Mineral Processing & Extractive Metall. Rev.

, 36: 7182, 2015

Copyright # Taylor & Francis Group, LLC
ISSN: 0882-7508 print/1547-7401 online
DOI: 10.1080/08827508.2013.868348

Scenario-Based Multi-Objective Genetic Algorithm

Optimization of Closed Ball-Milling Circuit of Esfordi
Phosphate Plant
A. FARZANEGAN1 and Z. S. MIRZAEI2
1
School of Mining, College of Engineering, University of Tehran, Tehran, Iran
2
Department of Mining, Faculty of Engineering, University of Kashan, Kashan, Iran

The main goal of this article is to demonstrate an approach based on integration of process simulation and Multi-Objective Genetic
Algorithm (MOGA) concepts to solve a real grinding circuit optimization problem by nding the best operating condition under
which process objectives can be achieved. Esfordi phosphate plant is located near city of Bafgh at Yazd province of Iran and
produces 5 Mt of phosphate annually. The ne particles (nearly
20 mm) in hydrocyclone underow which contain a high grade
of iron are subjected to over grinding. In addition to electrical energy loss, this causes problems in the downstream process, i.e., o-
tation stage. The main goals of this study were to solve this problem by adjusting operating condition so that (a) hydrocyclone over-
ow particle size can be increased from 94.2 mm to 100 mm and (b) increase hydrocyclone underow particle size from 205 to 500 mm.
The second process objective will decrease ne particles in hydrocyclone underow stream. First, plant sampling campaigns were
carried out to calibrate ball mill and hydrocyclone models to be used for performing simulation trials. Then, full circuit simulations
were done and optimized by MOGA search process to nd the best operating condition that produces hydrocyclone overow and
underow streams with predened particle sizes simultaneously. The results indicate that there are various solutions that can
be recommended for plant testing and performance improvements. The results of plant implementation of one solution for scenario
No. 4 showed improved circuit performance and also validated simulator predictions.
Keywords: comminution, esfordi phosphate plant, MOGA, multi-objective genetics algorithm, simulation

