Charla 1 SepulvedaMOLY-COP TOOLS 3.0

MOLY-COP TOOLS 3.0Jaime E. Sepúlveda

XII Simposio sobreProcesamiento de MineralesNoviembre, 2012

MOLY-COP TOOLS 3.0

Moly-Cop Tools 3.0 es un conjunto de 63 planillas EXCEL 2007 diseñadas para ayudar al Ingeniero de Procesos a caracterizar y evaluar la eficiencia operacional de un circuito dado de molienda, sobre la base de metodologías y criterios de amplia aceptación práctica.

Moly-Cop Tools 3.0 contiene una completa variedad de simuladores para diversas aplicaciones de trituración (Chancado y HPGR’s) y molienda (Semiautógena, de Barras, de Bolas y en Molinos Verticales), con sus correspondientes rutinas para balances de materiales y estimación de parámetros.

Lo anterior complementado con otras aplicaciones para cálculos típicos relativos a la Ley de Bond, el ‘algebra’ de las bolas y otras funciones de utilidad general.

Moly-Cop Tools 3.0UN POCO DE HISTORIA…

La primera versión de Moly-Cop Tools , con un total de 30 aplicaciones, nació precisamente en el X Simposio, que se llevó a efecto en Noviembre, 2001 en Termas de Puyehue, Chile.

Desde entonces - gracias a los continuos esfuerzos de distribución, aplicación e intercambio de experiencias con la comunidad minera internacional - Moly-Cop Tools ha llegado a ser reconocido como un conjunto de herramientas computacionales de verdadera utilidad para el análisis de procesos de trituración y molienda de minerales.

Resultado de este sostenido proceso de adaptación y desarrollo, la tercera versión - que hoy por primera vez presentamos - expande significativamente el alcance de las primeras dos versiones, incorporando ahora un total de 63 planillas de aplicación.

Moly-Cop Toolsestá disponible sin cargo para todos

los [email protected]

¡Mi Tata lo hizo!

¡Lady Gaga!

Moly-Cop Tools 3.0CONTENIDOS

Moly-Cop Tools 3.0¿QUÉ HAY DE NUEVO?

Moly-Cop Tools 3.0HPGR’s

HPGRSim_Open permite simular la respuesta de un HPGR bajo determinadas condiciones de operación y diseño.

HPGRParam_Open permite ‘sintonizar’ el simulador a la condición de interés, a partir de resultados a escala laboratorio, piloto o industrial.

La aplicación HPGRSim_Open puede ser integrada con otras aplicaciones de Moly-Cop Tools 3.0 para representar configuraciones de circuitos de mayor complejidad.

HPGR’sBASE TEORICA DEL MODELO

El modelo HPGR – adaptado de la Tesis de Magíster de Magín Torres (Univ. de Chile, 2010) - consiste de 3 ecuaciones para el cálculo del ‘Gap’ Operacional (mm), la Capacidad de Molienda (tph) y la Potencia Neta Demandada (kW), respectivamente; las que debidamente combinadas permiten la estimación de la Energía Específica (kWh/ton) aplicada al mineral, información clave para la posterior solución de las ecuaciones del ya tradicional Modelo Lineal de Molienda supuestamente aplicable a este diseño específico de dispositivos de trituración.

M

c gD/2

p

HPGR’s‘GAP’ OPERACIONAL

El ‘Gap’ Operacional o separación entre los rodillos se determina a partir de la relación geométrica:

g = 1000 D cos c (1 - cos c) / (rc/ra - cos c)

Valores típicos de c están en el rango de 7° - 9°.

M

c gD/2

p

HPGR’sCAPACIDAD DE MOLIENDA

La Capacidad de Molienda del HPGR está dada por:

M = 3.6 rc g L U c

donde c es un factor empírico que permite considerar la posibilidad de extrusión del mineral en su paso entre los rodillos.

Krupp Polysius recomienda U = 1.35 D0.5 cuando D < 1.82 m ó U = D cuando D > 1.82 m, con el propósito de evitar dicha posibilidad de extrusión.

M

c gD/2

p

Ensayos Piloto con Rodillos de 0.92x0.25 mCAPACIDAD DE MOLIENDA

565

0

10

20

30

40

50

60

70

0 10 20 30 40 50 60 70

Pred

icte

d Ca

paci

ty, t

ph

Actual Capacity, tph

Extrusion/Slippage Factor = 1.12

HPGR’sPOTENCIA NETA DEMANDADA

La Potencia Neta Demandada es función directa de la fuerza de compresión aplicada entre los rodillos, definida como:

F = 100 p D L Luego, considerando ambos rodillos:

P = 2 * Torque = 2 (2 p N/60) (D/2) ( m F) = m p N D F /30

donde m representa el Coeficiente de Fricción contra los rodillos.

