Documente Academic
Documente Profesional
Documente Cultură
on
tested by
A.R.MacPherson Consultants Ltd
at
SGS Lakefield Research Chile S.A.,
Santiago, Chile
for
Antamina
on
Submitted to
Antamina
TABLE OF CONTENTS
Page No
1 INTRODUCTION.................................................................................... 1
2 DROP WEIGHT TEST PROCEDURE ................................................... 1
2.1 Impact Breakage Testing........................................................... 1
2.2 Abrasion Breakage Testing ....................................................... 3
3 USING STANDARD DROP WEIGHT TEST RESULTS IN JKSimMet ... 3
3.1 SAG/autogenous Mill Model ...................................................... 3
3.1.1 High Energy or Impact Breakage........................................ 3
3.1.2 Low Energy or Abrasion Breakage ..................................... 3
3.1.3 Combined Breakage ........................................................... 4
3.2 Crusher Model ........................................................................... 4
3.3 Limitations ................................................................................. 4
4 RESULTS............................................................................................... 5
4.1 SAG/autogenous Mill Model Parameters................................... 5
4.2 Crusher Model Parameters ....................................................... 6
5 COMMENTS ON STANDARD DROP WEIGHT TEST RESULTS ......... 8
5.1 Resistance to impact breakage ................................................. 8
5.2 Resistance to abrasion breakage .............................................. 8
5.3 Effect of Particle Size on Resistance to Impact ....................... 11
6 ORE DENSITY MEASUREMENT ........................................................ 13
6.1 Results .................................................................................... 13
6.2 Comments on Ore Density ...................................................... 14
7 REFERENCES..................................................................................... 18
8 DISCLAIMER ....................................................................................... 19
TABLE OF FIGURES
Page No
Figure 1 - The JK Drop Weight Tester .................................................................. 1
Figure 2 – T10/Ecs Relationships for M4A, M4-M4A-M2, M-1 and MP................... 5
Figure 3 - Frequency Distribution of A*b in the JKTech Database...................... 10
Figure 4 - Frequency Distribution of t10@1kWh/t in the JKTech Database ......... 10
Figure 5 - Frequency Distribution of ta in the JKTech Database ......................... 10
Figure 6 - Variation of Impact Resistance with Particle Size for M4A ................. 12
Figure 7 - Variation of Impact Resistance with Particle Size for M4-M4A-M2..... 12
Figure 8 - Variation of Impact Resistance with Particle Size for M-1 .................. 13
Figure 9 - Variation of Impact Resistance with Particle Size for MP ................... 13
Figure 10 - Histogram of the Relative Density Measurements for 30 Particles
for M4A........................................................................................................ 15
Figure 11 - Histogram of the Relative Density Measurements for 30 Particles
for M4-M4A-M2 ........................................................................................... 15
Figure 12 - Histogram of the Relative Density Measurements for 30 Particles
for M-1 ......................................................................................................... 16
Figure 13 - Histogram of the Relative Density Measurements for 30 Particles
for MP.......................................................................................................... 16
TABLE OF TABLES
Page No
Table 1 - SAG/Autogenous Mill Parameters for the Four Samples....................... 5
Table 2 - Crusher Model Parameters for M4A ...................................................... 6
Table 3 - Crusher Model Parameters for M4-M4A-M2.......................................... 6
Table 4 - Crusher Model Parameters for M-1 ....................................................... 7
Table 5 - Crusher Model Parameters for MP ........................................................ 7
Table 6 - Parameter Interactions for the Four Samples........................................ 9
Table 7 - Relative Density Measurements for 25 Particles for M4A.................... 17
Table 8 - Relative Density Measurements for 25 Particles M4-M4A-M2 ............ 17
Table 9 - Relative Density Measurements for 25 Particles M-1 .......................... 17
Table 10 - Relative Density Measurements for 30 Particles MP......................... 18
1 INTRODUCTION
Drop weight test data for four samples, identified as M4A, M4-M4A-M2, M-1 and MP
from Antamina Project 3419 were received on July 9, 2003 from A.R.MacPherson
Consultants Ltd by JKTech for analysis. The analysis was completed on July 10,
2003.
The JKTech drop weight test provides ore specific parameters for use in the
JKSimMet Mineral Processing Simulator software. In JKSimMet, these parameters
are combined with equipment details and operating conditions to analyse and/or
predict SAG/autogenous mill performance. The same test procedure also provides
ore type characterisation for the JKSimMet crusher model. These ore specific
parameters have been calculated from the test results and are supplied to Antamina
in this report as part of the standard procedure.
