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ANEXO 7 Drop Weight Test
ANEXO 7 Drop Weight Test
on
Mansa Mina
Tested by
Codelco Norte
Mansa Mina
Submitted to
Codelco Norte
Tested by A.R. MacPherson Consultants Ltd.
at SGS Lakefield Research Chile S.A., Santiago, Chile
Codelco Norte
TABLE OF CONTENTS
1
2
7
8
Page No
INTRODUCTION.................................................................................... 1
DROP WEIGHT TEST PROCEDURE ................................................... 1
2.1
Impact Breakage Testing........................................................... 1
2.2
Abrasion Breakage Testing ....................................................... 3
USING STANDARD DROP WEIGHT TEST RESULTS IN JKSimMet ... 3
3.1
SAG/autogenous Mill Model ...................................................... 3
3.1.1 High Energy or Impact Breakage........................................ 3
3.1.2 Low Energy or Abrasion Breakage ..................................... 3
3.1.3 Combined Breakage ........................................................... 4
3.2
Crusher Model ........................................................................... 4
3.3
Limitations ................................................................................. 4
RESULTS............................................................................................... 5
4.1
SAG/autogenous Mill Model Parameters................................... 5
4.2
Crusher Model Parameters ....................................................... 6
COMMENTS ON STANDARD DROP WEIGHT TEST RESULTS ......... 7
5.1
Resistance to impact breakage ................................................. 7
5.2
Resistance to abrasion breakage .............................................. 8
5.3
Effect of Particle Size on Resistance to Impact ....................... 10
ORE DENSITY MEASUREMENT ........................................................ 12
6.1
Results .................................................................................... 12
6.2
Comments on Ore Density ...................................................... 12
REFERENCES..................................................................................... 15
DISCLAIMER ....................................................................................... 16
Codelco Norte
TABLE OF FIGURES
Page No
Figure 1 - The JK Drop Weight Tester .................................................................. 1
Figure 2 T10/Ecs Relationships for M-1, M-2 and MIXTO.................................... 5
Figure 3 - Frequency Distribution of A*b in the JKTech Database........................ 9
Figure 4 - Frequency Distribution of t10@1kWh/t in the JKTech Database ........... 9
Figure 5 - Frequency Distribution of ta in the JKTech Database ........................... 9
Figure 6 - Variation of Impact Resistance with Particle Size for M-1 .................. 11
Figure 7 - Variation of Impact Resistance with Particle Size for M-2 .................. 11
Figure 8 - Variation of Impact Resistance with Particle Size for MIXTO ............. 12
Figure 9 - Histogram of the Relative Density Measurements for 25 Particles for
M-1 .............................................................................................................. 13
Figure 10 - Histogram of the Relative Density Measurements for 25 Particles
for M-2 ......................................................................................................... 13
Figure 11 - Histogram of the Relative Density Measurements for 30 Particles
for MIXTO.................................................................................................... 14
TABLE OF TABLES
Page No
Table 1 - SAG/autogenous mill parameters for M-1, M-2 and MIXTO .................. 5
Table 2 - Crusher Model Parameters for M-1 ....................................................... 6
Table 3 - Crusher Model Parameters for M-2 ....................................................... 6
Table 4 - Crusher Model Parameters for MIXTO .................................................. 7
Table 5 - Parameter Interactions for M-1.............................................................. 8
Table 6 - Relative Density Measurements for 25 Particles for M-1..................... 14
Table 7 - Relative Density Measurements for 25 Particles for M-2..................... 14
Table 8 - Relative Density Measurements for 30 Particles for MIXTO................ 15
ii
Codelco Norte
INTRODUCTION
Drop weight test data for three samples, identified as M-1, M-2 and MIXTO from
Mansa Mina were received from SGS Lakefield Research Chile S.A. by JKTech for
analysis. The analysis was completed on July 22, 2003.
The JKTech drop weight test provides ore specific parameters for use in the
JKSimMet Mineral Processing Simulator software. In JKSimMet, these parameters
are combined with equipment details and operating conditions to analyse and/or
predict SAG/autogenous mill performance. The same test procedure also provides
ore type characterisation for the JKSimMet crusher model. These ore specific
parameters have been calculated from the test results and are supplied to Codelco
Norte in this report as part of the standard procedure.
This section provides a brief description of the drop weight test procedure.
