Search Documents

By W. H. A. Timm

Lake Dufault Mines, Limited, is located ten miles north of Noranda, Quebec. Following discovery of a copper-zinc orebody late in 1961, metallurgical investigations of diamond drill core were conducted by Lakefield Research Limited during 1962 and 1963. These were followed by pilot-plant tests in May and June of 1964, utilizing underground development ore. Milling operations commenced on August 16, 1964, and reached rated capacity of 1,300 tons per day by October 1, 1964 (Figure 1). Since that time, tonnage was gradually increased to a maximum of 1,400 tons per day and since January 1, 1968, gradually decreased to the present rate of 1,100 tons per day due to an increase in the hardness of the ore. The ore milled from start-up until January, 1968, was mainly massive sulphides, consisting of a complex mixture of iron, copper, zinc and minor amounts of lead sulphides with important associated values in gold, silver and cadmium (aver- age specific gravity 3.8). From January, 1968, until the present, the ore being processed is described geologically as a boxwork of sulphide stringers of chalcopyrite, pyrite and pyrrhotite and some local dissemination in siliceous rhyolite (average specific gravity 2.9) supplemented by the massive copper-zinc ore. The limited size of the orebody and the mining method employed (open stoping by blasthole and slash and bench methods) would have made grade control from the mine difficult and expensive. It was decided to try to cope with grade variations in the mill. The resulting rapid and wide swings in mill heads, hardness and specific gravity have presented many and varied challenges for the mill personnel.

Jan 1, 1970

By J. W. Keck

Pilot plant grinding and concentration test results indicate that conglomerate native copper ore can be ground and concentrated using conventional techniques. Single stage autogenous grinding and rod mill-ball mill grinding required the same amount of energy far the required comminution. Metallurgical results were comparable for both types of grinding investigated.

Jan 1, 1973

By O. A. Bascur

In recent years, metal-producing companies have increased their investment in automation and technological innovation, embracing new opportunities to enable transformational change. Transformation to a digital plant can fundamentally revolutionize how industrial complexes operate. The abundant and growing quantity of real-time data and events collected in the grinding and flotation circuits in a mineral processing plant can be used to solve operational issues and optimize plant performance. A grade recovery model is used to identify the best operating conditions in real time. A strategy for increasing the value of instrumentation in current plants is reviewed. An optimal Gaudin size distribution model provides augmented information from traditional sensors to find the optimal grind cut size to reduce metal losses in the flotation circuits. Sensors in flotation circuits enable an estimate of the recovery and determination of the optimal froth depth and aeration using an air hold up flotation model. A strategy of classifying data for online generation of insights to using operational intelligence tools is described. The implementation of a recovery/grind strategy with industrial examples in nonferrous mineral processing is presented.

By O. A. Bascur

In recent years, metal-producing companies have increased their investment in automation and technological innovation, embracing new opportunities to enable transformational change. Transformation to a digital plant can fundamentally revolutionize how industrial complexes operate. The abundant and growing quantity of real-time data and events collected in the grinding and flotation circuits in a mineral processing plant can be used to solve operational issues and optimize plant performance. A grade recovery model is used to identify the best operating conditions in real time. The strategy for increasing the value of instrumentation in current plants is reviewed. An optimal Gaudin size distribution model provides augmented information from traditional sensors to find the optimal grind cut size to reduce metal losses in the flotation circuits. Sensors in flotation circuits enable an estimate of the recovery and determination of the optimal froth depth and aeration using an air hold up flotation model. A strategy of classifying data for on-line generation of insights to using operational intelligence tools is described. The implementation of a recovery/grind strategy with industrial examples in non-ferrous mineral processing is presented.

By Steve Kral

The success of the industrial minerals end of the mining industry is often overshadowed by the high price of copper, the glamour of gold, and the nation's huge reserves of coal. Those three segments of the industry, however, along with every other business in the world, could not function without the products that are composed of a variety of industrial minerals. And, according to Haydn H. Murray, past president of SME, the value of industrial minerals in the United States is more than triple that of metals, about $19 billion a year versus $6 billion. In the developed countries of the world, he said, the value of industrial minerals is nearly always greater than the value of metallic minerals. Murray, also a professor of geology at Indiana University, was the luncheon speaker at the SME-sponsored Grinding of Industrial Minerals conference held in Asheville, NC this past September. Producers of industrial minerals know they must squeeze the maximum value out of the industrial mineral being mined and processed, Murray told the audience of about 100 people. Grinding and particle size, then, are vital to a commodity's profitability.