Introduction On the other hand, with advances in computing hardware,

Background
Optimization techniques target improving plant performance
through better utilization of energy and equipment. Gener-
ally, optimization is realized as better yields of valuable pro-
ducts (or reduced yields of contaminants), reduced energy
and reagent consumption, higher production rates, and fewer
shutdowns. In mineral processing plants, off-line and on-line
optimization methods have been applied to comminution
circuits consisting of crushers, mills, and classication sys-
tems to improve operation performance in terms of energy
consumption, throughput, and product size. Mathematical
modeling and its application in simulation and optimization
of mineral comminution systems have been an active research
area in mineral processing since decades ago (Epstein 1948;
Lynch et al. 1977, Guillaneau et al. 1995; Napier-Munn
et al. 1996; Austin, Klimpel and Luckie 1984; Herbst et al.
1973; King 2001).
Address correspondence to Z. S. Mirzaei, Department of
Mining, Faculty of Engineering, University of Kashan, Kashan,
Iran. E-mail: a.farzanegan@ut.ac.ir
Color versions of one or more of the gures in the article
can be found online at www.tandfonline.com/gmpr.
mainly central processing units and memory resources, there
had been a lot of progress in numerical search algorithms
and methods applied for solving optimization problem.
Traditional search algorithms have been used in mineral pro-
cessing software such as USIM PAC (Caspeo 2004) which
allows simulation-based design and optimization of commi-
nution circuits. However, mineral processing software such
as JKSimMet (Napier-Munn et al. 1996) or MODSIM (King
2001) still lacks integrated search algorithms for parameter
adjustment and optimization and their application is limited
only to process simulation.
Combining process simulation and numerical optimiza-
tion algorithms provides a more powerful tool for mineral
processors to nd the best circuit design and operation
parameters. In recent decades, Genetic Algorithm (GA) has
been applied as a powerful numerical search method to solve
optimization problems in various engineering elds. GA was
introduced by Holland (1975). Also, in mineral processing,
there had been several reports on using GA in plant optimiza-
tion studies (Huband et al. 2005; Biswas, Chakraborti, and
Sen 2009; Hasanzadeh and Farzanegan 2011). Nevertheless,
various benets of GA as a search tool and its incorporation
in comminution simulation and optimization software still
remain to be realized by mineral-processing researchers.
72
Farzanegan (1998) developed Ball Milling Circuit
Simulator (BMCS) in C language to simulate a ball mill in
closed circuit with a hydrocyclone. BMCS has been expanded
to simulate various processing units used in comminution
circuits and presently it includes ball mill, rod mill, HPGR
(Hasanzadeh and Farzanegan 2011), vibrating screen, air
separator, efciency curve, junction, split, and convergence
modules. After incorporating new modules to the software,
its name was modied and changed to BMCS-base Modular
Comminution Simulator (BMCS). In a previous research,
Farzanegan and Vahidipour, 2009, also imported BMCS into
MATLAB and linked it to GA toolbox of MATLAB to dem-
onstrate single optimization of a simple ball milling circuit.
Through tness function script, GA toolbox can call BMCS
simulator seamlessly for repeated grinding circuit simulation
and therefore searching for the best operating condition in
order to achieve predened process objectives.
Esfordi Phosphate Plant
Esfordi mine is the main phosphate producer in Iran
(Dehghani et al. 2012). The phosphate ore processing plant
is located at the mine site in central Iran. As it is shown in
Figure 1, the comminution circuit in Esfordi phosphate plant
is consisted of a rod mill in open circuit and a ball mill in
closed circuit with a hydrocyclone. The rod mill ground
product is discharged to a collection sump. The discharge
of rod mill will be mixed with the discharge of the ball mill
to form the feed to the hydrocyclone. The classied coarse
particles report to the hydrocyclone underow which enters
the ball mill for size reduction. The classied ne particles
report to hydrocyclone overow stream which will be fed
to downstream desliming hydrocyclone package.
Problem Statement
The ne particles (
20 mm) in hydrocyclone underow con-
tain a high grade of iron which is subjected to overgrinding
and cause some problems in the downstream process, i.e.,
otation stage. Therefore, the rst process objective was set
Fig. 1. Comminution circuit of Esfordi phosphate plant.
A. Farzanegan and Z. S. Mirzaei
as adjusting operating condition so that the d80 of overow
can be increased to 100 mm from current value of 94.2 mm.
The second objective was set as adjusting operating condition
so that the d80 of underow can be increased to 500 mm from
the current value of 205 mm. The considered process objec-
tives clearly dene a multi-objective optimization problem
with conicting objectives.
The main goal of this article is to fully demonstrate appli-
cation of linking a comminution circuit simulation algorithm
with the genetic algorithm to solve a real multi-objective
grinding circuit optimization problem. This research was
focused on optimization of the ball mill circuit of Esfordi
phosphate plant by combining of a grinding circuit simula-
tion algorithm with Multi-Objective Genetic Algorithm
(MOGA) under MATLAB1 (The MathWorks Inc. 2008)
environment.
Theory
Ball Mill Model
The applied model for ball mill in this software needs values
for breakage function, selection function and residence time
distribution which is Weller model (Weller 1980).
h i
md T I Sss
2 I Ssl
1 exp
Sspf T
1 mf 1
T is a square matrix which is calculated based on grinding
model parameters as follows:
ti;j 0; i < j
ti;j si ; i j
2
1 X i
1
ti;j bi;k sk tk;j ; i > j
si
sj k1
in where ti, j is a general entry of matrix T which is calculated
based on bi, j, noncumulative breakage function when a
particle breaks from size class j into size class i and si, selec-
tion function of size class i.
Scenario-Based Multi-Objective Genetic Algorithm Optimization of Closed Ball-Milling Circuit of Esfordi Phosphate Plant
md is a column matrix dening the particle size
distribution of discharge stream (percent retained), T is the
matrix dened by T
1[B
I]ST
S equation, B is a lower
triangular matrix dening the breakage function I is Identity
matrix, is a diagonal matrix dening the selection function, ss
is mean residence time of small perfect mixer unit in Wellers
model, sl is Mean residence time of large perfect mixer unit in
Wellers model, spf is Residence time of plug ow unit in
Wellers model, and mf is a column matrix dening the par-
ticle size distribution of feed stream (percent retained).
Hydrocyclone Model
Hydrocyclone underow particle size distribution and ow
rate are calculated based on Eq. 3 and hydrocyclone feed
data:


