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332

The Application of High-Chrome Grinding Media at MMG

Century Mine for Improved Grinding Media Consumption and
Metallurgy Performance
C Greet1, D Obeng2, J Kinal3 and P de Bosscher4
1. FAusIMM, Manager Minerals Processing Research, Magotteaux Australia Pty Ltd.
Email: christopher.greet@magotteaux.com
2. MAusIMM, Principal Metallurgist, MMG Century. Email: Daniel.Obeng@MMG.COM
3. MAusIMM, Manager Metallurgy Implementation, Magotteaux Australia Pty Ltd.
Email: jessica.kinal@magotteaux.com
4. Regional Manager Australasia and Pacific Rim, Magotteaux Australia Pty Ltd.
Email: Philippe.debosscher@magotteaux.com

ABSTRACT
The dual approach of examining the grinding media wear through a series of marked ball tests and
investigating the impact of grinding chemistry on lead and zinc metallurgy using the Magotteaux
Mill at MMGs Century mine (Century) has resulted in the conversion of the plant to high chrome
grinding media. The consequences of this change have been positive in terms of wear, with a
reduction in media consumption, and no adverse effect on either the lead or zinc metallurgy.
The paper outlines the methodologies employed on the Century ore to estimate the changes in wear
and metallurgy to establish if there were any advantages of advancing to plant trial. A detailed
description of the marked ball test procedure, and the results obtained is given. The Magotteaux Mill
test work is also described. These results were used to develop a business case for the plant to move to
trial.
Once Century agreed to trial high chrome grinding media, the plant was continuously monitored to
ensure that the predicted changes in wear and metallurgical performance were realised. The trial data
are discussed at length.

INTRODUCTION
Theory
Bruckard et al., (2011) recently published an article describing the effect of the grinding environment
on the flotation of copper sulphides. While this paper confined its discussion to copper sulphides, the
arguments presented apply equally to other sulphide mineral systems. Broadly, these studies indicate
that most sulphide minerals are more noble than the grinding media used during comminution.
Therefore, the sulphide minerals are cathodic with respect to the forged steel grinding media, and the
following reactions apply:
Cathode (sulphide mineral): O2 + H2O + 2e- 2OH2+

Anode (grinding media): Fe Fe + 2e

(1)
(2)

A galvanic couple between the grinding media and the sulphide mineral(s) exists, which increases the
corrosion rate of the forged steel media. The corrosion products of the grinding media, iron oxyhydroxide species, invariably precipitate on to the surfaces of the sulphide minerals thereby affecting
their floatability (Johnson, 2002).
The application of more electrochemically inert grinding media to real ore systems at an industrial
level to improve metallurgical performance has not gained universal acceptance. The aim of this paper
is to provide a protocol for conducting laboratory and plant test work that clearly demonstrate that
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metallurgical benefits are not only possible, but measureable, by way of example. In this case, the
work conducted at MMGs Century mine in north-west Queensland is described.

METHODOLOGY
It is not a simple matter of knocking on the door and telling the mining company that converting to a
more inert grinding media will solve all of their problems . . . there is no such thing as a magic bullet.
However, by careful experimentation it is possible to demonstrate in the laboratory that converting
from forged steel to high chrome grinding media will alter the pulp chemistry and have a positive
effect on metallurgical performance. The laboratory test regime is about mitigating risk (both
financial and technical), and when combined with a well-executed marked ball test (MBT) to establish
the potential reduction in media consumption, the customer is provided with sufficient evidence to
advance to plant trial.

Marked ball wear test

In order to assess the wear a series of MBT tests were completed over a period of two years. These
tests were designed to determine which high chrome alloy reduced the abrasive and corrosive wear
the most. To conduct a MBT nominally 200 carefully prepared balls of each alloy to be tested are
added to the mill. Each alloy is marked by drilling a distinctive pattern of holes in each ball, and
filling these holes with coloured resin. To make it easier to find the marked balls they are generally
larger than the top size ball being added to the mill. For example, if the mill is charged with 50 mm
balls, the marked balls will have a diameter of 60 mm. In addition to various high chrome alloys, a
sample of forged steel balls is added as a reference.
The test balls are then added to the mill at a predetermined time prior to the next shutdown, usually
several hundred hours. During the shutdown someone enters the mill and collects as many of the
marked balls as they can find. The balls that are found are cleaned, weighed and returned to the mill.
Ideally, three or four controls are completed for a MBT. From the weight loss, the operating hours and
the energy consumption it is possible to calculate the wear rate of each of the alloys tested in both mm
per 100 hours and grams per kWh. Then, by comparing the wear rate of each high chrome alloy back
to the reference it is possible to determine the percentage reduction in wear, and from this the best
alloy (in terms of wear) for the system under investigation.