Jan 1, 1990

By C. J. Greet

Grinding with an electrochemically inert grinding media (i.e., high chrome white iron) shifts the pulp potentials to more oxidising conditions, increases the dissolved oxygen content and reduces the EDTA extractable iron concentration when compared with milling with electrochemically active grinding media (forged steel). These changes in pulp chemistry produce cleaner particle surfaces, reduce reagent consumption, and increase concentrate grades and recoveries. This paper presents a robust laboratory test program that not only demonstrates the changes in the pulp chemistry, but also provide an indication of the magnitude of the metallurgical improvements that are possible. While laboratory studies are interesting, the proof is in the pudding! So, the paper provides an overview of plant trials conducted at several porphyry copper operations around the world: Newmont’s Cadia and Red Chris Operations, as well as Evolution Mining’s Northparkes Operation. These successful plant trials clearly demonstrate that selection of the right grinding media alloy will yield savings in grinding media consumption and reagent consumption as well as increases in revenue through improved copper and gold recoveries. However, many of the porphyry copper mines on the Eastern Pacific are copper-molybdenum deposits. The paper presents laboratory test results for typical copper-molybdenum operations and extrapolate these numbers to what might be expected should a plant trial occur.

Feb 1, 2025

By E. F. ‘Pat’ Nelson, Richard Broom

Our portion of this afternoon’s session is dedicated to the operation of automatic process control associated with small to medium size primary or SAG milling circuits. In recognition of the subject matter of this symposium, specifically precious metals, our historical reference is Rosario Dominicanna in the Dominican Republic, one of the largest gold producers in the Western Hemisphere. Plus a backward glance to review very briefly the initial performance of the big primary mills at Island Copper in British Columbia and Pima IV in Arizona. We will then get to the subject at hand with a discussion of a retrofit control logic recently installed on a 5000 hp primary mill. The focus of this review is the simple, inexpensive, and cost effective character of this retrofit installation.

Jan 1, 1984

By T. M. Needham

Increasing ore hardness led to a gradual reduction of mill throughput rates. This, combined with declining head grades and low gold price, prompted a review of milling practice at Kidston. Plant trials and computer simulation of the grinding circuit indicated the potential to increase mill throughput by up to 451 by reducing SAG mill feed size. Secondary crushing and additional ball milling capacity were installed. Commissioning was carried out successfully in September/October 1992. Design, operation and problems of the expanded circuit are discussed, and recent operating results are presented.

Jan 1, 1994

By Craig M. Sams

Phosphate mines in Florida are continuing to encounter higher dolomitic content host rock with the phosphate pebbles(1) necessitating a change in grinding conditions and/or circuits, One of these changes is to install hydrocyclones and close circuit the mill as opposed to the traditional open circuit grinding plant. Close circuiting of the grinding mill with hydrocyclones allows one to take advantage of reduced process mill power requirements by circulating the coarse mill discharge back into the mill for multiple chances of particle breakage. Additionally, as in this case, the hydrocyclones de-slime the pebbles, allowing for more efficient use of grinding power by reducing the amount of dolomitic material recycled to the mill.

Jan 1, 1986

By A. B. Phillips

The Randfontein Estates Gold Mining Company (Witwatersrand) Limited (REGM) operates three metallurgical complexes for the recovery of gold from the Witwatersrand Gold Reefs at the town of Randfontein, 40 kilometers west of Johannesburg. Mining operations in the. area commenced in March 1889 and ceased temporarily in 1965 when the viable ore reserves had been depleted. Exploratory drilling in the 1960's indicated viable deposits of gold in the Elsburg reefs, south of the Witpoortjie Horst Block, _which formed the Southern limit of the previously exploited areas. Three shaft complexes have been established to exploit this area, known as the Cooke secti'on. In 1983 the Doornkop shaft was sunk to the north of the Cooke section to mine Kimberley reef and the South reef.

