Modelling and Simulation of Grinding Circuit in Lahanos Copper Concentrator

Ö. Özcan, N. Aydoğan, H. Benzer

Hacettepe University Mining Engineering Department , Ankara, Turkey

B. Sönmez and M. Ağyüz

Demir Export A.Ş.

ABSTRACT: Simulation of the grinding circuits using mathematical models of the mills and
classifiers is a technique which is being used increasingly in comminution because of its low
cost and its ability to consider many variables simultaneously (Lynch 1977, Napier-Munn et
al., 1996). In this study, modelling and simulation studies to improve the performance of
grinding circuit of Lahanos Copper-Zinc Flotation Plant in Giresun, Turkey were presented.
After detailed sampling surveys, size distribution and solids content of the samples were
determined in laboratory. After laboratory studies, mass balance of the circuit was performed
using these datas. Using the data obtained, the models were developed for the mills and
hydrocyclones used in the grinding circuit. Finally, 9 different alternatives for a better
performance were evaluated by using computer simulation. The results showed that the
performance of the circuit could be improved and energy consumption in the grinding circuit
could also be decreased by changing operational parameters and flowsheet. At the end of the
simulation studies, some of them applied the plant conditions and plant capacity increased
nearly %16 and energy consumption decreased nearly %10.

INTRODUCTION

Simulation would provide the quantified information about the effects of the proposed
changes on the circuit performance in terms of size distribution, solid and water flowrates etc.
Such information could then be used to check the suitability of the existing equipment to the
modified conditions, and for equipment selection
The aim of the study was to develop mathematical models of ball mills and classifiers used in
the grinding circuit and to investigate the effects of the proposed modifications on the circuit
performance using simulation. For this purpose, sampling surveys were carried out around the
circuit. The size distributions of the samples formed the main data basis for the following
simulation studies. The raw data was first mass balanced. Then, they were used for the
calibration of the equipment models for the circuit. Finally, the effects of a number of
flowsheet changes as well as the effects of changing operating parameters on the circuit
performance were investigated by computer simulations using calibrated models.
MODELLING

Perfect mixing modelling approach is used for ball mill modelling (Whiten, 1972). The
model considers a ball mill or a section of it as a perfectly stirred tank. Then, the process can
be described in terms of transport through the mill and breakage within the mill. Ball mill
model for steady state operations includes two sets of model parameters, i. e. the breakage
function (aij) and a combined breakage/discharge rate (ri/di) function.
pi i
p
f i  ri   a ij .ri . i  p i  0 (1)
d i j 1 di

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 Classifiers are modelled using efficiency curve approach (Napier-Munn et al, 1996). The
mathematical model selected for the study is capable of defining the fish hook type efficiency
curves. The general form of the equation is presented below.

 
 1   . * . X exp   1 
E oa  C 
  
 exp  . . X  exp   2 
*
(2)

where;

di
X  (3)
d 50 c
In cases where the efficiency curve does not exhibit fish hook behaviour, the parameter β is
equal to zero and a simplified form of this equation is obtained:

 exp   1 
E oa  C   (4)
 exp . X   exp   2 

The classifier performance can be modelled in terms of d50c (corr), by-pass (1-C), the "fish
hook"(β), and the sharpness of the curve (α).

SAMPLING AND EXPERIMENTAL

To evaluate the performance of grinding circuits and to obtain the data required for the
modelling studies, three sampling studies were performed in the circuit. Samples were taken
from the points marked in Figure 1.

Figure 1 The sampling points around the grinding circuit of Lahanos Copper-Zinc
Concentrate Plant

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 For this purpose, pulp samples were taken from grinding circuits. All samples were dried,
weighed and sieved. Size distribution of each sample was determined down to 38 μm. Mass
balancing of grinding circuits was performed to calculate the flowrates in each stream. All the
size distributions of the samples taken were determined.
RESULTS AND DISCUSSION

Mass Balancing

To evaluate the existing performance of the grinding circuit mass balancing studies were
carried out by using the plant survey data. The flow rates are given in Figure 2. After mass
balancing, to compare the measured and calculated values, the size distributions of the
measured and calculated data were plotted. The following figures show this comparison for
each point in the circuit (Figure 3).

Figure 2 Calculated values around the circuit

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Figure 3 Experimental-Calculated particle size distribution of sampling studies

As shown in the Figure 2 and Figure 3, mass balance of each stream was obtained without
any significant correction on the measured data. Therefore, the data obtained from mass
balance could be used for modelling of the grinding circuit. Then, models for each unit in the
circuit were developed by using mass balanced data. The models used are the perfect mixing
model for ball mills and the efficiency curve model for separators.
In order to control the accuracy of the models, size distributions of each stream were
calculated by using only the size distribution of the feed. The following figure show the
comparison of balanced and predicted size distributions (Figure 4).
100
Fresh Feed
Pasiner Discharge
90 Clay Feed
250 mm Cyclone Feed
80 250 mm Cyclone U.F.
250 mm Cyclone O.F.

