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Proposed Grinding System based on Small-scale Data
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Proposed Grinding System
based on Small-scale Data
prepared for
I I vvaannhhooee M M iinnee s s L Lt t d d ..
at SGS Lakefield Research Limited
Progress Report 1 ARM-0566
LR -10044-070
July 14, 2003
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Table of Contents
Introduction....................................................................................................................................... 4
Discussion ......................................................................................................................................... 5
1 Ore Characterisation........................................................................................................... 5
1.1 JKTech Drop-weight Test Results..................................................................................... 5
1.2 MacPherson Autogenous Grindability Test....................................................................... 5
1.2.1 Autogenous Work Index............................................................................................ 6
1.2.2 Density Measurements............................................................................................... 8
1.3 Bond Ball Mill Grindability Test....................................................................................... 9
1.4 Bond Rod Mill Grindability Test..................................................................................... 10
1.5 Bond Abrasion Test ......................................................................................................... 11
1.6 Conclusion on Ore Characterisation ................................................................................ 12
APPENDIX A: MacPherson Autogenous Grindability Test Details
APPENDIX B: Bond Ball Mill Grindability Test Details
APPENDIX C: Bond Rod Mill Grindability Test Details
APPENDIX D: Bond Abrasion Test Details
ENCLOSURE: JKTech Report
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List of Tables
Table 1: JKTech Drop-weight Test Summary................................................................................... 5
Table 2: MacPherson Grindability Test Summary ............................................................................ 6
Table 3: Density Measurement .......................................................................................................... 8
Table 4: Bond Ball Mill Work Index Test Summary ........................................................................ 9
Table 5: Bond Rod Mill Work Index Test Summary ...................................................................... 10
Table 6: Bond Abrasion Test Summary........................................................................................... 11
Table 7: Grindability Testing Summary .......................................................................................... 12
List of Figures
Figure 1: MacPherson Autogenous Grindability Test Database ....................................................... 7
Figure 2: 18” Mill Product Database ................................................................................................. 7Figure 3: Bond Ball Mill Grindability Test Database ....................................................................... 9
Figure 4: Bond Rod Mill Grindability Test Database...................................................................... 10
Figure 5: Bond Abrasion Test Database .......................................................................................... 11
Figure 6: Work Index Correlations.................................................................................................. 12
Figure 7: Correlation between Autogenous Work Index and Drop-weight Test Data .................... 13
Figure 8: Correlation between Rod Mill Work Index and Drop-weight Test Data......................... 14
Figure 9: Correlation between Ball Mill Work Index and Drop-weight Test Data......................... 14
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Introduction
A.R. MacPherson Consultants Ltd. (ARMC) was requested by Ivanhoe Mines Ltd. (Ivanhoe) to
conduct a grindability study for the pre-feasibility design of the Oyu Tolgoi deposit.
The test program was directed by Monsieur Maurice Tagami Consultant to Ivanhoe.
Prepared by: Reviewed by:
________________________________ ______________________________
André McKen Mike Ounpuu
Technical Associate Senior Metallurgist
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Discussion
1
Ore Characterisation
The ore characterisation was performed on seven ore composites, and each composite was
submitted to the following grindability tests:
JKTech Drop-weight Test
MacPherson Autogenous Grindability Test
Bond Rod Mill Grindability Test
Bond Ball Mill Grindability Test
Bond Abrasion Test
1.1 JKTech Drop-weight Test Results
The drop-weight test was performed at Lakefield under the supervision of ARMC. The test results
were interpreted by Contract Support Services (JKTech’s North American agent), who issued a
separate report (Enclosure). The data are summarised in Table 1.
