Iron Ore Processing Improvements through Process Modeling and Computer Simulation
2001-06-15
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Iron Ore Processing Improvements through Process Modeling and Computer Simulation
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2001-06-15
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University of Minnesota Duluth
Type
Technical Report
Abstract
In 1997, under the auspices of the Iron Ore Cooperative Research Program, iron ore
mining companies operating on the Iron Range decided to work as a consortium in
establishing expertise in the development of math models of individual taconite
concentration operations and their use to simulate portions of the integrated concentration
process. This led to the establishment in 1998 of the Concentrator Modeling Center
within the Coleraine Minerals Research Laboratory (CMRL) of the University of
Minnesota - Duluth. Following discussions on the type of software to be used by the
Center, Usim Pac, mineral processing software developed by BRGM of France was
selected due to the availability of a larger number of models, and model incorporation
capability to add those to be developed in the future. The Center became fully operational
when Dr. Salih Ersayin started to work as the program director on Nov. 1, 1999.
While the application of modeling and simulation has provided significant benefits in the
processing of base metal ores, its application to the processing of magnetic taconite has
been hindered. This was caused by the need to incorporate the modeling of mineral
liberation into the comminution models for size reduction steps, which occur between
several stages of magnetic separation. An initial effort at integrating the modeling of size
reduction, mineral liberation was carried out by Wiegel1 for the Erie Mining Company
process in 1976. Plant scale implementation of the combined use process modeling and
plant testing was reported for the National Steel Company secondary grinding section
modifications 2 . Recently, Schneider 3 developed a mineral liberation model based on
liberation characterization by scanning electron microscopy measurements. He validated
his model using plant data obtained from the Fairlane Plant of Eveleth Taconite. For
simulation purposes, he integrated his liberation approach into a ball mill grinding model.
He also presented magnetic separator and hydrocyclone model structures compatible with
the type of data produced by the liberation model.
Despite of these developments, there still was a need to develop a simplified approach to
the integrated size reduction/liberation model for taconite processing, models for
magnetic separators, hydroseparators and fine screens, which would take into account the
significant operating and design parameters. Therefore, the initial efforts of the Center
were concentrated on development of simplified integrated mineral liberation/size
reduction and magnetic separator models using funds allocated by the Permanent
University Trust Fund (PUF), while providing a simulation service to taconite plant
operators with the available software. Data from four plants in the Range taken as a part
of an earlier Iron Ore Coop project was analyzed using the existing capabilities of the
software. The data was first mass balanced and performance of individual pieces of
equipment was examined. Results were presented to the plant engineers; their
implications and potential improvements were discussed. To illustrate the capabilities of
the software and potential benefits from the use of simulation, some modifications in
plant flow sheets and operating/design conditions were simulated using the same data as
a basis. These simulation results were also presented to the relevant engineers.
Description
Project #5600114
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Iron Ore Coop; University of Minnesota Duluth, Natural Resources Research Institute, 5013 Miller Trunk Highway, Duluth, MN 55811-1442; Coleraine Minerals Research Laboratory, One Gayley Avenue, Box 188, Coleraine, MN 55722
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Ersayin, Salih. (2001). Iron Ore Processing Improvements through Process Modeling and Computer Simulation. Retrieved from the University Digital Conservancy, https://hdl.handle.net/11299/188406.
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