SAG mill ball charge determination and its influence on ...

In semi-autogenous grinding (SAG), the grinding mill inventory, (i.e. volume of total charge, volume of ball charge, etc.) is important in determining the optimum operating condition for maximum production (tph), minimum specific energy (kwh/t) or lowest cost ($/t). A two-dimensional graphical method is presented for determining the actual ball charge within …

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Advanced Simulation for Semi-Autogenous Mill Systems: A ...

The model output variables are: power-draw, load level, ball load, mineral discharge rate and size distribution, water discharge rate, ball throughput, bearing pressure, pebble throughput, and toe and shoulder angles of the internal load. 2.1 SAG mill model The particles fed to the mill are ground in the milling chamber and subsequently

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AMIT 135: Lesson 6 Grinding Circuit – Mining Mill Operator ...

SAG Mill Circuit Example — Gold Processing SAG mill circuit example for gold processing [image: (135-6-3)] AG/SAG Mill. AG/SAG mills are normally used to grind run-off-mine ore or primary crusher product. Wet grinding in an AG/SAG mill is accomplished in a slurry of 50 to 80 percent solids. 2D and 3D simulations of particles in a SAG Mill

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Improving Energy Efficiency in Barrick Grinding Circuits

The discovery of excess mill pooling in the SAG mill prompted a review of the "pumping" capacity of the SAG mill. The excess slurry pool inhibited grinding and caused unnecessary power draw on the mill with the internally recirculating slurry. Crash stop …

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Dynamic modeling and simulation of a SAG mill for mill ...

The modeling and simulation of semiautogenous (SAG) mills have been widely used in the design and optimization of mill performance in terms of its power draw, processing capacity and product size distribution. However, these models are solved under steady approximation and do not provide any information on mill charge distribution in real time. This …

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Grinding Mill Computer Model

Approximate mill diameter is derived from: Power =5.*6115 DL24. 6* La= * D where a is the aspect ratio L/D derived from a regression equation on 25 manufacturers' mill size and power relationships For SAG mills the equation becomes Power=(5.6115+%balls*0.1438)*D24. 6* L Mill Critical speed Crit Crit D = 42.3 n - revs per min nC= s*Crit Cs is ...

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Mill power draw models - SAGMILLING.COM

You must manually check the motor's tent diagram to confirm that the predicted power draw is actually within the motor's capability at the indicated speed. Liner and grate design. The design of mill liners and SAG mill discharge grates will have a large effect on how efficiently the mill operates and the circuit throughput.

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Polycorp - Services

We perform power calculations for maximum power draw for Ball Mill liners for maximum throughput. Process Review. Study of slurry flow from SAG/AG mills for slurry pool or slurry flow back issues for mill throughput improvement. Study of …

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CMD Consulting uses Rocky DEM power calculations to ...

SAG mill design CDM Consulting used to test Rocky DEM power draw Empirical Model Rocky DEM Model Figure 1 - Morrell C-model for mill power draw Rocky calculations for power draw were shown to accurately replicate Morrell's C-model for power draw, an increasingly critical component in mill design validation

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AG/SAG/Ball Mill

AG/SAG/Ball Mill Sizing. Gross Power Draw and Specific Energy Calculator for Autogenous Grinding (AG), Semi-Autogenous Grinding (SAG) and Ball Mills. Exit Mill Calculator.

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Optimization of mill performance by using

Mill power Usually, plant operators use mill power readings as an indicator of ball filling degree and, often, try to keep it at the maximum level. It is well known that the mill absorbed power depends on operating parameters other than ball level, such as pulp density and liner configuration. Figure 2 shows that there is no linear relation between

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Autogenous and Semi-Autogenous Mills - ScienceDirect

AG/SAG Mill Power. In designing crushing–grinding flow sheets, correct estimations of mill power draw are important as it serves as one of the deciding factors for selecting an option between AG/SAG mills. In most cases, the circuit with the least or optimal power consumption is the preferred choice.

