Review , Grinding-2

Circulating Load ratio & Process Control

Objectives
 Control of Grinding Circuits
• The purpose of Comminution ( Crushing and Grinding operations) is
to reduce the size of ore particles to the point where “economic
liberation” of the valuable minerals takes place.
• Comminution Capacity ( Tons / Day )
• Product characteristics ( Particle size distribution)
• Variables affecting Control ( Changes in feed rate & circulating load; size
distribution and hardness; water / chemical addition; residence time; new
grinding media addition; intermittent stoppages etc.)
• Concentration / Separation Methods employed ( Gravity, Magnetic, Froth
flotation etc. )
 Process Control Objectives
• Control Objectives:
• ( a ) To maintain a “constant product size” at Maximum throughput.
• ( b ) To maintain a “constant feed rate” within a limited range of product size .
• ( c ) To Maximize “production per unit time” in conjunction with downstream
circuit performance ( Gravity, Magnetic, Electric, Froth Recovery etc. )

• Grinding : It is an Energy intensive process and the product from grinding

affects subsequent CONCENTRATION / SEPERATION processes . ( therefore
the need for “close size control” is very important ).
• “Ore feed rate and water addition” to the mill and classifier are the major
variables to CONTROL.
• Flowrates and Densities are measured continuously by use of “Magnetic
flowmeters” and “Nuclear Density Guages”.
 Vihanti No.2 Grinding Circuit
( F= Flow rate, W=Weight, T=Thyristor Control, D=Density, PR=Pressure,
PS=Particle Size, P=Power, L=Level, SP=Set Point, C= Controller
 Amax-Buik Concentrator- ZINC Circuit
F-Flow Rate, W- Weight, T-Thyristor Control, L-Level, PS-Particle Size,
SP-Set Point, C- Controller
Diagram of the SABC Circuit at New Crest Mining’s
Cadia Mine employing the Worlds Largest SAG Mill
and Ball Mills
Simple Closed Grinding Circuit

10 t/hr
13,14,15,
t/hr

10, …, ….. t/hr

3,4,5t/hr
 Circulating Load Ratio
• In the simple ball-mill-classifier circuit : Lets Say
( a ) New feed rate is F t / h
( b ) The circulating load (i.e classifier underflow) is C t / h then:
Circulating load ratio = C /F
A mass balance on the mill classifier gives:
ball-mill discharge = circulating load + product i.e.
F+C=C+F
• Samples of ball mill discharge, circulating load and classifier overflow ( circuit product ) are taken
and “screen Analysis” are performed.
• Let a,b and c be the percentage weights in any specific size fraction in the mill product,
circulating load, and classifier overflow, then a mass balance on the classifier in terms of such
sized material is :
( F + C ) a = Fc + Cb ………( 2 )
C / F = a-c / b-a ……( 3 )
• a,b,c can be measured online by ‘Nuclear density gauges’ and the circuit circulating load can be
continuously monitored.
 Circulating Load Ratio….. Cont.

• Using all the size analysis data available, the “BEST-FIT” value of the
‘circulating load ratio’ can be determined.
• The Circulating Load Ratio ( CLR) is an important parameter, that
determines the Crushing and Grinding efficiency, particle size
distribution, Energy Consumption etc.
• The ‘Cost and Time’ required for the entire comminution process is a
function of a large number of “CONTROL PARAMETERS” and the
Optimization of these values is the essence of “ Process Control”.
Conventional Designs of Pulp Lifters
Various Sections of an AG Mill
Hardinge Mill
 About Grinding Media
• Grinding balls are usually made of forged or rolled high –carbon of
alloy steel or cast alloy steel and consumption varies between 0.1 and
as much as 1.0 kg / ton of ore depending on hardness of ore, fineness
of grind, and medium quality.
• Good quality of grinding media may be expensive, but may be
‘economic’ due to lower wear rates.
• Medium consumption can be a very high proportion sometimes as
much as 40% of the total milling costs. Thus an important area of ‘cost
centre’.
• Autogenous Grinding ( AG) and Semi-Autogenous Grinding (SAG) mills
have become popular, so that the ‘media costs’ can be appropriately
OPTIMISED.
• Thank YOU