Chapter 17 ‘THE PREDICTION OF POWER DRAW TN COMMINUTION MACHINES. Moreland TJ. Napier-Munn Jute Kratscatt Mined Reseach Cee nes Road, Indoorooply, Queensland, Averaia J. Andersen ‘Wimmera instal Minerals Horsham, Vitor, Australia ABSTRACT ‘he very large quenties of energy wed for sie reduction in the minerals procesing industry esos the state prediction of commonaion machine pour draw for optim plant desi The [AMRC as deodeped fective male for predicting all mill, auogenous mill, semi Testu mil ed cer poner de When combined ith comminution mal Hey provide # rl tl for eocuating ot only the siz reluctn performance of plant design, bu power Iason ffleney a6 wel “Tris paper describes the stracre of the mil and crake power models. Data from a wide range of upon ies are prseied whch state the accuracy ofthese ol Iymnopucion ‘The energy consumed by somminaion opment in the minerals processing industry account fora ‘major pf the operating costo the plant Even small improvements fo the power wtization Miceney of commnuton elt can therefore have a sigifiant influence on the economic ‘evformance ofthe plan The application of simulation to explore the energy elceny of new Fant designs and fo opti existing plan therefore has aval oe playin thi gard “The Jus Krutch Mineral Research Centre KMRO) hasbeen invalved with the simalation of ‘mminuton and asifeaion cet for over 23 years. Recenly has developed mathematical {tehnigues for acura predicting the power draw of ball mils em-autogenows ml, fly ‘utogenous mile andl res which are reviewed i ls paper “The JKMRCS research actives have generated large Industrial comminution machine data ths! This hs cabled hese power mds tobe igoroust ested and refined. "THE RELATIONSHIP BETWEEN POWER DRAW AND SIZE REDUCTION ‘The size reduction action of grinding mills ifr fom that of crushers. This fs de tothe ‘Eiferenes in the way that power fe tanemited hy the machine to the ore, The power draw of frachines such oo and gyaiory crushers is dependent pen the ore fedrate and the ste Teuton across tMe machine, This in tun s diate by such factors as the crushing chamber romerygapetng, tow and liner prea condition. Powers raw on-demand when or ‘orton eich ae thers fo args to pase trough the case unchanged, are crushed. Power204 ‘CoMMINUTION. ‘is therfore del rated to the degree of se reduction and hence ts prediction mus eink in some way tots process ‘The crusher action contrasts with that of ining mills where the power dr edited by the ‘motion and magnitude ofthe charge. Size rdacon can therfore be viewed 4s byrprodct of ‘moving the charge around inthe ml In the cse of bal tls pata, this results n he power draw being largely independent of fed conditons and the amount of size reduction. Modeling of ml power draw can therefore be accomplished without reference to size eduction Only themotion a he charge neds ob conser. ‘The flowing sections wil describe the crusher and mall power models in tam. The diferences ‘betwen these machines In thelr le redaction action is refieced inthe very diferent structure of the model "THE PREDICTION OF CRUSHER POWER DRAW ‘The crusher power model enables the prediction of power draw from «knowledge of the breakage racers of the or, the size reduction af or by the ruses and the relative power ulation ‘tceny ofthe crusher. "The breabage characteristics are determined by 2 laboratory test on epresefative samples of ore. The power is then predicted from a spe rgresion equation ‘eltng the power acialy drown by the induaral machine in producing «pers prod ie ‘istsbution fo the gael power equtedt achive the sme sine rdton inthe laboratory test The rogresion coffients have physial meaning In terme of the power utstion of ‘arcu crusher types and installations” The model was developed by Andersen (98) based on {alr work by Awache (985, and an early varson Was describe by Andersen and Nepler Munn ‘95. Tthas mow been applied to several crusher types and hasbeen found fo provide stlatory redicons i each ease Ore-specific energy -size reduction relationships ‘The prod size dstibuton of mechani crshers uch grainy aed cone crushers is dependent