DESIGN AND OPERATION OF VERTIMILL® FOR SECONDARY GRINDING

Alex Jankovic, Metso Minerals Process Technology Asia-Pacific, alex.jankovic@metso.com

Walter Valery, Metso Minerals Process Technology Asia-Pacific

ABSTRACT

A silver/lead/zinc mine in Queensland, Australia was originally designed to treat 1.5 million wet
metric tonnes per annum. The original grinding circuit consisted only of primary autogenous
milling. In October 2003 a Vertimill®, for secondary grinding, was commissioned and the lead
and zinc flotation cleaner capacity was increased. This enabled the production rate to increase
to its current level of 2.5 million wet tones per annum with minimal capital expenditure.

The Vertimill® design was based on modelling and simulation techniques. Laboratory tests data
were used for the scale-up of Vertimill® size reduction performance. During and after
commissioning, several complete industrial surveys were carried out in order to assess the
circuit performance. Surveys and operating data are in good agreement with design simulation
results. The data also showed that the grinding circuit (with a Vertimill for secondary grinding
duty) is more energy efficient than a conventional circuit that has a ball mill for secondary
grinding duty.

INTRODUCTION

A rich silver, lead, zinc deposit located in Queensland, Australia was discovered in June 1990.
The high grade resource is classified at 42 million tonnes, 551ppm silver, 12.1% lead and 4.7%
zinc. The “Mine” is an underground operation and the main production technique is long hole
open stoping. After extraction of ore from a stope, paste backfill is used to fill open voids in
order to stabilise the area and allow mining of adjacent stopes.
The high grade ore is processed to produce approximately 250,000 tonnes per annum of a high
grade silver lead concentrate and approximately 100,000 tonnes per annum of zinc concentrate.
The concentrate is transported via road trains to a storage facility from where it is railed to port.
A facility at the port unloads, stores and loads vessels for shipment to Australian and
international customers.

MODELLING AND SIMULATION

Circuit surveys and ore breakage characterisation

The grinding circuit was designed to treat 180 t/h (1.5million tones per year) of ore, which was
achieved very quickly after commissioning in 1997. By the year 2000 the grinding circuit
throughput was increased to over 250 t/h.

As part of the optimisation program, a external survey team conducted two surveys (Survey
numbers A1 and A2) of the AG milling circuit. During the surveys the AG mill operated at high
mill load levels (41.4 and 40.0 % by volume, respectively). Mine staff conducted another two
surveys in July 2001 at 27.6% and 32.0% load levels (Survey No. A3 and A4) with the feed
characteristics being approximately the same as the previous surveys. Tables 1 gives the circuit
operating condition during the surveys.

Table 1: Summary of the operational conditions of the AG milling surveys

Survey number: A1 A2 A3 A4
Plant new feed rate (t/h) 280 281 238.5 260.7
AG mill power draw (kW) 4805 4812 3597 3777
Rock load volume (%) 41.4 40.0 27.6 32.0
Pebble returned (t/h) 63 58 40.1 44.9
Cyclone feed density (%Solids) 71.2 71.5 79.3 79.3
Cyclone O/F P80 ( m) 87 102 119 106
Feed samples of three typical ore types (FW, HW, GHB) were collected from the individual
stockpiles. Drop weight tests were performed on the three ore types to determine the ore
breakage characteristics. As the processing plant treated a blend of these three ores during the
surveys, the breakage parameters of the blended ore were determined based on the simulated AG
loads for individual ore types, then calculated from the blend ratio.

A sample of the blended ore from the feed conveyor belt was sent for the breakage
characterisation after the surveys. The summary of the ore breakage parameters for the samples
tested and the calculated one based on blend ratios is presented in Table 2.

Table 2: Summary of the ore breakage parameters

FW ore HW GHB ore Blend AG feed
calculation sample
A 76.1 70.8 75.7 74.8 73.5
b 0.95 1.08 1.16 1.1 0.99
Axb 72.3 76.5 87.8 82.3 72.8
ta 0.38 0.28 0.66 0.52 0.48

The value of A x b is an indicator of ore hardness with a smaller value of this parameter
indicating a higher resistance to impact breakage. Table 2 shows that the GHB ore is softer than
the two ore types, while FW lead ore is the hardest, but not too much different to the HW lead
ore. The values of ta indicate that the GHB ore has less resistance to abrasion breakage, while
FW and HW ores have a significantly higher resistance to abrasion. The calculated breakage
parameters based on the blend ratio are similar to the ones obtained from the AG mill feed
sample. This means that the survey results can be compared directly.

