JK Drop Weight Tester Training

Three Day Training Program for Metso

1. THEORY: Introduction to the JK Drop Weight Tester

2. PRE-PRAC: Conducting the JK DWT & SMC Test
3. PRAC: Using the JK DWT
• Safety and Pre Start
• Sample Preparation and Testing
• Data Entry
• Review

Delivered by Tyson Cronin

1. Introduction to the JK Drop Weight
Tester (DWT)

• Distribution
• 3 Generations of Breakage Devices
• Advantages
• Why the JK DWT?
• When to use the JK DWT?
• Types of tests
• Parameters measured
 DWT Distribution

Canada (4) Russia (3)

UK (1)
USA (5)
China (5)

DRC (1) Indonesia (2)

Peru (2)
Brazil (2) Botswana (1)
South Africa (5) Australia (9)
Chile (7)
3 Generations of Breakage Devices
First Generation Breakage
Device - Pendulum Tester
Non-stretch Rigid Frame
rope
Input
Pendulum
Rebound
Pendulum

Laser Source Release Pulley

Fins
and Detector and Rope
 Pendulum Tester
• A particle is placed on the rebound pendulum.

• The input pendulum is released from a known height.

• The rebound pendulum’s motion is measured.

• The energy balance is calculated for each particle break.

• The size distribution was measured for the broken particles.

• Finally, breakage models were developed using the data obtained.

 Second Generation
Device –
Drop Weight Tester
•The pendulum is turned on its side

•The rebound pendulum becomes fixed or immovable by

being attached to a 1m3 concrete block which is also fixed
to the ground

•It’s decided that the coefficient of restitution or rebound

off the anvil is insignificant.

•Finally, the maximum energy can be increased to 50kg

from height of 1.0m
 Third Generation Device
Rotary Breakage Tester - RBT
•The particles are inserted through a vertical
shaft on the lid of the device.

•The particles are ‘thrown’ by the rotor against

the internal wall of RBT.

•The particle velocity is proportional to the

speed of the rotor.

•The impact energy is calculated from the

velocity of the Particle.

•The breakage energy = particle mass x

(Velocity)²
 Advantages
Advantages of JK DWT
• The device is mechanically simple.

• The maximum energy allows for bigger

particles (50kg from 1.0m)

• The minimum energy allows for a greater

range of particles to be tested (2.5kg from
0.1m)

• The device enables you to generate JK

SimMet parameters & SMC DW Indices
which assist in developing simulation
models to improve SAG/AG mill
performance or crusher performance.
Advantages of
RBT.
• The device enables you to conduct
more breakage tests in less time.

• The Particles are broken with same

energy parameters.

• Testing on small particles down to

9.5mm is possible.

• The device can provide extremely

valuable data when applied to more
recent geometallurical test protocols
that are being offered to the mining
industry.
Why JK DWT?

• The JK-DWT provides ore specific

parameters for use in the JKSimMet
Mineral Processing Simulator software
• These parameters are combined with
equipment details and operating conditions
to analyse and/or predict SAG/AG mill
performance
• The JK-DWT provides ore type
characterisation data for JKSimMet crusher
model
• Finally, the JK-DWT can help in determining
ore characterisation parameters which
assist in making crushing and grinding
decisions.
 When to use JK DWT?

• In Greenfield or existing operations to determine breakage parameters of an ore

under SAG/AG milling conditions so that the circuit can be designed, optimised or
analysed for a range of operating conditions.

• To determine the parameters for a new or existing crusher, for design or

optimisation using JKSimMet crusher model

• When a number of SMC tests are to be done on an ore body. The DWT on the same
sample provides the best correlation for the ore body profile.
 Types of tests

• Standard JK Drop Weight test.

• SMC Test

• Both tests are used for ore characterisation for simulation and optimisation of
crushing and grinding circuits.
 Parameters measured

• The 3 parameters relevant to AG/SAG milling are A, b and ta

• A and b are used to characterise the impact breakage of the ore, ta is used to
measure resistance of the ore abrasion. In both cases the lower the value the
greater the resistance of the ore to that type of breakage.
• ta or abrasion (low energy) is determined by a tumbling test.
• A and b or Impact (high energy) is determined by the high impact breakage of a
particle from the DWT.
• All three parameters can be used in JKSimMet
• In JKSimMet the parameters are combined with equipment details and operating
conditions to model SAG/AG mill performance, the same details are used for
JKSimMet crusher model.
2. Conducting the JK Drop Weight Test
(DWT) & SMC Test

• DWT
– Safety
– Prerequisites
- Sample
- Equipment
– Impact & abrasion testing
– Outcomes & data entry
• SMC Test
Safety

The JK Drop Weight

Tester has the
potential to inflict
serious injury if
misused or not
maintained to a
safe operating
condition.
 Drop Weight Tester Safety

• Each Laboratory must evaluate the hazards and risks associated with using a
Drop Weight tester and ensure the appropriate controls are put in place i.e.
Safe Work Method, Isolation Procedure, Maintenance checks etc...