Table 1: JKTech Drop-weight Test Summary
Sample
Composite
Ore Zone A b A x b Percentile of
Hardness
ta Percentile of
Hardness
Ore Density
(g/cm3)
Sample #1 SW Oyu 49.9 0.98 48.9 58 0.42 22 2.82
Sample #2 SW Oyu 49.9 0.88 43.9 48 0.79 58 2.81
Sample #3 SW Oyu 52.1 0.69 36.0 77 0.46 51 2.82
Sample #4 Central Oyu 57.9 1.95 112.9 12 1.18 13 2.74
Sample #5 Central Oyu 58.6 1.03 60.3 36 0.84 20 2.85
Sample #6 Central Oyu 56.5 1.35 76.3 24 0.83 21 2.87
Sample #7 Central Oyu 53.4 1.62 86.6 19 1.01 16 2.75
1.2 MacPherson Autogenous Grindability Test
The MacPherson autogenous grindability test is a continuous test, which is performed in an 18”
mill (~46-cm). The test is run until steady state is reached, for a minimum of 6 hours. The test
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details are appended (Appendix A), along with a description of the test procedure, and
methodology.
1.2.1 Autogenous Work Index
The test results are summarised in Table 2, and the work index results are compared to our
database in Figure 1.
Table 2: MacPherson Grindability Test Summary
Sample
Composite
Ore Zone Feed
(kg/h)
F80
(µm)
P80
(µm)
Gross Work
Index (kWh/t)
Correlated Work
Index (kWh/t)
Percentile of
Hardness
Sample #1 SW Oyu 6.6 22121 310 24.2 17.9 77
Sample #2 SW Oyu 7.6 22206 319 21.6 16.8 69Sample #3 SW Oyu 6.2 22205 299 26.1 18.6 83
Sample #4 Central Oyu 18.0 22200 273 8.9 8.9 8
Sample #5 Central Oyu 11.7 22195 289 13.7 12.7 28
Sample #6 Central Oyu 11.2 22215 287 14.2 13.0 30
Sample #7 Central Oyu 12.9 22214 251 11.6 11.3 17
When the gross autogenous index is greater than 10.0 kWh/t (metric), a correlation factor is
applied to arrive at the index used in the grinding circuit design, as the 18” mill becomes less
efficient as the ore becomes harder. The correlation factor has been determined by grinding a
large number of samples in the 18” Aerofall mill and comparing the results obtained with data
from grinding the same type of material in a pilot and large commercial mill.
The ores showed a wide spread of hardness. The Southwest Oyu samples were generally hard,
ranking 69th
to 83rd
in our database. On the other hand, the Central Oyu samples were softer, all
below the 30th
percentile of hardness. The Composite sample number 4 was particularly soft.
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Frequency Curve of Autogenous Mill Work Indices
0
20
40
60
80
100
120
140
160
1 3 5 7 9 11 13 15 17 19 21 23 25 27 >28Autogenous Work Index - Metric
F r e q u e n c y
Dat abase Oyu Tolgoi
Figure 1: MacPherson Autogenous Grindability Test Database
0
10
20
30
40
50
60
70
80
90
100
2 5 7 5 1 2 5
1 7 5
2 2 5
2 7 5
3 2 5
3 7 5
4 2 5
4 7 5
5 2 5
5 7 5
6 2 5
6 7 5
> 7 0 0
MacPherson Mill Product K 80
F r e q u e n c y
Dat abase Oyu Tolgoi
Figure 2: 18” Mill Product Database
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The 18” product P80 is compared to our database in Figure 2. The P80’s for all the Oyu Tolgoi
samples were consistent, and ranged between 250 and 310 microns, which is lower than the
database median. Note that the 18” mill P80 is ore dependent, and is indicative of the actual P80
that can be obtained in industrial scale mills.
1.2.2 Density Measurements
Several density measurements are performed as part of the MacPherson grindability test
procedure. The results are presented in Table 3, and the drop-weight test densities are presented as
comparison.
