Low-Cost Approaches to Promote Performance of Comminution Circuit at Steel-Sirjan Iron Ore Complex

The energy consumed by the comminution equipment accounts for the main part of the operating cost of the mineral processing plants. In order to conserve energy, attempts were made to increase the efficiency of the conventional comminution equipment. As a case study, in this research work, a process audit was carried out in the comminution plant of the Steel-Sirjan Iron Ore Complex in order to find the low-cost solutions to improve the product quality and decrease the maintenance and operating costs. Three main steps of the audit were (1) studying the operating manuals and checking the standard process procedures, (2) process data analyzing, and (3) proposing and implementing the proper solutions. Plant audit revealed a low equipment efficiency. The main defects were the crusher operation in the half-full condition, high pressure grinding roll (HPGR) operation in a non-standard condition, high amounts of rejected materials in the HPGR circuit, and low efficiency of the screen. Following this, a series of modifications were made in the crushing and grinding circuit. This consequently caused an increase of 9.3% in the crushing plant throughput in the choked condition of the crushers as opposed to the half-full condition. By increasing the HPGR operational pressure and the hopper level, BBWI of the HPGR product in the super-choked condition was decreased from 16± 0.20 kWh/t to 14.9± 0.25 kWh/t. By modifying the screen process, the circulating load decreased from 79% to 59%, and the screen efficiency increased from 63.5% to 89.5%.The energy consumed by the comminution equipment accounts for the main part of the operating cost of the mineral processing plants. In order to conserve energy, attempts were made to increase the efficiency of the conventional comminution equipment. As a case study, in this research work, a process audit was carried out in the comminution plant of the Steel-Sirjan Iron Ore Complex in order to find the low-cost solutions to improve the product quality and decrease the maintenance and operating costs. Three main steps of the audit were (1) studying the operating manuals and checking the standard process procedures, (2) process data analyzing, and (3) proposing and implementing the proper solutions. Plant audit revealed a low equipment efficiency. The main defects were the crusher operation in the half-full condition, high pressure grinding roll (HPGR) operation in a non-standard condition, high amounts of rejected materials in the HPGR circuit, and low efficiency of the screen. Following this, a series of modifications were made in the crushing and grinding circuit. This consequently caused an increase of 9.3% in the crushing plant throughput in the choked condition of the crushers as opposed to the half-full condition. By increasing the HPGR operational pressure and the hopper level, BBWI of the HPGR product in the super-choked condition was decreased from 16± 0.20 kWh/t to 14.9± 0.25 kWh/t. By modifying the screen process, the circulating load decreased from 79% to 59%, and the screen efficiency increased from 63.5% to 89.5%.