To characterise ore breakage at different energy levels, the JKTech method uses two
complimentary techniques:
An vil
Concrete
platform
Figure 1 - The JK Drop Weight Tester
After release, the drop weight descends under the influence of gravity and impacts
the target particle.
The particle is broken and the drop-weight is brought to rest at a distance above the
anvil approximately equal to the largest product particle. The difference in distance
between the initial starting point and the final resting place of the drop-weight is used
to calculate the energy that is expended in breaking the particle. Thus
where:
Providing the drop-weight does not rebound after impact, the application of equation
(1) is valid. Where rebound occurs an additional term is required to account for the
energy re-transmitted to the drop-weight. Rebound has been seen to occur only at
elevated input energies. This energy will be assessed during the test work program.
It is likely, however, that its magnitude will be relatively small and can be ignored with
only a minimal loss in accuracy.
The assumption is made that all the energy provided is utilised in the breakage of the
particle. Thus
Ecs = Eis = Ei / m
where:
To test an ore type, the original 100 kg sample is sized into selected fourth-root-of-
two size fractions. Ten (10) to thirty (30) particles are required in each size fraction
for each energy level, depending on particle mass. Typically fifteen (15) size/energy
combinations are selected. The input energy levels for a particular test are designed
to suit ore hardness but a standard set of energies are used whenever possible.
The breakage products of all particles for each size/energy combination are collected
and sized. The size distribution produced is normalised with respect to original
particle size. For a wide range of energy inputs, particle sizes and ore types, the
relative size distributions remain similar in shape and can be described by a single
point on the distribution. The JKTech convention is to use the percentage passing
one-tenth of the original particle size. This is referred to as the "t10".
In the manner described above, a set of t10 and Ecs values are produced for the 15
energy/size combinations.
The standard abrasion test tumbles 3 kg of -55 +38 mm particles for 10 minutes at
70% critical speed in a 305 mm by 305 mm laboratory mill fitted with 4 x 6 mm lifter
bars. The resulting product is then sized and the t10 value for the product is
determined.
The mean particle size of the original size fraction 55 x 38 mm is 45.7 mm. The t10
size is:
t 10 = A(1 − e −bEcs )
where A and b are parameters used by the JKSimMet SAG/autogenous mill model to
reproduce this relationship.
ta = t10/10
ta = 4.0 / 10 = 0.40
The assumption is made that all brittle rock types break with the same general
pattern and that general pattern is built into the model. This assumption does not
mean that the amount of energy required to achieve a particular t10 is the same for all
brittle rocks. It simply means that if a single particle is broken to a particular t10 value,
then the complete size distribution of the broken fragments is known.
This assumption is not perfect but is quite adequate for the purposes of the
SAG/autogenous model.
To use the results of testing, the ore type parameters A and b (from drop weight
testing) and ta (from abrasion testing), are input in the SAG/autogenous mill model
available in JKSimMet, together with machine dependent parameters of mill size,
grate size, ball load, etc. The simulation predicts product size and mill load using
appropriate breakage rates. The simulator can then also be used to predict mill
performance with variations in screen and classifier configurations or even with
recycle crushing.
Details of the SAG/autogenous mill model are given in Leung (1987) and Leung,
Morrison, and Whiten (1987). The calculations on which the power prediction for
SAG/autogenous mills is based are described in Morrell (1996).
The assumption that all brittle rocks break with the same breakage pattern is not
made and the pattern for the ore under test is used. The crusher model uses the
parameters given in Table 2. The appearance function defines the shape of the
breakage distribution curve at various degrees of "broken-ness", as defined by t10.
The specific comminution energy table defines the amount of energy required to
achieve varying levels of "broken-ness". The form of the specific comminution
energy table reflects the fact that the energy required to achieve a certain degree of
breakage is sometimes found to be dependent on the initial particle size.
Details of the crusher model including power prediction are described in Andersen
and Napier-Munn (1988).
3.3 Limitations
Experience to date demonstrates that the drop weight test is appropriate for brittle
ores over a wide range of hardness. However, it is not useful for ores which undergo
plastic deformation rather than brittle fracture, such as those of high clay content.
The testing procedure is limited by the maximum particle size tested. If the ore is
fractured or weaker at larger particle sizes, then JKSimMet simulations will be
conservative.
For autogenous mills it is essential to have competent material in the range 150 mm
to 100 mm in the feed to form the media. If autogenous milling is seriously
contemplated, testing of media competency at larger particle sizes should be
conducted. This can be achieved by drop weight testing, media competency testing
or full pilot plant testing.
