Comminution modeling using mineralogical properties of iron ores

Comminution modeling aims to predict the size and liberation distribution of mineral particles and the required comminution energy. The current state-of-the-art comminution models provide a calculation of neither particle size distribution, grinding energy and throughput dependency with neither a broad understanding of how the mineral grade varies by size nor the liberation distribution of the product. The underlying breakage mechanisms affect the liberation of mineral grains and are dependent on modal mineralogy and mineral texture (micro structure). It has also been a challenge to model comminution systems to predict the optimal energy and size for better mineral liberation because of the variability of the mineral particle properties i.e. grains arrangement and composition. A detailed mineralogical study was carried out in order to broaden the understanding of the nature and distribution of comminuted particles in a ball mill product. Focusing on iron ore samples the study showed how the particle breakage rate decreases when the particles reach the grain size of the main mineral component. Below that size, comminution does not increase mineral liberation and therefore in most of the cases passing over that boundary is only a waste of energy. The study involving iron ores from Malmberget and Kiruna, Northern Sweden, showed that certain shortcuts can be applied to empirically model the mineral liberation distribution of the particles in a ball mill based on the mineral grade-by-size pattern from a geometallurgical program. In Malmberget and Kiruna the mineral grade-by-size pattern is depending on the mineral distribution and grain size of gangue as well as magnetite or hematite minerals. A significant difference between mineral breakage of the same grade and gangue minerals can be observed due to texture differences.