Laboratory test protocol

The Magotteaux Mill (Figure 1) allows the researcher to generate a product in the laboratory that has
nominally the same physical properties (particle size distribution) and pulp chemical properties (pH,
Eh, dissolved oxygen, temperature, oxygen demand and EDTA extractable iron) as an equivalent
sample taken from the plant. This is achieved by grinding an appropriate sample to achieve the
particle size distribution of the flotation feed, and manipulating the pulp chemistry, by purging the
system with an inert gas, so that it matches the plant mill discharge.
The experimental protocol adopted to achieve the desired outcomes is completed in three phases
(Greet et al., 2004):

Phase 1 - Plant data collection

The collection of plant data is vital to the success of the test program, for this data forms the basis of
the calibration process by defining the target parameters. This initial step involves:

The completion of a pulp chemical and EDTA extractable metal ion survey of the grinding
and adjoining flotation circuit
Determination of the oxygen demand at strategic points within the circuit
The completion of a metallurgical survey
The collection of a bulk sample of the grinding circuit feed for further testing.

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It is important to note that the metallurgical survey must include both a down-the-bank survey of the
flotation stage immediately following grinding, and a block survey of the plant to determine overall
metallurgical performance.

Phase 2 Magotteaux Mill calibration

The data collected in Phase 1 essentially describes the circuit under consideration, and provides
targets for the Magotteaux Mill calibration. The calibration process uses the same grinding media as
the operating plant. The objective of the calibration process is to produce a laboratory mill discharge
which has the same particle size distribution as the conditioned flotation feed, and the pulp chemistry
of the plant grinding mill discharge. To achieve this match involves careful manipulation of the Eh,
pH, dissolved oxygen and grinding time, such that all the measured parameters line up when grinding
the bulk sample collected during the metallurgical survey. This task is not trivial.
Once the Magotteaux Mill is calibrated, oxygen demand and flotation tests are completed on the
ground ore.

Fig. 1 - Schematic representation of the Magotteaux Mill.

Phase 3 Media testing

With the Magotteaux Mill calibrated, alternative grinding media are substituted into the mill for
testing. The procedure determined during the calibration process for the current grinding media is then
applied while grinding the bulk sample employing the alternative grinding media. In this way, it is
possible to measure changes in pulp chemistry and flotation response. The changes observed are
attributed to the variations in grinding media composition, as the only intentional parameter being
changed in the test is the grinding media.
Generally, a number of different ore types are tested to firstly validate the data generated, secondly
determine the variation in the magnitude of the improvement as the mineralogy of the sample
changes, and finally reduce the risk should the customer choose to advance to plant trial.

Plant trial protocol

Conducting grinding media plant trials are inherently difficult. The fact that the entire charge in the
mill must be replaced defines the difficulty. And, therein lies much of the resistance an operation has
to conducting grinding media plant trials. The need to replace the charge in a mill is a concept many
operational personnel have not contemplated. Furthermore, once the mill has been converted there is
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no desire to revert back to the original media type unless the trial results do not show an improvement.
Therefore, the classical randomised block on/off trial is out of the question.
Having demonstrated in preliminary MBT and laboratory tests that the new media will provide
positive benefits in wear, reagent consumption and metallurgy, it is time to make some decisions. The
first is how to convert the mill from one grinding media to another. This can be achieved by either
dumping the charge and replacing it with a new graded charge, or by gradually replacing the old
charge by topping up with the new media. Both methods have merit.
Dumping the charge realises the benefits of the new media earlier, and is the technically preferred
way of conducting a media trial. However, there are a number of aspects to this option that must be
considered. The first is where the funds come from to purchase the new charge. In most instances this
money comes from the capital budget a process which involves prioritising projects across the
operation. Once the expenditure has been approved, the next challenge is the logistics of dumping and
loading the mill in a reasonable time frame (generally during a maintenance shutdown). Another
consideration is what to do with the old charge. These financial considerations must be weighed
against the technical correctness of this methodology for converting the mill.
The top-up method, on the other hand, is easier to handle from a financial perspective. That is, the
cost comes from the operating budget which enables the metallurgy department to prioritise
expenditure. So too are the logistical issues of dumping and recharging a mill. However, this
methodology is complicated by the time it takes to purge the mill and the changes that occur during
this time. The purge period will depend on the size of the mill and the grinding media wear rate, with
purge periods of between three and 12 months common. As plant data from before the purge are
compared with information gathered once the purge is complete the trial time is considerably longer
than just the duration of the purge, and may extend out to 18 months. A lot can change in this time.
For example, ore mineralogy, feed grade, throughput, circuit configuration, reagent regime, operating
personnel, to name but a few. These variations present considerable challenges in the analysis of the
trial data.

