Search Documents

By Adrian Dance

Newmont Ghana Gold Limited?s Ahafo operation have been working with Metso Process Technology & Innovation (PTI) since early 2009 to increase mill throughput from a combination of controlled blasting practices and optimised primary crusher and grinding circuit conditions. For such Mineto- Mill projects, PTI?s methodology is termed Process Integration & Optimisation (PIO). Ahafo operate a SAG mill, ball mill and pebble crusher (SABC) circuit that processes a range of primary ore of varying hardness from different pits which is blended with soft oxide material. The PTI study focussed on ball mill limited material from the Apensu open pit. Following a benchmarking study of all blasting, crushing and grinding practices in January 2009, PTI recommended changes in both blasting and crushing conditions in order to generate a finer feed size to the SAG mill. Additional operating changes in the grinding circuit were recommended. A series of trials were conducted in November 2009 where three blasts were fired using a different blast design (hole diameter and explosive type) in the same area of the Apensu pit as the benchmarked material in January 2009. Top and bottom benches (or flitches) from each blast were sent exclusively to the grinding circuit and the material was tracked using PTI?s SmartTag? system. The results from the six trials showed a significant increase in primary ore throughput at a reduced blend of oxide material. Ahafo have since standardised on these modified blasting conditions for all Apensu ore zones and have been able to sustain higher throughput compared to historical performance on similar material. This paper summarises the phases of the PIO project, the changes made in operating practices and the outcomes of the blasting trials that validated the predicted increase in mill throughput.

Jan 1, 2012

By A. Karzhau, B. Aldamzharov, Y. Tussupbekov

"This case study produced for the metal mine operating in Kazakhstan, which has ventilation controlled manually and working continuously at maximum speed to keep air flowing through each part of the mine 24 hours a day. The mine auxiliary ventilation has been designed with the maximum length of ducting systems with extra air volumes to compensate for potential leakage. The mine provided auxiliary ventilation to all production stopes even to those, which for various operating reasons become temporarily inactive. However, mine safety has to consider risks associated with the deficit of fresh air for mine gases dilution and removal. The mine needs additional investments for re-designing ventilation network and therefore needs to estimate financial risks associated with it. The aim of this study is to conduct risk analysis for ventilation network optimisation processes at the operational metal mine in Kazakhstan. Mine ventilation surveys were undertaken for validation of the computerised ventilation model. The mine ventilation network modelling has been undertaken to be compliant with Kazakhstan mining regulations. Results of the mine ventilation optimisation processes were analysed in terms of financial risks for investments into reconstruction of the ventilation shafts, extension of the ventilation network, variable speed fans and automated regulators. Savings were resulted from improving ventilation system efficiency by reduce airflow in areas without mining activity and redistributing existing ventilation capacity. Based on savings derived from the optimised ventilation network an additional NPV has been received. Stochastic modelling use Monte Carlo simulation producing representation of possible outcomes for the additional NPV considering electricity pricing as a major variability. As result probability distribution for the optimised ventilation network demonstrates the additional NPV in a range of 1.6 - 2.2 million US$ in the corresponding defined value of 90%. Moreover, there is only 5% chance that the additional NPV to be less than 1.5 million US$. Conducted risk analysis for ventilation network optimisation processes gives considerations on volume of investments into the mine ventilation system.INTRODUCTIONCosts for mine ventilation are typically increasing when mines expand to deep levels. Some underground mines in Kazakhstan still use continuously operating fans at its maximum capacity. This is not helping to save energy and costs that are in many cases very significant. This case study produced for the metal mine operating in Kazakhstan, which has ventilation controlled manually and working continuously at maximum speed to keep air flowing through each part of a mine 24 hours a day. The mine auxiliary ventilation has been designed with maximum length of ducting systems and extra air volumes to compensate for potential leakage. The mine provided auxiliary ventilation to all production stopes even to those, which for various operating reasons become temporarily inactive. However, mine safety has to consider risks associated with the deficit of fresh air for mine gases dilution and removal from the mine workings (Sabanov, 2019). The mine needs additional investments for re-designing ventilation networks and therefore need to estimate financial risks associated with it. The aim of this study is to conduct risk analysis for ventilation networks optimisation processes at the operational mine in Kazakhstan. Mine ventilation surveys for validation of the computerised ventilation model have been undertaken"

