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Moly Cop Tools 1 PDF
Moly Cop Tools 1 PDF
Moly
Moly--Cop Tools
Moly--Cop Tools
Moly
DE QUÉ SE TRATA ?
d = (d1 * d2)0.5
100
80
% Retained
% Passing
10
10 100 1000 D80 10000
Particle Size, mm
100
80
% Passing
Product
Feed
10
10 100 P80 1000 F80 10000
Particle Size, mm
Test ID : Sample 1
Es decir:
A mas kWh/ton
kWh/ton,, menor P80 !
Leyes de la Molienda
Ley de
Bond
1 1
E 10 *Wi *
P80 F 80
Ley de
Bond
P
E
M
En la expresión anterior el par F80 y P80 se les denomina tarea de molienda; así mismo
permite estimar la energía (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)
11
Feed Size (F80) and the resulting
10 Product Size (P80).
7 Feed Size
4000 mm
6
2000 mm
5
1000 mm
4
80 100 120 140 160 180 200 220 240 260
Product Size, mm
N = Nc Ncrit Ncrit
donde D en ft y N en rpm.
N Pnet = c • W sin • N
Torque
with :
sin
W sin
W = rap J (pD2/4) L
0.0500
Conventional
SAG
0.0400
J = 26 %
.
= 40 °
0.0300
(kWh/ton)/rev
0.0200
0.0100
J = 38 %
= 32 °
0.0000
0 5 10 15 20 25 30 35 40 45
Effective Mill Diameter, ft
No basta con tener
Potencia disponible,
también hay que saber
Usarla con Eficiencia !
AREA ESPECIFICA DE LA CARGA DE BOLAS
8000 *(1 f v )
a R
dB
100
2”
80
Charge Area, m 2/m 3
2½”
60 3”
4
40
”
5”
Current Technology Limit
6”
20 8”
Conventional Grinding SAG Grinding
0
1 10 100
F80 Fresh Feed Ore, mm
Planilla Media Charge_Level ...
h
Moly-Cop Tools
TM
DETERMINATION OF CHARGE LEVEL IN A MILL
by Measuring Free Height Above the Charge
Remarks : Molino 1
30
20
10
Angle degrees 154.66
0
Charge Level, % 36.15
0.50 0.60 0.70 0.80 0.90 1.00
h/D Ratio
Media Charge Level
Planilla Mill Power_Ball Mills ...
TM 3.4 % Mayor Potencia
Moly-Cop Tools
CONVENTIONAL BALL MILL POWER ESTIMATION
Hogg & Fuerstenau Model
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 Mill Charge Weight, tons Apparent
Ore Density, ton/m3 2.80 Volume, Ball Slurry 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 Power_Ball Mills
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 Mill Charge Weight, tons Apparent
Ore Density, ton/m3 2.80 Volume, Ball Slurry 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
Planilla Bond_Op. Work Index ..
..Caso
Caso Base.
Base.
TM
Moly-Cop Tools
BOND'S LAW APPLICATION
Estimation of the Operating Work Index from Plant Data
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 Mill Charge Weight, tons Apparent
Ore Density, ton/m3 2.80 Volume, Ball Slurry 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
Planilla Bond_Mill Throughput ...
TM
3.4 % Mayor Capacidad
Moly-Cop Tools
BOND'S LAW APPLICATION
Estimation of a Conventional Ball Mill Grinding Capacity
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 Mill Charge Weight, tons Apparent
Ore Density, ton/m3 2.80 Volume, Ball Slurry 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
Las “Odiosas”
Limitantes Operacionales
Mandamiento #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 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 Mill Charge Weight, tons Apparent
Ore Density, ton/m3 2.80 Volume, Ball Slurry 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
Las “Odiosas”
Limitantes Operacionales
Mandamiento #2
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 Mill Charge Weight, tons Apparent
Ore Density, ton/m3 2.80 Volume, Ball Slurry 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
Las “Odiosas”
Limitantes Operacionales
Mandamiento #3
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 Mill Charge Weight, tons Apparent
Ore Density, ton/m3 2.80 Volume, Ball Slurry 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
Las “Odiosas”
Limitantes Operacionales
Mandamiento #4
Remarks : Molino 1.
Ore Properties :
Ore Density Work Index Feed Size, F80
ton/m3 kWh/ton (metric) microns
2.80 13.03 7000
AZZARONI's Formula :
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
Moly-Cop Tools
TM 7.5 % Mayor Capacidad
BOND'S LAW APPLICATION
Estimation of the Operating Work Index from Plant Data
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 Mill Charge Weight, tons Apparent
Ore Density, ton/m3 2.80 Volume, Ball Slurry 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
Planilla Bond_Mill Sizing ...
