Simulation

of Crushing
Circuit of
HGML
Plant

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A Dissertation Thesis Submitted
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M.SHARANA GOI'DA
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Under the Jolnt Guidance of
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Itr. P.C.Nagnoor
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Dept. of Mineral processino
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G.U.P.G. Centre, K.D.R.Naqa-r
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Sandur - 583119
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ARTIIIENT OF MINEnAL PROCESSTNG. g
G-ulbarga University post Graduate Centre.
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*SIMULATION OF
CRUSHING
IRCUIT H.G.M.L. PLANT USING

: HYGO[,41N
HUTTI

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r.ru'rr! GeLp_yj:l\IFFrfgffi"s*y LrMrrED

PO. HUTTI-584 115, Raichur District, Karnatska, lndia.

(A 08537-'175015 Fax-'ii5054, Emait.
hygomin @ sancharnet_in

Dt:15/Teb2005

cenify

rhat Sri.M,Staralagoud, I'ual year studeot of l\4Tech

Ibj:
(Miorsl
p.Gcer',e x.n.n.r.iuga., saoou.
ira
.Procssing),
alo o*
Mctallurgical Dcpart'cnt fo! his disscrtarioo work on"simulatioq
"ori"",tJd
ana Ntoocttiry or
Ctushin_g
unirs of HGML by using MODSIM,,, He worked
on tL, prq.",
froDr I7''Jan 2005 !o l5,r'Feb z{J{Ji.

t t"

d frrt

Sri. M.Sharanagouda wa,s fcund to bc sinccrc and

hard ivorkbe

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W"teg,4)d
B.S.tiangal
Genqral Manager
GENEML MANAGER
THE HUTTI GOLD MINES CO,

L'D.'

Jd.-Office: No. 6/13, curappa Avenue, Prjmtoso Road Cross, Banga lo r e. 5 6-- 2 b: 080,5323840/5323 e41 /8323842 F ax.l 080-5324245
E-mait; hgml @ vsnl. com.

(A GovL of Kamalaka Urdertakrng)

Telephone: 08537 275025, irax No: 08537 - 275054
E-Mail: hygomin@sancbrmet.m
Hutti^ Raichur Dist.

Dt:7/Marah?0o5.

TO WI{OM IT MAY CONCERN

This is to

c:rti!

rhst M. SharaDa C{uda, 6tral year student

of

N{_Te;h

(mineral processing), P.G. Cnh:e, Saodur bas beea worted on,.Si[rulatiotr

Modelling of Cershingra

l*

uniti of HGML by rlling MODSIM" in Hutti

Gold Miaes Coopany Limited

partial

ftHltlr@t oi

Mireral Processing ofculbega miversity is

by him rrrldqr our guidancc ard

a)

r"1i)"f

Sd. V.C.Suesh

Ku$ar

of Technologl in
ofhis wo* carried out

Master

a bonafid record

sqcrvision.

He hss fouod to b sioc4{. doLigear arrd

u.

ed

hsrdwo*hg duriag

the @urs

ofbis wofk.

,ftv
Sfi. M.Sltmkar couda

Meta{urgist

Head ofAssay

HGM Co.Ltd

HGM Co.Lrd.

& R&D Iab

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Project Report on

.SIMULATION OF CRUSHING
CIRCUIT
E.G.M.L. PLANT USING MODSIM 3.6.74"

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Suhmitred,tn paftiaf truffi((ment tror llie Award of lhe

Degree Of uaster Of lei1notogy ln M[neraf processin7.
A Dissertation Submifted
By

M.SHARANA GOUDA

Under the Guidance of

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w,il^_

S.M.Shashidhdr.

ME, MIE, MJSIE, D.<turdor.

Dept. of Electricals & Electronic

Vijayanagar Engineering College,

Be[ary

ARTMENT OF ETCTRICAI & EI.ECTBOMCS ENGINEERING

Affiliated to Gulbarga University

. _.(

Vijayanagar Engineering Gollege, Beliary.

KARNATAKA

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GULBARGA UNIVERSITY, GULBARGA

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Dar. r9

9ertificate
This is

to

certify that the dissertarion entitled ..SIMUI"AI tON OF

CRUSHING C|RCU|T HGML USTNC MODSTM 3.6.14,,

is subnrifted tor the
degree of master of technology in Mineral processing
is a record of bonalled

work carried out by Mr. m. SHARANA GOUDA. M.Tech.

Final year student

of the Department of Mineral processing, Gulbarga

Oniversity, p.G. centre,

Sandur, Kamataka, under the joint my guidance. This

work has not been

submitted elsewhere for the award of any Degree or

Djploma and may be ptaced

before the board of examination for consideration.

@r"c"-_.L
ol. o.6.noonobl\l

Lecturer
Department of Mineral processina
C.tl.P.G. Centre, KDR Nuou, "
SANDUII-sS3I I9
Bellary Dist, Karnataka State.

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GULBARGA UNIVERSITY, GULEARGA

sr..rn$$. rd:d1(f
JN^NA O nO qJl.e ROA.t051o&xAR AtAtGtitora
oEPARTHENT oF *|NERAL pRocEsst G p,G,cEr{rRE K.o.Rll^cin slnoun
&oddr, 4Flnorl OFrl D,{tt"cqd t(o4 de4 rkd66 drtd-do&d

t.

=.-

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aniot / Del!
l8- 4-2oos

Gertificate
This is to certlfy that the dissertation entitled ,.SlivlULATlON OF
CRUSHINC CIRCO|T HCML USING MODSIM 3.6,14,, is submitteci
for the
cegree of master of technology in Mineral processing is a record of
bonafied

rork carried out by Mr. m.

SFTARANA GOUDA, M.Tech. Final year student

of t}re Department of Mineral processing, Gulbarga University, p,C.

Sandur, Karnataka, under the joint guidance

centre,

of Dr, p.C. NAGNOOR e

S}I.SHASHIDHAR nssistant professor, Department

of

Electricat and

Electronics, Viiayanagara Engineering Coflege, Beflary. This work

has nor oeen
submitted elsewhere for the award of any Degree or Diploma
and may be placed
before the board of examination for consideration.

t"A
lv\
-4,t\

''.'-.--t

Dr. B. V. NADAAOoDA
Chair.rndn

Department of Mineral processing

C.U.P.Q. Centre, KDR Nagar
SANDUI? 5B3I 19
Bellary Dist, Karnataka State.

ACKNOWLTDCEMENT
This p[oject involes not oniy my sincere efforts,
but arso the invorvement of many
peopte v/e have di.ectly or indirectly guided
me in this dissertation work. With great
pieasure,

acknowledge them for encouragement and guidance

e),1ended throughout my

I take this oppo.tunity to express my deep gratirude

to Dr. B.V. N;dagouda, Dept.

of

\'lineral processing, p.G Cent.e. Nandhihalii for

his valuable suggestions and sending
me ro carryout my dissertation

work

at

Hutti Gold Mines Co. Ltd.

It is great pleasure for me to express my sincere thanks

to Sri S.M.Shashidhar, Asst.
Profbssor, Dept.

of

Elecrrical and Electronics Engg. Vijayanagar

Engineering College,

Beilary under whose guidance, constant encouragement

and supervision

brought out

ihis projecr work.

am very grateful to B,S. Gangat., Gene.al

Manager of HGML and Sri Malay

\[andal, Sr.Manager Metal]urgical Depa.tment,

HGML, for their encouragement and for
:roviding all the facilities during the course ofmy
work.
Prof Rp King ofUniversity ofUtah, USA

am very thankful to

Sri.M.L.prtit (Dept of Exploration) Dy.General Manager

of

HGML. S.i.P Srinivas Geologist, Sri,M.Shankargouda.

Head of Ass?y and R&D
Lab.Sri.C.R.Ravi,Manager Sri.suresh EIigar,
Manager. Sri.V.G. Suresh Kumar
\fetallurgists. Without their active guidance and
encouragement this work could not be
.rompleted.

It is my pleasure to work under such an experienced pe.sonalties

their

::lridance is greatly acknowledged.

also extends

Rudramuniyappa.

to my

deep regards

to Dr p.C

Dr. S.J. Gopalkishna. Dr. K.S.

Nagnoor Dr.M.R.patil. Dr.

Shivaprasad. C.Rudrappa Lecture

Dept of Mineral Processing P.G Cenlre Nandhihaili- SANDUR. For rhis timely
sugesstion and encourage me to throughout the academic course.

