How can you balance comminution energy consumption and productivity?

Fragmentation of your ore shots. Chemical energy is far more efficient than grind energy. Do some shots and plot the size fraction. There will be a sweet spot on cost - get the miners and millers together for operational and cost perspectives

The economics of a comminution circuit, alongside recovery rates, are pivotal driving factors. It's essential to understand the trade-offs, like power consumption versus liberation, and how they impact recovery. Conducting rough trade-off analysis to gauge the necessary circuit improvements against power costs is key. This approach ensures efforts are channeled towards designing a more optimal circuit.

It is key to take a look of the correlation of the comminution circuit in complete. Especially to look not only on single machine types, but the complete process. A clear collection of sensor data as basis there might be a good chance of controlling machines in a optimized manner looking not on the machines (like screens) isolated, but as per their effect on the circuit.

If water source is available one could create Hydro Quebec energy and use the kinetic energy produced to mill the ore at a very low cost and environment friendly process. Kinetic energy can be charged to seperate the ore at a early stage during the process and improve on productivity and recovery. Ultimately one would try and reduce the dilution during the mining stage with selective mining subject you have reliable updated geology models.

Balance comminution energy and productivity by optimizing equipment selection, employing advanced control systems, and utilizing energy-efficient technologies like HPGR. Adjust process parameters, explore recycling opportunities, and invest in employee training to enhance efficiency. Regular energy audits, benchmarking against industry standards, and life cycle assessments can identify inefficiencies and guide improvement efforts. Proper equipment sizing, maintenance, and the use of energy-efficient grinding media contribute to overall optimization. A holistic approach, integrating innovative technologies and continuous monitoring, is crucial for achieving a sustainable balance in mining operations.

Also to add the ultrafine grinding will require right equipment selection. The requirement for such equipment is also driven by the degree of liberation required for downstream processes. A grind liberation studies with guide required equipment.

Balance energy use and productivity in comminution by adjusting equipment settings like speed and feed rate. Use sensors to monitor real-time conditions and automatically control the process. Regularly analyze data to optimize the operation, ensuring efficient energy use while maintaining high productivity. Adjustments through process control help find the right balance in comminution.

Critical to determine optimal range % of critical speed calculated derived from studies, with varying feed psd, to ensure the right mill feed trajectory is maintained. This also critical in ensuring right economics of running mills. May also be important to consider use of feed rate to vary the mill residence time with aim of maintaining similar range product psd.

The key question for any process control, is what inputs or variables can you control, and what relationships exist between these and the outcome you want. For a semi-autogenous (SAG) or autogenous (AG) grinding mill, the input feed size distribution is a significant factor. As noted in my post in Q3 above, feed forward mill speed control is possible based on the right 3D imaging sensor for feed size distribution measurement. IGO Nova controls SAG mill speed, slowing down the mill when the feed size conta.ins more fines and small particles and speeding up when there is larger material to put more energy into breakage. They have transformed their SAG mill stability and downstream stability and significantly reduced SAG liner wear.

The cheapest is to optimize Mine to Mill. The ROM should be well fragmented using good blasting techniques in metal mines for example copper processing. Employ monitoring tool like #Fragtrack by Orica to continously monitor the type and size of material going in the crusher. Once this is done equipment such crusher liners mill liners and balls can now deal with the elasticity of the material.

Agree, good 3D modelling with quality data inputs from your plant. Follow up with a tech support team with time to analyse and then improve your process control automation and/or share findings from modelling with teams on the frontline using said equipment !

In my experience conducting grindability tests to understand ore characteristics, helps in optimal equipment choice. Adhering to best practices ensures an efficient balance between energy consumption and productivity in comminution processes. Balance energy use and productivity in comminution by following best practices. Choose equipment suited to ore properties, optimizing crusher and mill selection. Control feed size to minimize energy waste. Regularly assess performance and adjust operations accordingly.

To reduce energy consumption used in comminution, I suggest the process must start with a review of the blasting design of the in-situ ore to ensure the fragmentation is optimized and subsequent crushing work is as little as possible. Such design factors as blasthole spacing, depth, charge parameters, and timing can all be evaluated to ensure an optimized blast.