comparison of hpgr - ball mill and hpgr - stirred mill circuits to the existing ag/sag mill - ball mill circuits by chengtie wang b.eng., university of science and technology beijing, 2009 a thesis submitted in partial fulfillment of the requirements for the degree of master of applied science in the faculty of graduate studies

There was a discrepancy in the additional power required to reduce the final product size from 160 to 75 m for SABC circuit and HPGR-ball mill circuit. The HPGR-ball mill circuit when grinding to 75 um compared to 160 um used an extra 4.6 kWh/mt, but for the SABC circuit it only used an extra 1.8 kWh/mt.

Tropicana Gold Mine project is based on following parameters Average Annual Production First 3 years 470 to 490 koz pa Average Life-of-Mine Production 330 to 350 koz pa 3.6 Moz in total ... o Screen oversize recycled to HPGR Ball Mill product reports to CIL process .

Jun 01, 2016 A HPGR consumes 3050% less specific energy as compared to a ball mill which indicates higher comminution efficiency for a HPGR. Four circuit configurations of a HPGR can be used in grinding of cement raw materials, cement clinker and slag.

The circuit is comprised of five 746 kW cone crushers, four 2.4 m diameter (D) x 1.65 m length(L) 5.5 MW HPGRs, and four 7.9 m D x 11.9 m L (26 x 39 ft) 15.6 MW ball mills (Dunne et al 2007). The projected roll surface wear life was estimated to be 4,250 hours.

line No. 3 and line No. 4 before the ball mills. The HPGR units are operated in open circuits under the same condition. However, since start-up time, the grinding performance of these HPGR circuits had been unsatisfactory. The design goal behind installing HPGR units was to increase throughput of ball milling operation from current 100 t/h to ...

This relationship is essential, because it defines two key HPGR modelling parameters The dependence of the operating gap and the roll diameter

Plant Concept SAG Circuit HPGR Circuit Equipment 1 x SAG Mill 9.8 MW 1 x Secondary Crusher 750 kW 1 x Pebble crusher 450 kW 1 x HPGR 4.0 MW 2 x Ball Mills 5.6 MW each 2 x Ball Mills 5.6 MW each Screens and conveyors 0.5 MW Screens and Conveyors 1.5 MW Total drive capacity installed 21.95 MW 17.45 MW

Feb 01, 2011 Since the product of the HPGR circuit is rather fine, the cut sizes of both classifiers used in the circuit and the ball size distribution within the ball mill should be optimized. While design parameters of the circuit are presented in Table 3 , the simplified flowsheet of the circuit sampled and the measured and adjusted size distributions ...

an HPGR in primary grinding results in a lower overall power consumption the comminution circuit. In comparison to using staged crushing as ball mill feed prepara-tion, replacing the tertiary circuit with an HPGR frees up ball mill capacity (or reduces the size of the ball mills and grinding media consumption).

Note that in Tables 1-5 the work index efficiencies of the HPGR stages are consistently very low relative to the jaw crushers and ball mills. Given the fact that HPGR generates a large amount of fines, it would seem to be more realistic to compare results using alternative size parameters such as the fraction of - 75 m fines generated or the ...

Drive parameters can easily be made available to the overriding control system and parameter trends can be used for further process optimization. ... using one HPGR with both dry- and wet- screening before ball milling, or HPGR plus dry/wet classification to produce a 125-micron finished product. The authors commented that the HPGR in ...

For HPGR size reduction the parameter is labelled M ih. Mia values are provided as a standard output from a SMC Test whilst M ih values are obtained from a correlation with the DWi, which is also a standard output from the SMC Test . M ib values can be determined using the data generated by a conventional Bond ball mill work index test ...

Request PDF Simulation of combined HPGR and ball milling circuits in cement production plants In this paper, developing a novel approach based on

Summary This paper presents the effect of operational parameters on the performance of a closed circuit HPGR. For this study, six surveys in a cement grinding circuit operating in Turkey were performed. The relationships among operational parameters like gap, pressure and capacity and the effect of these parameters on the performance were investigated.

parameter ta and crusher model energy matrices, the SMC Test can be used to conduct AG/SAG mill and crusher circuit simulations through the use of JKSimMet. Independent of this it can be used in power-based calculations, which in conjunction with the Bond ball work index test, enable the prediction of the specific energy of comminution circuits

Dec 01, 2009 The specific energy consumption figures indicated approximately 15% energy saving in Horomilling case. However, as recorded in the literature, it is difficult to make a direct comparison as the energy efficiency figures will vary depending on the Horomill , HPGR, ball mill design, operational parameters and the circuit configuration. This ...

Mar 28, 2020 Several preliminary tests were carried out to define the parameters to obtain the quality abrasion index 4.5% smaller than 0.5 mm and CCS of 300 daN/p, based on ball mill/HPGR ground feed. Abrasion was measured in a rotating drum where fired pellets (6.3 mm) were submitted to 200 revolutions.