M

c gD/2

p

Ensayos Piloto con Rodillos de 0.92x0.25 mPOTENCIA DEMANDADA

0

20

40

60

80

100

120

140

160

180

200

0 50 100 150 200

Pred

icte

d Po

wer

, kW

Actual Power, kW

Friction Coefficient = sin(3.48� ) = 0.0608

HPGR’sMODELO LINEAL DE LA MOLIENDA

JCii exp(-Si

EE) R(E) dE (1 + SiEE /N)-N

0

(T JC T-1) f INf OUT =

Finalmente, conocida la Energía Específica, E = P/M, es posible calcularla granulometría del producto molido:

con:

HPGRParam_Open_Data FileESTIMACION DE PARAMETROSMoly-Cop Tools TM (Version 3.0)

Circuit Type OPEN (see Flowsheet ) Test N° 0

Remarks

HPGR Dimensions and Operating Conditions

Roll Diameter, D, m 0.90Roll Length, L, m 0.25

Peripheral Speed, U, m/sec 0.43Rotational Speed, , rpm 9.12Operating Pressure, p, Bars 30.00Specific Grinding Force, Newton/mm2 3.00Compression Force, kNewton 675Friction Coefficient, m 0.114Net Power Draw, P, kW 66.0

Critical Compression Angle, c, (°) 8.13Operational Gap, g, mm 19.0

As % of Roll Diameter 2.1Nipping Gap, mm 28.1

Extrusion/Slippage Factor 1.08 Edge By-Pass, Le, mm 57.0Grinding Capacity, M, ton/hr (wet) 21.1 As # of gaps 3.0Feed Moisture, % 5.0Grinding Capacity, M, ton/hr (dry) 20.0Specific Throughput, ton sec / m3 hr) 206.7Specific Energy, E, kWh/ton 3.30

Ore Density, r s, ton/m3 2.80Bulk Feed Particles % Voids 35.0 App. Density, rap, ton/m3 1.82Product Particles (Cake) % Voids 5.0 App. Density, rc, ton/m3 2.66

HPGRParam: Estimation of HPGR Grinding Parameters from Experimental Data.

Base Case Example

M

c gD/2

p

HPGRParam_Open_Data FileESTIMACION DE PARAMETROS

i Mesh Opening Mid-Size ton/hr % Retained % Passing % Retained % Passing % Retained % Passing % Retained % PassingDISCHARGE CENTER EDGES

1 1" 25400 100.00 100.00 100.00 100.002 3/4" 19050 21997 7.13 35.64 64.36 0.72 99.28 0.72 99.28 0.72 99.283 1/2" 12700 15554 5.01 25.03 39.33 7.26 92.02 7.26 92.02 7.26 92.024 3/8" 9525 10999 2.07 10.33 29.00 11.91 80.11 11.91 80.11 11.91 80.115 1/4" 6350 7777 1.80 9.00 20.00 11.99 68.12 11.99 68.12 11.99 68.126 4 4750 5492 0.81 4.03 15.97 6.42 61.70 6.42 61.70 6.42 61.707 6 3350 3989 0.79 3.97 12.00 6.87 54.83 6.87 54.83 6.87 54.838 8 2360 2812 0.41 2.04 9.96 5.52 49.31 5.52 49.31 5.52 49.319 10 1700 2003 0.31 1.56 8.40 5.72 43.59 5.72 43.59 5.72 43.59

10 14 1180 1416 0.26 1.31 7.09 4.32 39.27 4.32 39.27 4.32 39.2711 20 850 1001 0.20 0.98 6.11 3.74 35.53 3.74 35.53 3.74 35.5312 28 600 714 0.18 0.90 5.21 4.47 31.06 4.47 31.06 4.47 31.0613 35 425 505 0.15 0.73 4.48 2.74 28.32 2.74 28.32 2.74 28.3214 48 300 357 0.13 0.65 3.83 3.34 24.98 3.34 24.98 3.34 24.9815 65 212 252 0.12 0.58 3.25 2.22 22.76 2.22 22.76 2.22 22.7616 100 150 178 0.10 0.52 2.73 2.74 20.02 2.74 20.02 2.74 20.0217 150 106 126 0.09 0.45 2.28 2.21 17.81 2.21 17.81 2.21 17.8118 200 75 89 0.07 0.34 1.94 2.10 15.71 2.10 15.71 2.10 15.7119 270 53 63 0.06 0.30 1.64 1.91 13.80 1.91 13.80 1.91 13.8020 325 45 49 0.02 0.10 1.54 1.08 12.72 1.08 12.72 1.08 12.7221 -325 0 23 0.31 1.54 0.00 12.72 0.00 12.72 0.00 12.72 0.00

F99/Gap Ratio 1.33F99/Nipping Gap Ratio 0.90 1.00 0.00 0.00

Selection Function Parameters : 1.80 0.00 0.00alpha0 alpha1 alpha2 dcrit0.031595 0.324510724 3 90002 Ave. Error, % 1.80