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Publications - SMC Testing

Power Draw Of Wet Tumbling Mills And Its Relationship To Charge Dynamics - Part 1 A Continuum Approach To Mathematical Modelling Of Mill Power Draw Power Modelling Of Stirred Mills Predicting The Overall Specifcie Energy Requirements Of AG SAG Ball Mill And HPGR Circuits On The Basis Of Small Scale Laboratory Ore Characterisation Tests

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The engineering and process effects of choosing a motor ...

The SAG mill power draw model of Austin (using the cali-bration by Doll, 2013) is used to predict the process power draw at the mill shell, Pshell, and the efficiency losses for the drive's mechanical components based on Doll (2012) are used to determine the motor output power, P. The effect of varying the mill speed as a fraction of the critical

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Mill drives: the desire for increased power and the ...

SAG mill drives (as GMDs) by some operators and principal motor designers/manufacturers until the reasons for known problems in design or manufacturing were better understood and resolved. Accordingly, the latest 40 ft dia. SAG mill is rated at 29 MW and 78% C.S., with a 42 ft dia. mill built but not yet operational. The more recent option

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SAG Mill Grinding Circuit Design - 911metallurgist.com

SAG mills have a higher installed power density for a given plant footprint relative to AC mills. With the combination of finer grind and a lower installed power density (based on the lower density of the mill charge), a typical AG mill has a lower throughput, a lower power draw, and produces a finer grind.

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Evolution of SAG Mill Process Control at the Xstrata ...

- Mill power and bearing pressure indication - Flotation Feed assays : Cu, Ni, Fe ... shown in Figure 1, and included the SAG mill itself, a new oversize recycle Crusher, a double ... - Mill motor current draw and winding temperatures.

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SAG Mill Liner Selection to Maximise Productivity

Optimising SAG mills • Objective – Optimised load – Increased liner life – Increased throughput / flowrate – Optimise power draw = increase throughput • Limitations – Structural load limit – Noise impact limit • Restricted by shell liner design Lifters + liners = protects the shell from wear Charge (mill load) = rocks + steel ...

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TECHNICAL NOTES 8 GRINDING R. P. King

approach to modeling of mill power draw. Trans. Instn. Mining. Metall. (Sect C:Mineral Processing Extr Metall.) 105, January-April 1996 ppC54-C62. Austin LG A mill power equation for SAG mills. Minerals and Metallurgical Processing. Feb 1990 pp57-62. Gross power No load power Net power drawn by the charge (8.13) The net power is calculated from ...

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final project report

the SAG mill is drawing approximately 236-kW less power than before while maintaining the same level of production. In the first month there was extreme cycling and operators had to learn more. However, the power consumption is 0.3-1.3 kWh / ton lower than before. The actual SAG mill power draw is 230-370 kW lower.

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Size Reduction and Energy Requirement - ScienceDirect

SAG power index (SPI) and SAGDesign tests. During operation of SAG mills it is often found that the power draw as calculated by conventional methods does not agree with the power draw found in practice. This difference has been attributed to the variation of ore hardness as received from a mine.

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An improved method for grinding mill filling measurement ...

Abstract The fraction of mill volume occupied by rocks, grinding media and slurry in grinding mills are dominant factors influencing AG and SAG mill power draw and grinding rate. Hence accurate mill filling measurements are needed for modelling mills. To that end, it is usually necessary to enter the confined space of a grinding mill, a task that involves a degree of …

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ore processing sagmilling draw power optimization

SAG Mill power draw models are used in mill design and grinding circuit modelling to predict how much power will be consumed by a particular mill geometry and operating configuration. This paper will compare SAG mill models by Morrell, Loveday (using "Power Numbers" published by Barratt) and Austin against several published mill surveys.

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MILLING CONTROL & OPTIMISATION - Mintek

close to the maximum mill power draw. The power-load relationship ... Figures 8 and 9 on the right show results from a gold plant's SAG mill achieved with MillStar's Segregated Ore Feed Controller ... Mill Power Optimisation results for Case Study 2 Figure 9: Feed Control Distribution for Case Study 2.

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A comparison of SAG mill power models

SAG Mill power draw models are used in mill design and grinding circuit modelling to predict how much power will be consumed by a particular mill geometry and operating configuration. This paper will compare SAG mill models by Morrell, Loveday (using "Power Numbers" published by Barratt) and Austin against several published mill surveys.

