### Chapter - M MODELLING, SIMULATION, OPTIMIZATION

proposed flowsheet consists of existing SAG mill circuit followed by a new proposed ball mill in closed circuit with the existing hydrocyclone package. In all simulations, SAGT, CYCL and MILL models were selected to simulate SAG mill, Hydrocyclone packages and ball mill units. SAGT and MILL models both are based on the population balance model ...

### Minerals | Free Full-Text | Optimizing Performance of SABC ...

The final plan was to increase the ball charge in the SAG and ball mill to 10% v / v and 27% v / v, respectively; set the upper limit of the operating power in the ball mill to 5800 kW; use a TRIO TC Series crusher (without a power-/feed rate–controlling device, but with a feed bin) to crush pebbles for recirculation back to the SAG mill feed ...

### SIPS2015 - Ball Mill Simulation with Moly-Cop Tools

This work aims to optimize the ball mill in the plant 47 of Anglo American Phosphate Catalao-GO Company through simulations using the Moly-Cop optimization tools, and thereby improving energy consumption and grinding results. From real data supplied by company, the parameters of breakage and selection functions were obtained using the Moly-Cop ...

### SAG Mill Ball Size Evaluator | Evaluation Factors ...

The load of 4″ balls in this SAG is "good" but un-measured. SAG Ball consumption is "average" at 400 g/t while Ball Mill grinding media (3″ balls) …

### SAG Mill Ball Size Evaluator | Evaluation Factors ...

The SAG Mill has a "small" circulation load of oversize given be the 3/8″ trommel screen and the 1/2″ x 1 1/4″ discharge grates. The load of 4″ balls in this SAG is "good" but un-measured. SAG Ball consumption is "average" at …

### SAG Mill - Official Feed The Beast Wiki

The SAG Mill is a machine added by Ender IO.It uses Micro Infinity (µI) to grind (or mill) items into their crushed variants, like Ores into Dusts.The SAG Mill has four output slots; recipes can have 1-4 different outputs, with different chances of obtaining those outputs. Uniquely, the SAG Mill can use Grinding Balls made from various materials to increase energy efficiency …

### C O N S U L T I N G L T D TECHNICAL MEMORANDUM

The Bond-based method applied by Barratt involves deducting a SAG mill specific energy consumption, ESAG, from the overall circuit specific energy consumption, Etotal, with the difference being the ball mill specific energy consumption, Ebm. One of the advantages of this approach is it accounts for the tendency for SAG mills to make

### MILLING CONTROL & OPTIMISATION - Mintek

Figures 8 and 9 on the right show results from a gold plant's SAG mill achieved with MillStar's Segregated Ore Feed Controller combined with the Power Optimiser: • The standard deviation of the mill feed control is greatly reduced. • The cyclone feed is more stable, allowing for consistent size separation and feed to downstream processes.

### Benchmarking: Specific Energy Consumption Models ...

The throughput determined by the ball mill treatment rate is 710 t/h, versus observed 734 t/h (model is 3% conservative). Show details of benchmarking. Benchmarking: Bond/Barratt Single Stage SAG model Circuit Specific Energy Consumption - Yanacocha

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

The standard method for sizing secondary ball mills (usually the overflow type) in AG/SAG circuits follows published mill supplier information with aspect ratios in the range 1:1.5 to 1:2.0, depending upon product sizing and pulp flow, i.e., the highest expected circulating loads (Morrell, 2001). The applied net power, calculated from testwork

### What's the Difference Between SAG Mill and Ball Mill ...

The biggest characteristic of the sag mill is that the crushing ratio is large. The particle size of the materials to be ground is 300 ~ 400mm, sometimes even larger, and the minimum particle size of the materials to be discharged …

### Ball Charge and Grinding Efficiency - Grinding ...

I totally agree with you that the low charge rate directly affects the grinding efficiency, but in here there is another thing we have, that shouldn't be overlooked, it is the power consumption, at low charge rates below 20% the power consumption increase by 6-15% for the ball mills. (unknown) 6 years ago Like

### (PDF) Power Draw of Grinding Mills - its Measurement and ...

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.