It is also to lecard the he\p, insliratior

and encouragement that 1 got ftom \o\ing

parents and brothers, sisters throughoui mv course my thanks

s.t\ars

\hom \ha\e

i\rNefie$

mrssed.

with apologies to all the

qoNTENTS
CHAI'TER

I:

NTRODUCTI

I.l : Simulation
I.2: Simulation in Mineral processilg using
MODSIM

TURE REVIEW
2.1: Brief description of

IICML

2.2: Crushing Circuit

2.3: General Flow shet for treatment for gold ore at HGML

CHAP'I'ER3: DXPERIMENT
3.1: Flow sheet devetopmena of MODSIM
3.2: Models Used (Comminution Models)
3.2.1| Jawl

3.2.2:Staradsrd Cone Crusher

3.2.3:Short-head cone crusher
3.3: Modeh Paramelers
3.3.1: Or Characteristics
3.3.2: Feed StreaDs
3.4: Procedure for simllation Exercises

cHAP't'EIt 4:

$IUI,ATION

4.1:Dala Output

4.2tModsim Simulation Report

4.3: Stream Data Repora
4.4: Distribution Graphs

CHAPTER 5:
REFERENCE

APPENDIX

ND DrSCUlisroN

ej{AFTEq - I
\lar1,ore dressing opcrations are suf.ficrcnrly well understood to enable
-:'::s 10 be devcloped that can be usefully used to rlcscribe.,1her operatron
--i.:.:ativelv. Experimental data that has been obtarned by many rnvesngarors
:- --:. past couple ofdecades has provided that basrs for quantitative
models that
-:: :: i,rsed for design and srmulation of individual units rn arry flow sheet. .All

:::::=,-processing equipments exhibit complex operating behavlour

and burlding
:,-.1---:arire nodels lorthese operation rs not a stratghtfotuald
task II so re case

:c :-,c

fundamental principles

of a particular type of equipDent are ijl

5,-::_aOOd

l,.r most cases rhe complexity

r-r.

sts

ofthe

of the

operatron precludes any complex

ph1,sica1 a:rd chemrcalprocess that take place in

the equipment and

:i:rl jrs operation. ln spite of these difficultres much progress has been made rn
!i :.\ elopment of useful models fbi almost all of the more rmportant
ot
:

rype

:: a:_:;1 processlog equtpment

Physical separation of mrnerais requires that the vanous
mineral speores
::
-- le liberated by commjnution and thls imposes some strong .eclujrements on
:c ::..dels tltat are der.eloped. Mrneral libration is quite dfficult to model marnly
-,::-::se of the complexity of naturally occurring
nineralogical txtures and the
z: ruted complextty of the fracture process mat occrr when an ore is caushed

r: ;round pnor to processjng to sepante the mrrerals. In splte of these

: -::re\tty, some efI'ective modeling techniques have been develope<l. ModelLng
:. i:eratlon phenomena has been greatly facilitatd

::r::uter

by the development of

based tmage anaiysis systems. These methods hav

made it possible to

=-::'.lle the multicomponent mineral bearing particles and to observe the

-tosltlo.l of mlnerai Dhases

across panlcie population at first

hand. Modem
can revat rre minerat distribution
ur considerable detail and disital
are the rule rather than the exceptron
now' Cornpu1g1 sottware to. the
s or olgltai mages is reaoiiy available
and tlese range from comparatively
programs that provide rudulentary
rmage processtng and rmage analysls
to speclat purpose programs rhat provrcie
tacrlrties toinanrpulare and
s rmages and subsquentiy anaryze their
content usrrg a wide variety or
uns rhat hare been de,ielooed 5Decifrcallv
lo measue mreral l,berat,o,

n nahrrally occurring

ores

Mmeral liberation is natural linl< beFveen

comm]I1utton oDerations atd
recovery operations, and it is not possibre
to model elther rype effectivelv

proper allowance for the lrberarion

phenomenon. The approach that raken
Iberation modeling.
Models for the pefonnance of mineral processine
equipment are useful for
purpose plant and prccess design
and development, performance evaluation
assessment equipment ald process scare-up
but most importantly for
As a result the models all have a cornmon
so:ucture so that they can fit
seamiessly inside a plant simulator. The population
balance method

this ard

it is

comparatively simple for the products of

any one unit
to become the feed matenal for anothr

All of the models develooed are particularly sited

to computer calculations
ron of a wide range of engineering systems
is now accepted as tie only
procedure for their anaiysis. purely theoretical
methods that are aimed

at
and precise analltical solutions tdthe operating
equations that describe
mmeral 1a:ocessing systems a-re not general enough
to provid useful workrns
tn most cases. Very fast personal computer axe
now available to all

--ieeas wno rcculreo ro maKe cies,!!t and oDeratng decisrons conceming the
:!<:ation or mlleral processing piants
.{11

of the models described here are included in the MODSIM mherai

:rlesstrrg plant srmulator. This

is low-cost high

perfomance simulation lt can be

:-.<i to simulate the steady-state opeGtjo of any ore dressurg pl3pt. It has been
-c:-:3i piants and has been shown to be reliable. The
smulator shouid be regarded
15 -. resource t-hat can used by the reader to explore
the unplications ofthe rnooeis

:-:

are developed with the very few exceptrons, all of the models that
are
:.cdssed rn the MODSIM. It is a simpie matter to sjmuiate unit operatrons

-=:e. is thus ablc to observe the effect of changins paramter

anorne

values on the

=,:sels and their predictlons. In many cases multiple interchangeable models are
-:.rded for indir,rdual rmit operation

Chapter I
INTRODTICTION
llrhough a good computer simulation can provide information about the behaviour
:erformance ofa mineral processing plant.

.::

\fodels for the pe.formance of mineral processing equipment are

useful for many
:,::oses plant and process design and deveioprrent. peaformance evaluation
and

:i=iiment. equipment

and process scale_up but mosi important for simulation Many

of
to provide the building blocks for the simulation ofthe
:<:atjon of complete mine.al processing plants As a resuk the modeis alj have a

::=

:nodels that are describe

: - ..-:mon structure so that they can

fit togethel- seamlessly inside the plant simulator

\fodern iostruments can reveal the mineral distribution in considerable detail

: j.

ri imageq are the rule rather than e,,ceprion nor.

:.I

SDI UL,{TION

and

Simulation is any procedure that can be used to model a process without actuattv
--::r!ng it There are several ways in which a simulation can be achieved,
but by far, the

-:.r

effective is by digital computer. The computer is programmed

to mimic the

:':.:\our ofthe actual plant and can provide a description ofwhat the planl will do and
- .r \\ill it be perfo.med under the varieties of cjrcumstances. This is useful thing to do
_*-aause

a sjmlrlation can

expose many aspects

of plant

performance without the

::.tn\ience of operating the plant itself under experimental conditions.

An ore dressing plant simulato. is a set of computer programmes that provides
:::ailed numerical description of an oparation of an ore dressing plant The simulator

-rsr

::

be provided with an accurate description

ofore that js to

be processed. a descrrp on

rhe flowsheet that defines the process and an accurate description

:'::aviour ofeach unit operation that is inciuded in the flow sheet

of

operating

lhe nature of material to

be

processed its mine.alogical composition and structure,

-.- :ize distribution and tbe amou t that must be processed.

The operating char-acterstics

::\iption ol unit
::;-::rng

of

each unit

in the ilo\!

sheet. This requires full

operation and specification of the unjt parameters that defines the

characterstics of the individual unils

'. SES OF THE SIMLTIATOR

good simulator is a uselirl tool to the process plant enginee.. Essentially the
i -_.alors calt demonostrate attea$ approxlmately, what a plant will do under any

::-:;ular

:-

operating conditions

It

can do so cheaply and without any real risk to the

:Jcrion rate ofan operating plant or it can do so before a planr has to be built and it

::+i

so in the ensineer's

ofllce

"I DESIG\ STUDIES

1r rhe design stage a good simulator can be used to

ilelp the design engircer to find the besr florv sheet

!nsure that design specification wili be nret under ail rcquire operaiing operattons
Croose the most suitable unit operation to be included in the piant
Size the unit correctlv and so eliminate $,asteful over design and avoid the catashophe

:: -:der design
Optimize the plant operation b1, achieving best econom;c combination of grade and

ldentify potential production bottlenecks

Proride comparative assessment of comperting manulactures equipment
Deflne the performance gurantees that shouid be mer by suppliers

Fird our what wjlt happens ifpefonluncc guamnrees are not met.

:r

OPERAT|NTG PLANT PERFORI,TANCE

good simulator can be used to assist in the operation of a running piant

in [,ays
i,: r as the following.
Optimum perlormance ofthe plant can be approaclted.

