PREPRINT NUMBER

85-407

TESTING FOR AUTOGEMOUS AND SEMI-AUTOGENOUS GRINDING A DESIGNER'S POINT OF VIEW

D. J. Barratt

Wright Engineers Limited Vancouver, British Columbia

For presentation at the SME-AIME Fall Meetin

Permission i s hereby given to publish with appropriate acknowledgments, excerpts or summaries not to exceed one-fourth of the entire text of the paper. Permission to print in more extended form subsequent to publication by the Institute must be obtained from the Executive Director of the Society of Mining Engineers If and when this paper is published by the Society of Mining Engineers of AIME, it may embody certain changes made by agreement between the Technical Publications Committee and the author, so that the form in which it appears here is not necessarily that in which i t may be published later. These preprints are available for sale: Mail orders to PREPRINTS, Society of Mining Engineers, Caller No. D, Littleton, Colorado 80123.

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The application of autogenous and s e mi-autogenous grinding circuits i n recent years has contributed toward substantial savings i n capital and operating costs compared t o conventional circuib, particularly for large scale copper and molybdenum operations. Such savings have been realized from the deletion of operating, maintenance, equipment purchase and substantial civll/structural costs associated with secondary/tertiary crushing and screening, fine ore storage and conveying. In spite of the downturn i n the coppermoly industry i n North America, there is still an interest i n autogenous and semi-autogenous grincting for copper-zinc, gold and silver ores and i n the overseas market. Both single-stage and two-stage circldts are in operatton. Primary circuits operate autogenously or semi-autogenously in either open or closed4rcuit. Crltlcalsizes are extracted and crushed for recycle i n some cases (e.g. ABC circldt). Secondary grinding is conducted using b a m i l l s or pebble m i l l s . In view of these potential concepts, which result i n dirfering operating schedules and possible operating cost savings compared t o conventional grinding c;rcuits, what is the basis for a t e c h d c a l evaluation of autogenous or semi-autogenous grinding i n terms of power requirement and equipment selection a t the pre-design stage? The answer lies i n established testing methods, empirical calculations and the amount of time and money available for study. Most importantly, an unbiased approach toward the proble m and an objectivity which recogrdses the properties of the orebody i n question are indispensable attributes requbed of the m etallu@cal engineer and his colleagues. Basis For Evaluation Selectton of S a m p l e s The principal objective for the metallurgLcal en@neer is to determine the spe-c power requirement and mesh of grind necessary for subsequent processing. Normally, thisinvolves a study with the mine geologist and mine production engineer of the following p a n meters before testwork begins: Ore zones and ore types. M h e r a l o ~and j liberation analyses. D i a m ond drill core and logs. Accessible workings (e.g. trenches, pits, adits, drircs, etc.). Proposed mine plan and production sequence. Ore hardness (e.g. presence of cherts, clays, friable minerats or rocks). Fracturing (e.g. fault or joint planes, presence of gouge material). Types and degrees of mineral. alteration. All this information should be used to select samples for either batch o r continuous testing. The decision as to how much grinding teatwork is reqtdred Is more complex for autogenous or semiautogenous (collectively read AS A G f o r econo m y) grinding than f o r conventional grinding. Firstly, conventional crushing and grinding c i r c u i b can be designed confldenuy on the basis of small-scale. batch or locked-cycle tests requiring only 35 kg sample per test. Secondly, ASA G circuits can be designed usLng various methods each of which c a n h s an element of rlsk c o n mensurate wit3 the experience of the en@neem involved and the amount of sample tested. The magnitude of risk can be tabulated as i n Table 1 .

Traditionally, continuous testing has been used to develop engineering design criteria. The higher cost for continuous testing and the attendant least contingency and risk associated with testing bulk samples can be justified if the t o t a l cost, including sample acquisition and transportation, is less than the present value of potentidl savings i n capitdl and operating costs presented by the higher contingencies associated with the alternatives outlined i n Table 1. In contrast, for conventional crushing and grinding it is unnecessary t o t e s t bulk samples unless a contingent process k should be emphasized a t route requires piloting. I this point t h a t each ore type, which is s i g M c a n t L e . more than 10 $ ) i n terms of its rank or consistency in m i l l throughput, should be tested for either ASAG o r conventional zche m es. Bond Work Index and Hinerdlorn Prior t o testLng f o r autogenous or s e mi-autogenous grinding, it is important to have an understanding of the spedflc energy requirements f o r crushlng and grinding as w e l l a s mineralogy. The Bond Work Index is the generally accepted parameter f o r gauging specific energy require m ents i n conventional crushing and grinding. The results a r e highly reliable i f these tests are conducted on representative samples, usually of drill core, and follow the prescribed Bond method and t e s t equip m e n t ( l ) Analysis of Bond Work Index test results for crushing, rod milling and ball milling w i l l indicate unSormi t y or other& of breakage characteristics i n diffewe n t size ranges. Very often one is much higher (or lower) than the others and such variations can govern the power CfistribuUon between primary and secondary stages of grinding. Also, these obsemations , d i l l give an indication of the potentidl e m e n c e of a critical s h e relative t o autogenous or s e mi-autogenous grindi n g . For instance i n grinding a masslve sulphide ore, rod m131 Bond Work Index w a s found t o be 7.0 in contrast t o a ball m i l l Bond Work Index of 13.4. The W e r e n c e was indicazve of the mineralogLcal structure which showed t h a t the rod m i l l was breaking sulphide grains relatively easily away from harder siliceous mine* and the baJl m i l l w a s breaking these sulphide grains across boundaries i n order to prepare feed for d W f e r e n b l flotation of copper from zinc. The crushing Bond Work Index w a s higher than the rod m i l l Bond Work Index. Prediminary analysis concluded t h a t this ore would be amenable to ASA G and t h a t the chances of a critical size bldld-up would be l o w . In another exa m ple, the rod m i l l Bond Work Index of a siliceous copper-silver ore w a s found t o be 21.0 versus The fene a ball m i l l Bond Work Index of 12.8. dissemination of sulphide minerah showed t h a t energy had to be expended in breakage across siliceous grain boundaries before liberation of sulphides w a s poszible i n the ball milling stage. The chances of a bldld-up in critical size were considered to be high and so an A B C circuit would be r e c o a mended for inclusion in a t e s t program The determination of Bond WorJx Indices for rod milling and ball milling requires about 25 kg of sample crushed to minus 13 m m , some of which (about 5 kg) can be used to determine Abrasion Index f o r the prediction of m eta1 wear i n grinding m i l l s . In addition, Bond Work Index for crushing can be determined f o r a range of samples drawn from 100 lumps each 32 cm cube in sFze and weighing 100 grams using the high energy twin pendulum testC2) or 20 pieces each 90 cm cube i n the standard test.

