Design and Optimization of Comminution Circuits

Using CITIC SMCCs Integrated Software

CM-DOCC
Jianjun Tian, Stephen Morrell, Eric Wang

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Topics

1. Structure and key components of CM-DOCC

(CITIC Morrell Design & Optimisation of Comminution Circuits)
2. Recent development Flowsheet Simulator (GUI)
3. Applications
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Background
CITIC SMCC Process Technology was established in December
2012 as an independent metallurgical consulting company,
following CITICs exclusive acquisition of SMCC, a world leading
mineral processing consultancy firm founded by Steve Morrell in
2000.

CITIC SMCC serves the mining industry with its advanced and
proprietary comminution package (CM-DOCCTM) developed by
Steve Morrell over the past decades

Further new and enhancement development of CM-DOCCTM

commenced since 2013 and is ongoing.
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Design / Optimisation

How do you compare with everyone else?

Benchmarking: need good quality data from operations
- a lots of it!

How to ensure that you are the same as everyone else ?

Understanding comminution and having the tools to
apply this understanding
Validation by the operation data
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Understanding Comminution

Captured via equations and models

Power-based
Auxiliary
Simulation models

Validated by real operation data

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Power-based Models
Specific Energy - Uses SMC Test and BWI
Total Circuit
AG/SAG Mill
Ball Mill
Crusher
HPGR
Power draw - Advanced Morrell Equations
AG/SAG Mill
Ball Mill
Rod Mill
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Auxiliary Models
ROM size distribution predictor
AG/SAG Mill feed size distribution predictor
AG/SAG pebble rate model
Grate design
Pulp lifter flow model
Pulp lifter design
Trommel critical flow model
Ball mill critical flow model
HPGR throughput model
HPGR wear model
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Simulation Models

AG and SAG mills

Ball mills

HPGRs

Crushers

Stockpile size reduction

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Database 186 Operation Circuits

Circuits Data sets
Primary crushing 7
Secondary/tertiary crushing 17
Pebble crushing 7
Open/closed circuit HPGR 37
Rod/ball mill 2
Crush/ball mill 5
Crush/HPGR/ball mill 2
Single stage AG 8
Single stage SAG 1o crush 15
Single stage SAG 2o crush 2
AB 5
ABC-A 7
ABC-B 2
SAB 1o crush 30
SAB 2o crush 3
SABC-A 1o crush 30
SABC-A 2o crush 3
SABC-B 4
Total benchmarking data sets 186
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Database Parameter Range

Parameter Units Max Min
Ore characteristics
DWi kWh/m3 14.2 1.7
Bond ball Wi kWh/tonne 26 6
JK A*b 182 20
SG 4.63 2.45
AG/SAG mill circuits
F80 mm 212 19.4
T80 microns 7770 140
P80 (single stage mills only) microns 415 60
Diameter inside shell ft 40 6
Length (EGL) ft 33 2
Ball load % 25 0
Speed % crit 90 58
Length/Diameter ratio 2.0 0.3
Ball mill circuits
P80 microns 257 45
Diameter inside shell ft 26 10
Length (EGL) ft 40.5 13
Ball load % 45 20
Speed % crit 82 67
Length/Diameter ratio 2.0 1.0
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Total Specific Energy

45

40

35

30

R = 0.9628
Observed kWh/t

25
abc
20 sabc
ab
15 sab
ss ag
10 ss sag
crush ball
5 rod ball
HPGR/ball
0
0 5 10 15 20 25 30 35 40 45

Predicted kWh/t
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AG/SAG Specific Energy

45

40

35

30
Observed kWh/t

25

20

15

10

5
R = 0.9776
0
0 5 10 15 20 25 30 35 40 45
Predicted kWh/t
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Mill Power Draw

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Architecture of CITIC SMCCs CM-DOCC

Stand-Alone Models
Individual models and unit operations
DATA BASE

Linked Model
Engineering
Equipment sizing and flowsheet design
Design

Flowsheet Simulator GUI

Mass balance and option study
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Application of CM-DOCC

CITIC SMCC IP Databases

Models (from over 150 operations)

Power-based & Associated

Simulation Models
Models

CM-DOCC System

Flowsheet Design and Forecast of Milling Size Fraction Based Mass

Process Optimisation
Mill Sizing Throughput Balance
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New Development - Flowsheet Simulator (GUI)

Recoding CM-DOCC models and organising them into

component functions and implementing them in the C# language
as an Excel spreadsheet Add-In.
Capable to carry out full flowsheet simulation to produce size-
fraction based mass balance.
A friendly user graphical interface (GUI) developed using Limn
Solve engine.
Provides familiar Excel style access to the functionalities of the
integrated CM-DOCC models.
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Functionalities of Flowsheet Simulator (GUI)

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Master Flowsheet
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Example: SABC-A Flowsheet

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Mass Balance of Full Flowsheet

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Applications of CM-DOCC

Serving the over 250 mining projects around the world

at various project stage, areas and roles in the past 15
years.

Providing technical support to CITICs global business

Licensing the CM-DOCC to the selected mining

companies
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Global Project Footprints

Over 250 projects in ~ 150 mine operations

Europe 5
Au 2

Base Metals 3
Asia 15
N. America 8
Au 7
Au 6
Base Metals 8
Base Metals 2

Rest. Africa 18
Au/Ag 15

Base Metals 3

S. America 31
Au 8 S. Africa 18
Australasia 55
Base Metals 21 Au & PGM 5
Au 23
Fe & others 2 Base Metals/U 5
Base Metals/U 17
Diamond 8
Fe & others 15
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Recent South American Projects

Esperanza Sur
Los Pelambres
Spence
Antapaccay
Confluentia
Rodomiro Tomic
Samarco
Las Bambas
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Olympic Dam, South Australia

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Sino Iron, Western Australia

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Las Bambas, Peru

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Conclusion

CM-DOCC represents the advanced understanding of

comminution process, which is validated by the largest
known comminution operating database.
Recently developed new functionalities and the
enhanced CM-DOCC tools will be capable to provide
more complete process solutions for the mineral
processing projects.

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Muchas Gracias