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Corrientes Dentro Molino 1
Corrientes Dentro Molino 1
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THE INVESTIGATION OF EFFECTS OF PARTICLE SIZE ON FALCON CONCENTRATOR (ENHANCED GRAVITY CONCENTRATOR) PERFORMANCE AND APPLICABILITY TO
COPPER RECOVERY PLANT View project
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Abstract: In this study, an extensive sampling study was carried out at vertical roller mill of ESCH Cement Plant in Luxemburg.
Samples were collected from mill inside and around the circuit to evaluate the performance of each operation in the system,
individually. Particle size distributions of collected samples were determined by the combination of dry sieving and laser
scattering method down to 500 µm. Data obtained from two surveys were used to obtain best estimates of mass flow rate and
size distribution of each stream by mass balancing. Grinding and separation efficiency of vertical roller mill were evaluated. In
addition to these, performance figures of vertical roller mill and conventional closed ball mill circuit were compared. It was
concluded that vertical roller mill circuit has an advantage over conventional ball milling circuit in terms of energy consumption.
MATERIAL CHARACTERIZATION
STUDIES
As part of the characterization studies, the particle size
distributions of collected samples were determined. All
samples taken from the circuit were screened from 75
mm to 500 µm. The particle size distributions of the
minus 500 µm materials were determined by laser sizing
method. The particle size distributions of collected
samples are shown in Figure 3 and Figure 4 for survey
1 and 2, respectively.
FIGURE 2. Industrial scale vertical roller mill sampling
points
Design parameters of the vertical roller mill are
summarized in Table 2.
Survey-1
60
50
40
t10 (%)
30
20
Experimental
10
FIGURE 4. Particle size distributions of collected Calculated
samples (Survey 2) 0
0 5 10 15 20
ECS*X (kWh*mm/t)
Bond work indices and breakage characteristics under
compression were determined. Calculated Bond work FIGURE 5. ECS*X-t10 relationships of the clinker-1
indices of clinkers from survey 1 and survey 2 is 14.2
kWh/t and 13.45 kWh/t, respectively. Survey-2
60
Material characterization studies were performed by 50
using piston-die test equipment. Throughout the
studies the narrow size fractions were prepared for all 40
t10 (%)
122.88 tph
1536.94 tph
1536.94 tph 1536.94 tph 122.88 tph
Static Dynamic
Grinding
Classification classification
0 tph
1414.06 tph
126.52 tph
1693.26 tph 1693.26 tph
1693.26 tph 126.52 tph
Static Dynamic
Grinding
Classification classification
0 tph
1566.74 tph
FIGURE 9. Mass balanced particle size distributions FIGURE 10. Mass balanced particle size distributions
around the circuit for Survey 1 around the circuit for Survey 2
Survey 1
100 Actual Efficiency Curves
90
Cumualative Undersize (%)
100
80
90
70
80
60
70
50
60
40
50
30
Table feed 40
20
Table product 30
10
20 Survey 1
0
0.001 0.010 0.100 1.000 10.000 100.000 10 Survey 2
0
Particle Size (mm)
0.001 0.01 0.1
Particle Size (mm)
FIGURE 12. Particle size distributions of table feed and FIGURE 14. Actual efficiency curves of separator for
product (Survey 1) two surveys
Survey 2
Corrected Efficiency Curves
100
Feed Reporting to Coarse Product (%)
90 100
Cumualative Undersize (%)
80 90
70 80
60 70
50 60
40 50
30 40
Table feed 30
20
10 Table product 20 Survey 1
0 10 Survey 2
0.001 0.010 0.100 1.000 10.000 100.000 0
Particle Size (mm) 0.001 0.01 0.1
Particle Size (mm)
ACKNOWLEDGEMENTS
Authors would like to gratefully acknowledge Carsten
Gerold, Markus Stapelmann and Mathis Reichert from
Loesche GmbH for their valuable support. We would
also like to show our gratitude to the ESCH Cement
Plant for providing the access to the plant.
REFERENCES
Aydogan, N.A., A simple sampling method for VRMs,
ZKG International, 2015, 3, 50-55.
Eksi, D., Benzer, H., Sargın, A., Genc, O., A new
method for determination of fine particle breakage,
Minerals Engineering, 2011, .24, 216-220.