Comminution Program Research (AMIRA P9N) (2B2)
Project Status: Complete. Further work carried out under the 2B2 Extension project.
Project Participants: Alcoa, BHP Billiton, Newmont, Rio Tinto, University of Queensland, Xstrata, Anglo Platinum, Hatch, AMIRA
Project Leader: Emmy Manlapig (University of Queensland)
The major aim of this project was to help its sponsors achieve "best practice" in the design and operation of their mineral processing plants. This was done, principally though not exclusively, through the development of modelling and simulation techniques and measurement tools that will enable mining companies that sponsor the project to design better plants and operate their plants better. The AMIRA P9N extension has undertaken a range of integrated research projects addressing a number of key themes which have been defined by industry. CSRP has been actively involved in the comminution research area of the AMIRA P9N project.
The research topics in comminution and classification were divided into three themes: continuous improvement of current technologies; innovation and enabling technologies; and reduction of energy for comminution.
During 2007/08 the following outputs were achieved:
- A new breakage characterisation device (JK Rotary Breakage Tester) was developed and manufactured at the JKMRC (University of Queensland) and installed at the JKMRC pilot plant for routine research work. The JK Rotary Breakage Tester allows rapid characterisation of particle impact breakage properties.
- The first industrialised JK Rotary Breakage Tester was designed and manufactured by Russell Mineral Equipment and has been installed and commissioned at Anglo Research in Johannesburg, South Africa.
- Experience in commissioning and operating the first industrialised JK Rotary Breakage Tester resulted in a number of refinements to the design. These have been incorporated into the five additional units which have since been built and delivered to sponsors around the world.
- The effect of using High Pressure Grinding Rolls in new comminution circuit designs against conventional comminution devices such as SAG and ball mills, has been evaluated in terms of energy efficiency. It was observed that on average, a measured energy saving of 25-40 percent was achieved through a hybrid HPGR/ball milling circuit when compared with the conventional ball mill circuit.
- HPGR readily promotes particle micro cracks which is suitable for heap leaching ores and can reduce downstream mill energy requirements.
- It may be possible to model low energy multiple impacts in tumbling mills (under low load conditions) with breakage characterisation using the JK Rotary Breakage Tester.
- Investigation found that the piston and die test produced breakage products which are comparable to the laboratory scale HPGR unit. The piston and die test is now ready to be developed as a standard procedure for HPGR ore characterisation studies.
- A new test methodology and model have been developed that can predict grinding media wear in tumbling mills more accurately than the commonly used Bond Abrasion Test.
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