9 a1 7.596
Slurry, m3/hr 1883.7 950.8 932.9 a2 1.109
Slurry Dens., ton/m3 1.649 1.946 1.347 a3 53.836
% Solids (by volume) 36.1 52.5 19.3 a4 0.324
% Solids (by weight) 61.2 75.6 40.1 0.931
CLASSIFIERS PERFORMANCE
Mass Balance around the Classifiers
Classifier Constants
Classifier Efficiency Size Distributions, % Passing
Planilla Planilla BallSim_Direct BallSim_Direct ... ... (Flowsheet) (Flowsheet)
Moly-Cop Tools
TM
Simulation N 0
Remarks
40.10 % Solids
54.76 % - Size 18
psi 7.65 169.4 P80
# of Cyclones 6
Vortex 9.10 Circ. Load 2.77
Apex 4.51 0.349 Bpf m
3
/hr 1884
0.375 Bpw
% Solids 75.60
Water,
m
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/hr 464.4
ton/hr 504.0 Water, 262.0
F80 6913 m
3
/hr
Gross kW 4316.1
kWh/ton 8.56 % Balls 38.00
Wio 13.21 % Critical 72.00
% Solids 72.00
% Solids 61.24
Simulacin Molino 2.

Moly-Cop Tools
TM
Simulation N 0
Remarks
40.10 % Solids
54.76 % - Size 18
psi 7.65 169.4 P80
# of Cyclones 6
Vortex 9.10 Circ. Load 2.77
Apex 4.51 0.349 Bpf m
3
/hr 1884
0.375 Bpw
% Solids 75.60
Water,
m
3
/hr 464.4
ton/hr 504.0 Water, 262.0
F80 6913 m
3
/hr
Gross kW 4316.1
kWh/ton 8.56 % Balls 38.00
Wio 13.21 % Critical 72.00
% Solids 72.00
% Solids 61.24
Simulacin Molino 2.

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Process Optimization Process Optimization
DETERMINACION DEL TAMAO DETERMINACION DEL TAMAO
OPTIMO DE MEDIOS DE MOLIENDA OPTIMO DE MEDIOS DE MOLIENDA
Developed by Moly-Cop Grinding Systems
Moly-Cop Tools
TM
: Theoretical Framework
0.1
1.0
100 1000 10000
Particle Size, m
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3.0" String
2.5" String
2.0" String
EFECTO DE LA CARGA DE BOLAS EFECTO DE LA CARGA DE BOLAS
28 x 35 #
14 x 20 #
8 x 10 #
4 x 6 #
Moly-Cop Tools
TM
: Theoretical Framework
0.01
0.1
40 50 60 70 80 90 100
Exposed Charge Area, m
2
/ m
3
o
0
Series A
Series B
Series C
Series D
EFECTO DEL AREA SUPERFICIAL EFECTO DEL AREA SUPERFICIAL
Molienda de particulas finas Molienda de particulas finas
Moly-Cop Tools
TM
: Theoretical Framework
1
10
40 50 60 70 80 90 100
Exposed Charge Area, m
2
/ m
3
d
crit
Series A
Series B
Series C
Series D
EFECTO DEL AREA SUPERFICIAL EFECTO DEL AREA SUPERFICIAL
Molienda de particulas gruesas Molienda de particulas gruesas
Moly-Cop Tools
TM
: Theoretical Framework
0.01
0.1
1
40 50 60 70 80 90 100
Exposed Charge Area, m
2
/ m
3
EFECTO DEL AREA SUPERFICIAL EFECTO DEL AREA SUPERFICIAL
d
crit
/ 10
o
0
Moly-Cop Tools
TM
: Theoretical Framework
60
70
80
90
100
110
120
130
140
20 40 60 80 100 120 140
Specific Charge Area, m
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/m
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F80 = 9.8 mm
For each grinding application, there
exists an Optimal Make-up Ball Size
(charge area) that maximizes the
capacity of the grinding section.
EFECTO DEL AREA SUPERFICIAL DE LA CARGA EFECTO DEL AREA SUPERFICIAL DE LA CARGA
Tamao ideal de carga Tamao ideal de carga
Moly-Cop Tools
TM
: Theoretical Framework
40
60
80
100
120
140
160
180
200
20 40 60 80 100 120 140
Specific Charge Area, m
2
/m
3

