MODELOS PARA MOLIENDA SAG

Paul Daz
Daniel Luer

Metodologas estimacin CEE

SAG
JK con su simulador JKSIMMet, utiliza parmetros de dureza Axb
determinados por pruebas drop weight test, SMC or JKRBT
SGS con su simulador CEET, utiliza parmetros de dureza crusher index y SPI
Steve Morrell con metodologa publicada para determinar potencia total del
circuito de conminucin
Dereck Barrat que utiliza los indicadores de dureza desarrollados por F. Bond
para molinos de barras y bolas
Pruebas Piloto calibradas con alguna instalacin existente
I&T que utiliza ecuacin (publicada por S Morrell) basada en las propiedades
de los minerales y condiciones operacionales, la ecuacin se calibra con datos
industriales

Introduccin Simulaciones Conminucin

Fragmentation model
blasting

Crushing Circuit Model

Ore Characterization

Grinding Circuit Model

Introduccin Simulaciones Conminucin

Hardness
Metallurgical
Recovery

(PLT, BWI, Axb)

25 mts

Tons per Hour

Volume

15 mts

CuT
Tph_

Density

Con
Grade
X, Y, Z

Cu Rec

Mineralogy
cc, cv, cpy, py, etc

Lithology, Minzone,
Alteration, Domains
Structures

Introduccin Simulaciones Conminucin

kw
P80

Kwh/tsag = f(Axb, Dwi, Mia, Mib, Mic, F80, T80, Ops)

Kwh/tBM = f(Wi, T80, P80, Ops)
T80
kw: shell power,
kwh/t : specific energy,
F80: Feed size
T80: transfer size (m),
Wi: Bond work index (kwh/t),
P80: grinding product size (m).

kw

TPH Circuit

Ejemplo JK

Ejemplo JK

Resultados JK

Modelos con SPI

kw
P80

T80

kw

Modelo D Barrat
[Ecuacin Barrat]

Donde:
- WIC: Work index de chancado
- WIR: Work index Molienda de Barras
- WIB: Work index Molienda de Bolas
- FB, FC, FR, son tamaos 80% pasante de alimentacin
- PB y PC son tamaos 80% pasante de Producto

CEE por Morrel

SMC, muestras con datos de SG, Axb y Dwi (Test SMC y Bond)

Reference:
Using the SMC test to predict comminution circuit performance

CEE por Morrel

Reference:
Morrell, S., 2009., Predicting the overall specific energy requirement of crushing, high pressure grinding roll
and tumbling mill circuits, Minerals Engineering, (14 February 2009)

CEE por Pilotajes

Metodologa I&T para molienda SAG

DWi Equations for AG/SAG kWh/t

kWh/t K.F80a.DWib.(1+c(1-e-dJ))-1.e.f(Ar)
DWi
F80
J

f(Ar)

=
=
=
=
=

a,b,c,d,e
K

=
=

TPH

rock strength index

80% passing size of the feed
volume of balls (%)
mill speed (% of critical)
function of mill aspect ratio
(length/diameter)
constants
pebble crusher function

Power draw (kW) / kWh/t

Reference:
Morrell, S., 2004a. Predicting the Specific Energy of Autogenous and Semi-autogenous Mills from Small
Diameter Drill Core Samples. Minerals Engineering, Vol 17/3 pp 447-451

Metodologa
Se utilizaron los datos industriales diarios.
Se utilizo la informacin de los modelos de bloque
para determinar Axb (a nivel diario) y el % de
participacin de las unidades Geo metalrgicas.
Se realiza ajuste, mediante mnimos cuadrados, de la
ecuacin de JK para encontrar las contantes del
modelo
Finalmente se compara los resultados industriales
reales CEE (kwh/t) con los predichos por la ecuacin.

Base datos de resultados I&T

Base datos de resultados I&T

Muestreos I&T para molienda

Muestreos I&T

Ore supply:
Crusher set up:
Mill set up:
Cyclone set-up:
Conveyor belt speed check for
sample mass estimates
Selection of sample points and
cutters
Sample preparation procedure
for slurry and belt samples

Planning
Preparation

Stream sampling
Measurements
Data analysis and reporting

Steady state operation

(min. 1 hour)
Pulp sampling (1 hour)

Crash stop SAG mill (1 hour)

Restart operations (1 hour)

Muestreos I&T
ANDACOLLO SAG AND PEBBLE CIRCUIT

PEBBLE
CRUSHER
STOCKPILE
5

SAG
1
Mass
Sample
Stream
Name
Flow t/h point
(Yes/No) (Yes/No)
1
Fresh feed
Yes
Yes
2
SAG feed
Yes
Yes
3
SAG discharge
No
??
4
Screen O/S
Yes
Yes
5
Crusher product
Yes
No
6
Screen U/S
No
??

SCREEN

Muchas Gracias

Back Slides

Muestreos I&T
Planning

Simplificar y buck slides

Resources, Scheduling, Responsibilities

Preparation
Ore supply: hard competent Hypogene ore needed, P80 <x mm
Equipment set-up: crushers, mills, cyclones
Sample points, samplers, sizing procedures
Stream sampling
Steady-state operation (1-2 hrs), full stockpile and pebble bins
Slurry sampling: one cut every 10 minutes for one hour
Crash stop mill and sample belts
Measurements
SAG load, Pi system data download
Sample preparation, splitting, drying, sizing
Ore hardness: Axb, BWi
Data analysis and reporting

Muestreos I&T
Ore supply: hard competent Hypogene ore needed
Ideal P80 <x mm, Axb = y
Crusher set up: tighten gap settings for primary and pebble crushers
Mill set up: ball addition, single BM configuration?
Cyclone set-up: replace worn apex and vortex finders
Conveyor belt speed check for sample mass estimates
Selection of sample points and cutters
Cut access port to BM discharge, clear cyclone feed and U/F
ports
Sample preparation procedures for slurry and belt samples
Labelling, weighing, splitting, dewatering, drying, screening

Muestreos I&T
Steady state operation (min. 1 hour)

Stockpile and bin levels med-high

Fresh feed rate constant
SAG power and mill load stable
Water addition constant

Pulp sampling (1 hour)

Simultaneous stream cuts taken
Each slurry sample taken in duplicate
Take 6 cuts at 10 minute intervals for one hour as long as plant is
stable
Cuts combined to produce two composites for each stream
Crash stop SAG mill (1 hour)
Lock out SAG mill and all conveyors

Collect the three conveyor belt samples

Pull feed chute and measure SAG load
Restart operations (1 hour)