### AUTOMATION ADVANCED CONTROL EXPERT (ACE)

• Increased SAG mill throughput by 13.5% and reduced energy consumption per tonne by 9.3% Location: Minera Los Pelambres Mine • Reduced feed variability by 5.6% • Increased SAG mill throughput by 5.9% and reduced energy consumption per tonne by 5.4% SAG Mill ACE BENEFITS • Automatically account for changes in variation

### Grinding Balls For Ball Mill_Goldpro

Therefore, compared with the SAG mill, the diameter of ball mill,the particle size and the ball size is smaller;the running speed is relatively decreased and the filling rate is higher. The grinding balls mainly impact and grind minerals by cascading, and can't discharge unless the balls reach the specified size,which required high wear ...

### Sino Grinding | Grinding Media Design, Manufacturing ...

Superior Performance. Our SAG mill & ball mill media are designed and optimized for our customers' milling environments to improve steel consumption, wear rates, throughput and grind. Tell me more about SGI's products…. 7. SAG Mill Grinding Media Designs. 5. Ball Mill Grinding Media Designs.

### GrindingExpert™ - WordPress.com

Example Ball Mill GrindingExpert ™Solution The throughput and efﬁciency of a SAG mill depends on the volumetric load: An overloaded mill has reduced coarse ore breakage, as the cascading balls and rock cannot drop far enough, reducing kinetic energy for breakage. An underloaded mill will break coarse ore well, but at the expense of added

### Power-based modelling of single-stage AG and SAG mill …

WiBM is the Bond ball mill work index, unitless CFnet is an empirical adjustment to a ball mill circuit [CFnet = 2.35 - 0.29 × ln(P80)] Morrell Mi model: Morrell (2008) published a two-parameter model based on two equations (3 & 4) to describe a variety of comminution devices, including single-stage SAG and AG mills. The CEE

### Wear and Failure Analysis of Semi-Autogenous Grinding Mill ...

Grinding is one of the most important and expensive steps of mineral processing. Therefore, different types of grinding mills such as rod mills, ball mills, semi-autogenous (SAG) mills and autogenous (AG) mills can be utilized for comminution of mineral ores [].Up to today, SAG mills and AG mills have been widely used to reduce operation costs and increase …

### A Method to Determine the Ball Filling, in Miduk Copper ...

one SAG mill (9.75 dia.(m)*3.88 length(m)) following two parallel ball mills (5dia.(m)*7lenght(m)). The aim of this research work was to investigate on the ball filling estimation of Miduk semi-autogenous (SAG) Mill via an utilized method. Miduk SAG Mill circuit is shown in Figure 1. Figure 1: Diagram of Miduk Copper Complex

### Shihab khalifa - Processe plant Responsible - Groupe ...

(Follow up of orders and consumption… Implement of commissioning operation of the plant, treat 5000 TPD with SAG mill, 2 Ball mill, thickener type high rate, seven reactors in CIL unit by volume 28000 meter cubic. Prepare annual, monthly, weekly, …

### Operating work index is not the specific energy consumption

However, Bond Work Indeces are related to the type of equipment to be used (rod mill, ball mill, SAG uses Drop Ball parameter-Kwhr/m3-, so it is more complex than just specific energy consumption ...

### Simulation of a Laboratory Scale Ball Mill via Discrete ...

The simulations of dry mill were conducted by using a standard coefficient of restitution of 0.3 and a friction coefficient of 0.75 (ball-ball and ball-liner collisions) [ 20 ]. The charge consisted of powders and balls with filling of 40% of the charge (by volume). The specific gravity of the media is …

### (PDF) A comparison of wear rates of ball mill grinding media

abrasive and impact wear due to their large. (75 – 100 mm) dia meters. Ball mill balls. experience a greater number of impacts, but at. lower magnitude than SAG mill balls, due t o. the smaller ...

