Element based ball mill and hydrocyclone modelling for a copper ore grinding circuit

Abstract

Grinding is an intermediate stage that links the mining and the concentration processes. Concentration circuits consider the elemental analysis and the recoveries to express the efficiency where the size distributions are one of the key indicators for the grinding. However, using similar expressions or approaches for grinding operations or at least a joint consideration with the element distributions may create an environment with an improved synergy. From this perspective this study aimed at developing element-based model structures to provide a better understanding of the grinding and the subsequent operation. Within the scope, the given copper grinding circuit was sampled at two different production rates. Then the size reduction and classification performances were evaluated, and the model structures were developed for each element. For the classification, the model structure for the parameters of sharpness, bypass, and cut size parameters of efficiency curves were developed in correlation with the solid concentration, cyclone geometry and S.G. characteristics. For the ball milling, the breakage characteristics of a given ore were determined via drop-weight tester based on the elements. Then the model structure was developed by using the perfect mixing approach. As conclusion, the model of the whole grinding circuit can predict the element behaviours prior to the stage of concentration.