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5.0 mm
9.8 mm
16.0 mm
20.0 mm
F80 Feed Ore The Optimal Ball Size (Charge Area)
depends strongly on the Feed Size
of the ore.
EFECTO DEL AREA SUPERFICIAL DE LA CARGA EFECTO DEL AREA SUPERFICIAL DE LA CARGA
Carga Ideal en funcin del tamao de Alimentacin Carga Ideal en funcin del tamao de Alimentacin
Moly-Cop Tools
TM
: Theoretical Framework
TAMAO OPTIMO DE BOLA TAMAO OPTIMO DE BOLA
0
20
40
60
80
100
1 10 100
F80 Fresh Feed Ore, mm
C
h
a
r
g
e

A
r
e
a
,

m
2
/
m
3
Conventional Grinding
SAG Grinding
Current Technology Limit
2
2
3
4
5
6
8
The Optimal Ball Size for SAG
applications would be larger than
the largest commercially available
size (6.0").
Tamao Optimo de Bola
Podrian imaginar que siente
una pobre partcula cuando
Es atacada por una
bola de 6.0...?
0.1
1.0
100 1000 10000
Particle Size, m
S
i
E
,

t
o
n
/
k
W
h
3.0" String
2.5" String
2.0" String
EFFECT OF BALL CHARGE COMPOSITION EFFECT OF BALL CHARGE COMPOSITION
Laboratory Tests with Monosize Fractions Laboratory Tests with Monosize Fractions
28 x 35 #
14 x 20 #
8 x 10 #
4 x 6 #
Moly-Cop Tools
TM
: Theoretical Framework
Moly-Cop Tools
TM
: Theoretical Framework
Existe una natural creencia de que al recargar una
combinacin de bolas de distintos dimetros, se lograra
una mejor eficiencia de la molienda de las partculas
gruesas (por la accin de las bolas ms grandes) y a la
vez, una mejor eficiencia para las partculas finas (por la
accin de las bolas ms pequeas).
Sin embargo, as como las bolas de mayor dimetro seran
eficientes para fracturar las partculas ms gruesas, al
mismo tiempo, seran relativamente ineficientes para
fracturar las partculas ms finas ... mientras lo contrario
aplicara para las bolas ms pequeas.
El resultado combinado de ambos collares de bolas sera
equivalente al de un collar de recarga nica con bolas de
un tamao tal que exponga igual rea especfica en
m
2
/m
3
.
DIAMETROS MULTIPLES DE RECARGA DIAMETROS MULTIPLES DE RECARGA DIAMETROS MULTIPLES DE RECARGA DIAMETROS MULTIPLES DE RECARGA
Recarga Multiple
0.01
0.10
1.00
0.01 0.1 1 10 100
Particle Size, mm
S
i
E
,

t
o
n
/
k
W
h
54 m2/m3
67 m2/m3
EFFECT OF BALL CHARGE COMPOSITION EFFECT OF BALL CHARGE COMPOSITION
Industrial Scale Confirmation Industrial Scale Confirmation
Specific
Charge Area
Moly-Cop Tools
TM
: Theoretical Framework
Mina RRICA Case Mina RRICA Case
EFFECT OF MAKE EFFECT OF MAKE--UP BALL SIZE UP BALL SIZE
Recharge 100 % 100% 100% 50/50 % 100%
Policy 75 mm 64 mm 50 mm 50/38 mm 38 mm
Area, m
2
/m
3
63 76 94 108 126
alfa
0
, ton/kWh 0.00969 0.01128 0.01225 0.01273 0.01290
d
crit
, microns 7093 5079 3853 3370 3040
Current Condition Current Condition
Moly-Cop Tools
TM
: Theoretical Framework
100
120
140
160
180
200
220
50 60 70 80 90 100 110 120 130 140
Area Especfica de la Carga, m
2
/m
3
T
a
m
a

o

d
e

P
r
o
d
u
c
t
o
,

P
8
0
,

m
El area ptima de la carga sera 80 m
2
/m
3
,
correspondiente a una recarga con bolas
de 2.36|.
Sin embargo, la eficiencia de estas bolas
sera muy similar al de una recarga con
bolas de 2.5|, comercialmente disponibles
OPTIMIZACION DE LA FINEZA DEL PRODUCTO OPTIMIZACION DE LA FINEZA DEL PRODUCTO
en funcin del Dimetro de las Bolas de Recarga en funcin del Dimetro de las Bolas de Recarga
3.0 3.0 2.5 2.5 2.0 2.0 1.5 1.5
S
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i
n
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P
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o
c
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s
s

A
n
a
l
y
s
i
s
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r
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n
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r
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e
s
s

A
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GRACIAS GRACIAS
Developed by Moly-Cop Grinding Systems