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Sag Moly Cop

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From FAG … From FAG … (fully) (fully) to SAG … to SAG … (semi) (semi) to BAG ! to BAG ! (barely) (barely) The Theoretical Rationale behind The Theoretical Rationale behind CURRENT TRENDS IN OPERATING PRACTICE CURRENT TRENDS IN OPERATING PRACTICE OF SEMIAUTOGENOUS GRINDING OPERATIONS OF SEMIAUTOGENOUS GRINDING OPERATIONS Dr. Jaime E. Sepúlveda Dr. Jaime E. Sepúlveda Moly Moly-Cop Grinding Systems Cop Grinding Systems
Transcript
Page 1: Sag Moly Cop

From FAG …From FAG …(fully)(fully)

to SAG …to SAG …(semi)(semi)

to BAG !to BAG !(barely)(barely)

The Theoretical Rationale behindThe Theoretical Rationale behindCURRENT TRENDS IN OPERATING PRACTICECURRENT TRENDS IN OPERATING PRACTICE

OF SEMIAUTOGENOUS GRINDING OPERATIONSOF SEMIAUTOGENOUS GRINDING OPERATIONS

Dr. Jaime E. SepúlvedaDr. Jaime E. SepúlvedaMolyMoly--Cop Grinding SystemsCop Grinding Systems

Page 2: Sag Moly Cop

� Feed the mill with large rocks (up to 10”-12”), so avoiding the traditional crushing, classification and multiple storage stages of intermediate size particles.

� Use these rocks as a ‘zero-cost’ grinding media: Autogenous Grinding.

� Add large diameter steel balls (up to 6”):

� The concept ofAUTOGENOUS GRINDING was born from the idea of avoiding the use and

Basic ConceptsSEMIAUTOGENOUS GRINDING

Basic ConceptsSEMIAUTOGENOUS GRINDING

� Add large diameter steel balls (up to 6”): Semiautogenous Grinding.

� Considering that rocks are lighter than balls, it was assumed (wrongly?) that such rocks should fall from the highest possible position and therefore, SAG mills adopted their typical “pancake” shape: D>L.

avoiding the use and consumption of steel grinding balls, by replacing them with the same rockscontained in the fresh feed ore.

Page 3: Sag Moly Cop

Alternative Circuit ConfigurationsSINGLESTAGE GRINDING (FAG or SAG)

Alternative Circuit ConfigurationsSINGLESTAGE GRINDING (FAG or SAG)

ProductProduct

WaterWater

FeedFeed

Page 4: Sag Moly Cop

Alternative Circuit ConfigurationsDOUBLESTAGE GRINDING (DSAG)Alternative Circuit Configurations

DOUBLESTAGE GRINDING (DSAG)

WaterWaterFeedFeed

ProductProduct

WaterFeedFeed

Page 5: Sag Moly Cop

LargeLarge(> 4”)(> 4”)

Do they Do they Grind?Grind?

ROCKSROCKSDo theyDo theygrind grind

themselves?themselves?

Are they Are they ground by ground by media?media?

Yes, Yes, less thanless thanBallsBalls

YesYesNoNo

Semiautogenous GrindingSemiautogenous GrindingWHICH WOULD BE THE ACTUALWHICH WOULD BE THE ACTUAL

ROLE OF THE ‘ROCKS’?ROLE OF THE ‘ROCKS’?

Semiautogenous GrindingSemiautogenous GrindingWHICH WOULD BE THE ACTUALWHICH WOULD BE THE ACTUAL

ROLE OF THE ‘ROCKS’?ROLE OF THE ‘ROCKS’?� The mid size rocks, denominated Critical Sizes or Pebbles do not act as grinding media and they do notallow themselves to be ground.

� They use up space in the charge affecting the productivity of the mill.

� As a corrective measure, it has been

MediumMedium(2” to 4”)(2” to 4”)

SmallSmall(< 2”)(< 2”)

BallsBalls

VeryVerylittle !little !

NoNo

Very Very little !little !

Little ! Little ! requirerequire

large ballslarge balls

NoNoYesYes

measure, it has been arranged for such Pebbles to leave the charge through the mill grate, classifying and crushing them by conventional methods.

