SME Annual Meeting

Feb. 28-Mar. 03, 2010, Phoenix, AZ

Preprint 10-009

SQUEEZING THE EXTRA 30% OF A TYPICAL SABC CIRCUIT FOR 4.8 KWH/TONNE

S. Dixon, Goldcorp, Vancouver, BC, Canada

B. Olson, Goldcorp, Vancouver, BC, Canada
E. Wipf, Aerosion, Calgary, AB, Canada

INTRODUCTION 2007. The final report and recommendations was presented in

February 2008. The series of tests used to characterize the ore and
The Peñasquito deposit in Mexico is one of the largest grassroots generate scale up factors were:
precious metal discoveries to be developed in recent years Minera
Peñasquito, S.A. de C.V., a wholly owned subsidiary of Goldcorp Inc. 1. Abrasion wear estimation using the ATWAL HPGR
has developed the Peñasquito property to produce an average annual 2. Semi-industrial HPGR using the REGRO
production of 120 kilo tonnes of lead containing 0.5 million oz gold and 3. Bond ball mill test of HPGR product.
30 million oz silver and 250 kilo tonnes of zinc containing 20 thousand
oz gold and 1.5 million oz silver.. The Peñasquito property covers a ATWAL HPGR
39,000 hectare area in the western half of the Concepción del Oro The ATWAL HPGR is used to determine the wear rate of the ore.
district in the northeast corner of Zacatecas State, Mexico, The unit is a bench top HPGR using tires of 10 cm diameter and 3 cm
approximately 24°45'N latitude/101°30'W longitude. The sulfide width. The unit is equipped with smooth Nihard IV tires. The sample
reserves are 1,009 million tonnes containing 3.33 million tonnes of requirements are approximately 100 kg of ore crushed to less than 3
lead, 7.26 million tonnes of zinc, 16.5 million ounces of gold and 1,000 mm. The unit is choke fed to maximize the amount of ore processed.
million ounces of silver. This paper describes the work to justify the The grinding force, energy and specific flow rate are measured for
installation of HPGR to process the crushed SAG mill pebbles. each test. The tires are weighed before and after each test to define
The SAG mill-Ball mill and Cone crusher (SABC) grinding circuit the specific wear rate in grams of weight lost per tonne of ore
is an accepted grinding circuit to optimize power consumption relative processed. This specific wear rate is used to estimate the expected
to throughput. The installation of a HPGR to process the Cone crusher wear life of the tires on an industrial size HPGR.
product is the next step in optimizing the power consumption relative to Four tests were performed on the ore sample to define the
throughput. The concern expressed by some on not moving on this specific wear rate. These tests included an increase in moisture, a
change in grinding circuit was the capital and operating cost of a decrease in the grinding force and scalping of the feed. The results of
HPGR. The pebbles from the SAG mill can be the more abrasive and the tests are given in Table 1.
are the harder particles of the ore. Goldcorp investigated the wear and
processing costs of installing a HPGR to treat the crushed pebbles. Table 1. Specific Wear Rate for Peñasquito Ore.
The conclusion was the installation would be a very positive economic
factor in the operation of Peñasquito. Grinding Specific
Feed, Moisture,
Test Material Force, Wear Rate,
mm %
This is the first application of the use of HPGR to process crushed N/mm² g/t
pebbles. Minera Peñasquito and M3 Engineering selected Polysius to
provide a Polycom 2417 with twin 3,000 kW drives. A comprehensive Poly 0-
A1 1 4 7.8
test program at Polysius has shown for 7% higher circuit power it is metallic 3.15
possible to get approx 23% higher tonnage. This coupled with full Poly 0-
A2 3 4 10.8
utilization of the SAG and Ball Mill available energies and with proper metallic 3.15
control of the transfer size from the SAG to Ball mill circuit there is the Poly 1-
A3 1 4 10.6
potential to achieve 65,000 mtpd per line or a 30% total capacity metallic 3.15
increase. The cost of power for this increase in grinding capacity is 4.8 Poly 0-
A4 1 2 7.2
kWh/tonne. metallic 3.15