Route 2 considers particular care in preparation of feed to the HPGR, which receives the 63.5 mm material from secondary crushing, although material in the size ranges 12.76.35 mm and 6.35 mm is split between the HPGR and ball milling to prevent feeding the HPGR with an exceedingly fine material.

Feb 21, 2014 Whitens model parameters were determined by GA (genetic algorithm) toolbox of MATLAB software. Based on implemented models for modeling and simulation, optimization of circuits was carried out. It increased nearly 10.5% and 15.8% in

The HPGR (high pressure grinding rolls/rollers) is the core equipment of the high pressure grinding process. The machine reduces particles by compressing and crushing the feed between two counter rotating, parallel rollers with a small gap between them. This forces the rocks against each other and compresses the feeds density to 80% of its solid

Aug 19, 2019 HPGR wear vs conventional mills. Ball, SAG and rod mills all require their grinding media to be regularly replaced, unlike a HPGR. High Pressure Grinding Rolls have lower maintenance overheads than ball and rod mills, primarily because the grinding media in conventional mills needs to be replaced on a more regular basis.

grindability parameters of the ore, and the HPGR modelling parameters were grouped to generate the core process design criteria for the two mines as shown in Table I. Other ore parameters that were used in the design process were the complete crusher table parameters from the JK drop-weight tests and HPGR test results including the feed and

High pressure grinding rolls (HPGR) are becoming an increasingly popular energy efficient solution for comminution of hard rock ores. A significant barrier to the increased adaptation of HPGRs is the current requirement for large amounts of sample for pilot testing. The primary objective of the research was to develop a DEM based computer model for an HPGR to

mill revolution (laboratory ball mill) HPGR High Pressure Grinding Roll Mi Generic term for hardness parameters Mia, Mib, Mic, and Mih Mia Coarse ore ( 750 m) work index in tumbling mill circuit(s) (kWh/t) Mib Fine material ( 750 m) work index in tumbling mill circuit(s) (kWh/t) Mic Ore work index in crusher circuits (kWh/t)

NLMK began implementing HPGR technology in each of the plants four process lines in 2016. The first four grinding rolls supplemented traditional cone crushers and ball mills, and enabled the plant to boost the productivity of the sections by 12.5% and to grow iron ore concentrate output by 1 million mt to 16.6 million mt/y.

Jul 30, 2020 Energy requirements for crushing and HPGR options can now be determined in addition to AG/SAG mills, and with Mic, ball mills. The results from conducting the SMC Test are used to determine the so-called drop-weight index (DWi) which is

Ball mill tests were carried out in a mill with an internal diameter of 305 mm and a length of 305 mm, with conditions shown in Reference . A HPGR test was conducted using a unit of 25 cm diameter rolls and a width of 15 cm that was fully equipped to control and record the hydraulic pressures, which runs at 40 bar.

Oct 23, 2015 The comminution efficiency of a HPGR is better than ball mills such that it consumes 3050 % of the specific energy as compared to a ball mill. Four circuit configurations of HPGR can be used in grinding of raw materials, ... Design parameters of the Horomill are presented in Table 3. 2.6.4.1. Laboratory studies

Closed HPGR circuits As demonstrated, circulating load and classification efficiency have a significant impact on the efficiency and capacity of closed ball mill circuits. However, as the application of HPGR technology increases within the industry, it is important to consider the impact of these parameters on closed HPGR circuits and how this ...

The results showed that the HPGR - ball mill circuit achieved a 21% reduction in energy consumption over the existing SAG - ball mill circuit at the same P80 grind size of 160 m. At a grind of 80% passing 75 m, the HPGR - stirred mill circuit showed a 34% reduction in energy compared to the base case.

The most important parameters are the specific throughput and specific energy consumption what enables to size the HPGR for the required product fineness. It is defined ... It is important to mention that the particle size distribution (PSD) of HPGR products varies from a ball mill ground product. The PSD is not only shifted along the ...

energy intensive. The HPGR-ball option was the most energy efficient, and when subjected to a full cost benefit analysis, was found to be the most cost effective option for the TGP. Numerous flowsheet variations for the HPGR-ball circuit option were then

numbers, the amount of fine particles produced in HPGR was higher than that produced in a ball mill 1, 2, 6, 7 . A higher surface area was observed from HPGR treatment, associated with a higher porosity, more micro-cracks, a higher roughness and new surfaces. It was also observed that HPGR produced particles that were

The key parameters derived from the results of testing in a HPGR are - the specific throughput rate ... Projects00_Minerals2220 Mining Projects02 HPGR and Ball Mill Projects7959-MorrisonTESTSHPGR Test Report - Morrison - Pacific Booker 1.doc ...

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