How to Operate a Grinding Circuit

911metallurgist.com/blog/how-to-operate-grinding-circuit

LD April 25, 2016

Michaud

How hard a ball mill operator has to work depends partly on himself, and partly on the
kind of muck the mine sends over to the mill. In some plants, the ore may change two or
three times a shift, and a ball mill operator has to keep on his toes.

That’s why it would be just as well for you, as a ball mill operator, to study out a few
ways of doing your job easier and better, because there will be times, even in the best of
mills, when you’ll run into a lot of trouble. Collected here you will find some practical
suggestions, contributed by a number of good mill men, that might give you an idea or
two that would help get around some of that trouble.

To be sure we understand each other, let’s begin with the equipment. In a simple
grinding circuit there will be a ball mill and a classifier. Some circuits, especially in large
mills, have more units or two or three stages of grinding, but whatever is said here will
apply to the complicated circuits as well as the simple ones.

The two types of ball mill in general use are the grate mill and the open-end mill. Most
manufacturers make both kinds; the difference between them is that the grate mill has a
steel grid clear across the discharge end, but the open-end mill has only an open
trunnion at the discharge end, through which pulp flows freely. If you don’t already
know all about the inside of your ball mill and what it is supposed to do, it would be a
good idea to ask the shift boss, the metallurgist, or the superintendent to tell you about
it.

Mechanical classifiers make use of rakes, spirals, or a simple drag belt. For our purposes
it doesn’t matter which type you are working with, because you would handle them all
in pretty much the same way.

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In operation, you add water to the ball mill along with the ore. Flowing out of the ball
mill, the ground ore pulp pours into the classifier pool, where the finished material is
separated from the coarse sand. You do that by adding a lot more water to the pool, so
that the finer sand overflows the weir and goes on to the next step (flotation perhaps),
and the coarse sand settles to the classifier bottom and is raked back into the mill to be
ground finer. You, the operator, are supposed to control these actions in order to send
on to the machines below you the right amount of ore, ground just fine enough, and
with just the right amount of water with it.

To help you do this, and to make a. record of how things are going, you will have to take
samples of the pulp regularly. Different mills have different ideas on sampling, but all of
them take at least hourly samples of the classifier overflow. What it amounts to is
weighing a certain volume of the pulp to determine its density. Higher density means
thicker pulp and usually coarser sand. Lower density means thinner pulp and finer
sand. The shift boss will tell you what the density ought to be, and it will be up to you to
hold it there.

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You may also have to take density samples of the ball mill discharge, which runs a lot
thicker than the classifier overflow, and some mills also expect you to take measured
samples of the ball-mill feed and weigh them.

Another sample you may take is one for pH, which is a term that takes a little
explaining. You can find out exactly what pH means from a chemistry book if you want
to; but for all practical purposes, it is enough to know that pH is a number that tells you
how much acid or alkali there is in the pulp. A pH of 7 is alkaline.

Table I

Controls for Grinding Circuit

Feed Increase Coarser grind, more circulating load. Effect on classifier

Rate from too overflow depends on fineness of ore feed and amount of
low. increase in feed rate.

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 Decrease Finer grind, less circulating load. Probably more fine sand in
from too classifier overflow.
high.

Ball Mill Increase Coarser grind; may wash out mill if add too much water. May
feed increase circulating load and cause thinner classifier overflow.
water
Decrease Finer grind, but may choke mill if cut too far. May lower
circulating load and cause thicker classifier overflow.

Water to Increase Thinner and finer overflow; higher circulating load.

classifier
Decrease Thicker and coarser overflow; less circulating load.

In addition a few mills use a baffle board across the classifier pool. Shifting the baffle
toward the tail end throws out a coarser overflow; moving it ahead makes the
overflow finer and pulls out more sand into the circulating load. In a few mills the
classifier overflow weir can be raised or lowered. Raising it makes the overflow finer;
dropping the weir makes the overflow coarser. Variable rake speed is another control
used in few mills. Most operators think rake speed is better left alone.

If you add acid, the pH goes down below 7; if you add an alkali like lime, the pH will go
up, say to 9 or 10, depending on how much lime you add. In any case, you can bank on
it that if the brass hats want you to watch the pH at all, they have good reasons for
wanting you to hold it steady.

