Chapter 1

FACTORS WHICH INFLUENCE SELECTION OF COMMINUTION CIRCUITS

D. J. B a r r a t t M. A. Sochocky

Wright Engineers Limited Dravo Engineers

Vancouver, B.C. P i t t s b u r g h , PA.
Canada U.S.A.

INTRODUCTION t u r e o r s u p p o r t i n g systems may be

q u i t e a d e q u a t e t o accommodate t h e
Summary of F a c t o r s I n f l u e n c i n g r e q u i r e m e n t s o f any expansion o r new
Comminution C i r c u i t Design development. Hence, t h o s e f a c t o r s
may n o t have t o be c o n s i d e r e d . To
The s e l e c t i o n o f a n a p p r o p r i a t e c o v e r , however, t h e w i d e s t spectrum
comminution c i r c u i t f o r a s p e c i f i c o f p r o j e c t s , t h e f a c t o r s which have
o r e is one o f t h e most i m p o r t a n t been i d e n t i f i e d i n t h i s c h a p t e r a r e
decisions i n t h e design of a those which will have to be
processing p l a n t . The importance i s c o n s i d e r e d f o r t h e most complex o f
related t o the f a c t t h a t the c a p i t a l projects, t h a t of developing a n
and o p e r a t i n g c o s t s f o r c r u s h i n g and e n t i r e l y new mining o p e r a t i o n .
grinding plant generally represent,
a s is w e l l known, t h e major p o r t i o n The r a n g e o f f a c t o r s i s a s broad
of the plant costs. This chapter a s t h e range o f d i f f e r e n t o r e types.
w i l l , t h e r e f o r e , i d e n t i f y a s many a s Thus, each development must be
possible of the factors which treated with individualized care.
influence the selection of a The most i m p o r t a n t s t e p i n t h e
comminution c i r c u i t . development i s t h e a n a l y s i s and
understanding o f t h e o r e c h a r a c t e r i s -
The number of f a c t o r s which w i l l tics. The h a r d n e s s o f t h e o r e , i t s
have t o be c o n s i d e r e d f o r any abrasiveness, friability, moisture
comminution p r o j e c t will depend, content, grade, mineralization
among o t h e r t h i n g s , on t h e t y p e o f i n c l u d i n g gangue m i n e r a l i z a t i o n , l i b -
project. If, f o r example, the e r a t i o n s i z e , c h e m i s t r y , and o t h e r
p r o j e c t i s a n e n t i r e l y new mining c h a r a c t e r i s t i c s should be t h e first
development, t h e n most, if n o t a l l , t o be a n a l y z e d i n t h e i n v e s t i g a t i o n .
t h e f a c t o r s i d e n t i f i e d w i l l have t o The n e x t should be t h e d e t e r m i n a t i o n
be analyzed. If t h e p r o j e c t i s a n of f a c t o r s such a s p l a n t s i z e ,
expansion o f a developed mining throughput, location, climate,
o p e r a t i o n o r i f t h e new orebody i s a c c e s s i b i l i t y , and a v a i l a b i l i t y o f
adjacent t o a viable operation, then water.
t h e existing operation w i l l influence
t h e choice o f f a c t o r s o r d e s i g n The s e l e c t i o n o f samples f o r
constraints which need to be i n i t i a l bench s c a l e work and b u l k
considered. The e x i s t i n g i n f r a s t r u c - sampling (when needed) f o r f u r t h e r
 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS
testing, such as larger scale
laboratory investigations up to pilot
plant scale, are very critical. The
importance of careful sampling cannot
be over-emphasized.
With the development of the
first metallurgical flowsheet the
comminution engineer will obtain the
design criteria for liberation. He
will determine the circuit
configuration for stages of crushing
and grinding and any intermediate
beneficiation steps. If media
competency tests show that autogenous
grinding is possible, various
comminution circuits will have to be
tested and economically evaluated.
In many cases it will be the
comminution engineer who will dictate
the grinding stages rather than the
metallurgist. The advantages and
disadvantages of the various
comminution circuits are many, but
the final analysis involves practical
considerations as well as economics.
These considerations could be the
availability of items such as good
media, good straight rods, 10-12.7 cm
(4-5in.) balls in a remote
geographical area, or trained people
to run a sophisticated plant.
Finally, it is very important to
have a proper understanding of
current practices in similar or
related industries, to find out why
others did what they did, and to
learn from their experience.
Outline of Various Comminution
Circuits under Consideration
The variety of possible circuits
provides greater challenges for the
comminution engineer. To simplify
the analyses in this chapter, only
the most basic circuits predominantly
used and accepted by the mining
industry have been considered. These
are as follows:
- Crusher-Rod Mill-Ball Mill
- Crusher-Ball Mill-Ball Mill
- Crusher-Rod Mill-Pebble Mill
- Crusher-Single Stage Ball Mill
- Single Stage Autogenous
- Autogenous-Ball Mill
- Autogenous-Pebble Mill
- Single Stage Semi-Autogenous
- Semi-Autogenous-Ball Mill
- Autogenous-Ball Mill-Crusher
Each circuit has its advantages
and disadvantages. However, for any
particular ore, a specific evaluation
has to be made, and when it is shown
that the advantages outweigh the
disadvantages, that particular
circuit should be given additional
scrutiny. This does not mean that
each of the above circuits should be
tested. Needless to say, this would
be extremely time consuming and
costly. Relatively simple prelim-
inary tests such as media competency
tests and Bond crushing impact tests
are available and can be used to
eliminate a number of the above
possibilities.
Discussion of Project Development
Sequence as it affects the Choice
of Factors under Consideration
It is a pre-requisite for a
successful plant design that a
comminution engineer be specifically
assigned to a project to work right
from the beginning with the
metallurgical staff. The process of
gathering design criteria and the
evaluation of this data can be done
either by the owner's staff or by an
independent consulting firm. In
either case, the starting point is
the geologists8 report. This will
delineate the orebody and provide a
guide to initial sample acquisition.
The quantity of the ore sample is
usually limited at this point and
studies are done on a bench scale to
determine basic starting parameters.
These bench scale tests, together
with what one may call the
"experience factor", will allow the
metallurgist to propose a few
preliminary flowschemes for treating
the ore.
At this point a preliminary
economic viability study should be
prepared which would take into s e l e c t i o n should be t h e consensus of
account some f a c t o r s r e l a t i v e t o t h e b e s t knowledge a v a i l a b l e ( 1 , 2).
p l a n t l o c a t i o n , o r e t y p e , product
tonnage and q u a l i t y , even i f many
f a c t o r s have t o b e o n l y assumptions IDENTIFICATION OF FACTORS
o r educated guesses. W e need t o
concern o u r s e l v e s w i t h t h i s c r i t e r i a P r o p e r t i e s o f t h e Orebody o r
only inasmuch a s i t a f f e c t s t h e S e l e c t e d C i r c u i t Feed
comminution system design. The
m e t a l l u r g i c a l flowsheet w i l l s p e c i f y Geological I n t e r p r e t a t i o n o f D r i l l
t h e f i n e n e s s o f g r i n d r e q u i r e d and Core and Bulk Samples. The i n i t i a l
perhaps t h e need f o r m u l t i - s t a g e information gathering process should
g r i n d i n g with i n t e r m e d i a t e concen- s t a r t with the geologists1 report.
tration steps between grinding Sampling methods for feasibility
stages. Based on t h i s i n f o r m a t i o n , studies depend on geological
the comminution engineer should c h a r a c t e r i s t i c s of t h e deposit.
conduct the appropriate Bond
g r i n d a b i l i t y tests. For t h e purpose Initial sample acquisition
of t h i s i n i t i a l f e a s i b i l i t y study, a methods may v a r y and s h o u l d b e
c o n v e n t i o n a l , crushing-rod m i l l - b a l l a d a p t e d t o each p a r t i c u l a r d e p o s i t ,
m i l l c i r c u i t can b e assumed. T h i s i s but a t t h i s s t a g e of t h e p r o j e c t
a practical first step and development, t h e m e t a l l u r g i s t would
f a c i l i t a t e s the evaluation process most l i k e l y have diamond d r i l l c o r e
when c o n s i d e r i n g a l t e r n a t i v e schemes. samples and p o s s i b l y s u r f a c e g r a b
Samples should a l s o b e s e n t a s soon samples o r t r e n c h samples t o t e s t f o r
as possible to an accredited development o f d e s i g n p a r a m e t e r s ( 3,
l a b o r a t o r y f o r media competency tests 4).
and abrasion index testing.
Assuming, o f c o u r s e , t h a t t h e i n i t i a l The f a c t o r o f i n t e r e s t t o a
economic e v a l u a t i o n was f a v o u r a b l e , a comminution engineer, from the
more d e t a i l e d f u l l s c a l e f e a s i b i l i t y g e o l o g i s t s 1 r e p o r t , would be t h e
s t u d y should now be s t a r t e d . identification of mineral
c o n s t i t u e n t s present, t h e i r r e l a t i v e
This study will require a q u a n t i t y and d e g r e e o f d i s s e m i n a t i o n ,
thorough i n v e s t i g a t i o n o f a l l t h e t h e number o f d i s t i n g u i s h a b l e o r e
f a c t o r s . Depending upon t h e l o c a t i o n z o n e s and t h e main c h a r a c t e r i s t i c s of
and s i z e o f t h e p r o j e c t and t y p e o f each. The f o l l o w i n g f a c t o r s s h o u l d
d e p o s i t , t h e development w i l l r e q u i r e be e v a l u a t e d t o p r o v i d e t h e i n i t i a l
the acquisition of a larger background i n f o r m a t i o n f o r f u r t h e r
r e p r e s e n t a t i v e sample, o r sequence of d e c i s i o n making.
samples, more thorough bench s c a l e
work, and perhaps a pilot M i n e r a l o ~ i c a l Analysis. Examination
plant - scale investigation. Many o f m i n e r a l s ~ e c i m e n s can d e t e r m i n e
d e c i s i o n s w i l l have t o be made a t the i d e n t i t y , character, grain s i z e
this point by the comminution r a n g e and middling a s s o c i a t i o n s of
engineer. He should by t h e n have t h e t h e o r e m i n e r a l s and c o n s t i t u e n t s of
r e s u l t s of t h e media competency gangue rock ( 3 , 4 1. Such i n f o r m a t i o n
tests. The d e c i s i o n w i l l have t o be w i l l provide l i b e r a t i o n s i z e analyses
reached a s t o which comminution f o r primary, intermediate o r r e g r i n d
c i r c u i t s should be t e s t e d and a l s o a s a p p l i c a t i o n s of g r i n d i n g and t h e
t o t h e l e v e l of e f f o r t r e q u i r e d . appropriate concentration steps.
Each c i r c u i t t e s t e d w i l l have t o be
evaluated taking into account The examination method g e n e r a l l y
economic, m e t a l l u r g i c a l , and prac- u s e d is based on r e f l e c t e d l i g h t
t i c a l considerations with regard t o optical microscopy for polished
equipment sizing. The final s e c t i o n s o r stereoscopy f o r mineral
 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS

grains. Where m i n e r a l s have t o b e Bond g r i n d a b i l i t y t e s t s , a b r a s i o n

more s p e c i f i c a l l y i d e n t i f i e d , X-ray tests, and autogenous media
diffraction can be used. competency t e s t s . It should b e
Occasionally t h e minerals present i n emphasized that all the
the ore are in such complex aforementioned t e s t s r e q u i r e a small
a s s o c i a t i o n s t h a t they cannot be amount o f sample. The r e s u l t s , w h i l e
i d e n t i f i e d by s i m p l e o p t i c a l o r X-ray o b v i o u s l y used a s t o o l s t o o b t a i n
d i f f r a c t i o n techniques. In these f i n a l q u a n t i t a t i v e design parameters,
c a s e s , e l e c t r o n p r o b e a n a l y s i s can be a l s o enable the metallurgical staff
used to determine the mineral t o c h a r t a c o u r s e of a c t i o n through a
c h a r a c t e r i s t i c s and t h e o c c u r r e n c e o f better understanding o f t h e o r e
the element(s) i n question (5). characteristics. Analysis of t h i s
i n f o r m a t i o n should e v e n t u a l l y narrow
Chemical Analysis. A complete the number of circuit options
chemical analysis is always a available.
valuable tool. While i t i s more
relevant t o the design of the It s h o u l d b e emphasized t h a t i f
beneficiation flowsheet, i t might a n orebody i s n o t homogenous (and
p r o v i d e t h e comminution e n g i n e e r w i t h what o r e i s ? ) t h e d i s t i n c t o r e t y p e s
t h e first c l u e s t o p o s s i b l e problems s h o u l d b e sampled s e p a r a t e l y . Bond
i n comminution c i r c u i t d e s i g n and t o g r i n d a b i l i t y t e s t s , a b r a s i o n tests
the need for additional circuit and media competency tests should b e
design parameters. r u n on e a c h o r e t y p e which t h e mining
p l a n shows could b e , a t any t i m e , a
If, for instance, there is major p o r t i o n o f t h e m i l l feed. It
e v i d e n c e of a l k a l i e s o r s u l p h a t e s , i s recommended t h a t each t y p e o f o r e
s l i m i n g may b e a problem and s h o u l d be t e s t e d s e p a r a t e l y . Testing of
be anticipated. S u l p h a t e s may a l s o i n d i v i d u a l ore types w i l l give an
produce a n a c i d i c s l u r r y which would i n d i c a t i o n a s t o t h e degree o f
result in high media wear or f l u c t u a t i o n t h a t c a n b e expected i n
u n d e r l i n e t h e need f o r a n o r e washing mill performance. Testing of
s t a g e i n t h e flowsheet. c o m p o s i t e s should b e done i n t h e
p i l o t t e s t i n g phase (6).
Physical Properties (hardness,
friability, grain size distribution). Design Requirements
The f i r s t v i s u a l o b s e r v a t i o n s c a n
immediately g i v e a n i n d i c a t i o n o f t h e Review o f C i r c u i t Feed Parameters
h a r d n e s s , b l o c k i n e s s and f r i a b i l i t y (mine o u t p u t , p r o d u c t i o n s c h e d u l e s ,
o f t h e o r e and o f t h e amount o f t h r o u g h p u t and s i z e a n a l y s i s ) . It i s
primary fines or clay-type essential that the comminution
constituents, and other physical engineer have a clear overall
properties. These o b s e r v a t i o n s c a n u n d e r s t a n d i n g o f t h e p r o j e c t and i t s
p r o v i d e c l u e s t o p o s s i b l e problems i n conception. He s h o u l d b e f a m i l i a r
c r u s h i n g , s c r e e n i n g and g r i n d i n g and w i t h t h e mining p l a n s , s c h e d u l e s ,
can influence flowsheet design. m i n i n g r a t e s , minj.ng methods and
Examples a r e : t h e a v o i d a n c e o f s l i m e equipment s i z e s , e t c . These c a n
generation when processing tin, a f f e c t t h e s i z e and/or choice of
tungsten, lead, chromite, o r tantalum processing equipment, particularly
o r e s ; t h e r e l e a s e o f molybdenite a t a f o r c r u s h i n g o r primary m i l l i n g , a s
c o a r s e g r i n d from f r a c t u r e p l a n e s i n w e l l a s o p e r a t i n g h o u r s i n primary o r
a blocky granodiorite; the f i n e crushing, necessity f o r ore
e l i m i n a t i o n of problems i n a f i n e s t o r a g e , manpower r e q u i r e m e n t s and
c r u s h i n g p l a n t by u s e o f semi- t h e l o c a t i o n of t h e crushing o r
a u t o g e n o u s g r i n d i n g when p r o c e s s i n g a grinding plant.
clayey ore. However, f u r t h e r t e s t
samples s h o u l d b e made a v a i l a b l e f o r The primary c r u s h e r i s normally
 SELECTION OF COMMINUTION CIRCUITS 5