manly om the stor gap and to lesser extent on te liner profi and condition the feeds and the fd size CArderon, 18; Andersen and NepierAtann 1090, The power drawn bythe rusher toachiw that size distribution under given st of condivonsi then dependent upon te breakage ‘characterises or "harden of the re ‘The breakage characteristics are determined In the laboratory with a single particle (wi pedal impact device, desebed by Narayanan and Whiten (198). This device is used to {stalish a relationship between the energy used in beaking the pate and the resting product ‘Sze distrbution. The energy is expressed a th “specifi comminution energy” Ex unite W/O, and is calculated from simple energy balance ares the pend, andthe mass of the part ‘The product sie distrbuon expressed interme o the amily of curves stb by Narayanan and Whiten (1985), and in particalar the to prumeter Thee concepts ae an important element i ‘he power model and wil therefore te brify reviewed hee ‘A conventional cumulative size distribution obianed from the breskage of particles ofa given sae inthe twin pendulum can be characters Interns ofthe proportion of mae pasaing parler factions of he inl sine ofthe pres (igre 1 ‘The value (the proportion of material pasting 1/10 of the olga particles) usually taken as the characteristic value” By breaking partes witha ange of intial sizes at several Es ‘values, range of size distbations and thus 9 values is generate. Tt has been found I the ‘mulative percent fineness values are plot spans tip for oir characterise values uch = "a5 tn ete) a family of curves rests on which al the nll parte size/Ecs combinations ‘ai igure 2.PREDICTION OF POWER DRAW 235 Ys Tost parle oe ‘CUMULATIVE PERCENT PASSING % vine via via PARTICLE Size MMe Figuce 1 Cumulative ize catruron in tame of ty paramere Tooetm? y 2 foefrormr : 77 Ee e a tet 5 aw ‘as 8 0 Sensei os PRS ° ner er) ° [BREAKAGE DISTRBUTION PARAMETER 10 te 2 ~ Brskage Olatbutlon Fonction (Levee) for Argyle Ore ‘Such a family (or breakage function i pee othe or type tte. However the accumilation of ge volume of pendulum data from various sources in recent years has shown that mos ‘Somrentonl (bit oes can be descrbed by a ingle fara of eurves suggesting a common ‘realage charaterete and frter simplifying madel prediction algoritns. “The curves (eg Figure 2) can be numercly represented by spine functions. Ith 49 vale fora pacar industrial comminution proces can be predicted rom an appropriate model then these _Trtnbution of the process produc con be recone from the spline functions describing the ures (le the Brebkage fonction). Inthe crusher ase thes fund to bea characters of he prscular machine, installation and operating coniton,‘ComMNUTION ‘The final stage in the laboratory breakage charactriastion procedure is to cstablish the relationship Between the breakage parame 0) the Ina prtce size and the specie ‘ommintion energy, Bes, obtained from the pend est, gain, thse cre-specifie lationship ‘an Be represented numeral by spine fanctons ‘The Crusher Model ‘The breakage process in the crusher is described by the wellknown Whiten model (Whiten, 1972, which Is stated conceptually In Figure 3 gue 3 Sehemaic of the Whiton Crser Mods Isa vector representing the amount in each size fraction inthe crusher 1 the fod te distbuion vector 's the product sae disesbution vector {4 he’ chssication or breabage sleton mates, dacribing the proportion of parels in each sz neva entering the erushing zone [othe breakage distribution mati: giving the teat dstrbution ofeach sie racson ster breakage ‘The product size distribution vectors determin! bythe mass balance equation ped-Oxd-ncyts « hore sth uit mar isa function whese parameters are machine-spectic and depend on operating conditions (eg ‘Andersen and Nap Munn, 1988). The vals of the elements ih he orespeciceahoge mates ‘Beam be determined om the pendulim dried curves ‘The values fp ae then determined fom the spline functions describing the oe ape curves, given the vale of t19. The crusher mode), Exuaton 1, yas parometeied 50 sso Bt the tvee parameter of the clasifiation faction, C_ ard the parameter 