Table 3: Density Measurement
Sample
Composite
Ore Zone Feed -1/4"
Specific
Gravity*
Charge -1/4"
Specific
Gravity*
Charge +1/2"
Rocks
Density**
Drop-weight Test
Rocks (+1")
Density**
Sample #1 SW Oyu 2.81 2.82 2.81 2.82
Sample #2 SW Oyu 2.89 2.81 2.79 2.81
Sample #3 SW Oyu 2.92 2.82 2.82 2.82
Sample #4 Central Oyu 2.84 2.79 2.80 2.74
Sample #5 Central Oyu 2.95 2.89 2.86 2.85
Sample #6 Central Oyu 2.94 2.88 2.84 2.87
Sample #7 Central Oyu 2.87 2.87 2.85 2.75
* Gas Pycnometer in g/cm3; ** Water Displacement in g/cm3
The ore charge specific determinations were performed by 1) gas pycnometer on minus ¼
“sample, and 2) water displacement on 18 individual coarse rocks in the range ½” to 1-¼”. The
feed specific gravity was performed with a gas pycnometer on a minus ¼” sample. The ore
densities from the drop-weight test procedure are obtained by water displacement on 30 rocks in
the range 1” to 1 ¼”.
The results were consistent. The S.G.’s at fine size measured with the gas pycnometer were
slightly higher than those obtained with water displacement, which could be caused by the
presence of internal cracks in the coarser rocks. There was no significant build-up of heavier
material in the mill steady-state charge at the test completion.
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1.3 Bond Ball Mill Grindability Test
Bond ball mill grindability test was performed at 100 mesh of grind. The results are summarised
in Table 4, and compared to our database in Figure 3. Test details are Appended (Appendix C).
The Central Oyu and SW Oyu samples were soft and hard, respectively, with respect to Bond ball
mill work index.
Table 4: Bond Ball Mill Work Index Test Summary
Sample
Composite
Ore Zone Mesh of
Grind
F80
(µm)
P80
(µm)
Gram per
Revolution
Work Index
(kWh/t)
Percentile of
Hardness
Sample #1 SW Oyu 100 2221 111 1.12 19.1 91
Sample #2 SW Oyu 100 1579 118 1.35 18.2 85
Sample #3SW Oyu
100 1924 114 1.15 19.4 92Sample #4 Central Oyu 100 1539 112 2.54 10.4 12
Sample #5 Central Oyu 100 1913 116 2.14 11.9 21
Sample #6 Central Oyu 100 1758 110 1.98 12.3 25
Sample #7 Central Oyu 100 2197 115 2.04 12.0 21
0
50
100
150
200
250
300
1 3 5 7 9 11 13 15 17 19 21 23 25 27 >28
Bond Ball Mill Work Index - Metric
F r e q u e n c y
Database
Oyu Tolgoi
Figure 3: Bond Ball Mill Grindability Test Database
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1.4 Bond Rod Mill Grindability Test
Each composite was also tested for the Bond rod mill grindability test at 14 mesh of grind, and the
results are summarised in Table 5. The results are compared to our database in Figure 4. Test
details are Appended (Appendix D). The results of the rod mill work index were similar to those
of the ball mill. Again, the Central Oyu and Southwest Oyu samples can be grouped in two
different categories, i.e. soft and hard.
Table 5: Bond Rod Mill Work Index Test Summary
Sample
Composite
Ore Zone Mesh of
Grind
F80
(µm)
P80
(µm)
Gram per
Revolution
Work Index
(kWh/t)
Percentile of
Hardness
Sample #1 SW Oyu 14 9239 891 6.21 18.6 82
Sample #2 SW Oyu 14 10336 954 7.31 17.2 72Sample #3 SW Oyu 14 10247 908 5.57 19.7 90
Sample #4 Central Oyu 14 7139 879 15.00 11.3 18
Sample #5 Central Oyu 14 8024 892 12.80 12.2 24
Sample #6 Central Oyu 14 8132 894 11.62 13.0 33
Sample #7 Central Oyu 14 9124 907 11.59 12.8 32
0
20
40
60
80
100
120
140
160
180
1 3 5 7 9 11 13 15 17 19 21 23 25 27 >28
Bond Rod Mill Work Index - Metric
F r e q u e n c y
Database
Oyu Tolgoi
Figure 4: Bond Rod Mill Grindability Test Database
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1.5 Bond Abrasion Test
Each composite was tested for ‘abrasiveness’, with the Bond abrasion test. The test details are
appended (Appendix D) and the results are summarised in Table 6. Comparison to our database is
depicted in Figure 5. All the abrasion indices are softer than the database median, which is 0.3.