Plant trial planning

Once the plant has agreed to advance to plant trial and the conversion method fixed, the conditions
under which the trial will run must be examined to ensure that the trial has a higher probability of
producing a result. Ideally, the following items need to be considered when planning the plant trial:

Which mill(s) is to be converted

Access to sampling points within the grinding and flotation circuits
The stability of the operation during the trial period
The mine plan. Ideally, there should not be a major change in the ore blend entering the plant
during the plant trial
The introduction of any major equipment or circuit changes during the trial period that would
complicate the analysis should be avoided
Any reagent trials during the trial period that would complicate the analysis should be
carefully planned.

Obviously, there will be variations during the course of the trial simply because of the time required
to complete the test. However, if these variations can be foreseen, their impact on the trial can be
minimised. The key is to have good communication between the site metallurgist and the researcher
conducting the trial.

Data collection
The data collected during the plant trial can be divided into two categories namely that which is
collected by the researchers to measure changes in the pulp chemistry and routine inventory sampling
completed by the operation to measure reagent consumption and metallurgical performance.

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Pulp chemical data

In agreeing to conduct a plant trial, the researcher will ask for access to the site to complete pulp
chemical surveys of the grinding and flotation circuits before and after the mills have been converted
to the new grinding media. Each visit is nominally of two weeks duration. During each site visit pulp
chemical (pH, Eh, dissolved oxygen, temperature and oxygen demand), and EDTA extraction data are
collected from the following critical process streams as a minimum:

Ball mill discharge

Ball mill cyclone underflow
Ball mill cyclone overflow
Rougher feed (conditioned with reagents)
Rougher tailings.

Typically, the researcher will collect as much pulp chemical data as possible, generally 12 or more
data sets. These data are used to demonstrate the changes in the pulp chemistry that occur with the
change in grinding media.

Metallurgical data
By far the best source of information to measure the metallurgical performance as the plant moves
from grinding media to another is the shift mass balanced data. The shift data provides information
about:

Throughput
Particle size distribution
Feed grades (copper, lead, zinc, iron and sulphur)
Final concentrate grades (copper, lead, zinc, iron and sulphur)
Final recoveries (copper, lead, zinc, iron and sulphur).

These data are reviewed, and (in consultation with site personnel) cleaned by omitting shifts:

With major down time (i.e. less than 22 hours operating)

With any missing data
By removing outliers using standard residuals.

The cleansed data are then analysed using time series and cusum plots to observe variations in
performance with time. Quantitative statistical techniques (the Student t-test, comparison of
regression lines, and multiple variable regression analysis) are utilised to determine the magnitude of
any improvement to the metallurgical performance, and the confidence that can be given to the
improvement (Napier-Munn, 2005).

THE CENTURY MINE EXPERIENCE

Century mine
The Century concentrator treats ore from a sediment-hosted stratiform base metal deposit located in
north-west Queensland, Australia. The ore contains nominally 1.5 percent galena, 11 percent
sphalerite, 7 percent pyrite, and traces of chalcopyrite, silver and gold hosted in a carbonaceous shale,
siliceous siltstone and sandstone.
The ore is delivered to the concentrator from the open cut mine, where is it crushed and ground in a
SAG/ball mill circuit in closed circuit with cyclones to produce a flotation feed P80 of nominally 56
microns. The ground ore is processed in a sequential carbon/lead/zinc flotation circuit using tank cells
to produce lead and zinc concentrates. The complex textural relationships between sphalerite, silica
and the carbonaceous species require that part of the zinc concentrate is ground to 80 percent passing
7.5 microns. An excellent process description is offered by Obeng et al., (2013). Both concentrates are
pumped to Karumba where they are filtered, dried and shipped to smelters. The carbon pre-flotation
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concentrate and the zinc circuit tailing are stored in the tailings dam (Gao et al., 2007; Schwarz et al.,
2008; Schwarz et al., 2009).