 
di m
Ri Rf 1
Rf  1
exp
0:693 3
d50c
in where di is the particle size ith size class, Rf is the recovery
of feed water to underow, d50c is corrected cut size, and m is
sharpness of classication. The three parameters Rf, d50c, and
m are estimated based on Plitts model (Plitt 1976). Particle
size distribution of hydrocyclone overow, then, is calculated
based on hydrocyclone feed data and hydrocyclone under-
ow particle size distribution calculated using Eq. 3.
Multi-Objective Genetic Algorithm and Grinding Simulation
MOGA was introduced by Fonseca and Fleming (1993). In
many real world optimization problems, there are multiple
Fig. 2. Flowchart of MOGA algorithm with links to grinding simulation algorithm implemented in BMCS.
73
conicting objectives which must be achieved simultaneously.
In these cases, unlike single-objective genetic algorithm, there
is no single point as optimal solution and a family of points
represents the solution which is called Pareto-optimal set or
front. A Pareto-optimal front includes nondominated (non-
inferior) solutions at which the value of no objective function
can be improved without sacricing in some of the other
objective values.
Figure 2 shows how MOGA is linked with BMCS which
includes the algorithm for simulation of comminution cir-
cuits. Briey, MOGA generates a population of simulation
inputs and calls BMCS to simulate circuit performance based
on given input. BMCS performs circuit simulation and
generates the output result which is returned to the MOGA
for population evaluation.
Materials and Methods
Circuit Sampling
Samples were collected from various points of circuit every 10
minutes during a three-hour period. The samples were ana-
lyzed to obtain particle size distributions, weight, and percent
solids. In next stage, the obtained data set was subjected to
mass balance process by NORBAL software (Spring 1992).
Laboratory Tests
All collected samples except the one for rod mill feed were
slurry samples. Screen analysis tests were carried out to deter-
mine particles size distribution for each sample. The solids
content of all samples were also determined and recorded.
74 A. Farzanegan and Z. S. Mirzaei

The breakage distribution function of Esfordi phosphate

ore for all particle sizes reported by Dehgahni Ahmadabadi
et al., 2007 were used in present research as a required ball mill
model parameter. The authors also performed breakage dis-
tribution function determination tests for two particle sizes,
i.e., 600 and 212 mm. The grinding tests were done using a lab-
oratory ball mill with no lifter bars (Table 1). Then, breakage
function values were estimated using three methods: Berube
(Hodouin, Berube, and Everell 1978), Herbst and Fuerstenau
(Herbst and Fuerstenau 1968), and modied Herbst and
Fuerstenau methods (Herbst and Fuerstenau 1968) based
on laboratory grinding data. These breakage function esti-
mation methods have been implemented in BFDS (Breakage
Function Determination Software) computer program writ-
ten in Del language (Youse, Irannajad, and Farzanegan
2005). Breakage function values estimated using above-
mentioned methods were then tted using the model given
in Eq.4 proposed by Broadbent and Callcott (1956):
Bi1 U  RC 1
U  Rb 4 in this research.
In where, U, C, and b are model parameters and R is
the ratio of lower limit of size class i and the lower limit of
the rst size class.
The breakage distribution function measured by modied
Herbst and Fuerstenau method for 600 and 212 mm particle
sizes in both previous and present researches are shown in
Figure 3. Since there was a close agreement between breakage
functions obtained in both researches, the breakage distri-
bution function matrix reported by Dehghani Ahmadabadi
et al. was therefore used in simulations performed by authors.
The details of ore breakage function tests and procedure used
to compute breakage distribution function based on grinding
tests results has been discussed in Mirzaei (2011) and
Dehghani Ahmadabadi, Noaparast, and Shafaei (2007).
The selection function was estimated using Numerical
Grinding Optimization Tools in C (NGOTC) software based
on breakage distribution function, Wellers RTD (Residence
Time Distribution) model parameters (Esfordi Phosphate
Plant Process Division, private communication), particles
size distributions of ball mill feed, and discharge data. Based
on population balance model of continuous grinding process
in a ball mill, NGOTC back-calculates selection function
Fig. 3. The breakage distribution function of 212 and 600 mm
mono-sized samples for previous research (Dehghani
Ahmadabadi, Noaparast, and Shafaei 2007) and present research.
values for all particle size classes using a binary interval by
interval search. The details can be found in Farzanegan,
1998. Figure 4 shows the back-calculated mill selection func-
tion used in subsequent simulation and optimization studies
It is noted that BMCS simulation predictions using
estimated parameters, i.e., ore breakage function, selection
function, and RTD data was validated against various
measured data explained in Mirzaei (2011).
Scenarios and Operating Condition Design Space
Considering available choices for hydrocyclone underow
and overow diameters, four combinations were considered
as optimization scenarios (Table 2). Since hydrocyclone
underow and overow diameters have signicant effects
on particle size classication and comminution circuit perfor-
mances, plant operation must be adjusted accordingly.
Therefore, plant operating condition was planned to be opti-
mized under four scenarios by MOGA. The design space,
which must be searched for optimal state of operating con-
dition variables, was dened based on circuit ow sheet given
in Figure 1. Design space includes four continuous variables
(a) solids ow rate to the ball mill circuit, (b) solids content of
fresh feed to ball mill circuit, (c) water addition ow rate to
the hydrocyclone feed, and (d) water addition ow rate to
ball mill feed. In each scenario, the design space will be
explored by MOGA to nd the optimal values of variables.
As MOGA optimization should be done under various