':

:iant can be tuned to suit variatio in feed qualitv and flo\\, rates
: :-- :offlenecks can be fbund
and appropriate steps taken to questions
:i_:i1ons that are nol proped).understood can be identilied and appropriate research
- -- :(rlake t ro temedv sLrch d .;lualior.

-J :LO\\ SITEET STRUCTURE

:-

ant flo\\,sheet consist of a number of operations clrnnccteal rogerner 0v a

l-..'. srreams Nlaterial enters the plant a d passcs successively through lhe

- ..
- -...i -.::i ir accordance with rhe flousheet struclllre. sonletines recycling on itself
-- ':: , ii leaves the plant in one or other product stream The mate al in a
. : :i::::

processed b]. cach

unit in o.der to change the nature ofthe maienal or to

.a _-.:: t: ::io lts subconstttutent pafis.

-. ::;iber oldif'ttrent tYpes ofultit operations encountered

in ore dressing plants
-::::::r eir Iinlited and these can be classitied inlo three generic types

otu trtu sSt\L r \|

'-

e are

ls

oPt R\ f tO\-\

.,/\ th.ee bzsic ,rpe: ot-o/e .J.es.n]:j unn opcr?lioDs

:::-aion unIls rhat separate solid particles

: i-:le- Gravlt) separatio

without changing their characterstics. for

-:anstbrmation units that alter the characterstics ol the solid particles lbr example.
:-,.irng and grinding operations.

' .ir, rltdl separale.urid,

]t ts remarkable
: ."ilied
- _:iiator.

ard li,luid.urr.rituenrs

that the entire reponor of oae dressing units operalion can be

by such a simple scheme and rhis simplicir), is exploited ef].ectiveh. rn the

The plant can be tuned to suit

variation in feed quality and flow
rates.
Planl bofllenecks can be found
and appropriate sleps taken ro questions

Op.ations that are not properly

understood can be identified
and appropdate research
rts unde.taken to remedy such
a situation.

TI{E FLOWSITEET STRUCTTIRE

A plant flowsheet consist of a numbe

flow streams. Materiar errers,r"

;::fi[:';""::::J",t

units in accordance with the flowsheet

finally

it

leaves the plant

srucurq

fi:

sometimes recycling on itself

in one or other product st.eanl The

material in

processed by each unit in

orde. to change the nature of the
'ms
material or 10
it into its subconstitutent parts.

The nunber ofdifferent tJpes ofunit

operadons encountered in ore dressing
plants ls
paratively limited and these can be
classified into three generic t'?es.

THE ORE DRESSING I-INIT OPERATIONS:

There are only three basic q4,es ofore
dressing unit operations.
spa.ation units that sepa.ate sorid particres
without changing their characterstics, for
nple, Gravity separatioL

Transformation units that alter the characteEtics

of the solid particles for example,
fiing and grinding operations.
Utrits that separate solids and liquid
constituents.

It

is remarkable that the entire reportor

by such a simple

scheme and

of ore dressing units operation can

be

this simplicity is exploited effectively in the

characterstic of the unit modl is the

trr

SeDaration unils is always produce atleast

flow sfieams connections that

are

two produc slreams a concentrale

unit will
or an undeflow and an overflow Sometimes a single separation

. middlirg

product as well

water
cher hand, transfomation units produce only a single product stream'

in

predominantly
always produc two product streams one of which is always

IrlE ADVAN"AGES

OF THE SEQLINTIAL MODUTAR STRUCTLTRE

Vrasatility to desc.ibe any ore dressing plant.

Imerent perfornance for unit operation models by different users oan be easily
A varity of models is a available for most unit operatior It is usually describle to
igate and compare several ofthese during simulalion studies

IJnit models can be constructed and tested as standard modules.

Models must always be verified and calibrated against operating data.

This is done most effectively by comparison with data liom single-unit tests which
asy

to simulate

It is

cost effective to make use of existing models with minor modification and

aeosions to describe

new units or operaling regimes

Exchange ofmodels among users is easy.

U'

WHAT IS MODSIM?
MODSIM is a simulator that will calculate the detailed mass balance for any ore

-ssing plant. The mass balance will include total flow rates of water and solids, the
pticle size distribution ofthe solid phase, the distribution of particle composition and

ite average

assay

adal content

ofthe solid

phase. The assay can include mineralogical compositio4

and element content. Other special particle properties that are specific to

particslar systems can also be accounted for- Some are calorific valuq volatile mattet
pyretic sulfur, organic sulfur and ash content for coal, and mnetic susceptibility and
dectrical

Conductivity for mineral systems that are processed by magnetic or electrostatic

Other, sometimes very subtle, particle properties such as particle shape,

ical terlure and surface chamcteristics have important influences on the

of some of the unit ope.ations of mi[eral processing. MODSIM can
all ofthese particulate properties. The main unit operations ofore dressing
the size reduction operations, crushing and grinding, classification operations for

ion ofparticles on the basis of size, concentration operations thal separate particles

to their minenlogical composition and solidJiquid Sparations. MODSIM

a repertoire

ofstandard models for these operations.

MODSM has a complaely modular structu.g which allows models for the umt
to be added into the simulator. Thus the models that are used to simulate the
ion ofthe various unit operations can be developed and modified to suit the olant
ions

aer any opeating conditions and can be tuned to meet the needs of any application.

fo

characteristic of MODSIM also allows the user to develop and incorporate the

of ongoing research in the mathematical modeling of the unit operations of

processing. Th repertoire of models available to the svstem inqeases
sly as more are added by users. The user can call on any available model.

MODSIM calculates the coftposition and completely characterizes the particulate

ial in each stream ofthe plant. The oufput includes the total flowrates ofwater and
the particle-size distribution and the distribution of Danicle comDosition over the

i:le

population as well as the detailed assay

of

each sheam.

In

addition

ive report is produced for the performance of each unit in the plant. The

will vary according to the duty that the unit must handle in its position in the flow
The data in the repo.t can be used for detailed unit dsign ard sizing, for unit
iqg, for equipment selection and for equipment and process evaluation.

MODSIM is unique among cur.ently available simulators in that it can simulate the
ion of minerals during comminution operations. This aspect of mineral processing
operation

is becoming increasingly relevant as plant

managers seek greater

ing and plant efrciency.

is a steady-state simulator and is not designed to simulate dyramic operations.

trot suitable for the design and simulation of process control systems.

ChaPter 2

LITERATURE REVIEW

2r

Brief Description of HGML

Hutti Gold Mines Compary Limited (HGML) is the large gold mfuhg company and
ole produoer of primary gold in the country. The company has its corporate office at
B.ngalore and operates Hutti goid unit in Raichur district The Hutti Gold Unit comprises
Ertti Underground gold mine, Uti open cast min and Hira-Buddini exploratory mrne'

Ib

Hutti Gold unit are fully integrated unit with smelting capacities to process gold ore

d6,0o,000 tonnes per annum.

Hutti Gold Mines Company Ltd. In th state

has

joined the bandwagon ofthe leading

the 406 member ofthe World Gold

6old producing companies in the world by becoming
Canncil (WGC). The company is committed to developing long life, safe and

crvironmentally responsible operalions

During the yeat 2OO2-03 HGML'S production was 5,87,314 MT of ore which had
2709 kgs ofgold and a tumover ofabout Rs.142 crores, and fot the year 2003-04'

tilded

Ioduction target of30l7

kgs

ofgold

has been sel with

tumove' ofabout Rs l53 crores

EUTII GROUP OF MINES

The

Hutti

Maski schist belt bearing gold mineralization stretches over a length

about 70 km and an average width of about 6 km. It occupies an area of 750 sq km

rlich extqrds from Krishna river in the [orth up to Tungabhadra River in the soulh And

1 is the one of the most important auriferous archaen greenstone belts of the southem
Hian shield. After independencg search for noble metals was identified The past and

r@ent work

of

recommence and prelimillary regional explorations activity

by

th

by
Creological Survey of India (field season 196l-62 onwards) and detailed exploration
Exploration Corporation Limited (MECL) and HGML (1986 onwards) the belt

Mineral

of investigation, these includes regional mapping of the

and geo chemical surveys Large scale mapping, detailed &illing

witnessed a whole spectrum

entire belt, geophysical

ad

exploratory mining

in

selected areas. Nearly 15 deposits/ prospects have been

crplored in the northem and southem parts of the belt. The geological terain extending
tom Maski-Buddini to Uti is significant and important From thq.ecofomic point of
project
view. Three mines viz. Hutti Gol<t Mines, Uti gold mines and Hira-Buddini
oa'ned by HGML are p.oducing gold ore at present.

