Industrial Validation of The Functional Performance Equation - A Breakthrough Tool For Improving Plant Grinding Performance
Industrial Validation of The Functional Performance Equation - A Breakthrough Tool For Improving Plant Grinding Performance
Industrial Validation of The Functional Performance Equation - A Breakthrough Tool For Improving Plant Grinding Performance
Preprint 05-31
Abstract energy. Since energy costs and the closely related costs
for grinding media dominate grinding circuit operating
The “Functional Performance Equation for Ball costs, changes (i.e., process improvements) requiring
Milling” was first presented in 1988. It now has been used capital expenditure can then be financially justified.
successfully in more than a dozen mineral processing The writer was also taught the intricacies of slurry
plants. This powerful, yet simple tool provides a new pump and hydrocyclone process application engineering
level of understanding of closed circuit grinding. It shows while working for equipment manufacturers. It was
how grinding circuit efficiency is in reality comprised of learned how the hydrocyclone water and solids mass
two distinct efficiencies. It demonstrates how circuit splits and separation performance curve are calculated
production rate is related, collectively, to these two from the feed and product percent solids and size
efficiencies, mill energy input, and the grindability of the distributions, and that the cyclone selection procedure
ore. It links circuit performance to design and operating uses the same relationships. Given the cyclone feed,
variables that can be manipulated, and creates an effective achieving desired products is a process of choosing the
strategy for making plant improvements. This paper cyclone (dimensions and operating conditions, including
covers the derivation and industrial validation of this those provided by the pump) that provide the right
equation. As part of an engineering and management particle separation curve and water split.
system that also incorporates suitable metrics and process But what was found to be extraordinary as well was,
control, other operators can now use this tool to make that in the case of a closed circuit operation, the pump and
improvements and to manage the performance of their cyclones could be chosen to not only manipulate the
grinding operations with clarity and confidence. cyclone product size distributions, but the cyclone feed
size distribution as well (McIvor, 1984). The same
engineering procedures that were used to select cyclones
Introduction: The Initial Breakthrough in and pumps for a new application could be used to make
cyclone and pump changes in an existing plant in order to
Understanding manipulate the internal size distributions and related mass
flows (the circulating load) of a closed grinding circuit.
The writer’s interest in grinding was first sparked at Combining this new found knowledge with the critical
Allis-Chalmers, where grinding process technology was relationship between grinding circuit efficiency and
led by Fred C. Bond and Chester A. Rowland. These circulating load, as published by Davis in 1925 and
icons of grinding mill process engineering provided a Gaudin in 1939 (see Figure 1), created the realization that
rigorous mill sizing for application discipline, which there was a potentially important opportunity to improve
today remains the world standard (Bond, 1961; Rowland, grinding circuit efficiency. An observed poor (low)
2002). Having established a standard relationship for circulating load ratio could be increased by suitable pump
comparison of lab (predicted) versus plant (actual) energy and cyclone changes, thus increasing circuit efficiency.
use, a plant grinding circuit efficiency metric was also This in turn could be verified by Bond work index
created (Rowland, 1976). The ratio of plant operating to analysis, and the related operating cost savings used to
ore work index, provided a quantitative measure of justify the cost of the plant improvements.
overall grinding circuit efficiency. Using this, a
metallurgist could potentially find out whether changing a
circuit design or operating variable increased (or
decreased) efficiency in the plant grinding process.
Importantly as well, Bond work index analysis is based on
first, the classifier performance, which controls the which is being applied to coarse material (i.e., the
percentage of “fines” versus “coarse” material reporting efficiency of the mill grinding environment).
to the cyclone underflow/mill feed; second, the length of To incorporate the material’s grindability into the
time in the mill, which determines the amount of “fines” above equation 3, divide and multiply the specific
that accumulate during each pass through the mill.. Low grinding rate of coarse particles by the lab grindability of
circulating load equates to long mill residence time and the same material.
the build up of fines. Another factor which plays a role is
the breakage characteristic (the tendency to create fines PRNP = TMP x CSEff x SGRC/LabGr x LabGr (4)
during a breakage event) of the ore. But it is the
combination of classifier performance and circulating We can then define the ratio of plant to lab
load ratio that is key in determining the net outcome of grinding rates as the relative “ball mill grinding
circuit performance in terms of CSEff. efficiency”, or BMGEff.
