Long-term simulation of an industrial coke breeze grinding circuit

One important application of rod milling is in size reduction of coke breeze, which is used as solid combustible in iron ore sintering plants. The work applies modeling and simulation of an industrial circuit comprised of a flip-flow screen and a rod mi l l to predict the circuit response in long-term operation, following the strateg y used in the plant of replacing the rod charge only when it reaches the end of its life. Initially, the model for rod wear has been calibrated and the mi l l fillings estimated. Then the mi l l model has been validated with data from several industrial surveys, showing good agreement between the two. A long-term (approximately three-month) pseudo-dynamic simulation was then carried out to mimic the strateg y normally used in plant operation. Additional simulations were then carried out to compar e different scenarios of operation, demonstrating the benefit of increasing the rod charge and diameter, in particular when associated with operation of the mi l l at lower speed in the beginning of the charge life and progressive increase thereafter, besides partially replacing wor n rods in their midlife. For instance, simulations showed that an increase in initial mi l l filling from 15 to 20 %, progressive increase in fraction of critical speed from 0.40 to 0.65 in contrast to operation at constant speed and gradual reduction of throughput from 60.0 to 40.2 t/h resulted in 56 % increase in charge lifetime, 35 % reduction in variability in product quality and 12 % reduction in cost of operation per ton of coke breeze produced.

Automated summary

This study utilizes modeling and simulation techniques to predict the response of a rod milling circuit in long-term operation. The results show that increasing the rod charge and diameter, coupled with initially operating at lower speed and replacing worn rods during the midlife of the charge, can significantly improve the rod charge lifetime, reduce variability in product quality, and decrease the cost of coke breeze production per ton.