Improving Taconite Processing Plant Efficiency by Computer Simulation
2007-03-30
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Improving Taconite Processing Plant Efficiency by Computer Simulation
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2007-03-30
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University of Minnesota Duluth
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Technical Report
Abstract
This project involved industrial scale testing of a mineral processing simulator to
improve the efficiency of a taconite processing plant, namely the Minorca mine.
The Concentrator Modeling Center at the Coleraine Minerals Research Laboratory,
University of Minnesota Duluth, enhanced the capabilities of available software,
U sim Pac, by developing mathematical models needed for accurate simulation of
taconite plants. This project provided funding for this technology to prove itself in
the industrial environment.
As the first step, data representing existing plant conditions were collected by
sampling and sample analysis. Data were then balanced and provided a basis for
assessing the efficiency of individual devices and the plant, and also for
performing simulations aimed at improving plant efficiency. Performance
evaluation served as a guide in developing alternative process strategies for more
efficient production. A large number of computer simulations were then performed
to quantify the benefits and effects of implementing these alternative schemes.
Modification of makeup ball size was selected as the most feasible option for the
target performance improvement. This was combined with replacement of existing
hydrocyclones with more efficient ones. After plant implementation of these
modifications, plant sampling surveys were carried out to validate findings of the
simulation-based study. Plant data showed very good agreement with the simulated
data, confirming results of simulation. After the implementation of modifications
in the plant, several upstream bottlenecks became visible. Despite these
bottlenecks limiting full capacity, concentrator energy improvement of 7% was
obtained. Further improvements in energy efficiency are expected in the near
future. The success of this project demonstrated the feasibility of a simulationbased
approach. Currently, the Center provides simulation-based service to all the
iron ore mining companies operating in northern Minnesota, and future proposals
are pending with non-taconite mineral processing applications.
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Final Report, October 1, 2002 -December 31, 2006
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Mittal Steel USA - Minorca Mine Inc., (aka: ISPAT INLAND MINING COMPANY)
5910 Old Hwy. 53, PO Box 1, Virginia, MN 55792; University of Minnesota Duluth, Natural Resources Research Institute,
Coleraine Minerals Research Laboratory, PO Box 188, One Gayley Avenue, Coleraine, Minnesota 55722
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Bond, William M; Ersayin, Salih. (2007). Improving Taconite Processing Plant Efficiency by Computer Simulation. Retrieved from the University Digital Conservancy, https://hdl.handle.net/11299/193686.
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