p a r t o f any proposed p l a n t . It i s i n
r e q u i r e d t o o b t a i n Bond work i n d i c e s
most c a s e s a primary g y r a t o r y l o c a t e d
f o r rod m i l l i n g and b a l l m i l l i n g and
on s u r f a c e o r , f o r underground mines,
lump samples c a p a b l e o f g e n e r a t i n g
u s u a l l y a jaw c r u s h e r . The s i z e o f
7.7 cm ( 3 i n . ) cubes a r e n e c e s s a r y
these crushers w i l l be d i c t a t e d n o t
o n l y by t h e mining r a t e and t h e t o p f o r c r u s h e r impact t e s t s . If a n
s i z e o f t h e mined r o c k which w i l l b e economic ore deposit has been
d e l i v e r e d , b u t a l s o by t h e p r o d u c t e s t a b l i s h e d and p r e l i m i n a r y bench
s c a l e work shows promising r e s u l t s ,
size required. For instance,
depending upon t h e s i z e o f the f u r t h e r sampling w i l l b e needed.
autogenous m i l l s b e i n g c o n t e m p l a t e d , A l s o , i f p r e l i m i n a r y media competency
a feed size parameter of t e s t s have i n d i c a t e d t h a t t h e o r e h a s
15.25-30.50 cm (6-12 i n . ) may be autogenous or semi-autogenous
desirable. potential, samples have to be
obtained t o t e s t t h i s further. For
Another i m p o r t a n t f a c t o r which e i t h e r a n open p i t o r underground
t h e comminution e n a i n e e r h a s t o know mining o p e r a t i o n , p r e l i m i n a r y mine
i n the early stages of circuit development work o f t e n c o n s i s t s of
p l a n n i n g i s t h e tonnage t h r o u g h p u t driving adits o r shafts i n t o the
deposit. Typically f o r autogenous
requirements. These a r e determined
i n due c o u r s e by economic f e a s i b i l i t y
m i l l t e s t i n g , 22,700 - 45,400 k g (25-
50 t o n s ) o f r e p r e s e n t a t i v e sample f o r
s t u d i e s which a s c e r t a i n t h e q u a l i t y
each o r e type a r e r e q u i r e d for
and q u a n t i t y o f t h e p r o d u c t which
p r o c e s s i n g t h r o u g h a 1.7-1.8 m (5-1/2
w i l l b e needed f o r p r o j e c t v i a b i l i t y .
o r 6 f t . ) diameter p i l o t m i l l . The
These numbers a r e a v a i l a b l e s o o n e r , samples should be run-of-mine
b u t perhaps w i t h less a c c u r a c y , from p r e p a r e d i n t h e normal manner by
t h e head a s s a y o f t h e o r e and from
d r i l l i n g and b l a s t i n g t o a b o u t a
e x p e r i e n c e which c a n p r e d i c t t h e 20.3 cm ( 8 i n . ) t o p s i z e .
p r o d u c t s p e c i f i c a t i o n and tonnage
requirements.
The r e l a t i v e c o s t s o f o b t a i n i n g
s a m p l e s , t e s t i n g them and t h e time
Review Of Requirements for taken a r e significant f a c t o r s i n t h e
Testing Various Circuits. The of c i r c u i t t o b e i n v e s t i g a t e d .
and q u a n t i t y o f sample may v a r y . It
cannot b e s t r e s s e d - o f t e n -enough t h a t Identification of Contiguous
any p r o c e s s f o r a n y g i v e n orebody i s
Processes, t h e i r Requirements and
o n l y a s r e l i a b l e a s t h e sample upon Inter-relationships with Identified
which i t i s based. A company would
Comminution S t e p s . Each p i e c e o f
be well advised t o i n v e s t t h e time comminution equipment has its
and money t o o b t a i n p r o p e r samples. inherent characteristics. Thus, o n e
The q u a n t i t y of sample required s a y s t h a t rod m i l l s p r o d u c e fewer
cannot be d e f i n e d . The t y p e o r fines than ball mills; closed-
d e p o s i t and t h e m i n e r a l i z a t i o n w i l l circuiting reduces overgrinding;
d i c t a t e t h e sampling programme needs. autogenous m i l l s break o r e a l o n g
g r a i n b o u n d a r i e s and c o n s e q u e n t l y c a n
A s h a s been a l r e a d y mentioned i n l i b e r a t e values a t coarser s i z e s .
a previous section, preliminary These b a s i c t e n e t s , t o g e t h e r w i t h t h e
samples a r e usually obtained as particular properties of the ore,
d r i l l i n g progresses t o d e l i n e a t e t h e i n f l u e n c e t h e comminution e n g i n e e r ' s
orebody. The c o r e s a r e s p l i t i n h a l f thinking when he is selecting
and one h a l f g o e s f o r m e t a l l u r g i c a l
equipment which must produce a
testing. Sometimes s u r f a c e g r a b
product that has characteristics
sampling o r t r e n c h i n g is a l s o used a t
compatible with those required i n t h e
t h i s point t o g e t material for
feed f o r t h e subsequent c o n c e n t r a t i o n
preliminary testwork. Generally,
process. If a n o r e h a s t h e t e n d e n c y
22.7 kg (50 lb.) o f sample is t o slime, t h e c i r c u i t may i n c o r p o r a t e
 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS

high-efficiency classification in t h e p r i m a r y c r u s h e r requirements. In

closed-circuit with a grinding m i l l . underground mines, e s p e c i a l l y if t h e
This high-efficiency classification p r i m a r y c r u s h e r is underground, t h e
may c a l l f o r high-speed s c r e e n s o r mine p r o d u c t may be much f i n e r a s
two-stage cyclone classification. d i c t a t e d by t h e h a n d l i n g c a p a b i l i t i e s
Removal of a troublesome clay o f h a u l i n g o r h o i s t i n g equipment.
c o n s t i t u e n t may r e q u i r e d r y g r i n d i n g P r o c e s s development work might a l s o
and p r e - c o n c e n t r a t i o n b e f o r e t h e o r e be providing t h e f i r s t indications of
c a n b e wetted. t h e ground p r o d u c t s p e c i f i c a t i o n .
Conversely, the beneficiation Most comminution equipment i s
f l o w s h e e t might have t o accommodate a designed to work in a specific size
mesh Of grind that a piece Of r a n g e . However, a s u s u a l , g r a y a r e a s
comminution equipment naturally exist and t h i s makes l i f e f o r a
grinds This is true with comminution e n g i n e e r both c h a l l e n g i n g
autogenous m i l l s . and i n t e r e s t i n g .
This consideration can be How fine to crush before
illustrated by a recent plant g r i n d i n g i s one o f t h o s e a r e a s .
flowsheet f o r a t a c o n i t e i r o n ore. Recent developments in high-
Comminution c i r c u i t s f o r a t a c o n i t e e f f i c i e n c y c r u s h i n g c i r c u i t s make i t
o r e would commonly b e d e s i g n e d a s more a c c e p t a b l e t o do away w i t h rod
two-stage systems incorporating m i l l s and proceed d i r e c t l y t o b a l l
e i t h e r a rod m i l l - b a l l m i l l c i r c u i t m i l l s which do n o t have t h e same
o r autogenous g r i n d i n g f o l l o w e d by product and equipment size
ball mills. The r e c e n t f l o w s h e e t , l i m i t a t i o n s (8, 9, 10). I f rod
however, incorporated single-stage m i l l i n g is used, i t i s p r e f e r a b l e t o
autogenous grinding i n c l o s e d - c i r c u i t prepare t h e feed with closed-circuit
with magnetic separators and c r u s h i n g i n o r d e r t o a v o i d problems
cyclones. While t h e power e f f i c i e n c y caused by s e g r e g a t e d o v e r s i z e ( i . e .
o f t h e g r i n d i n g c i r c u i t was n o t a s forcing rods apart). I f crushing i s
f a v o u r a b l e a s t h a t o f t h e more common done underground and t h e mine p r o d u c t
two-stage p l a n t , t h e s i m p l i c i t y o f size is too small for primary
flowsheet offsetting the capital autogenous m i l l i n g , a s practiced i n
c o s t s o f g r i n d i n g m i l l s made o v e r a l l North America, the more even
economic s e n s e ( 7 ) . 1ength:diameter r a t i o type of m i l l ,
as used in South African or
Thus i t becomes c l e a r t h a t t h e S c a n d i n a v i a n p r a c t i c e , may be t h e
comminution a s p e c t s o f t h e f l o w s h e e t answer.
a r e closely i n t e r - r e l a t e d with t h e
beneficiation processes and close The Importance of Work Index and
cooperation i n designing t h e s e is Abrasion Index. The Bond work i n d e x
indispensable. method is a very useful and
c o n v e n i e n t t o o l f o r a comminution
I d e n t i f i c a t i o n o f Feed and P r o d u c t engineer. Application of test
S p e c i f i c a t i o n s f o r Each Comminution r e s u l t s t o t h e Bond work i n d e x
S t e p i n t h e Process. Feed and formula provides the initial
product s p e c i f i c a t i o n s begin a t t h e i n d i c a t i o n o f t h e u n i t power r e q u i r e d
earliest stages of flowsheet to grind any particular ore.
development. Size analysis of the Additionally, because the method
p l a n t f e e d o r mine o u t p u t i s t h e r e q u i r e s a s m a l l amount o f sample and
f i r s t item t o be determined, s i n c e c o s t s r e l a t i v e l y l i t t l e , u n i t power
t h e proportion o f f i n e s can influence r e q u i r e m e n t s f o r g r i n d i n g can b e
t h e necessity f o r screening a f t e r a s c e r t a i n e d q u i c k l y and a c c u r a t e l y
primary crushing. Open p i t mines c a n f o r a number o f d i f f e r e n t o r e t y p e s
a d j u s t t h e run-of-mine top size t o e a r l y i n t h e development o f a p r o j e c t
 SELECTION OF COMMINUTION CIRCUITS
by u t i l i z i n g d r i l l c o r e samples.
T h i s knowledge a t a n e a r l y s t a g e can
be very u s e f u l i n any economic
analysis. Work i n d e x should be
determined f o r d i f f e r e n t a p p l i c a t i o n s
of comminution, i.e. c r u s h i n g , rod
m i l l i n g and b a l l m i l l i n g . It i s
o f t e n a f a l s e assumption t o e x p e c t
work index t o be uniform f o r a l l
incremental s t a g e s o f s i z e r e d u c t i o n
i n a process. It i s important t o
recognize t h a t work i n d e x , W i , i s a
parameter which i s used t o determine
t h e u n i t power requirement. In these
days of m e t r i c a t i o n , work index i s
s t i l l r e p o r t e d on t h e b a s i s o f s h o r t
t o n s and can, if r e q u e s t e d ,
a d j u s t e d t o r e f l e c t m e t r i c tons.
Abrasion tests serve a s an
i n d i c a t i o n o f t h e m e t a l wear t h a t can
be expected i n c r u s h i n g and g r i n d i n g .
Once determined, t h e y may be a first
i n d i c a t i o n t h a t autogenous g r i n d i n g
should be i n v e s t i g a t e d a s steel wear
can be a s i g n i f i c a n t c o s t item.
Once a composite o f t h e e n t i r e
o r e deposit is established, Bond
g r i n d a b i l i t y work should be r u n t o
get the overall unit power
requirement. Mathematical a v e r a g i n g
of Bond work i n d i c e s f o r a series o f
o r e t y p e s normally d o e s n o t produce
the correct average unit power
requirement. Differential grinding
causes each o r e t y p e t o be ground t o
a d i f f e r e n t s i z e d i s t r i b u t i o n , some
f i n e r and some much c o a r s e r t h a n t h e
average (11). I f pilot testing is
needed because o f t h e complexity o f
t h e flowsheet and size of the
d e p o s i t , Bond g r i n d a b i l i t i e s should
be used d u r i n g t h e p r o c e s s o f t h i s
test work t o check on t h e g r i n d i n g
d a t a produced from t h e p i l o t m i l l .
Frequently, t h e s e m i l l s a r e o v e r s i z e d
i n respect t o t h e p i l o t beneficiation
circuit and therefore run
i n t e r m i t t e n t l y and a r e consequently
never p r o p e r l y balanced. In small
mills i t i s d i f f i c u l t t o measure
power consumed f o r g r i n d i n g because
o f t h e high p r o p o r t i o n o f power which
is absorbed i n d r i v e i n e f f i c i e n c i e s
and f i x e d load c h a r a c t e r i s t i c s . The
major requirement f o r a p i l o t m i l l i n
grinding testwork i s t o e s t a b l i s h a
reliable relationship between
g r i n d i n g power and measured power.
T h i s c a n be done i n two ways:
- by u s i n g s o p h i s t i c a t e d i n s t r u -
mentation t o t a r e t h e m i l l .
- by g r i n d i n g a number o f o r e s
w i t h known power consumption and
establishing an empirical
r e l a t i o n s h i p between p i l o t m i l l
power and a c t u a l g r i n d i n g power.
be I n c a s e s where t h i s k i n d o f p i l o t
m i l l c a l i b r a t i o n is n o t p o s s i b l e , t h e
Bond g r i n d a b i l i t y work i n d e x method
o f f e r s a n e x c e l l e n t power d e t e r m i n a n t
f o r an ore.
Determination o f Power Requirements.
Determination o f power requirement
may c e a s e w i t h Bond g r i n d a b i l i t y
work, and i n some c a s e s w i t h s m a l l e r
and more homogenous o r e b o d i e s t h a t
u t i l i z e t h e c o n v e n t i o n a l c r u s h i n g and
g r i n d i n g f l o w s h e e t t h i s may be t h e
c a s e . The more common p r a c t i c e is t o
r u n a p i l o t p l a n t and t o u s e o t h e r
means t o v e r i f y t h e Bond numbers.
Many firms have developed l a b o r a t o r y
t e c h n i q u e s t h a t have been c o r r e l a t e d
t o e x i s t i n g o p e r a t i o n s and r e f i n e d
over the years a s an a l t e r n a t i v e
s u c c e s s f u l method f o r d e t e r m i n i n g t h e
power requirements. When p i l o t p l a n t
m i l l s a r e used t o o b t a i n s p e c i f i c
grinding power, care should be
exercised t h a t t h e m i l l i s i n balance
and that the tests are run
s p e c i f i c a l l y t o obtain grinding data.
For autogenous g r i n d i n g , e s p e c i a l l y ,
a thorough test programme i s needed.
Most i n s t a l l a t i o n s now have a 1.7-
1.8 m (5-112-6 ft.) d i a m e t e r test
m i l l and r e q u i r e 22,700-45,400 kg
(25-50 t o n s ) of o r e f o r one test
programme. These tests c a n a l s o be
done a t t h e mine s i t e and w i t h v e r y
l a r g e and v a r i e d d e p o s i t s t h i s may
make sense. However, i t i s p r o b a b l y
more economical t o s h i p t h e sample t o
an established laboratory t h a t has
the people and the methodology
 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS

readily available. r e a l i z e d because o f h i g h e r l i n e r and

feed c h u t e wear i n comparison w i t h a
A method e x i s t s today which conventional c i r c u i t (14). Avail-
u t i l i z e s a s m a l l 450 mm m i l l t o a b i l i t y w i l l b e 90% o r l e s s f o r f u l l y
provide preliminary autogenous u n i t a u t o g e n o u s g r i n d i n g and up t o 92% h a s
power r e q u i r e m e n t s (Autogenous Work been a c h i e v e d f o r semi-autogenous
Index) which can establish the grinding. J.H. B a s s a r e a r ( 15 )
requirement f o r a f u l l s c a l e p i l o t r e p o r t e d on t h e e x p e r i e n c e o f Cyprus
test and e n s u r e t h a t t h e r e a r e no Pima Mining Co. where c o n v e n t i o n a l
g r i n d i n g s u r p r i s e s i n t h e orebody by and semi-autogenous m i l l s o p e r a t e on
p r o v i d i n g a n i n e x p e n s i v e way t o test i d e n t i c a l o r e . The comparison i s f o r
t h e various ore types (12). a f o u r - y e a r t i m e p e r i o d , 1974-1977.
It showed t h a t l i n e r consumption was
Thus, u n i t power r e q u i r e m e n t s 6.7% more and media consumption 14.5%
f o r many c o n v e n t i o n a l c i r c u i t s c a n b e more w i t h t o t a l s t e e l consumption
determined by Bond g r i n d a b i l it y being 13.5% higher for the
procedures, by v a r i o u s l a b o r a t o r y c o n v e n t i o n a l c i r c u i t compared t o t h e
m i l l s which have been c a l i b r a t e d and SAG m i l l c i r c u i t ; however, power
r e l a t e d t o e x i s t i n g p r o d u c e r s and i f consumption was 15.5% lower. Thus,
need b e by p i l o t p l a n t t e s t i n g . For f o r t h i s comparison, e x t r a s t e e l
autogenous a p p l i c a t i o n s preliminary costs incurred by one circuit
power may b e o b t a i n e d from 450 mm b a l a n c e d t h e e x t r a power c o s t f o r t h e
m i l l t e s t s but a s a r u l e p i l o t p l a n t other circuit.
work s h o u l d be run.
Unit power consumption for
Circuit Selection p e b b l e m i l l i n g c a n g e n e r a l l y be a s
e f f i c i e n t a s b a l l m i l l i n g i f one
Power ,Requirement versus Avail- c o n s i d e r s t h e power t h a t is used t o
a b i l i t y , Mode o f G e n e r a t i o n , C o s t and g r i n d p e b b l e s a s w e l l ( 1 4 ) . However,
S p l i t between C r u s h i n g and grind in^ i n r e a l terms t h e maximum power drawn
f o r Various C i r c u i t s . Needless t o by a g i v e n m i l l s i z e used f o r pebble
s a y , w i t h t h e e x c e p t i o n o f a few m i l l i n g i s o f t h e o r d e r o f 50% o f t h e
a r e a s i n t h e w o r l d , power i s t h e most power used by t h e same m i l l i f i t
c r i t i c a l i t e m i n any g r i n d i n g c i r c u i t were used a s a b a l l m i l l and hence
evaluation. A s mentioned b e f o r e , t h e t h e t o n n a g e p r o c e s s e d would be h a l f .
comminution c i r c u i t i s p r o b a b l y t h e Rod m i l l - b a l l m i l l c i r c u i t s have t h e
m a j o r u s e r o f power i n a n y m i n e r a l h i g h e s t u n i t power e f f i c i e n c y and
processing plant. While cost o f f e r 95% o r g r e a t e r a v a i l a b i l i t y .
a n a l y s i s may show t h a t a c i r c u i t T h i s is a l i t t l e lower t h a n a s i n g l e -
which i s l e s s e f f i c i e n t i n t h e u s e o f s t a g e b a l l m i l l o r a b a l l mill-ball
power c a n be more economical o v e r a l l mill circuit (which o f f e r s 97%)
( 7 , 131, t h e p o s s i b i l i t y o f f u t u r e because of down-time for rod
rapid escalation of power costs charging. Primary ball mill
r e q u i r e s a c a r e f u l examination a s t o circuits, which accept crusher
how power consumption c o u l d b e k e p t p r o d u c t a s f e e d , have a n i n h e r e n t l y
t o a minimum. This i s r e a l l y lower u n i t power e f f i c i e n c y compared
i m p o r t a n t i f one c o n s i d e r s t h a t u n i t to normal secondary ball mill
power consumption c a n b e 25% h i g h e r i n s t a l l a t i o n s and a f a c t o r o f 10-205
f o r semi-autogenous m i l l c i r c u i t s and h a s t o b e added t o t h e s t a n d a r d power
perhaps 100% h i g h e r for fully calculation. Grate discharge b a l l
a u t o g e n o u s m i l l c i r c u i t s compared t o m i l l s , a r e c a p a b l e o f consuming 15%
c o n v e n t i o n a l c r u s h i n g and g r i n d i n g more power t h a n o v e r f l o w b a l l mills
circuits. M e t a l consumption w i l l f o r t h e same u n i t power e f f i c i e n c y
n a t u r a l l y b e less b u t w i t h p r i m a r y but maintenance costs and
a u t o g e n o u s g r i n d i n g , o n l y a b o u t 60% a v a i l a b i l i t y would b e l e s s f a v o u r a b l e
of t h e t h e o r e t i c a l s a v i n g s can b e (2, 14).
 SELECTION OF COMMINUTION CIRCUITS 9

Recent advances in crusher complications. Many o f t h e s e are a

c i r c u i t automation, it i s c l a i m e d result of the responsiveness o f
(161, have s h i f t e d t h e s i z e s p l i t t o autogenous m i l l i n g t o feed v a r i a t i o n .
favour c r u s h i n g , p o s s i b l y e l i m i n a t i n g The o r e t e l l s t h e m i l l how it w a n t s
the need for rod milling and t o be ground as t h e s a y i n g g o e s . If
providing a b e t t e r o v e r a l l operating t h e o r e breaks along g r a i n boundaries
system. The twin pendulum t e s t h a s e a s i l y , t h e m i n e r a l v a l u e s can b e
been designed t o e s t a b l i s h s i z e l i b e r a t e d a t a c o a r s e r g r i n d and w i t h
a n a l y s i s o f t h e c r u s h e r p r o d u c t and h i g h e r e f f i c i e n c y t h a n w i t h media
unit power requirement so that grinding. With o t h e r o r e s a l o t o f
c r u s h i n g and s c r e e n i n g f l o w s h e e t s c a n s l i m e s may b e g e n e r a t e d . Another
b e designed t o minimize c a p i t a l and t h i n g t h a t c a n be o v e r l o o k e d i n t h e
o p e r a t i n g c o s t and maximize power a u t o g e n o u s p l a n t d e s i g n is t h a t f o r a
efficiency. Certainly more given product s p e c i f i c a t i o n t h e m i l l
s o p h i s t i c a t e d c i r c u i t c o n t r o l s , which may have a 50%-100% s w i n g i n f e e d
may i n c l u d e o n - l i n e computers, h a v e r a t e depending upon ore sizing,
made m i l l o p e r a t i o n s more e f f i c i e n t h a r d n e s s , and o t h e r c h a r a c t e r i s t i c s
and should be f u l l y e x p l o r e d . which w i l l have t o be accommodated by
the metallurgical circuits
I n summary t h e u n i t power c o s t , downstream. C e r t a i n l y t h e need f o r
which depends upon t h e mode o f power b e t t e r b l e n d i n g f o r f e e d homogeneity
g e n e r a t i o n and hence l o c a t i o n o f t h e t o a u t o g e n o u s m i l l s i s more o b v i o u s ,
comminution p l a n t , i s p r o b a b l y t h e a s w e l l a s t h e need f o r c l o s e
most s i g n i f i c a n t f a c t o r which c a n m o n i t o r i n g o f c i r c u i t performance.
i n f l u e n c e t h e s e l e c t i o n of equipment
and p l a n t d e s i g n i n o r d e r t o keep Generally with autogenous o r
o v e r a l l power c o s t s t o a minimum and semi-autogenous g r i n d i n g t h e r e i s a
to achieve the most economical six-month t o two-year l e a r n i n g c u r v e
c a p i t a l and o p e r a t i n g c o s t . I n North b e f o r e t h e o p e r a t i n g p r i n c i p l e s and
America t o d a y , p u b l i c u t i l i t i e s s e l l c h a r a c t e r i s t i c s a r e w e l l understood.
power a t p r i c e s r a n g i n g from 1.5 t o A d d i t i o n a l l y some a d j u s t m e n t s t o t h e
6.5 c e n t s p e r kw-hr. and i n i s o l a t e d p r o c e s s f l o w s h e e t might h a v e t o b e
areas requiring d i e s e l generation, made ( 1 4 ) . On t h e p l u s s i d e , i f a n
t h e c o s t c o u l d be a s h i g h as 15 c e n t s o r e is wet and s t i c k y and a r e a l
p e r kw-hr. For p r o j e c t s f o r c e d t o problem f o r c r u s h i n g and s c r e e n i n g
a b s o r b a h i g h power c o s t , i t i s e x i s t s , a SAG m i l l may b e t h e answer
unlikely t h a t potential savings i n and can override all other
l i n e r and media c o s t s t o b e r e a l i z e d considerations (15). The cost
by u s i n g autogenous g r i n d i n g c o u l d benefit of time and relative
offset the costs associated with production l o s s e s o r g a i n s f o r such a
h i g h e r u n i t power consumptions when c h o i c e h a s t o be worked o u t .
compared w i t h c o n v e n t i o n a l c r u s h i n g
and g r i n d i n g . Rod m i l l s have been c h o s e n i n
many c a s e s b e c a u s e o f t h e i r i n h e r e n t
Effect of Circuit Selection on f e a t u r e o f g r i n d i n g down t h e t o p s i z e
Metallurgical. With t h e p r e f e r e n t i a l l y and g e n e r a t i n g less
standard conventional circuit the f i n e s than primary b a l l m i l l s . This
q u e s t i o n is how much t o g r i n d p e r can a f f e c t magnetic recovery a s i n
s t a g e and whether t o c l o s e - c i r c u i t a t h e t a c o n i t e f l o w s h e e t s where c o b b e r
m i l l o r t o operate i n open-circuit. wet drum magnets f o l l o w t h e f i r s t
Feed v a r i a t i o n t o t h e m i l l , a l t h o u g h grinding step. It i s a m e t a l l u r g i c a l
never a d e s i r a b l e f e a t u r e , c o u l d be axiom t h a t v a l u a b l e m i n e r a l s s h o u l d
tolerated at least from the b e r e c o v e r e d from t h e s t r e a m a s soon
perspective of the comminution a s they a r e liberated. Ideally
c i r c u i t design. Autogenous g r i n d i n g multiple grinding steps, each
has brought numerous new f o l l o w e d by a b e n e f i c i a t i o n s t e p ,
 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS

would c o n s t i t u t e a more m e t a l l u r g - L a r g e r b a l l mills c a n b e b u i l t

i c a l l y e f f i c i e n t f l o w s h e e t t h a n one- from the structural/mechanica1
s t e p g r i n d i n g f o l l o w e d by o n e - s t e p standpoint, but t h e r e a r e indications
beneficiation. However, such a t h a t c a p a c i t y can be l i m i t e d t o below
f l o w s h e e t might n o t b e c o s t - e f f i c i e n t t h e m i l l ' s f u l l p o t e n t i a l i f maximum
b o t h from t h e c a p i t a l c o s t and power e f f i c i e n c y a t t h e d e s i r e d g r i n d
operating cost aspects and, is the objective. T h e r e f o r e , under
therefore, some m e t a l l u r g i c a l and c e r t a i n c i r c u m s t a n c e s , i t may n o t
g r i n d i n g power e f f i c i e n c y m i g h t h a v e make s e n s e t o d e s i g n a p l a n t w i t h
to be sacrificed to reach an t h e s e larger u n i t s . Experience
e q u i t a b l e balance. Flowsheets f o r i n d i c a t e s t h a t t h e r e c o u l d be a
processing tin, iron, tungsten, material flow-transport problem
c h r o m i t e , l e a d and t a n t a l u m o r e s a r e through the m i l l because s l u r r y
t y p i c a l i n t h i s regard. flowrate is r e l a t e d t o the available
m i l l c r o s s - s e c t i o n a l area, which i n
When compared w i t h a u t o g e n o u s t u r n increases i n proportion t o t h e
g r i n d i n g o r lump m i l l i n g , s y s t e m s s q u a r e o f t h e m i l l d i a m e t e r , whereas
u s i n g c o n v e n t i o n a l g r i n d i n g and s t e e l t h e m i l l power draw i n c r e a s e s a s t h e
media t o m i l l complex s u l p h i d e o r e s m i l l d i a m e t e r t o t h e power 2.3-2.4
can impair t h e recoveries o f copper, ( 9 , 14). P o t e n t i a l m i l l capacity is
l e a d , and z i n c by f l o t a t i o n ( 1 7 , 1 8 , a f u n c t i o n of t h e m i l l diameter t o
19). It s h o u l d b e emphasized t h a t t h e power 2.6 ( 9 ) .
t h i s effect i s n o t a l w a y s o b s e r v e d
with these types of ores. The Rod m i l l s i z e is currently
physico-chemical mechanisms which l i m i t e d by t h e l e n g t h o f t h e l o n g e s t
u n d e r l i e t h i s behaviour a r e not f u l l y s t r a i g h t rod t h a t i s o b t a i n a b l e , 6.1
understood. Investigators suggest m (20 f t . ) . To p r e v e n t rod- t a n g l i n g
t h a t f a c t o r s which a l s o i n f l u e n c e a l e n g t h t o d i a m e t e r r a t i o o f 1.3:l.O
results are ore type and iron i s recommended. The l a r g e s t r o d
c o n t e n t , n a t u r e o f gangue m i n e r a l s m i l l s i n e x i s t e n c e a r e 4.7 m d l a . x
(whether a c i d i c o r b a s i c ) , types o f 6.25 m (15-1/2 f t . d i a . x 20-1/2 f t . )
f l o t a t i o n c o l l e c t o r s and m o d i f i e r s l o n g e f f e c t i v e chamber l e n g t h (2, 9 ,
used, degree o f oxidation o f t h e 11, 1 B a l l m i l l s c a n be l a r g e r
s u l p h i d e s and t h e oxygen p o t e n t i a l o f and s o fewer p r o c e s s i n g l i n e s a r e
t h e pulp. The g e n e r a l c o n c l u s i o n required, which is the chief
seems t o b e t h a t i f s u c h o r e s a r e a t t r a c t i o n f o r c o n s i d e r i n g primary
competent enough to grind b a l l milling circuits. The l a r g e s t
autogenously then such a c i r c u i t b a l l m i l l d i a m e t e r recommended f o r
should be used, s u b j e c t o f course t o maximum u n i t power e f f i c i e n c y i s
economic a n a l y s i s . 5.0 m (16-1/2 f t . ) (14). Larger
m i l l s e.g. 5.5 m ( 1 8 f t . ) d i a m e t e r
General Cost Considerations for have been s e l e c t e d f o r primary b a l l
Various C i r c u i t s . Recent p r a c t i c e m i l l i n g and have e x p e r i e n c e d v a r y i n g
h a s s e e n a n i n c r e a s e i n comminution degrees of inherent inefficiencies
equipment s i z e s t o l a r g e r and l a r g e r involving charge l e v e l , speed, feed
units with the objective of sizing, media size, liner
decreasing capital and operating configuration, material residence
costs. C e r t a i n l y autogenous m i l l s time and mixing ( 2 0 ) . One 5.5 m ( 18
a r e being b u i l t i n larger s i z e s , f t . ) diameter b a l l m i l l has r e c e n t l y
s u b j e c t t o c o n s t r a i n t s imposed by been i n s t a l l e d t o r e g r i n d p r o d u c t
structural design rather than from a semi-autogenous milling
process. With c o n v e n t i o n a l m i l l s a c i r c u i t f o r a 13,600 mtpd (15,000
s i z e l i m i t seems t o have b e e n r e a c h e d s t p d ) copper-molybdenum project a t
f o r r o d m i l l s and t h e d e b a t e i s now H i l l s b o r o , New Mexico. This is a
c e n t e r e d on t h e e f f i c i e n c y of l a r g e r s i n g l e - l i n e c i r c u i t and equipment was
diameter b a l l m i l l s . chosen t o minimize c a p i t a l and
 SELECTION OF COMMINUTION CIRCUITS