Moly-Cop Tools TM
BOND'S LAW APPLICATION
Conventional Ball Mill Sizing
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
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
% Solids in the Mill 72.00 Charge Mill Charge Weight, tons Apparent
Ore Density, ton/m3 2.80 Volume, Ball Slurry 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
P80 = 150 mm
Vortex ? Distribución de producto
# of Cyclones ? Carga
Circulante
Apex ?
170 tph
F80 = 10500 mm
Water ?
1833 kW
Overflow
7
5
Cyclone
Feed
Underflow
6
1 2
Fresh Feed 4
3 Water
Overflow 7
Fresh 6 Underflow
Feed
1 4 2
Water 3
Cyclone
Feed
5
Eficiencia de Clasificación,
se denomina como la
fracción de tamaño en la
alimentación que es
recuperada en la descarga.
Se espera que alcance su
mas alto valor para las
partículas gruesas en la
alimentación y que el
contenido de partículas
finas sea mínimo
U‟flow
c
P=
a1 * Q1.78 * exp ( 0.0055 * psv =
E i B pw + (1 - )
B pw E i
DC . h . DI .( DU DO )
0.37 0.28 0.94 2 2 0.87
c di m
E i = 1 - exp [-0.693.( ) ]
Ecuación del tamaño de corte
d 50 c
corregido 2
Dc * h 0.15
m = 1 exp [ a4 - 1.58 * Rv ] * [ ]
Q
0.46
c DC * DI 0..60 * DO 1.21 * exp ( 0.063 * PSV)
d 50 = a 2 *
DU . h . Q .( - 1 )
0.71 0.38 0.45 0.5
Rv - . Rsc
B pw =
1 - * Rsc
Ecuación de la partición de pulpa. n
Rsc = i=1 fi. E i
c
Qu 0.54 3.31
h *(DU/DO ) *(DU DO )
2 2 0.36 S
S = = a3 * Rv =
Qo 0.24
H . DC
1.11 S +1
0.28
% Fines in Mill Discharge
P80 = 168 mm
Vortex= 9.1 Product Size Distribution
# of Cyclones= 6 Circulating
Load 279
Apex 4.5”
504 tph
F80 = 6912 mm
Water
4316 kW
BallBal_Direct
Moly-Cop Tools TM : Theoretical Framework
Developed by Moly-Cop Grinding Systems
Theoretical Framework
BATCH PROCEDURE
Descripción y Muestreos a Nivel Industrial
Condiciones Iniciales
% de sólidos % 75
Llenado intersticial % 40
Velocidad crítica % 73
Area
Tiempo de
Alimentación Collar Evaluado Superficial
Molienda
m2/m3
Theoretical Framework
MODELO GENERAL DE LA MOLIENDA
Caracterización Cinetica de la Molienda
t=t t = t + Dt
(1-S1Dt) f1
f1
2 S1Dt f1 2
f2 b21S1Dt f1
3 (1-S2Dt) f2 3
S2Dt f2
bi1S1Dt f1
fi
bi2S2Dt f2 i+1
i+1
bn1S1Dt f1
fn bn2S2Dt f2
n+1 n+1
10
Selection Function, ton/kWh .
0.001
1 10 100 1000 10000 100000
Particle Size, mm
100
Fraction 10x14 #
Fraction 14x20 #
Fraction 20x28 #
Por ejemplo, b52 = 0.10 ,
significa que el 10% de todos
b0 los fragmentos de partículas
Bij
10 b1
originalmente retenidas en la
fracción 2 resultan retenidos
en la fracción 5 inferior, como
consecuencia de un evento
primario de fractura.
fractura
Bij = b 0 (di /dj+1)b 1 + (1 - b 0) (di/dj+1)b 2]
1
0.01 0.1 1
Relative Particle Size, di / dj+1
Nuevos
Proyectos
Instalaciones
Existentes
Pruebas Piloto Nuevas Cond.
o de Laboratorio De operación
Implementacion Recomendaciones
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 m3/hr 1542
0.392 Bpw
% Solids 76.00
Water,
m3/hr 356.9
ton/hr 400.0 Water, 222.1
F80 9795 m3/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
Mill Dimensions and Operating Conditions 3348 Balls Charge Mill Charge Weight, tons Apparent
Diameter Length Speed Charge Balls Interstitial Lift 0 Overfilling Volume, Ball Slurry Density
ft ft % Critical Filling,% Filling,% Slurry Filling,% Angle, (°) 536 Slurry m3 Charge Interstitial Excess ton/m3
16.0 24.0 72.0 38.00 38.00 100.00 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
Sample N° 1
100
Weighting Factors :
Streams :
Mill Discharge 1
Cyclone U'flow 1
Cyclone O'flow 1
Size Distributions 1
% Solids 1 % Passing
Obj. Function : 0.011 Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.
