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Evaluation of grinding circuits for iron ore

Article in REM - International Engineering Journal · March 2019

DOI: 10.1590/0370-44672018720037

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 Marly Ávila de Carvalho et al.

Mining
Mineração
Evaluation of grinding
http://dx.doi.org/10.1590/0370-44672018720037 circuits for iron ore
Marly Ávila de Carvalho1,2 Abstract
Carlos Pereira1,3
Francielle Câmara Nogueira1,4 Grinding has become one of the most important unitary operations for producing
https://orcid.org/0000-0001-5912-011X pellet feed for direct reduction from low-grade ores and small liberation size, such as
compact itabirites. The aim of this study was to evaluate and compare two grinding
1
Universidade Federal de Ouro Preto - UFOP, circuits in an industrial iron ore plant, by evaluating the current operation through
Escola de Minas - Departamento de Engenharia sampling, industrial data analysis and mass balancing. The flows analyzed were the
de Minas, Ouro Preto – Minas Gerais – Brasil. grinding circuit, flotation throughput and desliming hydrocyclone overflow. In total,
two grinding circuits were tested. One circuit had two mills installed in series, with the
E-mails: [email protected], first mill operating in an open circuit and the second mill, in a reverse closed circuit.
3
[email protected], The second grinding circuit involved two mills operating in parallel, both in direct
4
[email protected] closed circuits. The results indicated that the parallel circuit produced 20% less slime
than the series circuit, with an additional 4.3% throughput in the flotation feed. No
circuit produced particles (> 0.15mm). The parallel circuit spent less 8.3% of energy by
not using one of the hydrocyclone batteries.

keywords: grinding circuits, iron ore, compact itabirite.

1. Introduction

The compact itabirite definition a particle size in the product by a par- these factors, the error in the energy
considers genesis and size liberation. It ticle size in the feed. Wills (2007) cites consumption prediction can be up to
is composed mainly of iron oxides and three theories;Von Rittinger (1867), 11.5%, especially in autogenous and
silicates banded in mm-cm layers, with Kick (1885) and Bond (1952). The Von semi-autogenous grinding mills.
20-55% Fe (Takehara, 2004) and associ- Rittinger theory considers that the en- Controlling the grinding circuit
ated with banded iron formation – BIFs ergy required for reducing the size of a is very important in relation to the
(Couto, 2009). Ribeiro (2011) correlates particle is directly proportional to the profitability of a processing plant.
the definition of compact itabirite to the surface area of the ground particle and Under-grinding will have an impact on
high mechanical resistance and high SiO2 that the bigger the diameter of the par- the recovery and overgrinding will not
content. Since reserves of hematite are very ticle, the smaller the surface area is. By only affect the recovery, but the plant
rare nowadays, the importance of com- analyzing the first theory, Austin (1973) operational costs as well. Pease et al.
pact itabirite with regards to pellet feed comments that the energy is constant, (2010) concluded that even ores with
production has increased significantly. As and the surface area produced in the a P80 (cumulative undersize in per cent)
the liberation size is usually considered to grinding is proportional to the grinding equal to 12 μm can be recovered, if it
be small (Vasconcelos et al., 2012), the time. The Kick theory correlates the is ground in an efficient and well con-
grinding process is a fundamental part of energy to the work required to reduce trolled grinding circuit. The corrects
achieving the required quality levels. Not the volume of the particles, before and selection of the mill and equipment for
only does grinding have a direct impact after grinding. The Bond theory cor- classification is very important. Accord-
on iron ore recovery, it also significantly relates the work index to the particle ing to Jankovic and Valery (2013) the
impacts costs. breaking. The work index (Wi) is the classification efficiency and circulating
The particles can be broken by comminution parameter that expresses load are the main influences on ball
compression, friction or impact. Wills the ore resistance to crushing and mill grinding efficiency. The grinding
(2007) explains that when the particle grinding. The Wi is equivalent to the efficiency is reduced when the circulat-
is broken by compression, the product needed kilowatt hour per short ton, in ing load increases. Research done by
is coarser than when the breakage hap- order to reduce an ore size distribution Wei and Craig (2009) concluded that
pens by friction. The bigger the particle, from the infinity value to 80%<100µm. 37% of the analyzed circuits have a
the more the energy required for rupture Morrell (2003) proposed two factors to single grinding stage in a closed circuit
and the lower the total energy of the be included in the Bond equation. One and 30% have two stages with the first
mass unit. is related to the ore breakage index mill being operated in an open circuit
The comminution theory corre- and the other is a constant to balance combined with a second mill in a
lates the energy required for achieving the unities. He mentioned that without closed circuit.
REM, Int. Eng. J., Ouro Preto, 72(1), 161-166, jan. mar. | 2019 161
Evaluation of grinding circuits for iron ore

2. Material and method

This industrial scale study com- lel lines, all fed from the same feed pile. ing circuit, which produces an underflow
pares two grinding circuits operating in Each line has an independent grinding that is directed to the flotation circuit
an iron ore process with a production circuit, with two ball mills and three feed, and an overflow which forms part
capacity of 12 million tons per year. hydrocyclones batteries. The product of the final tailings. Figure 1 illustrates
The plant has three identical paral- from the grinding circuit feeds a deslim- the plant flowsheet.