To characterise ore breakage at different energy levels, the JKTech method uses two
complimentary techniques:
1. To characterise breakage at moderate to high energy levels (ie. impact
breakage), a drop weight device is used.
2. To characterise breakage at low energy inputs (ie. the abrasion component
of breakage), a tumbling test is used.
2.1
The JK drop weight device comprises a steel drop-weight which is raised by a winch
to a known height. A pneumatic switch releases the drop weight which falls under
gravity and impacts the rock particle which
is placed on a steel anvil. The device is
enclosed in perspex and incorporates a
Drop
variety of features to ensure operator
weight
safety. By varying the height from which
Perspex
the drop weight is released and the mass
enclosure
of the drop weight, a very wide range of
Guide Rod
energy inputs can be generated.
A
schematic drawing of the device is given in
Rock
Figure
1.
specimen
Winch
An vil
Concrete
platform
Codelco Norte
The particle is broken and the drop-weight is brought to rest at a distance above the
anvil approximately equal to the largest product particle. The difference in distance
between the initial starting point and the final resting place of the drop-weight is used
to calculate the energy that is expended in breaking the particle. Thus
Ei = Mg(h - xM)
(1)
where:
Ei = energy used for breakage
M = drop-weight mass
g = gravitational constant
h = initial height of the drop-weight above the anvil
xM = final height of the drop-weight above the anvil.
Providing the drop-weight does not rebound after impact, the application of equation
(1) is valid. Where rebound occurs an additional term is required to account for the
energy re-transmitted to the drop-weight. Rebound has been seen to occur only at
elevated input energies. This energy will be assessed during the test work program.
It is likely, however, that its magnitude will be relatively small and can be ignored with
only a minimal loss in accuracy.
The assumption is made that all the energy provided is utilised in the breakage of the
particle. Thus
Ecs = Eis = Ei / m
where:
Eis = specific input energy
Ecs = specific comminution energy
m = mean particle mass
To test an ore type, the original 100 kg sample is sized into selected fourth-root-oftwo size fractions. Ten (10) to thirty (30) particles are required in each size fraction
for each energy level, depending on particle mass. Typically fifteen (15) size/energy
combinations are selected. The input energy levels for a particular test are designed
to suit ore hardness but a standard set of energies are used whenever possible.
The breakage products of all particles for each size/energy combination are collected
and sized. The size distribution produced is normalised with respect to original
particle size. For a wide range of energy inputs, particle sizes and ore types, the
relative size distributions remain similar in shape and can be described by a single
point on the distribution. The JKTech convention is to use the percentage passing
one-tenth of the original particle size. This is referred to as the "t10".
In the manner described above, a set of t10 and Ecs values are produced for the 15
energy/size combinations.
2.2
Codelco Norte
3.1
To represent the impact breakage mechanism in the model, the 15 pairs of t10/Ecs
data from the drop weight test are subjected to non-linear least squares techniques
to fit the following equation, which describes the relationship between breakage and
impact energy:
t 10 = A(1 e bEcs )
where A and b are parameters used by the JKSimMet SAG/autogenous mill model to
reproduce this relationship.
3.1.2
As discussed in section 2.2, the abrasion test results in a t10 figure. The abrasion
parameter used in the model, ta, is defined as
ta = t10/10
3.1.3
Codelco Norte
Combined Breakage
These two sets of parameters representing the two breakage modes are used in
combination by the model to generate an ore specific appearance function. The
scaling factor of 10 is applied in the calculation of ta so that the relative proportions of
high and low energy breakage represented in the combined appearance function are
correct.
The assumption is made that all brittle rock types break with the same general
pattern and that general pattern is built into the model. This assumption does not
mean that the amount of energy required to achieve a particular t10 is the same for all
brittle rocks. It simply means that if a single particle is broken to a particular t10 value,
then the complete size distribution of the broken fragments is known.
This assumption is not perfect but is quite adequate for the purposes of the
SAG/autogenous model.
To use the results of testing, the ore type parameters A and b (from drop weight
testing) and ta (from abrasion testing), are input in the SAG/autogenous mill model
available in JKSimMet, together with machine dependent parameters of mill size,
grate size, ball load, etc. The simulation predicts product size and mill load using
appropriate breakage rates. The simulator can then also be used to predict mill
performance with variations in screen and classifier configurations or even with
recycle crushing.