Marked ball test

In selecting the alloys to be investigated in a MBT the first consideration is the mineralogy of the ore
to be tested. Table 1 contains the modal analysis for the ball mill discharge. Based on Magotteauxs
data base, the levels of quartz and pyrite suggest that the grinding environment produces medium to
high abrasive conditions. And, the percentage of sulphide mineral present (galena, sphalerite and
pyrite) indicated that the conditions in the mill would be that of a medium corrosive environment. As
the ball mills are of the overflow type impact is comparatively low.
However, the combination of high abrasion and moderate corrosion present considerable challenges in
measuring the wear rate using MBT. The addition of a small number of high chrome balls to a forged
steel charge may markedly influence the wear rates of these marked balls as they can be galvanically
protected by the forged ball charge. This then significantly overestimates the reduction in media
consumption possible if the mill was to be converted to an appropriate high chrome alloy. By
developing a series of polarisation curves based on chrome content it was possible to determine which
alloys possessed good corrosion resistance. The initial MBT results suggested that DuromaxK would
reduce the media consumption by 70 per cent, and it was agreed to advance to plant trial. However, to
minimise the risk during the industrial test a tracer MBT was included in order to monitor closely the
effect of galvanic protection during the purge which started in June 2011.
Table 1: Modal distribution and mineral hardness for the ball mill discharge.
Mineral
Quartz
Clay fraction
Sphalerite
Galena
Pyrite
Siderite

Abundance, %
25.8
10.5
32.4
1.5
3.1
22.7

Hardness, HV
2012
236
105
1532
464

Figure 2 displays the results of the tracer MBT as the ball mills were converted from 100 per cent
forged steel to 100 per cent high chrome grinding media. It is evident that as the percentage of high
chrome media in the mill increased the coefficient of superiority decreased, but stabilised with around
30 per cent forged steel remaining in the charge. Under these stable conditions it was estimated that
the media consumption would be reduced by nominally 62 per cent.

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100

3.8
3.6

90
80

f ir

st

Coefficient of Superiority
% Steel Forged charge

70

st
ry

r2
ce

du

tr

in

d
3r

40

1s

tc

2.8

50

lt
ra

ct

rl

tr
a

2n
d

ce

ct

r1

rl

tc
1s
C

60

tr

tr

3.2

ac

lt
ra

er

ce

r1

Coefficient of Superiority

3.4

2.6

30

2.4

20

2.2

10

2
-2000

% Steel Forged remaining in the charge

0
0

2000

4000

6000

8000

10000

running hours

Fig. 2 - The coefficient of superiority and percentage forged steel remaining in the charge versus purge time.

The purge ended in April 2012, and industrial wear data has been collected and compared with
consumption data from January 2010 to June 2011. These data show that DuromaxK has reduced the
media consumption by 62 per cent and represents a significant cost saving to the site.

LABORATORY STUDY
A laboratory study examining the effect of grinding chemistry on the metallurgical performance of
Century lead/zinc ore was completed in March 2007 (Kinal, 2007). Following the protocols listed
above the plant pulp chemistry and a bulk sample were collected for testing.
The results indicated that changing from forged steel to high chrome grinding media had a positive
impact on the pulp chemistry. That is, the pulp chemistry became more oxidising as the Eh shifted to
more oxidising pulp potentials and the dissolved oxygen content increased (Table 2). There was also a
corresponding decrease in the EDTA extractable iron (Table 2). These changes in the pulp chemistry
indicate that when grinding with high chrome alloys the grinding media corrosion is reduced, and this
should lead to improvements in galena and sphalerite metallurgy.
The flotation test data for the lead circuit suggested that converting to high chrome grinding media
would result in an increase in the galena flotation kinetics, with only subtle changes in the flotation
rates of the gangue species (Table 3). The galena flotation rate constant was observed to increase by
more than 50 per cent, and the maximum lead recovery improved by at least 1.7 per cent. The data for
the zinc circuit (Table 4) indicated that a shift to high chrome grinding media should improve the
maximum recovery of sphalerite by at least 2.3 per cent. However, as the sphalerite kinetics increase
so too do the flotation rates of the gangue species. The better alloy for the Century system was
considered to be DuromaxK, which is in line with the MBT data.

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Table 2: The pulp chemistry of the Magotteaux Mill discharge by alloy.

