design processing rates of the Cadia Hill SAG mill circuit and that could be easily manipulated were; SAG Mill Load Ball Charge - SAG mill power draw was guaranteed by the vendor at 13% ball charge and 30% total volume to be 20.96MW for the 40 foot diameter SAG mill. In practice this power draw was never achieved I-14 (Dunne et al 2001).
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feeds the grinding circuit, whi ch consists of a SAG-ball mill-crusher (S ABC) circuit. The circuit differs slightly from a standard SABC flowsheet, with the SAG circuit product classified in its ...
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10%Decreasing ore grades make it necessary to reduce the overall specific energy and water consumption in order to maintain operational economic parity. For a given circuit, an optimal throughput is usually limited by the transport mechanisms in the mill. This is due to the complex rheology of the pulp at high percent solids.
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This included the bench-marking and optimization of the SABC comminution circuit, focusing on the primary (SAG mill) and secondary (ball mill) grinding mills, and estimating the outcomes of changes to circuit operating parameters (e.g., feed rate, mill load, ball charge, etc.). 2. Problem Validation and Analysis
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Powell, Yahyaei, Mainza, Tavares Presented at the AusIMM Mill Operators Conference June 2021 ABSTRACT Maintaining the work balance between the primary SAG mill and secondary ball mill(s) is an overlooked bottleneck, and thus opportunity, in an increasing number of circuits worldwide. As circuit c...
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4. Industrial applications 4.1. SAG mill optimization project The frst example is concerned with the optimization of a SAG mill grinding circuit at a gold operation in the western US. Over 4,000 tpd of ore is ground in a SAG mill-ball mill circuit and then leached by CIL. Profit is very ore tonnage sensitive at this plant.
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Your problem can occur in a SAG Mill or Ball Mill. Other point to consider is the particle size distribution, it is possible to receive a finer ore from the mine and the particle size distribution of the product from the crushing circuit is different, In this case, the residence time in the tumbling mill tend to be shorter.
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The Grinding Circuit Optimization Challenge. The Ball Charge in SAG and Ball Mills, in other words, the fraction of the mill volume constituted by balls, has a significant impact on the performance of a mill and the greater Grinding circuit. Running at the wrong Ball Charge adversely impacts not only throughput but the consistency of the ...
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Sag Mill Drawing. Optimization of mill performance by using - SAIMM, Model Predictive Control for SAG Milling in Minerals Processing Ore from primary crushers is combined with water in the mill where rotation causes the grinding, sagmilling Articl SAG Mill power draw models are used in mill design and grinding circuit modelling to predict how ...
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circuit capacity and feed slurry density. and In the case of SAG mill – ball mill circuits, the fluctuations in tonnage and grind are known to be high. The modelling approach described in this paper allows for changes in the measured flotation kinetic parameters in order to reflect the expected grind as determined by the comminution process.
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The IntelliSense.io Grinding Circuit Optimization application has been piloted at the Aktogay Plant of JSC "AK Altynalmas". A Digital Process Model of the SAG mill was created using first principle modeling and enhanced with machine learning algorithms – the combination which enables improved monitoring, performance prediction, and optimization to increase profitability.
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optimization of the SABC comminution circuit, focusing on the primary (SAG mill) and secondary (ball mill) grinding mills, and estimating the outcomes of changes to circuit operating parameters (e.g., feed rate, mill load, ball charge, etc.).
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Following implementation of these strategies, the SAG mill throughput when treating the harder copper/zinc ores increased from 2,750 tph to an average of 3,600 tph, and the optimization of the overall process improved energy efficiency, resulting in considerably less energy consumption per ton of product.
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optimized the oper ating strategies for the SAG mill circuit at Paracatu op eration in Bra zil. The focus of this project was to reach design t hroughput and final grinding product size, conditions...
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Example of a common multi-stage grind circuit. Optimization of hydrocyclone classification by on -line detection of coarse material in the overflow stream . Jerin Russell*, ... • SAG (Simi-autogenous Grinding) mill grate or trommel panel failure • Hydrocyclone liner/wall failure • Degradation or failure of SAG mill pebble removal
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• Ball Mill Limited: the overall grinding circuit is constrained by the Ball Mill capacity and the SAG mill and Pebble Crusher circuits have spare capacity. This limitation is commonly experienced during the processing of the low grade ores (less than 0.4%Cu). This also confirms theBWi ore hardness – grade correlation.