Details of the SAG/autogenous mill model are given in Leung (1987) and Leung,
Morrison, and Whiten (1987). The calculations on which the power prediction for
SAG/autogenous mills is based are described in Morrell (1996).
3.2
Crusher Model
For the crusher model, only the high energy or impact breakage test results are used.
These are presented in a somewhat different manner from the SAG/autogenous mill
model.
The assumption that all brittle rocks break with the same breakage pattern is not
made and the pattern for the ore under test is used. The crusher model uses the
parameters given in Table 2. The appearance function defines the shape of the
breakage distribution curve at various degrees of "broken-ness", as defined by t10.
The specific comminution energy table defines the amount of energy required to
achieve varying levels of "broken-ness". The form of the specific comminution
energy table reflects the fact that the energy required to achieve a certain degree of
breakage is sometimes found to be dependent on the initial particle size.
Details of the crusher model including power prediction are described in Andersen
and Napier-Munn (1988).
3.3
Limitations
Experience to date demonstrates that the drop weight test is appropriate for brittle
ores over a wide range of hardness. However, it is not useful for ores which undergo
plastic deformation rather than brittle fracture, such as those of high clay content.
JKTech Job No. 03004
Codelco Norte
The testing procedure is limited by the maximum particle size tested. If the ore is
fractured or weaker at larger particle sizes, then JKSimMet simulations will be
conservative.
For autogenous mills it is essential to have competent material in the range 150 mm
to 100 mm in the feed to form the media. If autogenous milling is seriously
contemplated, testing of media competency at larger particle sizes should be
conducted. This can be achieved by drop weight testing, media competency testing
or full pilot plant testing.
RESULTS
4.1
Table 1 shows the SAG/autogenous mill model parameters for M-1, M-2 and MIXTO.
The t10/Ecs relationships for the samples are given in.
Table 1 - SAG/autogenous mill parameters for M-1, M-2 and MIXTO
Ore Type
ta
M-1
59.4
1.30
0.51
M-2
62.5
1.35
0.60
MIXTO
60.7
1.36
0.56
90
80
70
t10 (%)
60
50
40
30
20
10
0
0.0
1.0
2.0
3.0
4.0
Ecs (kWh/t)
4.2
Codelco Norte
Table 2, Table 3 and Table 4 show the crusher model parameters for M-1, M-2 and
MIXTO respectively.
Table 2 - Crusher Model Parameters for M-1
t75
t10
t2
10.0
20.0
30.0
2.83
5.50
8.25
3.62
7.08
10.64
5.60
11.07
16.62
20.76
40.92
59.42
47.79
76.73
91.69
14.53
57.78
0.18
0.39
0.66
0.15
0.33
0.57
0.12
0.29
0.48*
t10
10
20
30
0.14
0.32
0.55
0.13
0.29
0.48
* This value is doubtful. The value from the next finest particles has been substituted.
t75
t10
10.0
20.0
30.0
t2
3.43
6.91
10.54
5.32
10.77
16.40
21.98
42.88
61.65
48.89
78.99
94.70
14.53
57.78
0.18
0.39
0.65
0.13
0.29
0.49
0.11
0.25
0.40
t10
10
20
30
0.14
0.31
0.52
0.12
0.26
0.43
Codelco Norte
t75
t10
10.0
20.0
30.0
t2
3.80
7.03
10.15
5.60
10.78
15.96
22.02
43.39
62.78
54.48
85.44
99.13
14.53
57.78
0.16
0.36
0.63
0.16
0.36
0.60
0.12*
0.26*
0.42*
t10
10
20
30
0.14
0.31
0.52
0.12
0.26
0.42
* These values are doubtful. Values from the next finest particles have been substituted.
5.1
One of the problems with the functional form used to represent the t10 v Ecs
relationship is that the parameters A and b are not independent and thus can not be
used directly for comparisons between ore types. Two alternative parameters give a
better comparison. These are the product A*b and the t10 achieved by the application
of 1.0 kWh/t of Specific Comminution Energy (Ecs). In each case, the smaller the
number the greater the resistance to impact breakage. These figures are given for
M-1, M-2 and MIXTO in Table 5, which also includes figures from the JKTech
database of ores tested.
The figures for M-1 put that material in the soft range of resistance to impact
breakage. 77.3 % of the 1438 ore types in by JKTech data base have lower A*b
values.
