Slurry Rheology Influence on the Performance of Mineral/Coal Grinding Circuit

The first part of this two-part article summarizes the result of a 10-year, multimillion dollar research and plant testing program involving operating mining companies throughout the world. The program was aimed at developing a better understanding of the influence of slurry rheology on the performance of mineral/coal grinding circuits. Part 1 presents the basic concepts identified, including typical laboratory results showing the influence on grinding behavior of controlled changes in percent solids, particle size, slurry temperature, and viscosity control chemicals. Part 2, in January, will illustrate typical industrial scale test results on both open and closed circuits using the concepts presented in Part 1. Special emphasis will be placed on identifying some industrial operating implications of controlling rheology by different methods. Introduction The industrial-scale practice of wet grinding minerals and coals in tumbling media mills (ball, rod, and pebble) is well-known to operating mineral processing engineers and plant design personnel. Over the last century, considerable experience and data has been collected, correlated, and put into rules or guidelines for successful circuit design and operation. Typical factors influencing circuit throughput that have been analyzed in some depth are mill diameter and length, grinding media size and loading, feed and product particle size, mill power use, and the interaction of classifier type and efficiency with the grinding device. Until recently, knowledge of slurry rheology influence on large scale grinding circuit performance has been limited. Even today slurry rheology effects are essentially ignored in plant design. Indeed, in most plant operations only qualitative guidelines are followed. For example, too thick a slurry causes throughput losses and too thin a slurry uses excessive water or causes water handling problems such as pumping limitations. A search of published literature and numerous discussions with experienced plant operating personnel has shown an awareness that changing the percent of solids in the mill influences grinding or the response of grinding involving fine feeds versus coarse feeds. However, most the work identified relative to rheology effects in mineral/coal grinding was qualitative. Even in the few studies that were more quantitative, the scope of the work was usually too narrow to draw general conclusions. Also, the detailed rheological characterization tied to observed breakage and the combination of laboratory to industrial-scale testing that is required to develop a broad understanding of any factor influencing grinding had not been done. In this environment, this detailed program began in 1967. It had three distinct goals: • To develop a basic understanding of slurry rheology influence on breakage characteristics in the laboratory. • To test general rheology concepts developed in the lab on the industrial scale. • To develop a commercially viable chemical approach to controlling slurry rheology that would lead to the use of chemical grinding additives or grinding aids. The goals have been met, at least in part, this year. A small fraction of the extensive laboratory and plant results have been made available in published literature. Much of the research program dealt with identifying and developing chemical grinding aids, but a lot of useful and practical information on percent solids, particle size, and slurry temperature influence on grinding circuit performance also was collected. The purpose of this article is to present a clear and concise sum¬mary of the results of the entire program. The importance of rhe¬ology control in grinding circuit behavior will be demonstrated using a series of carefully per¬formed industrial scale experi¬ments (both open and closed cir¬cuits) that have not yet been reported in general literature. Mining companies participating in the test program on a proprie¬tary basis have found the informa¬tion in this article to be useful in better understanding and improv¬ing circuit performance. Viscosity Effects in Grinding Studies In this program&apos;s previous labo¬ratory studies, it was shown that there is a consistent pattern of change in specific rates of break¬age of both mineral and coal slur¬ries as slurry fluidity changes. Using the net production rate of material smaller than some spec¬ified size-for example, kg/hr of <75 µm (200 mesh)-as an index of mill production in a standard batch mill test (with a given feed material, feed size, mill, and mill conditions such as constant time of grind), the following facts were established (see Fig. 1): • The normal range of low den¬sity, low viscosity slurry (region A) gave no variation in mill produc¬tion. The measured rates of break¬age exhibited normal first order grinding. • Grinding of a somewhat higher viscosity slurry (region B) could give increased production. The higher viscosity was obtained