The samples can be considered as mildly abrasive.
Table 6: Bond Abrasion Test Summary
Sample
Composite
Ore Zone Abrasion
Index
Percentile of
Hardness
Sample #1 SW Oyu 0.1116 17
Sample #2 SW Oyu 0.1904 31
Sample #3SW Oyu
0.1621 28Sample #4 Central Oyu 0.0803 10
Sample #5 Central Oyu 0.1986 32
Sample #6 Central Oyu 0.2000 32
Sample #7 Central Oyu 0.1095 17
0
5
10
15
20
25
30
35
0. 0 5
0. 1 5
0. 2 5
0. 3 5
0. 4 5
0. 5 5
0. 6 5
0. 7 5
0. 8 5
0. 9 5
1. 0 5
1. 1 5
1. 2 5
1. 3 5
1. 4 5
Abrasion Index
F r e q u e n c y
Database Oyu Tolgoi
Figure 5: Bond Abrasion Test Database
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1.6 Conclusion on Ore Characterisation
The grindability results are summarised in Table 7. The work index data for each sample were
consistent, and the correlation between the different Bond indices was good as depicted in Figure
6. This shows that the Oyu Tolgoi ore hardness is relatively invariable with size on the range
tested. The autogenous work index was generally slightly lower than both the Bond ball mill and
Bond rod mill work index.
Table 7: Grindability Testing Summary
Sample
Composite
Ore Zone AWi RWi BWi A x b ta Ai
Sample #1 SW Oyu 17.9 18.6 19.1 48.9 0.42 0.112
Sample #2 SW Oyu 16.8 17.2 18.2 43.9 0.79 0.190
Sample #3 SW Oyu 18.6 19.7 19.4 36.0 0.46 0.162
Sample #4 Central Oyu 8.9 11.3 10.4 112.9 1.18 0.080
Sample #5 Central Oyu 12.7 12.2 11.9 60.3 0.84 0.199
Sample #6 Central Oyu 13.0 13.0 12.3 76.3 0.83 0.200
Sample #7 Central Oyu 11.3 12.8 12.0 86.6 1.01 0.110
0
2
4
6
8
10
12
14
16
18
20
0 5 10 15 20
Autogenous Work Index (kWh/t)
B W i , R W i ( k W h / t )
Ball Mill Work Index
Rod Mill Work Index
Figure 6: Work Index Correlations
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Figure 7 shows that both the drop-weight test impact (A x b) and abrasion (t a) portions, correlate
well with the autogenous work index, which is expected as the autogenous work index test
measures both simultaneously. The values that diverge slightly from the trend are the “A x b”
from Sample #5, and the “ta” from Sample #2.
0
20
40
60
80
100
120
140
0 5 10 15 20
Autogenous Work Index (kWh/t)
A x b
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
t a
A x b
ta
Figure 7: Correlation between Autogenous Work Index and Drop-weight Test Data
The same correlation curves were presented, with the Bond rod mill and ball mill work. The
results are presented in Figure 8 and Figure 9. It shows that there is also a correlation between the
drop-weight test parameters and the Bond rod and ball mill work indices, but it is more scattered.
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0
20
40
60
80
100
120
140
0 5 10 15 20 25
Rod Mill Work Index (kWh/t)
A x b
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
t a
A x b
ta
Figure 8: Correlation between Rod Mill Work Index and Drop-weight Test Data
0
20
40
60
80
100
120
140
0 5 10 15 20 25
Ball Mill Work Index (kWh/t)
A x b
0.0
0.2
0.4
0.6
0.8
1.0
1.2
1.4
t a
A x b
ta
Figure 9: Correlation between Ball Mill Work Index and Drop-weight Test Data
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