Testwork for Vertimill® selection

The purpose of the laboratory ball mill test was to determine the cyclone underflow grindability
using different size grinding balls. A laboratory ball mill, (D x L = 0.2 x 0.26 m at 75 rpm
(approximately 80% of critical speed)) was used with a charge of 11 kg of balls. Three ball
charges with different size distributions were used in the grinding tests. The sample was tested at
71.4 % solids content i.e. 1000 g of solids and 400 g of water. Two batch grinding tests were
carried out for each ball charge, one at 3 minute grinding time and one at 6 minute grinding time.
The power draw was continuously recorded throughout the test. The idle mill power was also
determined separately in order to determine the specific net grinding energy. At the end of the
test, sieve sizing was carried out on the grinding product. The test conditions are summarised in
Table 3.

Table 3 - Summary conditions of the batch ball mill test

Test No Balls in the charge (kg) Net power Net (kWh/t)
25 mm 18 mm 11 mm (W) 3 min 6 min
1 6 - 5 70 3.5 7.0
2 - 6 5 70 3.5 7.0
3 - - 11 70 3.5 7.0

The results from the test with 25 mm balls were used to develop a simple model for simulation of
a Vertimill® for the purpose of grinding circuit expansion.

Expansion options
Operational data, modeling and simulation and experience indicated that the introduction of
suitable pebble ports and a pebble or recycle crusher would allow higher throughput to the
circuit, however, this would result in unacceptable coarser product size. In the initial stage of the
expansion study, to preserve the circuit product grind size, an option of splitting the cyclone
underflow between the AG mill and a Vertimill® was considered as presented in Figure 1.
 Cyclones

Pebble crusher Variable splitter

Vertimill®
Feed

AG mill

Figure 1. Initial expansion study flowsheet

Simulation results, shown in Table 4, indicated that throughputs in excess of 350 t/h could be
achieved with introduction of pebble crushing with a final product size below 95 micron should
be achieved with introduction of a 1.1 MW Vertimill®.

After the initial expansion study, the mine has commissioned a portable pebble crusher and
started experimenting with introduction of pebble ports. The number of grates with pebble ports
was gradually increased and so did the amount of pebbles discharged. By using the pebble
crusher for partial (or full) pebble crushing the circuit throughput was increased to 320 t/h. The
pebble crusher has also added another control option for keeping the circuit throughput stable
with variations in feed ore hardness and size. Based on this confirmation of the effect of pebble
crusher on throughput, a permanent Metso HP300 pebble crusher was installed. With higher
pebble crusher capacity and more pebble ports in the discharge grate, throughputs in excess of
350 t/h were achieved occasionally but could not be sustained due to coarse flotation feed and
associated recovery losses.
Table 4 – Simulation results for the initial expansion option – 65% pebble ports open area
in the AG mill

Feed Rate (t/h) 347 365

U/F split to Vertimill (%) 75 50
Mill charge % 41.46 41.35
Mill Power (kW) 4620 4700
Scats (t/h) 178 171
AG T80 (mm) 0.281 0.254
AG T50 (mm) 0.084 0.86
Crusher Power (kW) 166 223
Scats split to crusher % 65 100

Cyclone U/F (t/h) 1321 1252

Cyclone U/F P80 0.477 0.327
Verti Mill Product P80 (mm) 0.356 0.229
Verti Mill Power (kW) 1118 1118
Cyclone feed % solids 68 68
No. of cyclones 20 20
Cyclone O/F % solids 39.2 41.7
Cyclone O/F P80 (µm) 94 86
Wio (kWh/t) 17.03 15.82

During the engineering stage of the expansion project, Metso Minerals Process Technology
(MMPT-AP) staff carried out additional simulations. A circuit with two stage grinding was
simulated: the first stage consisted of the existing AG mill in closed circuit with the primary
cyclones and the second stage grinding consisted of the Vertimill® in closed circuit with
secondary cyclones, as shown in Figure 2. One of the major concerns was regarding the ability of
a Vertimill® to grind the coarse (+0.5 mm) particles present in the cyclone underflow.

A summary of the simulation results is given in Table 5. Three different primary cyclone sizes
were simulated: 250, 400 and 500 mm. It was not possible to obtain significantly coarser primary
cyclone overflow.
 Primary Cyclones

Pebble Secondary Cyclones

crusher

Feed

Vertimill
AG mill

Figure 2. Two stage grinding flowsheet

Compared to the first option of having the common cyclones, this option with separate primary
cyclones was considered to be “safer” for the Vertimill® application as it eliminated the coarser
particles from the Vertimill® circuit. After consultation with the cyclone suppliers regarding the
size, operating pressure and cut point for the primary cyclones, guaranties were obtained that
coarser then simulated primary cyclone cut could be obtained. Based on positive experience with
the 250 Cavex cyclones in the existing circuit, Cavex cyclones 400 CVX were chosen for the
primary duty.
 Table 5 Expansion options simulations: primary and secondary cyclones – Southern
ores blend