Jan 1, 2019

By Tanai Marin

Modelling of pyrometallurgical processes can become extremely challenging when the process involves complex chemical reactions, phase change, multiphase flows, heat and mass transfer and fluid flow. Traditionally modelling involving complex thermodynamic equilibrium and thermochemistry are treated separately from problems in which transport phenomena are dominant, such as CFD and heat transfer studies. The separation is also necessary due to the lack of modelling tools that can effectively couple both solution thermodynamic and transport phenomena or even multiphysics problems. However, there are, quite often, problems in high temperature process metallurgy in which it is not possible to simplify this two modelling approaches. Typical cases of this are for example, the modelling of slag freezing on furnace walls (electric or flash furnaces) to create a protective layer in front of the refractories hot wall, the formation of build up from the matte or metal phases at the hearth of the furnace, calcine smelting from charging piles into slag phase, etc. The problem is even more challenging in nonferrous pyrometallurgy as most, if not all, of the condense phases are highly non ideal solutions involving several components and exhibiting complex crystallization paths and miscibility gaps, such as the Fe-Ni-Cu-S matte, FeO-Fe2O3-SiO2, FeO-MgO-SiO2 slags, etc. In this paper, an approach to model coupled problems involving multiphysics and solution thermodynamic is presented. The approach consists in developing in-house a library containing the Gibbs energy minimization routines and using the local equilibrium concept for process modelling from a multiphysics commercial software (COMSOL). Simple test cases, such as building a non-ideal binary phase diagram on a CFD package is presented, the limitations and of other classic approaches such as equilibrium or Scheil cooling are discussed and compared to this model.

Jan 1, 2015

By H. W. Smith, R. D. Fournier

This paper presents the results of an investigation of a full-scale rod mill. Appropriate numerical techniques are developed for the experimental determination of the parameters of a dynamic mathematical model from steady state data. The results confirm that this full-scale rod mill behaves similarly to laboratory-scale ball mills for which results have previously been obtained. It is noted, however, that although the model presented is adequate for predicting over-all particle size distributions, the size distributions of individual components of a multicomponent ore cannot be predicted.

Jan 1, 1972

By Mingxia Liu, Hao Li, Qi Liu

"Laboratory batch flotation tests were carried out on fine (-20 µm) hematite to investigate the non-polar oil’s influences when sodium oleate, octyl hydroxamic acid, or oleyl hydroxamic acid were used as a collector. Batch flotation tests were performed with artificial mixed minerals (hematite:quartz = 1:1) under natural pH condition and kerosene was utilized as the model oil. The experimental results showed that kerosene emulsion behaved differently when used in conjunction with the three collectors. Kerosene helped improve the flotation when sodium oleate or oleyl hydroxamic acid was used as a collector. Nevertheless, it reduced concentrate weight yield, grade and recovery to a noticeable extent when octyl hydroxamic acid was used as a collector, especially at low dosages. In addition, single hematite batch flotation kinetics tests coupled with water recovery measurement were carried out to study the role of kerosene at different collector dosages. It was observed that water drainage and the resulting froth destabilization by kerosene was dominant at low collector dosages, especially in the flotation using octyl hydroxamic acid. At higher collector dosages, the water drainage and froth destabilization effect by kerosene was possibly counter-balanced by the higher hematite hydrophobicity and bubble surface tension gradient, which led to more stable froth layer.INTRODUCTION The minerals industry is facing a steady decline in ore grade, compounded by increasing complexity of mineral dissemination. As a result, the ore has to be ground sufficiently fine to have a suitable degree of mineral liberation, which produces large percentages of fine and ultrafine particles outside of optimal size range for ore dressing. Due to the unique characteristics of fine particles, i.e., small mass, high specific surface area, and problems such as increased solubility of complex minerals (Finkelstein, 1997; Finkelstein & Allison, 1976; Fornasiero & Ralston, 2005), high reagent consumption, fast surface oxidation in the case of sulfides (Collins & Read, 1971; Klassen & Mokrousov, 1963), severe particle entrainment (Subrahmanyam & Forssberg, 1988; Warren, 1984), low flotation rates (Glembotsky, 1953; Philippoff, 1952; Ye & Miller, 1988), slime coating (T. K. Mitchell et al., 2005; Parsonage, 1984), etc., flotation performance of these finely ground ores is very poor in terms of low concentrate grade and recovery."