Media
Forged
DuromaxK
DuromaxT
DuromaxU

pH
7.33
7.23
7.28
7.24

Eh, mV (SHE)
-36
21
25
16

Temp, oC
47.5
48.6
47.7
47.9

DO, ppm
0.04
0.08
0.12
0.12

EDTA Fe, %
1.43
0.66
0.62
0.69

Table 3: The flotation kinetics for the lead cleaner by alloy.

Test

Kinetic data
Pb
k, min-1 Rmax, %

Forged
DuromaxK
DuromaxT
DuromaxU

2.32
3.57
3.74
3.52

63.1
65.5
64.8
65.6

Zn

k, min-1

Rmax,%

k, min-1

0.37
0.36
0.40
0.36

3.4
3.2
3.9
2.9

0.21
0.15
0.22
0.17

IS
Rmax, %
7.7
8.6
6.5
7.6

NSG
k, min-1 Rmax, %
0.28
0.24
0.30
0.24

2.8
2.7
2.4
2.6

Plant trial
Based on the MBT results and the encouraging numbers obtained in the laboratory, an industrial test
was conducted in 2011/12 with the forged steel media charge in the ball mills replaced with high
chrome media using the top-up method for the changeover. Prior to adding high chrome grinding
media multiple pulp chemistry surveys were conducted through the Century grinding and flotation
circuits. This exercise was repeated once the purge was complete. Historical data for the period from
1 January 2011 to 9 October 2012 were provided and statistical analysis completed. The two periods
compared in this analysis were:

Period 1: 1 January to 9 June 2011 (forged steel)

Period 3: 9 June to 9 October 2012 (high chrome grinding media).
Table 4: The flotation kinetics for the zinc cleaner by alloy.
Test

Kinetic data
Pb
k, min-1 Rmax, %

Forged
DuromaxK
DuromaxT
DuromaxU

4.12
2.96
3.60
n/a

89.2
89.4
90.1
n/a

Zn

k, min-1

Rmax,%

k, min-1

2.55
2.22
2.93
n/a

82.4
84.7
90.6
n/a

6.38
5.44
5.39
n/a

IS
Rmax, %
93.9
95.2
93.8
n/a

NSG
k, min-1 Rmax, %
1.17
1.22
1.35
n/a

20.4
21.8
25.5
n/a

The intervening period (10 June 2011 to 8 June 2012) represents the time taken to purge the mill of
forged steel grinding media.

Plant pulp chemistry

Pulp chemistry surveys of the Century circuit were collected before and after the purge so that the
impact of the change in grinding media type on the chemistry could be determined. Figure 3 shows
the Eh profiles through the circuit. The pulp potential follows the same general trend through the
circuit for both media types. As the pulp passes through the ball mill the Eh is decreased to more
reducing values due to oxidative reactions occurring in the mill (i.e. oxidation of sulphide minerals
and corrosion of the grinding media). The pulp potential is increased to more oxidising Eh values as
the pulp comes into contact with air during flotation. The ball mill discharge pulp has a lower Eh
value when using forged steel media in the grinding circuit when compared with the high chrome
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period. That is, the ball mill discharge Eh shifted from an average of -50 mV (SHE) for the forged
steel period to 100 mV (SHE) when using high chrome grinding media. The increase in Eh is related
to the reduction in grinding media corrosion when employing high chrome grinding media which has
better corrosion resistance. During flotation the Eh for the two systems tends to be similar.
The dissolved oxygen profiles are presented in Figure 4. Again, the profiles through the circuit are
similar for the two periods. That is, the dissolved oxygen content of the pulp decreased through the
ball mill, and then increased as air is introduced during flotation. This broad trend is independent of
grinding media type. However, the data clearly shows that the level of dissolved oxygen in the pulp is
significantly higher when using high chrome grinding media. This is due to the reduction in corrosion
when using the high chrome alloy.
The EDTA extractable iron profiles through the grinding and rougher flotation circuits are provided in
Figure 5. Broadly, the EDTA extractable iron profile through the circuits is similar for both grinding
media types. That is, the EDTA extractable iron reaches a maximum in the cyclone overflow then
gradually decreases during flotation. These data clearly show that the level of EDTA extractable iron
when grinding with forged steel was significantly greater that the period employing high chrome
grinding media. That is, the cyclone overflow during the forged steel period averaged 0.9 per cent
EDTA extractable iron compared with 0.4 per cent for the high chrome period. This strongly suggests
that converting from the forged steel to the high chrome grinding media has had a significant impact
on the corrosive wear of the system. The reduced corrosion should produce cleaner mineral surfaces
and enhance lead and zinc concentrate grades and recoveries.