ASA G C i r c u i b

It is considered t h a t t h e determination of power requirement f o r a n ASAG m i l l reqldres t h e s a m e understanding of breakage characLteristics and Bond Work Index developed f o r conventional gt-lnding in testing particular ore samples. In addition, however, it is necessary t o know how c o m p e t e n t mn-of-mine o r primary crushed ore is i n t h e coarser s h e s and in what b generally t e r m e d t h e "critical size" range (75,000 to 13,000 microns) when operating in t h e presence of a reduced ball charge (up t o 125 by volume) o r when &ding autogenously. Variations in t h e competency W determine of these s h e s and feed size d i s t r b u t l o n k n o t only t h e b a l l ch=ge l e v e l required b u t also t h e power dr2w of t h e m i l l , product sizing and r a t e of production and hence l d o w a t t - h o u r s p e r tonne. Whereas with convenfonal grinding in which power is transmitted to t h e o r e through c o n t a c t uiL\ a higin l e v e l of media and power draw is relatively cons'ant with variations in production r a t e related to Bond Work Index, power i n a n ASAG m i l l is transmitted less efficiently. Autogenous m i l l s a r e usually l e s s e M c i e n t than SAG m i U s . Bowever, t h e introduction of a crusher i n closed-circuit with an autogenous m i l l i s a n zlternative which can improve power e M d e n c y and n t e r m s of operating c o s t compared to o f f e r savings L SAG (Le. no bail consumption and probably less h e r wear). Whereas t h e crusher s e r J e s t h e s a m e purpose as a ball load does in controlling t h e build-up of c r i t i c a l sizes, a coarser circuit product usually results with reduced s p e d l o power consumption. If secondary p h d i n g is n e c e s a r y , more power and c a p i t a l would have to b e applied in this a r e a with coarser feed s i z e s and so alternative studies would be necessary t o determine t h e most economical option. if a c r i t i c a l size does bldld-up in a SAG m i l l , conversion t o A B C , SABC o r SAC Is usually t h e result. Eow can t h e metallurgical engineer predict t h e bebav'lour of o x types i n SAG o r ABC & c u b a t reasonable c o s t ? The following s t e p s a r e suggested i n c o x i d e r a t i o n of t h e risk indicated in T a b h 1 : Step One: V k i t t h e property, exalcine d r X core, review rock qu&t'j d e t e r m i n a z o n ( R 9 D) analyses (which are a measwe of fracturing o r weakness), watch f o r ore types which exhibit a G h o r low ~ s k ' a n c e to breakage vhen being mined, d e t e r n i n e presence of c h e r t o r o t h e r f o r m s of hard +rn o ~ h o u s silica, conduct d e l d drop t e s t a on rock types. Step Two: Select s a ~ p l e sf o r d e t e r n i q a t i o n of aond Work h d e x f o r crdshing, rod milling and ball nilling t o final product size (com m e m u r a t e with liberation analyses and subsequent p m c e s s test require rn en&) and Abrasion Index. Step Three: Perform empirical c a k u i a t i o n s to size a n ASAG circuit and prepare p r e l i m i n r y c a p i t a l and operating c o s t estim ates. Step Four: If development o r e o r 150 m m dr'2.l core is available, conduct batch m i n d i n g tests (see Table 1 ) . To date, these can only b e done in t h e D r i l l COP? can a h o be used f o r United States. small scale continuous tests. Step Five: If t h e o r e value warrants a g r e a t e r degree of confidence h e . less contingency) in m i l l s i d n g , conduct continuous testa on bulk samples. To d a t e , these can be performed in Canada, t h e United S'cztes, Chile and in t h e future, Peru. Test f a d i t i e s also e a t i n Japan, Australia, Europ? and South Africa.

These calculations are based on r e f e r e n c e to d m l l a r ores. Caution should be exercised with regard to t h e assumption t h a t breakage characterisUcs and ball loading will be s i m i l a r to those of t h e r e f e r e n c e ores. The experience of t h e m etalh@cal engineer is c r l t i c a l i n this regard and t h e contingency which I s indLuded in t h e m i l l horsepower has to b e judged in t h a t light. ~ a r r a t t ( 3 )h a s suggested and has developed t h e following formulae based on aond 'rloric Index d e t e ~ minations f o r a pow e r - e m d e n t conventional scheme. F o r a t w o s t a g e SAG circuit:

EBM

'
Work Lqdex (metric) C = crushing R =rod m i l l B=ballmill K80 product f o r e a c h s t a g e (microns) K80 feed f o r each s t a g e (microns) Composite of correction f a c t o m f o r rod milling(4) including those f o r oversize feed, b u t excluding t h a t f o r m i l l diameter. ComposLte o r correction f a c t o r s f o r ball milling(4) including those f o r fine grinding, b u t excluding t h a t f o r m i l l dia m eter. K80 product selected f o r SAG s t a g e (microns) k Wh/tonne a t t h e m i l l w o n f o r SAG m i l L (before contingency f o r power swings) kWh/tonne a t t h e m i l l p i d o n f o r secondary s t a g e ball mFU.

Where: W i =

P F Kr
Kb

= = = =

PSAG = ESAG = EBM =

The m o s t c r i t i c a l p a r a m e t e r governing ESA G is t h e ' 80 p e r c e n t pa&g s h e of t h e primary circuit product, PSAG. In u i h g t h k formula, lower values of ESAG c a n be expected f o r c o m e r product s k i n s and these in turn depend upon ball loading and tine productlon of n a t u r a l fines. The usual relationships found i n t e s b g c o m p e t e n t ores, i e . those in which breakage Fs predomlnan'cly across @ boundaries, a e of t h e types shown i n Figures 1, 2, 3, and 4. If avaUztble f o r a r e f e r e n c e ore, they can s e r v e a3 a guide in selecting ? S A G and so f o r d e t e r m i n h g t h e power split between p r l n r y and s e c o n d a ~ stages. For those ores which break up more easily i n t h e coarser s i z e s (conglomerates and sandstbnes) o r which have a high clay component, t h e f a c t o r 1.25 in Equation (1) is still used but t h e p p h i c a l relationships can change. Product sLzLng and s p e d f i c power consumption have been known to be independent of ball loading with such o r e s d n c e reduction to a n a t u r a l h e appeared to be t h e governing factor. Single-stage d r c u i t s a r e m ore c o m q on fn such cases, e x c e p t where 'Ine grinding is a requirement. Once t h e specFfic power consunption ESAG, h a s been determined f o r each ore type using E q u a t i o n 3

a judgement has t o be made regarding t h e s a f e t y f a c t o r applicable t o account f o r expected power swings. In t h e absence of t e s t results, it is usual t o add 25 % t o t h e most representative value o f ESAG and size tine m i l l from Equation (3) and manufacturers' reco m m endations(5)

consists of a "graded" charge ranging in size from 64 m m to 13 m m. The m i l l is operated f o r a sufflcient t i m e (unspecified in t h e results) t o establish balanced conditions. 0 nce these conditions a r e established, t h e m i l l is operated f o r one t a two hours during which t i m e samples a r e taken. After this, t h e m i l l load is removed f o r volu m e t r k measurement and size analysis dlong with t h e feed and product samples. Net m i l l power is calculated fro m t h e fo* wing formula: Net M i l l Power
r

