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.

Solid transport in a pyrolysis pilot-scale rotary kiln: Preliminary results?stationary and dynamic results

Experiments for the investigation of the flow of granular solids in a pyrolysis pilot-scale rotary kiln are presented. These experiments consisted first in measuring the volumetric filling ratio (steady-state experiences) for several operating conditions and second in recording the exit flow rates after a positive or negative step in one of the operating parameters (dynamic experiences). A dynamical model computing the evolution of the flow rate of granular solids through the kiln has been developed based on Saeman model [Chem. Eng. Prog. 47 (1951) 508]. The simulations are compared with experimental results; the model gives good results for the rolling mode, but for the slipping mode too. (C) 2004 Elsevier B.V. All rights reserved.

Modelling comminution patterns within a pilot scale AG/SAG mill

The patterns of rock comminution within tumbling mills, as well as the nature of forces, are of significant practical importance. Discrete element modelling (DEM) has been used to analyse the pattern of specific energy applied to rock, in terms of spatial distribution within a pilot AG/SAG mill. We also analysed in some detail the nature of the forces, which may result in rock comminution. In order to examine the distribution of energy applied within the mill, the DEM models were compared with measured particle mass losses, in small scale AG and SAG mill experiments. The intensity of contact stresses was estimated using the Hertz theory of elastic contacts. The results indicate that in the case of the AG mill, the highest intensity stresses and strains are likely to occur deep within the charge, and close to the base. This effect is probably more pronounced for large AG mills. In the SAG mill case, the impacts of the steel balls on the surface of the charge are likely to be the most potent. In both cases, the spatial pattern of medium-to-high energy collisions is affected by the rotational speed of the mill. Based on an assumed damage threshold for rock, in terms of specific energy introduced per single collision, the spatial pattern of productive collisions within each charge was estimated and compared with rates of mass loss. We also investigated the nature of the comminution process within AG vs. SAG mill, in order to explain the observed differences in energy utilisation efficiency, between two types of milling. All experiments were performed using a laboratory scale mill of 1.19 m diameter and 0.31 m length, equipped with 14 square section lifters of height 40 mm. (C) 2006 Elsevier Ltd. All rights reserved.

Eliminating non-renewable CO2 emissions from sewage treatment: An anaerobic migrating bed reactor pilot plant study

The aim of this work was to demonstrate at pilot scale a high level of energy recovery from sewage utilising a primary Anaerobic Migrating Bed Reactor (AMBR) operating at ambient temperature to convert COD to methane. The focus is the reduction in non-renewable CO2 emissions resulting from reduced energy requirements for sewage treatment. A pilot AMBR was operated on screened sewage over the period June 2003 to September 2004. The study was divided into two experimental phases. In Phase 1 the process operated at a feed rate of 10 L/h (HRT 50 h), SRT 63 days, average temperature 28 degrees C and mixing time fraction 0.05. In Phase 2 the operating parameters were 20 L/h, 26 days, 16 degrees C and 0.025. Methane production was 66% of total sewage COD in Phase 1 and 23% in Phase 2. Gas mixing of the reactor provided micro-aeration which suppressed sulphide production. Intermittent gas mixing at a useful power input of 6 W/m(3) provided satisfactory process performance in both phases. Energy consumption for mixing was about 1.5% of the energy conversion to methane in both operating phases. Comparative analysis with previously published data confirmed that methane supersaturation resulted in significant losses of methane in the effluent of anaerobic treatment systems. No cases have been reported where methane was considered to be supersaturated in the effluent. We have shown that methane supersaturation is likely to be significant and that methane losses in the effluent are likely to have been greater than previously predicted. Dissolved methane concentrations were measured at up to 2.2 times the saturation concentration relative to the mixing gas composition. However, this study has also demonstrated that despite methane supersaturation occurring, microaeration can result in significantly lower losses of methane in the effluent (< 11% in this study), and has demonstrated that anaerobic sewage treatment can genuinely provide energy recovery. The goal of demonstrating a high level of energy recovery in an ambient anaerobic bioreactor was achieved. An AMBR operating at ambient temperature can achieve up to 70% conversion of sewage COD to methane, depending on SRT and temperature. (c) 2006 Wiley Periodicals, Inc.

