Evaluation of conventional and emerging geometallurgical models for specific energy prediction in a Brazilian gold mine
Lorena Campolina Milan Lucrécio; Leonardo Junior Fernandes Campos; Andreia Bicalho Henriques; Douglas Batista Mazzinghy
Abstract
Geometallurgy integrates geological, mining, and metallurgical information to improve operational predictability and support mine planning. In comminution, productivity models are used to estimate throughput and specific energy consumption based on ore characteristics. Traditionally, the Bond Work Index (BWi) is employed for this purpose; however, its applicability to SAG-Ball mill circuits is limited. This study compares conventional and recent geometallurgical models for predicting specific energy consumption in a Brazilian gold operation using operational data collected between January and July 2023. The evaluated approaches included the Bond, Bond (Valle), SMC, SPI-based, operational throughput models, and a new proposed model. Model performance was assessed using statistical metrics and the percentage of predictions within ±10% of the measured values. The SPI (2001) + Bond model achieved the best overall performance, with 81.9% predictions falling within the acceptance interval, followed by the new proposed model (78.7%). The results demonstrate that local calibration has a greater influence on predictive accuracy than the complexity of the model, highlighting the importance of calibrated geometallurgical models for improving performance forecasting and mine planning.
Keywords
References
1 Schneider C. Geometarlurgia, mineração de precisão e sustentabilidade. Revista Mineração e Sustentabilidade. 2014:Volume 1:46-47.
2 Montoya-Lopera P. Geometallurgical Mapping and Mine Modelling - Comminution Studies: La Colosa Case Study, AMIRA P843A [thesis]. Hobart, Tasmania, Australia: University of Tasmania; 2014.
3 Coward S, Vann J, Dunham S, Stewart M. The primary-response framework for geometallurgical variables. In: Seventh International Mining Geology Conference. Melbourne: AusIMM; 2009. p. 109-144.
4 Dominy SC, O’Connor L, Parbhakar-Fox A, Glass HJ, Purevgerel S. Geometallurgy: a route to more resilient mine operations. Miner. 2018;8(12):560.
5 Lishchuk V, Koch P-H, Ghorbani Y, Butcher AR. Towards integrated geometallurgical approach: critical review of current practices and future trends. Minerals Engineering. 2020;145:106072.
6 Morales N, Seguel S, Cáceres A, Jélvez E, Alarcón M. Incorporation of geometallurgical attributes and geological uncertainty into long-term open-pit mine planning. Minerals (Basel). 2019;9(2):108.
7 Madenova Y, Madani N. Application of gaussian mixture model and geostatistical co-simulation for resource modeling of geometallurgical variables. Natural Resources Research. 2021;30(2):1199-1228.
8 Moraga C, Kracht W, Ortiz JM. Process simulation to determine blending and residence time distribution in mineral processing plants. Minerals Engineering. 2022;187:107807.
9 Morrell S. A global and mining industry perspective of the role of comminution in the 1.5C future. In: Proceedings of the 2023 SME Annual Conference & Expo; Denver, CO. Englewood, CO: SME; 2023.
10 Fuerstenau DW, Abouzeid AZM. The energy efficiency of ball milling in comminution. International Journal of Mineral Processing. 2002;67(1-4):161-185.
11 Fuerstenau DW, Lutch JJ. The effect of ball size on the energy efficiency of hybrid high-pressure roll mill/ball mill grinding. Powder Technology. 1999;105(1-3):199-204.
12 Lopez P, Reyes I, Risso N, Momayes M, Zhang J. Machine learning algorithms for semi-autogenous grinding mill operational regions’ identification. Minerals (Basel). 2023;13(11):1360.
13 Jeswiet J, Szekeres A. Energy consumption in mining comminution. Procedia CIRP. 2016;48:140-145.
14 Wills BA, Napier-Munn TJ. Mineral processing technology: an introduction to the practical aspects of ore treatment and mineral recovery. 8th ed. Oxford: Butterworth-Heinemann; 2016.
