Determination of lifter design, speed and filling effects in AG mills by 3D DEM

The power required to operate large gyratory mills often exceeds 10 MW. Hence, optimisation of the power consumption will have a significant impact on the overall economic performance and environmental impact of the mineral processing plant. In most of the published models of tumbling mills (e.g. [Morrell, S., 1996. Power draw of wet tumbling mills and its relationship to charge dynamics, Part 2: An empirical approach to modelling of mill power draw. Trans. Inst. Mining Metall. (Section C: Mineral Processing Ext. Metall.) 105, C54-C62. Austin, L.G., 1990. A mill power equation for SAG mills. Miner. Metall. Process. 57-62]), the effect of lifter design and its interaction with mill speed and filling are not incorporated. Recent experience suggests that there is an opportunity for improving grinding efficiency by choosing the appropriate combination of these variables. However, it is difficult to experimentally determine the interactions of these variables in a full scale mill. Although some work has recently been published using DEM simulations, it was basically. limited to 2D. The discrete element code, Particle Flow Code 3D (PFC3D), has been used in this work to model the effects of lifter height (525 cm) and mill speed (50-90% of critical) on the power draw and frequency distribution of specific energy (J/kg) of normal impacts in a 5 m diameter autogenous (AG) mill. It was found that the distribution of the impact energy is affected by the number of lifters, lifter height, mill speed and mill filling. Interactions of lifter design, mill speed and mill filling are demonstrated through three dimensional distinct element methods (3D DEM) modelling. The intensity of the induced stresses (shear and normal) on lifters, and hence the lifter wear, is also simulated. (C) 2004 Elsevier Ltd. All rights reserved.

Comparison of grinding media - Cylpebs versus balls

Cylpebs are slightly tapered cylindrical grinding media with a ratio of length to diameter of unity. The manufactures have made conflicting claims regarding the milling performance of Cylpebs in comparison with balls. One major point of interest is which one grinds finer at the same operating conditions. The difficulty in comparison is due to the shape difference. The two grinding media have different surface area, bulk density and contact mechanisms in grinding action. Comparative tests were conducted using the two types of grinding media in a laboratory Bond ball mill at various conditions of equality such as media mass, size distribution, surface area and input specific energy. The laboratory results indicate that at the same specific energy input level the Cylpebs produce a product with slightly less oversize due to their greater surface area, but essentially the same sizing at the fine end as that produced with the balls. The reason may be that the advantage of greater surface area is balanced by the line contact and area contact grinding actions with the Cylpebs. A new ball mill scale-up procedure [Man, Y.T., 2001. Model-based procedure for scale-up of wet, overflow ball mills, Part 1: outline of the methodology. Minerals Engineering 14 (10), 1237-1246] was employed to predict grinding performance of an industrial mill from the laboratory test results. The predicted full scale operation was compared with the plant survey data. Some problems in the original scale-up procedures were identified. The scale-up procedure was therefore modified to allow the predicted ball mill performance to match the observed one. The calibrated scale-up procedure was used to predict the Cylpebs performance in the full scale industrial mill using the laboratory tests results. (C) 2004 Elsevier Ltd. All rights reserved.

HPGR model verification and scale-up

This paper summarises test results that were used to validate a model and scale-up procedure of the high pressure grinding roll (HPGR) which was developed at the JKMRC by Morrell et al. [Morrell, Lim, Tondo, David,1996. Modelling the high pressure grinding rolls. In: Mining Technology Conference, pp. 169-176.]. Verification of the model is based on results from four data sets that describe the performance of three industrial scale units fitted with both studded and smooth roll surfaces. The industrial units are currently in operation within the diamond mining industry and are represented by De Beers, BHP Billiton and Rio Tinto. Ore samples from the De Beers and BHP Billiton operations were sent to the JKMRC for ore characterisation and HPGR laboratory-scale tests. Rio Tinto contributed an historical data set of tests completed during a previous research project. The results conclude that the modelling of the HPGR process has matured to a point where the model may be used to evaluate new and to optimise existing comminution circuits. The model prediction of product size distribution is good and has been found to be strongly dependent of the characteristics of the material being tested. The prediction of throughput and corresponding power draw (based on throughput) is sensitive to inconsistent gap/diameter ratios observed between laboratory-scale tests and full-scale operations. (C) 2004 Elsevier Ltd. All rights reserved.