Characterizing the physical and chemical properties of a vermicompost filter bed

Vermicompost filtration is a new on-site waste treatment system. Consequently, little is known about the filter medium properties. The aim of this preliminary study was to quantify physical and compositional properties of vermicompost filter beds that had been used to treat domestic solid organic waste and wastewater. This paper presents the trials performed on pilot-scale reactors filled with vermicompost from a full-scale vermicompost filtration system. Household solid organic waste and raw wastewater at the rate of 130 L/m(2)/d was applied to the reactor bed surface over a four-month period. It was found that fresh casts laid on the bed surface had a BOD of 1290 mg/g VS while casts buried to a depth of 10 cm had a BOD of 605 mg/g VS. Below this depth there was little further biodegradation of earthworm casts despite cast ages of up to five years. Solid material in the reactor accounted for only 7-10% of the reactor volume. The total voidage comprised of large free-draining pores, which accounted for 15-20% of the reactor volume and 60-70% micropores, able to hold up water against gravity. It was shown that water could flow through the medium micropores and macropores following a wastewater application. The wastewater flow characteristics were modeled by a two-region model based on the Richards Equation, an equation used to describe porous spatially heterogeneous materials.

Performance of a substratum-irradiated photosynthetic biofilm reactor for the removal of sulfide from wastewater

The performance of a sulfide-removal system based on biofilms dominated by green sulfur bacteria (GSB) has been investigated. The system was supplied with radiant energy in the band 720-780 nm, and fed with a synthetic wastewater. The areal net sulfide removal rate and the efficacy of the incident radiant energy for sulfide removal have been characterized over ranges of bulk sulfide concentration (1.6-11.5 mg L-1) and incident irradiance (0.21-1.51 W m(-2)). The areal net sulfide removal rate increased monotonically with both increasing incident irradiance and increasing bulk sulfide concentration. The efficacy of the radiant energy for sulfide removal (the amount of sulfide removed per unit radiant energy supplied) also increased monotonically with rising bulk sulfide concentration, but exhibited a maximum value with respect to incident irradiance. The maximum observed values of this net removal rate and this efficacy were, respectively, 2.08 g m(-2) d(-1) and 2.04 g W-1 d(-1). In-band changes in the spectral composition of the radiant energy affected this efficacy only slightly. The products of sulfide removal were sulfate and elemental-S. The elemental-S was scarcely released into the liquid, however, and reasons for this, such as sulfur reduction and polysulfide formation, are considered. Between 1.45 and 3.85 photons were needed for the net removal of one electron from S-species. Intact samples of the biofilm were characterized by microscopy, and their thicknesses lay between 39 +/- 9 and 429 +/- 57 mum. The use of the experimentally determined rates and efficacies for the design of a pilot-scale system is illustrated. (C) 2004 Wiley Periodicals, Inc.

Particle bed charge decay behaviour under high tension roll separation

A new theory of particle discharge in high tension roll (HTR) separation is presented. The discharge dynamics of an isolated charged particle resting on a conducting surface are studied first. The analysis is extended to particle discharge in a homogenous particle bed. Finally, the paper looks at the more realistic scenario of particle discharge in a non-homogenous particle bed. The consequences of the resulting theory on HTR separation are discussed. Predictions from the new theory are tested against experimental HTR separations at the pilot scale. (c) 2005 Elsevier Ltd. All rights reserved.

Modelling of two-stage anaerobic digestion using the IWA Anaerobic Digestion Model No. 1 (ADM1)

The aim of the study presented was to implement a process model to simulate the dynamic behaviour of a pilot-scale process for anaerobic two-stage digestion of sewage sludge. The model implemented was initiated to support experimental investigations of the anaerobic two-stage digestion process. The model concept implemented in the simulation software package MATLAB(TM)/Simulink(R) is a derivative of the IWA Anaerobic Digestion Model No.1 (ADM1) that has been developed by the IWA task group for mathematical modelling of anaerobic processes. In the present study the original model concept has been adapted and applied to replicate a two-stage digestion process. Testing procedures, including balance checks and 'benchmarking' tests were carried out to verify the accuracy of the implementation. These combined measures ensured a faultless model implementation without numerical inconsistencies. Parameters for both, the thermophilic and the mesophilic process stage, have been estimated successfully using data from lab-scale experiments described in literature. Due to the high number of parameters in the structured model, it was necessary to develop a customised procedure that limited the range of parameters to be estimated. The accuracy of the optimised parameter sets has been assessed against experimental data from pilot-scale experiments. Under these conditions, the model predicted reasonably well the dynamic behaviour of a two-stage digestion process in pilot scale. (C) 2004 Elsevier Ltd. All rights reserved.

A glass transition temperature approach for the prediction of the surface stickiness of a drying droplet during spray drying

The development of surface stickiness of droplets of sugar and acid-rich foods during spray drying can be explained using the notion of glass transition temperature (T-g). In this work, criteria for a safe drying regime have been developed and their physical basis provided. A dimensionless time (psi) is introduced as an indicator of spray dryability and it is correlated with the recovery of powders in practical spray drying. Droplets with initial diameters of 120 mum were subjected to simulated spray drying conditions and their safe drying regime and 41 values generated. The model predicted the recovery in a pilot scale spray dryer reasonably well. (C) 2004 Elsevier B.V. All rights reserved.