The figures for M-2 put that material in the soft range of resistance to impact
breakage. 80.0 % of the 1438 ore types in by JKTech data base have lower A*b
values.
The figures for MIXTO put that material in the soft range of resistance to impact
breakage. 79.6% of the 1438 ore types in by JKTech data base have lower A*b
values.
The frequency distribution of the parameters A*b and t10@1kWh/t from the JKTech
database of ores tested are given in Figure 3 and Figure 4 respectively.
5.2
Codelco Norte
Data Base
Min (hardest)
Data Base
Median
Data Base
Mean
Data Base
Max (softest)
M-1
M-2
MIXTO
A*b
ta
Value
Rank
Value
Rank
Value
Rank
15.8
13.8
0.06
47.1
719
50
32.3
719
50
0.46
707
50
71.2
1054
73
35.1
856
59
0.67
1003
71
955.4
1438
100
82.2
1438
100
5.78
1413
100
77.2
84.4
82.6
1113
1152
1145
77.3
80.0
79.6
43.2
46.3
45.1
1130
1190
1175
78.5
82.7
81.6
0.51
0.60
0.56
800
940
891
56.5
66.5
63.0
Codelco Norte
125
100
75
50
25
Mor
190
175
160
145
130
115
100
85
70
55
40
25
10
0
Ax b
Frequency
100
80
60
40
20
82
76
70
64
58
52
46
40
34
28
22
16
10
0
t10 @ 1 kWh/t
Frequency
250
200
150
100
50
3.6
3.3
2.7
2.4
2.1
1.8
1.5
1.2
0.9
0.6
0.3
0
ta
5.3
Codelco Norte
Variation of impact resistance with particle size is important in both crusher power
draw and SAG/autogenous mill media competency considerations. Some ores
exhibit significant decrease in impact resistance with increasing particle size and
others show no variation with size. The opposite trend of increasing impact
resistance with increasing particle size is extremely rare.
The data in Table 2 indicate that for particles of M-1 up to 63 mm, some variation of
impact resistance with particle size occurs.
The data in Table 3 indicate that for particles of M-2 up to 63 mm, some variation of
impact resistance with particle size occurs.
The data in Table 4 indicate that for particles of MIXTO up to 63 mm, some variation
of impact resistance with particle size occurs.
The data for the three ore types presented in Figure 6, Figure 7 and Figure 8 are the
t10 values for up to 5 different particle sizes, all broken with the very similar specific
comminution energies (0.25 kWh/t, 1.0 kWh/t and 2.5 kWh/t). These data generally
follow the frequently observed trend of decreasing slope with decreasing energy (Ecs
values). However, it is both the slope and the absolute values of the low energy t10
values that are of interest for SAG/autogenous milling as these data give an
indication of the ability of media particles to survive. If the trend of the t10 values with
increasing particle size is significantly upwards, it can be inferred by extrapolation
that particles in the 100 200 mm size range (normal media size) will not be strong
enough to survive. The same argument applies if the absolute values of t10 at low
energy are sufficiently high.
For M-1, the data indicate that media survival is likely to cause a problem for
autogenous milling.
For M-2, the data indicate that media survival is likely to cause a problem for
autogenous milling.
For MIXTO, the data indicate that media survival is/is not likely to cause a problem
for autogenous milling.
10
Codelco Norte
0.25
1.0
2.5
80
t10 (%)
70
60
50
40
30
20
10
0
10
15
20
25
30
35
40
45
50
55
60
0.25
1.0
2.5
80
t10 (%)
70
60
50
40
30
20
10
0
10
15
20
25
30
35
40
45
50
55
60
11
Codelco Norte
0.25
1.0
2.5
80
t10 (%)
70
60
50
40
30
20
10
0
10
15
20
25
30
35
40
45
50
55
60
6.1
Results
As part of the standard JKTech ore property assessment procedures, the relative
density of 30 randomly selected particles in the size range 31.5 mm to 26.5 mm is
determined by weighing each particle in water and in air. The results are given in
Table 6, Table 7 and Table 8 and shown graphically in Figure 9 Figure 10 and Figure
11.
It should be noted that this method does not account for internal porosity in the
particles tested.
More accurate determination is available using a Helium
Pycnometer.
6.2
At the coarse particle size tested, it is normal to find a range of relative densities as
the mineralogy of the particles varies.