4 RESULTS
Ore Type A b ta
50
40
30
20
10
0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
Ecs (kWh/t)
The figures for M4A put that material in the soft range of resistance to impact
breakage. 78.2 % of the 1438 ore types in by JKTech data base have lower A*b
values.
The figures for M4-M4A-M2 put that material in the soft range of resistance to impact
breakage. 71.6 % of the 1438 ore types in by JKTech data base have lower A*b
values.
The figures for M-1 put that material in the moderately soft range of resistance to
impact breakage. 68.8 % of the 1438 ore types in by JKTech data base have lower
A*b values.
The figures for MP put that material in the soft range of resistance to impact
breakage. 76.4 % of the 1438 ore types in by JKTech data base have lower A*b
values.
The frequency distribution of the parameters A*b and t10@1kWh/t from the JKTech
database of ores tested are given in Figure 3 and Figure 4 respectively.
With a ta of 0.35, M4A falls into the hard abrasion range compared with the other ore
types in Table 6. 28.8 % of the 1413 ore types in the JKTech database have lower ta
values.
With a ta of 0.40, M4-M4A-M2 falls into the moderately hard abrasion range
compared with the other ore types in Table 6. 37.5 % of the 1413 ore types in the
JKTech database have lower ta values.
With a ta of 1.63, M-1 falls into the very soft abrasion range compared with the other
ore types in Table 6. 92.7 % of the 1413 ore types in the JKTech database have
lower ta values.
With a ta of 0.40, MP falls into the moderately hard abrasion range compared with the
other ore types in Table 6. 38.6 % of the 1413 ore types in the JKTech database
have lower ta values.
The frequency distribution of the ta parameter from the JKTech database of ores
tested is given in Figure 5.
Data Base
15.8 1 0 13.8 1 0 0.06 1 0
Min (hardest)
Data Base
47.1 719 50 32.3 719 50 0.46 707 50
Median
Data Base
71.2 1054 73 35.1 856 59 0.67 1003 71
Mean
Data Base
955.4 1438 100 82.2 1438 100 5.78 1413 100
Max (softest)
M4A 79.9 1126 78.2 44.0 1143 79.4 0.35 411 28.8
M4-M4A-M2 68.7 1031 71.6 41.0 1079 75.0 0.40 531 37.5
M-1 103.7 990 68.8 51.9 1291 89.7 1.63 1311 92.7
175
150
125
Frequency
100
75
50
25
0
10
25
40
55
70
85
100
115
130
145
160
175
190
Mor
Ax b
140
120
100
Frequency
80
60
40
20
0
10
16
22
28
34
40
46
52
58
64
70
76
82
t10 @ 1 kWh/t
300
250
200
Frequency
150
100
50
0
0
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
2.7
3.3
3.6
ta
The data in Table 2 indicate that for particles of M4A up to 63 mm, some variation of
impact resistance with particle size occurs.
The data in Table 3 indicate that for particles of M4-M4A-M2 up to 63 mm, some
variation of impact resistance with particle size occurs.
The data in Table 4 indicate that for particles of M-1 up to 63 mm, some variation of
impact resistance with particle size occurs.
The data in Table 5 indicate that for particles of MP up to 63 mm, some variation of
impact resistance with particle size occurs.
The data for the four ore types presented in Figure 6 to Figure 9 are the t10 values for
up to 5 different particle sizes, all broken with the very similar specific comminution
energies (0.25 kWh/t, 1.0 kWh/t and 2.5 kWh/t). These data do not consistently follow
the frequently observed trend of decreasing slope with decreasing energy (Ecs
values). However, it is both the slope and the absolute values of the low energy t10
values that are of interest for SAG/autogenous milling as these data give an
indication of the ability of media particles to survive. If the trend of the t10 values with
increasing particle size is significantly upwards, it can be inferred by extrapolation
that particles in the 100 – 200 mm size range (normal media size) will not be strong
enough to survive. The same argument applies if the absolute values of t10 at low
energy are sufficiently high.
For M4A, the data indicate that media survival is not likely to cause a problem for
autogenous milling.
For M4-M4A-M2, the data indicate that media survival is not likely to cause a problem
for autogenous milling.
For M-1, the data indicate that media survival is likely to cause a problem for
autogenous milling.
For MP, the data indicate that media survival may cause a problem for autogenous
milling.
