Sajjad Chehreghani Hojjat Hosseinzadeh Gharehgheshlagh Sahand Haghikia

Power consumption management and simulation of optimized operational conditions of ball mills using Morrell Power model a case study

2022, Rudarsko-geološko-naftni zbornik (The Mining-Geological-Petroleum Bulletin), https://doi.org/10.17794/rgn.2022.2.11 [Citation Link]

The amount of comminution or fineness of minerals in the mill can be described by various parameters, the most important of which is  (80% passing size). The purpose of this study is to investigate and simulate the optimal operating conditions of a ball mill in a copper processing plant. The actual operating conditions in the intended mill are performed with a 300 tph tonnage, 267 seconds retention time, and discharge . Laboratory studies showed that the optimal economical and metallurgical recovery of copper in this plant is achieved in  with Flotation Recovery (R) = 90.16%, Economical Efficiency (EE) = 93.04% and Separation Efficiency (SE) = 88.64%. In this study, having the optimal  for the concentration unit, the mill data, and utilizing the Excel Software and Morrell method, first the total power for the optimal set of  was calculated, which is equal to 7790 to 8005 kW. Then, according to these power values, the corresponding retention times were calculated, which are equal to 236 and 247 seconds respectively. Finally, utilizing the retention time-tonnage relationship and taking into account the specific filling of the mill, the optimal corresponding tonnages to the obtained retention times were calculated, ranging from 324 to 340 tph. The results of these studies showed that by reducing the level of comminution from  to , in addition to increasing flotation efficiency to R = 90.16%, EE = 93.04% and SE = 88.64%, about 4.21% to 7.09% energy savings and 8.00% to 13.33% tonnage increase will occur.

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