Additionally, lhere are many small deposits such as Tuppadur, Maski-Buddini'

wonnalli, Chinchergi, Kadoni, and Ballapur block with limited potential in oompanson
and
Tbe southem part of the belt is not well explored A \;vast arca between Maski
rodhem end of the schist belt is corered by thick black cotton soil and is covered by

caal irrigation.
LOCATION OF HUTTI GOLD MINES
Hutti is located about 80 kms west ofRaichur, about 500 km north of Bangalore
metal mines in India
-d is considered as one of the prestigious stable underground
Hutti
l-ocared at the North-Westren periphery of the Hutti-Maski green stone bek
(after
Iloderground gold mine of HGML is one ofthe deepst working mines in India
Since
tbe closer ofKolar gold mines ofBGML and the Mosabani copper mines ofHCL)
|he deepest development point of which has reached a depth of about 800m The Hutti
gold mines (including satllite mines) have so far produced 51 15 tonnes ofgold metal

8om 8.65 million tones of ore al an average grade of 5 91 g/t (up to the end of March
,03) during the lest 56 years of mining. The surface geological and structural plan of

Erni gold mines area is shoun

in Figure-1

GEOLOGY & STRUCTURT OF THE AREA

All the nine well defined, parallel to

sub parallel, tabular auriferous quartz reefs

l)

Main ree{ 2) Prospect ree{ 3) Oakley's Reef, 4) Middle Reei 5) Zone-I, 6)

llage

ree{ 7) Strike, 8) Foot wall strike reef and 9) new East-Ree{ occur with in the
ics. Dominantly composed of rnainly fine and medium grained pillowed
s and

subordinate bands of rhyodacitic compositio4 which occur intermittently

concordant narrow bodies. In the Hutti mine block out of nine'auriferous zones, the
ion comes from six lodes only viz l)Oakley's, 2) Middle, 3) Zone-I, 4) Village,
and 6) Foot wall strike ree{ developed to an average strike length
ized zones in the lease hold area is about

1.3

5.1

ofthe individual

km

XODE OF OCCURRENCE
Gold occurs in native fo.m as minute globules, thin stringers, films and smears

lmg

rh

the fractures vrith in the quartz. It also ocqrrs associated with sulphide minerals,
as arsenop)nite, py.rhotitq plaire, chalcopyrite and sphaleritg in the altered wall

Fc*s that occurs as lenses with in the quartz vein and on either side of it. The total
dphide content ofthe lodes varies fiom 2 to 5olo.
RESOURCES OF HUTTI BELT

TABLE-1:
PROSPECT NA}IE

CUMULATI\,'E

R.f,SOURCES,

STRII(E

MT

LENGIE, (M)
Hutti
Kadoni

24,000,000
400

52000

Wondalli

5,300

79600

Chinchangi-Tapaldadi

1,600

2,080,000

uti

3,210

8,800,000

Ballapur

200

260,000

Udbal

t00

110,000

Maski

300

390,000

1,000

209000

300

1,300,000

Buddini
Tuppadhur

20,500,800

TOTAL
CRUSHING CIRCUIT

35
Ore crushing at Hutti plant is carried out in 3 stages; primary Crushers run by
These Crushers are capable ofhandling about 50 tonnes ofore per hour and

dotors.

+2
operated in parallel. RoM is screened before being fed to these cru5hs15 6nd

l/2'

only goes to the Crushing machine. Primary Crusher house is attached to

Shaft bin that is the main sources ofore- Ore from olher shafts viz Central and
Shafts is obtained by Locos and also fed to the Primary crushers via a surface brn

picking belt- The 200 tons surge bin at the end of primary crusher House acts as a
ir for Secondary Crusher Section.
Secondary crushing and te.tiary crushing are carried out
Secondary omshing

is from 2.112" size to

l"

in a separate crusher

size accomplished by a set of 3'

Cone Crusher operaled in paratlel and run by 75 HP motor' Crushed ore is

bir Tertiary crushiry is carried out using 2 nos. of3' short head
crushers and 2 nos.of 4' short head cone ctushers operated in parallel 3" Crusher
in 400 tons

re run by 75 HP motor and have a capacity of3o to 35 tons per hour, while 4' Crushers
rE operated by 150 HP motor and give a through- put of about 50 tons per hout 3 nos
Crushers in Tertiary Crushing arc normally in operation to give a through -put of 100
120 tph. Crusher operates for about 16 hours to do the required lonnage of 1800 tons
day.

Tertiary Crushing is in closed circuit with 3/8" screns iNtalled prior to crusher
tnsure tiat the product is 100 percent-gmm. Fine ore in sampled before going to
and weighed using and automatic belt weigher installed on the conveyor delivering
crushed ore

to l500lons capacily mill

brn

ii

t\\{'N}'

"

CENERAL TLOW SHEET FOR TR.EATI\ITNT OF COLD ORE AT HG]\''L

i
HIGH RATE TEICKENER

vrlilrATrNc

h/F

PRIMARY
.-D]TSIIfN.]
VIBRATING SCREEN
>?5

Ex*

s[aoNDARY cRUsHTNG I
3'S1d. Cone ero!bcr!92,,1

^ry

PROCESS

AGITATORS, TWO

WATER TAI{X

SERIES

,1000
Decant

Cub.mlr

Water
CIP, 2 No 1000 TPD

/-l^-^rk,

Idded

Itral,Rqidue

VIRRATTN(] SCREEN
l0m

Carbon

SAND

TERTIARY CRUSITING
l'Sh Hd.-2 no, 4'Sb fid -2 no.

ELUTION &
DETOXIFICATION

FINE ORf, BIN,

15OO
I

TAIL DI]MP

PRIMARY PEBBLE
DD

STRAKE TABLtr

ffi

StriDoed Carbotr

CARBON
A

'-T'TI/

A'TIlr| N

Cold Iradcd Steel Wool

CYCL oNn. 12"

SECONDA RY PEBBLE

MII-I ,6-Mills.

i"d

SII(AAI:/

IAj'I,I,

r.";t
ACID TRTATMXNT

DAII

I\?ITI T

'['iII.

KNELSON CONC,2 No.

mil

Ioil
firF1

cY( ll-oNE,

JAMES

Rf)ASTIN.:

SMT'I,TIN(]

BULLIqN

P"

+ :ll''

=
!:

.s

if
=
=

t"

:z

i:j

z
=

.!

3
=:

J!3

l,'

'z

32

MODELS USED (COMMnTUTTON MODELS)

Most ofthe models that arc incorpoEted in MODSIM require one or more paramelers

be specified so that the model

will

describe the unit as

it is

set up

in the flowsheet.

hrameter specification is done through forrns that are specifically designed for the
grpose. The Unit paxamete.s entry on the main menu will bring up a form for tlle
-lction of units for parameter spcifi cation..
Unit number Unit type A list of unit numbers ftom the flowsheet and the
conesponding type of unit.

A single click on any unit is this field will display the list of

rodels that are curently available ia MODSIM for the selected unit.
Models A list ofmodels that are cunendy available for the unit that is selected in the

Unit t}?e list. Double click on the model to choose it for the unit. The parameter
specification form for that model will be brought up. The model that appears at the
top ofthe list is the oqe that is curently selected for the unit.

THE UNIT MODELS

At the heart of MODSIM are the unit models. The simulator is only

as good as the

eodels that it contains. If any model does not accuntely describe the operation of the
Enit the simulator can not give a reliable picture of the behavior of the plant. Models must
be chosen with care and for accurate work they should be carefirlly calibrated against

appropriate experimental data. A brief descdption ofeach ofthe unit models that axe

spplied

as standard is given in this secrion.

3.2.1 JAW1: Simple model for a jaw crusher.

This model produces a size dishibution in the product that is of standard t,?e which
is
independent

of the size distribution in the Ged

except that the crusher cannot

discharge

mderial in size classes that have size laxger than the largest size in the feed.

PARAMETERS
l...Open-side setting.
2...Impact work index ofthe material in this unit.

3r.2: Standrrd

Cone crusher

PARAMETERS

l...Closed side setting for cone crushets, open side setting fqr gFatory or jaw
2...Proportion offines produced during breakage events.
3...Impact work index ofthe material.
4...Factor for classification parameter.

3.23: Short-head cone crusher.

This model is based on the crushing zone and intemal classification behavior

&cribed
PARAMETERS
l,..Closed side setting

ir

meters.