Figure 1
Line A-grinding circuit with mills in series.

All three lines can be operated overflow is directed to the desliming ball mills are operated in parallel in a
individually and have the flexibility to hydrocyclone battery. The underflow direct closed circuit with hydrocyclones
utilize two different grinding circuits. of the second classification stage feeds batteries in each. In this flowsheet, there
In one circuit, illustrated in Figure 1, the the second ball mill, which is operated is only one classification and the hy-
two mills run in series. The first mill is in in a reverse closed circuit. The overflow drocyclones in the second classification
an open circuit and the ground product streams from the second classification battery are not operated. The overflow
feeds the first classifying hydrocyclone stage and from the classification of the of the hydrocyclone that closes the ball
battery. In the overflow of the first clas- second grinding stage are both directed mill circuit, feeds the desliming hydro-
sification stage, particles that are already to desliming. In this circuit, all ball mills cyclone battery.
the correct size for flotation are removed and hydrocyclones visualized in the flow- In both circuits, the overflow of
to avoid over grinding. The underflow sheet are in operation. the desliming hydrocyclone battery is
stream feeds a second classifying hydro- Alternatively, Figure 2 shows the directed to the final tailings and the un-
cyclone battery, in which the respective second grinding circuit, where the two derflow feeds the flotation circuit.

Figure 2
Line B - grinding
circuit with mills in parallel.

The objective of this analysis desliming hydrocyclone overflow, and • Characterization of the ROM –
was to identify the best performing flotation throughput, considering also Run of Mine
circuit to be operated in the plant. The the percentage of particles >0.15mm in • Industrial test evaluation from
parameters evaluated were grinding the flotation feed. online data
circuit throughput (whilst maintaining T he study was completed in • Industrial test evaluation from a
the target P80), the mass of solids in the three steeps: sampling campaign

Characterization of the ROM – Run of Mine

A composed sample from the ROM The sample used for mineralogy and microscopy (Zeiss—Axioplan model),
was crushed to < 3.35 mm, homogenized chemical characterization was ground where the minerals were quantified, and
and divided into two samples for mineral- up to a top size of 0.15 mm. The ground the mineral associations identified. For
ogical and chemical characterization and ore was divided into samples for mineral- the mineral liberation study, the Gaudin
for Bond Work Index testing. ogical and liberation analysis with optical method was used, where at least five
162 REM, Int. Eng. J., Ouro Preto, 72(1), 161-166, jan. mar. | 2019
 Marly Ávila de Carvalho et al.

hundred particles were counted and their The Bond Work Index test was size to P80=0.106mm. The mill used was
mineral of interest composition estimated. completed according to the international 305x305mm with rounded corners and
The chemical analysis was undertaken ball mill grindability test procedure, to smooth lining, operated at 70 +/- 3 rota-
using X-ray fluorescence to quantify the estimate the required energy consumption tions per minute with 20kg of grinding
%Fe, %SiO2, %Al2O3 and %P. to reduce the particles from 3.35mm top media, equivalent to 285 balls.

Industrial test evaluation from online data

An industrial test was carried the ball mills arranged in series as fed with the same ore during the test.
out for 30 days, comparing two lines demonstrated in Figure 1 and line B The operational conditions during
of the iron ore processing plant. Dur- utilizing them in parallel, as demon- the industrial tests for each line are
ing the test, line A was operated with strated in Figure 2. Both lines were detailed in Table 1.

LINE A: TWO MILLS IN SERIES LINE B: TWO MILLS IN PARALLEL

Mill size 18’x29’ 18’x29’

Power 4500 kW 4500 kW

First Mill- balls with 3” 50% – 3”
Balls diameter
Second Mill – balls with 2” 50% – 2”
Hydrocyclone GMAX GMAX
Apex 3.25” 5”
Table 1
Vortex 8” 10”
Operational conditions of industrials test.