473.7 % of GapBreakage Function Parameters :

beta0 beta1 beta20.378331715 0.363039662 4

Weighting Factors

Feed Size Distribution Product Size Distributions

HPGRParam_Open_Control PanelESTIMACION DE PARAMETROS

Moly-Cop Tools TM (Version 3.0)

Test N° 0

Weighting Factors: Center Sample 0.00 Edge Sample 0.00 Overall 1.00

Edge By-Pass, As # of gaps 3.0

SELECTION FUNCTION PARAMETERS: alpha0 0.060000 alpha1 0.250 alpha2 3.0 Dcrit 7000

BREAKAGE FUNCTION PARAMETERS: beta0 0.40000 beta1 0.400 beta2 4.0

Objective Function 31.37

HPGRParam_Open : Estimation of HPGR Grinding Parameters.

Note : Current calculations are not valid, if SOLVER has not been run after the last data modification.

1

10

100

10 100 1000 10000 100000

% P

assi

ng

Particle Size, microns

FeedDischarge (Exp.)Discharge (Adjusted)SiE * 10

Estimaciones Iniciales

HPGRParam_Open_Control PanelESTIMACION DE PARAMETROS


Test N° 0

Weighting Factors: Center Sample 0.00 Edge Sample 0.00 Overall 1.00

Edge By-Pass, As # of gaps 3.0

SELECTION FUNCTION PARAMETERS: alpha0 0.031595 alpha1 0.325 alpha2 3.0 Dcrit 90002

BREAKAGE FUNCTION PARAMETERS: beta0 0.37833 beta1 0.363 beta2 4.0


HPGRParam_Open : Estimation of HPGR Grinding Parameters.


1

10

100

10 100 1000 10000 100000

% P

assi

ng



Después de ejecutar SOLVER

HPGRSim_Open_Data FileSIMULADOR HPGR


Circuit Type OPEN (see Flowsheet ) Simulation N° 0

Remarks

HPGR Dimensions and Operating ConditionsDefault Values

Roll Diameter, D, m 2.25Roll Length, L, m 1.40

Peripheral Speed, U, m/sec 2.01 2.25 MaxRotational Speed, , rpm 17.06Operating Pressure, p, Bars 40.00Specific Grinding Force, Newton/mm2 4.00Compression Force, kNewton 12600Friction Coefficient, m 0.056 0.077Net Power Draw, P, kW 2850.0

Critical Compression Angle, c, (°) 8.80 8.0Operational Gap, g, mm 54.6

As % of Roll Diameter 2.4Nipping Gap, mm 81.0

Extrusion/Slippage Factor 1.00 1.00 Edge By-Pass, Le, mm 163.7Grinding Capacity, M, ton/hr (wet) 1476.7 As # of gaps 3.0Feed Moisture, % 3.5Grinding Capacity, M, ton/hr (dry) 1425.0Specific Throughput, ton sec / m3 hr) 225.1Specific Energy, E, kWh/ton 2.00

Ore Density, r s, ton/m3 2.80Bulk Feed Particles % Voids 35.0 35.0 App. Density, rap, ton/m3 1.82Product Particles (Cake) % Voids 4.6 5.0 App. Density, rc, ton/m3 2.67

i Mesh Opening Mid-Size ton/hr % Retained % Passing

1 3" 76200 100.002 2" 50800 62217 45.87 3.22 96.783 1.5" 38100 43994 35.75 2.51 94.274 1" 25400 31109 319.60 22.43 71.845 0.742" 19050 21997 324.87 22.80 49.056 0.525" 12700 15554 290.67 20.40 28.657 0.371" 9500 10984 101.96 7.16 21.498 3 6700 7978 66.51 4.67 16.839 4 4750 5641 39.54 2.77 14.05

10 6 3350 3989 29.21 2.05 12.0011 8 2360 2812 23.96 1.68 10.3212 10 1700 2003 19.41 1.36 8.9613 14 1180 1416 18.93 1.33 7.6314 20 850 1001 14.92 1.05 6.5815 28 600 714 13.87 0.97 5.6116 35 425 505 11.92 0.84 4.7717 48 300 357 10.40 0.73 4.0418 65 212 252 8.89 0.62 3.4219 100 150 178 7.58 0.53 2.8920 150 106 126 6.48 0.45 2.4321 -150 0 53 34.66 2.43 0.00

F99/Gap Ratio 1.23F99/Nipping Gap Ratio 0.83

Selection Function Parameters :alpha0 alpha1 alpha2 dcrit

0.03160 0.325 3 90002165.0 % of Gap

Breakage Function Parameters :beta0 beta1 beta2

0.378 0.363 4

HPGRSIM: Open Circuit HPGR Simulator.