Table 1. Specication of laboratory ball mill used for breakage

function determination tests
Property Value

Mill length (mm) 200

Internal mill diameter (mm) 205
Mill rotational speed (rpm) 55
Mill critical speed (rpm) 98.6
Ratio of mill speed to critical speed (%) 55.7
Mill lling (%) 1015
Number of 31, 21, and 17.5 mm 70, 50, and 20,
grinding balls respectively Fig. 4. Mill selection function back-calculated by NGOTC.
Scenario-Based Multi-Objective Genetic Algorithm Optimization of Closed Ball-Milling Circuit of Esfordi Phosphate Plant 75

Table 2. Optimization scenarios dened based on choices due to limited capacity of the hydrocyclone feed sump, an
of hydrocyclone overow and underow diameters upper boundary equal to current value (50 m3=h) was also
considered to prevent sump overowing. Variable x4 is water
Scenario No. DOF (cm) DUF (cm)
addition to the hydrocyclone underow or ball mill feed.
1 20.32 7.62
2 20.32 10.16 MOGA Optimization
3 22.86 7.62
4 22.86 10.16 Considering variable boundaries, MOGA was used to
optimize circuit operating condition based on various
boundaries settings or constraints (Figure 5).
Table 3. Operating condition variables dening design space

Range Results and Discussion

Lower Upper
Based on screen analysis tests and mass balancing particle
Variable boundary boundary size distribution and ow rate of various streams were
determined. The d80 of each stream is shown in Table 4.
Solids ow rate, x1 (t=h) 45 inf The circulating load was calculated 471.7% at steady state
Solids content, x2 (%) 45 65 which is much higher than its design value (150%).
50 65 The particle size distribution of streams around the hydro-
Water addition to hydrocyclone 40 50 cyclone, ball mill feed, and discharge is shown in Figure 6. It
sump, x3 (m3=h) 40 69 is noticeable that the particle size distribution of hydrocy-
Water addition to ball mill 25 45 clone underow (ball mill feed) is very close to hydrocyclone
sump, x4 (m3=h) feed, which implies unsatisfactory performance of hydrocy-
clone due to poor classication.
Figure 7 shows actual and tted hydrocyclone efciency
constraints, the lower and upper boundaries of all variables curves. It is observed that actual efciency curve displays a
were dened by consulting plant personnel. high slope followed by a plateau between 50 and 90 mm which
Boundaries of operating condition design space variables is unusual. According to mineralogical studies, Esfordi
are shown in Table 3. These boundaries are constraints on phosphate ore contains two major components: uorapatite
search variables. Variable x1 is solids rate to the ball mill cir- as light component and hematite as heavy component
cuit, currently about 45 t=h. While practically there is a limit (Figure 8). The unusual shape of the hydrocyclone efciency
for circuit throughput, however no upper boundary was con- curve was attributed to the existence of two light and heavy
sidered for this variable. From plant operating point of view, components in hydrocyclone feed. It is noted that exact
a throughput higher than current throughput (lower bound- calculation of d50c was not possible due to unusual shape of
ary) probably indicates a better operating situation. Variable the curve.
x2 is weight percent solid of fresh feed to the ball mill circuit To assess the performance of comminution circuit, the
that was set between 45% and 65%. During several MOGA operating condition at present situation was compared with
optimization executions, it was observed that this variable is the operating condition suggested in design specication.
always adjusted at lower boundary. Therefore, to ensure The purpose of this comparison is to obtain sufcient criteria
appropriate rod mill performance, another lower boundary
setting equal to 50% was also considered.
Variable x3 denotes water addition to the hydrocyclone Table 4. Particle size d80 of various circuit streams,
feed. It is possible to set this variable to 69 m3=h. However, reduction ratio of mills and Plitts model parameters
Stream d80 (mm)