You may also have the job of adding balls to the mill each shift. The shift boss tells you
how many or what weight, and you put them in. Drop them into the scoop if you have a
grate mill, or put them in through the discharge trunnion if it is an open-end mill.

The controls you will have to work with are given in Table I, and are also indicated in
the drawing. As to which one of these controls is most important, mill men don’t all
agree. Probably it depends on what kind of ore you are grinding. Most good operators,
though, say that the classifier water valve should be the first one to adjust, because it
controls directly the kind of finished material you send on down the line to the next
man.

The most important point is this: You cannot adjust any one of these controls without
paying some attention to the other two. For example, if you change the feed rate, you
will probably have to reset the two water valves. They all work together. In fact, the
whole grinding circuit acts like a team of horses, and as the time at first.

What to Look For in a grinding circuit

In Table II you will find some suggestions on what to look for to help you decide how to
use these controls. In the column headed “if you find,” there are set down the things
you‘ll run into if something is wrong with the circuit. That is, if the ball-mill feed gets

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finer than it usually is, the top line tells you what to expect and what to do. But don’t
think you have to do all these things all the time. Do only as much as you are sure you
have to do.

The classifier overflow is really the most important spot in the circuit, because whatever
comes over that weir is out of your hands, and your work will be judged by how good a
product it is. Most operators believe that if there is any change in setting to be made, the
density of the classifier overflow is where you make it first. Remember, more water to
the classifier means thinner pulp and finer overflow; less water means thicker pulp and
coarser overflow.

Watch the Mill Feed

The matter of feed to the ball mill brings up a point that is important in keeping you out
of trouble. You can find out by asking the old- timers how each kind of ore is going to
act when it hits the mill, and if you for each change as it comes along.

For example, suppose you are working in a lead-zinc flotation mill where there are two
kinds of ore— one that is coarse and low grade, and another that is finer and higher
grade. Keep the feed to the ball mill lower when the coarse stuff comes along, because it
takes longer to grind and you don’t want to overload the mill. Then when the fine muck
shows up, increase the feed and also run the classifier density higher. That will throw
the high grade over into the flotation cells where it belongs.

You see, the high-grade mineral is heavier than the low grade, and it takes a little higher
density in the classifier to lift it out. If you carry a low density, too much lead and zinc
mineral keeps going back into the ball mill, and eventually may be ground into slime
and lost altogether. Doing extra little things like this is what marks a really good
operator, and you can learn these things only by study and asking questions.

Looking for Trouble

“Keep ahead of trouble” is good advice for flotation operators, and it is just as good for
bail-mill men. A good operator can take care of even big changes in muck so smoothly
and easily that if you were watching him, you’d never know anything was running
differently.

On the other hand, consider Joe Blow, the Wonder Boy. That’s him down there sitting
on the rail near the ball mill, swinging his heels and probably wondering whatever
happened to that little blonde hasher over at the Greasy Spoon. Suddenly Joe looks up.
He has heard a splashing sound that doesn’t belong there. The ball mill is strangely
quiet. Joe looks at the feed box, and finds pulp pouring out on the floor.

Joe can tell right away what has happened. The mill has been overloaded and the grate
has plugged. Quick as a flash, Joe races around and shuts the feed off, then whips open
the valve pouring water into the mill. He’s fast; he wants action.

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He gets it. The mill comes unstuck with a vengeance and belches sand into the classifier
like a tidal wave. Joe, the dope, flushes water into the classifier, too, and you can almost
hear it groan as the rakes get buried. The flotation man down below is tearing his hair
and spinning valves. What he says about Joe blisters the paint on the concentrate
launders, but Joe can’t hear him. Joe is up under the mill shovelling cleaned up before
the shifter comes.

Table II

Handling the Grinding Circuit

IF YOU FIND IT MEANS YOU SHOULD

#1 Finer Mill will grind Increase classifier water to

faster, classifier raise circulating load;
Ball-Mill Feed overflow will perhaps raise mill feed.
thicken and get
coarser.

Coarser Mill will grind Cut down classifier water,

slower, and may need to cut mill
classifier feed and water.
overflow will thin
out, get finer. If
fed too fast, a
grate mill may
plug.