Jan 1, 1992

By Zong‑yu Li, Shao‑jian Ma, Xiao‑jing Yang, Jin‑lin Yang, Xing‑nan Huo, Heng‑jun Li

Optimizing and adjusting the particle size composition of grinding products is of great significance for improving economic benefits and resource recovery and utilization. In this study, grinding contribution and quantitative separation of impact and grinding mechanism in cylindrical mill were creatively researched, and the grinding technical efficiency of impact and grinding was coupled to the grinding technical efficiency of grinding in drop-off mode. The results showed that the contribution rate of impact and grinding in grinding in drop-off mode varied with the grinding time. On the whole, the contribution rate of impact action increases with the grinding time and gradually becomes stable, and the contribution rate of grinding effect was just the opposite. Under the experimental conditions, the main contribution of the grinding process is impact action, and the contribution of grinding action is auxiliary. In addition, the contribution rate of impact and grinding effect in grinding in drop-off mode was also related to the feed particle size. The contribution rate of impact effect decreased with the decrease of feed particle size, while the contribution rate of grinding increased inversely.

Aug 3, 2023

By A. L. Mular

Introduction The cost of grinding may be divided into a fixed equipment cost portion and an operating cost portion. The fixed equipment cost is the amount of money required to purchase the grinding mill itself. This amount may be kept separate from the installation cost which, often, is taken as a percentage of the fixed equipment cost. A good average is 43%; therefore a $100,000 ball mill would cost approxi¬mately $143,000 installed. Operating costs are variable and paid per unit time for power, liner replacement, grinding charge replenishment, labor, and mainte¬nance including major parts replacement. Such costs depend on the geographical location and will vary with the cost of labor. Operating costs are difficult to estimate. Most mining companies consider such information proprietary. This section provides a means to obtain an estimate of the equip¬ment cost of a grinding mill with a rated accuracy of±l0%. Compara¬ble methods to determine operating costs are not available. Such costs are presented in table form with suggestions for updating them. Esti¬mating the cost of liners and steel replacement is possible as described in a later section. Capital Costs of Grinding Mills Grinding mill costs have been related,124 by means of equations and corresponding graphs, to the nominal horsepower requirements of mills. All graphs are based on a Marshall and Stevens cost index for Mining and Milling of 300, where a cost index is a ratio used to estimate current prices of equipment from obsolete prices. Where (Cost Index Now) Cost Now = (Cost Then) (Cost Index Then) (I) For example, the cost of an autogenous mill that requires a 3000¬hp motor is estimated as $500,000 (Fig. 95). This was the estimated price when the M&S (Marshall and Stevens, Mining and Milling) cost index had a value of 300. If the index is currently at 400, then the estimated current price of the autogenous mill is: Cost Now = ($500,000) (400) (300) = $667,000 Most professional journals will publish current values of cost indices at least once a month. In subsequent pages, each graph of grinding mill cost vs. mill horsepower has an associated graph of capacity vs. horsepower along with a table that relates mill size to horsepower. The associated graph and the table must be used with caution, since both apply to an average ore under average conditions. Example calculations showing how graphs should be used are shown in the following. It should be stressed that the cost data incorporated herein ex¬cludes the cost of pumps, motors, lines, and classifiers, unless other¬wise stated. Costs are not direct quotes; they are the averages of quotes supplied by manufacturers and analyzed by means of regression analysis. Example 1. Calculate the power required to grind 100 tons of dry solids per hour (in a closed circuit with a classifier) when the