Jan 1, 2017

By C Carbonneau

In order to successfully produce columbium pyrochlore concentrates, St. Lawrence Columbium and Metals Corporation had to face two principal problems met in several new operations but possibly made more acute than usual owing to the newness of the project. 1.-The ore is particularly complex, as it is made up of an elaborate intermingling of carbonates and discontinuous ultra-alkaline rock bodies of various ages and types in which no less than seventy mineral have been re-ported. Obvious petrographic or structural controls are lacking. Ore boundaries have to be defined on the basis of assay results and the determination of several minerals which occur in trace amounts. 2.-The pyrochlore concentrates produced had to com-ply with a set of stringent specifications. This fact, combined with the low Cb205 content of the ore, necessitated the use of a beneficiation process that would have to operate at a concentration ratio greater than 100:1. A brief description of the mill circuit is given. Mill stability was obtained through extensive mineralogical study of the mill feed coupled with close geological and engineering control of the mining operations.

Jan 1, 1965

By M. G. Stamatakis, C. Zagouroglou, C. Helvaci, J. Kanaris

"Abstract -Borate minerals, such as colemanite, ulexite and borax, have been reported in Tertiary continental basins of West Anatolia, Turkey, and Samos Island, Greece.Tuffaceous rocks interbedded with the borates are rich in authigenic silicate minerals such as zeolites, potassium feldspar and opal-CT, all of which have a genetic association with the borates. Chemical analyses of the tuffaceous rocks show variation in major elements due to the varying percentage of carbonaceous, detrital, and volcanic derived material.The volcanic activity in the vicinity of each particular lacustrine basin created ion-rich fluids from which a series of borates were precipitated under arid climate. Additionally, the saline-alkaline character of these fluids was responsible for the diagenesis of the silicic glass of the tuffaceous rocks, altering them to silicates and silica polymorphs."

Jan 1, 1993

By B. K. Choi, S. H. Kang, G. E. Kim, K. B. Kim, S. Noh, T. K. Kim, H. J. Jin

Oxide dispersion strengthened (ODS) steel is being considered as an in-core structural material of future nuclear reactor systems because of its excellent creep and irradiation resistance on the basis of uniformly distributed nano-oxide particles with a high density, which is extremely stable at high temperature in a ferritic/martensitic matrix. Up to now, ODS steels have been intensively studied and developed to apply these materials to the in-core structural component of future nuclear systems. The primary activity is to develop high strength advanced ODS steel, fabrication technology for the structural components and key joining technology for the component fabrication. As a result, a Fe-10Cr-1Mo alloy with a superior creep resistance at high temperatures has been developed. An optimized fabrication process of this alloy system has been established through various process conditions in mechanical alloying, hot/cold working, and heat treatment processes. Joining technology for the ODS steel components is also being developed using solid-state welding such as magnetic pulse welding, friction stir welding and diffusion boding. These R&D activities will contribute to the realization of ODS materials for future nuclear reactor system applications.

Jan 1, 2015

By X. S. Fan, T. R. Feng, D. Chen

To meet the flotation process requirements, the large-scale flotation cell must be designed for sufficient pulp mixing, reasonable air dispersion and solid suspension, which is very difficult to design for super large-scale flotation cell. Hence, the flotation cell scale-up and optimization for a short period is a challenge for super large-scale flotation cell design. Computational fluid dynamics simulation has been applied in flotation cell study, which is effective, timesaving and low cost in the study of the flow field distribution for super large-scale flotation cell. This paper demonstrates the flow field characteristics in the 600m3 flotation cell by CFD. The flotation cell model is meshed with hexahedral grid and the high mesh quality assures the computational precision. MRF model, namely a steady-state approximation, ensures that individual cell zones can be assigned different rotational speed. Euler-Euler approach is chosen for multiphase flow simulation to treat different phases as interpenetrating continua. Numerical simulation of single phase, two-phase and three-phase are investigated respectively. Results suggested that the flotation cell has the apparent upper and lower flow circulation. In condition of the impeller rotation, the air is dispersed reasonably. In addition, the solid phase volume concentration distribution in the cell has a little difference.

Jan 1, 2015

By Xiang-dong and Zhu, Xia-jie Hao, Yi-lin Fan, Quan Jiang, Lian-xing Hu, Xia-Ting Feng, Shao-jun Li