0.682 (3.2

- 3 Lf) x Lf x g

Where: s e

Ushg n e t mill power and 8 0 % passing sizes of feed and p m d u c t a n Autogenous Work Indexw (A Wi) a s deffied by Mac~herson(7) is calclulated using Bond's formula. This Autogenous Work Index is then used to estiD z L = mate t h e f u l l scale plant Operating Work Index, Wio, using a plot of A W i versus Wio from a library of testing and operating informati0n(7,~). The Operating Net grinding power, e, is a function of m i l l speed and m i l l charge volume. The figures given a r e f o r m i l l Work Indices apply to single-stage o r two-stage speeds i n t h e n o r m a l range of 72 75 percent of circuits t o f i n a l product size and t h e objectiv.' is t o c r i t i c a l and m i l l c h a r s e volumes of 30 t o 35 % and a r e r e l a t e A W i t o t h e Wio f o r a s i m i l a r ore. This suitable f o r use in preliminary sizing. correlation is proprietary information which is n o t ~o.veday(~ re ) f e r s t o a power number, p, which is g e n e r a y available t o the en&teering fraternity. e q u i v a l m t to: MacPherson shows t h a t A W i is directly proportional to 1 and ores i n this Wio f o r values of A iJi of l e s s than 1 categorf "should grind efficiently on a fully autogenous b a d " . Further, he shows, this proportiondity and varies with m m charge volume f o r a &ven speed. f& off inversely a s A 'rli increases above 1 1 and t h a t ores ir this range should require t h e addition of a ball He has prepared'a plot of d a t a from pilot and production m i l l s and has related it t o a standard ball m i l l charge t o t h e primary m i l l o r t h e r e m o v a l of pebbles curve f o r a c r i t i c a l speed of 7 3 % . He suggests t h a t t o enhance power efficiency. The method, apparently, ball m i l l curves f o r different speeds can be used t o cannot be used to assess the e f f e c t of variable circulpredict power numbers f o r ASAG m i l l s . These power ating loads resulting from changing clasiiiication o r numbers do not appear t o account f o r expected power ball charge volume nor can it be used t o fi-mly predict swingsin a n ASAG m i l l . t h e choice of an ABC circuit over semi-autogenous. Most SAG miUs of North American design have The advantages of such a method a r e t h a t r e h t i v s l y been built using a m i l l d i a m e t e r 2 t o 4 t i m e s t h e m i l l s m a l l sample w d g h t s a r e required, t h a t results can be length. Choice of r a t i o involves p r a c t i c a l consideraobtained in a s h o r t e r t i m e span compared with full tions such a s transportation, economics of manufacs c a l e pilot plant and t h a t choices f o r f a l l s c a l e pilot turing and retention time. In a single-stage circuit, plant testing can be i d e n t f l e d w i t h regard t o circuit more emphasis is likely t o be placed on length t o type and different o r e types. guarantee sufflcient retention time f o r t h e production With r e f e r e n c e to t h e power distribution between of final product. In two-stage circuits, t h e primary primary and secondary grinding stages(8), t h e relationm i l l dimensions will usually be selected t o provide ships D u s t r a t e d in F i g r e 4 demonstrate Ynat M h a r i m p a c t and a s h o r t retention t i m e r a t h e r than attripower efficiencies can be obtained with a coarser tion, s o t h a t a coarser product can be ground more primary product s e n t to ball milling. There a r e some efficiently in a ball m i U . The split between E s ~ ~ a n d exceptions (see t h e Section on Empkical Calculations), EBM f o r two-stage circdb w i l l have been selected t o but generally industrial practice has been t o utilize achieve t h e Pighest power efficiency and m i l l dimensecondary ball m i l l i n g capacity t o t h e P A s t and, if sions f o r both s t a g e s will &o b e selected with thi3 necessarj, install more. B a l l m U t g capacitj. can be objective it mind. justified if t h e i n c r e m e n t a l decrease in specific power consumption f o r t h e primarf m i l l , f o r example beS m a l l Scale Continuous Tests tween 500 and 1000 microns f o r primary m i l l circuit p m d u c t in FQuro 4, is g r e a t e r than the corresponding One laboratory, Polysius Aerofall, in t h e United increase in specific power consumption required f o r S t a t e s is currently offering autogenous grindability ball milling t h e coarser product. This a p p ~ a c h would t e s t s in a 450 m m (18 inch) d i a m e t e r m i l l . S a mple be followed in t h e i n t e r e s t of minimizing c a p i t a l c o s t requirement Fs between 136 and 227 kg per test. This and operating c o s t through t h e c o r r e c t choice of material is crushed t o minus 32 m m i n preparation f o r primary m i l l product size, circnuit bjpe and power split. t h e t e s t which is performed on dry material with a n With regard to contingency placed on results pre18.12 kg ball charge, o r about 1 0 % of m i l l volume. dicted f m m determination of A W i , no information has The m i l l is supple m ented by a d r a f t f a n and product been published. However, Hac Pherson claims good Plus 14 mesh material is recycled. collection system correlation between throughputs calculated from A W i The m i l l is a p e e p h e r d l discharge n i i l fed by a and those experienced in i n d u s t r i d plants p r o d d e d t h e vibrating f e e d e r and controlled by sound l e v e l to sample f o r A W i determination is crushed in a manner m a b a r m i l l loading. The m i l l is usually operated ( u n s p e d e d ) which simulates tlne method of o r e breakwith t h e peripheral p a r t s closed. The ball charge a g e h m miling bulk samples(7). Readers have t o

n e t grinding power per metre length of a 3 metre d i a m e t e r m i l l with a grinding charge having a bulk density of 2.5 = 72 k W 2 2 k W. bulk density of t h e mill charge in tonnes per cubic metre. m i l l d i a m e t e r inside liners in m etres. milllength W d e l i n e n in meters.