8 10 data obtained from plant Erveys. Appropriate nonce parame etna gues wee employed, Tals proadure ‘State valve oft which Bat reproduced the dat for hat parte Inaliation In the development ofthis model plant surveys of 40 (2.19) cone risers were undertaken at ‘Mount is Mines (ccpper ore, Bougainville Copper, Argye Dismond Mines and Hamer ron (Tom Price) Andersen, 1980. ‘Pendulum tts were contd onal he fed ores, and ween spline regression was used to represent the resling tearves. The 0 parameter wa ited tea ‘instalation specifi constant, with values Ing in the narrow range 183199,PREDICTION OF POWER DRAW ‘The Power Model ‘the power model relates the actual power dra by the crusher to the power required by the pandalum a aceve the ame sz reduction. Its te frm ReeAPpsPa, o ‘where athe power drawn by th rusher under Toad) Dp isthe ealaated penculsm power GW) hs the power drawn bythe crsher unde ola GW). ‘Ales dimensions constant fora parteular erusher, ‘obtained by repression “The caution ofthe pendulum power, Psi bast onthe rsher model asad in Figare 3. In this model € is ewentally a selection funtion describing the probaly of parcies ofa given Sie reporting for breakage Te vector x the shy ae mate flow of parle in the crusher {Gia Fhe product Cixi therefore the mass owe parce of se reporting to Breakage. When feed and product mace flow and sae ditbution data are avalable fom pant surveys, and the Treshage fonction Bis known iron theprevalng ve of hen Che can be alata by sing {he sie bysie mare balance indices in Figure 3. The specific comminution energy, Ec, "ppropriate to each ie, cam be obtained rom te spline descriptions ofthe orespeie Echo: ‘Se elationahipe obtained fromthe pen est. The pendulum powers then given by: syed saaacen ° where Essugh = spedificcommination energy {Ho for sie | (WI /) 1 = umber of size ners & prota of breakage of size x ‘ass flow of sae inthe crusher (/P te proving value of pi therefore the ttl enegy equines to eae the crusher fe sae lstribution to the product se inibtion, al the redution tok place inthe pend. By surveying the same crusher unt a variety of power draws an size eduction, i possible to ‘labloha valu for Ain Equation 2 by simplest squares near regression. The parame Aan ‘be interproted as representing the Hnaficeney f power uullsation by the crusher (including anomission inefences) compared to that of the penduliem 1007A ts the crusher power ars perceniage of he pendulum power. Power efficiencies in the range 70-80% have been ‘stmted for conventional cone shes ns vant of mineral processing dts Since the power mode! takes account ofthe acs ze redetion achieved and the tonnage treated bythe ensher itpovidess means of comparing ts power fisony of diferent paters and types ‘truer, ter of A (or 10/A). The asa per draw ofthe crusher ina arial daty a of oure be eximated by substituing dre in Equation 2 with a value of Fp corresponding Yo the ty ofinerest, Application of the Model “The power made hasbeen tested in several indus sites and on several machine types and ies. In prticula, maliple data sot corresponding oa range of operating conditions (patclaly Fecdate and lsed-side sting) were obtained from tre stesso hem operating 7 fot 213 0 cone crahers The crusher ype sn ange of operating conditions studied are summarised in Tiel.‘commnuTion Ed rave Hameniay Mica Winer ‘conditions | Diamonds rom (Copper TomPrise’™ __Concntate) Grsher Type] Rabe tA) Nordberg Nordberg Hyrone ‘SxHD ‘SxHD EHDS/si ——shorthead ——_shorthead with Hiydrowet Day Teninny ——Srcondany ‘rroughptt 9.298 “e050 Feed Gam) an 2439 ‘C35 (men) 136 mat Power draw GW) min 12080 [Novoad Power 7 10 ew) No. data ste 8 2 a Table 1 ~ Summary of mduatal Crusher Test Cond Equation 2 was fit othe industrial data i ne form eR APp o vith ting estimated by incr regretsion witha suppressed (aero Intercept, The els forthe thre rushers sted in Table I were Asgyle Te = UatpemOKW ano; RECON" Hamersley (Tom Pe) Peo 13 ppetI7AW—— Gen020, Raosty Moun aa Mines Pe = 1207p et0KW Geen, R= 08) ‘The satisfactory ually ofthe fis are apparentin Figuce 44s ° © Data obtained in joint CSIRO - Hamers ron research project sed with permission + se-=-standard enor of ited coetcent 2 coefcentof multiple determinationPREDICTION OF POWER DRAW 29 404 Predeted Power (kN) § ‘Observed Power) Preicd Power (kW) 190120. 