CONTENT AND STRUCTURE OF A PLANT GRINDING

PERFORMANCE MANAGEMENT/IMPROVEMENT SYSTEM

*O. Arafat ¹, R.E. McIvor ² and K. Bartholomew³

¹Metcom Technologies, Inc.

37 Hillsdale Court
Hamilton, ON, Canada L9H 6K1
(Corresponding author:omar@metcomtech.com)

²Metcom Technologies, Inc.

Suite B, 1021 Baraga Ave. West
Marquette, MI, USA 49855

³Metcom Technologies, Inc.

309 SE 3rd Ave
Grand Rapids, MN, USA 55744

ABSTRACT

The Functional Performance Equation for ball milling circuits provides plant staff with a new
means to improve circuit performance. However, successful execution of a plant processing performance
improvement project, with verifiable improvements, requires a significant number of accompanying steps
beyond using this equation. In order to identify and articulate all these steps, a study was undertaken with
the metallurgical staff from two milling operations and process application specialists from a grinding
media manufacturing company. “Task analysis” of improving plant grinding performance was carried out.
This analysis identified the required steps, and ultimately yielded a “Plant Grinding Circuit Processing
Performance Management/ Improvement System.”

KEYWORDS

Management system, grinding, ball milling, rod milling, AG/SAG milling, classification, circuit
optimization, functional performance.

148
 47th Annual Canadian Mineral Processors Operators Conference©, Ottawa, Ontario, January 20-22, 2015

INTRODUCTION: THE BUSINESS NEED

A management system can be defined as the framework of processes and procedures used to
ensure that an organization can fulfill all tasks required to achieve its objectives. (Anderson, 2005)

Grinding circuits are complex systems. There are large numbers of active variables, and
complicated interactions exist between them, which determine the “output”. The complexity of these
circuits warrants a systematic approach to their analysis and improvement of their processing performance.

In addition to complexity, there is an overwhelming volume of technical literature and other

resource material relating to the topic of grinding. Many references are conflicting and/or theoretical in
nature. Computerized circuit models can be extremely complex, to the point of being unusable by most
except devoted, expert users. This makes it challenging for plant metallurgists, with limited time and
resources, to identify what information is useful for them. An effective plant grinding management system
must provide a “tool kit” with everything needed to measure and improve plant grinding performance. Just
as importantly, in order to be time effective, it must exclude things that are not needed.

Direct grinding costs for energy and grinding media comprise a major portion of total plant
operating costs. As well, the characteristics of the grinding circuit product largely determine downstream
mineral separation performance, and thusly plant revenue. The business goal of operating a mineral
processing plant is to maximize profit. A system is needed which facilitates making changes to grinding
circuits which can be verified as clearly increasing (or failing to increase) operating profit.

Finally, in order to gain support for making changes to circuit design and operation, a system
which can be understood by all plant personnel is the most ideal.

OPPORTUNITY PROVIDED BY THE

FUNCTIONAL PERFORMANCE EQUATION

Since its discovery, development and industrial validation, the "Functional Performance
Equation" has emerged as a practical tool for characterizing ball mill circuit performance. It has been
applied at a large number of mineral processing plants to improve ball milling circuit performance (for
example, see McIvor et al, 2000, 2006, 2014). The equation demonstrates that the overall production rate
of a ball mill circuit depends on four fundamental factors.

Production Ball Mill Classification Ore Ball Mill

Rate of New = Power ˟ System ˟ Grindability ˟ Grinding
Product Draw Efficiency Efficiency

Each element of this equation can be determined from a sampling survey of a ball mill circuit in
steady state. The equation allows metallurgists to study the effects of various design and operating
variables on overall circuit performance by observing how these variables affect each element of the
equation.

