OPTIMIZATION OF COMMINUTION CIRCUIT THROUGHPUT AND PRODUCT SIZE DISTRIBUTION BY SIMULATION AND CONTROL
The goal of this project is to improve energy efficiency of industrial crushing and grinding operations (comminution). Mathematical models of the comminution process are being used to study methods for optimizing the product size distribution, so that the amount of excessively fine material produced can be minimized. The goal is to save energy by reducing the amount of material that is ground below the target size, while simultaneously reducing the quantity of materials wasted as ''slimes'' that are too fine to be useful. This will be accomplished by: (1) modeling alternative circuit arrangements to determine methods for minimizing overgrinding, and (2) determining whether new technologies, such as high-pressure roll crushing, can be used to alter particle breakage behavior to minimize fines production. During this quarter, work was focused on three areas: (1) The mathematical relationship developed for predicting plant throughput was improved, based on ore work index and equipment parameters measured in the plant over an extended period. It was determined that the model would need to fit two distinct regimes of grinding circuit operation, depending on the work index of the feed ore. (2) Plans for a proposed change in the circuit configuration at an iron ore plant are being made, to test predictions based on the work done to date in the project. After determining the desired circuit change, which would require screening a portion of the grinding slurry, samples were sent to an industrial screen manufacturer for pilot plant scale testing. These tests indicated that the screening could be carried out economically, and plans are proceeding to conduct trials of the proposed circuit alteration. (2) The mathematical model used for hydrocyclone simulations was found to be unable to fully predict the ''fish-hook'' behavior that is seen in the plant samples. The model was therefore improved by including empirically-determined terms so that it would be able to account for the observed phenomenon. A more advanced model is currently under development that will take account of measured slurry viscosity, in order to more accurately model the behavior of hydrocyclones with concentrated slurries of very fine particles.
- Research Organization:
- Michigan Technological University (US)
- Sponsoring Organization:
- (US)
- DOE Contract Number:
- FC26-01NT41062
- OSTI ID:
- 821285
- Resource Relation:
- Other Information: PBD: 1 Apr 2003
- Country of Publication:
- United States
- Language:
- English
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OPTIMIZATION OF COMMINUTION CIRCUIT THROUGHPUT AND PRODUCT SIZE DISTRIBUTION BY SIMULATION AND CONTROL
OPTIMIZATION OF COMMINUTION CIRCUIT THROUGHPUT AND PRODUCT SIZE DISTRIBUTION BY SIMULATION AND CONTROL