RMF 9835.04
RMD 209.52
BMF 205.89
BMD 189.40
CYCF 195.10
COF 98.15
CUF 205.89
Reduction ratio Current Past
Rod mill 46.98 64.65
Ball mill 1.08 1.15
Parameter Value
Fig. 5. Tree representation of all possible MOGA optimizations Recovery of uid to underow (Rf) 0.34
for each scenario considering boundaries settings of operating Corrected cut size (d50c) 51.74
condition variables x1, x2, x3 and x4. Sharpness of classication (m) 1.50
76
Fig. 6. Particle size distributions of streams around the hydrocy-
clone, ball mill feed, and discharge.
Fig. 7. Esfordi hydrocyclone classication efciency curve (Ri:
Recovery of solid to the cyclone underow for particle in size
class i).
Fig. 8. XRD analysis of plant feed.
A. Farzanegan and Z. S. Mirzaei
for circuit optimization. In order to obtain a complete
understanding of current comminution circuit performance,
because rod mill discharge forms fresh feed to ball mill
circuit, present operating condition of rod mill was also
compared with design base. So an increase in discharge solid
content (from 30 to 66.5) and a decrease in fresh feed solid
ow rate (from 57.5 to 47.10) were observed.
Under current operating condition, following problems
were identied during various investigations and process
analyses:
. Inefcient comminution in ball mill unit
. Inefcient classication in hydrocyclone unit
. High solids content of hydrocyclone feed
. Existence of ne particles in hydrocyclone underow
. Increased ne particles containing iron in hydrocyclone
overow which causes inefciency in downstream otation
process
The existence of two components in plant feed is the basic
reason for these problems. In hydrocyclone unit, the ne par-
ticles of heavy component, i.e., hematite, enter the hydrocy-
clone underow stream and increase the circulating load
and solids content of ball mill feed. The particles containing
iron should be much ground to become sufciently light to
enter hydrocyclone overow stream. Therefore, these particles
are subjected to overgrinding and consequently ne particles
with a high grade of iron will be produced. In addition, simul-
taneous increase in ball mill feed solids content and feed rate
leads to inefcient grinding of coarse particles. Also, the lim-
ited capacity of hydrocyclone feed sump makes it impossible
to add more water to increase the hydrocyclone feed dilution.
The rst process objective was set to increase the d80 of
underow to 500 mm from the current value of 205 mm. The
second process objective therefore was set to adjust the d80
of overow at 100 mm instead of current 94.2 mm. Increase
Scenario-Based Multi-Objective Genetic Algorithm Optimization of Closed Ball-Milling Circuit of Esfordi Phosphate Plant 77