PLANT DESCRIPTION Polysius classifies the specific wear rate into three classes. The
Peñasquito ore is classed as a low abrasive material.
The process plant was constructed in two stages, with each line
capable of a nominal capacity of 50,000 MTPD. The first stage “Line Class Specific Wear Rate
1” is currently in operation and “Line 2” is in construction. The primary Very Abrasive >40 gpt
crusher will feed a common conveying system, and stockpile area Medium Abrasive >10 but <40 gpt
sized to handle the total tonnage for both lines. Each 50,000 MTPD
Low Abrasive <10 gpt
grinding/flotation line consists of one SAG mill, 11.6 m dia. x
6.1 m EGL SAG mill powered by a Siemens 19,300 kW gearless mill
The estimated wear life of the tires in an industrial unit with this
drive system capable of operating with up to a 15% ball charge. Two
level of specific wear rate is 7,000 to 9,000 hours. The estimation was
pebble crushers, Sandvik H8800 with 600 kW each treat the pebbles
based on previous experience of processing whole ore not SAG mill
from the SAG mill. Two ball mills of 7.3 m dia. X 11.3 m EGL, each is
pebbles. The SAG mill pebbles will be crushed. But the pebbles are
driven by twin 6,000 kW low-speed synchronous motors. The design
the harder than particles passing through the SAG mill. The estimated
flotation feed is P80 of 125 micron.
wear life of the tires was reduced to 6,000 hours to be conservative.
HPGR TEST PROGRAM The operating cost of the industrial HPGR for Peñasquito accounted
for this reduced wear life.
Minera Peñasquito contracted with Polysius in August 2007 to
carry out a series of HPGR tests to define parameters for scale-up and
estimate life of the roller tire. The sample was delivered in November
1 Copyright © 2010 by SME
 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

REGRO HPGR was based on the experience of Polysius to optimize energy

consumption and tire wear.
The REGRO HPGR unit is a pilot size (0.71 m diameter & 0.21 m
width) using studded tires for autogenous grinding. A series of six pilot
tests evaluated two levels of moisture content and three levels of
specific grinding force. Two of the tests (R2.2 & R2.3) were operated in
closed circuit with a circulating load of 40% (circulating ratio of 1.4).
The recirculation tests used fresh feed and the screen oversize of the
previous REGRO product. A summary of the tests is presented in table
2.
Table 2. Summary of Results from REGRO Tests.
Grinding Specific Specific % Wt % Wt % Wt
Test %
Force Energy Throughput Passing Passing Passing
# Moisture
N/mm² kWh/t ts/hm3 <0.2 mm <4 mm <8 mm
R1 3.40% 2.54 1.47 197.5 18.4% 58.5% 79.6%
R2.1 3.40% 3.34 1.85 191.3 17.6% 60.8% 79.6%
R2.2 3.40% 3.41 1.75 197.5
R2.3 3.40% 3.41 1.78 195.3 19.4% 61.0% 82.7%
R3 3.40% 4.10 2.23 186.5 20.0% 62.9% 81.6%
R4 5.80% 3.40 1.86 195.8 22.1% 62.5% 83.0%
Mean 194.0 19.5% 61.1% 81.3%
Stdev 4.3 1.7% 1.7% 1.6%

Figure 2. Specific Energy vs. Grinding Force.

The product formed flakes that easily broke down during dry
screening using a 6 mm mesh. The circulating load was 40% using the
dry screening. The use of wet screening should reduce the circulating
load. The screen analysis of the product from each test was
comparable. Figure 1 presents the cone product, HPGR feed, HPGR
product, minus 6 mm undersize and plus 6 mm over size for the closed
circuit simulation. The minus 6 mm product is pumped to the cyclone
feed sump. The design flotation feed is P80 of 125 micron. The size
distribution of the scalped undersize indicates that close to 40% of the
weight is flotation feed size. This is the primary benefit of using HPGR
to process SAG mill pebbles. The crushed pebbles that fed the HPGR
had less than 5% flotation feed.