The “effective mill power” (or EMP) can then be
defined relative to the total mill power (or TMP) as SGRC/LabGr = BMGEff (5)
follows. It is the percentage of total mill power draw (or
mill energy, the power draw over time) delivered to the Substituting in Equation 4 gives us the
“coarse” ore, as defined by CSEff. “Functional Performance Equation” for ball milling.
EMP = TMP x CSEff (1) PRNP = TMP x CSEff x LabGr x BMGEff (6)
Sample Calculation and Dimensional Analysis The total mill power draw (TMP), measured at the
Table 1 presents the data from Les Mines Selbaie pinion, was 523 kW.
grinding circuit survey no. 2, which was performed with The ore grindability, from the Bond test in this case,
the crusher fines stream off, on a standard closed grinding was 2.32 gms/rev (grams of new product per revolution of
circuit (as depicted in Figure 3). the Bond test mill).
The classification system efficiency, CSE, is the
average of the amount of plus 106 micron material in the
Table 1. Les Mines Selbaie Grinding Circuit Survey mill feed and discharge.
No.2, 1985
CSEff = [(100% – 21.8%) + (100% – 36.1%) / 2] = 71.0%
Circuit Feed Rate 70.3 t/h So far, the functional performance equation for this
survey is as follows.
Feed Size, F80 1,160 um
% - 106 um 30.3% PRNP = TMP x CSEff x LabGr x BMGEff
Bond Test W.I. 11.8 kWh/t 33.3 t/h = 523 kW x 71.0% x 2.31 gms/rev x BMGEff
Grindability 2.31 gms/rev
Solving, BMGEff = 0.0388 (t/kWh)/(gms/rev). The
Cyclone Overflow P80 115 um units are the ratio of the specific grinding rate of coarse
%-106 um 77.6% material in the ball mill in tons per kilowatt-hour being
applied to the coarse material, over the grinding rate of
Ball Mill Feed %-106 um 21.8% coarse material in the lab mill in grams per revolution.
Discharge 36.1% This has also been termed the “grinding rate ratio”.
So finally, the functional performance equation for
Mill Power Draw 523 kW this plant experiment can be written as follows.
Evaluation of Different of Grinding Media Figure 4. Simplified schematic of the Dome ball
Some years after the above described test, Les Mines circuit.
Selbaie undertook an investigation of different types of
ball mill grinding media (McIvor et al, 1991). This lead to Functional Performance of Dome Survey No. 1
a subsequent circuit survey for evaluation of ball mill (calculated at the actual P80 of 60 microns):
grinding efficiencies (mill percent solids was maintained PRNP = TMP x CSEff x LabGr x BMGEff
constant), as summarized below. 53.9 t/h = 865 kW x 85.5% x 1.32 gms/rev x 0.0552
(t/kWh)/(gms/rev)
For Selbaie New Media Grinding Survey, 1989:
PRNP = TMP x CSEff x LabGr x BMGEff Functional Performance of Selbaie Survey No. 2
(calculated at the actual P80 of 115 microns):
32.1 t/h = 539 kW x 71.5% x 1.69 gms/rev x 0.0493 PRNP = TMP x CSEff x LabGr x BMGEff
(t/kWh)/(gms/rev) 33.7 t/h = 523 kW x 68.5% x 1.79 gms/rev x 0.0525
(t/kWh)/(gms/rev)
Comparison with the above results from baseline
Survey No.2 shows that the mill grinding efficiency The classification system efficiency at Dome, with
increased from 0.0388 to 0.0493, or approximately 25%. two stage cycloning and high cyclone feed water addition,
During the 1989 survey, the work index efficiency is higher than that of Selbaie, by a factor of approximately
calculated out to 117%, or about a 16% relative increase. 25%. The grinding efficiency at Dome also calculated out
Each method confirms that a very significant to be slightly higher. With an operating work index of 8.5
improvement was achieved, although basic differences in kWh/t, compared to an ore work index of 11.5 kWh/t, the
the two models (e.g., Bond’s 1952 third theory) dictate work index efficiency for the Dome survey calculated out
that they will not coincide quantitatively. at 136%, compared to 101% for Selbaie No.2. Note that
the constraint on total water addition before flotation at
Evaluation of a Different Classification System Selbaie made adoption of the same practice as Dome
The Dome Mill grinding circuit employed coarse impractical.