"Columnar jointed basalt (CJB), which typically originates from lava flows, is characterized by a special geological structure. The joint network inside the CJB is self-organized into a rough hexagonal arrangement. The field test and measurement during the unloading excavation showed that the columnar joint sets and other internal joint sets not only are important for determining the mechanical properties of the CJB, but also induced its asymmetric unloading deformation and failure. A constitutive model, which considered mechanical deterioration of both the joint sets and rock blocks, was also developed to simulate the unloading behaviour of the CJB. The crack-confinement supporting method for surrounding CJB was developed to overcome the failure of columnar jointed rock mass in the diversion tunnel. Application to the CJB segments of the diversion tunnels in the Baihetan project indicated that this supporting method was reasonable and efficient. INTRODUCTIONColumnar jointed basalt (CJB) rock mass, which typically originates from lava flow, is characterized by a special joint structure. The joint network of the CJB is self-organized into a roughly hexagonal arrangement and leaves behind an ordered colonnade. The widely accepted current view regarding the formation of columnar jointing involves a thermally induced contraction–cooling mechanism (Peck and Minakami, 1968; Degraff and Aydin, 1987; Budkewitsch and Robin, 1994; Lore et al., 2000; Goehring et al., 2006). Although the columnar basalt formation mechanism is fairly understood, the geotechnical characteristics of such rock mass are not well established. In practice, joint sets always induce the multi- failure modes of surrounding rock in the tunneling space (Ibarra et al., 1996; Waltham and Swift, 2004; Mahendra and Bhawani, 2008).According to conventional wisdom in rock mechanics, structural joints affect the mechanical response of rock mass by introducing strong anisotropic effects (Barton and Bandis, 1980; Hudson and Priest, 1983; Brady and Brown, 1985). The columnar jointed rock mass should be considered an anisotropic material given that the joint sets are distributed with some principal directions and characteristic spacing distributions (Cundall and Fairhurst, 1987; Hoek et al., 1998; Wu and Wang, 2001; Budetta and Nappi, 2011; Fortsakis et al.,2012). Columnar jointed rock mass would result in structurally controlled failure patterns, even serious disasters during underground excavation because of the low shear and tensile strengths of intensely joints (Gencer,1985 ;Ishida and Uchita, 2000; Jia and Tang, 2008). The CJB rock mass in the Baihetan hydropower station has exhibited serious stability issues, including sliding, fracturing and even collapse (Shi et al.,2008). Therefore, the geotechnical and geomechanical characteristics of such rock mass should be assessed through in situ investigation and numerical analysis to minimize future accidents during underground unloading excavation."

Jan 1, 2015

By R. Liu

As Building Information Modeling (BIM) becomes widely adopted by the construction industry, it holds undeveloped possibilities for supporting Facility Management (FM). Some FM information systems on the market claim to address the needs for FM requirement. However, the question of whether the functionalities provided by the current BIM-based FM software companies are those actually required by the FM Professionals still need to be answered. The data is required by FM professionals in the operation and maintenance phases of facilities and type of maintainability problems that frequently occur, which can be solved early in design phase, have not yet been addressed. The aim of this paper is to clarify the frequently occurring maintainability problems and to investigate the potential areas that can use BIM technology to solve the maintenance problems in early the design phase. A survey was conducted to collect perspectives from the industry practitioners for the maintenance problems and their frequency. The survey results indicated that maintainability considerations should be taken into consideration during the facility design phase. The results also address the perceived areas by practitioners that need maintainability consideration in design phase

Aug 1, 2013

By John Stubbles

Data are presented on the global warming issue to reinforce the decision by the U.S to reject the Kyoto protocol. The evidence that CO2 is a problem rather than a benefit is inconclusive and will be discussed in this paper. Nevertheless, for economic reasons alone, the US steel industry will continue to minimize CO2 emissions (and the release of real pollutants) per ton of steel through energy reduction programs. However, relative to inevitable increases in absolute CO2 emissions from the utility industry and the transportation sector, future reductions by the steel industry will be inconsequential in the "big picture."

Jan 1, 2004

By L O. Montpetit

The economics of the asbestos mining industry of Canada, and the physical and chemical characteristics of asbestos fibre, as well as exploration, mining, milling and quality control methods, have been described by several authors in the past few years. The scope of this presentation is to survey the application of asbestos fibres in the major product groups of the construction industry in North America. Principal categories considered include flooring materials, asbestos-cement pipes and building products, high-temperature insulation, textiles, saturated asbestos felts and asphalt com pounds. During 1962, the asbestos mining industry of Canada produced an estimated 1.3 million tons of chrysotile fibre grades, and production capacity is expanding. The market demand for chrysotile fibre, on this continent, has been in the order of 50 per cent of the production volume. The asbestos industry is dependent for growth on the construction industry. Product research is active in finding new uses for asbestos fibre; some of the new developments are presented, including the use of short-fibre asbestos grades for extending the life of asphalt pavement.