Figure 3. Specific Throughput vs. Grinding Force.

Figure 1. Size Distribution.

The relationship of grinding force used to the specific energy
consumed is presented in Figure 2. The linear relationship was not
influenced by the difference in moisture content (3.4% vs. 5.8%).
The relationship of grinding force to specific throughput is
presented in Figure 3. The closed circuit tests were separated to show
that the specific throughput was not constrained by closed circuit
operation.
The relationship of specific throughput to specific energy Figure 4. Specific Throughput vs. Specific Energy.
consumed is presented in Figure 4. The specific throughput increased
BOND BALL MILL WORK INDEX
with reduction in specific energy consumed.
The point has been raised in the past on the potential reduction in
The relationship of percent passing 6 mm to the specific energy
Bond WI on material that had been processed by HPGR. The
consumed is presented in Figure 5. The percent minus 6 mm in the
formation of microfractures in the particles by the compressive force of
product was slightly influenced by the specific energy consumed (over
the HPGR is used as a reason for any reduction in Bond WI. This was
the range tested).
evaluated for the Peñasquito ore. Table 3 summarizes the results of
The conclusion of the tests recommended an operating grinding the Bond WI tests for Peñasquito ore that was not treated or treated by
2
force of 3.5 M/mm or a specific energy consumption of 1.9 kWh/t. This HPGR. The operating conditions for the HPGR treatment was test

2 Copyright © 2010 by SME

 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

R2.3. The product of R2.3 was used as the feed for the Bond WI test.
The reduction in Bond WI was 14-15%.
The Grate screen opening should prevent oversize material
coming from the crushing circuit. However, if a Grate segment is
broken inside the SAG Mill the product size from crushing circuit could
be affected and larger feed could make it into the HPGR.
COMPARISON OF GRINDING CIRCUITS
The conventional SABC circuit processes the pebbles from the
SAG mill in cone crushers. The crushed product is recycled into the
SAG mill. The percent of the crushed product that is less than 12 mm
will pass through the SAG trommel. The trommel undersize is
combined with the ball mill discharge in a cyclone feed sump. The
crushed product will have less than 5% weight in particles smaller than
2 mm. The flotation feed requires a P80 of 125 micron. The amount of
flotation feed in the crushed product is less than 1%. The design of the
Peñasquito grinding circuit before the installation of the HPGR is
50,000 tonnes per day per grinding line.

