Luleå Univ. of Technology Simulation Mineral Proc.

1(3)
Div. of Mineral Processing 2010-09-22
Bertil Pålsson

ASSIGNMENT – SIMULATION OF GRINDING CIRCUIT

In a concentrator for complex sulphide ores, a conventional rod and pebble mill circuit
was sampled. The flowsheet is given in the figure below, solids flows and chemical
analyses in Table 1, particle size distributions in Table 2, machine data in Table 3, and
minerals data in Table 4. Data for hydrocyclones was provided in part 01 of the course.

Given the figure and the data in the tables, you are to build the equivalent circuit in
MODSIM.

To
flotation
Pebbles

Feed

Pebble
Rod Mill
Mill

Middling from
CuPb-flot

Table 1. Solids flow data and analyses

Product Measured flows Dilution ρs Cu Zn Pb S
(tonne/h) ratio (g/cm³) (%) (%) (%) (%)
Rod mill discharge 38.5 0.483 3.61 1.11 2.57 0.26 27.6
Pebbles 9.7 0 3.43 1.02 2.34 0.32 23.1
Pebble mill discharge 0.404 4.11 1.16 2.57 0.29 37.6
Midd's from CuPb-flot. 13.1 3.128 3.97 3.69 20.6 0.72 33.5
Calc. Hydrocyclone feed 0.72 3.94 1.37 4.17 0.32 34.4
Underflow hydrocyclone 76.0 0.308 4.22 1.17 2.60 0.29 39.4
Overflow hydrocyclone 1.244 3.65 1.62 6.15 0.36 28.1
Simulation of grinding circuitSimulation Mineral Proc. 2
2010-09-22

Table 2a. Particle size distributions - fine products (cum. per cent passing)
Product 350 µm 177 µm 125 µm 88 µm 63 µm 44 µm
Rod mill discharge 91.5 75.0 62.5 53.5 42.0 34.5
Pebble mill discharge 96.0 92.5 83.5 70.0 45.5 36.0
Midd's from CuPb-flot. 100.0 99.5 99.0 98.5 92.0 83.5
Calc Hydrocyclone Feed 93.9 87.9 79.1 69.1 49.9 40.6
Underflow hydrocyclone 89.0 79.5 66.5 50.5 26.0 18.5
Overflow hydrocyclone 100.0 98.5 95.0 92.5 80.0 68.5

Table 2b. Particle size distributions - coarse products (cum. per cent passing)
Product 50 mm 40 mm 20 mm 10 mm 1 mm 44 µm
Rod mill feed 100.0 100.0 98.8 90.0 30.0 4.0
Pebbles 100.0 98.8 10.0 4.0 0.5 0.1

Table 3. Equipment's data

Rod mill Ø2.4×3.6 m, 230 kW, nc 0.65, q 0.35, Wi 12.0 kWh/tonne
Pebble mill Ø3.75×4.525 m, 375 kW (max 600 kW), nc 0.68, q≈0.35 (max 0.45),
grate 4x8 mm
Hydrocyclone one 500 mm unit, ca. 100 kPa, d50(c) 68 µm, d50 58 µm, XL 0.24

Table 4. Minerals data

Mineral Formula Density (g/cm³)
Chalcopyrite CuFeS2 4.2
Sphalerite (Zn,Fe)S, ca. 60% Zn 4.0
Galena PbS 7.5
Pyrite FeS2 5.0
Gangue - 2.7
Simulation of grinding circuitSimulation Mineral Proc. 3
2010-09-22

1 EXERCISES
1.1 Simulation of rod mill
Calibrate a simulation model for the rod mill.
a) Create a circuit with only feed and discharge to the mill and a mill water stream
b) Define the system data with the enough particle size fractions and the correct
number of minerals. Make sure that you enter the real sieve analyses and the
chemical analyses for the feed and discharge streams.
c) Select a suitable rod mill model.
d) Run a first simulation and compare the particle size curves with the known data.
Adjust the model in a appropriate way until the discharge screen analysis fit the
measured data reasonably well.
e) Document the model.

1.2 Simulation of pebble mill

Calibrate the simulation model for the pebble mill under the condition that model
FAGM is applicable.

1.3 Simulation of hydrocyclone

Calibrate a simulation model for the hydrocyclone using the model CYCL. What are the
the cut sizes for each mineral?
Note! Make sure to have the correct feed pulp density!

1.4 Simulation of circuit

Draw a flowsheet in MODSIM, and add where needed mill/dilution water.

Do a direct simulation using the models and parameters found for the individual units.
Compare with the measured data and try to adjust the parameters to hit the solids flows
and particle sizes measured. Document the circuit!

2 REPORT
The documentation shall be in a technical report that for each simulation contains:
• Flowsheet with flyouts containing solids flow, water flow, weight % solids and
an analysis.
• Table with simulated solids flows, water flows, pulp volumes, pulp densities and
particle sizes (d80).
• Table with condensed model and machine parameters.
• Plots with measured (where available) and simulated particle size distributions.
• Discussion of achieved, or not achieved, results.