BallParam_Direct
TM
Moly-Cop Tools Simulation N° 1
BALLPARAM_ DIRECT
Planilla Conventional Closed Circuit Grinding Simulator
Size Distributions
Mill Mill
i Mesh Opening Mid-Size Feed Discharge
Theoretical Framework
SIMULACION DE CIRCUITOS DE
MOLIENDA / CLASIFICACION
Datos Operacionales
PRODUCT : 76% - 100 #
CYCLONES : max. 10
P80 : < 0.18 mm
Psi : < 13
CLASSIFIERS :
% Sol. : < 80 6 Cyclones @ 26”
Moly-Cop Tools
Moly-Cop Tools TM : Theoretical Framework
Planilla BallSim_Direct ... (Data_File)
Feed Size Distribution
i Mesh Opening Mid-Size ton/hr % Retained % Passing
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
Planilla BallSim_Direct ... (Data_File)
Planilla BallSim_Direct ... (Data_File)
CIRCUIT MASS BALANCE
Planilla Configuration : DIRECT
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 m3/hr 1884
0.375 Bpw
% Solids 75.60
Water,
m3/hr 464.4
ton/hr 504.0 Water, 262.0
F80 6913 m3/hr
Gross kW 4316.1
kWh/ton 8.56 % Balls 38.00
Wio 13.21 % Critical 72.00
% Solids 72.00
% Solids 61.24
Developed by Moly-Cop Grinding Systems
Process Optimization
DETERMINACION DEL TAMAÑO
OPTIMO DE MEDIOS DE MOLIENDA
EFECTO DE LA CARGA DE BOLAS
1.0
8 x 10 #
SiE, ton/kWh .
4x6#
14 x 20 #
28 x 35 #
3.0" String
2.5" String
2.0" String
0.1
100 1000 10000
Particle Size, mm
0.1
Series A
Series B
Series C
Series D
0
0.01
40 50 60 70 80 90 100
Exposed Charge Area, m2 / m3
10
dcrit
Series A
Series B
Series C
Series D
1
40 50 60 70 80 90 100
Exposed Charge Area, m2 / m3
dcrit / 10
0.1
0
0.01
40 50 60 70 80 90 100
Exposed Charge Area, m2 / m3
110
ton/hr
100
90
80
70
60
20 40 60 80 100 120 140
Specific Charge Area, m 2/m 3
200
F80 Feed Ore The Optimal Ball Size (Charge Area)
180 depends strongly on the Feed Size
5.0 mm of the ore.
160 9.8 mm
16.0 mm
140
ton/hr
20.0 mm
120
100
80
60
40
20 40 60 80 100 120 140
2 3
Specific Charge Area, m /m
2½”
3”
60
4”
40 5”
Current Technology Limit
6”
20 8”
Conventional Grinding SAG Grinding
0
1 10 100
F80 Fresh Feed Ore, mm
Moly-Cop Tools TM : Theoretical Framework
Podrian imaginar que siente
una pobre partícula cuando
Es atacada por una
bola de 6.0”...?
EFFECT OF BALL CHARGE COMPOSITION
Laboratory Tests with Monosize Fractions
1.0
8 x 10 #
SiE, ton/kWh
4x6#
14 x 20 #
28 x 35 #
3.0" String
2.5" String
2.0" String
0.1
100 1000 10000
Particle Size, mm
Recarga Multiple
Moly-Cop Tools TM : Theoretical Framework
EFFECT OF BALL CHARGE COMPOSITION
Industrial Scale Confirmation
1.00
SiE, ton/kWh
0.10
Specific
Charge Area
54 m2/m3
67 m2/m3
0.01
0.01 0.1 1 10 100
Particle Size, mm
Current Condition
OPTIMIZACION DE LA FINEZA DEL PRODUCTO
en función del Diámetro de las Bolas de Recarga
160
140
100
50 60 70 80 90 100 110 120 130 140
GRACIAS
Developed by Moly-Cop Grinding Systems