2...Proportion offiles produced during breakage events.

3...Impact work index ofthe material.
4...Factor for classification parameter

DATA ENTRY
Once the flowsheet has been constructed, MODSIM

will

take you tbrough a sequence

ofmenus that will define the data set required by the flowsheet and the included
models.
The data is separated into two sections. The first defines the system and plant
data which
includes all idormation required to define the plant stluctule afld the charactenstrcs

of

the

material. The second section includes all the paiameters required by each of
the
rmit models included in the flor+sheet. These axe the unit pammetem. Each secuon may
be accessed separately fiorn the main mcnu.
fee$_

Some familiaxity with tlle terminology of particulate mineml systems is necessary to

iry the data correctly and the user is referred to the book Simulatine Mineral
ing Plants for assistance in this regard.

MODEL PARAMETERS

ooutre cridh n hodetto ste.i il

j*l

irl
The system data describes the characteristics of the ore that is processed in the
fowsheel These characteristics rcmain fixed throughout the florsheet and hence the

Eme system data. System data is also

used

to characterize the plant feed streams. The

rystem data form is used to set up the system data and to identify shearns that Jeed ore to
lhe plant that have experimental data which is to be compared to the simulator output.

cpdlA'dprl

The data fields in this form are described in the sections that follow. Th fiame
labeled ORE CIIARACTEzuSTICS on this form is reserved for the specification
Foperties that characterize the natue ofthe solid material that is processed in the plant.

33

ORE CHARACTERISTICS

of

This composite fie1d is used to specifi the physical properties of the orc that is to be
in the plant.

Number of minerals: Specifu the number of mineml species that are significant in
simulation.

Mineral names: The names of the minerals must be specified in this field. There
be as many names as are specified in the Number of minerats field. Only tl-re first
letters ofthe mineral nane are sisnificant.

Mineral specific gravities: The specific gravities of the indiviaual minerals can be
here.The specific gmvity of individual particle types can be spcilied in one of
ways: either they are calculated ftom tlle mineral composition ofthe paxticle tlTre and
specific gravity ofthe individual minerals or the specific gravities ofthe padicle types

en

be specilied explicitly. One of the two methods is chosen on this form. If the latter

-hod

is chosen the specific gravities of the padicle

fi,es must be specified

on Form 4.

Number of size cl&sses: Specii! the number of size classes that you want MODSM

use for the simulation. 25 is recommended since this

will irovide the geatest

rsolution with respect to size. The number specified here need not be equal to the

reber

tia

of sizes that are available as data that defines the plant feeds nor to the number

classes that are available in expedmental data that is available

of

for comparison with

ae simulator output. If particle size effects will not be significant in the simulatioq the
rmber of padicle size classes can be set to I and MODSIM will consider that all
lnticles have the same size equal to that specified in the largest particle size field.
Largest particle size: Specifr the largest particle size that is of interest in the
simulation. This should be just larger than the largest size in the feed. Note that the size
must be specified in meters.

Numbi of grade classes: Specifl. the number of gmde classes that are required to
&fine the liberalion characteristics ofthe ore. Ifmineral liberation will not be significant.
This field should be set equal to the number of minerals. The number of grade classes

$ould never be less than the number of rninerals otherwise the simulator

carmot

disinguish between the separate mineral species.

Nimber of

S-classes:

In MODSM S-classes allow the particle population to

be

distributed over an additional physical variable such as the magnetic susceptibility fo!

. Distribution over several values of the flotation mte constant is uobablv the
known example ofthe use of S-classes in ore dressing plant simulations.
Setting up the Grad Classes: Sgt up grade classes cootrol on thg systems data form.

Couposition: This form requires the composition of

each gtude class to be specified.

composition for each grade class is specified in terms of either the mass fiaction or
volume fi:action of each mineral in the particle. The entry for each
grade class is a vector

Specifrc

Fctes

in

gavily of

ofmineral compositions. The ordering ofthe minenls in the

class: By default MODSM calcula&s the specific

each grade class

fiom the mineral ftactions in the paiicles and the speoifio

gravities ofthe minerals that are specified on the system data form. Ifdata on

Ficle

3.3'

gavity of

the

acrual

spcific gmvities are available these may be entqred on this form.

FEED STREAMS

The feed streams to the plant must be completely specified with rcspect to their

ftwiates, composition and

size distribution. These specifications are made using the feed

*eam form.
Stream: The number of the stream in the flowsheet is specified here. You can
docate a descriptive name to ihe steam to assist identification of the stream dala from

lb simulator. The name that is specilied hgre is tansferred to the feed steam field in
ft system data form. Steam names must start with an alphabetic character. Number of
dzes: Speci! here the number ofmesh sizes that are available in the distribution data for

Itis

stream. This need not be the same as the number specified on the system data form.

Size: List the mesh sizes that define the size distibution for this steam.
ToPassing: Specifu the cumulative size distribution as percent passing the mesh size.
mouse click to convert existins sizes to a new unit.

sF c'll . nisenFl.r.

lht .ilr.nm ii!:il inn r4{h,r

P"tt'n9 s,""'n nu*", +l

nnmE rof

'n

dumber nl rresh
2

3tlt9 a

alrrlrnlitl :

''r''nc3'

siii. h,l'o!r deta

?rl

a nicrrn a hn ,^ .n 6 fi -

1.i46E.3

inch

1.250E.3
32508-.1
3 12SE

.1

221tE

Use Rosin Rehmier dlSrihution

lr4l rrle

s.rlds

5 5-i56Er0

a
6 kgs
a lonn6rrf a
SFe.ilt

grDn i.nsrhf
Lnnq

lon.rti

ri de dis flbdnins

i:--li4
Percent solids: Speciry the percent solids in this steam.

Speciry grade distributions: Define the mineralogical composition ofthis strearn by

specirying the distribution of particles over the grade classes distribution form'

Specify distribution oYer s-classes:

.ontolto bring

If

up the s-class distribution form

s-classes have been requested

click this

PROCITDUI{E I]OR SIMUI-ATION EXEITCISES

1

DrrwlnA lhr Ilowtheet

| (io ro 'l'ilc l|rc,tr, Jr'{l.li(k'Slnrt a n.w i(,b'

ii (]ol(''lilir"n,cn,,ad.lcli.kl{(nrioncursln.lh.irursora}'pcarsodth(,sc(r{lindil
sll,rld l{ Jrlitr<t in .dr\lrricrrt po$i lior or lho s,:rccD.
' (:li.k lln cqoil,rlcnl ind thc l\'Irf 1.
rii. i i,r l!,'Scl,rr' n(rru lrxl
(l:x{rmtlc: Crushcr> l.t' crushcr)
i\. (lo n)'Irlit' rr,nu irrd (lick 'llubLx'r hifil cursu'. Nolv .lrnlv lh( sLrcin,s. .r( {({ thc k,cd
.

n.d an!ib(r' to, 1lt ptud,rl a,rd otl,(ri

Acc.pl

ahc flolvshect

(;o

tditii6

t,r

'Ll.'

Sysled

,nc,,u .lick

rc.(Pl llolvsh.ct ihcn

dinkrS bot

rtF.\rs

n'trj

$p(rih .loh ni.rc.

d'tr

(;) k"tilit nltru ind.lick 'lidil

l.

as rrqui,c.1.

svntenr dnta. A f'o\

hrrn.l fri\ljG', 'Sh(.. nr (1.t.'. (lli.k

'a

nirpt.K

n)

spe.ily

'(\e

ccrrft'.

Choosing Nlode, ,nd Nlo.lel l'!ran,etc,s

i. Click r{Jjt nnrl U it lto<iel prra'r(kjrs
ii. ('hrx,{ Lh(:Mod.l
ui Sellcl DFdcl pammckl's.

i!. Cli.k ,('(cft'

.. (,,, L nl. ,,x ru,nrd srve thF irl:

Si'nul!tion Sl,ge

(;o io 'tidit'ndr! rnd click 'R! s'mu h tion', Ihcn a bor .r ppr\1rs 'Sunul.r trotr (ornFlet.\l
suc.csslullv'. Anoth.r t"or appears 'data olrtprt filc.oorpiclerl succcssfully'. Click'OX'

G{, k'

'!irw',n!n{ rnd .li.k 'fiowsh.d',

it aPt'd,rrs with fl!,ouLs displnynrF thf strcntrl

ii. Co l,,1ic$' D.nu nnd .rlrk'rrForl fild, il rppcn16 on th. scrc,1,.

iii. (j,, k"ri,{r'rh(nu rd.li.k'rtrcrm dali', it.rp|e.rrs (!r lhc$.rc('n.
(l,i 16 'vn'vr'
i,rd.l,.l( 'r,ze distrhrlio'r Frnphs', it.f'f.!rs otr the scurr.
'!.r. (hnr'rics
'n.nu
,))cru l''l clict'l-ib. rn|'l disuibuiotr traphr'. it rnr.irinn tlr scr':.rr.