gold removal in the grinding circuit primary cyclone
underflow (See Figure 4.). As a result of water addition in Evaluation of Pebble Mill Operating Percent Solids
the coarse gold removal process, a second stage of Following extensive preparations to maximize the
cycloning was used on the primary cyclone underflow to quality of the data, a series of surveys were carried out on
raise the percent solids of the material feeding the ball the Tilden pebble milling circuit (Figure 5) over a period
mill (the secondary cyclone underflow) to a suitable level. of several years. The first fourteen plant tests were
The secondary cyclone overflow was returned to the mill directed at a evaluation of a number of different variables,
discharge sump. The primary cyclone overflow was such as grate discharge design, media (pebble) sizing, and
therefore very dilute, going to a thickener before carbon pump and cyclone adjustments (McIvor et al, 2000). The
in pulp gold recovery. A survey was conducted on this last two were run at extremes of low and high mill feed
circuit, including a Bond grindability test with a closing water addition rates to develop the trend line of the
screen of 200 mesh (75 microns). For comparison with pebble mill grinding efficiency (PMGEff) vesus mill
the Selbaie circuit, the elements of the functional percent solids relationship. The results are shown in
performance equation relative to each of the circuits’ P80 Figure 6. This lead to the practice of operating the mills at
product sizes were calculated, as follows (McIvor et al, increased percent solids, which yielded major energy cost
1992). savings as a result.
Summary and Conclusions isolate the effect of different design and operating
variables under his/her control. As these examples attest,
Since its inception, Functional Performance methods it can make development and execution of a plan to
have been applied in fifteen to twenty mineral processing improve and manage plant grinding performance a very
plants. Some of these studies have been published by the effective exercise. Combined with other available tools,
plant operators (e.g., Blythe, 1992). The writer has been i.e., Work Index analysis, computer modeling, and a
closely involved in ten such projects, several of which are systematic approach which also incorporates suitable
described in the references. The others were carried out metrics and process control (McIvor, 1989-2004),
by individuals who became familiar with the method and Functional
moved on to other operations. Of those that the writer is
familiar with, several studies provided unexpected Performance Analysis provides the process engineer
conclusions that there was no effect from changes in with the opportunity to take plant grinding operations to a
certain design or operating variables. One audit showed new level of performance.
that the circuit was operating near its potential peak of
classification system efficiency. Two generated
significant efficiency gains through mill water Acknowledgements
optimization. Three studies produced benefits through use
of more efficient grinding media. One of these was in This work was made possible by the generous
open circuit ball milling, to which it can also be applied sharing of knowledge, and the inspiration to learn,
(McIvor et al, 1994). Four studies produced provided by Gilles Cardin, Tom Steele, Bob Jermyn, Chet
improvements in classification system efficiency through Rowland, Andy Mular, Terry Kirk, Richard Klimpel, Ken
pump and/or cyclone modifications. Operating cost Wood, and Jim Finch. The staff at the Tilden concentrator
savings are measured in the millions of dollars annually. is also recognized for their dedication to quality in plant
Several more studies are ongoing. test work.