S. Zare; M. Maleki Moghaddam; J. Pourshaabadi
Abstract
The energy consumed by the comminution equipment accounts for the main part of the operating cost of the mineral processing plants. In order to conserve energy, attempts were made to increase the efficiency of the conventional comminution equipment. As a case study, in this research work, a process audit ...
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The energy consumed by the comminution equipment accounts for the main part of the operating cost of the mineral processing plants. In order to conserve energy, attempts were made to increase the efficiency of the conventional comminution equipment. As a case study, in this research work, a process audit was carried out in the comminution plant of the Steel-Sirjan Iron Ore Complex in order to find the low-cost solutions to improve the product quality and decrease the maintenance and operating costs. Three main steps of the audit were (1) studying the operating manuals and checking the standard process procedures, (2) process data analyzing, and (3) proposing and implementing the proper solutions. Plant audit revealed a low equipment efficiency. The main defects were the crusher operation in the half-full condition, high pressure grinding roll (HPGR) operation in a non-standard condition, high amounts of rejected materials in the HPGR circuit, and low efficiency of the screen. Following this, a series of modifications were made in the crushing and grinding circuit. This consequently caused an increase of 9.3% in the crushing plant throughput in the choked condition of the crushers as opposed to the half-full condition. By increasing the HPGR operational pressure and the hopper level, BBWI of the HPGR product in the super-choked condition was decreased from 16± 0.20 kWh/t to 14.9± 0.25 kWh/t. By modifying the screen process, the circulating load decreased from 79% to 59%, and the screen efficiency increased from 63.5% to 89.5%.The energy consumed by the comminution equipment accounts for the main part of the operating cost of the mineral processing plants. In order to conserve energy, attempts were made to increase the efficiency of the conventional comminution equipment. As a case study, in this research work, a process audit was carried out in the comminution plant of the Steel-Sirjan Iron Ore Complex in order to find the low-cost solutions to improve the product quality and decrease the maintenance and operating costs. Three main steps of the audit were (1) studying the operating manuals and checking the standard process procedures, (2) process data analyzing, and (3) proposing and implementing the proper solutions. Plant audit revealed a low equipment efficiency. The main defects were the crusher operation in the half-full condition, high pressure grinding roll (HPGR) operation in a non-standard condition, high amounts of rejected materials in the HPGR circuit, and low efficiency of the screen. Following this, a series of modifications were made in the crushing and grinding circuit. This consequently caused an increase of 9.3% in the crushing plant throughput in the choked condition of the crushers as opposed to the half-full condition. By increasing the HPGR operational pressure and the hopper level, BBWI of the HPGR product in the super-choked condition was decreased from 16± 0.20 kWh/t to 14.9± 0.25 kWh/t. By modifying the screen process, the circulating load decreased from 79% to 59%, and the screen efficiency increased from 63.5% to 89.5%.
Mineral Processing
M. Maleki Moghaddam; E. Arghavani; A.R. Ghasemi; S. Banisi
Abstract
Liner design has become an increasingly more important tool for the AG/SAG mill performance optimization. The Sarcheshmeh copper complex concentration plant uses a SAG mill lined with 48 rows of Hi-Low type liners. Because of breakage of Low type liners and cold welding, the liner replacement task of ...
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Liner design has become an increasingly more important tool for the AG/SAG mill performance optimization. The Sarcheshmeh copper complex concentration plant uses a SAG mill lined with 48 rows of Hi-Low type liners. Because of breakage of Low type liners and cold welding, the liner replacement task of Low with new Hi type liners has become very difficult and time-consuming. With the objective of finding a new design for liners, numerical (3D DEM; discrete element method) simulation and physical modelling in a laboratory mill were used. It was found that changing the liner type from Hi-Low to Hi-Hi could provide an appropriate charge trajectory. The new Hi-Hi type shell liners were designed, manufactured, and installed. With the new liners, the number of broken liners over liner life reduced from 6 to 0 piece, the total changing time for one liner decreased from 21 to 16 minutes, and no cold welding of shell liners was observed. Comparison of the feed rate before and after installation of the new liners for a period of liner life showed an increase from 750 to 850 t/h, which was indicative of a higher flexibility of the mill in encountering ore hardness variations.
Mineral Processing
M. Maleki Moghaddam; A. R. Hasankhoei; E. Arghavani; A. Haji-Zadeh; M. Yahyaei; S. Banisi
Abstract
Liner design is becoming an increasingly more important tool for the AG/SAG mill performance optimization. The Gol-E-Gohar iron ore concentration plant uses three 9 m × 2.05 m autogenous mills (AG) in parallel in a dry operation. Due to large variations in feed characteristics and inadequate ...
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Liner design is becoming an increasingly more important tool for the AG/SAG mill performance optimization. The Gol-E-Gohar iron ore concentration plant uses three 9 m × 2.05 m autogenous mills (AG) in parallel in a dry operation. Due to large variations in feed characteristics and inadequate blending, the performance of AG mills has been lower than the target value. In order to increase the circuit throughput while maintaining the desired product size, based upon physical and numerical simulations, it was proposed to convert the AG mills to SAG mills. Simulation of the charge trajectory indicated that increasing the liner lifter face angle from 7 to 30° could provide an appropriate charge trajectory in the SAG mode. Installation of the new liners and conversion of AG mill No. 2 to SAG mill, by adding 5% (v/v) balls, resulted in an overall increase of 31% in throughput (from 419 to 548 t/h). Measurement of the wear profiles of shell liners indicated that the wear along the liner length was not uniform. In order to arrive at a uniform wear profile, a new liner design was proposed. Installing the second liner design in AG mill No. 1 and converting it to SAG mill increased the mill throughput by 18% (from 413 to 489 t/h), while the liner life showed a 7% increase. Measurement of the wear profiles of the second liner set indicate that the maximum wear occurs in the centre of the mill. A new liner design was then designed by increasing the width of the lifter top from 12.5 to 15 cm and increasing the lifter height from 16 to 26 cm to enhance the liner life.