Feed Size Distribution

Base Case Example

M

c gD/2

p

HPGRSim_Open_ChartSIMULADOR HPGR


Simulation N° 0 Remarks :

HPGRSim_Open : Open Circuit HPGR Simulator

Base Case Example

1

10

100

10 100 1000 10000 100000

% P

assi

ng


Fresh Feed

HPGR Discharge

Edges

Size Distributions

HPGRSim_Open_ReportsSIMULADOR HPGR

Simulation N° 0

Remarks:

Roll Diameter, D, m 2.25 Critical Compression Angle, c, (°) 8.80

Roll Length, L, m 1.40 Operational Gap, g, mm 54.6As % of Roll Diameter 2.4

Peripheral Speed, U, m/sec 2.01Rotational Speed, w, rpm 17.06 Grinding Capacity, M, ton/hr (wet) 1476.7Operating Pressure, p, Bars 40.0 Feed Moisture, % 3.50

Grinding Capacity, M, ton/hr (dry) 1425.0Friction Coefficient, m 0.056Net Power Draw, P, kW 2850.0 Specific Energy, E, kWh/ton 2.00

Ore Density, rs, ton/m3 2.80Bulk Feed Particles % Voids 35 Apparent Density, rap, ton/m3 1.82Product Particles (Cake) % Voids 4.5857275 Apparent Density, rc, ton/m3 2.67

Moly-Cop ToolsTM, Version 3.0HPGRSIM_Open

Open Circuit HPGR Simulator

Base Case Example

HPGRSim_Open_ReportsSIMULADOR HPGR

HPGR HPGR Rolls RollsFeed Discharge Center Edge

Ore, ton/hr 1425.0 1425.0 1091.8 333.2 Water, m3/hr 51.7 51.7 39.6 12.1 Slurry, ton/hr 1476.7 1476.7 1131.4 345.3 Slurry, m3/hr 560.6 560.6 429.5 131.1 Slurry Dens., ton/m3 2.634 2.634 2.634 2.634 % Solids (by volume) 90.8 90.8 90.8 90.8 % Solids (by weight) 96.50 96.50 96.50 96.50

i Mesh Opening

1 3" 76200 62217 100.00 100.00 100.00 100.002 2" 50800 43994 96.78 99.70 99.76 99.483 1.5" 38100 31109 94.27 98.95 99.14 98.354 1" 25400 21997 71.84 93.63 94.62 90.395 0.742" 19050 15554 49.05 84.40 86.47 77.636 0.525" 12700 10984 28.65 71.14 74.29 60.827 0.371" 9500 7978 21.49 61.32 64.82 49.888 3 6700 5641 16.83 52.43 55.95 40.899 4 4750 3989 14.05 45.57 48.92 34.60

10 6 3350 2812 12.00 40.05 43.16 29.8711 8 2360 2003 10.32 35.46 38.32 26.0912 10 1700 1416 8.96 31.69 34.33 23.0613 14 1180 1001 7.63 28.05 30.46 20.1414 20 850 714 6.58 25.05 27.26 17.7915 28 600 505 5.61 22.21 24.23 15.5916 35 425 357 4.77 19.67 21.51 13.6517 48 300 252 4.04 17.38 19.04 11.9318 65 212 178 3.42 15.33 16.84 10.4119 100 150 126 2.89 13.52 14.87 9.0920 150 106 53 2.43 11.90 13.11 7.92

D80, microns 29821 16777 15478 20164

alpha0 alpha1 alpha2 Dcrit Beta0 Beta1 Beta20.03160 0.325 3 90002 0.378 0.36 4.00

Breakage Function ParametersSelection Function Parameters

Size Distributions, % Passing

HPGRSim_OpenEFECTO VELOCIDAD DE GIRO

0

1000

2000

3000

4000

5000

6000

7000

1.60 1.80 2.00 2.20 2.40 2.60 2.80

Peripheral Speed, m/sec

Power, kW

Capacity, ton/hr

18.0

18.5

19.0

19.5

20.0

20.5

3.0

3.2

3.4

3.6

3.8

4.0

4.2

4.4

4.6

4.8

5.0

1.60 1.80 2.00 2.20 2.40 2.60 2.80

% -

100#

kWh/

ton

Peripheral Speed, m/sec

Specific Energy, kWh/tonProduct Size, % - 100#

HPGRSim_OpenEFECTO PRESION DE COMPRESION

0

1000

2000

3000

4000

5000

6000

7000

8000

35.00 40.00 45.00 50.00 55.00 60.00 65.00

Pressure, Bars

Power, kW

Capacity, ton/hr

16

18

20

22

24

26

28

3.0

3.5

4.0

4.5

5.0

5.5

6.0

35.00 40.00 45.00 50.00 55.00 60.00 65.00

% -

100#

kWh/

ton

Pressure, Bars


HPGRSim_OpenEFECTO TAMAÑO DE ALIMENTACION

0

1000

2000

3000

4000

5000

6000

7000

8000

5 10 15 20 25 30 35

F80, mm

Power, kW

Capacity, ton/hr

17

18

19

20

21

22

23

3.0

3.5

4.0

4.5

5.0

5.5

6.0

5 15 25 35 45 55

% -

100#

kWh/

ton

F80, mm


Moly-Cop Tools 3.0MOLINOS DE BARRAS

RodSim_Open_Data FileSIMULADOR MOLINOS DE BARRAS


Circuit Type OPEN (see Flowsheet ) Simulation N° 0

Remarks

Mill Dimensions and Operating Conditions 213 RodsEff. Diam. Eff. Length Speed Charge Rods App. Dens. Interstitial Lift 0 Overfilling