### A Mathematical Model for the Prediction of Large Diameter ...

In the case of SAG mills, where the make-up balls may be as large as 6"f diameter, breakage and spalling mechanisms are significant contributors to total ball consumption, although not to the extent of overriding wear mechanisms.Ball wear has been well characterized by the Linear Wear Theory, as presented at the last CMP 2014.

### Estimating Ball Consumption - Molycop

For an improved understanding, the wear rate constant is directly related to the grinding media consumption rate expressed in grams of steel per kWh drawn by the mill, using the simple expression: where dr represents the diameter of the new make-up balls periodically charged to the mill.

### Orway Mineral Consultants Canada Ltd. Mississauga, ON ...

and ball mills, have almost become obsolete in the move to higher milling rates required to process lower metal grades. Grinding circuits with fully autogenous (AG) or semi-autogenous (SAG) mills, often combined with ball mills are now the standard to meet the high capacity requirement for processing ores with lower metal grades.

### Grinding circuit optimisation to increase throughput and ...

GrindingExpert™ SAG Mill The GrindingExpert solution will automatically adjust feed rate, mill speed and water addition to reduce upsets, eliminate grind-outs and increase tonnage in SAG / ball mills. Secondary grinding can be optimised as well with automation on cyclones and pumps. This grinding expert solution is an add on to LoadIQ. Benefits

### TECHNICAL NOTES 8 GRINDING R. P. King

mill is the energy consumption. The power supplied to the mill is used primarily to lift the load (medium and charge). Additional power is required to keep the mill rotating. 8.1.3 Power drawn by ball, semi-autogenous and autogenous mills A simplified picture of the mill load is shown in Figure 8.3 Ad this can be used to establish the essential ...

### Size Reduction and Energy Requirement - ScienceDirect

A Bond ball mill work index is then performed on the mill product for the design of SAG-ball mill circuits. This is important because it was found that there was a 1–1.5 kWh/t higher ball mill work index if the –3.35 mm ball mill test feed size is obtained by SAG mill grinding compared with crushing.

### SAG Mill Grinding Circuit Design - 911metallurgist.com

SAG circuits may employ low to relatively high ball charges (ranging from 2% to 22%, expressed as volumetric mill filling) to augment autogenous media.

### Toward a Simple Approach Determining Single Stage SAG mill ...

the SAG mill and ball mill depends on the energy requirement between both duties. ... Since the power draw P(kW) is the product of the specific energy consumption (kWh/t) and …

### FREDA REBECCA SAGMILLING CIRCUIT OPTIMIZATION

Installing a 1000kW regrind ball mill increased plant capacity by 56% through treating 29% of the cyclone underflow and reduced the SAG mill specific energy from 20.66 to 16 kWh/t and the investment has a payback period of 1 year and a month, in 10 …

### When Should We Add the Grinding Balls for Ball Mill - Fote ...

Then we can use the result times the daily output of ball mill, the daily consumption of the grinding balls can be obtained. 4. According to the flat surface reduction height of grinding balls in ball mill. ⑴When measuring the inner sphere of ball mill, first we should stop feeding, and stop the ball mill running after 10 minutes.

### SAG Mill Optimization using Model Predictive Control

Control of -SemiAutogenous Grinding(SAG) mill weight is an example of an important process that exhibits many of these aspects. Maintaining the SAG mill weight at the optimum value is critical for achieving maximum grind rate efficiency and mill production (Powell, M.S., van der Westhuizen, A.P., & Mainza, A.N. 2009).

### Energy Efficiency & Copper Hydrometallurgy

SAG mill, ball mill, float, smelt, refine (Base case) HPGR, ball mill, float, smelt, refine SAG mill, ball mill, float, HT Concentrate Leach SAG mill, ball mill, float, MT Concentrate Leach HPGR, ball mill, float, MT Concentrate Leach 47,468 41,169 47,055 45,453 39,186 -13.3% 0.9% 4.2% 17.5% 1 Includes energy for mining through final cathode ...

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