Where Lf g

= fractional filling of t h e m i l l
= density of total m i l l load, l b / f t 3

make t h e accurnption t h a t t h e industrial plants to which he r e f e r s a r e power-efficient. Batch Tests These t e s t s a r e proprietary in t h a t only one m i l l manufacturer ( M P m is equipped t o conduct t h e t e s t s and scale-up t e s t results. Observation of t h e t e s t s is mandatory with representatives of both t h e mine owner and a n indeaendent consu1t;ing metallurgical engineer being present t o note characteristics of o r e breakage. The basic t e s t requires a 227 kg sample t o b e ground f o r a spe-&ied t i m e period (Le. power input) i n a 1.83 m dia. x 0.30 m m i l l with a specified ball charge. The m i l l charge is then sized and a specif'lc pnwer consumption is calculated i n t e r m s of k w h p e r tonne of s o u n d product which passes a s e t screen mesh. Alternate t e s t conditions can be designed f o r which t h e s i z e distribution of t h e feed, ball charge volum a, ball s k e s and ball charge composition can be varied. It is very i m p o r t a n t t h a t an independent m e t a l l x g i c a l engineer participates in designing t h e s e t e s t conditions based on his knowledge of all t h e properties of t h e samples which h e has selected and his background knowledge of the orebody. Up t o four tests, 1000 kg, can be completed each day. For each o r e type it is necessary to t e s t a t l e a s t t h r e e levels of ball addition and one variation of feed size distribution f o r a t o t a l of six t e s t s (1500 kg). Samples should be selected from development rounds, pit benches o r 150 m m dri?l core with o v e r s h e crushed t o pass 200 m m. Each sample should be screened i n t o p h s 100 m m , minus 38 m m and t h e i n t e r m e d i a t e fraction so t h a t t h e t e s t feed samples can b e compodted with a bis toward coarser o r f i n e r fractions a s Mixtures of ore well a s t h e natural size dist!bution. types in varying r a t i o s can also be tested. in t h i s way, any variations i n s p e d i c power consumption w i l l be observed and used as a t o o l i n sizing t h e mill. This t e s t facility w i l l s c a l e up t e s t results t o give a n expected specific power consu m ption f o r continuous operation. The method of scale-up i s proprietary information but t h e independent observer can assess t h e .resat on t h e basis of h i s experience. Sizing of t h e n f l w i l l follow t h e s a m e principles discussed i n t h e previous section on Empirical Calcuh t i o n s , using E q u a t i ~ n(3). Cve should be taken in applying a contingency. Firstly, it should n o t b e applied to t h e batcn t e s t results b u t only t o t h e prediction f o r continuous operation which is t h e most r e p r e s e n h t i v e of expected plant feed. Secondly, t h e e m p i ! c a l calculations should also be done as a check based upon Bond Work Index data. Generally, a contingency O f between 1 5 $ t o 20 $ has been found to be adequate@) but t h e r e have been exceptions. Examhation of t h e size distribution of t h e m i l l charge w i l l indicate any signs of bum-up o f c r i t i c a l shes. The size distribution of t h e minus 1 3 m m (expected t r o m m el undersize) fraction of t h e charge will indicate t h e 80 dp passing size of tine expected SAG m i l l product. This should be used as a guide in sizing a secondary grinding stage. It is important therefore t h a t a metallurgical engineer's judgement should be obtained i n such circumstances, which is independent from any given by m i l l manufacturers, regarding t h e power required f o r a particular operation. The d e e n of t h e t e s t program, t h e nature of t h e samples t e s t e d , and t h e interpretation of t h e results should benefit from such independent expertke.

The media competency t e s t s outlined by ~ o w l a n d ( l O )a r e conducted in a similar size t e s t m i l l but no a t t e mpt is made to measure power o r predict specific power r e q u i r e m e n t s Whereas t h e individual c o s t of such a t e s t is similar t o t h e s m a l l s c a l e Aerofall con'inuous o r t h e MPSI batcn test, t h e information obtained is still preliminary and should be used t o plan continuous testing programs. The decision t o utilize media competency t e s t s in any investigation is one of economics. Since information from continuous pilot plant testing is much cheaper than it used t o be, t h e alternative of proceeding d i r ~ c t l ywith piLOt plant testw ork k more a t t r a c t i v e if sa m ples are available. Continuous Tests The requirements f o r continuous pilot testin of o r e s have been adequately described by WyslouzilTll). However, a summary of t h e flowsheet options which a r e available and a discussion of some of t h e t e s t p z m m e t e r s and t h e i r importance t o t h e plant desiqner is given here to complete t h i s com m entary on t e s t options. Recognized com mercial t e s t facilities i n Nortin America are located a t CSM RI, Lakefield, MPSI Polysius-Aerofall and Witteck. In South A m erica, CIM M in Chile h a s been operating f o r t w o years and t h e r e is a possibility of a n i n s h l h t i o n becomirrg available i n Peru. Other t e s t m i l l s a r e located i n Australia, France, Japan, Portugdl, South Africa and Sweden. The University of British Columbia is currently experimenting with a 0.61 m d i a m e t e r m i l l which shows promise as a t o o l f o r simulation of of g e n e r a t i l g process variables with t h e potentinformation f o r equipment sizing. The principal f a c t o r governing t h e c o s t of a t e s t program is t h e length of t i m e required t o achieve s t a b l e conditions under which t h e circuit can b e sampled. Until recantly, s e v e r a l days of operation witin periodic checks of load l e v e l and successive sample campaigns were required to ensure confidence i n results. The application of load cells t o t h e support P a m e of t h e t e s t m i l l has i n most cases considerably reduced t h e t i m e taken t o achieve stability. Use of t h i s t o o l w i Y enable t h r e e o r f o u r t e s t conditions t o b e i n v e s t b a t e d during a 24 hour period. Exceptions a r e usually very hard ores f o r which c r i t i c a l s i z e s have t o be crushed and recycled. The flowsheet options which should be available in any t e s t facility a r e a s follows:

Full.] Autogenous i n closed-circuit with a screen Screen undersine can be f i n a l and/or dlassifier. product o r may requk-2 secondary grinding in a ball mill. Fully Autogenous with extraction of pebbles, optional crushing of pebbles f o r recycle and/or secondary grinding in a ball o r pebble m i l l . Semi-Autogenous i n closed-circuit with a screen and/or classifier. Screen undersize can be f i n a l product o r may require secondary grinding i n a ball mill. Semi-Autogenous with extraction of pebbles, optional crushing o f pebbles f o r recycle and/or secondary grinding in a ball m i l l o r pebble m i l l .

The ease with which any of these circuit options c a n b e assembled and operated is another f a c t o r which w i l l b f l u e n c e t e s t program c o s t and selection of a t e s t facility.