(.,'ll,)'i)lr'nid. h lr-t ri.rdu .C.trt..rll)n t.li.;rr,!,nrr'n

ODSIM SIMUL ATION REP

MENT DA'TA

ber

3t

model name JAWi

to be processed
per hour

'l op size in feed is

approxlmately .31 cms

"Fall through" material in

feed lO0.0O percent.
Scalping ofthe feed is
recommended.
Size distribution in product

Size
setttng 9.140

ibution in feed
7o Passing

99.86
98.63
94 09
84.52
70 80
55.61

4l.49
29.7a
20.80
14.26
9.66
6.44
4.33
2.88
1.91

42
42

|.26
.84
.55

7o passing

cms

.42t
.297
.2to
.t49
.I05

2.18

L56

t
2638-0l

.371E-0
l

E6E-01

.l3lE-ot

.16

.l

.o7
.05

.00

SECRECATING BIN
Unit number I
MODSIM model name SEGB
Job name: mineral
technology

CRTTICAL SIZE .254

LOC SLOPE .240
RECOVERY OF SOI-IDS TO
FINER S'IREAM .550

.41

.29
.21

.O2

lE-03

.01
.01
.01
.01

.290E-03
.205E-O3

PARAMETERS:
RECOVERY OF FINES .550
RECOVERY OF
INTERMEDIATE SIZES
.660

.|6E-O2

.821E-O3
.581E-03

.000

lE-03

.80
.57

.00
.00
.00

.r45E-03

E-03
E-03

1.12

.9298-02 .15
.651E-02 .ll
46sE-02 .08
.328F-02 .05
.232E-02 .04
.164F-02 .03

.4t

UNIT EQUIPMENT DATA

sHEE--t

5.91

4.25
3.05

.743E-0t
.526E-0t
.

Estirnated power
reouirements -l 19. Ku;

lmpact work index of th

material is 16.00 kwhr/ton
80% passing size in feed is
l.3l mms.
80o% passitg size in product
is 123.97 mms.

UNIT EQUIPMENT DATA

SIIEET - WET SCREEN
Unit number 3
MODSM model name SCRt
PARAMETERS: D5O size
100 0 microns
Water split to undersize
.95
Sha.pness pammeter alpha
1.000

Particle size distribution in

the feed.

Size

o/o

passing

mms

4.21
2.97
2.10

99 86
98.63
94.09

a4 52
70 80
55 6l
41 .49
29'78
20 80

.58t

4l

1.26

.84
.55

E42
E42
E42

.24

.t6

.ll

.o7
.05
.00
size distribution in
oZ

passing

99.85
98.53
93.69
E3.47
6E.82
52.60
37.52
25 02
15.44
8.45
3.70

|.57
7E-0\
I
-01
-01

.40
.22

64E-01

".12
' o"1

t6E-0 |
I E-02

o4
.03

.o2

.41tE-o2 .ol
290E-02 0l
.205e-o2 .00
t45E-O2 .00

.000

t426
9.65
I
6.48
4.33
I
2. E8
I
r9l

E-02

'l'onnage to be processed
45.76 to'rs per hour
Opcn-side selting I40

Size distribution in feed

.00

Size
Particle size distribution in
the

underflo*

Size

o/o

passing

n|ms

4.21
2.9't
2.t0
|.49
1.05
743
.526
.371
.263
.186
.l3l

t00.00
100.00

100.00
100.00
100.00
100.00
100.00
100 00
100 00
100.00
97.44
.929E-0t 78.95
.657E-01 56.90
.465E-01 39.38

.328F'-01

26."79

.2328-01 18.09
.r64E-01 12.t4
.l

l6E-01

8.09

.82tE-O2 5.39
.58tE-02 3.58

.4llB-o2

2.38

.290E-02 t.58
.205F-02 l.o4

.t45E-02

000

.69
.00

INIT EQUIPMENT DATA

SHEET.
JAW CRUSHER

Unit number 7
MODSIM model name JAWI

oZ passing

cms

.4/t '
.297
.2lo
.149
.r05

99.85
98.57
93.87
83.93
69.69
.7 43E-01 53 .92
.526E-Ol 39 .25
.311E-Ot 27 10
.2638-01 17.7a
.1868-0t t0.99
.l3tE-01 6.30
.9298-02 3 .12
.657E-O2 2.32
.465E-02 I .48
.324F-02 .96
.232D-02 .62

.t648-02
.116842

.41

.27

.821E-03 .17
.581E-03 .n
.41l

E-03

.08
.05
.205E-03 .03
.|
.o2
.00

.290E43

458-03

.000

Top size in fecd is

approximstely .32 cms
"Fall through', material in
feed I00.00 percent.
Scalping ofthe feed is
recommended.

Size distribution in product

Size

o%

passirrg

9l

4.25
3.05
2.18

4l

)56
1.t2

-0t

{Jt

.41

{]l

.29

2l
t5
.l I

-o2
J)2
J)2

08
.05

-o2

.\)4
.03

-o2

.o2

E-03

.01

E,0l

.01

1E,03
-03

01

0t

00

E-03

.0cl

1.000
Particle size distribution in
the feed.
9/o passing

Size

work index ofthe

rs 16.00 kwhr/ion
passing size in feed is
pirssrng stze rn product

enrs -179.

kW

EQUIPMENT DA'I'A

tiE'r

lVEI'SCREEN
2

model name SCRI

ETERST "
sze 100.0 microns

.263
.186
.t3t

t s.44
E.45

3.'70
|.5'1
.'76
.4658-01 40
.328E-0t .22

.9298-01
.6578-01

.232F.

99 86

Ol,

.t2

9E.63

.r64+01
.l r6E-01

94 09
a4 52
70.80

.581E-02

.02

.41|

.01

55.61

4t.49

29.7a
20.80
t4.26
9.65
.929E-01 6.48
.6578-0t 4.33
.465E_01 2.88

.328E-0t

.232E-01

.1648-0t

l6E-01

.821E-02
.581E-02

.4tlE-02

.91

.26
.84
.55

.37
.24
16

.290E-O2 .l

I
.07
.05
.00

.205E-02
.1458-02

000

97 mn)s.

nu,nber

4.21
2.97
2.t0
149
Los
.743
.526
.37 |
.263
.t86
.t 31

.l

.{.x)

Sharpness parameter alpha

.80

-{) I

-1)

Watersplit to undersize
.95

Particle size distribution in

the ovcrllorv.
Size o/o passing
mnls
421 99.85
2.97 98.53
2 to
93.69
| .49
a3.47
l 05 68.82
743 52.60
.526 37.52
.371 25.02

82tE-O2

E-02
.290E 02

.o7
.04
.03

.2051.'02
.t45F,,O2

.00
.00
.00

.000

Particle size distribution in

the underflow
oZ passing

Size
rnnrs

2t
2.97
2 r0
t.49
I 05
.743
.526
.371
.263
.186
.r3|
4

t00.00
t00.00
100 00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
9',7.44

9298-01

.657E-0

.465ti-ot

78 95
56 90
39 38

.3288-01 26.79
.232E-01 18.09

.1648-0t

rr6E-01

82tF,-O2

.s8lE-02

l2.t 4
809
5.39

1.58

41lE-O2 2.38
.290E-02 |.58
.205E-O2 I 04

.145E-02

.69

00

Totri size in feed is

approximately .32 cms

IPMENT DATA

ber

model name JAWI

"Fall through" mate.ial in

feed 100.00 percent.
Scalping ofthe feed is
recommended.
Size disrribution in product

to be processed
hour

Size

s per

|(lcsc ing 9 t4r)

bution in feed
?6 passing

99 85
98.53
93.69
a3.47
68.82
-0t
52.60
l
E4l 25.02

t5.44
-01

E.45

lE-01

3.70

-o2

L57

-o2
E-O2

tl--o2

E-02
E-02

t6E-02
tE-03
tE-03
tE-03

.40
22
.12
.07
.04
.03
.02
.01
.01

E-03
45E-O3

-.00
'.oo
00

oZ passing

cms

.421
.297
.2lo
.149
to5

5.91

4.25
3.05
2.18

L56

743E-Ol

.371E_0t

.80
57

.263E_Ol

.186E-0t

.41

E_01

.29

.l3

.21

.9298_02 .l5
.657E-02 .I I
.465E-02 .08
.328E_02 .05
.232E-02 .04
.t64F'-02 .03
.116F.-02 .02

