A Study of Ore Breakage Characterization for AG/SAG Mill Modelling

Stephen Larbi-Bram (2009). A Study of Ore Breakage Characterization for AG/SAG Mill Modelling PhD Thesis, Julius Kruttschnitt Mineral Research Centre, Sustainable Minerals Institute, The University of Queensland.

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Author Stephen Larbi-Bram
Thesis Title A Study of Ore Breakage Characterization for AG/SAG Mill Modelling
School, Centre or Institute Julius Kruttschnitt Mineral Research Centre, Sustainable Minerals Institute
Institution The University of Queensland
Publication date 2009-08
Thesis type PhD Thesis
Supervisor Dr. Frank Shi
Dr. Toni Kojovic
Total pages 295
Total colour pages 73
Total black and white pages 222
Subjects 04 Earth Sciences
Abstract/Summary Abstract In the existing JKMRC breakage testing method for AG/SAG mill modelling, ore is characterised using mainly high energy single impact tests. However, recent DEM studies have suggested that breakage in AG/SAG mills is mainly due to low energy repetitive (or multiple) collisions rather than single high energy impacts. Furthermore, several of the published AG/SAG ore hardness tests developed outside the JKMRC use laboratory tumbling mills to quantify the specific power required to grind the ore to a set product size. Comprehensive experiments were carefully designed using two mill diameters of 1.1 and 0.6 m to mimic the reported low energy repetitive impact breakage under low load conditions. The ore breakage characterisation parameters derived from high energy single impact tests were used to predict the low energy repetitive impact breakage behaviour. Significant bias has been shown to be associated with the traditional high energy single impact characterisation approach, suggesting an alternative method was required. An extensive experimental program with more than 1400 tests was conducted using a newly developed JKRBT (JKMRC Rotary Breakage Tester) device, gravity drop test and laboratory tumbling mills. Comprehensive data were collected and analysed to provide an understanding of low energy repetitive impact breakage of particles and high energy single impact breakage. Details of the experimental study and findings are presented in Chapter 5. A breakage characterisation model has been developed, which takes into account the various impact energy classes and their associated body breakage and surface breakage responses. The breakage conditions were analysed and used to derive two sets of impact breakage parameters (body breakage and surface breakage). These parameters were then combined using a procedure believed to account for the two key breakage modes in tumbling, and successfully applied to predict the breakage in the two laboratory tumbling mills. Chapter 6 presents the breakage modelling approach and results. Based on the understanding of different breakage modes, a novel particle breakage characterisation method for AG/SAG mill modelling has been proposed and validated. Different from the prior-art JKMRC approach in which the breakage tests are conducted at high energy single impact, the proposed method incorporates high energy single impact, low energy multiple impacts and a simplified tumbling test. Both breakage probability and degree of breakage are used to characterise the breakage behaviour of ores. The details of the new characterisation method can be found in Chapter 7. The studies conclude that • The JKRBT can be used to investigate rock breakage characteristics under single and repetitive impacts; • The breakage of rocks in tumbling mills (under very low load conditions) can be likened to the low energy JKRBT repetitive impact breakage. • The behaviour of particle breakage as observed in AG/SAG milling can be modelled using a combination of JKRBT and tumbling ore breakage characterization; • A methodology for ore breakage characterization for AG/SAG mill modelling has been proposed and validated using independent sets of ores samples.
Keyword ore breakage characterization, breakage probability, degree of breakage, body breakage, surface breakage, minimum energy threshold, repetitive impacts, single impact
Additional Notes 25, 41, 43, 51, 55, 67-68, 70, 77, 80, 82-84, 88, 91-92, 94-95, 98-99, 101, 103-104, 109, 111-112, 119, 121-124, 126-132, 134-135, 138, 142-145, 148, 150, 153-155, 157, 161, 164-170, 173-175, 185, 187, 189, 191-192, 197-199, 293-295.

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Created: Thu, 18 Mar 2010, 14:25:49 EST by Mr Stephen Larbi-bram on behalf of Library - Information Access Service