ft ft % Critical Filling,% Filling,% ton/m3 Slurry, % Angle, (°) 33 Slurry7.5 12.0 72.0 30.0 30.0 5.38 100.0 45.0 246 Net kW

rpm 20.14 10.0 % Losses274 Gross kW

Ore Density, ton/m3 2.70Rods Density, ton/m3 7.75 P80 3729% Solids Mill Discharge 71.9 Wio 54.30 0.946Feedrate, ton/hr (dry) 92.6 % Fines MD 9.19 2.297Feed Moisture, % 1.5


1 1.05 25400 100.002 0.742 19050 21997 0.00 0.00 100.003 0.525 12700 15554 0.00 0.00 100.004 0.371 9500 10984 8.00 8.64 91.365 3 6700 7978 25.78 27.84 63.526 4 4750 5641 18.66 20.15 43.377 6 3350 3989 10.05 10.86 32.518 8 2360 2812 8.05 8.70 23.819 10 1700 2003 4.61 4.97 18.84

10 14 1180 1416 3.40 3.67 15.1711 20 850 1001 2.24 2.42 12.7512 28 600 714 1.89 2.04 10.7013 35 425 505 1.42 1.54 9.1714 48 300 357 1.23 1.32 7.8415 65 212 252 0.98 1.06 6.7916 100 150 178 0.88 0.95 5.8417 150 106 126 0.73 0.79 5.0518 200 75 89 0.67 0.72 4.3319 270 53 63 0.55 0.60 3.7320 400 38 45 0.29 0.32 3.4221 -400 0 19 3.16 3.42 0.00

Selection Function Parameters : Expanded Form :alpha0 alpha1 alpha2 dcrit alpha02 alpha120.003642 0.65 3.5 14414 0 1

0 1 Suggested Default Values

Breakage Function Parameters : Expanded Form :beta0 beta1 beta2 beta01

00.2 0.3 4 0 Suggested Default Value

(*) Contributed by Javier Jofré from Moly-Cop Chile S. A.

RODSIM : Open Circuit Grinding Simulator(*)


Base Case Example

Main Simulated Outputs

fE, KWh/ton

Adaptación del Modelo General de la Molienda al caso particular de molienda no-lineal, característica de los molinos de barras, en que las partículas de mayor tamaño quedan preferentemente expuestas a la acción de las barras.

RodParam_Open_Data FileESTIMACION DE PARAMETROS


Remarks Test N° 0

Mill Dimensions and Operating Conditions 213 RodsEff. Diam. Eff. Length Speed Charge Rods Lift 0 Overfilling

ft ft % Critical Filling,% Filling,% Angle, (°) 33 Slurry7.50 12.00 72.0 30.00 30.00 45.02 246 Net Power

rpm 20.14 10.0 % Losses274 Gross kW

% Solids (by weight) 71.9 Charge Apparent Mill Flowrate, tph (dry) 92.6Ore Density, ton/m3 2.70 Volume, Rod DensitySlurry Density, ton/m3 1.83 m3 Charge Interstitial Excess ton/m3 Total Energy, kWh/ton 2.66Rods Density, ton/m3 7.75 4.51 20.98 3.30 0.00 5.381 Rods Energy, kWh/ton 2.30Feed Moisture, % 1.5

% wi wi (error) 2̂

i Mesh Opening Mid-Size % Ret % Pass % Ret % Pass % Ret % Pass Exp Adj. Error

1 1.05 25400 100.00 100.00 100.002 0.742 19050 21997 0.00 100.00 0.00 100.00 0.00 100.00 100.00 100.00 0.00 1 0.003 0.525 12700 15554 0.00 100.00 0.00 100.00 0.00 100.00 100.00 100.00 0.00 1 0.004 0.371 9500 10984 8.64 91.36 0.00 100.00 0.67 99.33 100.00 99.33 0.67 1 0.455 3 6700 7978 27.84 63.52 0.98 99.02 3.25 96.07 99.02 96.07 3.06 1 9.386 4 4750 5641 20.15 43.37 6.94 92.08 7.69 88.39 92.08 88.39 4.17 1 17.437 6 3350 3989 10.86 32.51 13.08 79.00 11.85 76.54 79.00 76.54 3.21 1 10.298 8 2360 2812 8.70 23.81 17.89 61.11 13.75 62.79 61.11 62.79 (2.68) 1 7.209 10 1700 2003 4.97 18.84 12.10 49.01 12.16 50.63 49.01 50.63 (3.20) 1 10.25