Pebble Ports (%) 60 60 60

Feed Rate (t/h) 345 343 343
Mill charge % 41.35 41.25 41.35
Mill Power (kW) 4650 4620 4650
Scats (t/h) 193 192 190
AG T80 (mm) 0.295 0.297 0.307
AG T50 (mm) 0.083 0.084 0.082
Primary cyc size (mm) 250 400 500
Primary cyc pressure (kPa) 23 28 25
Primary cyc feed (%) 75 75 75
Number of prim. cyclones 20 9 5
Primary cyc o/f P80 ( m) 114 117 127
Primary cyc u/f solids t/h) 561 531 437
Crusher Power (kW) 162 160 155
Scats split to crusher % 70 68 65
VM Cyclone U/F (t/h) 1182 1014 1043
VM Cyclone U/F P80 0.148 0.146 0.153
Verti Mill Product P80 (mm) 0.136 0.133 0.138
Verti Mill Power (kW) 1118 1118 1118
VM Cyclone feed % solids 65 65 65
No. of VM cyclones 20 18 18
VM Cyclone O/F % solids 38.1 41.2 40.3
VM Cyclone O/F P80 (µm) 75 78 80

COMMISIONNING OF THE NEW GRINDING CIRCUIT

The new grinding circuit was commissioned at the end of October and beginning of November
2003. Metso Minerals Process Technology (MMPT-AP) was part of the commissioning team
providing process support and optimization services together with Metso Equipment team that
was involved in the mechanical side of the commissioning. MMPT-AP team facilitated the rapid
achievement of target circuit performance and subsequent maintenance of optimum performance.
Low grade ore was available during that period which created limitations in the flotation tailing
thickener and auxiliary equipment. The grinding circuit throughput had to be restricted to 330 t/h
due to the tailing handling limitations.
The commissioning team conducted six surveys. The first two surveys were conducted around
the primary and secondary cyclones, and the Vertimill®. The third and fourth surveys were full
circuit surveys and the last two surveys were conducted around the Vertimill® and secondary
cyclones only. Table 6 summarises the survey data:

Table 6 Surveys conducted during commissioning

Survey Fresh feed Autogenous Pebble Vertimill Secondary Operating
number tonnage mill crusher cyclone work index
overflow
(tph) (kW) (kW) (kW) (µm) (kWh/t)
1 319.9 4569 n/a 640 76 14.6
2 320.5 4561 25.83 631 106 17.3
3 329.8 4527 24.17 614 94 15.6
4 319.3 4544 28.98 619 109 17.6
5 335.2 4921 40.54 685 100 17.4
6 337.0 4849 45.30 754 93 16.7

The operating work index for the overall circuit ranged from 14.6 kWh/t to 17.6 kWh/t. The
Bond ball mill work index for the ore samples collected from surveys 3 and 4 was 17.2 and 18.7
kWh/t, respectively. Table 6 shows that the overall circuit operation index was close to work
index, which is interpreted by most in the industry as an indication of efficient circuit operation.

Secondary cyclone
0.12
80% passing size (mm)

0.10

0.08

0.06

0.04

0.02

0.00
64 65 66 67 68 69 70 71
Cyclone feed % solids

Overflow

Figure 3: Secondary cyclone overflow P80 vs. cyclone feed % solids

Figure 3 shows that the secondary cyclone feed density affected secondary cyclone overflow
product size. Finer product was obtained at low (64.5 %) cyclone feed density. Similar trend was
observed with the primary cyclones. This suggested that cyclone feed density was a primary
variable for the product size control.

CURRENT OPERATION

After removing the flotation tailing handling limitations the plant throughput was increased to
380 t/h at the beginning of 2004. New production targets were also set up to over 400 t/h. In
order to achieve this, the mine and MMPT-AP conducted optimisation work to optimise the
pebble port/grate design. Survey results and operation experience suggest that the circuit
throughput can be further increased but at the expense of the grind size. Additional grinding
power is required to keep the circuit product size below 130 microns at 400 t/h throughput.

CONCLUSION

An optimisation and expansion study was successfully conducted by Metso Minerals Process
Technology and the mine staff. The grinding circuit throughput was increased from 180 t/h to
380t/h. This was achieved by: the installation of pebble crusher and pebble ports in the primary
grinding circuit (AG mill), the installation of a Vertimill® for secondary grinding duty, and the
introduction of hydrocyclones in both the primary and secondary grinding circuits. Laboratory,
industrial scale data, modelling and simulations were used during the design and subsequent
optimisation. Further increases in throughput to more than 380 t/h while keeping the grinding
circuit product size P80 below 130 microns will require additional grinding power.
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