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THE ENGINEERING AND PROCESS EFFECTS OF CHOOSING A …

The SAG mill power draw model of Austin (using the calibration by Doll, 2013) is used to predict the process power draw at the mill shell, Pshell, and the efficiency losses for the drive's mechanical components based on Doll (2012) are used to determine the motor output power, P. The effect of varying

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Model Predictive Control - Rockwell Automation

may be measured in SAG mill circuits and used for control purposes: The weight of the ore and water needs to be controlled within the accepted operating range – too high and the mill becomes inefficient, too low and the autogenous effect is not used properly. Water addition is an important variable for control of mill power draw.

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Metcom Training

Mill Power Draw To determine mill power draw characteristics and capabilities for rod, ball and AG/SAG mills. $139: none: 2.50: 3. Mill Power and Charge Level Measurements To determine the actual mill power draw and volumetric load of your mill from plant readings and measurements. $139: 2: 2.50: 4. ...

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Application of Operating Work Indices in Autogenous ...

WAG/SAG, WBM are the respective power draw of AG/SAG and ball mills. Note that the ball mill operating work index is applied only on the portion that needs the additional grinding (Q2), which renders to the AG/SAG mill the credit for the fraction of the material that had been already ground to final product (Q1).

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OSTI.GOV Technical Report: Improving Energy Efficiency Via ...

Depending on the mill size the SAG mills draws between 2 MW and 17 MW. The product from the SAG mill is further reduced in size using pebble crushers and ball mills. Hence, typical gold or copper ore requires between 2.0 and 7.5 kWh per ton of …

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Modelling SAG milling power and specific energy ...

the mill power and the efficiency of the mill operation (Van Nierop and Moys, 2001). If a SAG mill has been designed with a conventional power or specific energy model which do not con-sider the projected feed size distribution it is likely that this mill will reach the expected power consumption but will not satisfy

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Dynamic Modeling and Simulation of SAG Mill Circuits …

where two SAG mill power models are developed. The first model calculates the mill power draw by combining several individual data-driven algorithms. The second model uses historical data to forecast the mill power draw in advance. These data-driven methods can make high

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Membership functions for SAG mill feed power draw ...

As an example, consider Figure 4 which shows MFs for SAG mill power draw as an input variable for fuzzy system. Five linguistic expressions …

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SAGMILLING.COM

SAG mill power draw models are used in mill design and grinding circuit modelling to predict how much power will be consumed by a particular mill geometry and operating configuration. The importance of conducting surveys suited to model calibration …

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MODULE #5: FUNCTIONAL PERFOMANCE OF BALL MILLING

Figure 2 illustrates that the total mill power draw multiplied by the classification system efficiency is the effective mill power draw *. The effective mill power draw is the power draw that is applied to the grinding of coarse particles. Figure 2. The "effective mill power draw". Now let's see how the remaining two terms, ore grindability and ...

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An improved method for grinding mill filling measurement ...

The fraction of mill volume occupied by rocks, grinding media and slurry in grinding mills are dominant factors influencing AG and SAG mill power draw and grinding rate. Hence accurate mill filling measurements are needed for modelling mills. To that end, it is usually necessary to enter the confined space of a grinding mill, a task that involves a degree of safety risk and a …

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Optimizing your SAG mill operation - International Mining

It is imperative to ensure the efficient removal of both slurry and coarse pebbles (critical size) in order to ensure the efficient operation of AG/SAG mills. Elimination of the above mentioned material transport problems will allow the mill to respond truly in terms of power draw for changes in mill load which depends on feed ore characteristics.

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and sizing of sag mill

For example, the SAG mill may have 10 MW of power draw available and the two ball mills each of 7.5 MW of power draw available for a total of ratio of 10:15 (1:1.5). Publications | Starkey and Associates Inc. · A RAPID SAG MILL GRINDABILITY AND MILL SIZING ANALYSIS PROGRAM by John Starkey, Jenna Hedderson, and Spencer Reeves ...

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