Conventional Circuit
Feed
Figure 5. % Passing 6 mm vs. Specific Energy.
Table 3. Summary of Bond Work Index Tests.
Before HPGR After HPGR
Pi 90 90 Primary  AG or  Pebble 
G 1.28 1.62 Crusher SAG Mill Crusher
F80 2299 2019 O/F
P80 63.1 65.2
Wi(st) 12.3 10.5
Wi(mt) 13.5 11.6 Cyclone Trommel  +12 mm
The size distributions of the ore before and after HPGR for the
Product U/F Screen
feed and the final product generated from the Bond tests are presented
in Table 4.
‐12 mm
SCALE-UP TO INDUSTRIAL HPGR Ball Mill
The pilot testing was done on ore that had been crushed to 18 Cyclone 
mm and a working gap between the rolls of the REGRO of 18 mm. The
planned crushed product will be 50 mm. The working gap of the
Feed 
industrial HPGR is planned at 50 mm. Polysius recommended one Sump
Polycom 2417 instead of two 1915. The larger unit allows for a slower
tire speed and tire wear is related to tire speed. The addition of the HPGR will generate a product containing 30-
40% by weight of flotation feed. The questions are where will the
Table 4. Particle Size Distribution. HPGR product be sent and how it will be processed. The placement of
Before HPGE Cum % After HPGE Cum % the HPGR product back into the SAG mill is the simplest as the
Passing Passing material can be placed on the SAG mill feed conveyor. This is where
Size, mm Feed Product Feed Product the cone crushed product is added back to the SAG mill.
2,800 93 96
This flowsheet eliminates the wet screening and the ancillary
2,000 72.3 79.6
equipment but the result is the HPGR product will consume 0.5-1.0
1,400 57.6 65.4
kW/tonne of SAG mill power and displace volume in the SAG mill that
1,000 48.3 56
could be used to grind fresh feed instead of breaking up flakes of
0,710 41.5 49.1 material that is 100% less than 12 mm. This use of the SAG to break-
0,500 34.9 42.2 up the flakes of the HPGR product is expected to reduce the
0,355 29.6 36.5 incremental tonnage processed, due to the addition of HPGR, to 20%.
0,250 24.5 31.2 The processing of the HPGR product by the SAG mill will increase the
0,200 23.4 29.5 potential for sulfide oxidation or iron oxide precipitation on the mineral
0,125 19.7 24.8 surface or generation of extra slimes.
0,090 17.5 99.9 22.1 99.9
0,063 80.1 78.4 The preferred flowsheet selected by Peñasquito has the HPGR
0,045 65.4 64.1 product wet screened at 6 mm. The plus 6 mm fraction is recycled with
the crushed product to the HPGR. The + 6 mm fraction fills voids in the
0,032 55.1 54.7
crushed material and is expected to improve the efficiency of the
HPGR operation. The minus 6 mm fraction is pumped to the cyclone
The larger 2417 was selected since it had the capability to handle
feed sump. The benefit of this flowsheet (shown below) is the particles
any oversize material from the crushing circuit should any upset
of flotation feed size generated by the HPGR are given a chance to
condition occur. The larger unit was selected as a precaution to
move to the flotation circuit without being contacted with grinding steel.
handling any steel that may bypass the magnets and metal detector.
The lack of oxidation or precipitation of salts on the mineral surface will
The operating gap during operation of the 2417 should be 65-75mm
result in an increased recovery by flotation compared to particles
(Cerro Verde is 71mm average) versus 54-60mm for a 1915 HPGR
ground in the ball mill. There have been reports of 5% higher copper
size. This allows a larger particle of steel to pass between the rolls with
and gold flotation recovery on ore ground with HPGR. The HPGR will
no contact to both rolls surfaces at the same time.
generate 30-40% flotation feed. Assuming 70% of this material

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 SME Annual Meeting
Feb. 28-Mar. 03, 2010, Phoenix, AZ

bypasses the ball mill, a 5% increase in flotation recovery will result in

an overall increase of 1-2%.

Peñasquito Circuit
HPGR 
Feed 2417

Primary  AG or  Pebble  +6 mm Wet 

Crusher SAG Mill Crusher Screen
O/F

Cyclone Trommel  +12 mm ‐6 mm

Product U/F Screen

‐12 mm
Ball Mill
Cyclone 
Feed 
Sump

An alternative flowsheet is proposed for operations where pebble

production from the SAG mill is less than the capacity of the HPGR or
where blast fragmentation generates a significant amount of minus 200
mm particles. A fraction of the feed to the SAG mill would be screened
at 50mm. The plus 50 mm would go to the SAG mill. The minus 50 mm
would be processed by the HPGR. This flowsheet may be used if the
current primary crusher is undersized and a second is needed.

Alternative Flowsheet
Feed Dry  ‐50 mm HPGR 
Screen 2417

+50 mm
Primary  AG or  Pebble  +6 mm Wet 
Crusher SAG Mill Crusher Screen
O/F

Cyclone Trommel  +12 mm ‐6 mm

Product U/F Screen

‐12 mm
Ball Mill
Cyclone 
Feed 
Sump

REFERENCES
1. High-Pressure Grinding Tests on Peñasquito Poly-Metallic ore for
Minera Peñasquito/Goldcorp – Polysius Research Centre Feb 7,
2008

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