During the industrial test, online which has a lower volume at the desliming (Process Information Management
measurements were collected simultane- hydrocyclone overflow System). With PIMS, the data can be
ously every hour from both circuits. • Flotation feed (t/h). The best per- accessed anytime from a server data
The online data analyzed was forming circuit will be the one that has a base that stores data collected from
as follows: higher flotation throughput the plant every millisecond. The server
• Grinding circuit throughput (t) • Flotation feed particle size distri- receives online information directly at
• Desliming hydrocyclone overflow bution. The percentage of particles above PLC (Programmable Logical Control-
(t/h). This flow is equivalent to the slime 0.15mm that is not sufficiently liberated ler), which receives the measurements
produced in the grinding circuit and is a for flotation from the instruments installed in the
part of the final tailings from the process The online data used for this process plant.
plant. The best performing circuit is that analysis was compiled from PIMS

Industrial test evaluation from the sampling campaign

Samples were collected in both of • Second classification of the hy- • First ball mill discharge
the tested lines. In total, 6 increments drocyclone battery Overflow • First classification of the hydro-
from each flow were collected during 2 • Second ball mill discharge cyclone battery Underflow
hours of sampling. The throughput of • Underflow from hydrocyclone • First classification of the hydro-
both lines remained constant during the battery for second grinding classification cyclone battery Overflow
sampling. The collected flows in the line • Overflow from hydrocyclone bat- The collected increments were
A circuit (mills running in series) were: tery for second grinding classification combined in a unique sample per flow
• Grinding circuit feed In line B, the sampling was com- and the samples were sent for chemical
• First ball mill discharge pleted in only one mill with its respec- analysis (x-ray fluorescence), particle
• First classification of the hydro- tive classification from the hydrocyclone size analysis and solids percentage de-
cyclone battery Underflow battery. It was assumed that both termination. The results were then used
• First classification of the hydro- mills in the circuit had the same per- for mass balancing. The sampling was
cyclone battery Overflow formance. The collected flows in the undertaken when both circuits were
• Second classification of the hy- circuit were: stable, and all operational conditions
drocyclone battery Underflow • Grinding circuit feed were monitored.

3. Results

Characterization of the ROM – Run of Mine

The mineralogical analysis in- goethite). The liberation analysis dem- obtained using optical microscopy. The
dicated that the ROM was primarily onstrated that from 81-100% of the particles labelled ‘A’ are mixed particles
composed of 56% compact hematite, quartz was free in the fraction <0.15 of hematite (in white) and quartz (in
25% free quartz, 16% non-liberated >0.75mm. Figure3 illustrates the images dark gray). The particles labelled ‘B’ are
quartz and 3% of hydrated ores (mainly of the ROM (fraction <0.15 >0.75mm) free particles of quartz.
REM, Int. Eng. J., Ouro Preto, 72(1), 161-166, jan. mar. | 2019 163
Evaluation of grinding circuits for iron ore

Figure 3
Photomicrography of ROM
sample. (A)Hematite (B) Quartz.

The assay of the ROM produced and 0.026% P and the Bond Work Index ROM from 100% < 3.35mm to 80% <
42.9% Fe, 37.3% SiO2, 0.714% Al2O3 test indicated that for reducing one ton of 0.106mm,7.8 kWh of energy are required.

Industrial test evaluation from online data

The data from the industrial test to the flotation feed was 2.8% lower lower, indicating that it was the most
indicated that the throughput of cir- and overall, 20% more slimes were stable circuit. The descriptive statisti-
cuit A (mills run in series) was 1.3% produced. The standard deviation in cal analysis is shown in Table 2.
higher, however, the flow equivalent circuit B (mills run in parallel) was

Table 2
Descriptive statistical analysis.

LINE A: TWO MILLS IN SERIES LINE B: TWO MILLS IN PARALLEL

New feed Flotation %>0.15 Slime New feed (t/h) Flotation %>0.15 Slime
(t/h) Feed (t/h) mm (t/h) Feed (t/h) mm (t/h)
Mill 1 Mill 2
Average 1070 879 11 191 534 522 903 10,8 153
Standard deviation 49 155 4 75 54 55 118 3 58
Coefficient of variation (%) 4.6 17.6 35,7 39.5 10.1 10.6 13.1 24.5 38.3
Median 1101 918 11 169 550 544 936 11 142
Minimum 1000 279 5 28 378 336 469 3 46
Maximum 1202 1157 76 530 603 603 1122 19 622
Interval 202 878 71 501 225 267 654 16 577

The highest throughput was ex- the throughput in line B was lower than in gains can be around 35%.
pected in line B, where both mills were line A, was that the grinding media used The difference between new feed,
operated in closed circuits and the effec- in both circuits was the same size (2 balls desliming hydrocyclone overflow and
tive feed (new feed + circulating load) was sizes: 50% with 3” of diameter and 50% fraction of % 0.15 mm fraction in the
smaller, enabling the use of small diameter with 2”). The correct adjustment of the hydrocyclone underflow for lines A and
grinding media with a higher grinding grinding media size can increase the circuit B of the two circuits analyzed is shown
surface area. However, the reason that capacity. According to Wills (2007), the in Figure 4.

