EVALUATION OF THE BATCH

PRESS AS A LABORATORY TOOL

TO SIMULATE MEDIUM PRESSURE
ROLLER CRUSHERS
Jan van Schoor
IRR 12th Annual Conference on Crushing and Grinding

10 to 12th October 2011

First presented at the SAIMM Iron and

Manganese Ore Conference
5 to 6 September 2011
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CONTENTS

1.0 Aim of the project

2.0 Background
HPGR and VRM applications in
mining industry increase
Green fields projects
Research tools

3.0 Methodology of comparison

4.0 Comminution models

5.0 Results

6.0 Conclusions

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1.0 AIM OF THE PROJECT

3
 AIM OF THE PROJECT

To compare the batch press with the Vertical roller mill.

H y d ra u lic
C y lin d e r

200 m m

P is to n

1 38 m m

O re s a m p le 25 0 m m
50 mm
50 mm

240 m m
C y lin d e r 50 m m

L o a d c e ll

Low er bed

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2.0 BACKGROUND

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 BACKGROUND

•Research tool for new projects and understanding of different ore types

•Limited samples and sample size in green field projects

•Cost and time for pilot plant work.

•Lack of data from pilot plant work to validate models.

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3.0 METHODOLOGY

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 METHODOLOGY

To compare the batch press with the Vertical Roller mill.

•Direct comparison

•Simple scale-up

•Seeking a model that would fit both applications

•Model studied

•E~Wi*1/Pn

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 METHODOLOGY

To compare the batch press with the Vertical Roller mill.

Initial crushing Packed bed

Batch Press

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 METHODOLOGY

•Plot energy consumption versus P80/P50 for the VRM and press.

•Determine the operating work index for at all the data points

•Determine the value of n in the formula E~Wi*1/Pn

•Change the value of n until the value of Wi is a constant

•Determine energy necessary to crush the material to F80

•Add this to the energy used in the tests

•Wi is the amount of energy to mill the material to 100µm and must be the
same value as determined from the data

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METHODOLOGY

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4.0 COMMINUTION MODELS

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COMMINUTION MODELS FROM HUKKI (1988)

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5.0 RESULTS

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RESULTS

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RESULTS

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RESULTS

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RESULTS

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 RESULTS

Results
Values of OWi and n for the Loesche mill, batch press and ball mill for Foskor ore
Horomill Batch press Ball mill
F80 F50 P80 P50 F80 F50 P80 P50 P80
(µm) (µm) (µm) (µm) (µm) (µm) (µm) (µm) (µm)
OWi n OWi n OWi n OWi n OWi n
15300 3000 9.51 1.05 7.5 2.31 2008 620 5.33 0.24 4.7 0.85 12 1.05

Values of OWi and n for the Loesche mill and batch press for Rosh Pinah ore
Top Loesche mill Batch press
size
F80(µm) F50(µm) P80(µm) P50(µm) F80(µ F50(µm) P80(µm) P50(µm)
m)
OWi n OWi n OWi n OWi n

3 mm 1500 530 6.68 1.10 3.33 0.83 1500 530 2.67 0.77 1.69 0.79

5 mm 3000 1600 7.18 1.22 3.43 0.95 3000 1600 3.04 0.65 1.73 0.80

10 mm 5800 3350 9.89 1.36 4.42 0.95 5800 3350 3.04 0.68 1.71 0.79

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 RESULTS

Values of OWi and n for banded iron stone

Top Size F80(µm) OWi n F50(µm) OWi n
5 mm 3350 13.4 0.21 2300 9.9 0.21
3 mm 1750 13.2 0.21 950 9.3 0.21
Batch press 3350 9.1 0.21 2300 15.7 0.18

Values of OWi and n for titanium slag

Top Size F80(µm) OWi n F50(µm) OWi n
10 mm 2200 35 0.9 1350 55 0.06
10 mm 2600 3.6 0.5 1500 5.55 1.4

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 RESULTS

Energy consumption and operating work indices plotted as a

function of Product size P80 for the Rosh Pinah ball mill.
20.0
Operating work index (kWh/ton)

15.0

100 to 120 µm: n = 0.72

Owi = 11.1
10.0

5.0

0.0
80.0 100.0 120.0 140.0
P80(µm)

OWi:100 to 120 µm Power (Energy consumption)

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6.0 CONCLUSION

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 CONCLUSION

•The batch press can not be used to simulate the VRM

•The value of the coefficient “n” is a function of the material as well

as the product size

•E = Wi*100f(P)*(1/Pf(P)-1/Ff(P))

•Wi = K/(P0.23*G0.82*(1/P80n-1/F80n))

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Conclusion

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