However, of great concern in
SAG/autogenous milling is the possibility of a component in the ore which is both
high density and resistant to breakage. Such material will concentrate in the load in
a SAG/autogenous mill and result in higher than expected power draw.
The M-1 data contain no evidence of bimodality in the relative density distribution,
that is, no evidence of a dense component which could concentrate in the mill load
and cause power problems.
The M-2 data contain some evidence of bimodality in the relative density distribution,
that is, some evidence of a dense component which could concentrate in the mill
load and cause power problems.
JKTech Job No. 03004
12
Codelco Norte
The MIXTO data contain no evidence of bimodality in the relative density distribution,
that is, no evidence of a dense component which could concentrate in the mill load
and cause power problems.
Mansa Mina M-1
16
Number of Particles
14
12
10
8
6
4
< 5.2
< 5.0
< 4.8
< 4.6
< 4.4
< 4.2
< 4.0
< 3.8
< 3.6
< 3.4
< 3.2
< 3.0
< 2.8
< 2.6
< 2.4
Number of Particles
10
< 5.3
< 5.1
< 4.9
< 4.7
< 4.5
< 4.3
< 4.1
< 3.9
< 3.7
< 3.5
< 3.3
< 3.1
< 2.9
< 2.7
< 2.5
13
Codelco Norte
Number of Particles
14
12
10
8
6
4
< 5.3
< 5.1
< 4.9
< 4.7
< 4.5
< 4.3
< 4.1
< 3.9
< 3.7
< 3.5
< 3.3
< 3.1
< 2.9
< 2.7
< 2.5
2.77
2.75
2.80
2.73
2.75
2.84
2.45
2.77
0.15
3.21
2.45
2.68
2.82
3.54
2.58
2.72
2.68
2.62
2.88
0.28
3.66
2.58
14
Codelco Norte
2.74
2.56
2.69
2.61
2.69
2.87
2.70
3.09
3.17
2.76
2.61
2.75
2.73
0.14
3.17
2.56
REFERENCES
Andersen, J. and Napier-Munn, T.J., 1988. "Power Prediction for Cone Crushers",
Third Mill Operators' Conference, Aus.I.M.M (Cobar, NSW), May 1988, pp 103 106.
Leung, K. 1987. "An Energy-Based Ore Specific Model for Autogenous and
Semi-Autogenous Grinding Mills." Ph.D. Thesis. University of Queensland
(unpublished).
Leung, K., Morrison, R.D. and Whiten, W.J., 1987. "An Energy Based Ore Specific
Model for Autogenous and Semi-autogenous Grinding", Copper 87, Vina del
Mar, Vol. 2, pp 71 - 86.
Morrell, S. 1996. "Power Draw of Wet Tumbling Mills and Its Relationship to Charge
Dynamics - Parts I and II." Transaction Inst. Min. Metall. (Sect C: Mineral Process
Extr. Metall.), 105, 1996, pp C43-C62.
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Codelco Norte
DISCLAIMER
All JKTech Pty Ltd reports are subject to a standard disclaimer as follows:
1. JKTech Pty Ltd and University staff operating with JKTech Pty Ltd make
reasonable efforts to ensure an accurate understanding of client requirements.
The information in this report is based on that understanding and JKTech Pty Ltd
strives to be accurate in its advice.
2. While reasonable care has been taken in the preparation of this report/proposal,
this report/proposal and all information, assumptions, and recommendations
herein are published, given, made, or expressed without any responsibility
whatsoever on the part of JKTech Pty Ltd, whether arising by way of negligence,
breach of contract, breach of statutory duty or otherwise.
3. No warranty or representation of accuracy or reliability in respect of the
report/proposal is given by JKTech Pty Ltd or its directors, employees, servants,
agents, consultants, successors in title and assigns.
4. If liability is not, by law, capable of exclusion, then JKTech Pty Ltd accepts liability
to the minimum level set by that law.
5. This disclaimer shall apply to liability to any person whatsoever, irrespective of
how such liability arises, whether by use of this report/proposal by that person or
you or any other person or otherwise.
6. JKTech Pty Ltd is not responsible in any way whatsoever for the error neglect or
default of others upon whom it has placed reliance in the preparation of this
report/proposal.
7. You shall indemnify JKTech Pty Ltd and its directors, employees, servants,
agents, consultants, successors in title and assigns against any claim made
against any or all of them by third parties arising out of the disclosure of the
report/proposal, whether directly or indirectly, to a third party.
16