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• W99554669 abstract "This study evaluates the effect of using high pressure grinding rolls (HPGR) in newncomminution circuit designs in comparison to conventional comminution devices such asnSAG and ball mills, in terms of energy efficiency. The total energy to achieve similarnproduct sizes was measured directly in the process by using a new digital energy meter.nThe difference between the measured energy as a percentage of the conventional ball millnenergy constituted the energy efficiency or energy saving of the circuit configuration.nnnnnnn n The analysis is based on laboratory data that compares the performance of hybridnHPGR/ball mill circuits against that of conventional grinding mill circuits. The circuitsnare evaluated in terms of the total comminution energy, resultant mineral liberation andnthe eco-efficient effect of significantly reducing grinding media consumption. Threendifferent ore types are studied, viz. a lead/zinc ore, a bauxite/aluminum ore and anplatinum/chrome ore. Total circuit energy is compared using both Bondrs third theory andnwork index values, and a newly developed methodology of direct energy measurement.nnnnnnn n In order to validate the results of the digital energy meter, measured energy results madenin the Bond ball mill were compared to several other energy evaluation techniques thatnincluded mill power models, DEM and Bond energy lback-calculationr methods.nComparable results have confirmed that the digital energy meter can measure specificncomminution energy directly.nnnnnnn n Bondrs empirical method is also critically reviewed. The Bond method which uses annempirical equation and the well known Bond work index to predict comminution energynrequirements appears to be based on 60 J/rev (Bond, 1952a 1952 b). This so-called millnenergy defines an equivalent net energy in the Bond ball mill test to realise the same for an2.4 meter wet grinding mill. Bondrs empirical equation results can thus be reproducednusing 60J/rev and the mill test data.nnnnnnn n Bondrs original paper published in 1949 stated that the net energy input to the laboratorynscale ball mill is 93 J/rev (Bond, 1949). This is comparable to the digital energy meternmeasurement of 91.4 J/rev. Bondrs empirical relationship thus suggests that there is anbuilt in scale factor of 0.645 which accounts for the differences between dry laboratorynmilling tests and a full scale (2.4m) wet grinding mill and is the reason for the stated 60nJ/rev.nnnnnnn n The digital energy meter was subsequently used to measure the energy consumption in thenball mill and compares this with the energy required to produce the same product sizendistribution in several hybrid HPGR/ball mill circuits. It was observed that on average anmeasured energy saving of 25-40% was achieved through the hybrid HPGR/ ball millingncircuit when compared with the conventional ball mill circuit.nnnnnnn n Results obtained from measuring energy directly are compared with results obtained bynusing Bondrs work index and third theory equation. When Bondrs method is used, anmethod frequently used in research, negative energy savings sometimes result. The Bondnthird theory and work index should not be used under these circumstances. nnnnnnn n The characteristics of the liberated mineral products were measured using the JKMRCnmineral liberation analyser (MLA). For each of the experimental circuit products,nliberation characteristics concluded that the enhancement of liberated mineral through thenuse of HPGR technology was not founded. However, extensive particle micro-crackingnwas visible in the HPGR produces that were visible in the MLA backscatter images. Thisnwas not observed in the conventionally crushed products. The HPGR micro cracks arenbelieved to be responsible for particle weakening and the resultant reduced milling energynrequirements of ball mill processes that follow with the total circuit energy requirementsnsignificantly reduced.nnnnnnn n Greater eco-efficiency can also be realised by reducing the consumption of mill liners andngrinding media. Though the ldollar costr of comminution is normally accounted for as andirect electricity expense in the process and is rarely considered for its overall energy costnor lembodied energyr of manufacturing the steel which amounts to up to 4-6 kWh/t. Eco-efficientnand sustainable development initiatives are linked to lenergy costr and notnalways ldollar costr savings. Rather the direct and indirect energy cost savings and thenimpact on the environment should be targeted.nnnnnnn n Direct energy use in comminution processes is reviewed. It is shown that 0.56% (87nTWh) of the global net electrical energy consumption of 15,500 TWh per annum is usednto crush and grind non-ferrous ores. Of this, 33% and 53% of the energy is required tonprocess gold and copper ores respectively. This suggests that the HPGR should bentargeted at gold and copper mining operations in the future to be effective in reducingncarbon emissions. As such new eco-efficient flowsheets that use multiple HPGRrs innseries could be considered. HPGR would be employed as primary comminution devicesnfollowed by small ball mills.nnnnnnn n All of the data presented in this thesis is provided in the accompanying CD.n" @default.
• W99554669 created "2016-06-24" @default.
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• W99554669 date "2007-01-01" @default.
• W99554669 modified "2023-09-26" @default.
• W99554669 title "Energy efficient mineral liberation using HPGR technology" @default.
• W99554669 hasPublicationYear "2007" @default.
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