(a) (b)

(c)

Figure 4
Circuits analysis a) New feed (Grinding
circuit throughput) b) Desliming
hydrocyclone overflow c) % 0.15mm
fraction in the hydrocyclone underflow.
164 REM, Int. Eng. J., Ouro Preto, 72(1), 161-166, jan. mar. | 2019
 Marly Ávila de Carvalho et al.

During the interval of 1050-1150t/h, In line B, during 12.8% of the time, the tested circuits.
line B (parallel circuit) tended to be oper- desliming hydrocyclone overflow had Although the circuit where the
ated with lower throughput. Line A (series more than 200t/h, whereas in line A (just mills were in series (line B) had a higher
circuit) was operated 23.6% of the time one mill in closed circuit),27.6% of the throughput, it also produced more slime.
with a higher throughput than 1150 t/h, time desliming overflow flow rates above More overgrinding was observed in this
while the parallel circuit was 16.1%. The 200t/h were observed. Mills operated in circuit and consequently more ore was
desliming hydrocyclone overflow is a part closed circuits have lower residence times sent to the tailings without being pro-
of the final tailings, consequently, reduc- when compared with open circuits, lead- cessed by the flotation circuit. The circuit
ing it, increases the plant recovery. Line B, ing to a reduction in overgrinding and with the mills in parallel was the opposite,
where both mills were in closed circuits, the production of slime (Wills, 2007). since less ore was directed to the desliming
produced less slime and subsequently There was no significant variation in the overflow and more ore was directed to the
had the highest flotation throughput. quantity of particles above 0.15mm in the flotation circuit.

Industrial test evaluation from sampling campaign

Figure 5 illustrates the mass balance for line A (mills run in series) and line B (mills run in parallel) respectively:

(a) (b)

Figure 5
Mass balance a) Line A - series circuit
b) Line B - parallel circuit.

In the circuit where the ball mills solids and D80=0.192mmandthe product not used, so there was less consumption
were in series, line A, the throughput was had a P80=0.166 mm. The final product of of spare parts and energy.
998t/h and P80 =3.7mm sieve size that the grinding circuit where the mills were The mass balance indicated that
80% of the feed material passes. The operated in series, was composed of the the circuits were similar, with the same
first ball mill was operated with 71.6% overflow from the three hydrocyclones op- throughput and same P80, but as discussed
solids and P80=0.181mm. The underflow erated in the circuit, with P80=0.104mm. in the online data analysis, the significant
from the first classification hydrocyclone For the circuit with the ball mills in difference between the circuits was the
battery and the circulating load of the parallel, line B, each ball mill was fed with production of slimes, and the desliming
second ball mill (285%) combined to 499t/h at 64.7% solids, P80= 3.714mm circuit wasn’t sampled. However, the size
make the secondary classification stage and the mill discharge P80 =0.153mm. distribution analysis completed within the
feed. The secondary classification stage The product of the circuit was the hydro- grinding circuit final product, equivalent
is responsible for removing particles cyclone overflow and had P80= 0.104mm. to the desliming feed, indicated that in line
from the grinding circuit that are already The underflow was directed as the cir- A, 52% of the particles were <0.045mm,
within the correct size distribution for culating load, which was observed to be while in line B, the value was 42%. There-
flotation, avoiding any overgrinding. 300%. One advantage of this circuit was fore, the circuit with the mills in series
The second ball mill was fed with 75.4% that the third hydrocyclone battery was produced 24% more particles <0.045mm.

4. Conclusions

The parallel circuit was the most ef- after grinding, no significant difference 8.3% of the total energy consumption in
ficient considering the production of slimes between the circuits was observed. the grinding circuit.
and flotation throughput. It produced The series circuit operated with The parallel circuit can offer opera-
20% less slimes and the flotation circuit three classification hydrocyclone batter- tional flexibility, allowing for the possibil-
was fed with a higher throughput, 4.3% ies, whilst the parallel circuit operated ity to plan the maintenance in one section
on average. with two. The third battery, which was of the circuit without compromising the
Considering the coarse particles not required in the parallel circuit, saved total line production.

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Received: 10 April 2018 - Accepted: 27 September 2018.

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