70 Çubuklu Discharge
Fin Discharge
Cumulative % Undersize

125 mm Cyclone Feed

60
125 mm Cyclone U.F.
125 mm Cyclone O.F.
50
Fresh Feed
Pasiner Discharge
40 Clay Feed
250 mm Cyclone Feed
30 250 mm Cyclone U.F.
250 mm Cyclone O.F.

20 Çubuklu Discharge
Fin Discharge
125 mm Cyclone Feed
10
125 mm Cyclone U.F.
125 mm Cyclone O.F.
0
0.01 0.1 1 10 100
Particle Size (mm)

Figure 4 Particle size distribution of the sampling studies (Calculated by modelling)

(Markers indicate mass balance data and lines show the modelling data)
The figure addresses clearly that the plant conditions can be simulated perfectly by the
models derived. Thus, several operation alternatives were tested during simulation studies to
obtain optimum conditions.

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 In order to characterize the breakage characteristics of the ores Work index and drop weight
breakage function were determined. Bond work index of the sample was determined as 11.59
kWh/t.
Breakage function of the ore was also measured to expose the breakage behaviour of the
ores. These data give us the opportunity to reflect different breakage characteristics to the
model structure. Breakage function of the sample is illustrated in Figure 5.

Figure 5 Breakage function of fresh feed sample broken in 2 kWh/t energy level

SIMULATIONS

Mass balance studies indicated that the mills were operating under their normal filling
ratios which are 33-36 %. During the simulation studies the simulation of the existing
conditions was achieved. These figures provided a basis for further simulation studies. Then,
simulation studies were performed by modifying ball size, cyclone geometry, feed size and %
solids in the ball mills to obtain optimum conditions for the existing and alternative flowsheets.
Simulation results are summarized in Table 1.

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 Table 1 Simulation results
Product Finenes
RESULTS OF SIMULATION STUDIES Feed Rate (t/h)
(% -38 µm)

Operating Condition 15.23 82.05

Changing % Solid of 250 mm Diameter Cyclone Feed - %40 15.23 82.03

Changing % Solid of 250 mm Diameter Cyclone Feed -%47 15.23 81.97

Using 125 mm Diameter Cyclone Group Instead of 250 mm

15.23 82.57
Diameter Cyclone

Effect of Tonnage Increase on the Production Fineness in the

16.65 79.73
Actual Production Condition

Performance of Circuit with Removing of Çubuklu Mill in the

15.21 79.58
Actual Condition

Prediction of Grinding Circuit Performance with Increased Ball

17.50 82.10
Filling Ratios by Approximating Normal Levels

Removing of Çubuklu Mill and Load Mills to the Original Ball

15.21 82.00
Filling Ratios
Removing of Çubuklu Mill and Load Mills to the Original Ball
Filling Ratios and Chancing the Location of Pasiner and Fin It was ssen that there is no important change in
Mills the plant capacity and production fineness.

Changing the Location of Pasiner Mill and Çubuklu Mill in

18.00 81.90
Actual Production Condition
Changing the Location of Pasiner Mill and Çubuklu Mill in
Actual Production Condition and removing of Fin Mill from the 15.00 76.69
Circuit

CONCLUSIONS

In this study, the performance of the existing grinding circuit in Madneuli copper plant was
determined. The results showed that the existing performance of the grinding circuit could be
improved and the fineness of the flotation feed could be increased to the desired value.
According to the results of simulation study 3 the plant capacity may increase up to 16 tph.
This simulation study can be concluded that a 5 % increase in the production capacity can be
expected.
Effect of ball filling ratios on the grinding circuit performance was simulated in the sixth
simulation study. Capacity increased from 15.2 tph to 17.5 tph when mills are loaded to their
original filling ratios and during these studies the production fineness wasn’t influenced
negatively.
As a conclusion of all the simulation studies, the classification systems were operating
efficiently. There are some requirements in order to improve the grinding efficiency. The
simplest way is to increase the ball filling ratios at the existing mill conditions. If this is
achieved several alternatives can be applied as described above.

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REFERENCES
NAPIER-MUNN, T.J., MORRELL,S., MORRISON, R.D. and KOJOVIC,T. 1996. Mineral
comminution circuits: their operation and optimisation. JKMRC., pp. 413.
Whiten, W.J., 1972, A model for Simulating Crushing Plants, J.S.Afr. Inst. Min. Metall., 72:
257-264
Whiten, W.J., 10th International Symposium on Application of Computer Methods in Min. Ind.,
Johannesburg, (1972) 317.

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