The "production rate of new product" is calculated from the survey data. "Ball mill power draw"
is measured during the survey, and can be maximized or adjusted to suit production requirements.
"Classification system efficiency" is measured from mill feed and discharge size distributions, and it
defines the fraction of input mill power that is being applied to coarse particles. It can be maximized
through specific adjustments to the pumping and classification equipment. The "ore grindability" is
measured on a sample of mill feed collected during a survey to characterize the ore resistance to grinding.
“Ball mill grinding efficiency” is calculated from the other measured equation components, and it
represents the mill’s capacity to convert coarse material into fine material as a function of energy applied
to coarse material and ore grindability. "Ball mill grinding efficiency" can be maximized through
appropriate media selection and ball mill slurry percent solids adjustments.

149
 47th Annual Canadian Mineral Processors Operators Conference©, Ottawa, Ontario, January 20-22, 2015

By providing a clear relationship between circuit output (production rate) and the circuit inputs:
mill power, classification system performance, ore resistance to grinding, and mill grinding efficiency, the
Functional Performance Equation provides a unique opportunity for the plant metallurgist to systematically
improve performance.

ELEMENTS OF THE GRINDING PROCESS

IMPROVEMENT/MANAGEMENT SYSTEM IDENTIFIED

When applied to industrial plant grinding operations, functional performance analysis has been
proven to be highly effective for measuring and improving ball mill circuit efficiency. However, the
equation does not itself provide all the necessary means to optimize a plant grinding circuit. It was
recognized that an extensive technical and economics based support system was needed if functional
performance analysis was to be effectively exploited in an industrial context.

For the purpose of identifying all the topics that need to be addressed for a plant grinding
performance improvement program to be effective, extensive discussion with the staffs operating two
milling circuits, along with supply company specialists responsible for proper application of grinding
media, and a grinding specialist, were carried out with . Through this “task analysis”, the following were
identified as “essential tasks” in the overall job of measuring and improving plant grinding performance.

“Task Analysis” Identified Essential Elements of Grinding Circuit Performance Improvement

• Measure circuit ore tonnage

• Measure circuit size distributions
• Measure and achieve desired mill power draw(s)
• Measure ore resistance to breakage
• Determine Work Index Efficiency (Efficiencies)
• Tabulate direct costs and define circuit product value
• Study/tune the primary (rod mill) grinding stage
• Apply Functional Performance: Determine Classification System Efficiency and Ball Mill
Grinding Efficiency
• Achieve desired slurry pump performance
• Achieve desired cyclone performance
• Achieve desired ball mill conditions (media, water)
• Conduct circuit sampling surveys
• Implement grind control

Completion of all thirteen of these tasks was deemed likely to achieve the desired goal of
improved grinding circuit performance, i.e., verifiable increased plant profitability. Many other topics
related to the general field of “grinding optimization” were excluded. That is not to say some resources
(e.g. pilot plant studies, laboratory media size testing, computer modelling, etc.), outside of this system
could not be used, potentially, to supplement it. Rather, they are not needed in the plant metallurgical
staff’s “toolbox” for managing plant processing performance.

It is noteworthy that exclusion of even one of the thirteen identified essential tasks can (and often
will) result in failure of the system to achieve verifiable circuit performance improvements. This is a key
characteristic of any “system”.

THE SYSTEM STRUCTURE

The above list provided the basis for a plant grinding process management system. It was noted
that any of these tasks could be categorized into one or more of the following three general areas.

• Design
• Control

150
 47th Annual Canadian Mineral Processors Operators Conference©, Ottawa, Ontario, January 20-22, 2015

• Measurements and information

“Design” includes the selection of suitable design and operating variables to achieve maximum
circuit capacity, efficient circuit operation, and good product quality. The sub-elements of this area were
therefore identified as (1) grinding energy input; (2) grinding energy efficiency; and (3) grinding circuit
product quality. Grinding energy input is addressed through mill power draw characteristics (equations).
Circuit efficiency is addressed via Bond Work Index (see Rowland, 1976) and Functional Performance
efficiencies. Grinding circuit quality is addressed by comparing the mineral distribution by size in the
grinding circuit product to particle size by size mineral separation circuit performance (McIvor and Finch,
1991). Circuit design and operating variables are then considered in terms of their relationship to each of
these sub-elements of “design”. For example, ball mill dimensions, speed, media loading, etc., determine
its power draw.