140 160189 200 ‘Observed Power (ki) Praictod Power (k™) 190 180 200 250 300 950 400 (Observed Power (iW) Observed ve Pradicted Total Power Oram tien Cone Crush‘comminuTION, “Th Yo ofthe coon are sent te sr, the power efficiency (10/4) ranging fom 70% to €% Shai tests ofthe signance ol the ferences between the eximated oeticens {Gased on the standard errors ofthe estimates) sagges thatthe two orthend crushers have Simul eoetcients, bat hat the Argyle Hydrcone has &signcanly higher value than that of the Mla shorthead. The tests were conducted under very diferent condition, and wold therefore be tnvrise to over interpret the result, However t may be evidene thatthe power “usatonefiencyt achieve aren size edscton docs dapend upon mechanics deg [No stious losin predictive capability I incued ithe mean value of he coeficens for the Tom ‘ce and ML Isa SXHD shorted uns swt represent bath machines Peel288Fp + nolead power ° igure shows the odes fit forthe combine dat set 200 Precctd Power kW) 0 100 200 300 400 600 Observed Power Ga) Flows, Obuava vu rand Tota Por Drm ‘THE PREDICTION OF GRINDING MILL POWER DRAW A grinding mil draws power toi its charge of balls and/or ore an to provide it with motion. By Sng poston ofthe eement Power cam be defined in ers of torque (and rottina ate (a5 lows:244 ‘COMMINUTION Power=2eNt oo For grate discharge mills, by intgrating beter the limits Os and Or and between and im the net ower Pat) sven by tm rastente | J Net cas dode as where Ne roalonal rat at radia distance r mil rive ‘i charg surface aia ae Figure 10) y= angular postion af th shoul, 6 = angular poston of the to. Fr overiow mills an addtional erm mast beaded to Equation 15 to account forthe su between ‘osions Grand fg (ee Figure 10. The dns of hs potion ofthe charge wl be ilar fo at ‘ofthe discharge slurry. ‘The density ofthe mal charge willbe diferent and le eta from the ‘ore and sie! sg. ther relatve proportions atin the charge the woidagesssociated with each faction and the degre of sary filing. The value of 89 and yar obtoned ftom equndona describing the mation of charge of fonction of al sped nd charg eel (Morel, 199 No-Load Power ‘The no-lud power draw fe that drawen bythe ml when completly empty is asscated with ‘various lectcal and mechanical energy loses. The ain one are toy, gearing an bearng lowes. None of thesis xed over the mls fll operating range. Some, however ay have fxd component. For example, bearing losses du to fiction wil be dated by the tis deed ‘eight (hough even ths will vary as lines and lire wea), and the el charge weight Which ‘il leary ary with grinding condition ‘To determine the relationship betwen no lad power and mill design parameters, data from pilot and industrial mils anging from 17-72 min ameter were analysed. The parameter DUUN was ‘grees against no load power and found ts provide a good ft Figure 1. The relationship ‘veloped was o fll: [No Load Power kW) #3345 (09 L NPS 06) 82-0956; n=5) ‘where _D-= ml diameter (m) Es ml ength [Nj = ll tation rate (rov/se0)PREDICTION OF POWER DRAW 25 ‘Observed i) a Prdlte gore 11 - Observed ve Fited No Lond Power Model Accuracy “Toe most recent JKMIRC database curently inlaes power data rom 4 diferent ball SAG and AG nile Detis are shown in Tabi 2. Tange of De air a SAGIAG Diameter ‘91-35 12-375 Length 15-88 58-65 Se Crea! Speed eas-340 ‘tal Lod 0-48 Charge Level (®) ‘Gro Power cw) 7-400 Gress. 26-45 Nov Mis 76 ‘No. Dat Sets 3 “ebie 2 = MUI Dua Base Det ‘The power model was appa ots database an found to give excelent result (Figure 12, The ‘lander deviation of the relative err ofthe mocel was cleats fo be 65%, “The mode therefore requires knowledge only f mil dimensions and sped, ball charge, volume ‘ecupled by alls sd pulp, and te oe specie gray. Full details of the model are given in Morr (98D.