#2 Thinner Feed too slow Increase feed if too slow;

Ball-Mill Discharge or too coarse; cut feed if too coarse Cut
too much water feed water. Check density
in feed. Mill will in classifier and adjust with
be underloaded water.
and classifier
too dilute.

Thicker Feed water too Increase feed water

low; feed too carefully. Check on feed
fast or too fine. and other water conditions,
Mill may be and adjust where
overloaded, necessary.
classifier
overflow may
get too coarse.

Stops or Grate plugged Shut off feed and classifier,

slackens or trunnion leave head water on. Muck
blocked. Pulp will start running in a
backs up, spills minute. How did you get
from feed box. into this mess?

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#3 Loud, metallic Mill is nearly Raise feed, cut head water
rattle empty of muck; if necessary. Increase
Sound of Mill balls banging classifier water to build
each other and load.
wearing out
liners.

Thick mushy Mill choked with Cut down feed, increase

sound. Quiet muck, not head water carefully. Cut
grinding. classifier water a little.

#4 Power Trouble coming. Check all other indicators

dropping Mill either and make required
Ball Mill Drive overloaded or adjustments. Try to head
Amps underloaded. off whatever is going
Can tell by wrong.
sound, feed, or
appearance of
discharge.
Checking
ammeter
especially
important on
grate mills.

Power rising All OK, if no Looks like you’re doing all

mechanical right. But don’t let power go
trouble. above normal without your
finding out why.

#5 Density rising Muck getting More water to classifier

finer; perhaps (but slowly) and to mill feed
Classifier Overflow too little water to if necessary.
feed; classifier
water too low.

Density falling Muck coarser or Cut down classifier water

coming too fast; and mill feed water.
too much water Reduce feed if necessary.
to classifier; too
much water in
feed.

#6 Finer Feed to mill is Cut down classifier water.

getting coarser. Check feed and feed
Classifier Overflow See “Ball- Mill water.
Feed.”

Coarser Feed to mill is Add more water to

getting finer. classifier. Check feed and
See “Ball-Mill feed water.
Feed.”

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 #7 Rising If circulating Don’t do anything unless
load too high it indications are that serious
Circulating Load means classifier overload of classifier is on
pool is too thin. way. Then, cut down
Mill feed may be classifier water, reduce
coarser, or feed rate, or reduce head
coming too fast water. If classifier gets
Remember, overloaded, don’t raise
though, that rakes. Things would only
circulating load get worse. Keep rakes
should be kept digging and adjust circuit
up good and as indicated.
high.

Falling Classifier pool Do something right away,

too thick, may because it is a good idea to
throw too much keep rakes loaded up
sand into unless mill is choked. Add
overflow. Muck more classifier water,
is coming finer increase feed rate and
or too slowly. head water.

Watching the mill discharge (2) will tell you what goes on inside the mill. Some
operators note how high on the side of the discharge flange the wave of pulp is carried
when the mill is running right. Then if the wave runs higher or lower than that, they
know something is wrong.

If the mill is low on muck, (3) it rattles and bangs like a boiler factory, and a lot of good
steel goes to waste. But if the mill is too full of muck, you can hardly hear it. Keep your
ear peeled for the sound of the mill that you know is right.

Many operators feel the classifier overflow (6) by nibbling their fingers together with
their hands in the stream, and with a little experience, you can tell pretty accurately
whether or not the overflow is fine enough.

The amp-meter (4) is really as good a guide to the condition of the mill as the sound or
the discharge. It tells you how much power the mill drive motor is drawing, but
remember that if you overload the mill, or if you underload it, it draws less power.

You check on the circulating load (7) by watching the height of the sand on the rakes or
spiral flights as they push it back to the mill feed launder. The shift boss will tell you
about how high the sand ought to come.

The funny part of it is that if Joe thinks about this at all, he probably says to himself,
“It’s a lucky thing for the company it was me that was on shift when that happened.”

What was wrong? He shouldn’t have let the mill plug in the first place. But suppose it
plugged anyway, he should have cut off the feed all right, but he should also have shut
down the classifier, and increased the head water only a little. Then he should have cut
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down on the classifier water and then increased it, little by little, when the mill opened
up. He should have done his best to keep things balanced instead of slamming
everything out of adjustment at once. Well, he’ll learn. He will, or the boss will murder
him some dark night.