For single-stage circuih i n which the primary m i l l is operated autogenously, t e s t parameters to be investiqated are feed rates, specific power consumption and, i f necessary, the effect of pebble crushing in varying quantities on feed r a t e and specific power consumption (kWh/tonne) to produce a final product &zing. Where the primary m i l l is semi-autogenous, the principal variables are ball charse volume and ball size dlztribution. For two-stage circuits, the t e s t parameters which should be investigated in order to establish the most power-efficient d e a n criteria for the primary m i l l and the overall circuit are:

tion of the desiqn/evahation engineer:

Description of test equipment so t h a t he can compare the capabilities of different t e s t laboratories. Pebble port and grate openings should be specified so that they conform ~ i t h operational practice for maxiinurn power efficiency. preparation of t e s t samples, circuit sampling procedures, screen analysis procedures for bulk samples, processing of t e s t d a b and report content. Method for recording and rn essure m ent of gross and no-load power on the t e s t m i l l s and the consistency or reasons for vwhtion of no-laad power. Specific power consumption reported from a pilot milk this w i l l be calculated fro m the net power a t the speed reducer output shaft. An inefficiency of the remaining drive components m u s t be assumed or stated to arrive a t a f i g r e which is equivalent to that a t a m i l l pinioz (Le. does not include losses i ? m i l l bearings and sprocket drive). Method of m i l l load m easdre m ent: in addition to measurement by load cell, visual checks should be made before, during and following a t e s t of m i l l charge leveL T:.ljs should be maintained a t a level just below critical to ensure that specific power consu m ptions reflect the most efficient operation of the test m i l l which is practically attainable. A level of between 23 and 27% is generall-I considered to be optimum depending upon ore characterktics. M i l l charge sizing: this can be done a t the end of each test or group of tests and should be examined for signs of any bd3-up in critical size. Variations Fn feed size distribution since feed rate, product siziflg and specific power consumption can be mfilenced by an increase/decrease in the proportion of very coarse or f f i e materiaL However, o&j sucn variations a s are expected in run-of-mine or 2rimary cmshed ore should be tested. Variations in ore ktqrpes since unexpected conditions have m a t a w e d in co m mercial plants because certain important ore hypes have not been included in a conOLnuous t e s t pmgram. The mine production schedule should be r e d e wed for any such variations and the siyniilcant ore types, i.e. those representing more than 10% of the t o t a l during an e s t ~ b b h e d time u t e r v a l , should be included in bulk samples which, in turn, shouU be selected so t h a t harder, softer and expected composites of varying hardness can be tested separately. Variations in the meed of the primary m i l l and the ~ f f e c tof sucn variations on feed rate, specitrc power consumption and product sizing: these observakions are important for projects for which the m i l l feed rate is to be controllel to a specific target on harder or softer ores for subsequent processing.

Screen or trom me1 mesh opening on the primary m i l l since this can influence feed rate and soecific power consumption. The coarser the product prepared for secondary ball milling the more efficient w i l l become the overall circuit a s discussed In the case of pebble milling the previously. maximum r a t e of pebble consumption which can be tolerated w i l l influence the proportion of power applied to pebble milling. Mesh openings can vary from 35 mesh t o 10 m m , providing measures are taken to protect the primary m i l l discharge pump in the case of coarser openings. Circulating load of screen oversize which is returnr the case of s e n i ed t o the primary m i l l . i autogenous grinding where t " load, i n percentage terms, increases with increase in feed r a t e reallzed from increasing ball charge volu m es (and coarser product sizing), this is one indication t h a t autogenous grinding w i t " crushing of pebbles should be tested (the others being limitations on feed r a t e and s p e c i f c power consumption). Ball charge volume with a gLven ball size distribution: a t least three ball charge volumes should be tested (3, 6, 9 % and possibly 12 % ) in order to prepare curves f o r product size vs specific power consumption (Figure I), product size vs percentage steelload by volume (Figure 2) and product size vs feed r a t e (Figure 3). These relationships are typic a l of the majority of ores but there are significant exceptions (see co m m ents Empirical Calculations). Maximum ball size since this can influence the size distribution within the primary m i l l , product sizing and specific power consumption. Pebble crushing since this can improve tkne power efficiencies of both autogenous and se mi-autogenous m i l l s through the extraction and crushing of a critical size which is limiting feed rate. In either case, all or a portion of the pebbles can be crushed and recycled to the primary m i l l feed depending upon whetiner pebble m i l l s are being used. I f all the pebbles a r e being crushed, it is conceivable t h a t a portion could be recycled and the rest t r a n s f e m d t o secondary b a l l milling or the t o t a l amount could be reground in the secondary stage. It is important t h a t equipment is available which is capable of crushing pebbles to 100% passing the no mind grate opening i n the case of 100 recycle s t o an autogenous m i l l and t h a t such recycling i continuous. Pebble consumption and maintenance of a constant pebble charge level when pebble m m g : early recognition of any changes in charge level w i l l avaid time wasted in andysing spurious results.

For any of the circuib discussed, the following observatLons are imperative vhich deserve the atten-

The resdt.3 of properly conducted Pall. s c d e 2ont.L~uous test3 are the most accurate of the methods discussed for scale-up purposes. The provlso "properl.~ conducted" does not just apply to indi-itdull test procedures; it applies also to the planning of the

T.hb plant began com missioning in April 1985. Operating resul% are not y e t available.

The E s c a h n t e Project (750 mtpd) w a s desianed foliowing t w o s t a g e s of study. FirsQy, a comparison of c a p i t a l and operating costs was conducted based on empirical scale-up .Porn Bond Work Index data. Product f o r cyanidation was s e t a t 80 % passing 44 microns and various drill core sections were tested f o r g r i n d a b a t y . Scale-up para meters were developed a s shown in Table 3. Next, once ;nine devebpm e n t permitted, a 2 tonne blJlk sample was selected f o r batch testing. Besults a r e shown i ? Table 4. It can be seen t h a t i q Test No. 1, which featured a sample having the natcal s h e distribiltion a s r e c d v e d by the laboratory, t h e Q h e s t spe&Tc power reading was ObC&ed with an 8 % ball charge by volu m e. This result was 636, of t h a t c d c u h t e d by t h e empirical method f o r t h e s a n e product s i z e ( % a 0 800 microns). It w a s decided t o e r r on the side of the empirical method in specifying the m u f o r purchase. Current operational results show t h a t t h e SAG m i l l is oparath'ung a t 5 % bdL charge l e v e l by volume and is delivering a K80 800 micron product a s predicted. ?eve* drawn a t t h e pi?ion i s 448 k U , 13.617 icXh/tonne (SAC; niiU and 570 k W , 17.325 kWh/'anne ( b a l l zilU when proce-g 32.9 mtph, f o r a total of 30.942 kk'h/tonne or 14.6; above t h e conventional estimzte. A b f i charge volume ilhich is lower than those S s t e d has been selected b~ order to minimize v e w . 0 bviously, t h e SAG m i l l ki consu nirig n o r e and t h e 5 d l mill hsi power Vnan w a s predicted by t h e empirical method, but t h e oversll t o t a l is 99.5 $ of t h e predicted tot-aL The primary m i 2 is t c n f i ~ g towards t h e au:ogenol;s mode by drawing more p o v e r f o r t h e design tnwugh?ut. The en@eer was c o r r e c t in selecting t h e next size of m i l l (4.89 n e t r e dh.) over t!ac o r n a y y o p o s e d by t h e t o s t fi-ty (4.27 metre Cia.) Lr t h e aasence of conCriuous t e s t results. L ? this case, t h e i?cre n e n t a l c o s t iqcrease was s m a l l and t h e increased n i i l v o l u n e ennbled t h e operator t o s e l e c t more fzi.ourable opera'hg conditions by reducini; t h e ball chargn. These results do, hovever, indicate t h a t r , t h e b t e r p r e t a t i ~ nof caution should be exercised i Satcn t e s t r e s u l k on very hard siliceous ores. For p o r 2 h j . r ~ copper w p e ores (e.6. Quintanal, bat,zh t e s t r e s : d b have been obtained which a r e closer t o operaty,~ r5s,d33).