operating costs. The o p e r a t i n g variation. One of the

e f f i c i e n c y of t h i s m i l l is awaited d i s a d v a n t a g e s is t h a t t h e SAG
f o r comparison w i t h o t h e r m i l l s o f m i l l must be k e p t f u l l o f o r e ,
t h e same diameter. otherwise ball and liner
breakage may r e s u l t . Surges i n
Other cost considerations, throughput a s t h e o r e becomes
everything e l s e being e q u a l , a r e : s o f t e r o r f i n e r c a n r e s u l t and
u n l e s s downstream equipment i s
- P l a n t s with m u l t i - u n i t s i n g l e - o v e r s i z e d , containment problems
s t a g e primary m i l l s a r e more a r e i n e v i t a b l e (15).
c a p i t a l intensive than p l a n t s
with two-stage g r i n d i n g . This Water Supply Source A v a i l a b i l i t y and
is because primary m i l l s r e q u i r e Cost v e r s u s P r o c e s s Requirements.
expensive feeding and ore Water i s t h e normal media for
s t o r a g e systems, g e n e r a l l y w i t h physical beneficiation of ores. Very
more l i n e s i n f i n e c r u s h i n g and few o r e s a r e up-graded i n t h e d r y
screening. However, single- state. However, t h e r e a r e a r e a s i n
s t a g e comminution c i r c u i t s c o s t t h e world where water i s s c a r c e ,
l e s s t o o p e r a t e as o p e r a t i n g expensive, o r n o t a v a i l a b l e a t a l l .
labour is l e s s and maintenance Some o f t h e s e o r e s a r e l o c a t e d n e a r
is lower (21). t h e s e a c o a s t and s e a w a t e r can be
used. With others, dry pre-
- Since pebble m i l l media h a s c o n c e n t r a t i o n i s sometimes p o s s i b l e .
lower d e n s i t y , pebble m i l l s a r e Dry primary g r i n d i n g , w i t h d r y i n g a s
l a r g e r and more expensive f o r n e c e s s a r y , might be followed by d r y
t h e same power a s b a l l m i l l s , magnetic cobbing, o r dry gravity
but the u n i t operating c o s t s a r e concentration. The p r e - c o n c e n t r a t e
usually l e s s (21). is t h e n shipped t o a n a r e a where
water is available for final
- Semi-autogenous m i l l s draw more processing.
power t h a n autogenous m i l l s o f
t h e same s i z e and t h e r e f o r e a r e Dry autogenous mills, ball
l e s s expensive t o i n s t a l l f o r m i l l s , and rod m i l l s have been used.
t h e same throughput. D. J. They r e q u i r e more power, need c l o s e
Barratt ( 13) attempted to temperature and m o i s t u r e c o n t r o l and
demonstrate comparative c a p i t a l require sophisticated dust control
c o s t , o p e r a t i n g c o s t and s p a c e equipment. Many dry grinding
requirements f o r semi-autogenous i n s t a l l a t i o n s a l s o e x i s t where t h e
and conventional c i r c u i t s o v e r a m a t e r i a l cannot be w e t t e d , e.g.
range o f throughputs up t o cement c l i n k e r , t a l c and g o e t h i t i c
72,600 mtpd (80,000 s t p d ) u s i n g d i r e c t s h i p p i n g i r o n o r e s which a r e
typical circuit designs and ground t o p e l l e t i z i n g f i n e n e s s and
equipment s i z e s . While t h i s could never be f i l t e r e d i f t h e y were
paper requires updating to ground wet. These would be p r o c e s s e d
r e f l e c t t h e l a r g e r equipment d r y even i f w a t e r were p l e n t i f u l .
s i z e s c u r r e n t l y i n u s e and
higher power costs, it F i n e grind in^ Concepts. The amount
demonstrates t h e d i f f e r e n c e s i n of regrinding necessary for an
c o s t f o r g r i n d i n g equipment and intermediate concentrate o r a f i n a l
t h e space advantage a t h i g h e r concentrate t o generate additional
throughputs o f f e r e d by semi- " s u r f a c e a r e a " c a n o n l y be developed
autogenous c i r c u i t s . In fact, when t h e f l o w s h e e t i s e s t a b l i s h e d and
the semi-autogenous-ball mill a n up-graded p r o d u c t is a v a i l a b l e f o r
c i r c u i t h a s proved t o be a testing. It might seem t h a t t h i s i s
s u c c e s s f u l and p o p u l a r c h o i c e . a r e l a t i v e l y e a s y assignment because
It h a s a good t o l e r a n c e f o r f e e d r e a l l y o n l y a b a l l m i l l c a n b e used.
 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS

(Recently, in a new copper altitude, e.g. Chilean copper

installation in the southwestern projects. Roughness o f t e r r a i n o r
United S t a t e s , a tower m i l l was i n a c c e s s i b i l i t y may p r e c l u d e t h e u s e
selected for this application. ) o f l a r g e r equipment, e.g. limit-
However, power c a l c u l a t i o n c a n b e a t i o n s o f s p l i t t i n g c r u s h e r frames
misleading. Bond g r i n d a b i l i t y i n d e x and mill shells into Smaller
c a n b e u s e d , b u t extreme c a r e s h o u l d components t o p a s s road bed l o a d i n g s
be taken s i n c e Bond g r i n d a b i l i t y o r r a i l t u n n e l dimensions.
t e s t s r e q u i r e a r a t i o of r e d u c t i o n of
about 6:l t o o b t a i n accurate r e s u l t s Pre-concentration or crushing
(11). S p e c i a l t e s t s w i l l have t o b e p r i o r t o shipment t o a c o n c e n t r a t o r
r u n and some i n t e r p o l a t i o n s made. In o r r e - p r o c e s s i n g p l a n t i s common i n
many i n s t a n c e s jar m i l l s o r Abbey t h e i r o n o r e i n d u s t r y where crushed
m i l l s a r e used and a t i m e / s u r f a c e o r e o r c o n c e n t r a t e is r a i l e d a few
curve is established. This kind o f hundred m i l e s t o a f i n i s h i n g p l a n t on
t e s t m i l l can be calibrated with tidewater. Water quality or
known o r e s and a s p e c i f i c power c a n a v a i l a b i l i t y might r e q u i r e t h a t a d r y
b e determined. Whether t o r u n t h e g r i n d i n g system b e used o r t h a t
r e g r i n d m i l l i n open - o r closed- c h e m i c a l a t t a c k on g r i n d i n g media h a s
circuit depends on the product t o b e avoided. The a v a i l a b i l i t y and
characteristics required and on q u a l i t y o f manpower might d i c t a t e t h e
current practice in similar degree of sophistication i n the
applications. approach to circuit design and
control. C o n s i d e r a t i o n s t h a t may
C o n s i d e r a t i o n s f o r Both Large and a p p l y t o a l a r g e o p e r a t i o n may n o t
Small P l a n t s w i t h Regard t o P l a n t h o l d t r u e f o r a small p l a n t , and i n
L o c a t i o n , S i t e Topography and Layout, each c a s e t h i s becomes a q u e s t i o n of
Accessibility, C l i m a t e and P r e c i p - economics. A small p l a n t is a
i t a t i o n , M a t e r i a l s T r a n s p o r t a t i o n and r e l a t i v e term, i t s t i l l h a s t o b e
Handling, Capital and Operating large enough t o b e economically
Costs, Economical Evaluation and f e a s i b l e , and t h i s may v a r y w i t h many
P a r t s Inventory. Proper f a m i l i a r i - factors, but comminution circuit
z a t i o n with t h e geographic location, d e s i g n c o n s i d e r a t i o n s may a l s o be
climate, physical c h a r a c t e r i s t i c s o f affected. For l a r g e p l a n t s many of
t h e mine s i t e , a c c e s s i b i l i t y and t h e s e r v i c e f u n c t i o n s such a s r o a d s ,
precipitation is paramount when railroads, warehousing, etc., are
designing a comminution plant. p a r t o f t h e b a s i c design without
Whereas t h e l o c a t i o n o f t h e orebody which a l a r g e p l a n t c a n n o t be
cannot be a l t e r e d , t h e p h y s i c a l lay- contemplated. There i s such a t h i n g
o u t o f t h e p r o c e s s p l a n t and e q u i p - a s economics o f s c a l e . For s m a l l e r
ment s e l e c t i o n c a n b e a d a p t e d t o p l a n t s , f a c t o r s s u c h as a c c e s s i b i l i t y
a l l o w a d v a n t a g e t o b e t a k e n o f more o r l o c a t i o n may b e a much more
equitable conditions. c r i t i c a l c o s t consideration. Supply
o f c r i t i c a l items necessary t o d a i l y
For instance under arctic o p e r a t i o n s , such a s s p e c i f i c r e a g e n t s
c o n d i t i o n s a compact p l a n t d e s i g n i n f o r f l o t a t i o n , a v a i l a b i l i t y of proper
one building o f f e r s a n opportunity t o r o d media o r 10-12.7 cm (4-5 i n . )
conserve energy and provide b a l l s f o r semi-autogenous mills may
c o m f o r t a b l e working c o n d i t i o n s , e.g. be decisive factors in circuit
Fox Mine and Arvik. Primary selection, especially if the
c r u s h i n g , l o c a t e d c l o s e t o t h e mine economics of scale have been
which may b e a t a h i g h a l t i t u d e and researched. More o f t e n t h a n n o t ,
subject to avalanches, could be s u p p l y firms w i l l s e t up s p e c i a l
s e p a r a t e d from t h e f i n e c r u s h i n g and o p e r a t i o n s t o s e r v i c e a major mine
grinding plant by underground operation, while small plants do not
conveyor t o a safer p o i n t a t a lower have t h a t k i n d o f l e v e r a g e . The s i z e
 SELECTION OF COMMINUTION CIRCUITS