M4A
100
90 0.25
1.0
80
2.5
70
60
t10 (%)
50
40
30
20
10
0
10 15 20 25 30 35 40 45 50 55 60
Particle Size (mm)
M4-M4A-M2
100
90 0.25
1.0
80
2.5
70
60
t10 (%)
50
40
30
20
10
0
10 15 20 25 30 35 40 45 50 55 60
Particle Size (mm)
M-1
100
90 0.25
1.0
80
2.5
70
60
t10 (%)
50
40
30
20
10
0
10 15 20 25 30 35 40 45 50 55 60
Particle Size (mm)
MP
100
90 0.25
1.0
80
2.5
70
60
t10 (%)
50
40
30
20
10
0
10 15 20 25 30 35 40 45 50 55 60
Particle Size (mm)
6.1 Results
As part of the standard JKTech ore property assessment procedures, the relative
density of 30 randomly selected particles in the size range 31.5 mm to 26.5 mm is
determined by weighing each particle in water and in air. The results are given in
Table 7 to Table 10 and shown graphically in Figure 10 to Figure 13.
It should be noted that this method does not account for internal porosity in the
particles tested. More accurate determination is available using a Helium
Pycnometer.
The M4A data contain evidence of bimodality in the relative density distribution, that
is, evidence of a dense component which could concentrate in the mill load and
cause power problems.
The M-1 data contain evidence of bimodality in the relative density distribution, that
is, evidence of a dense component which could concentrate in the mill load and
cause power problems.
The MP data contain evidence of bimodality in the relative density distribution, that is,
evidence of a dense component which could concentrate in the mill load and cause
power problems.
M4A
6
Number of Particles
0
< 2.6
< 2.8
< 3.0
< 3.2
< 3.4
< 3.6
< 3.8
< 4.0
< 4.2
< 4.4
< 4.6
< 4.8
< 5.0
< 5.2
< 5.4
Relative Density (top of Range)
M4-M4A-M2
12
10
Number of Particles
0
< 2.7
< 2.9
< 3.1
< 3.3
< 3.5
< 3.7
< 3.9
< 4.1
< 4.3
< 4.5
< 4.7
< 4.9
< 5.1
< 5.3
< 5.5
M-1
12
10
Number of Particles
0
< 2.3
< 2.5
< 2.7
< 2.9
< 3.1
< 3.3
< 3.5
< 3.7
< 3.9
< 4.1
< 4.3
< 4.5
< 4.7
< 4.9
< 5.1
Relative Density (top of Range)
MP
16
14
12
Number of Particles
10
0
< 2.3
< 2.5
< 2.7
< 2.9
< 3.1
< 3.3
< 3.5
< 3.7
< 3.9
< 4.1
< 4.3
< 4.5
< 4.7
< 4.9
< 5.1
7 REFERENCES
Andersen, J. and Napier-Munn, T.J., 1988. "Power Prediction for Cone Crushers",
Third Mill Operators' Conference, Aus.I.M.M (Cobar, NSW), May 1988, pp 103 -
106.
Leung, K. 1987. "An Energy-Based Ore Specific Model for Autogenous and
Semi-Autogenous Grinding Mills." Ph.D. Thesis. University of Queensland
(unpublished).
Leung, K., Morrison, R.D. and Whiten, W.J., 1987. "An Energy Based Ore Specific
Model for Autogenous and Semi-autogenous Grinding", Copper 87, Vina del
Mar, Vol. 2, pp 71 - 86.
Morrell, S. 1996. "Power Draw of Wet Tumbling Mills and Its Relationship to Charge
Dynamics - Parts I and II." Transaction Inst. Min. Metall. (Sect C: Mineral Process
Extr. Metall.), 105, 1996, pp C43-C62.
8 DISCLAIMER
All JKTech Pty Ltd reports are subject to a standard disclaimer as follows:
1. JKTech Pty Ltd and University staff operating with JKTech Pty Ltd make
reasonable efforts to ensure an accurate understanding of client requirements.
The information in this report is based on that understanding and JKTech Pty Ltd
strives to be accurate in its advice.
2. While reasonable care has been taken in the preparation of this report/proposal,
this report/proposal and all information, assumptions, and recommendations
herein are published, given, made, or expressed without any responsibility
whatsoever on the part of JKTech Pty Ltd, whether arising by way of negligence,
breach of contract, breach of statutory duty or otherwise.
4. If liability is not, by law, capable of exclusion, then JKTech Pty Ltd accepts liability
to the minimum level set by that law.
6. JKTech Pty Ltd is not responsible in any way whatsoever for the error neglect or
default of others upon whom it has placed reliance in the preparation of this
report/proposal.
7. You shall indemnify JKTech Pty Ltd and its directors, employees, servants,
agents, consultants, successors in title and assigns against any claim made
against any or all of them by third parties arising out of the disclosure of the
report/proposal, whether directly or indirectly, to a third party.