invesf5&%tlon which should be d e a n e d to facilitate analysis of resulta The irdividual para m e t e m outlined here should each be investiqated in an orderly manner with certain changes made according t o t h e behaviour of t h e ore. For instance, trom q el slzs opening (and circulating load) should be i 7 v e s Q a t e d f o r a given ball charge volume so t h a t t h e optimum opening in t e r m s of power efficiency can be selected before studying t h e e f f e c t s of variation i n ball charge volume. If such changes a r e made a t raddom, t h e chances of missing t h e most power efficient condition a r e increased. It shoulri also be re membered t h a t t h e defFnitive selection of a n ABC ci-cuit can only be made by r u n d q g continuous tes'cs. Results f r o m a hill range of t e s t s should be evaluated t o determine t h e most pouer-2fficient circuit(s) consistent with equip m e n t m g p o d b i l i t i e s . Normally, t h e sp-lected result f o r the primary m i l l speci?c power consam ption Is scaled-up &ectly t o the production r a t e d horsepower a t t h e pinion with 3 1 0 % contingency. SizFqg of t h e m i l l then follows t h e principles outlined in t h e section c o n c e r m g Empirical Calcula5ons using Equation (3). It is important, also, t o ensure t h a t sufficient ball m i l l power is available f o r efficient secondary grinding. Secondary ball m i l l s should be &zed on t h e b a s k of Bond Work L?dex applied to t h e o r e f o r ball milliig with checks on t h e ASAG m i l l product ob-ed durir,g contiiiuous testing. The reasoning behind k ! s t a t e ment is t h a t micro-fractures in a t e s t product could and very often do, give a lower pilot plant o p e r a f i g Work Index f o r ball milling c o o p a r e d t o aond Work Index and com mercial-scale plant operating Work Lrdex d e t e r rnilations(l2). It is evident, therefore, t h a t a consulting metallurg i c a l engineer should participate in t h e conduct of t h e H i s opLnion r e g a r d h g t e s t s on t h e Owner's behalf. circuit adjustments, dealirg with unexpected conditi o c s and s?ecifying t e s t i n f o r m a e o n wbich should be reported, w i l l ensure t h a t design triter*? f o r m i l l s e l e c d o n meets the objectives of aower efficiency and capacity f o r treating expected variations in ore types.

Teck-Corona The tiemlo gold p n j e c t of Teck-Comna (1000 n t p d ) provides an example of m i l l sizin3 & ? g the The sitilation e n pirical calculation method alone. facing Teck-Corona was t h e i r inability t o obtain samples f o r batch o r contiiuous k s t i n g . Underground access was n o t possible in sufficient t i m e to provide bulk samples. A t i g h t construction schedule dictated t h a t engineering proceed on t h e basis of informatLon obtainabl5 only from drill core. This meant t h a t Bond 'rlork Indices had to be used f o r m i l l d d n g which w s s r e d e wed with m i l l manufacturers and o t h e r consultants. A two s t a g e S A G m i W b a l l mFU circ-xit was chosen a f t e r a c o m p a r i i n with a rod mill/bd.l aill ci-cuit showed appreciable c a p i t a l c o s t szvings. Motor horsepower selections followed Equations (1)and (2) t o give a two-stage circllit designed to produce K80 54 micron feed f o r cyanidation. Dee& of the calculation a r e found in Table 2. W t o @re a 25 % The SAG m i l l v a s sized with 746 k contiqgency f o r power swings on t h e calculated power. The bail mill was sized a t 1120 k W . Total i x t a l l e d power f o r c o n minution exceeded t h a t required f o r conventional grinding by a f a c t o r of 1.163 (including secondary crushing).

Key Lake Continuous tesL5ng f o r a uranium ore a t Key Lake specCic power requirements f o r grinding and product s k i n g f o r tine subsequent Isaching process. P r e l i m i n a q irdications from m i l l manufacturers based on examination of drill core had exhibited a wide v a r h t i o n in specific power r e q d r e entS and i+, was decided t h a t t h e ore value j u s L I e d a n ore extaxsLve t e s t program. Two ore types, o.ri@tating fr3m open pits, coc'ai? h i r d quartzite, bouiders, clays and sand wMch a r e f . r z e n in winter and sticky a t o t h e r times. Sa ples of 30 tonnes each, were piioted t o each ore ty?e, 25 produce a coarse, minus 500 micron, p m d u c t in a &?g?e-stase cbcllit. S p e p X c poiler consumption and product siziriq were found to be iridependent of each other. The only rpdationship which could be drawn was

-as necessary t o con*n

For larger scale projects, it has been demonstrated t h a t preliminary estimates of s p e d % power requirements using empirical calculations based upon Bond scale Work Index can be verified by continuous testing. Since results f o r softer ores do not exhibit the same degree of agreement, it appears t h a t lower scale-up factors can be used in such cases. The importance of a thorough understanding of t h e mineralogy of ore types, variation of Bond Work Index and the use of reference ores i n predicting P S A G I O r t h e 80 % p a s i n g size of the primary m u product, when usFng e m p i r i o d calculations o r batch scale tests is stressed. P S A G can only be d e t e r mined experimentalFurther, ly by conducting continuous scale tests. P S A G is a singularly important parameter in t h e design of power-emcient autogenous o r semi-autogenous grinding drcuitz. It appears t o be a function of ore hardness in t h e case of crystalline rock, takLng into account factors such as supergene alteration of sulphides, hydrothermd alteration of siliceous rock For ore types in which and compre&ve strength. crystal g d n s o r ore values a r e more loosely cemented, PSA G is limited by t h e natural grain size and a single-stage grinding circuit is usually selected where this suits downstream processes. The power split between primary and secondary grinding stages i n a two-stage circuit is a function of P S A G f o r maximum power e-ency. Since ball milling involves a more e M c i e n t transmission of energy f o r comminution compared t o autogenous o r s e mi-autogenous grinding, t h e selection of P S A G f o r ball m i l l feed is made a t t h e point where it begins t o cost less t o grind by baJl milling than it does t o produce a finer product by primary grinding. The agreement in the examples between specific power require m ents forecast by e m pirical calculations and either continuous pilot plant tests o r operating results demonstrates the validity of t!e scale-up f a c t o r 1.25 i n Equation (1) f o r competent crystalline ores. There is some evidence i n the bxamples t o suggest t h a t the contingencies outlined i n Table 1 are valid f o r the empkkal. calculation method and continHowever, contingencies uous pilot plant testwork. applied to batch scale testwork can vary widely depending upon t h e amount of t e s t v o r k performed, partLcularly with regard to variation i n b a l l charge volume. Comparison of industrial plant operating Work Indices and Bond Work Indices on pilot plant secondary m i l l feed with pilot plant operating Work Indices f o r ball milling suggests t h a t the dedgner should use a Bond Work Index f o r ball milVqg in designing the secondary stage, In sum mary, t h e plant desiqner has a choice of testing methods f o r a given ore. The c h o k e must be made based on the degree of risk acceptable and the costs willing t o be paid t o minimFze the mk. A good understandfneS of mineralok~ as weIL as a thorough investigation of rock types is reqlrired of the designer. Supervision of pre-design testwork by a n independent m etaIh$cal engineer is strongly reco m mended. H i s input a t an early s t a g e in any project's life is import a n t so t h a t comparative concepts can be estimated and =alysed often before bulk samples are available f o r testing.