10 14 1180 1416 3.67 15.17 9.38 39.63 10.34 40.30 39.63 40.30 (1.65) 1 2.7211 20 850 1001 2.42 12.75 6.29 33.34 7.12 33.17 33.34 33.17 0.51 1 0.2612 28 600 714 2.04 10.70 5.42 27.93 5.50 27.67 27.93 27.67 0.92 1 0.8413 35 425 505 1.54 9.17 4.04 23.89 4.13 23.55 23.89 23.55 1.44 1 2.0814 48 300 357 1.32 7.84 3.43 20.46 3.29 20.26 20.46 20.26 0.97 1 0.9515 65 212 252 1.06 6.79 2.87 17.58 2.65 17.61 17.58 17.61 (0.14) 1 0.0216 100 150 178 0.95 5.84 2.29 15.30 2.26 15.34 15.30 15.34 (0.30) 1 0.0917 150 106 126 0.79 5.05 1.93 13.36 1.93 13.41 13.36 13.41 (0.39) 1 0.1518 200 75 89 0.72 4.33 1.62 11.74 1.70 11.72 11.74 11.72 0.23 1 0.0519 270 53 63 0.60 3.73 1.53 10.22 1.46 10.26 10.22 10.26 (0.37) 1 0.1320 400 38 45 0.32 3.42 1.04 9.17 1.06 9.19 9.17 9.19 (0.19) 1 0.0421 -400 0 19 3.42 0.00 9.17 0.00 9.19 0.00 0.00 0.00 0.00 0 0.00

(*) Contributed by Javier Jofré from Moly-Cop Chile S.A. sum 19.00 62.35

% Passing

Objective Function

Base Case Example

Feed Size Distributions

Mill Feed Mill Disch. (exp) Mill Disch. (adj)

Mill Charge Weight, tonsSlurry

InterstitialSlurry Filling,%

100.00

RODPARAM_OPEN : Estimation of Grinding Parameters from Plant Scale Data(*)

RodParam_Open_Control PanelESTIMACION DE PARAMETROS


Test N° 0

SELECTION FUNCTION :

alpha0 0.006000 alpha1 0.650 alpha2 3.5 Dcrit 10000 Expanded Form alpha02 0.000 alpha12 1.000

BREAKAGE FUNCTION :

beta0 0.2 beta1 0.3 beta2 4.0 Expanded Form beta01 0.000f 0.946


RODPARAM_OPEN : Estimation of Grinding Parameters from Plant Scale Data


1

10

100

10 100 1000 10000 100000

% P

assi

ng



Estimaciones Iniciales

RodParam_Open_Control PanelESTIMACION DE PARAMETROS


Test N° 0

SELECTION FUNCTION :

alpha0 0.003642 alpha1 0.650 alpha2 3.5 Dcrit 14414 Expanded Form alpha02 0.000 alpha12 1.000

BREAKAGE FUNCTION :

beta0 0.2 beta1 0.3 beta2 4.0 Expanded Form beta01 0.000f 0.946


RODPARAM_OPEN : Estimation of Grinding Parameters from Plant Scale Data


1

10

100

10 100 1000 10000 100000

% P

assi

ng



Después de ejecutar SOLVER

Moly-Cop Tools 3.0MOLINOS VERTICALES (VERTIMILLS)

VertimillsBASE TEORICA DEL MODELO

El modelo matemático aquí propuesto para describir la operación de Molinos Verticales (Vertimills) es una simple extensión del Modelo Lineal de la Molienda, normalmente aplicable a molinos de bolas, modificando la ecuación que permite el cálculo de la Potencia Neta Demandada en función de sus condiciones específicas de diseño y operación.

VertimillsPOTENCIA NETA DEMANDADA

Para tal efecto, se hace referencia al modelo publicado Nitta, Furuyama, Bissombolo y Mori (“Estimation of the Motor Power of the Tower Mill through Dimensional Analysis”, Proc. XXIII International Mineral Processing Congress, pp.158-161, Sep. 2006), según el cual:

Pnet = h Pgross = K (H*Jb)0.884 S2.232 DG N1.232

donde K es una constante ajustable con un valor nominal 312.