Jan 1, 1963

By A. Idegami, M. Imamura, S. Heguri, Y. Ozaki

"Nickel powder can be produced by the reduction of a nickel ammine complex solution by hydrogen at high temperature and pressure. To minimize the deposition of fine nickel on the surface of the reactor and other equipment, seed crystals are added to the initial solution to promote nucleation of the nickel powder. Such seed crystals catalyze the precipitation of the nickel particles on the surface of the seed and enhance grain growth. In this study, nickel nuclei were precipitated by the addition of a polymer to the nickel ammine complex solution, resulting in the production of nickel powder. Thus, we herein propose a model that explains the effect of the polymer in the precipitation of nickel nuclei.INTRODUCTIONNickel powder is commonly produced via a hydrometallurgical process from the hydrogen reduction of a solution containing a nickel ammine complex at high temperatures and pressures, and this process was commercialized in the 1950s by Sherritt Gordon (Sherritt International, Canada, Benson & Colvin,1973; The Staff, Research and Development Division, Sherritt Gordon Mines, Ltd., 1958).In the above transformation, upon the injection of hydrogen gas into the solution, nickel is reduced as outlined in Equation(1), ultimately resulting in the production of nickel powder.Ni(NH3)nSO4+ H2?Ni+ (NH4)2SO4+ (n-2)NH3(n:2–6)(1)In this process, seed crystals are added to the reactor to suppress the precipitation of fine nickel (scaling) and to enhance nickel reduction (Benson & Colvin, 1973; Mackiw, Lin & Kunda, 1957). More specifically, iron sulfate and a small amount of dispersant polymer are added, which leads to the formation of nuclei. Upon subsequent hydrogen reduction, the reduced nickel can then be deposited on the nuclei, allowing nickel particle growth to take place. However, this results in iron contamination in the final nickel product, and so the use of pure nickel as a seed crystal is desirable to produce high quality nickel powders."

Jan 1, 2017

By F. E. Lathe

RECENT events have emphasized with renewed force the well known fact that war greatly intensifies the demand for certain metals, particularly for iron, copper, and zinc. Any increase in the use of iron and steel, whether in war or peace, is also accompanied by increased consumption of those metals which find their chief application as ferro-alloys, such as nickel, chromium, manganese, molybdenum, tungsten, and vanadium. Further, since high temperatures are essential for the production of all these metals, activity in the metal industry is inevitably accompanied by an insistent demand for refractories. For example, in North American practice the consumption of magnesitic hearth refractories is frequently expressed in pounds per ton of steel. This quantity (not including straight dolomite) ranges on individual plants from about 7 to 12 pounds. When the industry is operating at approximately full capacity, the ratio of refractory to steel tends to increase, since the tonnage of steel produced is recognized as of paramount importance, and this leads to the harder driving of furnaces and less regard for the effect on refractories. It should also be observed that the cost of refractories per ton of metal produced is always so low, in comparison with other items, that it may even increase while the cost of metal per ton is being reduced through more continuous operation and the use of higher temperatures. As one prominent Canadian copper metallurgist has tersely expressed it, he is "not in business to save refractories but to smelt ore". The effect of war demands and of general industrial activity upon the production of basic and neutral refractories is clearly shown in Figure 1, which gives the value of chrome ore and magnesitic-dolomite produced in Canada during the period 1907 to 1937. Tonnages have not been shown, as these are not available for the full period; such figures as have been published from time to time are not strictly comparable, since both raw rock and finished products have on occasion been included. The preliminary figures for 1938, which are now available, have been prepared by the Dominion Bureau of Statistics on a different basis from those immediately preceding, and have therefore not been shown.

Jan 1, 1940

By George J. Simandl, Donald F. Gunning

At the beginning of the 20 century, British Columbia produced a wide variety of quality dimension stone products for both domestic and foreign markets. The industry flourished until the 1930s when most of the producing quarries closed as a result of the Depression. During the 1990s, British Columbia experienced the resurgent North American dimensional stone production trend. The industry benefited from increased prospecting activity and from substantial new investment in processing equipment, particularly in the granite sector. These activities resulted in new quarry developments, the reopening of abandoned quarries such as on Granite and Fox Islands <www.quadrastone.com>, and a renaissance in downstream value-added activities. British Columbia has reestablished itself as an important, reliable and innovative source of high-quality stone products.

