SAG MILL Cross-section view of a SAG mill. MINING BENEFITS • Estimated energy savings of 30% in SAG mill operations • Reduced ball consumption and equipment wear • Operational cost-savings near $4 million per year APPLICATION This technology applies directly to most crushing and grinding
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It is also possible to use the −1″ fraction that shows a positive effect on the SAG mill throughput (the power consumption decreases, but the specific energy decreases more) because the mineral goes faster to the mill discharge, leaving a greater part of the grinding task to the secondary ball mills.
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This enhanced system for separating and removing balls, chips or scats in a typical ball/SAG mill operation replaces the dead weight of ball magnets with fresh ore. By effectively removing 80 percent or more of the worn/broken media, the Eriez Trunnion Magnet reduces power consumption from the mill drive and prevents expensive damage to other
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Three SAG/ball mill circuits were surveyed revealing that on average, 91% of the supplied energy results in he at losse s, leavin g on ly 9 % for o re bre akage. The slurry absorbs most of the
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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 can reach 0.1 mm. The calculation shows that the crushing ratio can reach 3000 ~ 4000, while the ball mill’s
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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 400 g/t while Ball Mill grinding media (3″ balls) usage in 550 g/t.
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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
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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
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The SAG mill specific energy consumption (E SAG) is calculated using the 1979 Barratt equation and the ball mill specific energy consumption (E bm) This model includes a phantom cyclone effect in the equations due to the ball mill being calculated by difference and not being calculated by the normal Bond equation. The resultant operating work
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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
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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).
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The analysis of the influence of ball sizes in SAG grinding hasn''t been developed in detail by considering the effect on process parameters inside the mill, grinding efficiency or internal classification. Historically a conventional grinding reference has been made on the empirical procedure developed by Azzaroni (1980).
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The processing capacity of ball mills and rod mills is usually calculated by volumetric method or power consumption method, and the selection of ore mill should meet the following requirements: 1) Rod mills are mostly used for rough grinding, with a discharge particle size of 1~3mm, which can be ground to 0.5mm in a gravity separation plant.
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In general, the SAG mill manufacturers will control the addition amount of medium such as steel ball at 2-8%, so that the capacity of semi SAG mill to process materials can be increased by 10-30%. The SAG mill liners wear will increase by 15% due to the impact of medium such as steel ball during the SAG mill operation.
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The results showed that the HPGR-ball mill circuit achieved a 21% reduction in energy consumption over the existing SAG-ball mill circuit at the same P80 grind size of 160 mircons (μm). At a grind of 80% passing 75 μm, the HPGR-stirred mill circuit showed a 34% reduction in energy compared to the base case.
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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).
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Attrition mill is a type of grinding mill by kinds of media to crush lump to powder-like substances. The impact can be rock on rock such as in an Autogenous Grinding (AG) mill, rock and a small ball charge (~10%), used in Semi Autogenous Grinding (SAG) mills, balls of various sizes in Ball Mills and less commonly these days, steel rods in Rod Mills.
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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 can reach 0.1 mm. The calculation shows that the crushing ratio can reach 3000 ~ 4000, while the ball mill’s
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Download scientific diagram | Size analysis of SAG mill feed and underscreen for the second sample from publication: Application of SPI for Modeling energy consumption in Sarcheshmeh SAG and ball
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1. SAG mill is the primary tool for grinding. SAG mill is used before the other mills. Ball mill is a secondary, and it is used after the SAG mill. 2. SAG mill breaks the raw material into pieces for the further grinding. Ball mill is used to grind the pieces of raw material into. powder-like structures. 3.
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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 400 g/t while Ball Mill grinding media (3″ balls) usage in 550 g/t.
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SAG mill. SAG is an acronym for semi-autogenous grinding. SAG mills are autogenous mills that also use grinding balls like a ball mill. A SAG mill is usually a primary or first stage grinder. SAG mills use a ball charge of 8 to 21%. The largest SAG mill is 42'' (12.8m) in diameter, powered by a 28 MW (38,000 HP) motor.
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The trunnion magnet is mounted at the SAG ball mill discharge point and is used in place of a trommel screen. total mill power consumption dropped 8% from an average of 7,600 kW to 7,000 kW. The mill work index dropped 10% from an average of 5.5 kW-hr/T to 5 kW-hr/T. Retrofitting a ball mill with a trunnion magnet is easy, particularly when
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comparison of hpgr
The SAG mill specific energy consumption is deducted from the total circuit specific energy consumption to get the ball mill specific energy consumption: E bm =E total −E SAG (8) Determine Mill and Motor Size Knowing the SAG and ball mill specific energy consumption allows mill sizes to be calculated if a desired throughput rate is known.
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The trunnion magnet is mounted at the SAG ball mill discharge point and is used in place of a trommel screen. total mill power consumption dropped 8% from an average of 7,600 kW to 7,000 kW. The mill work index dropped 10% from an average of 5.5 kW-hr/T to 5 kW-hr/T. Retrofitting a ball mill with a trunnion magnet is easy, particularly when
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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 29,171 25,429 24,144 23,556 19,833 -12.8% 17.2% 19.3% 32.0% 1 Includes energy for mining through final cathode
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processing in ball/SAG mill operations. Depending upon mill capacity, ball size and other However, the total mill power consumption dropped 8% from an average of 7600 kW to 7000 kW. The mill work index dropped 10 percent from an average of 5.5 kW-hr/T to 5.0 kW-hr/T.
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The SAG mill and ball mill original design was reviewed and a change resulted in the application of a gearless drive wrap-around motors on both machines. This immediately delivered energy savings as the units areinherently more efficient in transferring incoming power to the shell of the mill. The use of
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considered, such as a primary SAG and secondary ball mill circuit where the individual stages would be ESAG and Eball, and the combined total circuit CEE would be Etotal. In all cases, the specific energy consumption is defined as the motor power consumed relative to the shell of the mill (a.k.a.
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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
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