15 Bond FC. The third theory of comminution. Trans AIME. 1952;193:484-494.
16 Morrell S. An alternative energy-size relationship to that proposed by Bond for the design and optimization of grinding circuits. International Journal of Mineral Processing. 2004;74(1-4):133-141.
17 Peche RV. A new general formula to predict the specific energy of grinding in ball mills and vertimills. In: IMPC2020 Congress; 2020; Cape Town, South Africa. South Africa: SAIMM; 2020. p. 658-669.
18 Peche RV. Innovación de la predicción de energía específica de conminución y determinación de su eficiencia energética relativa. In: III Congreso Internacional sobre la Reducción del Tamaño de los Minerales; 2022 Dec 1-2; Lima, Perú. Lima: InterMet; 2022.
19 Doll A. Workindex comminution activity [Internet]. LinkedIn; 2022 [cited 2026 Jun 2]. Available at: https://www.linkedin.com/posts/alex-doll-66b57465_workindex-comminution-activity-6935422189697470464-JLCm/
20 Doll A. Comminution grindability SMCTest activity [Internet]. LinkedIn; 2024 [cited 2026 Jun 2]. Available at: https://www.linkedin.com/posts/alex-doll-66b57465_comminution-grindability-smctest-activity-7152238024792121344-7hB0/
21 Starkey J, Dobby G. Application of the Minnovex SAG Power Index at five Canadian SAG plants. In: Mular AL, Barratt DJ, Knight DA, editors. Proceedings of the International Conference on Autogenous and Semiautogenous Grinding Technology (SAG ’96); 1996; Vancouver, Canada. Vancouver: University of British Columbia; 1996. p. I-345-I-360.
22 Dobby G, Bennett C, Kosick G. Development of a SAG Power Index (SPI®) calibration for design and forecasting of SAG milling performance. Toronto: MinnovEX Technologies Inc.; 2001. Technical report.
23 Campos LJF, Silva PH, Mazzinghy DB, Tavares LM, Campos PHA, Galery R. O índice de trabalho de Bond para moagem de bolas (BWI) é uma variável aditiva? In: Anais do 28º Encontro Nacional de Tratamento de Minérios e Metalurgia Extrativa; 2019; Belo Horizonte, MG. Belo Horizonte: ENTMME; 2019. p. 4-8.
24 Tavares LM, Kallemback RDC. Grindability of binary ore blends in ball mills. Minerals Engineering. 2013;41:115-120.
25 Gomes MP, Tavarez L Jr, Nunes ES, Colacioppo J, Jankovic A, Valery W. Optimization of the SAG mill circuit at Kinross Paracatu Brazil. In: Proceedings of Comminution ’10; 2010 Apr 13-16; Cape Town, South Africa. Falmouth: Minerals Engineering International; 2010. p. 298-311.
26 Kinross Brasil Mineração. Dados experimentais de SMC. Paracatu (MG): Kinross Brasil Mineração; 2017. Technical report.
27 Global Mining Guidelines Group. Determining the Bond efficiency of industrial grinding circuits [Internet]. Toronto: Global Mining Guidelines Group; 2021 [cited 2026 Jun 2]. Available at: https://gmggroup.org/wp-content/uploads/2024/07/GUIDELINE__Determining-the-Bond-Efficiency-of-Industrial-Grinding-Circuits_2021.pdf
28 Global Mining Guidelines Group. The Morrell method to determine the efficiency of industrial grinding circuits [Internet]. Toronto: Global Mining Guidelines Group; 2021 [cited 2026 Jun 2]. Available at: https://gmggroup.org/wp-content/uploads/2024/07/GUIDELINE_The-Morrell-Method-to-Determine-the-Efficiency-of-IndustrialGrinding-Circuits_2021-1.pdf
Submitted date:
06/23/2026
Accepted date:
08/01/2026