Using the Table

Now, just because all these things to look for and to do have been put down in a table,
don’t think you ought to walk your shift carrying this operating manual in one hand and
a density sample can in the other. It is no use trying to run a mill out of a cookbook. But
what we did want to do was to set these things down here so you could think about
them, and keep thinking about them, while you are working.

Just go at the problem the way things are arranged in the table . When something in the
circuit begins to change, make sure you know exactly what is happening; then ask
yourself what is causing it. Then, when you have answered that question, decide what to
do about it. Think out each thing you do, and don’t do things in a rush or without
knowing why you are doing them. Don’t be a Joe Blow, in other words.

One thing more, and a very important thing: When you do make a change, allow a little
time, say 15 or 20 minutes, for the effect to show up before you make another change.
Don’t over-control. For instance, if the density in the classifier is up a little and you add
more water, don’t expect the density to change right away, and don’t go back and open
the valve even wider just because nothing seems to have happened. It will; just wait a
while. A super¬operator who can’t let well enough alone gets on everybody’s nerves.

Starting and Stopping

In starting the grinding circuit after anything but a very short shut spitars enough to
clear the same packed on the tank bottom, start the classifier overflow pump, then start
the classifier, and after that, the ball mill. But don’t throw in all these switches at once.
You’ll get the electricians down on you if you do. Keep the water fed to the circuit down
low until the load builds up a little; then set the valve hand wheels at about the point
they should be for normal operation. You can check on this setting by marking one spot
on the rim of the wheel and counting turns, or by counting exposed threads on the valve
stem. Don’t forget to lower the classifier rakes again as the load builds up.

In shutting down the mill, cut off the feed a few minutes before the shutdown is due.
That will give time to grind out some of the circulating load and will make starting
easier. Then when you are ready to stop, shut down the mill, then the classifier (raise the
rakes), then the pump for the classifier overflow, if there is one.

If the power fails suddenly, shut off the water valves and raise the classifier rakes. And
for goodness sake, don’t forget to shut off any drip cans or siphon feeders of pine oil or
other reagent you may have running somewhere in the circuit.

So far as mechanical trouble goes, there will probably be little of that if the equipment is
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reasonably good. Ball mills spring leaks from time to time because the bolts holding in
the liner plates work loose. If a leak develops near the discharge end of the mill, shut
down right away and fix it. This is especially true of an open-end mill. The point is that
you don’t want sand getting into the out in short order.

Safety
Now a word about safety, a subject that I am putting last because I want to leave it first
in your minds. Whatever else you do, don’t go poking aimlessly around the mill or the
classifier, sticking your nose or your fingers in here and there to see how the machinery
works. I wouldn’t make that statement if I hadn’t seen a man or two doing just that. Nor
have I forgotten the time I was routed out of bed at two a.m. to help bandage a man
whose right-hand fingers had just been taken off by the ball-mill scoop as effectively,
though not as neatly, as a surgeon could have done it. He had been “just poking
around,” too. Remember your company, and your country, need you on that ball-mill
floor, and you wouldn’t be happy holding down a hospital bed these days. So just be
careful.

How to Operate a Flotation Circuit

How to Operate a Thickener

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This Public Domain Robert Ramsey article is based in large part on experiences
and opinions generously supplied by the following mill men: Clyde Simpson, Bagdad
Copper Co., Hillside, Ariz.; E. J. Duggan and M. E. Kennedy, Climax Molybdenum Co.,
Climax, Colo.; John Palecek, Keystone Copper Corp., Copperopolis, Calif.; Frank M.
McKinley, Bunker Hill & Sullivan M. & C. Co., Kellogg, Idaho; Malcolm Black, Wright-
Hargreaves Mines, Ltd., Kirkland Lake, Ont.; and the concentrator staffs at Hudson
Bay Mining & Smelting Co., Flin Flon, Manitoba, and Sherritt Gordon Mines, Ltd.,
Sherridon, Manitoba. https://archive.org/details/malozemoffmining00platrich

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