and number of unit operations occur a s sandstones such a s i n

r e q u i r e d f o r a smaller p l a n t , s a y up Wyoming, Texas, New Mexico and on t h e
t o 4,536 mtpd ( 5 , 0 0 0 s t p d ) , c a n Colorado P l a t e a u . The s a n d s t o n e
i n f l u e n c e c a p i t a l c o s t and o p e r a t i n g g r a i n s a r e e s s e n t i a l l y b a r r e n and c a n
cost significantly when one b e r e l e a s e d by moderate g r i n d i n g from
c o n s i d e r s , a s a n example, t h e s p a c e t h e i n t e r g r a n u l a r cement which i s
and l a b o u r r e q u i r e m e n t s f o r a f i v e uraniferous. T y p i c a l mesh of g r i n d
s h i f t s p e r week v e r s u s a t e n s h i f t s f o r t h e s e o r e s is 80% minus 35 mesh.
p e r week c r u s h i n g p l a n t p r o d u c i n g t h e
same rod o r b a l l m i l l f e e d tonnage. The e a r l y p r o d u c e r s i n Canada
With l a r g e r p l a n t s , equipment is p r o c e s s e d o r e s from t h e Beaverlodge
manufactured t o c o p e w i t h l a r g e r a r e a o f Saskatchewan and from t h e
incremental i n c r e a s e s i n throughput B a n c r o f t and E l l i o t Lake a r e a s o f
and t h e r e is o f t e n less f l e x i b i l i t y Ontario. T h e i r m i l l i n g c i r c u i t s were
i n t h e number o f c r u s h i n g s h i f t s c o n v e n t i o n a l c r u s h i n g and g r i n d i n g i n
o p e r a t e d p e r week. the usual multi-stage fashion.
A 1 t hough the Elliot Lake
One c o n s i d e r a t i o n , which is conglomerates were capable of
o f t e n o v e r r i d i n g , is t h e e f f e c t o f generating pebbles, pebble m i l l i n g
f u t u r e plans f o r p l a n t expansion on was n o t i n c o r p o r a t e d u n t i l much l a t e r
the selection of crushing and d u r i n g p l a n t e x p a n s i o n s e.g. the
g r i n d i n g equipment. For larger Quirke m i l l . Consequently, all
plants, processing l i n e s a r e usually m a t e r i a l was c r u s h e d and ground t o
added whereas w i t h v e r y s m a l l p l a n t s , t h e l i b e r a t i o n s i z e o f t h e uranium
a n i n c r e a s e i n b a l l c h a r g e and m i l l mineral i n t h e matrix. The Madawaska
speed can achieve significant m i l l a t Bancroft incorporated pebble
increases i n throughput. m i l l i n g as p a r t o f its r e a c t i v a t i o n
i n 1978 t o p r o c e s s a p e g m a t i t e o r e .
SPECIFIC SITUATIONS There h a s been a r e c e n t t r e n d
toward t h e u s e o f semi-autogenous
Uranium g r i n d i n g a s a move t o e l i m i n a t e
p o t e n t i a l h a z a r d s o f r a d o n g a s which
The comminution p r a c t i c e s i n t h e is r e l e a s e d i n t o t h e atmosphere
uranium mining i n d u s t r y o f North during t h e crushing process. By
America d i f f e r c o n s i d e r a b l y between g r i n d i n g i n a wet environment w i t h a s
Canada and t h e United S t a t e s . These c o a r s e a f e e d a s p o s s i b l e , r a d o n is
differences a r e primarily a r e s u l t o f dissolved i n water. The o p e r a t i o n a t
v a r i a t i o n s i n o r e t y p e s found i n t h e Beaverlodge pioneered this
two c o u n t r i e s . development in 1964 with the
i n s t a l l a t i o n o f a double-compartment
Canadian o r e s a r e c l a s s e d as m i l l , 5.8 m d i a . x 5.2 m ( 1 9 f t . d i a .
"hard r o c k w and o c c u r a s v e i n s as a t x 17 f t . ) f i t t e d with a c e n t r a l
Beaverlodge, Athabasca B a s i n and t h e peripheral g r a t e discharge. The m i l l
Wollaston Fold i n Saskatchewan o r a s is powered by a 2 , 0 0 0 HP motor,
conglomerates as a t E l l i o t Lake and a c c e p t s a jaw c r u s h e r p r o d u c t ( s e t a t
Agnew Lake i n O n t a r i o . Canadian 152 mm O.S.S. 1, uses 0.75 k g / t
conglomerates exhibit particularly (1.5 l b . / t o n ) of 152 mm (6 inch)
s t r o n g a d h e s i o n which r e q u i r e s t h a t b a l l s and is i n c l o s e d - c i r c u i t w i t h a
the quartz pebbles contained t h e r e i n s t a t i c screen. Other o p e r a t i o n s
have t o b e ground i n o r d e r t o r e l e a s e which have t a k e n a d v a n t a g e of t h i s
the uraniferous values in the c o n c e p t a r e R a b b i t Lake ( f o r m e r l y
cementing medium. Liberation s i z e s Gulf M i n e r a l s o f Canada), which h a s a
of 50% minus 200 mesh a r e common. SAG m i l l - b a l l m i l l c i r c u i t , B l u e w a t e r
(Anaconda M i n e r a l s Co.), Panna Maria
U.S. ores, on t h e o t h e r hand, (Chevron Resources I n c . ) , Church Rock
 DESIGN, INSTALLATION OF COMMINUTIONCIRCUITS

(Kerr McGee Nuclear Corporation), liberation. There are eight

Bear Creek (Rocky Mountain Energy p e l l e t i z i n g operations. These are a t
Co.) and L-Bar (Sohio), a l l of which Butler Taconite, National Steel,
employ single-stage semi-autogenous Hibbing Taconite, Minntac, Eveleth,
grinding in closed-circuit with Minorca, Erie and Reserve.
screens or cyclones.
Reserve and Erie a r e the older
Primary crushing followed by plants and employ rod and b a l l m i l l
impact crushing and single-stage rod circuits. However, of the more
milling t o produce a coarse grind is modern plants t h a t were b u i l t or
practised by other operations i n expanded when autogenous grinding was
Wyoming and New Mexico. Cluff Lake well accepted, three u t i l i z e some
(AMOK, SMDC), Saskatchewan, is using form of autogenous grinding and three
conventional crushing and single- use the conventional rod mill-ball
stage rod milling. The rod m i l l is m i l l approach.
replaced by two-stage b a l l milling by
some operators i n the Grants, New The two newest plants, Hibtac
Mexico area and the fineness of grind ( s t a r t e d 1976) and Minorca ( 19771,
i s dependent upon whether a sandstone use grinding methods that are
or a limestone type ore i s being completely different and yet they are
processed. The Key Lake project i n i n close proximity t o each other.
northern Saskatchewan w i l l employ a The Hibtac flowsheet has single-stage
gyratory crusher, hammermill and autogenous milling while Minorca has
single-stage b a l l m i l l c i r c u i t . a rod mill-ball mill c i r c u i t .

The requirements of governmental Hibtac's evaluation ( 7 ) of the

and industrial health monitoring various flowsheets started by
agencies and labour do and w i l l obtaining a 1,360 m t ( 1,500 ton)
continue t o be f a c t o r s influencing representative bulk sample. The goal
the design of comminution c i r c u i t s was the lowest possible c a p i t a l cost
f o r uranium ores. with the provision t h a t additional
capital could be expended if
Iron operating cost savings returned the
additional capital within three
The comminution p r a c t i c e s i n the years. Prior t o p i l o t testing,
i r o n ore industry a r e some of the laboratory bench scale studies were
more varied. Iron ores can range i n conducted t o indicate t h a t the ore
character from blocky magnetites, l i b e r a t e d a t 80% minus 44 microns.
l i k e the Minnesota taconites, to A 1 terna t i v e flowsheets were
specular hematites, s i m i l a r t o the investigated i n the following order:
Labrador and Quebec ores and t o
weathered ores of goethite or - Rod mill-ball m i l l combination.
limonite which a r e l a t e r i t i c i n t h e i r This conventional taconite
physical behaviour s i m i l a r t o ores f lowsheet was selected a s the
from Venezuela o r Western Australia. base for economic comparisons.
Each p a r t i c u l a r ore type is processed
using c e r t a i n established methods of - Autogenous-ball mill circuit.
comminution. But even here the It showed a 16% lower c a p i t a l
p r a c t i c e s can vary s i g n i f i c a n t l y a s c o s t and a 15% lower operating
can be i l l u s t r a t e d by the p l a n t s i n c o s t compared t o the base case.
Minnesota treating magnetic
taconites. These average 25-35% Fe - Autogenous-pebble m i l l c i r c u i t .
and about 60-70s of the t o t a l is Pebbles were extracted from the
magnetic ore. The ore i s very hard autogenous m i l l . This f lowsheet
and abrasive and must be ground t o gave lower operating costs, but
80-955 minus 44 microns for the capital costs were
 SELECTION OF COMMINUTION CIRCUITS

approximately t h e same a s t h e b u t t h e o p e r a t i n g c o s t was 11%

rod m i l l - b a l l m i l l flowsheet. lower. Again, one should n o t e
However, when compared t o t h e t h a t selection of the single-
autogenous-ball m i l l flowsheet s t a g e flowsheet was n o t based on
the operating cost savings power e f f i c i e n c y b u t on o v e r a l l
payback was more t h a n t h r e e economic c o n s i d e r a t i o n s .
years. During t h e o p e r a t i o n o f
the autogenous-pebble mill I n t h e c a s e o f M i n o r c a v s 2.6
flowsheet, a n i n t e r e s t i n g e f f e c t million l t p y plant, four grinding
was noted. Removal o f 5% o f t h e f l o w s h e e t s were compared: i ) Rod
crude o r e f e e d a s 25-75mm mill-ball m i l l , i i ) Ball mill-ball
pebbles r e s u l t e d i n a 15-202 m i l l , i i i ) Autogenous m i l l - b a l l m i l l ,
increase in the primary and i v ) Autogenous mill-pebble m i l l .
autogenous mill throughput. The economical comparison was done i n
This i n d i c a t e d t h a t a c r i t i c a l g r e a t d e t a i l . It showed t h a t t h e rod
s i z e was p r e s e n t i n t h e m i l l . m i l l - b a l l m i l l c i r c u i t had t h e lowest
c a p i t a l cost. The autogenous-pebble
- Autogenous-ball mill-crusher m i l l flowsheet was lower i n o p e r a t i n g
(ABC) c i r c u i t . It was found c o s t , b u t n o t s i g n i f i c a n t l y lower t o
t h a t by c r u s h i n g approximately j u s t i f y t h e higher c a p i t a l c o s t s .
5%-10% o f t h e c r i t i c a l m a t e r i a l ,
based on crude f e e d r a t e , a 20% Copper and Molybdenum
i n c r e a s e i n throughput could be
attained. It was a l s o found Crushing and g r i n d i n g p r a c t i c e s
t h a t t h e f i n e n e s s o f g r i n d could used i n t h e p r o c e s s i n g o f North
be c o n t r o l l e d by v a r y i n g t h e American copper and molybdenum o r e s
amount and t h e s i z e o f m a t e r i a l have been i n f l u e n c e d o v e r t h e y e a r s
crushed. This f l o w s h e e t had t h e by t h e f o l l o w i n g f a c t o r s :
lowest c a p i t a l c o s t of all
tested. However, t h e s i n g l e -
s t a g e g r i n d i n g c i r c u i t had a
- Ore type: whether t h e o r e is a
low-grade porphyry o r h i g h e r -
much lower o p e r a t i n g c o s t and s o g r a d e massive s u l p h i d e .
the ABC f lowsheet was
eliminated. - Region: whether p l a n t d e s i g n
a l l o w s f o r t h e p r o c e s s i n g of
Single-stage autogenous cir- wet, sticky ores originating
cuits. Liberation characteris- from open p i t s i n a r e a s o f h i g h
t i c s of t h i s ore indicated the rainfall, frozen ore during
possibility t h a t a single-stage prolonged w i n t e r s o r , i n a more
g r i n d i n g c i r c u i t could produce equitable climate, multi-stage
t h e r e q u i r e d c o n c e n t r a t e grade. c r u s h i n g and s c r e e n i n g by t a k i n g
A s i n g l e - s t a g e autogenous m i l l advantage o f t h e o p e r a t i n g c o s t
g r i n d i n g i n c l o s e d - c i r c u i t with maxim t h a t it i s "cheaper t o
wet drum magnets and c y c l o n e s c r u s h t h a n t o grindt1.
r e q u i r e d c o n s i d e r a b l y more power
than any o f t h e o t h e r f l o w s h e e t s - Throughput : whether a
tested. This alternative p a r t i c u l a r concept f o r equipment
generated a 14% lower c a p i t a l s e l e c t i o n and p l a n t d e s i g n a t
c o s t and a 27% lower o p e r a t i n g d i f f e r e n t l e v e l s o f throughput
c o s t compared t o t h e base c a s e , can demonstrate savings in
i n s p i t e of t h e higher u n i t c a p i t a l and o p e r a t i n g c o s t s ,
power consumption. T h i s lower minimize p r o d u c t i o n l o s s e s and
operating cost returned the problems a t s t a r t - u p and show a
i n c r e a s e d c a p i t a l i n 2.7 y e a r s . more a t t r a c t i v e r a t e o f r e t u r n
Compared t o t h e ABC f l o w s h e e t , on investment compared t o a l t e r -
the capital c o s t was h i g h e r natives.
 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS

northern Mexico, for instance,

- Ore c h a r a c t e r i s t i c s : whether s i n g l e - s t a g e b a l l m i l l i n g h a s found
t h e o r e i s hard and a b r a s i v e o r g r e a t e r acceptance than rod m i l l - b a l l
s o f t and p o s s i b l y clayey. m i l l combinations over a span o f Some
40 y e a r s . Even though multi-stage
- T e c h n o l o ~ y : whether t h e r e a r e c r u s h i n g and screening i s r e q u i r e d t o
p r e p a r e b a l l m i l l feed, i t i s claimed
l i m i t a t i o n s placed on equipment
s i z i n g and t h e number of u n i t s t h a t s a v i n g s i n o p e r a t i n g c o s t and
employed by t h e c u r r e n t s t a t e of i n c r e a s e d a v a i l a b i l i t y (up t o 98%)
t e c h n o l o g i c a l development, e.g. can o f f s e t higher capital costs
m i l l s h e l l , head and g e a r design a s s o c i a t e d with t h e e x t r a s c r e e n i n g
o r competent rod l e n g t h . and materials handling capacity
r e q u i r e d f o r p r e p a r a t i o n of a f i n e r
- Power c o s t : whether u n i t power feed. Typical p l a n t s range i n
consumption f o r one concept i s throughput from ASARCO S i l v e r B e l l a t
more o r l e s s i n comparison t o 11,800 mtpd ( 13,000 s p t d ) through t o
a l t e r n a t i v e s and i n t h e l a s t h v a l S i e r r i t a a t 83,400 mtpd (92,000
a n a l y s i s c o n t r i b u t e s toward a stpd). C i t i e s S e r v i c e ' s P i n t o Valley
higher o v e r a l l operating cost. plant u t i l i z e s 5.5 m d i a . x 6.4 m
(18 f t . d i a . x 21 f t . ) b a l l m i l l s i n
- Sampling: whether t h e c o s t s t h e f i r s t i n s t a l l a t i o n of t h i s m i l l
incurred for development, s i z e i n North America f o r such an
application. Throughput i s 43,000
c o l l e c t i o n and t e s t i n g of bulk
samples o f s i g n i f i c a n t o r e t y p e s mtpd (47,500 s t p d ) .
within an orebody can
demonstrate a s a t i s f a c t o r y r a t e Rod m i l l - b a l l m i l l combinations
of r e t u r n on i n v e s t m e n t compared a r e t h e normal choice f o r massive
to alternatives after s u l p h i d e o r e s and, u n t i l 1971, were
c o n s i d e r a t i o n of o t h e r c a p i t a l also selected for large tonnage
costs. porphyry copper and molybdenum o r e s
i n Canada. S i g n i f i c a-n t ~. l a n t sa r e a s
follows: Gibraltar 37,200 mtpd
Until 1967, conventional ( 4 1,000 s t p d ) , Endako 25,400 mtpd
c r u s h i n g and g r i n d i n g had been t h e (28,000 s t p d ) , Brenda 27,200 mtpd
normal c a n d i d a t e f o r p r o c e s s i n g both (30,000 s t p d ) , w i t h exceptions t o
massive s u l p h i d e and porphyry-type single-stage b a l l milling practice i n
copper o r e s , w i t h t h e number o f Arizona being ASARCO Mission
s t a g e s being dependent upon o p e r a t o r 20,400 mtpd (22,500 s t p d ) , ANAMAX
preference and cost analysis. Twin B u t t e s 36,300 mtpd (40,000 s t p d )
Commissioning o f autogenous and semi- and Magma Copper Company I s San Manuel
autogenous c i r c u i t s i n North America
began i n New Mexico i n 1967 and s i n c e
p l a n t 58,000 mtpd (64,000 s t p d ) . The
prime o b j e c t i v e i n designing p l a n t s
t h e n o t h e r p l a n t s have come on s t r e a m to t r e a t t h e low-grade o r e s of
i n B r i t i s h Columbia, Arizona and B r i t i s h Columbia d u r i n g t h e 1960's
Colorado. For t h e purposes o f t h i s was, and s t i l l i s , t o minimize
p a p e r , d i s c u s s i o n o f molybdenum o r e s capital and o p e r a t i n g c o s t s and
w i l l be i n c l u d e d under porphyry-type maximize throughput by i n s t a l l i n g t h e
o r e s , even though t h e y a r e u s u a l l y l a r g e s t p r a c t i c a l p i e c e of equipment
associated with g r a n i t i c stocks. t h e n i n e x i s t e n c e , e.g. 4.1 m d i a .
(13-1/2 f t . ) rod mills and i n t h e
Conventional p r a c t i c e h a s v a r i e d 1 9 7 0 f s , 5.0 m d i a . (16-1/2 f t . ) b a l l
depending upon o p e r a t o r p r e f e r e n c e mills. An added benefit was
and t o some e x t e n t d i f f e r e n c e s can be p r o v i s i o n o f a compact p l a n t s i z e
a s s i g n e d r e g i o n a l boundaries. In t h e which i s important when considering
porphyry copper province of energy and h e a t i n g c o s t s i n a cold
southwestern United States and climate.
 SELECTION OF COMMINUTION CIRCUITS