Jan 1, 2001

By L H. Warren

The types of equipment available for generating a plasma have been reviewed. The efficiency and potential of the plasma generating equipment used in performing extractive metallurgical reactions have been determined. A general classification of the reactions that might be per-formed in a plasma has been proposed. Experimental work done on extractive metallurgical plasma reactions, heat transfer between the plasma and solids, and the quench of the products of plasma reaction has been summarized. From the preliminary results it appears that the high-intensity are or the transpiration-cooled anode plasma torch offer the most promising areas for further research. C ONSIDERABLE world-wide research effort is currently being devoted to the development of processing technologies which employ the new high-temperature generating devices that have appeared over the past few years. The plasma flames produced by these devices offer the potential for subjecting materials to any single gas or mixture of gases at temperatures up to 20,000°K. With these conditions available, many reactions in extractive metallurgy,

Jan 1, 1965

By W. R. Cowan

The Caledon Outwash is a large deposit of glaciofluvial gravel and sand located 55 km north west of down town Toronto. For the most part it was laid down in a meltwater channel fronting the Paris Moraine about 14,000 years ago. Applying the braided bar model of Eynon and Walker (1974) the principal facies present are imbricated coarse gravels (bar corefacies); crudely stratified, imbricated bar top sandy gravels; and trough crossbedded side channel sands and gravelly sands. Of lesser importance are crossbedded bar front gravels, shallow braided stream facies gravels, and stoss side facies sands and pebbly sands (rare). Lithologically these deposits are characterized by FIGURE I. Geological relationships of Caledon Outwash. Industrial Minerals in Canada up to 95% Ordovician limestone and siltstone in the gravel fraction. A siltstone content of up to 34% requires that beneficiation be carried out for the production of better quality aggregates. Resources remaining are estimated to exceed 500 million tonnes in 3000 ha of the most suitable part of the deposit. Present production is about 4.5 million tonnes per year, shared by several producers.

Jan 1, 1984

By R. Boom

Corus Umuiden, formerly Hoogovens, was the first steel plant in Europe after Voest to introduce oxygen steelmaking. In the decision-making process contacts with Dofasco in Canada about the production of formability steel grades were crucial. In developing oxygen (LD-) steelmaking high liquid steel output rates had to be combined with accurate process control. For ingot casting static models with input control and sampling during interrupted blowing were sufficient to deliver liquid steel within the required carbon, phosphorus, sulphur and temperature windows. Computers were introduced to perform the complicated charge calculations. Continuous casting called for strict control of composition and temperature at process end point and made predictable timing crucial. Dynamic control was introduced based upon sub lance measurements and waste gas analysis. Reliable disposable measurement sensors were developed in a concerted international action. Dissolved oxygen at blow end deteriorated the quality of low carbon aluminium killed steel grades. Blowing gases through the converter bottom improved process kinetics, resulting in lower carbon-oxygen products, yield increase and better phosphorus removal and generated new families of hybrid blowing processes. Introduction of secondary metallurgy facilities such as argon stirring stations, vacuum degassers and ladle furnaces relieved the demands for strict BOF end point control. Desulphurisation of hot metal became standard practice. In regions with scrap shortage hot metal desiliconisation followed by dephosphorisation, was introduced in the blast furnace cast house and hot metal transfer ladles. Later redundant converter vessels were used for pre-treatment, resulting in a two-stage process. The fundamentals of oxygen steelmaking are described and a vision on the future is presented.

Jan 1, 2004

By R. M. de Carvalho

Empirical and phenomenological models of SAG and AG mills have dominated the scene for the last few decades, being used nearly every time a mill is scale-up or an attempt is made to improve its performance. However, in spite of their success, these models fail to describe the details of both the grinding environment and the breakage mechanisms. The result is a generally good track record, with a few ? but very important ? instances when these models fall short in their predictions, which can be very costly. Further, nearly all of these models require detailed calibration to industrial and pilot plant data, being costly in their application, although still with limited predictive capabilities. Recognizing these challenges, a new model framework has been proposed which overcomes the limitations of currently used models by coupling the microscale population balance model, the discrete element model and functions that describe internal classification at the mill grate. This model framework has already been applied to describe breakage in ball mills, with showing very promising results. However, in the case of SAG and AG mills a much greater level of complexity is involved in the model, given the interaction between the mechanical environment that is formed totally or, in part, by the ore itself, and the breakage response in the mill. The paper describes the model framework, demonstrating how it can address appropriately effects such as mill speed, mill filling and size distribution, on the response from the mill. Some of the advantages of the model are related to its intrinsic multi-component and dynamic nature, which allows simulating appropriately mixtures of ores of different competences in a transient manner.

Jan 1, 2012