The Effect of HPGR and Conventional Crushing on the Extent of Micro-Cracks, Milling Energy Requirements and the Degree of Liberation: A Case Study of UG2 Platinum Ore

Abstract

Comparative high pressure grinding rolls (HPGR) and cone crusher pilot-scale tests were conducted using Upper Group 2 (UG2) platinum-bearing ore in order to determine the impact of micro-cracks in HPGR products toward energy requirements in ball mills and the degree of liberation. The ball mill was fed with HPGR and cone crusher products of similar particle size distributions (PSDs). Qualitative analysis of the degree of micro-cracking on the HPGR and cone crusher products performed using scanning electron microscope (SEM) and image analysis software showed that an HPGR product had more micro-cracks than the equivalent cone crusher product. Milling energy requirements were evaluated using size-specific energy consumption indices calculated based on three grind sizes of 300 µm, 150 µm and 75 µm. The effect of residual micro-cracks in the products of HPGR and cone crusher on the milling size-specific energy requirement is inconclusive. The kinetic parameter k in the cumulative rate kinetic model for ball milling cone crusher products and for ball milling HPGR products were similar. Quantitative Evaluation of Minerals by Scanning Electron Microscopy (QEMSCAN) was used to determine the degree of liberation of various mineral phases in the mill products. At a coarser grind size (P80 of 300 µm), the sulfides in the mill products pre-crushed using the cone crusher have consistently poorer liberation than in the equivalent HPGR pre-crushed sample. However, at a finer grind size (P80 of 75 µm), the sulfides in the mill products pre-crushed using the cone crusher and using an HPGR showed similar liberation.