• All operators of the DWT must undergo training before using the device.

• All operators must show they are aware of the hazards and risks involved in
operating the machine and they must adhere to the SWM.

• The DWT must always be maintained and kept in a safe working condition.
 Drop Weight Tester Safety
Dust Particles

• The generation of dust creates the risk of the operator inhaling hazardous fibres
from the particles being tested.

Recommended controls to put in place are as follows:

• Ensure you have full knowledge of the sample composition.

• Ensure dust extraction is fitted to the unit or at least on in the testing room.
• Set the air gun on a low pressure when cleaning is required to minimise dust being
suspended in the air for too long.
• Ensure a dust mask is used if dust is being generated when dropping.

If the above controls are followed the dust risk level is low.
 Drop Weight Tester Safety
Noise pollution.

• The noise generated by the weight dropping onto the anvil can become quite loud
when dropping the heaviest weights from the greatest height, this may lead to
hearing damage over time.

Recommended controls to put in place are as follows:

• Any person operating the machine must wear hearing protection i.e. Ear plugs, ear
muffs etc...
• Any person working close by when the machine is in use must also wear hearing
protection.

If the above controls are followed the noise risk level is low.
 Drop Weight Tester Safety
Flying projectiles.

• The force of the weight coming down onto a particle can result in splinters of rock
becoming air born and potentially lodging themselves into a persons eye or skin
resulting in eye damage or cuts and bruises to the body.

Recommended controls to put in place are as follows:

• Every drop weight test is fitted inside a clear Perspex box to eliminate the chances
of the operator coming into contact with the machine at any time during the
dropping process.
• Do not bypass any interlocks on the machine door
• Always wear clear safety glasses

If the above controls are followed the risk of injury from flying projectiles is low.
 Drop Weight Tester Safety
Overexertion or muscle strain

• Overexertion or muscular strain can occur when the operator is changing the drop
weight heads, the head can be almost 50kg when fully loaded with the lead
weights.

Recommended controls to put in place are as follows:

• Operators are encouraged to remove the lead weights from the drop weight head
before removing the entire drop weight head from the Drop Weight Tester.

If the above controls are followed the risk of overexertion or muscular strain is low.
 Drop Weight Tester Safety
Working at height.

• To adjust the drop height the operator must use a ladder or a step to measure and
make the adjustment on the unit. It’s imperative that the operator securely
position the ladder or step to prevent over balancing and falling.

Recommended controls to put in place are as follows:

• All operators must be made aware of the risks of using a step ladder or a step.

If the above awareness training is provided the likelihood of a fall from a height is low
 Drop Weight Tester Safety
Crush/pinch points

• If the drop weight falls onto an operators hands or arm the risk of severe injury
such as amputation or broken bones is very high.

Recommended controls to put in place are as follows:

• All operators must be aware of how to do a pre-start inspection before using the
unit.
• An Interlock on the access door must be fitted and in a working order.
• The safety stop must move into place before the door will open.
• All operators must place particles on the anvil with tongs and remove broken
fragments with a long handled brush.
• At no time should an operator have their hands under the weight or on the anvil if
the weight is in the “ready to drop position”

If the above precautions are followed the likelihood of severe injury is low.
DWT Prerequisites
•100kg of ore sample
•5 different size fractions to
be broken at 3 different
energy levels per fraction
•An abrasion test
•A relative density test
•Size distribution
Size Range and Breakage Energy
 DWT Sample Requirements
DWT Sample Requirements.
• At least 60 kg of minus 100+12 mm rock.
• A 100 kg sample is preferred.
SMC Sample Requirements.
• Small quantities (a few kilograms).
• A 30- 40 kg sample is preferred.
• Core or Rock
DWT & SMC - Equipment
DWT & SMC - Equipment
DWT & SMC - Equipment.
Impact Breakage Testing & Abrasion
Testing
 Impact Breakage
Testing
• Each size fraction is broken at three
energy levels, giving fifteen
size/energy combinations
• All breakage products for each
size/energy combination are sized.
The t10 value is based on the original
particle size and interpreted from the
particle size distribution.
• JKTech uses the percentage passing
one-tenth of the original size, known
as the t10
 Impact Breakage Testing
• For each size fraction the original particle size is estimated by the geometric mean of
the size range eg. -63 x +53 = √3339 = 57.8 (round up to nearest 0.1)
• This enables a set of t10 and Ecs values to be produced for the 15 size/energy
combinations. The following equation relates to the amount of breakage, t10, to the
specific energy, Ecs (kWh/t)

