SINGLE OBJECTIVE OPTIMIZATION OF CLOSED BALL MILLING CIRCUIT OF ESFORDI PHOSPHATE PLANT Print

The subject of this project is optimization of closed ball-mill circuit at Esfordi phosphate plant, based on integration of process simulation and genetic algorithm (GA) concepts. The BMCS® (BMCS-based Modular Comminution Simulator) under MATLAB software was used in this investigation to search for the optimal operating condition of the comminution circuit so that a pre-defined process goal can be achieved. The search process is done using genetic algorithm. The main problem in the circuit is the existence of fine particles with a high degree of iron content in the hydrocyclone underflow stream which is recycled to the ball mill unit. These particles are subjected to over grinding and cause some problems in downstream processes, i.e., flotation, which leads to a low production quality. Therefore, the goal of this project was set to improve ore grinding in ball mill unit and increase the efficiency of particle size classification by hydrocyclone unit. The GA optimization was done in a single objective form that the optimization goal was to achieve a pre-defined particle size for overflow or underflow streams separately. The circuit simulations optimized by GA produced various results and conditions that each of them can be recommended for plant testing and performance improvements.