Using DEM to model ore breakage within a pilot scale SAG mill

The best accepted method for design of autogenous and semi-autogenous (AG/SAG) mills is to carry out pilot scale test work using a 1.8 m diameter by 0.6 m long pilot scale test mill. The load in such a mill typically contains 250,000-450,000 particles larger than 6 mm, allowing correct representation of more than 90% of the charge in Discrete Element Method (DEM) simulations. Most AG/SAG mills use discharge grate slots which are 15 mm or more in width. The mass in each size fraction usually decreases rapidly below grate size. This scale of DEM model is now within the possible range of standard workstations running an efficient DEM code. This paper describes various ways of extracting collision data front the DEM model and translating it into breakage estimates. Account is taken of the different breakage mechanisms (impact and abrasion) and of the specific impact histories of the particles in order to assess the breakage rates for various size fractions in the mills. At some future time, the integration of smoothed particle hydrodynamics with DEM will allow for the inclusion of slurry within the pilot mill simulation. (C) 2004 Elsevier Ltd. All rights reserved.

Simple texture-based liberation modelling of ores

Mineralogical analysis is often used to assess the liberation properties of particles. A direct method of estimating liberation is to actually break particles and then directly obtain liberation information from applying mineralogical analysis to each size-class of the product. Another technique is to artificially apply random breakage to the feed particle sections to estimate the resultant distribution of product particle sections. This technique provides a useful alternative estimation method. Because this technique is applied to particle sections, the actual liberation properties for particles can only be estimated by applying stereological correction. A recent stereological technique has been developed that allows the discrepancy between the linear intercept composition distribution and the particle section composition distribution to be used as guide for estimating the particle composition distribution. The paper will show results validating this new technique using numerical simulation. (C) 2004 Elsevier Ltd. All rights reserved.

Stickiness measurement techniques for food powders: a review

The importance of sticky behaviour of amorphous food powders has been recognized over many decades in the food industry due to its influence on process and handling abilities and quality of the powders. This paper emphasizes the role of stickiness in the food powder industry as well as reviews the stickiness characterization techniques developed to date. This paper also attempts to correlate the stickiness behaviour of food powders to the instrumental analysis such as glass transition temperature. (C) 2004 Elsevier B.V All rights reserved.

Application of X-ray microtomography to numerical simulations of agglomerate breakage by distinct element method

Computer-aided tomography has been used for many years to provide significant information about the internal properties of an object, particularly in the medical fraternity. By reconstructing one-dimensional (ID) X-ray images, 2D cross-sections and 3D renders can provide a wealth of information about an object's internal structure. An extension of the methodology is reported here to enable the characterization of a model agglomerate structure. It is demonstrated that methods based on X-ray microtomography offer considerable potential in the validation and utilization of distinct element method simulations also examined.

Modern environmental improvement pathways for the coal power generation industry in Australia

In this work we assess the pathways for environmental improvement by the coal utilization industry for power generation in Australia. In terms of resources, our findings show that coal is a long term resource of concern as coal reserves are likely to last for the next 500 years or more. However, our analysis indicates that evaporation losses of water in power generation will approach 1000 Gl (gigalitres) per year, equivalent to a consumption of half of the Australian residential population. As Australia is the second driest continent on earth, water consumption by power generators is a resource of immediate concern with regards to sustainability. We also show that coal will continue to play a major role in energy generation in Australia and, hence, there is a need to employ new technologies that can minimize environmental impacts. The major technologies to reduce impacts to air, water and soils are addressed. Of major interest, there is a major potential for developing sequestration processes in Australia, in particular by enhanced coal bed methane (ECBM) recovery at the Bowen Basin, South Sydney Basin and Gunnedah Basin. Having said that, CO2 capture technologies require further development to support any sequestration processes in order to comply with the Kyoto Protocol. Current power generation cycles are thermodynamic limited, with 35-40% efficiencies. To move to a high efficiency cycle, it is required to change technologies of which integrated gasification combined cycle plus fuel cell is the most promising, with efficiencies expected to reach 60-65%. However, risks of moving towards an unproven technology means that power generators are likely to continue to use pulverized fuel technologies, aiming at incremental efficiency improvements (business as usual). As a big picture pathway, power generators are likely to play an increasing role in regional development; in particular EcoParks and reclaiming saline water for treatment as pressures to access fresh water supplies will significantly increase.

Focused beam reflectance technique for in situ particle sizing in wastewater treatment settling tanks

Due to the complexities involved with measuring activated sludge floc size distributions, this parameter has largely been ignored by wastewater researchers and practitioners. One of the major reasons has been that instruments able to measure particle size distributions were complex, expensive and only provided off-line measurements. The Focused Beam Reflectance Method (FBRM) is one of the rare techniques able to measure the particle size distribution in situ. This paper introduces the technique for monitoring wastewater treatment systems and compares its performance with other sizing techniques. The issue of the optimal focal point is discussed, and similar conclusions as found in the literature for other particulate systems are drawn. The study also demonstrates the capabilities of the FBRM in evaluating the performance of settling tanks. Interestingly, the floc size distributions did not vary with position inside the settling tank flocculator. This was an unexpected finding, and seriously questioned the need for a flocculator in the settling tank. It is conjectured that the invariable size distributions were caused by the unique combination of high solids concentration, low shear and zeolite dosing. (C) 2004 Society of Chemical Industry.

