1.

Accurate feed sample size distribution - it is very important to accurately know what the
fresh AG feed distribution was for a given survey. However, the AG feed can only be
sampled during a crash stop AFTER the main survey period is completed. Also, it is
important that steady-state conditions were maintained throughout the sample period
prior to the crash stop. If there were any significant process upsets, including known
variations or interruptions in feed, it would be better to cancel the survey and start a new
one. To accurately know the size distribution of a coarse dry feed usually requires large
amounts of sample, per the principals of statistics applied to sampling. JKTech suggests
a simplified approach. An important preparatory step is to measure belt speed accurately
with a tachometer. This, combined with the weight of sample taken from a known length
of belt, will provide a check against the weightometer reading for tph. Once the belt is
stopped, select a length (minimum 3 meters, but more preferably 5-6 meters if possible)
to be sampled. Using a 76 mm "one hole screen" (a metal device, fabricated in your
shop, with 76 mm x 76 mm opening). Have someone move along the belt using the
"one-hole screen" to visually and manually select all rocks larger than 76 mm and throw
them into a 55 gallon drum for later sizing - this is the coarse fraction. Then go back
along the length of belt selected and clean off all of the minus 76 mm material into a
separate drum. You will probably have close to 200 kg in each drum if the cut was
around 5 meters in length. The contents of the two drums can then be sized at your
convenience any time after the survey. For the coarse rocks, the easiest method is to
make more "one-hole screens" of 100 mm, 125 mm, 150 mm and 200 mm in size (add
250 mm and 300 mm if you think you have rocks that large in the feed). Just dump out
the coarse fraction contents onto a concrete pad and using the "one-hole screens"
manually sort the rocks into the appropriate sizes of +76 mm, + 100 mm, + 125 mm, +
150 mm, +200 mm, etc. You can probably use tared 20 or 40 liter buckets as
receptacles for the individual sizes. Weigh and record each size fraction. As for the fines
drum, you should record the total weight of sample but do not need to size the entire
sample - use standard splitting procedures (roll, cone and quarter) to reduce the sample
down to a representative sample of size that can be easily sieved in the laboratory. Then
perform the sieve analysis to determine the following sizes: +50 mm, +38.1 mm, +25 mm,
+19 mm, + 12.7 mm, +6.35 mm, +4.76 mm, +2.38 mm, etc. in a root-2 series down to
and including 37 microns. (For JKSimMet modeling, it is important to know the fines in
the AG feed down to the finest practical sieve size). Once you have the coarse and fine
size distributions, use the total sample weights to recombine them for the total sample
size distribution. The key to determining the length of belt to be cut is to have a minimum
of at least 50 rocks that are plus 76 mm in size contained within the sample - much less
than 50 rocks reduces the confidence limits of the coarse size fraction. The fine portion
actually measured can be much smaller (as indicated by the procedure above) as the
fines tend to be more evenly distributed along the belt than the coarse rocks. In our
experience, 3 meters of belt is usually the shortest length that will contain enough (50 or
more) large rocks.
2. After sizing, recombine the coarse and fine fractions and send at least 150-200
kg sample to SGS (Lakefield) for JK drop and abrasion testing. To calibrate the
JKSimMet model, it is important that the actual survey feed material be drop tested to
provide the A, b and ta parameters used by the AG model to characterize the ore
hardness.
3. Mill crash stop is important. After survey, mill should be shut down with minimum number
of revolutions after shutting off feed to avoid grindout of charge. Also ensure ALL water
to mill is shut off at same time as feed to avoid false estimate of water content in charge.
Also following the crash-stop of the mill at the end of the survey, it is very important to
enter the AG mill to measure the following:
• total mill load level at at least three points within the mill - feed, middle and discharge
• internal mill dimensions (to account for liner wear up to the point of the survey),
including plate to plate diameter, height and width of lifter bars, so as to allow later
calculation of an effective inside liner diameter to determine mill volume. If digital
 camera is available, photographs should be taken,using a marked 100 cm plastic
disk as dimensional reference. Photos should include lifters, end liner/lifters and mill
charge in several locations (could possibly be used for later digital image analysis of
load size distribution)
• measure state of grates by taking length and width of representative grate openings
at several locations. also note if any significantly worn or broken grates - phots here
will be of immense help later
• Consult plant safety personnel for proper procedures for entering mill (lockout
procedure, waiting period required to avoid falling or exploding balls, and other
hazards) - never enter mill without prior consideration of safety procedures. If safety
conditions preclude entering mill to determine load and liner conditions, at minimum
attempt to look into mill (usually via feed or discharge trunnion opening) to visually
estimate mill load levels and liner/grate conditions. Use a measuring stick or plumb
line device to infer load level by estimating distance from trunnion lip to charge top.
• estimate level of pulp (fines plus water) relative to total charge (includes rocks and
balls) by using a measuring stick to determine pulp level in the pulp lifter at the
bottom vertical position after crash stop.
4. During survey period, prior to crash stop, be sure to measure mill power draw for at least
one hour (presumably via DCS. An average reading for mill power draw will be used as
representative of the conditions during survey. It is important to know if the DCS power
reading represents power drawn at motor or power after subtraction of motor and drive
losses. It would be good (but not essential) if an electrician could take an actual power
reading across the mill motor leads during the survey as a check against DCS readings.
During survey also be sure to check and record mill speed in rpm using a tachometer.
5. The only other dry samples to be taken after crash stop include the AG screen (or
trommel) oversize and the recycle crusher product. These are fine enough that a 1-2
meter belt cut will suffice to obtain a representative sample. As with the feed sample,
measure belt speed with a tachometer and use sample weight per unit of length as a
check against weightometer tph readings. The oversize sample should be sized to as
fine as practically indicated by visual inspection of the sample. Choose the largest
screen for this sample based on retaining no more than a few percent on that size (10-
20% retained on 25 mm screen would indicate that there are significant quantities of
large rocks such as 38.1 and 50 mm, perhaps). As for the crusher product, screen the
sample all the way down to 37 microns, as there will be fines.
6. Remaining samples should all be wet samples taken during the survey period. JK
recommends taking 4 cuts for each sample at 15 minute intervals (15 minutes after start,
30 minutes after start, 45 minutes after start and 60 minutes after start) - as there are
multiple samples of this type, you will need several personnel standing by to take the
samples at the same time intervals during the survey. Samples should be composited in
tared 20-40 liter buckets. After survey, the samples should be weighed wet, then dired
in an oven and weighed dry to calculate % solids (DO NOT RELY ON MARCY
READINGS FOR % SOLIDS - NOT RELIABLE ENOUGH FOR MODELING). Sample
points should include (if possible) AG discharge (possible in some plants), AG screen
undersize (also ball mill feed sump?), cyclone feed, cylone overflow, cyclone underflow
and ball mill discharge. The AG and ball mill discharge samples may not be truly
representative due to difficulty of access, but if they can be taken, are always a good
check on the other data. The cyclone underflow and overflow are essential to performing
a balance around the circuit. If there is a mag flowmeter reading for the cyclone feed it
should be recorded.
7. During survey, all water addition points should be measured for flowrates - if flow is
intermittent, we'll need multiple readings to determine an average of each flow.
8. Ball mill power should be recorded as should cyclone pressure during the one-hour
survey period.
 9. After survey, check cyclone dimensions and record, including number of operating
cyclones, diameter of cyclone, vortex finder diameter, apex diameter, cylinder length,
cone angle.
10. After survey, visually inspect ball mill charge and measure or estimate charge level and
liner conditions.

This information should provide the basis for a reasonably accurate model of the circuit. I hope
this helps. Please let me know if you have any questions