Jan 1, 1985

By J. Lovering, H. Wilhelm, P. Siewert

Introduction The Afton property is located 290 km (180 miles) by air east-northeast from Vancouver and 14 km (8.7 miles) west of Kamloops, a city of 60,000 people, in south central British Columbia, Canada. The mine is adjacent to the Trans-Canada Highway at an elevation of 670 m (2198 ft) above sea level. The ore body is a porphyry copper deposit that has undergone supergene alteration. The major economic minerals in the supergene zone are native copper and chalcocite with chalcopyrite and bornite in the hypergene areas. The grade is 1% with an overall copper distribution - 70% native, 25% chalcocite, and 5% chalcopyrite with bornite and covellite. The ore also contains important but variable amounts of gold and silver. The mill was designed to treat 6350 t/d (7000 stpd). Semiautogenous grinding was selected to minimize capital cost and because of the expected high clay content of the ore, which would have caused problems in a conventional crushing and screening plant. Test work indicated that a recovery of 87% was possible in a circuit incorporating both flotation and gravity separation. Flowsheet Run-of-mine ore is crushed in a 1.06 x 1.65-m (3.5 x 5.4-ft) Allis Chalmers gyratory crusher set at 228.6 mm (9 in.), closed side setting. The surge pocket, below the crusher, is emptied by a Hydrastroke feeder onto number one conveyor, which discharges onto a 180,000-t (198,416-st) coarse ore stockpile. Six Hydrastroke feeders on two conveyors withdraw the crushed material from the bottom of the pile. These two conveyors, in turn, discharge onto the belt feeding the semiautogenous mill. The live storage in the stockpile is approximately 22,000 t (24,250 st), sufficient for three days' mill feed. Primary grinding is accomplished in an 8.5-m (28-ft) diam by 3.7-m (12-ft) long Koppers (Hardinge Cascade) mill (Fig. 1) containing a 10% ball charge and driven by a 4000-kW dc variable speed motor. The mill dis¬charge is pumped by a 10 x 12 G.I.W. pump to a 1.22 x 4.88-m (4 x 16-ft) stationary screen sloped at 20°. Screen oversize returns to the semiautogenous mill (SAM), and the undersize flows by gravity to the ball mill discharge pump box. Secondary grinding is performed in a 5-m (16.4-ft) diam by 8.84-m (29-ft) Koppers overflow ball mill driven by a 3430-kW synchronous motor through an air clutch. The mill is in closed circuit with a Krebs Cyclopac containing 10 635-mm (25-in.) cyclones and the cyclone overflow, at 35% solids and 65% to 70% -200 mesh, is flotation feed. In order to limit the buildup of native copper, circulating in the secondary grinding circuit, a portion of the underflow from the cyclones is processed in a circuit containing screens, cyclones, and shaking tables to produce a finished metallic copper concentrate. Primary mill variable speed drive The overall waste to ore ratio at Afton was 4.5:1. The mining was to be done with only three shovels, which meant that it was highly unlikely that more than one of them would be in ore at any one time. The resulting inability to blend the mill feed made it impossible to prevent wide swings in the grade and grindability. The variable speed do drive motor installed on the semiautogenous mill was selected because of the extreme variability of the Afton ore body. This variability has persisted throughout the lifetime of the mine. There are times, however, when due to ore conditions, the mill is operated at full speed (78% of critical) for extended periods of several shifts duration. There are other times when the mill speed may be changed several times in a 12-hour shift due to changing ore conditions. When ore is processed that contains a fairly large proportion of fine native copper, the primary mill speed and, consequently, the tonnage may be reduced to improve the secondary grind and to maintain an acceptable grind and recovery. High clay ores require less mill speed and more dilute grinding densities. In the latter case, the slower primary mill speed also helps to minimize damage to the mill liners. Approximately 57% of the time the mill operates between 90% and 100% of full speed or between 71% and 78% of critical. The variable speed is also used for inching during mill relines.

Jan 1, 1987

By John Lovering

The Afton property is located 180 air miles East-Northeast of Vancouver and nine miles West of Kamloops, a city of 60,000 people, in South Central British Columbia, Canada. The mine is adjacent to the Trans-Canada Highway at an elevation of 2,200 feet above sea level. The orebody is a porphyry, copper deposit that has undergone supergene alteration. The-major economic minerals in the supergene zone are native copper and chalcocite with chalcopyrite and bornite in the hypergene areas. The grade is one percent with an overall copper distribution: 70% native, 25% chalcocite and 5% chalcopyrite with bornite and covellite. The ore also contains important, but variable amounts of gold and silver.