Process control maintains (1) the desired circuit product specifications, and, (2) circuit operating
conditions which provide high capacity and efficient circuit performance, with disturbances (changes in
circuit inputs). Product size control is achieved through elimination of disturbances and by applying the
basic strategy of varying circuit feed rate to achieve the product grind size target (McIvor et al, 1988).

“Measurements and information” covers all the information needed to assess circuit performance,
to change it in a predictable way, and to verify improved performance. (1) Existing data includes all
equipment details (e.g., mill, cyclone and pump dimensions, mill and motor details, pump and cyclone
manufacturers’ processing performance information, etc.). (2) Required data is generated primarily through
detailed circuit sampling surveys.

DISCUSSION OF SYSTEM COMPONENTS

The Functional Performance Equation served as both the “core” evaluation tool and the driving
force for the development of the management system. It takes in to consideration both the classification
system and mill grinding performance and relates them to overall grinding circuit efficiency. Having these
two distinct efficiencies combined in one formula permits metallurgists to make changes to the
classification system parameters (adjustments to the pumps and hydrocyclones) and/or to mill grinding
variables (the media sizing and water usage of the ball mill) and then observe overall circuit performance
improvements.

Energy is the primary input of the size reduction process. It is also a major cost in mineral
processing. The efficiency of this process is measured on the basis of energy consumption as this energy is
delivered to the ore through the grinding mill. Using the industry-accepted mill power draw formulas
developed by Bond (1961) and his successors at Allis-Chalmers, the management system provides methods
for characterizing and changing rod, ball and AG/SAG mill power draw.

Mill power and charge level measurement are needed to characterize grinding mill power draw.
The management system includes procedures for measuring mill power draw at the pinion and the
volumetric loading in rod, ball and AG/SAG mills. Proper measurement of mill volumetric loading allows
plant operators to generate "power draw versus volumetric loading" curves for their mills. Plant
metallurgists can then apply this knowledge to achieve the desired mill power draw, normally to maximize
it.

A grinding management system must establish a basis for measuring the overall efficiency of a
grinding circuit. From this basis, it can benchmark a circuit’s efficiency compared to other circuits;
determine the potential for improving its efficiency; and evaluate the effects of various design and/or
operating variables on the overall circuit efficiency. When changes occur in a grinding circuit, whether
they be intentional (e.g. an experiment with water addition rates) or, imposed (e.g. a change in the
grindability of the ore), an overall efficiency metric is required to evaluate if the change produces a net
positive or negative result. The system uses the Bond Work Index method, as further developed by

151
 47th Annual Canadian Mineral Processors Operators Conference©, Ottawa, Ontario, January 20-22, 2015

Rowland (1976 and 2009), for measuring grinding circuit efficiency. It compares the Work Index of the ore
to the operating work index of the circuit. This approach is useful because:

• It applies to all size reduction circuits.

• It is a widely known and accepted standard throughout the industry.
• It is relatively simple and inexpensive.
• It provides a direct link to grinding economics

Direct costs for grinding energy and media are typically 20 to 40% of the operating costs for the
entire mineral processing plant. These direct costs are primarily dominated by energy and grinding media
consumption. Moreover, when the product from the grinding circuit is not optimally suited to the
downstream process (either too coarse or too fine), the subsequent losses of valuable minerals are indirect
grinding costs. The management system relates grinding efficiency to grinding costs and provides a step-
by-step methodology for making best economic use of potential grinding circuit improvements. Grinding
efficiency gains can be exploited in one of three ways: by reducing direct grinding costs (energy and media
consumption); by producing a finer grind (to improve recovery in mineral separation); or by increasing
tonnage. The determination of which is best (maximizes profit) for the operation is dependent on metal
prices, direct grinding costs, and the existence of constraints in the particular operation.