t10 =A(1-e-bEcs)
• Using the 15 energy/size combination data values, the best fit A and b parameters are
calculated using a minimisation or error squared.
• The A and b parameters are related to the resistance of the ore to impact breakage
• The product of A*b, which represents the slope of the curve at an Ecs of 0 kWh/t, is a
measure of the ore impact breakage resistance and is used for comparison with other
samples with lower values indicating harder ore in term of impact breakage.
 Abrasion
Breakage Testing
• Abrasion breakage testing is
characterised using a tumbling test of
selected single size fractions
• The test tumbles 3kg of -55 + 38mm
particles for 10minutes at 70% critical
speed (53rpm) in a 305mm by 305mm
mill.
• The resulting product is then sized and
the t10 value determined.
• The geometric mean for the original
size -56 + 38 = 45.7mm
• The t10 size is :1/10 x 45.7 = 4.57mm
• The abrasion parameter, tais then
defined as: ta= t10/10
 Outcomes & Data Entry
• The data collected during the JK DWT is entered into the data entry templates to
determine the following:
- Crusher appearance function
- A & b (t10 Ecs plot)
- A & b sizes
- A * b versus size
- Break versus size
DWT Data Entry Templates
 Crusher Appearance Function
Sample 1
100
90
80
t2
Cumulative % Passing

70
60 t4
50
t1
40 0
30 t2
20 5
10
0
0 10 20 30 40 50 60 70
t10

The crusher appearance function allows the other “t” values to be related back to the t10
value, allowing characterisation of the full PSD from the t10 value.

The crusher appearance function is used in JKSimMet

 A & b (t10 Ecs plot)
Sample 1 Weighted Fit
100 63 x 53
A = 65.0, b = 0.53 and Axb = 34.5 (Wtd Fit)
90 45 x 37.5

80 31.5 x 26.5

22.4 x 19
70
16 x 13.2
60
t10 (%)

50

40

30

20

10

0
0 0.5 1 1.5 2 2.5 3 3.5 4
Ecs (kWh/t)
 A & b Sizes
Sample 1
60
A = 65.0, b = 0.53 and Axb =
50
63 x 53
40
45 x 37.5
30
t10

31.5 x 26.5
20
22.4 x 19
10
16 x 13.2
0
0.0 1.0 2.0 3.0 4.0
Ecs

Predicted t10 values derived from the A and b values for each particular size fraction.

The A and b values are particle size dependent and the final A and b are for the average
particle size

Curves should be in order from largest to lowest fraction

 A*b versus size
Sample 1
50
45
40
A x b Impact Parameters

35
30
25
20
15
10
5
0
0 10 20 30 40 50 60 70
Particle Size (mm)

Shows trend in A*b with particle size

 Break versus Size
Sample 1
100
90 2.5
80 1.0
70
0.25
60
t10 (%)

50
40
30
20
10
0
10 20 30 40 50 60
Particle Size (mm)

T10 trend with particle size, shown for 3 energy levels

Slope should increase with energy, however it’s not unusual for this trend to not be
followed especially as you hit a limiting value for the 2.5 energy level
SMC Test
Size Range and Breakage Energy
Breakage Testing
• 5 energy levels for 1 size fraction.
• Product Sizing only at one sieve size, i.e. t10
size.

Size Range Energy kWh/t

31.5 – 26.5
22.4 – 19.0 0.25 0.5 1.0 2.5 3.5
16.0 – 13.2
 SMC Test
SMC Test Results.
• DWi ‘Drop Weight Index’
• T10-Ecs results which are used to derive the
DWi, along with other parameters; A, b & Mi

60

50

40
t10

30

20

10

0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5
Eis
SMC Test Data Entry Template –
Calculates Test Conditions, Check
List, Work Sheets, Result Entry
SMC Test – Sample Preparation

Cut Core Pieces or Crushed Rock Test Particles

SMC Test - Sample Preparation.
Cut Core Method
 SMC Test
SMC Test Output.
• DWi Drop Weight Index
• DWi used to predict
comminution circuit
throughput for a given ore
• A large number of SMC
tests & Bond Ball Mill WI
tests used to profile ore
bodies
• Report issued by JK Tech.
 SMC Testing and Reporting
Protocol
Steps
• Client sends sample to Licensed Laboratory
• Licensed Laboratory Conducts SMC Test.
• Lab sends results file to JK Tech.
• JK Tech QC data check.
• SMCT conducts Data Analysis & compiles Report.
• JK Tech issues SMC Report to Lab.
• Licensed Laboratory issues report to client
3. Practice Using the JK Drop Weight
Tester (DWT)

• Safety and Pre Start

• Sample Preparation and Testing
• Data Entry
• Review