VertiMillSim_ReverseSIMULADOR PARA VERTIMILLS


Circuit Type REVERSE (see Flowsheet ) Simulation N° 0

Remarks

Mill Dimensions and Operating Conditions 869 BallsChamber Chamber Screw Screw Balls Wall/Screw App. Dens. Power 0 Overfilling

Diameter, m Height, m Diameter, m Speed, rpm Filling, % Gap, m ton/m3 Constant 128 Slurry4.10 4.80 3.10 24.0 40.0 0.50 5.34 312.0 997 Net kW

Tip Velocity, m/sec >>> 5.2 117.9 <<< tons of Balls 10.0 % Losses1108 Gross kW

Cyclone Dimensions (inches) and Operating ConditionsNumber Diameter Height Inlet Vortex Apex

26 10.0 30.0 2.50 3.50 1.09Suggested Default Values: 30.0 2.5 3.5 1.8

% Solids O'flow 25.0% Solids U'flow 76.0% Solids Mill Discharge 65.0 49.7 microns

19.97 kWh/tonCirculating Load 1.988 (Guess) 20.79

1.988 (Actual) 563 m3/hr0.000 (Delta) 0.164

4.7 psiOre Density, ton/m3 2.80 180.0 m3/hrBalls Density, ton/m3 7.75

Feedrate, ton/hr (dry) 120.0Feed Moisture, % 60.0


1 1.05 25400 100.002 0.742 19050 21997 0.00 0.00 100.003 0.525 12700 15554 0.00 0.00 100.004 0.371 9500 10984 0.00 0.00 100.005 3 6700 7978 0.00 0.00 100.006 4 4750 5641 0.00 0.00 100.007 6 3350 3989 0.00 0.00 100.008 8 2360 2812 0.00 0.00 100.009 10 1700 2003 0.00 0.00 100.00

10 14 1180 1416 0.00 0.00 100.0011 20 850 1001 0.00 0.00 100.0012 28 600 714 0.00 0.00 100.0013 35 425 505 0.00 0.00 100.0014 48 300 357 6.68 5.57 94.4315 65 212 252 2.98 2.48 91.9516 100 150 178 4.95 4.13 87.8317 150 106 126 10.27 8.56 79.2718 200 75 89 15.96 13.30 65.9719 270 53 63 13.38 11.15 54.8220 400 38 45 13.33 11.11 43.7121 -400 0 19 52.46 43.71 0.00

Make-up Ball Size, mm 25.4 1.00 inches

# Reactor in Series 20.0

Selection Function Parameters : Expanded Form :alpha0 alpha1 alpha2 dcrit1 alpha3 dcrit20.014286 0.650000 2.500000 50000 2.0 100

0 Suggested Default Value

Breakage Function Parameters : Expanded Form :beta0 beta1 beta2 beta01

0.4 0.65 4 00 Suggested Default Value

Classifier Constants :a1 a2 a3 a4 l Bpc

9.680 1.401 54.964 0.523 0.950 0.000 9.044 1.514 60.607 0.818 0.950 0.000 Suggested Default Values

(*) Application contributed by Dr. Alvaro Videla, Moly-Cop Chile S. A.

VertiMillSim : Simulation of a Closed Circuit Regrinding VertMill (*).

Base Case Example


P80 Wio % Fines MD Q Bpf Pressure Total Water

Main Simulated Outputs

Very Important :Simulation results are not valid until the Iterate button has been clicked after any input data changes.

Iterate

Moly-Cop Tools TM (Version 3.0)Simulation N° 0

Remarks

25.00 % Solids97.86 % - Size 1849.7 P80 Bpc 0.000 4.65 psi

Bpf 0.164 Bpw 0.173 26 # of Cyclones

3.50 Vortex 1.09 Apex

ton/hr 120.0F80 109 76.00 % Solids

Water, 53.1 Water, m3/hr m3/hr 126.9

Gross kW 1107.9% Balls 40.00 Circ. Load 198.80

% Critical 24.00 m3/hr 563% Solids 65.00 % Solids 45.16

kWh/ton 9.23Wio 19.97

Base Case Example

VertiMillParam_Reverse_Data FileESTIMACION DE PARAMETROS


Circuit Type REVERSE Sample N° 1

Remarks

Mill Dimensions and Operating Conditions 869 Balls Charge ApparentChamber Chamber Screw Screw Balls Wall/Screw Power 0 Overfilling Volume, Ball Density

Diameter, m Height, m Diameter, m Speed, rpm Filling, % Gap, m Constant 128 Slurry m3 Charge Interstitial Excess ton/m3

4.10 4.80 3.10 24.0 40.0 0.5 312.0 997 Net Power 25.35 117.87 17.42 0.00 5.337rpm 1.17 10.0 % Losses

1108 Gross kW Feedrate, ton/hr (dry) 120.0Cyclone Dimensions (inches) and Operating Pressure (psi) Ore Density, ton/m3 2.80

Number Diameter Height Inlet Vortex Apex psi Balls Density, ton/m3 7.7526 10.0 30.0 2.50 3.50 1.09 4.65 Make-up Ball Size, mm 25.40

Default Values: 30.0 2.5 3.5 1.8

i Mesh Opening Mid-Size ton/hr % Retained % Passing ton/hr % Retained % Passing ton/hr % Retained % Passing ton/hr % Retained % Passing ton/hr % Retained % Passing