‘CoMmNUTION ew ° 2000 ”~«4000=~~=C«w00 S000 Predicted (ew) Figure 12 - Obeerved ve Prost Ml Power Draw ‘CONCLUSIONS -POWER MANAGEMENT IN COMMINUTION CIRCUITS, ‘This paper has desrbad procedures forthe prediction af power draw by comminton machines Industral mineral proceting plants Thess proces provide the ably accurately to etna the otal power inventory regulred for partir dre configurations, machine sles a operating ‘onatons for both esting Pants and green daigne A feature ofthe techniques, as noted ener, the diference in methodologies appropiate for rushers ae tumbling mils which elects the iffrnce in the way hese clases of machine se power to aleve brentage. In crasing sigan proportion ofthe power island diety i Ifactre, and the prediction method must Derefoe take account of the size reduction being schioved. In bal tll the majoty of power ito rotate the mil and move the ball targe ‘The power draw can therefore be aecrtely pried witht aking any assumption a abet the degree of breakage beng achieved [AG and SAG mila somewhere between these wo cases. The ore component ofthe charge in such iil and hence the power wed to move ti sgnficant. Tease efucton simulation has tobe nace in ode pri the mass of ore preset inte charge Despite these necessary difereces, ther is a tong synergistic eect in bringing together the two ‘computational procedures as tals to analyse the power inventories of particule and 10 ‘optimise crul desig and machine sclection with respect o power draw. An example of such a study was described recently by Morell et 2 (191), n which it was shown that the energy ‘cen ofa single stage SAG mil/ball ill drei teatlng gold ore equalled hat ofa ml Sage crushing and milling cei weting the same ore, ot tat the later incurred oe prac in ‘maintenance and Iabour, the SAG mill ll dec ws therefore the prefer open. ‘A common problem in both existing pnts ard new design to optimise the power wilson betwen the varios Glasses of machine (crushers, AG/SAG ml, ball mil). Th existing plants,PREDICTION OF POWER DRAW ‘his implies making best use of he installed power avallabe. In new plant, a crcit must be “Goigne and equpinent selected which wil achieve te desired le reduction at manimam projet, SERN both hots hetecrigucs described inthis paper, combined with exblished proces: ‘Straation methods (eg McKee & Napier Munn 1990), tere powerfel tol for the design and ‘Spimisonofconseition eeu. AcknowtepceMents “The work deserted in thie paper was conducted within a IKMRC research proc in miners procesing. sponsored ty &lnge numir of ming industry companies through the Australian ‘finer tndustrics Rescarch Assocation. Parise tanks are dve to the management and ‘elalurgeal staff of Argle Diamond Mines Lined, Dominion Mining Limited, Hamerley iron iy Linsted and Mout lea Mines Limite, on howe tes data reported inthis paper ere Colieced. ‘The authors would alo lke to espectlly thank De. Keilh Weller of the CSIRO Bivison of Mineral & Proceas Engiesring for peislon fuse data cbained rom the Tom Price ferry crusher ina nt CSIRO = Hamesey ion research programme. REFERENCES ‘Andersen J. & Napier Munn T1888, Power prediction for cone crushers, Prec. Sr Mil Ops. ‘Conf, Cobar As. Inst Min Met, Andere |S. Napler Mun TJ, 190. Theluene finer contion on cone crusher pefomnc. “Mirra En, Val 3 NO. 1/2, 18-16. Anderton JS, 1988, Development ofa cone crusher model. -M fng (Se) thesis, University of ‘Gasolina, [Awachle SE.A., 1983. Development of crusher models using laboratory data. PRD thesis, ‘Universi of Queensland. Mekee DJ & Napier Munn}, 190. The tats of comminution simulation in Astras, Minas ng 3 No-1/2,722. Morrell, 1981, The Prediction of Grinding Mil ower. Accepted fr publication in Trans. Ia. ‘Min Met Morr, Johnson G. &e Revy 199. A compton though observation and simulation ofthe [power station performance of two Sinsimiarcomminution plans. Proc 4 Mil peor Cofrou, Bari, Tasmania, Aus Inst Min. Met. [Narayanan SS, & Whiten W3, 1968. Determination of comminuton characteristics from single uve breakage tents and ie application ball ll seale-up. Trans Inst Min. Met 97, Guiscize ‘Whiten WJ, 1972 The simulation of crushing plats with models developed using multiple pine rogresion. JS. Inst Min Met, 72,287 26 27ee