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Please cite this article as: Narasimha, M., Mainza, A.N., Holtham, P.N., Powell, M.S., Brennan, M.S., A semi-mechanistic model of hydrocyclones -developed from industrial data and inputs from CFD, International Journal of Mineral Processing (2014), doi: 10.1016/j.minpro.2014 This is a PDF file of an unedited manuscript that has been accepted for publication. As a service to our customers we are providing this early version of the manuscript. The manuscript will undergo copyediting, typesetting, and review of the resulting proof before it is published in its final form. Please note that during the production process errors may be discovered which could affect the content, and all legal disclaimers that apply to the journal pertain. A C C E P T E D M A N U S C R I P T ABSTRACTThe flow behavior in hydrocyclones is extremely complex, leading the designers to rely on empirical equations for predicting cyclone performance. A number of classifying cyclone models have been developed and used in mineral comminution circuit simulators in the past. The problem with these empirical cyclone models is that they cannot be used outside the range of conditions under which they were developed. A semi-mechanistic hydrocyclone model is developed using the dimensionless approach based on both the fluid mechanics concepts from

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The application of comminution technology such as the High-pressure grinding rolls (HPGR), which is able to generate a high density of cracks in the ore particles, is favourable for leaching processes. Extraction of metallic values by the heap leach process, can take place on the particles with partial exposure of mineral grains, if it can provide sufficient surface front for chemical attack by leaching solution. The aim of this study was to assess the benefits of high crack density in the ore particles produced using the HPGR and how it could diminish due to inadequate percolation of the leaching agent.A zinc ore was comminuted using HPGR at three different pressure settings and with a cone crusher for the control experiment. Subsamples from the (+23/-25, +14/-16, +5.25/-6.75 mm) size fractions were characterized and packed into leach reactors. The reactors were stopped from time to time to investigate the progress of crack and micro-crack growth and its effect on metal extraction using the X-ray computed tomography (CT). The results are validated with those obtained using traditional techniques such as SEM and QEMSCAN. Investigation of the leach reactors residue indicated significant changes in the particle size distribution (PSD) of initial feed toward the fine size fraction. The residues from the reactors leaching the material prepared using the HPGR product contained more fine particles than the reactors, which were fed by cone crusher product. These differences were up to 10.3%.

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