Classification is a critical component of closed circuit grinding. A grinding management system

must provide the tools that assist plant operators in evaluating the performance of their pumps and
hydrocyclones. The management system provides this knowledge as well as step-by-step procedures for
pump and hydrocyclone adjustments in order to achieve the desired classification system performance. The
system provides guidelines for manipulating hydrocyclone underflow percent solids, hydrocyclone water
usage, and the circulating load ratio in the most advantageous manner.

The “classification system efficiency” has a direct effect on overall ball mill circuit efficiency and
circuit output. It is a key part of functional performance analysis. The “classification system efficiency” is
defined by the percentage of coarse particles in the ball mill. This can be measured by taking the average of
the percentage of coarse solids in the ball mill feed and discharge. The system provides procedures for
achieving the best practical “classification system efficiency” in the ball mill circuit. For a number of
examples of plant improvements using “classification system efficiency”, see McIvor (2014).

The process of identifying and gathering the data required to achieve improvements in grinding
performance is detailed in the management system. The relationships between circuit variables can be
established by conducting grinding circuit surveys. Proper sampling is fundamental. The system provides a
comprehensive guide to help ensure that all the needed operating conditions at the time of the survey are
recorded and the required samples for subsequent analysis are properly collected.

The system provides detailed procedures for circuit sample handling and analyses, including
percent solids determinations, sample splitting (sub-sampling), solids specific gravities, and screen
analyses.

Bond tests provide the ore rod and ball mill grindabilities and work indices. The system provides
all the details regarding the equipment and procedures for conducting Bond rod and ball grindability
testing. Comparison with the circuit operating work index provides the Bond work index efficiency of the
circuit.

On-site tests can be developed to measure the grindability of the ball mill feed. The on-site test
provides a quick measure of ore resistance to grinding that is used to calculate ball mill grinding efficiency
using the Functional Performance Equation. Selection of equipment and test procedures for conducting on-
site batch grindability tests are provided.

152
 47th Annual Canadian Mineral Processors Operators Conference©, Ottawa, Ontario, January 20-22, 2015

The system provides mass balance software. By subjecting survey data to mass balancing around
the cyclones, the quality of size distribution data is checked, the solids circulating load ratio is calculated,
and cyclone feed stream characteristics are determined.

The system describes circuit design and operating variables which affect rod mill grinding
efficiency. Based on the data collected from one or more surveys, the metallurgist can evaluate the effects
of variables such as water addition rate.

Both work index efficiency and functional performance analysis are used for evaluating circuit
arrangements. Methods are presented to show the likely effects of alternative circuit arrangements, and the
resulting effects on overall circuit efficiency.

“Grind control” can be defined as the corrective actions which are necessary to maintain the
desired product quality and the design and operating conditions which provide a high level of circuit
performance, despite disturbances which occur to the circuit. Identifying these disturbances and
implementing suitable corrective actions form the basis of an effective control system. A clear conceptual
model for grind control is provided that ensures that metallurgical performance remains the focus of any
control systems implemented.

"Evaluation of Autogenous and Semi-Autogenous Milling” has recently been added to the system.
It provides metallurgical staff with a structured framework which they can use to increase overall
efficiency and production capacity of the AG/SAG-ball mill grinding circuit. Not unlike “Functional
Performance”, the two functions of the primary mill/circuit are divided into (1) slurry transport and product
size removal, and (2) size reduction. The latter in turn can be described in terms of the impact versus
abrasion mechanisms, their comparative energy usage and product size characteristics, the interactions
between them, and the effect they then have on the downstream ball milling circuit.