.82t8_03
.5818-03

.ot

.4t

.01

IE_03

290E-o3

.205E_03

.01

.01

.00
.00
.00

.r4sE_03

.000

SEGREGATING BIN
Unit nrurrber

Impact work index of the

materiat is 16.00 twhr/ton
passing size in feed is
, -8090
8@/o passing sizein product
rs 121.97 mms.
Estimeted power
requtrements _gl.g kw

M0ttSIM modcl

0/

nanre SEcB
PARAMETERS:
RECOVERY OF FINES .55O
RFCOVERY OF
IN'TERMEDIAl'E SIZES

.660

cRt' c^t. stzE

LOc st_oPti .240

o5o

RECOVERY OF SOt,IDS TO

TJINUR S

1.12

.526E_Ot

UNTI EQUIPMENl' DATA

SI{EE1'

IREAM

55O

UNTI EQUIPMENI' DA'I.A

SHEEl'_
WOT SCRf,EN
Unit number l2
MODSIM model name SCRI
PAR METERS:
D50 size 100.0 microns
Water split to undersize.95
Sharpness pammeter alDha

|.000

Psrticle sizc distribution in

the feed

Size

o/o

passing

n)n)s

21
2.97
2.10
.49
L05
.743
.526
.371
.263
.186
.t3t
4

8.90
7.29

6.t3

5.29
4.69
4.26
3.95
3.73
3.57
3.45
3.29
.9298_01 2.65
1

I.91
| .32
90

-o

.61

-{)

.41

.24

.t8
.12
.08
.05
o4
02
.00
size d;stribution in
7o passing

5.08

3.89

Size

4.21
2.97
2.to
1.49
t.05
.143
.526
.37t
.263
.I86
.f 3l

o%

passing

00.00
t00.00
to0.o0
t00.00
t00.00
| 00.00
100.00
100.00
100.00
100.00
99.76
.9298-Ot 89.50
.657F-Ot 68.83
.465E-0t 49.56
.3288,01 34.65
.2328-01 23.89
|

t.98
L66
|.43

00

l. l6
|.00
.58

.31

.t7

I
I

.10
06

.03

-01

.o2

E-02
E-02

.01

tE42
42

.00

E02
e size

.01

00
.00
.00
.00

distribution in

lIltDs

421 67]
2.9',7 5.08
2.t)
3.89
1.49 3.01
1,05, 2.42
.743 L98
.526 t.66
37 t
1.43
.263 |.27
186 lt6
t.00
.tll
.

929E-01
.6578-01

.58
.31

.465E-Ot t'l

.l

.411E.02 3.33
.290F-02 2.23
.205E-02 1.49
.145E-O2 .99

-0t

passrng

4.98

303

.000

o%

7.41

.82t
.58t

t27

Size

.328E-01
.232E-01
.1648-01

.164E-01 t6.29
.1168-01 l l.0l

E-02
E-02

Size distribution in feed

l6E-01

.a2tE-o2
.581E-02
4t1E-O2
.2908-02

|0
.06
.

.03

.02
.01
.01

.00
.00
.205t:.-o2 .00
. | 45E-02 .00
.00

.000
UNTf EOUIPMENT DA'TA
SHEET
S'IANDARD CONE
CRUSIIER
Unit number l5
MODSIM model name CRSH
PARAMETERS:
Fines fraction .2000
Classification function
parameters .004 -026
Tonnage to be processed
53.72 tons per hour
Closed side setting 25.40
mms

Top size in feed is

approxinlatelv 668.'nnN
Opel| side feed opel|ing
must be at least 835 mms
Size distribution in product
7o passing
mms

Size

4.21
2.97
2.t0
| 49
l 05
.743
.526

100 00
100 00

t00.00
100.00
100 00

100.00
95 82

78 t:]

6l

15

49 05
4Q.10
-01
-01

32.95
27.35
22.A7

19.1 8

-01

t6.lo

l3.52

-0t
tE-02
lE-02

I 1.36

9.55
8.03

1E-02

567
E-02

4.77
4.Ol

E-O2

.{J0

work index ofthe

is 16.00 kwhr/ton
passing size in feed is
mms.

passing size in product

power

420.

kW

EQUIPMENT DATA
SC'REEN

number 11
model name SCRI

TERS:
| 00.0 microns
splil lo undersize

size

ess parameter alpha

le sizadistribution in
9'o

passing

.7

.l

.82

]--u2

5.29

581E-02

4.69
4.26
3.95
3.73
3.57
3.45
3.29

.4t I

E-02

.2328-0t
.I64E-O|

.61

.t

.2a

.41

l6E-01

.a2tB-02 .l8
.581E-02

.4ttB-02

.2908-02
.205F-02
.145E-02

.12
.08
.05
.O4

.o2
.00

Panicle size distribution in

the overflow
% passing
mms
6.73
5.08

Size

4.2t
2.97
2.10
1.49
1.05
.743
.526
.37 |
.263
.t86
.t3l

3.89
3.03

2.42
1.98

1.66

|.43
t.27

LI6
1.00
.58

.929E-01

.657E_O1

.465E-01

.3288-0t
.232E_Ot

164[-0t
t6E,0t

8.90
't.29
6 t3

.929E-01 265
.65?E-01 l.9l
.465E-01 1.32
.328E-Ot .90

.000

mms.
ts

4 2l
2.97
2.to
1.49
L05
43
.526
.371
.263
.186
.r3I

.31

.17
.10
.06

0-l
02

.0t
.01

.00
.00
.20s8-o2 .00
145E.02 .00
.o0

.290l;_02

.000

Particle size distribution in

the underflow
7o passing
mms
100.00

Size

4.21
2.97
2.10
|.49
1.05
.?43
.526
.371
.263
.186
.l3l

100.00
100.00
100.00
r00.00
100.00
100.00
| 00.00
100.00
100.00
99.76
.929E-01 89.50
.657E-01 68.83
.465E-01 49.56
.328E-01 34.65
.232E-01 23.89
.1648-0t 16.29
.l t6E-01 I l.0l

.821E-02

.58t842

7.41

4.98
3.33
.2908-02 2.23
.2058-02 | .49
.t 4sE-O2 .99
00
.4r

lE-02

.000

UNIT EQUIPMENT DATA

SHEE'I'_
STANDARD CONE
CRUSIIER

ber 14
model name CRSH
ERS:

ion.2000
.026

to be Processed
tons per hour
side setling 25 40

distribution in fced

o/o

Passing

ns

97
-10

49
-o5
3
26
7t
263
,186
-l3l

508
3 89
2 42

1.2'l

Ol

1.00

.465F.-01

l6E-01

.11
.10
.06
.03
.o2

.a2lE-OZ

.01

.2908

6. 1 0

8 03

6.75
5-67

02

.2O58-OZ 41'l

.31

4 01
00

.000

lmpact work index of the

material is 16 00 kWhr/ton
ts
80Yo Passing size in feed
187.46 mms.
809/0 Passing size in Product
.38 mms.
Estinrated Power
requirements 344. kW

.01

1E-O2

.00
.00
.205F-02 .00
.145E-02 .00
.00

is

000

ToP size in feed is

668

cruTlcAL slzE .oso

I oG St-oPE .240
nlcovrnv ot- sot tns
FINER S]'REAM 55I)

ro

IiQUIPMIN I DAI A
Stltrt f - SE(;RF(iA IING
BIN
TJNTI-

Unit nunrber 27
MODSIM model name 5EUt'
P^RAMETERS:
'neiovenY on
sso
RECOVDRY OF
INTERMEDIATE STZES
.660
CRITICAL SIZE .O5O

ntlrs

kg8i"'8[?