Flow regime, hydrodynamics, floc size distribution and sludge properties in activated sludge bubble column, air-lift and aerated stirred reactors

This paper presents a comparative study how reactor configuration, sludge loading and air flowrate affect flow regimes, hydrodynamics, floc size distribution and sludge solids-liquid separation properties. Three reactor configurations were studied in bench scale activated sludge bubble column reactor (BCR), air-lift reactor (ALR) and aerated stirred reactor (ASR). The ASR demonstrated the highest capacity of gas holdup and resistance, and homogeneity in flow regimes and shearing forces, resulting in producing large numbers of small and compact floes. The fluid dynamics in the ALR created regularly directed recirculation forces to enhance the gas holdup and sludge flocculation. The BCR distributed a high turbulent flow regime and non-homogeneity in gas holdup and mixing, and generated large numbers of larger and looser floes. The sludge size distributions, compressibility and settleability were significantly influenced by the reactor configurations associated with the flow regimes and hydrodynamics.

Effect of granule morphology on breakage behaviour during compression

In the area of dry particle breakage, Discrete Element Method (DEM) simulations have been widely used to analyse the sensitivity of various physical parameters to the behaviour of agglomerates during breakage. This paper looks at the effect of agglomerate shape and structure on the mechanisms and extent of breakage of dry agglomerates under compressive load using DEM simulations. In the simulations, a spherical-shaped agglomerate produced within the DEM code is compared with an irregularly shaped agglomerate, whose structure is that of an actual granule that was characterised with X-ray microtomography (muCT). Both agglomerates have identical particle size distribution, coordination number and surface energy values, with only the agglomerate shape and structure differing between the two. The work here details the breakage behaviour with a number of traditional DEM output parameters (i.e., contact/cluster distributions) with showing vastly different behaviour between the two agglomerates. (C) 2004 Elsevier B.V. All rights reserved.

Dynamic interfacial tension of aqueous solutions of PVAAs and its role in liquid-liquid dispersion stabilization

In liquid-liquid dispersion systems, the dynamic change of the interfacial properties between the two immiscible liquids plays an important role in both the emulsification process and emulsion stabilization. In this paper, experimentally measured dynamic interfacial tensions of 1-chlorobutane in the aqueous solutions of various random copolymers of polyvinyl acetate and polyvinyl alcohol (PVAA) are presented. Theoretical analyses on these results suggest that the adsorption of the polymer molecules is controlled neither by the bulk diffusion process nor the activation energy barrier for the adsorption but the conformation of polymer molecules. Based on the concept of critical concentration of condensation for polymer adsorption, as well as the observation that the rate at which the dynamic interfacial tension changes does not correlate to the PVAA's ability to stabilize a single drop, it is postulated that the main stabilization mechanism for the PVAAs is by steric hindrance, not the Gibbs-Marangoni effect offered by the small molecule surfactants.

Dynamic and steady-state rheology of Australian honeys at subzero temperatures

The rheology of 10 Australian honeys was investigated at temperatures -15C to 0C by a strain-controlled rheometer. The honeys exhibited Newtonian behavior irrespective of the temperature, and follow the Cox-Merz rule. G/G' and omega are quadratically related, and the crossover frequencies for liquid to solid transformation and relaxation times were obtained. The composition of the honeys correlates well (r(2) > 0.83) with the viscosity, and with 24 7 data sets (Australian and Greek honeys), the following equation was obtained: mu = 1.41 x 10(-17) exp [-1.20M + 0.01F - 0.0G + (18.6 X 10(3)/T)] The viscosity of the honeys showed a strong dependence on temperature, and four models were examined to describe this. The models gave good fits (r(2) > 0.95), but better fits were obtained for the WLF model using T-g of the honeys and mu(g) = 10(11) Pa.s. The WLF model with its universal values poorly predicted the viscosity, and the implications of the measured rheological behaviors of the honeys in their processing and handling are discussed.

A comparison between capillary and imaging techniques for sizing bubbles in flotation systems

This communication reports a laboratory and plant comparison between the University of Cape Town (UCT) device (capillary) and the McGill University bubble sizing method (imaging). The laboratory work was conducted on single bubbles to establish the accuracy of the techniques by comparing with a reference method (capture in a burette). Single bubble measurements with the McGill University technique showed a tendency to slightly underestimate (4% for a 1.3 mm bubble) and the UCT technique to slightly overestimate (1% for the 1.3 man bubble). Both trends are anticipated from fundamental considerations. In the UCT technique bubble breakup was observed when measuring a 2.7 mm bubble using a 0.5 mm ID capillary tube. A discrepancy of 11% was determined when comparing the techniques in an industrial-scale mechanical flotation cell. The possible sources of bias are discussed. (C) 2003 Elsevier Ltd. All rights reserved.