Jan 1, 1985

By J. T. Winkelmann

The Mineral Park Mine is an open pit copper-molybdenum mine located in northwestern Arizona, approximately twenty miles northwest of Kingman, Arizona. The concentrating facility has been regarded, with the expansion in 2011, as a plant capable of treating fifty thousand short tons of feed per day for the mixture of supergene and hypogene ores available. The grinding circuit consists of two 32? x 14? SAG mills and four 20? x 28? ball mills. As ores became harder with greater depth in the adjacent pit areas, however, the SAG mills became severely throughput limited. The traditional treatment for similar properties is the installation of a recycle pebble crushing circuit. Because the cost of such an installation is quite elevated, and preliminary testing and research was inconclusive regarding the predicted throughput increases, management and technical personnel set out to find another solution to the problem. The result entailed a redesign of SAG lifters/liners and a nearly unique circuit change which was, at best, a difficult step that defied current grinding logic. This paper describes these changes, events leading up to them, and the results.

Feb 23, 2014

By M. D. Baker

Coal-water slurry preparation requires fine grinding and cleaning of coal by flotation. Finer grinding leads to increased ball wear and its effect on the surface properties of coal becomes of concern. Marked ball wear tests were performed to study the effects of oxygen, pH, the soluble species of coal and the addition of pyrrhotite on ball wear. The synergistic action of coal and oxygen greatly enhanced the corrosion of mild steel balls during grinding. Electrochemical measurements on a mild steel electrode in coal slurries and SEM observations of grinding ball surfaces were carried out to explore the corrosive wear mechanism.

Jan 1, 1989

By Vathsala Rajagopal, lwao lwasaki

The grinding media materials for the mining industry require corrosion and abrasion resistance properties not only to minimize the wear but also to improve the flotation recoveries of sulfide minerals. The media wear mechanisms and the factors influencing the grinding ball wear during grinding are discussed with respect to abrasion, corrosion and impact wear of grinding media materials. Interactions between the grinding media and sulfide minerals in a ball mill adversely affect the floatabilities of the ground minerals. The possible galvanic interactions between grinding medium-mineral and their effects on the flotation responses of sulfides are also reviewed. The selection criteria for alloy composition that reduces the overall wear along with adverse effects on flotation are brought out.

Jan 1, 1992

By D. C. Dahlin, W. K. O’Connor, G. E. Rush, C. A. Summers, S. J. Gerdemann

The Albany Research Center (ARC) conducted studies of mechanical activation by conventional and ultra-fine grinding techniques to enhance olivine reactivity in mineral carbonation reactions. Activated olivine is one of several solid feed materials used at ARC in reactions with carbon dioxide to form carbonate minerals. This paper compares grinding techniques via energy demand data and product characteristics, including particle size distributions, surface areas, full width at half maximum (FWHM) XRD analyses, and particle morphology by SEM analyses. Reactivity was gauged by percent conversion to carbonate in subsequent carbonation tests.

Jan 1, 2004

By S. McTavish

Since mechanically suitable grinding mills were available in 1908, mill operators have been searching for the best material and design with which to line the mills. These liner systems had to fulfill several criteria. First and foremost they had to last long enough in an operating mill to protect the mill structure from the abrasive wear of the ore and the grinding media. In addition they had to be able to efficiently transfer the energy from the mill to the mill charge in order to facilitate the grinding process. The liners also had to be easily attached to the mill when new and removed from the mill when worn out. The first liners used were generally made of cast white iron, Hadfield manganese, unalloyed high carbon steel and composites of steel and concrete or cemented in flint blocks or natural stone. 1

Jan 1, 1989

By N. Arbiter, C. C. Harris

The economic advantages of large diameter ball mills can be compromised by unexpected capacity limiting conditions. These arise because media rotational flow to ore axial flow ratios, and the number of mill revolutions that ore is subjected to during residence, are both inversely proportional to mill diameter. Because of this, mixing efficiency and grinding kinetics may decrease and become capacity limiting when mill diameters reach a critical range. There are two possible scale-up problems involved in the design and use of mineral processing machinery: • Selecting the size and operating conditions for available larger equipment, to insure that operating results will match those obtained with smaller units; or •Extending the size ranges of equipment beyond existing limits. Previous research at Columbia University into flotation machine hydrodynamics has demonstrated the importance in scale-up of internal flow relationships; these perform a similar role in grinding (Arbiter and Harris, 1980).

Jan 1, 1982