in circuit throughput was also of interest simultaneously. Table 5. Comparison of present ball mill and hydrocyclone
Hence multi-objective optimization was sought to ensure operating condition and Bond work index with design
simultaneously achieving main process objectives dened specication
above at the same circuit throughput or at a higher value.
Ball mill, work index
The dened process objectives are obviously in conict to
each other. An increase in the d80 of hydrocyclone underow Parameter Design Present
is associated with a decrease in d80 of hydrocyclone overow.
For this reason, MOGA generates a Pareto-optimal front Slurry ow rate to closed circuit (t=h) 46 61.50
which displays a decreasing second tness function vs. rst Feed size, d80 (mm) 75 205.89
tness function curve. It is, therefore, necessary to select Product size, d80 (mm) 100 189.40
an appropriate point on the Pareto-optimal front by con- Circulating load ratio (%) 150 471.41
sidering the relative importance of process objectives. In Reduction ratio 7.5 1.08
the following sections, the results of MOGA optimization Bond work index 7.50 9.47
for each scenario obtained under various boundaries settings Hydrocyclone
Feed solids ow rate (t=h) 172.50 232.28
of variables are explained.
Feed slurry ow rate (m3=h) 260.10 202.78
Cut size (mm) 100.00 51.47
Scenario No. 1 Hydrocyclone overow size, d98 (mm) 150.00 175.72
MOGA was applied to nd the optimal values of design Hydrocyclone feed solids content (%) 45.00 63.00
space variables under this scenario. Considering boundaries Hydrocyclone overow solids content (%) 25.00 30.70
settings of variables given in Figure 5, four Pareto-optimal Hydrocyclone underow solids content (%) 75.00 81.10
fronts and four sets of optimized variables were obtained.
In Figure 9 Pareto-optimal fronts corresponding to all
boundaries settings of variables are shown. In these plots, given. Simulated optimal particle size distributions of ball
a curve has been tted to the optimal non-dominated points mill feed and discharge and streams around the hydrocyclone
to predict the value of second tness function based on the for the best values of rst and second tness functions
value of rst one. In these plots, the horizontal axis shows applying the rst boundary compared with actual data are
the value of tness function related to rst objective function shown in Figures 1013.
(achieving d80 of underow equal to 500 mm) and the vertical Among these variables, it is seen that x4 has sharp
axis shows this value for second objective function (achiev- changes through the optimization. It is clear that the values
ing d80 of overow equal to 100 mm). It is clear that the best are reasonable and practical.
condition is obtaining the minimum of these functions sim- Considering Figure 10, Figure 12, and Table 8, it is clear
ultaneously. that in optimal condition, ball mill will act more effectively
In Table 7, the optimal and real values of operating than before. The circulating load decreases and weight
condition variables and corresponding tness functions are percent solid of streams is in normal ranges. Finally, increase

Fig. 9. Pareto-optimal fronts obtained for scenario No. 1 (a) rst boundaries settings, (b) second boundaries settings, (c) third
boundaries settings, and (d) fourth boundaries settings.
78 A. Farzanegan and Z. S. Mirzaei

Table 6. Ball mill and hydrocyclone physical specications

Ball mill

Parameter Value

Discharge type Grate

Motor power (kW) 315
Mill length (m) 3
Mill Diameter (m) 2.4
Hydrocyclone
Hydrocyclone diameter (cm) 50
Apex diameter (cm) 10.16, 7.62
Fig. 10. Real and simulated optimal particle size distributions of
Vortex nder diameter (cm) 22.86, 20.32
ball mill feed and discharge generated by applying the rst
Inlet diameter (cm) 17.52
boundaries settings of variables for the best value of rst tness
Height (cm) 180
functions.
Pressure (bar) 0.6

in d80 of underow stream cause to decrease in ne particles.

According to Figure 14, the abnormal shape of curve has
changed into an S shape. So the existence of two compo-
nents in feed can be overcome by adjusting operating
conditions.
All these information can be extracted from optimization
results for any groups of answers.

Scenario No. 2
In this scenario, the value of rst and second tness function
varies in range of 195225 and 110210, respectively. In com-
pare with the results obtained for other scenarios, these
values suggest that the combination of a diameter size of
Fig. 11. Real and simulated optimal particle size distributions of
streams around the hydrocyclone generated by applying the rst
boundaries settings of variables for the best value of rst tness
functions.