1 1.05 25400 100.00 100.00 100.00 100.00 100.002 0.742 19050 21997 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.003 0.525 12700 15554 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.004 0.371 9500 10984 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.005 3 6700 7978 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.006 4 4750 5641 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.007 6 3350 3989 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.008 8 2360 2812 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.009 10 1700 2003 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00

10 14 1180 1416 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.0011 20 850 1001 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.0012 28 600 714 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.0013 35 425 505 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.00 0.00 0.00 100.0014 48 300 357 6.68 5.57 94.43 0.94 0.40 99.60 7.62 2.13 97.87 7.62 3.20 96.80 0.00 0.00 100.0015 65 212 252 2.98 2.48 91.95 2.44 1.02 98.58 5.42 1.51 96.36 5.41 2.27 94.53 0.00 0.00 100.0016 100 150 178 4.95 4.13 87.83 6.03 2.53 96.05 10.98 3.06 93.30 10.98 4.61 89.93 0.00 0.00 100.0017 150 106 126 10.27 8.56 79.27 18.30 7.68 88.37 28.57 7.97 85.32 28.54 11.97 77.95 0.03 0.02 99.9818 200 75 89 15.96 13.30 65.97 52.06 21.85 66.52 68.02 18.98 66.34 65.46 27.47 50.49 2.54 2.12 97.8619 270 53 63 13.38 11.15 54.82 67.71 28.41 38.11 81.09 22.63 43.71 64.75 27.17 23.32 16.34 13.62 84.2420 400 38 45 13.33 11.11 43.71 41.30 17.33 20.79 54.63 15.25 28.46 31.06 13.03 10.28 23.57 19.65 64.5921 -400 0 19 52.46 43.71 0.00 49.54 20.79 0.00 101.99 28.46 0.00 24.51 10.28 0.00 77.51 64.59 0.00

Totals 120.00 100.00 238.32 100.00 358.32 100.00 238.32 100.00 120.00 100.00

% Solids 40.00 65.00 45.16 76.00 25.00Slurry Density, ton/m3 1.346 1.718 1.409 1.955 1.191Weighting Factor 1.000 1.000 1.000 1.000

Slurry

Cyclone U'flow Cyclone O'flowCyclone FeedFresh Feed Mill DischargeEXPERIMENTAL SIZE DISTRIBUTIONS

VertiMillParam_Reverse : Simultaneous Mass Balance Closure and Grinding Parameters Estimation.

Base Case Example

Mill Charge Weight, tons

VertiMillParam_Reverse_Control PanelESTIMACION DE PARAMETROS


Sample N° 1

Weighting Factors :Streams : Mill Discharge 1 Cyclone U'flow 1 Cyclone O'flow 1

Size Distributions 1% Solids 1

Grinding Parameter Guesses :alpha0 alpha1 alpha2 dcrit1

0.02 0.65 2.5 50000 4alpha3 dcrit2

2 1000 0 Default Values

beta0 beta1 beta20.4 0.65 4

beta0100 Default Value

Classifiers Parameter Guesses :Bpf Bpc d50c m0.200 0.000 50.0 2.500

Circulating Load: 2.000 Delta: 0.376

Obj. Function: 5.254

VertiMillParam_Reverse : SIMULTANEOUS MASS BALANCE CLOSURE AND GRINDING PARAMETERS ESTIMATION


1

10

100

10 100 1000

% P

assi

ng


Mill DischargeCyclone U'f lowCyclone O'f lowFresh Feed

VertiMillParam_Reverse_Control PanelESTIMACION DE PARAMETROS


Sample N° 1

Weighting Factors :Streams : Mill Discharge 1 Cyclone U'flow 1 Cyclone O'flow 1

Size Distributions 1% Solids 1

Grinding Parameter Guesses :alpha0 alpha1 alpha2 dcrit1

0.014286 0.65 2.5 50000 4alpha3 dcrit2

2 1000 0 Default Values

beta0 beta1 beta20.4 0.65 4

beta0100 Default Value

Classifiers Parameter Guesses :Bpf Bpc d50c m0.164 0.000 45.8 2.253

Circulating Load: 1.986 Delta: 0.002

Obj. Function: 0.028

VertiMillParam_Reverse : SIMULTANEOUS MASS BALANCE CLOSURE AND GRINDING PARAMETERS ESTIMATION


1

10

100

10 100 1000

% P

assi

ng


Mill DischargeCyclone U'flowCyclone O'flowFresh Feed

AGRADECIMIENTOS

Oscar De GaticaJavier JofréAlvaro VidelaRodrigo MurandaLevi Guzmán

Charla 1 SepulvedaMOLY-COP TOOLS 3.0

Documents

Transcript of Charla 1 SepulvedaMOLY-COP TOOLS 3.0