As o r e g r a d e s continued to m i n e r a l s was a f a c t o r i n t h e
d e c l i n e and u n i t o p e r a t i n g c o s t s t o c h o i c e o f autogenous g r i n d i n g
e s c a l a t e , a t t e n t i o n was turned t o t h e f o r the i n i t i a l operation i n
advantages o f e l i m i n a t i n g secondary- 1967 which processed underground
tertiary crushing and screening o r e (2,700 mtpd) and f o r t h e
p l a n t s through t h e u s e o f autogenous expansion (4,200 mtpd) i n 1973
o r semi-autogenous g r i n d i n g . which processed open p i t o r e .
The operation claimed that
Capital and operating cost autogenous g r i n d i n g produced a
s a v i n g s were s i g n i f i c a n t enough t o f i n e r product f o r f l o t a t i o n by
encourage some o p e r a t o r s t o t a k e t h e reducing t h e coarser f r a c t i o n s .
plunge. Their d e d i c a t i o n h a s ensured The optimum proportion of
that semi-autogenous grinding m a g n e t i t e i n t h e o r e was 20% f o r
circuits, at least in British smooth o p e r a t i o n .
Columbia, can a c h i e v e a v a i l a b i l i t i e s
o f 92% and i n one c a s e (Lornex) 94%. Utah Mines Ltd., Vancouver
In order of commissioning date I s l a n d , B.C. (231, i s l o c a t e d
commencing i n 1967, t h e f o l l o w i n g i n a n a r e a o f high r a i n f a l l , 80-
p l a n t s have been brought on stream: 100 i n c h e s p e r y e a r , which would
UV I n d u s t r i e s , New Mexico 2,700 mtpd make a fine crushing and
(3,000 s t p d ) , Utah Mines Ltd. I s l a n d screening plant difficult to
Copper 29,900 mtpd (33,000 s t p d ) , o p e r a t e on account of clay-
Newmont Mines Ltd
13,600 mtpd
.
(15,000 s t p d ) ,
Similkameen
Lornex
forming m i n e r a l s c o n t a i n e d i n
t h e ore. The s i m p l i c i t y o f
Mininu Corp. Ltd. 43,500 mtpd using primary crushing and
( 48,000 s t p d ) , Cyprus Pima expansion coarse o r e storage t o prepare
12,700 mtpd (14,000 s t p d ) , Climax feed t o t h e grinding c i r c u i t s
Henderson 27,200 mtpd ( 30,000 s t p d ) , was a prime f a c t o r in the
Afton Mines 6,350 mtpd (7,000 s t p d ) , choice. The p l a n t was d e s i g n e d
CYP~US Bagdad 36,300 mtpd for 29,900 mtpd (33,000 s t p d )
(40,000 s t p d ) , Highmont Mining Corp. using single-stage autogenous
22,700 mtpd (25,000 s t p d ) and grinding. I n i t i a l production
Quintana Minerals Corp. Hillsboro, achieved l e v e l s o f h a l f t o two-
N.M. 13,600 mtpd (15,000 s t p d ) . The t h i r d s o f designed c a p a c i t y . It
l a s t operation l i s t e d has t h e f i r s t was known t h a t t h e Bond work
i n s t a l l a t i o n o f a 5.5 m d i a . x 8.5 m index v a r i e d from 15.5 t o 25.0
(18 f t . d i a . x 28 f t . ) b a l l m i l l f o r depending upon o r e t y p e and t h a t
secondary g r i n d i n g o f a SAG m i l l the abrasion index for the
product. Cyprus Thompson Creek a t a n d e s i t e o r e t y p e was 0.4894,
22,700 mtpd (25,000 s t u d ) is hence t h e c h o i c e o f autogenous
scheduled f o r commissioning i n 1983. g r i n d i n g and t h e a v o i d a n c e o f
Bagdad and Highmont a r e o p e r a t i n g u s i n g s t e e l media. The c r u s h e d
autogenous-ball mill-crusher (ABC) run-of -mine ore contained on
circuits. a v e r a g e 75% a n d e s i t e and 10-15s
of p l u s four-inch m a t e r i a l . In
Other f a c t o r s which i n f l u e n c e d contrast, feed t o t h e p i l o t
t h e d e c i s i o n t o u s e autogenous o r plant over a period o f ten
semi-autogenous g r i n d i n g were, for months was 10,000 tons of
s e l e c t e d o p e r a t i o n s and a t t h e r i s k b r e c c i a , a l t e r e d porphyry w i t h
o f s i m p l i f i c a t i o n and omission: some c l a y , l e s s f r a c t u r i n g and
containing from 40-605 plus
- UV I n d u s t r i e s I n c . , F i e r r o , New four-inch rock. Consequently,
Mexico (221, processed a owing t o the deficiency of
s u l p h i d e copper o r e c o n t a i n i n g c o a r s e rock i n t h e m i l l f e e d ,
magnetite and g a r n e t . The high t h e change t o semi-autogenous
specific gravity of these grinding was authorized
 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS

progressively until all six by b a l l m i l l i n g o f f e r e d t h e b e s t

l i n e s had been c o n v e r t e d and a r e s u l t s with regard t o grinding
comparison with autogenous media consumption.
g r i n d i n g had b e e n made. The
m i l l s e v e n t u a l l y c o n t a i n e d 7-69 Upon commissioning, s t e e l b a l l s
b a l l c h a r g e by volume, t h e power were added u n t i l a 6-82 b a l l
consumption decreased and c h a r g e by volume was reached and
throughput increased t o designed b a l l consumption was 0.25 k g / t
capacity. Addition o f t h r e e (0.5 l b . / t o n ) o f feed. This
b a l l m i l l s i n 1973 t o r e g r i n d consumption was twice that
p a r t o f t h e primary cyclone predicted i n t h e p i l o t plant.
underflow resulted in a
p r o d u c t i o n i n c r e a s e t o a nominal The importance o f t a k i n g s t e p s
34,400 mtpd (38,000 s t p d ) and t o blend o r e t y p e s h a s been
a v e r a g e power consumption o f documented (26) with
22.4 kw-hr./ton. observations t h a t blending can
reduce b a l l consumption and
Lornex Mining C o r p o r a t i o n Ltd., m i l l i n g r a t e f l u c t u a t i o n s and
Highland Valley, B. C. can contribute to higher
( 2 4 , 25, 2 6 ) , conducted pilot t h r o u g h p u t s , e s p e c i a l l y when t h e
p l a n t t e s t s on 20,000 t o n s o f proper load sharing balance
o r e over a period o f nine between primary and secondary
months. Alternative c i r c u i t s c i r c u i t s i s maintained. The
i n v e s t i g a t e d were: single-stage o p e n i n g s i n t h e primary m i l l
ball milling, single-stage grates are a significant factor
autogenous, autogenous ( semi- in this balance and are
autogenous) and s e c o n d a r y b a l l eventually selected through
milling, and a r o d m i l l - b a l l t r i a l and e r r o r , a s is t h e l i n e r
m i l l combination. Bond work m a t e r i a l and its c o n f i g u r a t i o n .
i n d e x ranged from 13 t o 22. I n t h e absence o f blending,
Lornex recommend t h a t i n s t a l l e d
S i n g l e - s t a g e b a l l m i l l i n g was power on the primary m i l l
discounted because of the exceeds the expected design
p r e s e n c e o f f a u l t gouge mud horsepower by 25% t o a l l o w f o r
seams which would h i n d e r t h e power f l u c t u a t i o n s .
o p e r a t i o n o f a f i n e c r u s h i n g and
screening p l a n t i n producing a Lornex e s t i m a t e t h a t working
f i n e b a l l m i l l feed. c a p i t a l f o r t h e commissioning
period should allow f o r t h e
Single-stage autogenous g r i n d i n g possibility of the plant
was r u l e d o u t b e c a u s e o f wide operating at 50% o f rated
f l u c t u a t i o n s i n power consump- capacity f o r t h e f i r s t three
tion. months, 60% f o r t h e n e x t t h r e e
months and 100% t h e r e a f t e r (25).
Rod m i l l i n g f o l l o w e d by b a l l
m i l l i n g g a v e a s t e e l consumption
of 0.47kg/t (0.951b./ton) Newmont Mines Ltd., Similkameen,
which was c o n s i d e r e d u n a c c e p t - B.C. (25, 2 7 ) , p r o c e s s e s two
able. porphyry c o p p e r o r e s c o n t a i n i n g
bands o f h o r n f e l s with Bond work
Autogenous g r i n d i n g f o l l o w e d by i n d e x r a n g i n g from 22.8 t o 30.3.
b a l l m i l l i n g reduced throughput I t was e s t i m a t e d t h a t a rod
f l u c t u a t i o n s and power consump- m i l l - b a l l m i l l combination would
tion. consume 16-1 7 kw-hr/ton and
1.1 k g / t (2.2 l b . / t o n ) g r i n d i n g
Semi-autogenous g r i n d i n g f o l l o w e d media. Also, a requirement f o r
 SELECTION OF COMMINUTION CIRCUITS

a compact p l a n t s i t e i n a n a r e a reduce c r i t i c a l s i z e . Whereas

o f s t e e p t e r r a i n meant t h a t c a p i t a l c o s t s were s i m i l a r , t h e
autogenous o r semi-autogenous operating cost for the
g r i n d i n g deserved c o n s i d e r a t i o n . autogenous alternative was
e s t i m a t e d t o b e 65% o f t h e c o s t
The p i l o t p l a n t i n v e s t i g a t i o n i n c u r r e d by f i n e c r u s h i n g and
covered t h e f o l l o w i n g a l t e r - b a l l milling. The f o l l o w i n g
n a t i v e s u s i n g o r e from under- criteria was set for the
ground development: s e l e c t i o n of autogenous g r i n d i n g
a s s i s t e d by a c r u s h e r :
i) Single-stage autogenous
g r i n d i n g t o produce a minus - lowest estimated operating
60 mesh f i n i s h e d p r o d u c t . cost

ii) Primary a u t o g e n o u s g r i n d i n g - e a s e w i t h which t h e g r i n d

t o produce a p r o d u c t s u i t a - c o u l d b e c o n t r o l l e d by a
b l e f o r pebble milling. crusher f o r reduction o f
critical size
i i i ) , Single-stage autogenous
g r i n d i n g t o produce a minus - ease with which the
60 mesh f i n i s h e d p r o d u c t selected equipment and
with a crusher t o reduce plant size f i t t e d into the
trommel o v e r s i z e t o minus selected plant s i t e
25 mm.
- comparable capital cost
iv) Primary a u t o g e n o u s g r i n d i n g estimate to that for
to produce a product single-stage b a l l milling.
s u i t a b l e f o r pebble m i l l i n g
with a crusher t o reduce The p l a n t was d e s i g n e d t o p r o -
trommel o v e r s i z e t o minus c e s s 13,600 mtpd ( 1 5 , 0 0 0 s t p d )
25 mm. with three l i n e s i n t h e grinding
c i r c u i t , e a c h r a t e d a t 218 mtph
v) Single-stage semi-auto- (240 s t p h ) . I n i t i a l production
genous g r i n d i n g w i t h two i n t h e a u t o g e n o u s mode was n o t
l e v e l s of b a l l a d d i t i o n , s u c c e s s f u l s i n c e power consump-
227 kg and 453 kg. t i o n was h i g h , 49 kw-hr./ton in
No. 1 m i l l , and t h r o u g h p u t was
Preliminary t e s t i n g o f a l t e r n a - one t h i r d o f t h e d e s i g n e d r a t e .
t i v e s narrowed o p t i o n s t o flow- A f t e r t h r e e months* o p e r a t i o n ,
s h e e t s i i i ) and v ) ( w i t h 453 k g s t e e l b a l l s were added t o e a c h
of balls). Analysis o f r e s u l t s m i l l and t h r o u g h p u t i n c r e a s e d t o
showed t h a t t h e semi-autogenous t h e designed r a t e . Power con-
c i r c u i t c o u l d p r o c e s s a b o u t 3% sumption was a b o u t 2 4 kw-hr.
more t h r o u g h p u t f o r t h e same /ton, ball consumption was
power consumption and g r i n d i n 0.75 k g / t (1.5 l b . / t o n ) and t h e
t h e product b u t a t a c o s t o f b a l l c h a r g e by volume a v e r a g e d
0.42 k g / t (0.84 l b . / t o n ) g r i n d - 7%. The c y c l o n e o v e r f l o w s i z i n g
i n g media. Comparative c a p i t a l was 63.2% minus 200 mesh
and operating costs were compared to 75.4% with
estimated f o r a p l a n t capacity autogenous grinding.
of 18,100 mtpd (20,000 s t p d )
using e i t h e r single-stage b a l l Expansion o f t h e p l a n t t o t r e a t
milling or single-stage 19,950 mtpd (22,000 s t p d ) was
autogenous with a c r u s h e r t o a u t h o r i z e d i n 1974 and was
 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS

accomplished by i n s t a l l i n g two on t h e e x t r a c a p i t a l c o s t f o r
b a l l m i l l s i n closed-circuit the crusher and associated
with cyclones t o regrind a conveyors was e s t i m a t e d t o be
c o a r s e r p r o d u c t from t h e semi- l e s s t h a n one y e a r . Additional
autogenous c i r c u i t s . cost benefits anticipated are
reduced maintenance c o s t f o r
The r e a s o n s f o r c o n v e r s i o n t o l i n e r s and pumps, etc. and
semi-autogenous g r i n d i n g l i e i n increased a v a i l a b i l i t y .
t h e f a c t t h a t c o a r s e r o c k , 20-
23 cm i n s i z e , d i d n o t s u r v i v e Successful operation of an
l o n g i n t h e p r i m a r y m i l l s and s o autogenous-crusher circuit is
accumulation o f mid-size and dependent upon consistent
c r i t i c a l s i z e m a t e r i a l occurred a v a i l a b i l i t y o f c o a r s e competent
which loaded the mill and r o c k t o a c t a s g r i n d i n g media.
reduced i t s c a p a c i t y r a t i n g . The inherent risks incurred
The s i z e o f t h e mine d i c t a t e d through the nature of the
t h a t p r o d u c t i o n came from one orebody and v a r i a t i o n s i n r o c k
s h o v e l and t h e r e f o r e b l e n d i n g o f t y p e , which c o u l d a f f e c t t h e
ore types t o ensure a c o n s i s t e n t a b i l i t y t o produce such media,
f e e d , which i s n e c e s s a r y f o r c a n be reduced by having t h e
e f f i c i e n t autogenous operation, capability to operate Semi-
could not be a t t a i n e d . In the autogenously. With two p a r a l l e l
last analysis, two-stage l i n e s a t Highmont, each c a p a b l e
grinding offers f l e x i b i l i t y f o r of processing 11,340 mtpd
ores of variable hardness i n (12,500 s t p d ) and designed t o
that distribution of mill o p e r a t e i n e i t h e r mode, t h e
loadings can be a d j u s t e d t o s u i t opportunity for comparative
conditions. testing exists. To d a t e ,
however, t h e p l a n t h a s been
- Highmont Mining Corporation, operating at the designed
Highland V a l l e y , B.C., c o n d u c t e d throughput following a s h o r t
p i i o t p l a n t t e s t s i n 1970 t o tune-up p e r i o d o f s i x months.
i n v e s t i g a t e a u t o g e n o u s and semi-
autogenous grinding with I n summary, t h e d e s i g n o f l a r g e
variations in ball loading, tonnage grinding circuits for
coupled with secondary ball p r o c e s s i n g porphyry copper-molybdenum
milling for preparation of o r e s should account f o r t h e t e s t i n g
f l o t a t i o n feed. o f d i f f e r e n t o r e types within an
orebody and t h e i r e f f e c t on power
The e f f e c t o f o p e r a t i n g t h e consumption, media consumption, l i n e r
primary m i l l a u t o g e n o u s l y i n m a t e r i a l wear r a t e s , throughput r a t e s
closed-circuit with a cone and p r o d u c t s i z i n g . The d e s i g n
c r u s h e r was a l s o s t u d i e d . In s h o u l d be s e l e c t e d s o t h a t t h e
these tests the critical a n t i c i p a t e d p l a n t tune-up h a s been
o v e r s i z e from t h e m i l l d i s c h a r g e w e l l planned i n o r d e r t o p r o c e s s o r e
was s c r e e n e d o u t and c r u s h e d t o o f known c h a r a c t e r i s t i c s and s o
p a s s 13 mm. From t h e s e s t u d i e s , minimize t h e p e r i o d and working
i t was e s t i m a t e d i n 1981 ( 2 8 ) capital required to attain the
t h a t an operating c o s t saving o f designed r a t e . Cash flow l o s t a t t h e
Can. $0.25/st was p o s s i b l e beginning o f a p r o j e c t ' s l i f e can
through elimination of the n e v e r b e r e c a p t u r e d i n terms of
p r i m a r y m i l l b a l l c h a r g e and a p r e s e n t v a l u e . Such p l a n t s should b e
r e d u c t i o n i n l i n e r wear compared d e s i g n e d w i t h some f l e x i b i l i t y where
to predictions for semi- i t i s known t h a t o r e c h a r a c t e r i s t i c s
a u togenous grinding. The c a n change. This is i n contrast t o
payback a r i s i n g from t h i s s a v i n g experience with taconite ores.
 SELECTION OF COMMINUTION CIRCUITS 21

F l e x i b i l i t y i n l o a d s h a r i n g between and N a n i s i v i k ( l e a d ) h a v e u n i t c e l l s
primary and s e c o n d a r y s t a g e s o f i n t h e g r i n d i n g c i r c u i t which a c c e p t
g r i n d i n g and t h e u s e o f ABC o r SAG as f e e d t h e combined d i s c h a r g e from
options are examples. One an open-circuit rod m i l l and a
c o n s i d e r a t i o n , which t o d a t e h a s closed-circuit b a l l m i l l (29, 30).
a f f e c t e d p r o d u c e r s i n t h e United At Minera Real de Angeles,
S t a t e s more t h a n i n w e s t e r n Canada, S.A. d e C.V. in Mexico, two
h a s been t h e l i n k w i t h a d o m e s t i c 4.57 m d i a . x 6.1 m ( 1 5 f t . d i a . x
smelter. The fixed rate of 2 0 f t . ) r o d m i l l s were i n s t a l l e d f o r
concentrate production usually a 10,800 mtpd ( 11,900 s t p d ) p l a n t
r e q u i r e d by such s m e l t e r s and which t r e a t i n g l e a d - z i n c - s i l v e r o r e and a r e
i s s u p p l i e d by a n o p e r a t i n g u n i t believed t o be t h e l a r g e s t i n current
w i t h i n t h e same c o r p o r a t e s t r u c t u r e u s e on s u c h o r e s .
normally d i c t a t e s t h a t o r e p r o c e s s i n g
r a t e s be f i x e d . Canadian p r o d u c e r s A t t h e p r e s e n t time, it is
in British Columbia have more believed t h a t t h e r e a r e no operations
f l e x i b i l i t y i n t h a t , during periods in North America which employ
o f h i g h world demand, they can a u t o g e n o u s , semi-autogenous o r p e b b l e
maximize throughput and have t o b e mills. Research, however, h a s been
prepared f o r t h a t event a t s h o r t conducted for potential projects
notice. The u s e o f semi-autogenous (18).
grinding has demonstrated this
f l e x i b i l i t y t o a g r e a t e r degree than Gold, S i l v e r and Mercury
c o n v e n t i o n a l c r u s h i n g and g r i n d i n g ,
though s u c h a s t a t e m e n t s h o u l d t a k e The p r o c e s s i n g o f gold and
i n t o a c c o u n t t h e d i f f e r e n c e s beween s i l v e r o r e s i n North America h a s
hard and s o f t o r e s as e x p e r i e n c e d , traditionally made use of
for instance, a t Gibraltar. c o n v e n t i o n a l c r u s h i n g and g r i n d i n g
methods. Rod m i l l - b a l l m i l l , two-
Lead and Zinc stage b a l l m i l l o r single-stage b a l l
m i l l c i r c u i t s a r e t o b e found. Tube
Modern p r a c t i c e i n North America m i l l s are s t i l l used i n some o f t h e
f o r c r u s h i n g and g r i n d i n g l e a d - z i n c o l d e r mills, e. g. Pamour P o r c u p i n e
or copper-lead-zinc ores is and Dome Mines, O n t a r i o ( 3 1 ) . In
c o n v e n t i o n a l w i t h v a r i a t i o n s on a each c a s e where g o l d is formed e i t h e r
theme. Mineralogy and g r a i n s i z e as c o a r s e n a t i v e p i e c e s o r i n c o a r s e -
p l a y a l a r g e p a r t i n t h e development g r a i n e d s u l p h i d e s , i t i s r e c o v e r e d by
of flowsheets, p a r t i c u l a r l y with t h e gravity concentration i n t h e grinding
more complex o r e s . c i r c u i t i n a d d i t i o n t o recovery of
f i n e r v a l u e s by c y a n i d a t i o n . Jigs
S i n c e f l o t a t i o n is t h e a c c e p t e d are the most common types of
method of concentration, most equipment u s e d and are u s u a l l y p l a c e d
operations s t r i v e t o f l o a t lead t o intercept the b a l l m i l l discharge
m i n e r a l s from a s c o a r s e a f e e d a s prior to classification. One
p o s s i b l e t o a v o i d s l i m i n g and r e l y on exception t o t h i s p r a c t i c e is a t
regrind stages to upgrade Homestake, Lead, South Dakota, where
concentrates f o r e i t h e r lead, zinc o r r i f f l e d l a u n d e r g o l d t r a p s are used.
both. Some Canadian o p e r a t i o n s , e.g.
United Keno H i l l , Kidd Creek and Lime and sodium c y a n i d e a r e
Hudson Bay M i n i n ~ and S m e l t i n g a t almost universally used in the
F l i n Flon, f i n d i t n e c e s s a r y t o dissolution of precious metals.
conduct primary copper or lead There is c o n s i d e r a b l e a d v a n t a g e i n
f l o t a t i o n and r e g r i n d t h e t a i l i n g a d d i n g them t o t h e g r i n d i n g c i r c u i t
prior to secondary ( scavenger) s i n c e high d i s s o l u t i o n r a t e s usually
f l o t a t i o n followed by z i n c f l o t a t i o n . r e s u l t from a g i t a t i o n and o x y g e n a t i o n
Two o p e r a t i o n s , Lake D u f a u l t ( c o p p e r ) o f t h e pulp during t h e grinding
 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS

action. c r u s h i n g and s c r e e n i n g p l a n t .

Semi-autogenous milling of Tungsten, Tin, Chromium, Tantalum and

p r e c i o u s m e t a l s and mercury o r e s h a s Niobium
been p r a c t i c e d s i n c e 1975 i n t h e
U.S.A. I n s t a l l a t i o n s a t McDermitt, The minerals wolframite,
Nevada ( 3 2 ) and DeLamar, I d a h o ( 3 3 ) scheelite, cassiterite, chromite,
were d e s i g n e d t o p r o c e s s o r e s o f h i g h t a n t a l i t e and p y r o c h l o r e a r e n o t o n l y
c l a y c o n t e n t and s o c i r c u m v e n t t h e f r i a b l e compared t o q u a r t z b u t t h e y
problems a s s o c i a t e d with crushing a r e a l s o dense. Specific gravities
such o r e s in, f i n e crushing p l a n t s . range from a maximum 7.9 for
Both o p e r a t i o n s have one 5.48 m w o l f r a m i t e t o a minimum o f 4.2 f o r
d i a . x 2.75 m (18 ft. dia. x 9 f t . ) pyrochlore. Two properties,
Cascade m i l l which was d e s i g n e d t o f r i a b i l i t y and g r a v i t y , govern t h e
o p e r a t e semi-autogenously. d e s i g n o f g r i n d i n g and c l a s s i f i c a t i o n
c i r c u i t s f o r t h e p r e p a r a t i o n of feed
A t t h e McDermitt mercury mine, a to subsequent concentration
s i l i c e o u s " o p a l i t e n r o c k is q u a r r i e d processes. These p r o c e s s e s u s u a l l y
s p e c i f i c a l l y f o r u s e as g r i n d i n g employ g r a v i t y methods, f l o t a t i o n o r
media r e p l a c i n g steel b a l l s . Whereas a combination o f both.
formerly the mill operated
autogenously, s t e e l b a l l s a r e now The principal objective in
added t o cope w i t h d i f f e r e n t r o c k p r o c e s s i n g o r e s o f t h e s e m i n e r a l s is
characteristics. t o eliminate slime generation other
t h a n by n a t u r a l d e g r a d a t i o n . Removal
A t t h e DeLamar S i l v e r Mine t h e of liberated mineral from the
o r e c o n t a i n s up t o 30% o f c l a y g r i n d i n g c i r c u i t a s soon a s i t is
minerals as well as varying g e n e r a t e d is o f t h e f i r s t importance,
q u a n t i t i e s o f cherty material having since slimes (generally classed a s
a work i n d e x o f 2 0 p l u s . They p r e f e r minus 10 micron m a t e r i a l ) c a n reduce
t o o p e r a t e a u t o g e n o u s l y on a b l e n d o f r e c o v e r y o f v a l u e s r e g a r d l e s s of
h a r d and s o f t o r e , b u t i f t h r o u g h p u t whether g r a v i t y o r f l o t a t i o n methods
decreases, s t e e l b a l l s o r coarse a r e used. Flotation practice for
lumps from t h e s t o c k p i l e a r e added. t h e s e m i n e r a l s , which is becoming
A v i s c o s i t y i n h i b i t o r is added as more a t t r a c t i v e a s lower g r a d e o r e s
r e q u i r e d t o t h e SAG m i l l i n o r d e r t o a r e b e i n g c o n s i d e r e d , d i f f e r s from
maintain a higher pulp density i n t h e that for sulphide ores because
c y c l o n e o v e r f l o w t h a n would o t h e r w i s e s e l e c t i v i t y is more dependent upon
b e obtainable with clayey ores. the types of reagents used.
Consumption of collectors and
The E s c a l a n t e S i l v e r Mine o f modifying a g e n t s , p a r t i c u l a r l y a c i d s ,
Ranchers E x p l o r a t i o n and Development i n c r e a s e s a s t h e p r o p o r t i o n of s l i m e s
C o r p o r a t i o n i n S.W. Utah was d e s i g n e d increases. For this reason,
t o u s e semi-autogenous g r i n d i n g on desliming ahead of f l o t a t i o n is
t h e b a s i s o f r e a l i z i n g c a p i t a l and n e c e s s a r y and c o n s e q u e n t l y any a c t i o n
operating c o s t savings. The o r e i s t a k e n t o r e d u c e p r o d u c t i o n of s l i m e s
competent h a v i n g a work i n d e x i n t h e contributes to increased metal
r a n g e o f 15.0 and is v e r y s i l i c e o u s . recovery. T h e r e f o r e , t h e u s e of
Plant capacity is 450 mtpd cyclones alone and other wet
(500 s t p d ) . P l a n t d e s i g n was v e r y c l a s s i f e r s is t o b e avoided s i n c e
s e n s i t i v e t o l o c a t i o n with regard t o concentration of liberated heavy
r o c k c o n t o u r s and i n c o m p e t e n t s o i l s . minerals in underflow or sand
Consequently, a compact l a y o u t was p r o d u c t s which a r e r e c y c l e d t o t h e
chosen which t o o k a d v a n t a g e o f sound g r i n d i n g c i r c u i t i s i n e v i t a b l e and
b e d r o c k , minimum o p e r a t i n g l a b o u r and r e s u l t s i n overgrinding. Consequen-
t h e d e l e t i o n o f a secondary-tertiary t l y , screens a r e almost universally
 SELECTION OF COMMINUTION CIRCUITS

used t o c l o s e such g r i n d i n g c i r c u i t s ignored.

