ARBS Comminution Circuit for Sulphide Ore Energy Reduction
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Solution Overview
Problem
Conventional comminution circuits for processing sulphide ore systems, such as SAG/ball mill circuits, are energy-intensive and do not produce a steep enough particle size distribution curve, limiting downstream processing efficiency and increasing energy consumption.
Innovation Solution
The integration of an Accurate Rock Breakage System (ARBS) circuit, which uses a vertical stack of horizontally-opposed rolls for single particle breakage, producing a steeper particle size distribution curve and reducing energy requirements, combined with a coarse particle flotation circuit to separate valuable coarse particles from waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional comminution circuits (SAG/ball mill) are used to process sulphide ore, then the ore is comminuted to produce fines for flotation, but the energy consumption is excessive and the particle size distribution curve is not steep enough
Solution Approach 1:
The patent changes the comminution method from conventional SAG/ball mill to high pressure grinding rolls (HPGR), altering the physical parameters of the comminution process to achieve a steeper particle size distribution curve with lower energy consumption. This parameter change transforms the comminution mechanism to produce finer particles with less energy input.
Solution Approach 2:
The patent replaces the mechanical tumbling action of SAG/ball mills with a different mechanical system - high pressure grinding rolls that apply compressive force to break particles. This substitution of mechanical system achieves better particle size distribution and reduced energy consumption.
2Productivity
If conventional comminution circuits are used, then processing can proceed, but downstream processing efficiency is limited due to insufficient particle size distribution
Solution Approach 1:
The patent applies preliminary comminution action using HPGR before flotation to produce a steeper particle size distribution curve. This preliminary action with optimized particle size distribution prepares the ore for more efficient downstream flotation processing, improving overall productivity.
3Loss of energy
If coarse particles are not separated, then all material goes through comminution, but energy is wasted on already sufficiently fine particles
Solution Approach 1:
The patent extracts and separates coarse particles from the feed stream before comminution using a coarse particle flotation circuit. This extraction of coarse particles that do not require further comminution eliminates energy waste on already sufficiently fine particles while maintaining processing throughput.
Solution Approach 2:
The patent segments the processing stream into coarse particle fraction and fine particle fraction, directing each to appropriate processing paths. Coarse particles undergo flotation while finer particles proceed to comminution, optimizing energy usage across different size fractions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The ARBS circuit enhances energy efficiency and downstream processing options by minimizing energy consumption and producing a more favorable particle size distribution, allowing for improved recovery of gold and copper through optimized comminution and flotation processes.
Implementation Method 1
high pressure grinding rolls (HPGR) for comminution of at least a portion of the primary crushed ore
Implementation Method 2
a coarse particle flotation circuit for separation of valuable coarse particles from waste material
Data Source
AI summary
A process and a plant for recovering valuable material in the form of gold and/or copper from sulphide ore systems that includes an Accurate Rock Breakage System (“ARBS”) circuit.