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The value T80 is the "synthetic" transfer size between the SAG mill and ball mill – a fines-corrected 80% passing size 2 of the SAG mill product (or the combined SAG mill product and crushed pebbles if the circuit is sending crushed pebbles …
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The grinding circuit investigated in the current study is a two-stage grinding circuit in which two overflow type mills are arranged in series and operated under wet condition.The run-of-mine ore was crushed to 10 mm, and it was then fed to the first ball mill, which was closed by a rake classifier.The second mill operated in a combined closed circuit with two cyclones …
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SAG mill discharge slurry flow rates and densities. The implementation of soft sensors to estimate these variables can provide additional information to aid circuit optimization as well as increasing advanced control system availability. The SAG mill charge estimator combines the SAG mill mass
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As a result, mines have shifted their emphasis in optimization from ball mills to SAG mills. The rock load in the mill essentially depends on ore characteristics and the discharge rate of broken particles through the discharge end. The discharge rate depends on how efficiently the discharge pump (grate and pulp lifters) operates.
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Following implementation of these strategies, SAG mill throughput when treating the harder copper/zinc ores increased from a target of 2,750 mt/h in 2007 to 4,000 mt/h in 2009 and 4,400 mt/h in 2010-11. Optimization of the overall process also resulted in less energy consumption per ton of product. Continuous Improvement Delivers Further Benefits
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Autogenous Grinding (SAG) mill in closed circuit with a hydrocyclone package. The gold ... In this research, an optimization study of Aghdarreh plant grinding circuit performance was done to lower the product particle size (P 80) from 70 Pm to approximately 40 Pm by maintaining current throughput using modeling and simulation approach. After ...
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(MPC) is described for a SAG mill circuit in a bauxite processing refinery at Wagerup, Australia (Refs: Gopinath, Mathur et al, 1995 and Le Page, Freeman et al 1996, Luse, Mathur et al 1997). The MPC ... An optimization problem is then set up to …
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The interaction of grinding circuit variations and how these affect the froth flotation process performance need to be understood for proper optimization. Typical disturbances in the grinding circuits are: Mill feed particle size distribution due to crusher circuit operation and bin or stockpile segregation
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Open Circuit Grinding. Open circuit grinding consists of one or more grinding mills, either parallel or in series, that discharges a final ground product without classification equipment and no return of coarse discharge back to the mill. Some very simplistic examples of open circuit grinding are see below and are made of a Rod mill, Ball Mill ...
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Generally, the discharge from AG/SAG mills consists of one or both of the following components: slurry (water and finer particles) and pebbles (20-100 mm). Single stage AG/SAG mills have to handle large amounts of slurry as they are generally in closed circuit with classifiers whose circulating loads reach as high as 400-500%.
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However, open circuiting the SAG mill by feeding crushed pebbles directly to a ball-mill circuit is often considered as a technique to increase SAG throughput.
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SAG Mill power draw models are used in mill design and grinding circuit modelling to predict how muc h pow er wi... [↓ read more ↓] Alex Doll: modelling: A simple estimation method of materials handling specific energy consumption in HPGR circuits
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Following a successful commissioning and start-up, we believe that two grinding lines at Las Bambas, Perú, each consisting of one SAG Mill and one Ball Mill (this mill combination is uniquely specific to Las Bambas ore types), are operating at design throughput of close to 140,000 tpd and within the range predicted by DJB from a managed multi-sample …
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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.
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The circuit consists of a 34' x 20' EGL SAG mill, a Raptor 900 pebble crusher and two 24' x 39'6" ball mills. Each mill is equipped with a 2 x 8500HP dual pinion drive system. The plant was designed to process 1585 h mtpof SAG feed. From startup, the mill struggled to meet the required production rates.
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Sossego was the first Vale SAG mill operation to process copper-gold ore. It is located in the State of Para, southeastern Amazon region of Brazil. In the first three years of continuous operation, Vale investigated different alternatives for improving the circuit`s performance by investigating operating conditions, mainly focusing on the SAG mill.
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Optimization of the energy distribution of SABC circuits Daozhen Gong 1,2, Stefan Nadolski 2 ... (SAG mill-Ball mill-Crusher) circuit is the most widely used grinding configuration in large metal mines. It has been proven that reducing the feed size of the SAG mill can improve the energy efficiency or throughput of SABC circuits (Morrell and ...
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Case Study #1 – Improving Circuit Stability OMC have been assisting an African gold mine in optimising the comminution circuit, with a focus on operations practices and plant utilisation. The original circuit configuration consisted of a primary crusher followed by a SAG mill with a pebble crusher and a ball mill (SABC).
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ABC closed circuit, Autogenous-Ball-Mill-Crusher. Another similar technique is the ABC open circuit where the crusher product feeds the ball mill rather than the autogenous mill. Crusher product is typical feed to a ball mill using large diameter balls but not much grinding of 20-25 mm ore can be accomplished in an autogenous mill.
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A SAG mill operates with a 10000 hp motor. Typical power draw is 80% of maximum. The 80% passing feed size to the mill is 5 inches and the mill discharge has an 80% passing size of 2.1mm. How do i calculate the Operating Work Index for this mill if …
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