f o r feed r a t e and pilot m i l l n e t power (k W), shown i n Mgure 5, f o r each ore type. Specitto power consumption decreased with increase i n ball charge volume f o r clay ore but increased in t h e case of cobble ore. With a ball charge volu m e of 12 8 , both ore types and blends could be processed with a specific power consumption in the range 3.0 3.8 kWh/tonne. This compares to 7.71 kWh/tonne derived f 2 . o ~t h e e m p i r i c d formula. The tendency of sandstone and clays t o comminute easily t o grain size is considered t o be the prime contributor t o Ynis power eMciency, with grinding power required mainly to break up t h e harder quartzite and basement materiaL The production size m i l l w a s rated to draw 300 hP with a contingency of 50% in t h e expectation t h a t wide power swings could occur with materials of differing hardnesses and t h a t ball charges of up t o 15 % by volume would be required i n a t o t a l m i l l volume of up t o 30%.

Cerro Verde
A r e c e n t study involving full scale continuous pilot plant testing f o r Sd G and A B C circuits on t ' i w e l l known copper ore from P e r u was preceded by preliminary estimates of spedLfSc power requirements using the empirical calculation featured in this paper. Three ore composites were tested wtdch were each made up from material drawn from ten ore types identifled in t h e open pit. Each composite w a s representative of a particular production period i n which harder o r softer ores would be mined as w-dl as a blend. A distinction between primary and secondary sulphides as w e l l as potassic and phyUlc alteration was made i n deffning the ten ore types. The comparative data f o r preliminay and pilot plant work is given in Table 5. I t can be seen t h a t there is good agreement between the predictbns and pilot plant resultz f o r all three types but t h e following points must be re m e m bered: The pilot plant drcuit had t o be converted fro m S A G t o A B C in order t o reach a s i m i l a r forecast power efneiency. This c o n v e d o n w a s necessary a f t e r ball charge volumes of up t o 1 2 % had been tested, Le. t h e critical. size w a s very hard and there w a s doubt whether k t h e r increases i n ball charge would have had any beneficial effect. The product size from the primary m i l l i n the case of the s o f t e r ore sample was much coarser and so the power split between grinding stages was very different from t h e other composites and also fiom pr-diminary calculations.

Acknowledgement The authors wish to thank the t e s t facilities and companies mentioned i n the examples for suppkf~g the data included in this paper. Also, the management

This paper has outlined the processes by which testing f o r autogenous and semi-autogenous grinaing clrcuita can be orga&ed a t reasonable cost i n preparation f o r equipment sizing and plant design. Emphasis has been placed on discusing t h e parameters which, if investigated, w i l l result in a pow er-efflcient design. Examples have been presented which demonstrate the beneflts available to owners of smaller scale properties through the use of e m p i r i c d calculations and/or batch testing t o size equipment f o r a com m ercial installation. The beneflts and limitations offsred by s m a 3 l scale continuous +*sting have been oumed.

of Wr55ght Engineers U m l t e d fs to be thanked f o r p e r m M o n to prepare and submit thls paper to t?le S M E.

1 . Bond, F.C., C ~ s ' h t n g and Grinding Cdlculatlons (Revised January 1961), AUls-Cham e n Publication 07 R9235B.
2. Flavel, M.D., Selection and U q g of Crushers, Deskn and Instdllation of Chapter 21, Com minution Cbcuits, M&-, Jergensen, Editors.

3. Barratt,

D.J., Semi- Autogenous Grinding: A Compa,&on with t h e Conventional Route, CIM Bulletin, November 1979.

4.

Rowland, C.A., Selection of Rod M i l l s , Ball M D , Pebble M i l l s and Regrind M U s , Chapter 23, Deskn and Installation of Com minutlon Circuits, Mular, Jergensen, Editors, and Basswear, J.H., Primary GllLnding Mills: Selection, Slzing and Current Practices, Chapter 24, Dean and Installation of Com minution Circuits, Mular, Jergensen, Editors.

5. Dorr, A.A.

6. Loveday, B.K., Prediction of Autogenous Milling f'rom Pilot Plant Tests, =venth Com monwealth Mining and Metalhrgical Congress, 5ong Kong, May 1978.

7. MacPherson, A.R., A Simple Method b Predict t h e

Autogenous G b h g M i l l Require menta f o r Processing Ore f r o m a New Deposit, Society of Mining Engbeers, AIME Transactions, VoL 262, September 1977.

8. NacPherson,

A. R., Power E M c i e n t Autogenous Grinding Plants, presented a t t h e SM E-AIM E Fall. Meetinq, Denver, C O., November 1981.

9. Hood, M., Pena, F., Avelar, F.T. and Bailey, J., Quintana Minerals Copper Flat Project, presented a t t h e SME-AIME A9nua.l Meeting, Atlanta, G A., March 1983. 10. Rowland, C.A., Pilot Plant Data f o r t h e Design of Primary Autogenous and Semi- Autogenous M i l l s , CIM Bulletin, Nove m b e r 1981.
1 1 . Wysloudl, D. M., Standard Laboratory-Pilot Plant Tests f o r Equipment Selection, Chapter 15, De-n and I n s t d b t i o n of Corn minution C i i d t s , Mular, Jergensen, Editors.

I , M.J., The Highmont 12. Fukuhara, R.S. and Grinding Circuit Operating Experience with 5.0 m (16 1/2' dia.) aall M i l l s in an A-B-C circuit presented a t t h e SME-AIME Fall Meeting, Salt Lake City, U T, October 1983.