"'J3"'*

FINER STREAM '550

'"

.145E-02

.2901'.-02

rpp(oximately

.660

13 52

.581E-02
.411E-O2

Ll6

.58lE-02

Unit number 2S
MODSIM model name SEGB
PARAMETERS'
5:{.)
RECOVERY OF FINES
RECOVERY OF
INTERMEDIATE SIZES

.l l6E-01 11 36
.a2lE 02 9 55

1.43

929E-Ot
.65?E-01

.4t

4.21
2.9't 100 00
2)0 100 00
1.49 100 00
1.05 100.00
:743 lo0.o0
:26 95.a2
.311 78 13
.263 6l .3 5
186 49.05
40.10
.13 |
.929F'Ol 32 95
.651E Ol 2715
.1648-01

| .66

.164E-01

mms

Size distribution in Product

7o Passing
mms
100.00

.232E

L98

32'aE-ol
.2328-Ol

E35

.4658-01 2281
.3288-01 19 18

301

.58

must be at least

Size

ion function

oo4

0pen side feei oPeotng

mms

UNIT EQUIPMEN'T DAIA

SHEET . WET SCREEN
Unit number 20
MODSTM model nanre SCRI
: PARAMETERS:
100.0
D50 sizc
Water sPlit to undersize
.95
Sharpness Parameler alPna

UNIT EQUIPMENT DATA

1.000

SHEET

Particle size distribution in

the feed

SEGRECATING BIN

7o Passlng

t00 00
t()0 0o
I00.00
100.00

t(x) o()

4t lri,-oz

q5.92

74.64
62.24
50.23
41 4E

-ot

34.2'7

| 28.32
1 23 49
-01 r9.54
1
-01

E-01

E42
E-02
tE42
E-02

16.24
13.59

l r.36
9.50
7.96
6.67

559

4.69
3.94
.00

size distribution in
o%

passing

00.00
| 00.00
100.00
100.00
100.00
100.00
94 (]3
68.76
44.78
r

21.21

14.86

?E-ot
E-01
9F.-0t

2l

5 16
3.51

L83

i.38
l.o7

.l I6ti-ol
.82tF.02
.58 | E-02

lfi).u)

249

.3288-01
232E-Ol
.t 64n-01

.84
.67

.45
.205E 0?
.31
.t 45E-02
Partiole size distribution in
the underflow
Size 9/o Passing
mms
100.00
100.00
100.00
100.00
100.00
100.00
100.00
100.00
.37
100.00
100.00
99.03
.9298-01 90.58
.657E-01 74.37
.4658-01 66.69
.2904i,-o2

4.21
2.97
2.10
1.49
L05
.743
.526
|
.263
.186
.131

.328E-01 t6.38
.2328-01 47.52

.t64E-01
.1168-0t

39 .91

33.60

.a21E-02 28.22
.581E-O2 23.70
.41I

E-02

19.90

.290E-02 t6.71
.20sE-02 | 4 .03
.145E-02 lt.79

.000

.00

UNIT EQUIPMENT DATA

SHEET_
SI]ORT HEAD CONf,
CRUSHER

Unit number 22
MODSIM nlrdcl name StllID
I'ARAMIi'I'I,:RS:
lrincs fiaction .2t)00
Breakage function
K(x/y)^o.518 + (lK)lxlv)"2 475
Classification furrclion
pammeters .!O5 .O29 n=2
Tonnage to be processed
tons pet hour. Closed
10.00 mms
setting
side

20.68

Size distribution in feed

Size

o/o

Passing

mms

4.21
2.97
2.t0
1.49
L05
.'743
.526
.371
.263
86
.i3t
.1

100.00
100.00
100.00
100.00
100.00
100.00
94.03
64.16
44.',78

27.21

14.86

.929E41

8.21

.657E-01
.4658-01

5.16
3.51

.328E-0t 2.49
.232E-0t L83
.164E-01 1.38
.l

l6E-0t

.a2lE-02

l.o7

.205E-O2

.44
.61
.55
.4s
.37

.t45E-O2

.31

.581E-02
.4t

tE-oz

.2908-02

.000

.00

Top size in feed is

approxinraiely.6J8

mnrs

Stream Data Re ort

trumber: I
ti 22.50 tonne/hr
0

L/rnn

flowrate 6.25 kg/s

flowBte:
m^3/s
solids by mass:
%
solids by volume:
vo

solids: 22.50 %
size distribution
ofsize classes: 25

.4llE-05

.16

.000

.07
.05
.00

.290E-05
.205E-05
.145E-05

.ll

Stierm number: 2
Solid flowrate: 25 ?6 tonne'/hr
Water flo\rrate: 0ljmin
Slurry flowlate: 7.16 kg/s
Slurry volumetric flowrate:
.35"198-02 n{3/s
Percnt solids bY mass:
100.00 %
Percent solids bY volume:
100.00 %

ztn

Yield of solids: 25.76 %

isml

3m

Simulated size distribution

Number ofsize classes: 25

isinl slze:

3m
o/o

lE-02

Passing

99.86
98.63

80olo passing size:

.136E'-02 m
50oZ passing size:

.703E-03 m

0E-02

94.O9

20oZ passing siz:

t49E-02
t05E-02

a4.52
70.80
55.61
41.49
29.78
20.80
14.26
9.65
6.48
4.33
2.88

.316E-03 m

:1438-03
71E-03

lE-03
l86E-03
-131E-03

.929F,04
.65TE-U
-4658-O4

l 9l
.328F-04
1.26
.232E 04
"a.84
.164F-04
.55
.116E-04
.37
.821E-05
.58lE 05

.24

Size

Yo Passing

merers

.42rE-02 99.85
.7,TF.O2 9A.53
.2108-02 93.69
.149E-02 A3.4'7
.105E-02 68.82
.7 43E-03 52.60
.526F-03 37.52

.37lYO3

25.02
.263F-03 15 .44
.186E-03 8.45
.131E-03 3.70
.9298-04 1.57
.65TF-04 .76
.4658-04 .40

.3288-04

.232F-M
.\64F-04

.22
.12

.0'l

.116E-04 .04
.821E-05 .03
.581E-05 .02
.411E:05 .ol
.290E-05 .01
.205E'-05 .00
.1458-05 .00

.000

.00

Stream number: 3
Solid flowrate: 1 43 tome/hr
lvater flowrate: 0 L/min
Slurry flowrale: .40 kg/s
Slurry volumetric flowrate:
.1985E-03 m^3/s
Percent solids bY mass:
100.00 %
Percent solids bY volume:
100.00 %
Yield ofsolids: 1.43 %
Simulated size distribution
Number ofsize classes: 25
8070 Passing size:

.941E-04 m
5flo passing size:
.5'7TE-04 m
207o Passing size:
.253F-04 n

Size

o/o

Passing

metels

.421E-02 100.00
.29T8-02 loo.o0
.210E-02 100.00
.1498-02 100.00
.105E-02 100.00
.743E-03 100.00
.526E-03 100.00

__-

____.6u.a

?3

--__.S1.eon36

/j1
/*'-/

taE

Psr

2.34E{r

1.36E{2

[-

ticlc

SlFw r.r.6r

iar

ffidhd.t

+.+: DISTRlBUT]ON

6RAPHS

CONCLUSIONS

dynamic

flow

sheet

of the HGML qushing circuit

was

constructed using MODSIM 3.6.14. The simulation was ex@uted successfirlly

and results were obtained- Also the crushing data of the HGML werc collected
and compared with the simulation rcsults.

It was found that the simulation results

Dearly

tally with tho'praJtical data of thg

Dlant .

The simulation studies of HGML plant crushing circuit helpful in many

ways.

l.

just a graphic image

The flowsheet is dynamic, unlike the static one which is
plant
Here every rmit and the whole circuit mimics the v'iay the circuit and the
behave.

2.

The simulation studies help tune the plant to

vsy the feed quantity

&

the

qualrty.

3.
4.

Perfonnance changes could be investigated by working ofwhat

ifpossibilities'

Optimum performance ofthe plant can be approached '

Simulation and modeling of mineral processing plant demands a tbrough
mathematical analysis; but computer based MODSM simulation obviates the
hcHles of the mathematics. Hence we could focus more on mineral Focessing

operalion rather than on mathematics. We can corclude that the

sirnulation

yielded reliable and valid description of acnral crushing circuit operation'

REF'ERENCE

l.

R.P.King Modeling and Simulation ofMineral processing system (2001) UsA

Utah University.

MODSM 40 edition Mineral Technologies. Inc. ofuser manual (2001)'

2.

B.A.Wills Mineral processing Tecbnology 5' edition ,

4- Sangurmath prabhakar (2001): Uti gold deposit evolving
3.

sPQo.

Hhlti-Maski

Green store belt , India Geol Surv. Ind Spl, pub No, 58 pp289-292

Roy A (1991) The Geology of gold Minemlization at Hutti-Maski schit belt'

5.

Kamataka-India Brazil gold

6.
7.

E.A Laderia (E.D) Bakena publicalion pp539-540

Gotden Jubilee celebration olHutti Gold Mines (1998) editor

of Dr' M'L'Patil