Table 7. The optimal and real values of operating condition 20.32 cm for hydrocyclone overow and a diameter size of
variables for the best values of rst and second tness functions 10.16 cm for hydrocyclone underow is the worst case scen-
by applying the various boundaries settings of variables ario which cannot satisfactorily achieve process objectives.
(scenario No. 1)
Scenario No. 3
Real values
Application the rst boundaries settings of variables, the
x1 x2 x3 x4 values of the rst and second tness function vary in range
47.08 62.60 69.80 35.00
First boundaries
x1 x2 x3 x4 F1 F2
Fitness function #1 49.28 63.58 42.18 26.37 74.47 87.42
Fitness function #2 45.53 50.40 65.82 25.75 151.53 0.00
Second boundaries
x1 x2 x3 x4 F1 F2
Fitness function #1 54.13 64.97 41.98 26.19 61.45 117.07
Fitness function #2 45.14 45.10 49.81 25.19 144.00 0.64
Third boundaries
x1 x2 x3 x4 F1 F2
Fitness function #1 48.18 64.74 40.31 25.66 69.22 96.82
Fitness function #2 45.04 50.29 48.81 25.79 128.59 8.94
Fourth boundaries Fig. 12. Real and simulated optimal particle size distributions of
x1 x2 x3 x4 F1 F2 ball mill feed and discharge generated by applying the rst
Fitness function #1 54.30 64.94 40.50 26.44 58.52 125.21 boundaries settings of variables for the best value of second
Fitness function #2 45.03 50.30 66.11 28.01 155.75 0.00 tness function.
Scenario-Based Multi-Objective Genetic Algorithm Optimization of Closed Ball-Milling Circuit of Esfordi Phosphate Plant 79

Fig 13. Real and simulated optimal particle size distributions of

streams around the hydrocyclone generated by applying the
rst boundaries settings of variables for the best value of second Figure 14. Esfordi hydrocyclone classication efciency curve
tness function. according to data related to best value of rst tness function
(ri: recovery of solid to the cyclone underow for particle in size
class i).
of 35140 and 1600, respectively. By applying the second
boundaries settings of variables, the values of rst and
second tness functions vary between 30140 and 0160, tness function varies from 0 to 65. When MOGA optimiza-
respectively. In Pareto-optimal front produced by applying tion is done by applying the second boundaries settings of
the third boundaries settings of variables, the value of the variables, the values of the rst and second tness functions
second tness function could not get close to zero. vary between 115180 and 850, respectively. Also, applying
the third boundary leads to produce a value for rst tness
function between 125 and 170 and second tness function
Scenario No. 4 between 12 and 75.
Finally, the Pareto-optimal fronts for this scenario produced
with various boundaries settings of variables. In this Pareto,
the rst tness function varies from 128 to 195 and the second Plant Scale Verication
It is noted that during sampling, hydrocyclone overow and
underow diameters had been set to 20.32 and 10.16 cm (scen-
Table 8. Circuit parameters for the best value of rst and second
ario No. 2), respectively. As mentioned above, scenario No. 2
tness functions (scenario No. 1)
is the worst case scenario for achieving process optimization
First tness Second tness objectives. Hence, based on GA search results, it was decided
Parameter function function to practice scenario No. 4 in order to improve circuit perfor-
mance. To verify predicted grinding circuit performance
Stream d80 (mm) d80 (mm) under optimal operating condition found by GA search and
FF 264 264 automated simulation trials, the best series of parameters
BMF 396 294 obtained from scenario No. 4 (for second boundaries settings
BMD 238 208 of variables) was applied in Esfordi plant. Theoretically, there
CYCF 252 235
are innite numbers of solutions on Pareto-optimal front to
COF 126 100
choose from for plant testing purposes. Considering the
CUF 396 294
Reduction ratio
higher importance of rst process objective, the set of operat-
Ball mill 1.66 1.41 ing variables corresponding to a nondominated solution
Hydrocyclone parameters which minimizes the rst objective function was selected.
d50c (mm) 142.00 103.00 The suggested (optimal) and applied values of parameters
P (kPa) 30.45 49.48 are shown in Table 9.
S 0.13 0.12
m 3.60 3.53
Table 9. Suggested and applied operating parameters for
Rf 0.05 0.03
optimization
Weight percent solid
Stream Suggested Applied
FF 63.58 50.40 Parameter value value
BMF 52.28 61.63
CYCF 45.12 39.89 Circuit solid fresh feed (t=h) 47 47
COF 33.74 25.03 Fresh feed solid (%) 47 47
CUF 87.11 92.53 Additive water to cyclone feed (t=h) 67.6 11.6
Circulating load 70.00 104.35 Additive water to ball mill feed (t=h) 28 45.2
80 A. Farzanegan and Z. S. Mirzaei