i n o r d e r t o remove v a l u e s a c c o r d i n g
t o liberation size. Most of the scheelite is
r e c o v e r e d by g r a v i t y and t h e t a i l i n g
The operations of Canada is reground i n a b a l l m i l l p r i o r t o
Tungsten M i n i n ~ C o r p o r a t i o n Limited r e c o v e r y o f r e m a i n i n g s c h e e l i t e and
i n t h e Northwest Territories of c o p p e r s u l p h i d e s by f l o t a t i o n .
Canada i s a f i n e example which
i l l u s t r a t e s most o f t h e f o r e g o i n g A t Tantalum Mining C o r p o r a t i o n
points. The o r e c o n t a i n s s c h e e l i t e o f Canada Limited, B e r n i c Lake,
in iron and copper sulphides, Manitoba ( 3 4 ) , t h e o r i g i n a l g r i n d i n g
l i m e s t o n e and pyroxene. c i r c u i t consisted o f a single-stage
r o d m i l l i n c l o s e d - c i r c u i t w i t h DSM
The crushing plant is s c r e e n s a t t h e head o f a n a l l - g r a v i t y
conventional three-stage w i t h jaw concentrator. Another s m a l l e r r o d
c r u s h e r , s t a n d a r d c o n e c r u s h e r and m i l l was a v a i l a b l e as a r e g r i n d m i l l .
s h o r t head cone c r u s h e r w i t h p r i m a r y Over t h e y e a r s , t h e o r e grade
and secondary s c r e e n s . The g r i n d i n g d e c r e a s e d and t h e t a n t a l u m m i n e r a l s
c i r c u i t c o n s i s t s o f two-stage rod became more f i n e l y d i s s e m i n a t e d . The
m i l l i n g with c y c l o n e s and s c r e e n s primary r o d m i l l was c o n v e r t e d t o a
c l o s i n g t h e second s t a g e . The g r a t e d i s c h a r g e b a l l m i l l and a
primary m i l l is i n o p e n - c i r c u i t and middling regrind ball mill was
d i s c h a r g e s i n t o a c y c l o n e f e e d pump i n s t a l l e d t o t a k e up t o 25% of t h e
box t o g e t h e r w i t h t h e s e c o n d a r y m i l l f e e d a s sand t a b l e m i d d l i n g s . It is
discharge. Cyclone u n d e r f l o w is i m p o r t a n t i n s u c h c i r c u i t s t o remove
s i z e d on t r o m e l s c r e e n s f i t t e d w i t h tramp metal and a b r a d e d i r o n p r i o r t o
50 mesh c l o t h . Screen o v e r s i z e concentration i n order t o maintain
c o n s t i t u t e s feed t o t h e s e c o n d a r y c o n c e n t r a t e grades.
mill. Most of t h e power used i n t h e
g r i n d i n g c i r c u i t is a p p l i e d t o t h e The Niobec I n c . c o n c e n t r a t o r a t
primary rod m i l l (450 HP) w i t h 250 HP St. Honore, Quebec, Canada ( 3 4 ) ,
t o t h e secondary mill. This employs a c o n v e n t i o n a l r o d m i l l - b a l l
arrangement is t h e r e v e r s e o f what mill circuit using DSM screens
might b e expected, b u t i t e n s u r e s instead o f cyclones t o c l o s e t h e b a l l
t h a t power i s a p p l i e d i n t h e first m i l l circuit. Rod m i l l f e e d is
stage t o achieve p a r t i a l l i b e r a t i o n prepared by open-circuit crusher
of s c h e e l i t e a t a b o u t 50% minus 6 5 without any surge capacity in
mesh before sliming becomes a between. C o n c e n t r a t i o n by f l o t a t i o n
The c h o i c e o f a smaller follows desliming i n cyclones.
a rod m i l f o r t h e second
s t a g e ens;&--rn r e s i d e n c e time i n L a t e r i t e s ( N i c k e l , Aluminum, e t c . )
t h e m i l l i s s h o r t and c r e a t i o n o f
slimes i s minimized. Finished L a t e r i t e s v a r y w i d e l y from one
l i b e r a t i o n s i z e i s o f t h e o r d e r of l o c a t i o n t o a n o t h e r b u t s h a r e many
100 mesh. common c h a r a c t e r i s t i c s which are o f
i n t e r e s t t o t h e comminution e n g i n e e r .
An i n t e r e s t i n g f e a t u r e i n t h e Laterites are weathered ores
c a l c u l a t i o n o f power f o r t h e p r i m a r y containing a high percentage of
s t a g e is t h a t , with a r a t i o o f ultra-fines, usually with high
r e d u c t i o n o f 40:l and t h e e x p e c t e d amounts o f m o i s t u r e ( b o t h s u r f a c e and
low power e f f i c i e n c y , t h e power combined) and w i t h v a r i o u s q u a n t i t i e s
requirement and product size of s o l i d rock inclusions. Such r o c k
d i s t r i b u t i o n are e x a c t l y as would b e is e i t h e r r e j e c t e d o r processed
p r e d i c t e d from s t a n d a r d c a l c u l a t i o n s depending o n i t s m i n e r a l c o n t e n t .
p r o v i d e d t h e high r a t i o o f r e d u c t i o n Even i f t h e s e b o u l d e r s are d i s p o s e d
f a c t o r f o r rod m i l l i n g , EF6, i s of, t h e y may s t i l l h a v e t o b e
24 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS

screened, crushed, scrubbed o r d r i e d c a n b e a problem. To s c r e e n on 9 mm,

to facilitate handling and to t h e o r e i s f i r s t d r i e d t o a b o u t 5%
maximize m i n e r a l r e c o v e r y . moisture.

The s t i c k y n a t u r e o f t h e o r e i s
t h e main c o n s i d e r a t i o n when d e s i g n i n g ACKNOWLEDGEMENT
crushing and s c r e e n i n g f a c i l i t i e s .
One p l a n t ( 3 5 ) u s e s w o b b l e r f e e d e r s The a u t h o r s wish t o t h a n k t h e
a n d a r u b b l e r , which is a t u m b l i n g respective managements of Dravo
autogenous mill fitted with E n g i n e e r s a n d C o n s t r u c t o r s a n d Wright
p e r i p h e r a l g r a t e d i s c h a r g e s a n d low E n g i n e e r s Limited f o r p e r m i s s i o n t o
lifters. This design avoids breaking p r e p a r e t h i s paper. The s t a f f
the boulders and cleans their assistance required for its
s u r f a c e s t o release h i g h e r g r a d e production is g r e a t l y appreciated.
fines for processing. Residual
boulders are d i s c a r d e d t o waste
through the open-ended discharge REFERENCES
trunnion.
1. F r o h l i n g , E.S. a n d Lewis, F.M.,
F a c t o r s which i n f l u e n c e g r i n d i n g F e a s i b i l i t y Study, Chapter 1,
plant design depend on product M i n e r a l P r o c e s s i n g P l a n t Design,
r e q u i r e m e n t s a n d are d i c t a t e d by 2nd Edition, Mular , Bhappu,
subsequent processing needs. Nickel- Editors.
bearing laterites, employing
p y r o m e t a l l u r g i c a l recovery methods, 2. Lewis, F.M., Coburn, J.L. and
d o n o t h a v e t o b e ground. For Bhappu, R.B., Comminution: A
hydrometallurgical processing, Guide t o S i z e - R e d u c t i o n System
g r i n d i n g is done d r y i n b a l l m i l l s . Design, Mining Engineering,
Drying o f t h e material t o w i t h i n 2 . 0 September 1976 and November
to 2.5% surface moisture is 1976.
necessary. Proper design f o r air
sweeping t h e m i l l , d u s t c o l l e c t i o n , 3. Coleman, R. L. , Metallurgical
m i l l a i r temperature c o n t r o l and c h a t Testing Procedures, Chapter 9,
removal have t o be g i v e n s p e c i a l M i n e r a l P r o c e s s i n g P l a n t Design,
consideration. Material which is t o o 2nd Edition, Mular , Bhappu,
dry (i.e. less t h a n 2.0% s u r f a c e Editors.
moisture) can be d i f f i c u l t t o control
when w i t h d r a w i n g from b i n s . 4. Sinclair, A.J., Sampling a
Mineral Deposit f o r F e a ~ i b i l J ~ t y
In the aluminum industry, Studies and eta-Mica1
b a u x i t e is f i r s t crushed and t h e n Testing, Chamr , Mineral
ground wet i n b a l l m i l l s u s i n g t h e P r o c e s s i n g ' P l a n t Design, 2nd
return caustic liquor from the E d i t i o n , Mular, Bhappu, E d i t o r s .
e v a p o r a t o r s as t h e l i q u i d medium.
5. Smith J r . , P.R. and B u t t s , G.E.,
Limonitic o r g o e t h i t i c i r o n o r e s Design o f M i n e r a l P r o c e s s i n g
a r e processed i n t o d i r e c t shipping Flowsheet, Case H i s t o r y , C h a p t e r
lump o r e o r s i n t e r f e e d fines. 42, Mineral Processing P l a n t
Proper selection of screens and Design, 2nd Edition, Mular,
c r u s h e r s and c a r e f u l design o f t h e Bhappu, E d i t o r s .
material h a n d l i n g components ( b i n s ,
transfer points) is of utmost 6. Rowland J r . , C.A., Pilot-Plant
i m p o r t a n c e . The o r e s o f V e n e z u e l a a t Data f o r t h e Design o f P r i m a r y
Ferro-Minera O r i n o c o are s c r e e n e d a n d Autogenous a n d Semi-Autogenous
crushed i n cone crushers. In the ~ i l l i , CIM B u l l e t i n , November
r a i n y season s c r e e n i n g and handling 1981.
 SELECTION OF COMMINUTION CIRCUITS 25

McDermott, W.F., Lipovetz, G . J . , P r a c t i c e s , presented a t t h e SME- -

and Peterson, H.R., The D o l l a r s AIME F a l l Meeting, Denver CO.,

and Sense of Autogenous November 1981.
Grinding, presented a t t h e SME-
AIME Annual Meeting, San F l a v e l , M.D. and Rimmer, H.W.,
Francisco, CA., February 1972. P a r t i c l e Breakage S t u d i e s i n an
Impact Crushing Environment,
Sochocky, M.A. and Mok, J.K., p r e s e n t e d a t t h e SME-AIME Annual
Coarse Grinding i n a B a l l M i l l , Meeting, Chicago, IL., February
presented a t t h e SME-AIME Annual 1981.
Meeting, San Francisco, CA. ,
February 1972. Rey, M. and Formanek, V., Some
Factors affecting S e l e c t i v i t y i n
Rowland Jr. , C. A. , Applying t h e D i f f e r e n t i a l F l o t a t i o n of
Large Grinding M i l l s , presented Lead-Zinc Ores, p a r t i c u l a r l y i n
t h e presence o f Oxidized Lead
~ i n e r a l s , P r o c e e d i n ~ so f t h e 5 t h
I n t e r n a t i o n a l Mineral P r o c e s s i n g
Congress, The Institution of
F l a v e l , M.D. and Rowland Jr., Mining and Metallurgy. London,
C. A., Selecting Circuits to 1960.
Prepare Beneficiation Circuit
Feed from Primary Crusher Thornton, E., The E f f e c t o f
Product, presented a t t h e SME- Grinding Media on Flotation
AIME F a l l Meeting, Denver, CO., s e l e c t i v i t y , Proceedings of t h e
November 1981 . 5 t h Annual Meeting,
Mineral Processors,
Canadian
Ottawa ,
Rowland Jr., C.A. and Kjos, January 1973.
D.M., Rod and Ball Mills,
Chapter 12, Mineral P r o c e s s i n g Iwasaki, I., Reid, K. J . , Lex,
Plant Design, 2nd Edition, H.A. and Smith, K.A. The E f f e c t
Mular, Bhappu, E d i t o r s . o f Autogenous and B a l l M i l l
Grinding on Sulphide F l o t a t i o n ,
MacPherson, A.R., A Simple p r e s e n t e d a t t h e SME-AIME F a l l
Method t o P r e d i c t t h e Autogenous Meeting, Denver, CO., November
Grinding M i l l Requirements f o r 1981.
Processing Ore from a New
Deposit, Society of Mining H a r r i s , C.C. and A r b i t e r , N.,
Engineers, AIME, Transactions Grinding M i l l Scale-up Problems,
Vol. 262, September 1977. Mining En~ineering, January
1982.
B a r r a t t , D.J., Semi-Autogenous
Grinding: A Comparison w i t h t h e MacPherson , A. R. and Turner,
Conventional Route, CIM B u l l e t i n R. R., Autogenous Grinding from
November 1979. T e s t Work t o Purchase o f a
Commercial Unit, Chapter 13,
Kjos, D.M. , Grinding C i r c u i t s Mineral P r o c e s s i n g P l a n t Design,
Current S t a t u s and Projected 2nd Edition, Mular , Bhappu,
Future Developments, a n A l l i s Editors.
Chalmers p u b l i c a t i o n , p r e s e n t e d
a t t h e 52nd Annual ~ e e t i no~f UV Industries, Inc., private
t h e Minnesota S e c t i o n , AIME, communication w i t h c o n c e n t r a t o r
Duluth, MN. , January 1979. s t a f f , November 1979.

Bassarear , J. H. , Autogenous and Brown, C., I s l a n d Copper Mine,

Semi-Autogenous Grinding Milling for Copper and
26 DESIGN, INSTALLATION OF COMMINUTION CIRCUITS

Molybdenum, Western Miner, 16, P i c k e t t , E d i t o r .

-
December 1974.
35. Ferguson, B.A., Camposano, G.
24. S t a f f , Lornex Mining C o r p o r a t i o n and Aponte , J. , Falconbridge
Ltd., Western Miner, August Dominicana Ore Handling and
Preparation, Chapter 8,
1972
I n t e r n a t i o n a l L a t e r i t e Symposium
25. Canadian Mineral Processors Evans, Shoemaker and Veltman,
(B.C. S e c t i o n ) , F a l l Meeting Editors.
( m i n u t e s by Wright Engineers
Limited S t a f f ) , November 1972.

26. McManus, J., G r i n d i n g Copper

Ores in British Columbia,
P r o c e e d i n g s o f t h e Autogenous
Grinding Seminar, Volume 2,
Trondheim, Norway, May 1979.

27. C h r i s t i e , D. J . , Semi-Autogenous
Grinding at Simi lkameen
Concentrator, Proceedings of t h e
Auto~enous Grinding Seminar,
Volume 1 , Trondheim, Norway, May
1979.
28. Sibbald, C.V., The Highmont
Concentrator, CIM Bulletin,
March 1981.

29. mill in^ Practice in Canada,

Chapter 7 , C I M S p e c i a l Volume
16, P i c k e t t , E d i t o r .
-
30. AIME World Symposium o n Mining
and M e t a l l u r g y o f Lead and Z i n c ,
Volume 1 , Rausch and M a r i a c h e r ,
Editors.

31. Milling Practice in Canada,

C h a p t e r 4 , C I M S p e c i a l Volume
16, P i c k e t t , E d i t o r .
-

32. Sisselman, R., New McDermitt

mine j o i n t v e n t u r e emerges a s
dominant f o r c e i n U.S. mercury
production, Engineering and
Mining J o u r n a l , December 1975.

33. T a l b o t t , L.W. and H a r t z o g , L.D.,

Semi-Autogenous G r i n d i n g a t t h e
DeLamar S i l v e r Mine, p r e s e n t e d
a t t h e SME -AIME Annual Meeting,
Las Vegas, NV., F e b r u a r y 1980.

34. Milling Practice in Canada,

Chapter 10, C I M S p e c i a l Volume