Simulation of grinding circuit at Gumuskoy silver plant, Turkey

The comminution circuit at the plant has experienced severe problems arising from a feed containing much larger amounts of clay and having a higher moisture content than expected. Three solutions were proposed: replacement of the crushing circuit by tooth roll-type crushers; using washing drums; and introducing primary autogenous/semi-autogenous millling instead of crushing. Computer simulations studied the effects of the first two solutions on the circuit capacity. Laboratory and industrial scale ball mill batch grinding tests were carried out. The parameters of a kinetic model were determined. The ball mill circuit was sampled and operating model parameters were calculated. The ability of batch grinding parameters to represent the operating conditions was studied. Tests failed to find acceptable model parameters, but parameters from an industrial size batch mill were found to be suitable for simulation studies. The simulations indicated that a continuous feed of -12 mm provided by tooth roll crushers would maintain the desired capacity. Increasing the feed size to -25 mm would reduce the capacity by 8-15%. The use of washing drums could also solve the capacity problem, but small fluctuations in water flow rates might result in problems of excess water in the grinding circuit.