Fig. 3 - The Eh profiles through the grinding and flotation circuits.

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Fig. 4 - The dissolved oxygen profiles through the grinding and flotation circuits.

It is pleasing to note that the changes in pulp chemistry recorded in the plant were similar to those
noted in the Magotteaux Mill. That is, the laboratory study suggested that a change from forged steel
to high chrome grinding media would see an increase in Eh to more oxidising pulp potentials of
nominally 60 mV in the ball mill discharge, the dissolved oxygen content of the pulp increase by
approximately 0.1 ppm, and the EDTA extractable iron decrease by about half.

Fig. 5 - The EDTA extractable iron profiles through the grinding and flotation circuits.

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Plant metallurgical performance

As with all trials of this nature, comparing before and after a significant change within a circuit there
is a danger that the feed to the concentrator will not be the same, and as such making it impossible to
make a valid comparison. After cleansing the data (Table 5) it was found that during the high chrome
period the throughput, lead and zinc head grades were higher for Period 3 compared with Period 1
(Figure 6). This essentially means that in Period 3 the plant received more lead and zinc metal units
than during Period 1, and this complicates the statistical analysis. Further, when the data post 9
October 2012 were examined it was found that the feed characteristics had changed significantly.

Carbon pre-flotation
The statistical analysis of the metallurgy of the carbon pre-flotation circuit indicated that there was a
very strong relationship between mass recovery and the recovery of carbon, lead and zinc to the preflotation concentrate. The introduction of high chrome media to the ball mills did not have any
notable effect on the pre-flotation selectivity.

Lead metallurgy
In the first instance the t-test was used to determine the impact the change in grinding media had on
the recovery of lead and silver. This analysis revealed that the lead recovery was increased by 1.2
1.0 per cent, and the silver increased by 1.4 0.3, both with a confidence of greater than 98 per cent
when using high chrome grinding media. However, as the mass recoveries during Period 3 were
approximately double those of Period 1, it is highly likely that this was the cause of the increased
recovery of lead and silver recoveries, and not the change in grinding media. It is probable that the
higher mass recovery also contributed to the lower lead concentrate grade (Figure 7).
Table 5: A comparison of the feed parameters using the cleansed data sets from the forged steel
and high chrome periods.
Parameter
Throughput, tonnes per shift (tps)
Difference (high chrome forged), tps
Confidence, %
Pb feed grade, %
Difference (high chrome forged) , %
Confidence, %
Zn feed grade, %
Difference (high chrome forged), %
Confidence, %

Forged steel
8430

High chrome
8892
462 134
>99

0.74

1.07
0.32 0.02
>99

11.6

11.9
0.3 0.1
>99

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Fig. 6 - Lead and zinc feed grade comparison for Periods 1 and 3.

The application of a multiple variable regression analysis to the data identified mass recovery and lead
feed grade as the two dominating components driving the lead recovery. The lead recovery regression
model is as follows:
Lead Recovery = 41.6 + 64.6 (mass recovery) 56.0 (Pb feed grade) 8.1 (Zn losses) + 0.7 (Zn:Pb
feed ratio) 0.5 (Pb concentrate grade) 1.9 (C recovery) + 0.77 (high chrome) 0.2 (Pb losses)
This analysis suggested that converting to high chrome grinding media had a small positive impact on
the lead recovery (0.77 per cent), but this improvement was overwhelmed by changes in the mass
recovery and lead feed grade.

Fig. 7 - The relationship between concentrate mass and lead concentrate grade.

