Application of Taguchi-Based Response Surface Methodology to Optimize Process Parameters for a Small-Scale Wet Ball Mill for Use in Gold Mining

International Journal of Mechanical Engineering

© 2024 by SSRG - IJME Journal

Volume 11 Issue 4

Year of Publication : 2024

Authors : Oklunongnon Augustin Zossou, James Kuria Kimotho, James Wamai Mwangi, Joshua Kimtai Ngoret, Mathew Ndeto Kyalo

10.14445/23488360/IJME-V11I4P101

How to Cite?

Oklunongnon Augustin Zossou, James Kuria Kimotho, James Wamai Mwangi, Joshua Kimtai Ngoret, Mathew Ndeto Kyalo, "Application of Taguchi-Based Response Surface Methodology to Optimize Process Parameters for a Small-Scale Wet Ball Mill for Use in Gold Mining," SSRG International Journal of Mechanical Engineering, vol. 11,  no. 4, pp. 1-10, 2024. Crossref, https://doi.org/10.14445/23488360/IJME-V11I4P101

Abstract:

A ball mill is a machine used in the mining industry to reduce the size of the ore to a desirable size in order to liberate the minerals. Effectively controlling the fineness of a ball mill's product necessitates an understanding of the impacts of various input parameters. In this study, Taguchi-based Response Surface Methodology (RSM) was employed to investigate the impact of feed size, slurry solid content and feed rate on the product’s Particle Size Distribution (PSD) of a small-scale wet ball mill. Taguchi’s L9 orthogonal array was utilized for experimental design to minimize the number of runs, while RSM was applied to optimize the input variables. Additionally, analysis of variance was employed to identify the most significant parameter influencing PSD within the range -150 + 75 µm. The findings revealed that, under the considered levels of the parameters, the average feed size exerted the most significant influence, followed by feed rate and solid content, respectively. The response optimizer indicated that a maximum PSD of 72.24% could be attained by maintaining an average feed size of 7.5 mm, a solid content of 60%, and a feed rate of 0.025 m³/h. The experimental PSD closely matches the predicted value with a 3.01% error, indicating a good fit.

Keywords:

Ball mill, Feed rate, Feed size, Particle size distribution, Solid content, Taguchi-based Response Surface Methodology.

References:

[1] Lorena Guldris Leon, and Magnus Bengtsson, “Selective Comminution Applied to Mineral Processing of a Tantalum Ore: A Technical, Economic Analysis,” Minerals, vol. 12, no. 8, pp. 1-15, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[2] François K. Mulenga, Akhona A. Mkonde, and Murray M. Bwalya, “Effects of Load Filling, Slurry Concentration and Feed Flowrate on the Attainable Region Path of an Open Milling Circuit,” Minerals Engineering, vol. 89, pp. 30-41, 2016.
[CrossRef] [Google Scholar] [Publisher Link]
[3] Barry A. Wills, and James Finch, Wills’ Mineral Processing Technology : An Introduction to the Practical Aspects of Ore Treatment and Mineral Recovery, Elsevier Science, pp. 1-512, 2015.
[Google Scholar] [Publisher Link]
[4] Susan Keane et al., “Mercury and Artisanal and Small-Scale Gold Mining: Review of Global Use Estimates and Considerations for Promoting Mercury-Free Alternatives,” Ambio, vol. 52, no. 5, pp. 833-852, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[5] Szymon Ogonowski et al., “Comparison of Wet and Dry Grinding in Electromagnetic Mill,” Minerals, vol. 8, no. 4, pp. 1-19, 2018. [CrossRef] [Google Scholar] [Publisher Link]
[6] Umirzoqov Azamat, and Abdurashidovich, “Prospects for the Development of Small-Scale Gold Mining in Developing Countries,” International Journal of Academic Multidisciplinary Research, vol. 4, no. 6, pp. 38-42, 2020.
[Google Scholar] [Publisher Link]
[7] Augustine B. Makokha et al., “Optimization of in-Mill Ball Loading and Slurry Solids Concentration in Grinding of UG-2 Ores: A Statistical Experimental Design Approach,” Minerals Engineering, vol. 39, pp. 149-155, 2012.
[CrossRef] [Google Scholar] [Publisher Link]
[8] Ugur Ulusoy et al., “Combination of the Particle Size Distributions of Some Industrial Minerals Measured by Andreasen Pipette and Sieving Techniques,” Particle and Particle Systems Characterization, vol. 23, no. 6, pp. 448-456, 2007.
[CrossRef] [Google Scholar] [Publisher Link]
[9] Halil Dogacan Koca et al., “Effect of Particle Size on the Viscosity of Nanofluids: A Review,” Renewable and Sustainable Energy Reviews, vol. 82, pp. 1664-1674, 2018.
[CrossRef] [Google Scholar] [Publisher Link]
[10] N. Mangesana et al., “The Effect of Particle Sizes and Solids Concentration on the Rheology of Silica sand Based Suspensions,” Journal of the Southern African Institute of Mining and Metallurgy, vol. 108, no. 4, pp. 237-243, 2008.
[Google Scholar] [Publisher Link]
[11] Xiaoling Tian et al., “Study of the Ball Milling Condition Effect on Physicochemical and Structural Characteristics of Wheat Flour,” Journal of Food Processing and Preservation, vol. 46, no. 1, pp. 1-8, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[12] Sina Ghassa et al., “Effects of Flow Rate, Slurry Solid Content, and Feed Size Distribution on Rod Mill Efficiency,” Particulate Science and Technology, vol. 34, no. 5, pp. 533-539, 2016.
[CrossRef] [Google Scholar] [Publisher Link]
[13] Liyuan Liu et al., “Mild Cognitive Impairment Understanding: An Empirical Study by Data-Driven Approach,” BMC Bioinformatics, vol. 20, pp. 1-13, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[14] Bhalchandra K. Vaidya et al., “Enhanced Production of Amidase from Rhodococcus Erythropolis MTCC 1526 by Medium Optimisation Using a Statistical Experimental Design,” Journal of Industrial Microbiology and Biotechnology, vol. 36, no. 5, pp. 671-678, 2009.
[CrossRef] [Google Scholar] [Publisher Link]
[15] Nikolay Vasilev et al., “Structured Plant Metabolomics for the Simultaneous Exploration of Multiple Factors,” Scientific Reports, vol. 6, no. 1, pp. 1-15, 2016.
[CrossRef] [Google Scholar] [Publisher Link]
[16] R. Adalarasan, M. Santhanakumar, and M. Rajmohan, “Application of Grey Taguchi-Based Response Surface Methodology (GT-RSM) for Optimizing the Plasma Arc Cutting Parameters of 304L Stainless Steel,” International Journal of Advanced Manufacturing Technology, vol. 78, pp. 1161-1170, 2015.
[CrossRef] [Google Scholar] [Publisher Link]
[17] Mingzhao He, Yanmin Wang, and Eric Forssberg, “Slurry Rheology in Wet Ultrafine Grinding of Industrial Minerals: A Review,” Powder Technology, vol. 147, no. 1-3, pp. 94-112, 2004.
[CrossRef] [Google Scholar] [Publisher Link]
[18] Aoao Chen, and Qin Zhang, “Influence of Measuring Process Properties on Phosphate Rock Slurry Rheology Based on Brookfield Method,” Physicochemical Problems of Mineral Processing, vol. 58, no. 6, pp. 1-11, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[19] Jyh-Ping Hsu, and Anca Nacu, “On the Factors Influencing the Preparation of Nanosized Titania Sols,” Langmuir, vol. 19, no. 10, pp. 4448-4454, 2003.
[CrossRef] [Google Scholar] [Publisher Link]
[20] H. Bakhsh et al., “Semibatch Emulsion Copolymerization of Butyl Acrylate and Glycidyl Methacrylate: Effect of Operating Variables,” Journal of Applied Polymer Science, vol. 117, no. 5, pp. 2771-2780, 2010.
[CrossRef] [Google Scholar] [Publisher Link]
[21] C. Tangsathitkulchai, “Acceleration of Particle Breakage Rates in Wet Batch Ball Milling,” Powder Technology, vol. 124, no. 1-2, pp. 67-75, 2002.
[CrossRef] [Google Scholar] [Publisher Link]
[22] Hyunho Shin et al., “Effect of Ball Size and Powder Loading on the Milling Efficiency of a Laboratory-Scale Wet Ball Mill,” Ceramics International, vol. 39, no. 8, pp. 8963-8968, 2013.
[CrossRef] [Google Scholar] [Publisher Link]
[23] M.M. Soleymani, M. Fooladi Mahani, and M. Rezaeizadeh, “Experimental Study the Impact Forces of Tumbling Mills,” Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, vol. 231, no. 2, pp. 283-293, 2017.
[CrossRef] [Google Scholar] [Publisher Link]
[24] Diah Kusuma Pratiwi et al., “Investigation of Welding Parameters of Dissimilar Weld of SS316 and ASTM A36 Joint Using a Grey-Based Taguchi Optimization Approach,” Journal of Manufacturing and Materials Processing, vol. 7, no. 1, pp. 1-16, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[25] Mohsin Iqbal Qazi et al., “An Integrated Approach of GRA Coupled with Principal Component Analysis for Multi-Optimization of Shielded Metal Arc Welding (SMAW) Process,” Materials, vol. 13, no. 16, pp. 1-22, 2020.
[CrossRef] [Google Scholar] [Publisher Link]
[26] G. Danha, N. Hlabangana, and E. Muzenda, “Effect of Ball and Feed Particle Size Distribution on the Milling Efficiency of a Ball Mill: An Attainable Region Approach,” South African Journal of Chemical Engineering, vol. 25, no. 1, pp. 79-84, 2018.
[Google Scholar] [Publisher Link]