Table 10. Circuit parameters for simulated optimal and real The measured and calculated circuit parameters are shown
conditions in Table 10. Generally speaking, it can be concluded that
circuit performance has been modied and it is now closer
Parameter Simulated optimal Real
to predened objectives. However, in some cases there are
Stream d80 (mm) d80 (mm)
noticeable differences between predicted and real values
FF 192.00 192.00 due to various reasons. These are mainly attributed to the
BMF 235.00 265.00 ner feed from rod mill discharge (Figure 15) inadequate
BMD 191.00 208.00 regulation of water addition ow rates to cyclone and ball
CYCF 191.00 203.00 mill feeds when grinding circuit performance was tested
COF 95.00 112.00 under scenario No. 4.
CUF 235.00 265.00 In Figures 16 and 17, the particle size distribution of
Reduction ratio streams around the ball mill and hydrocyclone are compared
Ball mill 1.23 1.27 for optimal and executed values. It can be clearly observed
Hydrocyclone parameters that measured particle size distributions of hydrocyclone
d50c (mm) 89.00 112.00 underow (or ball mill feed) and overow streams are differ-
P (kPa) 52.45 33.97 ent from predicted ones while particle size distributions of
S 0.22 0.25 ball mill discharge and hydrocyclone feed streams are very
m 3.04 3.06 close to predicted values. Real (measured) particle size distri-
Rf 0.11 0.14 butions of hydrocyclone overow and underow streams
Weight percent solid
both are ner than predicted (simulated) particle size distri-
Stream
bution, which is attributed to ner feed to ball milling circuit.
FF 47.00 47.00
BMF 57.25 73.50
CYCF 39.52 65.80
COF 24.03 30.00
Conclusions
CUF 77.16 84.60 Unlike single objective optimization in which only one
Circulating load (%) 132.00 537.00 solution is found as an optimal operating condition point,
in multi-objective optimization a Pareto-optimal front is
produced on which any point can be considered as an optimal
operating condition. On any Pareto-optimal front, an operat-
ing point can be selected then according to the importance of
one grinding process objective verses the other one. It was
observed that end points on Pareto-optimal front plots rep-
resent optimal solution if only one of the process objectives
is considered to be optimized. In fact, these points are the
same points when considering just one of the process objec-
tives in single GA optimization. The middle points on
Pareto-optimal fronts represent an optimal solution when
both process objectives are of equal importance.
Generally, it was observed that scenario No. 2 causes a
decrease in comminution circuit efciency. The results show
that the hydrocyclone pressure will be reduced increasingly
and a good particle size classication will not occur. In order
to adjust plant practice based on operating condition sug-
Fig 15. Comparison of Rod mill discharge particle size gested by a point on a Pareto-optimal front, some criteria
distribution before and after shift to scenario No. 4. must be considered. In addition to the tness function value,
cumulative percent passing from 100 mm in hydrocyclone

Fig 16. Comparison of simulated and real particle size distributions of ball mill feed and ball mill discharge.
Scenario-Based Multi-Objective Genetic Algorithm Optimization of Closed Ball-Milling Circuit of Esfordi Phosphate Plant
Fig 17. Comparison of simulated and real particle size distributions of streams around the hydrocyclone.
overow stream, ball mill feed solids content, cumulative
percent passing from 74 mm in hydrocyclone underow
stream, and volumetric ow rate of hydrocyclone feed must
be considered as criteria for evaluating the results.
The results of plant implementation of a selected
nondominated solution proposed by GA search for scenario
No. 4 showed improved performance with regard to prede-
ned process objectives. The results also generally validated
simulator predictions.
Acknowledgment
The authors thank members of process division of Esfordi
phosphate plant for their sincere cooperation and numerous
help during plant visits and samplings.
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