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Zinc metallurgy
The statistical analysis of the zinc metallurgy was complicated by the large difference in zinc metal
units entering the plant between Periods 1 and 3. The t-test analysis suggested that the zinc recovery
during Period 3 was 1.6 0.4 per cent lower than Period 1, with greater than 99 per cent confidence,
and the zinc concentrate grade remained unchanged.
Digging deeper into the data it was quickly realised that increasing the throughput had a negative
impact on zinc recovery independent of grinding media type (Figure 8). Completing multiple variable
regression analysis on the data produced the following model:
Zinc recovery = 32.4 - 0.06 (Zn feed units) + 0.07 (Zn concentrate units) + 0.27
(Zn rougher recovery) + 0.24 (Zn cleaner recovery) +0.10 (High chrome)
This analysis indicated that the application of high chrome grinding media may have had a small
positive effect on zinc recovery. The available data strongly suggests that the loss in zinc recovery is
linked to the higher zinc metal units entering the circuit, with both the rougher and cleaner circuits not
having sufficient capacity to successfully capture the additional sphalerite. Further analysis is required
to fully understand this behaviour. However, what can be said is that during Period 3, with the higher
zinc metal units in the plant feed, even with a lower zinc recovery resulted in an increase in the tonnes
of zinc concentrate at 57.7 per cent grade produced by 6.5 per cent.
Taking into account the higher zinc feed values, essentially, the statistical analysis indicated that high
chrome grinding media did not have an adverse effect on the zinc recovery.

Plant trial summary

While the pulp chemistry of the system changed to more oxidising conditions, it would appear at first
glance that the change to high chrome grinding media had an adverse effect on flotation. However,
upon further investigation it is apparent that there were significant differences in the feed to the plant
between Period 1 and Period 3, and that these differences, namely the increase in lead and zinc metal
units in the feed, dominated the changes in recovery of galena and sphalerite. So, conservatively the
change to high chrome grinding media has had little or no effect on the lead and zinc recoveries. That
is, the status quo has been maintained.

Fig. 8 - The throughput versus zinc recovery relationship for Periods 1 and 3.

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In addition to the shift metallurgical data the reagent consumption information was also analysed.
These data suggested that the xanthate and dextrin additions to the lead circuit were increased during
Period 3. This corresponds well with the significant increase in lead units entering the circuit, and the
higher lead recoveries during this time. However, in the zinc circuit the copper sulphate and dextrin
additions were reduced by at least 7 per cent during the same period with higher zinc metal units
arriving in the plant. It is felt that the cleaner chemistry of the new system lends itself to further
reagent optimisation, and it is likely that further reductions in consumption are possible.
However, at the end of the day while the statistical analysis did not show measurable increases in
galena and sphalerite recovery, it did show the complexities involved in conducting a plant trial of this
nature where the purge period extended over 12 months. It should not come as a surprise that almost
all parameters in this very complex system will change during a trial of this duration, and it is unlikely
that the judicious use of powerful statistical tools will yield strong proof that one condition is better
than another.

ECONOMIC EVALUATION
The final step in this analysis is to evaluate the economic benefit in using high chrome grinding media
in the Century plant. Any economic evaluation should take into account:

The wear benefits (consumption and transport costs)

Any reduction in reagent consumption
Any improvements in metallurgical performance.

It is apparent that the change from forged steel to high chrome media has dramatically reduced the
grinding media consumption (by 62 per cent): a saving of $1,215,000 USD per annum, thereby
making this change in media cost effective based on wear alone. While there is some evidence to
suggest that it is possible to reduce the reagent consumption there is no reliable data to accurately
assess this at the time of publishing this paper. Also and in spite of the higher lead and zinc feed
values, the statistical analysis suggested that the metallurgical performance was not adversely affected
by the high chrome grinding media.

CONCLUSIONS
The paper provides an account of the test work completed at Century mine to demonstrate the benefits
of high chrome grinding media on wear and metallurgical performance. The work completed
extended over a number of years, and eventually lead to a full plant trial.
The MBT predicted that the media consumption would decrease by nominally 60 per cent, while the
laboratory studies indicated that converting to high chrome grinding media had a positive effect on the
pulp chemistry and metallurgical response. The Magotteaux Mill test work indicated that the Eh
would shift to more oxidising values, the dissolved oxygen content would increase and the EDTA
extractable iron would decrease as the media corrosion rate diminished. These changes in the pulp
chemistry resulted in improvements in lead and zinc recovery in the laboratory.
When advanced to plant trial the concentrator was monitored in terms of both the pulp chemistry and
metallurgical performance. The pulp chemistry changes observed in the plant were larger than those
noted in the laboratory, but the metallurgical benefits were clouded by the changes in plant feed over
the two years that the trial ran.
An economic analysis of the plant trial indicated that the 62 per cent reduction in wear rate equated to
a saving of some $1,215,000 USD per annum. Further gains (especially in lead and zinc recoveries)
are possible if the reagent regime was optimised for the new pulp chemistry.

ACKNOWLEDGEMENT
The authors wish to thank MMG and Magotteaux for granting permission to publish this paper.

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