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Comminution Services
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ORE CHARACTERIZATION, PILOTING, DESIGN AND PLANT OPTIMIZATION FOR GRINDING APPLICATIONS
We design circuits and provide operating advice to maximize milling efficiency, considering both steel and power consumption. Our practical experience also ensures that we recommend circuit configurations that offer ease of operation and maximum flexibility. All of our metallurgical testing facilities can provide bench scale testing and limited piloting.The most extensive piloting facilities are located in Canada. Our comminution experts travel the world as needed, providing support to comminution testwork programs. Most comminution testwork is conducted in-house at our facilities in Canada, Chile, Australia and South Africa. We also conduct comminution testing and piloting programs at remote client sites.
We have experience in many techniques, including the model-based approach and the empirical power-based approach, using the Bond and autogenous grindability tests. All data is analyzed and related to previous testing results. We compliment the JKTech models with mass-balancing, using the Bilmat program. We suggest that the most robust results are obtained when more than one approach to grinding circuit testing and design is used.
The Bond Impact Test determines the Bond Impact Work Index which is used to calculate net power requirements for sizing crushers. The Abrasion Test determines the Abrasion Index, which can be used to determine steel media and liner wear in crushers, rod mills, and ball mills. The JK Drop-Weight Test is used to confirm the breakage response of an ore or to evaluate ore variability. The test determines energy vs. breakage distribution functions. We use JK Drop-Weight test breakage parameters and the JK SimMet software package to simulate comminution circuits. Simulation is a powerful complement to traditional bench-scale power-based grindability tests. Simulation allows prediction of the size distribution, mass and volumetric flows of all streams in a circuit, as well as the effect of changes in operational conditions. The MacPherson Autogenous Grindability Test determines the MacPherson Autogenous Work Index. We have evaluated more than 750 ore samples from more than 300 deposits using the 18” mill test. This test, in conjunction with the Bond MacPherson work index determinations guide the design of power-efficient grinding circuits Additional Equipment
Comminution pilot-plant capabilities at our Canadian operations include a 1.68 m diameter, fully instrumented Nordberg autogenous mill, and a wide variety of rod and ball mills. Circuit configurations, including AG, SAG, ABC or SABC, are evaluated easily. The circuit employs an integrated Bailey Distributive Control System (DCS) for monitoring plant conditions. Feed rate, mill speed, power, mill load, particle size distribution and other data are updated, trended, and recorded automatically for later retrieval. This full-instrumented pilot plant allows circuit changes to be brought to steady-state more rapidly and avoids wasted pilot plant time. We have completed more than 150 pilot plant programs. A typical test program involves investigation of the response of the ore to fully autogenous grinding and SAG mill primary grinding. In the SAG mill testwork steel addition, SAG product classification size and ore feed size distribution would be varied. If necessary, pebble crushing or mill speed could also be investigated. Tests are evaluated on the basis of feed rate, power consumption and product size analysis. Unless single-stage autogenous grinding is considered, it is recommended that the secondary ball or pebble mill circuit be operated in all tests to provide overall power data and to allow adjustment of the secondary mill conditions to obtain the desired fineness of grind. Simulation Studies Applications
Investigative Capabilities
Simulation Studies Deliverables
Simulation Studies for Pilot-Plant Applications
For more information, you may contact our Comminution experts. |
