Grinding circuits are fed at a controlled rate from the stockpile or bins holding the crusher plant product.
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This greatly reduces the masses being fed to the secondary ball mill and reverse flotation, thereby greatly reducing the total processing cost. From the plant results for this flow sheet, an iron concentrate containing 67.5 Fe could be produced from a run-of-mine ore containing 30.1 Fe, at a mass yield to the iron concentrate of 34.9, an.
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The high unit capacity SAG millball mill circuit is dominant today and has contributed toward substantial savings in capital and operating costs, which has in turn made many low-grade, high-tonnage operations such as copper and gold ores feasible. Future circuits may see increasing use of high pressure grinding rolls Rosas et al., 2012.
Autogenous grinding or semi-autogenous grinding mills can be operated in open or closed circuit. However, even in open circuit, a coarse classifier such as a trommel attached to the mill, or a vibrating screen can be used. The oversize material is recycled either externally or internally. In internal recycling, the coarse material is conveyed by a reverse spiral or water jet back down the center of the trommel into the mill. External recycling can be continuous, achieved by conveyor belt, or is batch where the material is stockpiled and periodically fed back into the mill by front-end loader.
SAG mill product feeds two parallel ball mills of 6.6m11.1m internal diameterlength, each with a 9.7MW twin pinion drive. The ball mills are operated at a ball charge volume of 3032 and 78.5 critical speed. The SAG mill trommel undersize is combined with the ball mills discharge and pumped to two parallel packs clusters of twelve 660mm diameter cyclones. The cyclone underflow from each line reports to a ball mill, while the cyclone overflow is directed to the flotation circuit. The designed ball milling circuit product is 80 passing 150m.
Several large tonnage copper porphyry plants in Chile use an open-circuit SAG configuration where the pebble crusher product is directed to the ball mills SABC-B circuit. The original grinding circuit at Los Bronces is an example the pebbles generated in the two SAG mills are crushed in a satellite pebble crushing plant, and then are conveyed to the three ball mills Mogla and Grunwald, 2008.
Figure 9.8. Partition curves for cyclones and screens in the grinding circuit at El Brocal concentrator.
Changeover is not one way, however a recent example is a switch from screen to cyclone, to take advantage of the additional size reduction of the denser payminerals Sasseville, 2015.
Fine wet screening definition, mechanism, and rules of thumb Development . of single stage ball mills in closed circuit with single or double stage hydrocyclones . Circuit product from all lines is combined and pumped to the flotation plants. Get Price.
S.L. Chryssoulis, J. McMullen, in Gold Ore Processing Second Edition, 2016.
D. Lunt, T. Weeks, in Gold Ore Processing Second Edition, 2016.
Ultrafine grinding UFG has continued to evolve in terms of equipment development. A number of specialist machines are commercially available including Xstratax27s IsaMill, Metsox27s Vertimill, Outotecx27s High Intensity Grinding HIG mill, and the Metprotech mill. UFG equipment has been developed with installed powers of up to 5MW.
Compared with conventional ball or pebble milling, the specialist machines are significantly more energy efficient and can economically grind to 10m or lower, whereas the economical limit on conventional regrind mills was generally considered to be around 30m. Coupled with improvements in downstream flotation and oxidation processes, the rise of UFG has enabled treatment of more finely grained refractory ores due to a higher degree of liberation in the case of flotation or enhanced oxidation due to the generation of higher surface areas.
Ultrafine grinding is used to liberate gold finely disseminated in metallic sulfides. KCGM is the first gold mine using ultrafine grinding followed by cyanidation Ellis and Gao, 2002. The gold sulfide concentrate is grind with an IsaMill to a P80 of 1012m. In the first 3years of operation, high consumption of cyanide and high gold content in leach residues were experienced with difficulty overcoming these issues Deschnes etal., 2005.
Figure26.15. Effect of duration of pretreatment on gold extraction from the Eleonore flotation concentrates. Pretreatment 0.25Lminkg oxygen, pH 11.0 cyanidation 2000ppm NaCN, pH 11.0, DO 35ppm, 20C, 35 pulp density Deschnes and Fulton, 2013.
For the addition of oxygen in the pretreatment, it was found that increasing the flow rate of oxygen addition from 0.13Lminkg to 0.25Lminkg reduced the cyanide consumption from 6.4kgt to 6.0kgt Figure26.16, as well as the gold content of the leach residue from 2.52 to 1.92gt Au. When the oxygen addition was increased to 0.53Lmin, the gold content of the leach residue increased to 2.46, while the cyanide consumption went to 5.5kgt NaCN Figure26.16.
Figure26.16. Effect of oxygen flow in the pretreatment on gold extraction from the Eleonore flotation concentrate. Pretreatment 2.00kgt lead nitrate, pH11.0, 16h cyanidation 2000ppm NaCN, pH 11.0, DO 35ppm, 20C, 35 pulp density Deschnes and Fulton, 2013.
Figure26.17. Effect of lead nitrate in the pretreatment on gold extraction from the Eleonore flotation concentrate. Pretreatment 0.25Lminkg oxygen, pH 11.0, 16h cyanidation 2000ppm NaCN, pH 11.0, DO 35ppm, 20C, 35 pulp density Deschnes and Fulton, 2013.
Figure26.18. Effect of cyanide concentration on gold extraction from the Eleonore flotation concentrate. Pretreatment 0.25Lminkg oxygen, pH 11.0, 16h, 5.5kgt lead nitrate cyanidation 0.5kgt lead nitrate, pH 11.0, DO 35ppm, 20C, 35 pulp density Deschnes and Fulton, 2013.
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