Slurry flow in mills with TCPL - An efficient pulp lifter for ag/sag mills

The difficulties associated with slurry transportation in autogenous (ag) and semi-autogenous (sag) grinding mills have become more apparent in recent years with the increasing trend to build larger diameter mills for grinding high tonnages. This is particularly noticeable when ag/sag mills are run in closed circuit with classifiers such as fine screens/cyclones. Extensive test work carried out on slurry removal mechanism in grate discharge mills (ag/sag) has shown that the conventional pulp lifters (radial and curved) have inherent drawbacks. They allow short-circuiting of the slurry from pulp lifters into the grinding chamber leading to slurry pool formation. Slurry pool absorbs part of the impact thus inhibiting the grinding process. Twin Chamber Pulp Lifter (TCPL) - an efficient design of pulp lifter developed by the authors overcomes the inherent drawbacks of the conventional pulp lifters. Extensive testing in both laboratory and pilot scale mills has shown that the TCPL completely blocks the flow-back process, thus allowing the mill to operate close to their design flow capacity. The TCPL performance is also found to be independent of variations in charge volume and grate design, whereas they significantly affect the performance of conventional pulp lifters (radial and curved). (c) 2006 Elsevier B.V. All rights reserved.

Analysis of stirred mill performance using DEM simulation: Part 2 - Coherent flow structures, liner stress and wear, mixing and transport

Stirred Mills are becoming increasingly used for fine and ultra-fine grinding. This technology is still poorly understood when used in the mineral processing context. This makes process optimisation of such devices problematic. 3D DEM simulations of the flow of grinding media in pilot scale tower mills and pin mills are carried out in order to investigate the relative performance of these stirred mills. In the first part of this paper, media flow patterns and energy absorption rates and distributions were analysed to provide a good understanding of the media flow and the collisional environment in these mills. In this second part we analyse steady state coherent flow structures, liner stress and wear by impact and abrasion. We also examine mixing and transport efficiency. Together these provide a comprehensive understanding of all the key processes operating in these mills and a clear understanding of the relative performance issues. (C) 2006 Elsevier Ltd. All rights reserved.

Analysis of stirred mill performance using DEM simulation: Part 1 - Media motion, energy consumption and collisional environment

Stirred mills are becoming increasingly used for fine and ultra-fine grinding. This technology is still poorly understood when used in the mineral processing context. This makes process optimisation of such devices problematic. 3D DEM simulations of the flow of grinding media in pilot scale tower mills and pin mills are carried out in order to investigate the relative performance of these stirred mills. Media flow patterns and energy absorption rates and distributions are analysed here. In the second part of this paper, coherent flow structures, equipment wear and mixing and transport efficiency are analysed. (C) 2006 Published by Elsevier Ltd.

Biodegradation of the cyanobacterial toxin microcystin LR in natural water and biologically active slow sand filters

A bacterium (MJ-PV) previously demonstrated to degrade the cyanobacterial toxin microcystin LR, was investigated for bioremediation applications in natural water microcosms and biologically active slow sand filters. Enhanced degradation of microcystin LR was observed with inoculated (1 x 10(6) cell/mL) treatments of river water dosed with microcystin LR (> 80% degradation within 2 days) compared to uninoculated controls. Inoculation of MJ-PV at lower concentrations (1 x 10(2)-1 x 10(5)cells/mL) also demonstrated enhanced microcystin LR degradation over control treatments. Polymerase chain reactions (PCR) specifically targeting amplification of 16S rDNA of MJ-PV and the gene responsible for initial degradation of microcystin LR (mlrA) were successfully applied to monitor the presence of the bacterium in experimental trials. No amplified products indicative of an endemic MJ-PV population were observed in uninoculated treatments indicating other bacterial strains were active in degradation of microcystin LR, Pilot scale biologically active slow sand filters demonstrated degradation of microcystin LR irrespective of MJ-PV bacterial inoculation. PCR analysis detected the MJ-PV population at all locations within the sand filters where microcystin degradation was measured. Despite not observing enhanced degradation of microcystin LR in inoculated columns compared to uninoculated column, these studies demonstrate the effectiveness of a low-technology water treatment system like biologically active slow sand filters for removal of microcystins from reticulated water supplies. Crown Copyright (c) 2006 Published by Elsevier Ltd. All rights reserved.