Comparison of open and closed circuit HPGR application on dry grinding circuit performance

Altun, Okay; Benzer, Hakan; Dündar, Hakan; Aydoğan, Namık A.

doi:10.1016/j.mineng.2010.08.024

Cited by 26 publications

(9 citation statements)

References 2 publications

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“…Other investigations also showed improvements in the beneficiation indicators of ore processing such as: improvement of operational recovery of the ore, significant reduction in energy consumption of subsequent grinding and obtaining higher proportion of fines products compared to the jaw crusher (Gutsche and Fuerstenau, 2004;Michaelis, 2005;Daniel, 2007). Studies also emerged on the ability of HPGR in terms of higher size reduction ratio compared to capacity, lower grinding media consumption, smaller footprint, less noise, and better adaptability (Maxton et al, 2003;Tavares, 2005;Zhao et al, 2011;Altun et al, 2011;Fan et al, 2012). The impact of microfractures has been thoroughly examined in recent studies conducted by Gao et al (2019) and Nghipulile et al (2023).…”

Section: Introductionmentioning

confidence: 99%

A quantitative study between HPGR and cone crusher aided ball mill grinding: mathematical modeling by evaluating the possible microfracture effect produced by HPGR technology and cone crusher

Rodríguez-Torres,

Tuzcu,

Reyes

et al. 2023

Physicochem. Probl. Miner. Process.

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High Pressure Grinding Rolls (HPGR) have been used in the mining industry for decades. However, there are limited quantifications of the particle properties after comminution. Furthermore, the influence of microcracks in grinding provided by this technology has not been extensively quantified. In the recent work, there were two comminution paths tested: 1 (Jaw crusher + cone crusher + ball mill) and 2 (Jaw crusher + HPGR + ball mill). The possible weakening effect aiding ball mill grinding due to microcracks of HPGR path was shown via specific energy, fines generation and breakage rate measurements. To achieve a quantification about the impact of microcracks and the high rate of reduction rate of HPGR technology, first the product was reconstructed using Rosin Rammler's Weibull double formula and the similar particle size distribution was obtained by a conventional cone crusher. By this way the feed size distribution to the grinding stage remained constant regardless of the type of crushing process (HPGR or cone crusher). The results showed that the microfractures generated by the HPGR technology influence the specific energy consumption, fines generation and breakage rates. Ball mill after HPGR consumed 12.46 kWh/t of specific energy, however ball mill after cone crusher consumed 14.36 kWh/t of specific energy. The experimental methodology proposed in this paper maintains a consistent feed size range (-1500 to +41.31 µm) to show that the size reduction observed in the sample undergoing HPGR grinding is not the primary factor contributing to reduced energy consumption and increased fines generation. Instead, it is predominantly associated with the microfractures generated through the compression in HPGR technology; the energy reduction (optimization) of a grinding path is shown in the study.

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Section: Introductionmentioning

confidence: 99%

A quantitative study between HPGR and cone crusher aided ball mill grinding: mathematical modeling by evaluating the possible microfracture effect produced by HPGR technology and cone crusher

Rodríguez-Torres,

Tuzcu,

Reyes

et al. 2023

Physicochem. Probl. Miner. Process.

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“…The ball mill load, the outlet temperature, the hot air pressure, the recycle air pressure, the negative inlet pressure, the different inlet-outlet pressure, and the outlet pressure of the fine and coarse separators are just some of those influential variables [6][7][8][9][10]. However, few studies have explored the possible relationships between operating variables and ventilation for an industrial ball mill in a cement plant [11,12].…”

Section: Introductionmentioning

confidence: 99%

Ventilation Prediction for an Industrial Cement Raw Ball Mill by BNN—A “Conscious Lab” Approach

et al. 2021

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In cement mills, ventilation is a critical key for maintaining temperature and material transportation. However, relationships between operational variables and ventilation factors for an industrial cement ball mill were not addressed until today. This investigation is going to fill this gap based on a newly developed concept named “conscious laboratory (CL)”. For constructing the CL, a boosted neural network (BNN), as a recently developed comprehensive artificial intelligence model, was applied through over 35 different variables, with more than 2000 records monitored for an industrial cement ball mill. BNN could assess multivariable nonlinear relationships among this vast dataset, and indicated mill outlet pressure and the ampere of the separator fan had the highest rank for the ventilation prediction. BNN could accurately model ventilation factors based on the operational variables with a root mean square error (RMSE) of 0.6. BNN showed a lower error than other traditional machine learning models (RMSE: random forest 0.71, support vector regression: 0.76). Since improving the milling efficiency has an essential role in machine development and energy utilization, these results can open a new window to the optimal designing of comminution units for the material technologies.

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“…Dry methods constitute air classifying and air flotation techniques [19]. Air classifiers are usually employed in an open or closed circuit with a grinding mill [20,21]. Dry processing of kaolin is water conserving, but has relatively lower efficiency and results in a lower quality product than wet processing [19,22].…”

Section: Introductionmentioning

confidence: 99%

Quadratic Mathematical Modeling of Sustainable Dry Beneficiation of Kaolin

et al. 2021

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Clay minerals are one of the most utilized minerals among non-metals. These are hydrous aluminum silicates with a layer (sheet-like) structure. Kaolin is a hydrous aluminosilicate mineral with a thin platelet structure. Kaolin is extensively used in paper, paint, and many other industries. Wet processing of kaolin will not be sustainable over the long term because global freshwater resources are becoming scarce. Hence, a process is necessary that does not consume water during the beneficiation of kaolin. This study developed a dry beneficiation process for low-grade kaolin of 59.6%, with 12% quartz and about 6% titaniferous impurities from Nagar Parkar, Sindh province, Pakistan. To develop a size difference between kaolinite and impurities, steel balls clad with rubber were used as the grinding media in a selective grinding unit. Screens of 60 and 400 mesh were employed to classify the feed of air classifier. Oversize +60 mesh was reground, 400 to 60 mesh fractions were sent to an air classifier, and −400 mesh was considered to be a product with the grade and recovery of 90.6% and 20.5%, respectively. Air classifier experiments were designed using central composite design. An experiment using a fan speed of 1200 rpm and a shutter opening of 4.0 showed optimum results, with maximum kaolinite grade and recovery of 91.5% and 35.9%, respectively. The statistical models developed for grade and recovery predicted the optimum results at a fan speed of 1251 rpm and shutter opening of 3.3 with the maximum kaolinite grade recovery of 91.1% and 24.7%, respectively. The differences between experimental and predicted grade and recovery were 0.1% and 2.4%, respectively. The characterization results showed the total upgrade of kaolin from 59.6% to 91.2%, with 27.1% recovery. The designed methodology has the potential to improve the yield of the product by focusing on its recovery. Furthermore, the designed process can be improved by using different sized balls in the selective grinding unit. This beneficiation process can utilize more than one air classifier in series to achieve the targeted results.

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Comparison of open and closed circuit HPGR application on dry grinding circuit performance

Cited by 26 publications

References 2 publications

A quantitative study between HPGR and cone crusher aided ball mill grinding: mathematical modeling by evaluating the possible microfracture effect produced by HPGR technology and cone crusher

A quantitative study between HPGR and cone crusher aided ball mill grinding: mathematical modeling by evaluating the possible microfracture effect produced by HPGR technology and cone crusher

Ventilation Prediction for an Industrial Cement Raw Ball Mill by BNN—A “Conscious Lab” Approach

Quadratic Mathematical Modeling of Sustainable Dry Beneficiation of Kaolin

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