SYSTEM IMPLEMENTATION

Two plants and their staffs initially participated in the development of the system and the
associated training program, along with technical personnel from a media supply company. Experts in the
field of instructional design were engaged. After completion of “front end analysis”, which concluded that
a training program would be a suitable means of facilitating transfer of the new technology, the “task
analysis” was carried out to define the needed content of the training program. The “systematic approach to
the design of training” was subsequently applied to also: (a) establish program specifications based on
learner and context characteristics; (b) design, write, and test prototypes of the instructional modules; and
(c) deliver the training to plant staff (Lavallée, McIvor, and Stolovitch, 1992).

Implementation typically consists of training the plant’s metallurgical staff while they work
through planning, execution and analysis of an initial grinding circuit survey, either with or without added
technical assistance from Metcom. The metallurgist assigned responsibility for grinding improvements
completes the full program, while other personnel are assigned partial programs based on their particular
jobs. Many examples of plant studies conducted to date have been reported (Blythe, 1992; McIvor et al,
2000).

SUMMARY AND CONCLUSION

Successful implementation of grinding circuit improvements requires a basic understanding of

grinding circuit interactions, provided by the Functional Performance Equation, and a management
framework to ensure all of the steps in the systematic circuit performance improvement process are
completed. A list of essential tasks to effectively manage plant grinding processing performance has been
compiled and the tools and methods developed to complete these tasks form a comprehensive plant
grinding management system. The system, by design, includes all topics needed for industrial grinding
plant management, and excludes any topics which do not directly contribute to the goal of maximizing

153
 47th Annual Canadian Mineral Processors Operators Conference©, Ottawa, Ontario, January 20-22, 2015

plant profit. The tools, methods and overall system are now being applied throughout industry. Delivery to
plant personnel takes place through a specially constructed training program.

REFERENCES

Anderson, C., 2005, “How to Build Effective Management Systems”, Bizmanualz.com, posted January 26,
2005.

Bond, F.C., 1961 “Crushing and Grinding Calculations” British Chemical Engineering, pp. 378-385 and
543-548, June and August.

Blythe, P.M., 1992, “Productivity and Cost Reduction Strategies at Gibraltar Mines Ltd. Milling
Operation”, 14th CIM District 6 Meeting.

McIvor, R. E., 1990, “Introduction to the G.P.D Management System for plant Grinding Operations”,
Presented at the McGill Mineral Processing Professional Development Seminar, Montreal.

McIvor, R.E., Moys, M.H., Finch, J.A. and LaPlante, A.R., 1988, “Value Based Grind Control”,
Proceedings of Canadian Mineral Processors Annual Meeting, Ottawa.

McIvor, R. E., 1989-2014, “The Complete Training Program on the Metcom Grinding Process
Management System”, Metcom Technologies, Inc.

McIvor, R.E. and Finch, J.A., 1991, “A Guide to Interfacing Plant Grinding and Flotation Operations”,
Minerals Engineering, v.4, no.1, pp. 9-23.

McIvor, R.E., Weldum, T.P., Mahoski, B.J., and Rasmussen, R.S., 2000, “A Systems Approach to
Grinding Improvements at the Tilden Concentrator”, Mining Engineering, Feb., pp. 41-47.

McIvor, R.E., 2006, “Industrial Validation of the Functional Performance Equation for Ball and Pebble
Milling Circuits”, Mining Engineering, Nov., pp.47-51.

McIvor, R.E., 2014, “Plant Performance Improvements Using Grinding Circuit “Classification System
Efficiency”, Mining Engineering, Sept., pp.72-76.

Lavallée, M.L., McIvor, R.E. and Stolovitch, H.D., 1992, “The Design of Instruction to Introduce New
Technology - A Case Study in Canadian Mineral Processing” Proceedings of Canadian Mineral
Processors Annual Meeting, Ottawa.

Rowland, C.A., Jr., 1976, “The Tools of Power: the Bond Work Index, a Tool to Measure Grinding
Efficiency,” SME Fall Meeting, Denver.

Rowland, C.A., Jr. and McIvor, R.E., 2009, “The Bond Standard for Comminution Efficiency”, Recent
Advances in Mineral Processing Plant Design, SME, pp. 328 – 331.

154