TABLE 1 COST AND R I S K ASSOCIATED WITH TESTY ORK (Direct Laboratory Costs Only) AUTOGENOUS AND SEMI-AUTOGENOUS GRINDING Size o f Sample Each O r e Type Cost Rbk Level Primary H j l l Hotor HP Contingency ' :

Type o f Testuork

E mpirical Calcula%ions and Scale-up from Bond ' + ork I Indices ( Crushhg, Rod M i l l and B a l l M F W 35 Small Scale Continuous Testing (45 c m dia. m i l l ) Batch Testing (1.8 m dia. mill) Large Scale Continuous Testing (1.8 m dia. m i W 136 2

kg

2,000 227 kg 1,500 3 ,000

High High t o Medium Medium

25
N/A

tonnes

15

20

30

tonnes

20,000 TABLE 2

Low

10

SAG UILL 5 N G USING THE EMPIRICAL CALCuLAnOH FROM BOND W O R K INDICES TECK-CORONA PROJECT CONVENTIONAL
W i Crushing (Metric) W i Rod M i l l (Xetric) W i Ball H i l l (Metric) Feed K a O Crusher Feed K80 Rod M i l l Product K80 Rod M i l l Product K80 B a l l M i l l

SAG 17.6 17.6 22.1 Microns Microns Microns Microns (for scaleup) k U:?/tonne k W h/tonne k Wh/tonne k Wh/tonne k W h/tonoe microns
k H h/tonne k W h/tonne

17.6 17.6 22.1 127,000 Microns 18,850 Micmns 1,168 Microns 50 Microns

127,000 18,850 1,168 110

LI 4

F~ed mtph Power a t Pinion Crusher Rod M i l l Ball Yill Total

0.790 4.988 24.497 30.275

k W h/tonne k W h/tonne kWh/tonne k W h/tonne

(X

Product KaO SAG M i l l Power a t Pinion Ball xill -SAG M S U Ball H i l l Totat Factor on Conventional

0.790 4.988 14.572 20.350 1.25) 25.438 700 12.690 12.748 22.540 35.288 1.166

(700 110 microns) (to 700 microns) (700 50 micmns)

k Wh/tonne k W h/tonne

10
TABLE

S A G HILL SlZLHG U 9 N G THE EMPIRICAL CALCULATION F R O H B O N D WORK I N D I C E S ESCALANTE PROJECT CONVENTIONAL

W i Crushing (Metric) W i Rod MillCMetric) W i B a l l M i l l (Metric) Feed K 80 Crusher

SAG

Feed K80 Rod M i l l Product K80 Rod M i l l Product K 80 B a l l M i l l

20.1 18.2 16.4 88,900 Microns 18,850 Microns 800 Microns 44 Microns 32 0.788 5.781 20.433 27.002
k Wh/tonne k Wh/tonne kWh/tonne k U h/tonne
(X

88,900 18,850 800 110 32 0.788 5.781 9.855 16.424 1.25) 20.530 800 9.855 10.675 20.433 31.108 1.152

- Ball M r n - Total
- Ball M - Total

Feed mtph Power a t Pinion Cmher Rod M i l l

20.1 18.2 16.4 Microns Microns Microns Microns (for scaleup) kVh/tonne k Wh/tonne k Wh/tonne kWh/tonneV k Wh/tonne microns kUh/tonne kWh/tonne kUh/tonne k W h/tonne

Product K80 S A G M i l l Power a t Pinion

E

-SAG Mill Ball M i l l

Factor on Conventional

(800 110 microns) (to 800 microns) (800 44 microns)

TABLE

4
.

SAG HILL S I Z I N G
BATCH TEST RESULTS- ESCALANTE

Test Number Feed % W t :

+4It -4" -1 4" 3" 2"

1 -

2 40.9 53.0 6.1 630 310 235 10.37 3.8 17.4 20.0 11.0 2.6 45.2

1-1/21! -1/2"

Balls lbs:

% MUVolume:
M U Product
wt: -4" -3" -2" 1 " -1/2"

40.9 53.0 6.1 420 285 235 8.30 4.2 17.2 28.8 14.4 3.8 31.6

+ 411

+
+

3" 2" 1 " 1/2"

Total M i l l Charge % Millvolume: Net k ! d h / t o ~ e of m i n u s 800 Micron product Screen Analysis of Minus 1/2" : ! cumulative retained on: nicmns

TABLE 5 CERRO VERDE ORE C O M P A R I S O N O F P R E L I M I N A R Y H I L L S L Z I N C WITH P I L O T P L A N T R E S U L T S Preliminary ( S A C ) U s i n g A-C B o n d W o r k Indices for Crushing, Rod H i l l a n d Ball Hill

Pilot P l a n t ( A B C ) 0 B o n d Work Index P r o c e d u r e for B a l l Histing

From 10 m M h

Pilot P l a n t ( S A G ) U s i n g B o n d W01% Index P r o c e d u r e f o r Ball M m g M m 1 0 H-h

Softer O r e Power Drav, k Wh/tonne at M i l l Pinion - PrLm vf t 4 i I h Secondary M i l l s Total Secondary Circuit Feed,, Keg (Microns) Secondar;r C i r c d t Product, K80 (Microns)

9.830 17.848 780 74

Average Ore Hix

Power Drr w , k Y h/tonne a t M i l l pinion ? r i m a r j MFUs ~econdir, M i l l s Total n Secondary C i r c d t Feed, K ~ l (Microns) k 80 ( Hicrons) Secondary C i r c u t ~ r o d u z t ;

74

Harder O r e

Power Draw, kk'h/tonne a t : d i l l Pinion P r i m a-y M i l k Secondary M i l l s Total Secondn-qr Cir:uit Feed, K80 (Microns) Secondarf Circuit Product, K 80 ( Hicrsns)

11.645 21.143 840 74

* ULrg S 5

V/V

aall Zhhrge Volu m e

Figure 1 AUTOGENOUS PILOT TESTS KWH PER TONNE VS K80 PRODUCT

STEEL LOAD

PRODUCT K80 (IIIICROHS)

1
mw-2 NTOGENOUS PILOT TESTS % S E E 1 LOAD BY YOL. VS K80 PRODUCT

m.

DO.

F % -

NJTOGENEOUS PLOT TESTS PRODUCrION RATE Kg* VS KBO PRODUCT

Figure 4
SEMI. ALITOGENOUS GRINDING EXAMPLE : VARIATION OF POWER DRAWN vs PRIMARY MILL PRODUCT SIZING

Figure 5 PILOT MlLL RESULTS VARIATIONS O F MlLL POWER V S FEED RATE 6 BALL LOAD
YEWD

'

I
M FEED VYD

FIGURES REPRESENT BALL CHARGE LEVEL

0
2

I 6

AVERAGE NET MILL POWER kW