Page 6: Sag Moly Cop

Alternative Circuit ConfigurationsAlternative Circuit ConfigurationsDOUBLESTAGE GRINDINGDOUBLESTAGE GRINDING

WITH PEBBLE CRUSHING (SABCWITH PEBBLE CRUSHING (SABC--1)1)

Alternative Circuit ConfigurationsAlternative Circuit ConfigurationsDOUBLESTAGE GRINDINGDOUBLESTAGE GRINDING

WITH PEBBLE CRUSHING (SABCWITH PEBBLE CRUSHING (SABC--1)1)

WaterWater

ProductProductPebblesPebbles

WaterWaterFeedFeed

Page 7: Sag Moly Cop

WaterWater

ProductProductPebblesPebbles

Alternative Circuit ConfigurationsAlternative Circuit ConfigurationsDOUBLESTAGE GRINDINGDOUBLESTAGE GRINDING

WITH PEBBLE CRUSHING (SABCWITH PEBBLE CRUSHING (SABC--2)2)

Alternative Circuit ConfigurationsAlternative Circuit ConfigurationsDOUBLESTAGE GRINDINGDOUBLESTAGE GRINDING

WITH PEBBLE CRUSHING (SABCWITH PEBBLE CRUSHING (SABC--2)2)

WaterWaterFeedFeed

Page 8: Sag Moly Cop

� Since Fully Autogenous Grinding (FAG) was first proposed, early last century, there has been a continuous evolution in operational practices with regard to:� The addition of increasing amounts of steel balls

as ancillary grinding media,� The sustained increment in diameter of such

balls,� The removal and crushing of the critical sizes

(pebbles) that otherwise would accumulate in the load and …The pre-crushing (elimination) of either the

� With time, the fully AUTOGENOUS option has been gradually diverting from its original conception to

load and …� The pre-crushing (elimination) of either the

larger rocks or the intermediate particle size fractions contained in the fresh feed ore.

� Consequently, little is left today of the original intention of using the larger rocks as autogenousgrinding media for the smaller particles.

� This presentation is aimed at illustrating the theoretical rationale behind the observed current trends in SAG operating practices, with the aid of Moly-Cop Tools 2.0.

diverting from its original conception to become nowadays just a simple case of a poorly operated CONVENTIONAL BALL MILL …

Page 9: Sag Moly Cop

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Mineral Grinding

Mineral Grinding

Mineral Grinding

Mineral Grinding

Mineral Grinding

Mineral Grinding

Mineral Grinding

Mineral Grinding

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Software for the Analysis of

Mineral Grinding

Mineral Grinding

Mineral Grinding

Mineral Grinding

Mineral Grinding

Mineral Grinding

Mineral Grinding

Mineral Grinding

Processes

Processes

Processes

Processes

Processes

Processes

Processes

Processes

2.0

Page 10: Sag Moly Cop

My Grandpa made it!

MolyMoly--Cop ToolsCop ToolsMolyMoly--Cop ToolsCop Toolsis available is available free of chargefree of charge to to

all interested partiesall interested [email protected]@molycop.cl

Page 11: Sag Moly Cop

0.100

1.000

SiE

Balls on Particles Rocks on Particles Self-Breakage Overall

Theoretical BackgroundSPECIFIC SELECTION FUNCTION,

ton/kWh

Theoretical BackgroundSPECIFIC SELECTION FUNCTION,

ton/kWh

� The model included in Moly-Cop Tools was first published at the SAG 2001 Conferenceby J. E. Sepúlveda, “A Phenomenological Model of Semi-Autogenous Grinding Processes in a Moly-Cop Tools Environment”, Vol. 4, pp. 301-315, Vancouver, Canada.

� After that, the model has been providing quite satisfactory

0.010

10 100 1000 10000 100000 1000000

Particle Size, microns

Squite satisfactory descriptions of actual SAG processes, in all cases where the proper plant and/or pilot scale data has been made available.

Page 12: Sag Moly Cop

Simulation N° 0 Remarks Base Case Example

Ore Density, ton/m3 2.80

0.017 1000 ton/hr (all mills)0.9 40.00 % Solids

4 76.72 % - 100#167.0 P80

# of Cyclones 4.00 243 d50cDiameter 26.00 0.315 Bpf

Height 78.00 0.331 Bpw Mesh # Inlet 10.00 Opening Vortex 10.00 76.10 % Solids By-Pass Apex 5.00 D50/D Circ.

1000 ton/hr, Fresh FeedMesh # 1 131488 F80

Opening 304800 2.90 % Moisture By-Pass 0.000 D50/Ds 1.00 1

m 100.00 Upper 0 ton/hrSplit 0.00

Mesh # 1 1Opening 304800 Lower 0 ton/hrBy-Pass 0.000 0.00 % of Feed 369 ton/hr D50/Ds 1.00 2.90 % Moisture 36.91 % of Feed

m 100.00 2.90 % Moisture

61.50 % - 1/2" 61.50 % - 1/2"

2

F80 131488 % - 1.5" 58.97

Water, m3/hr 344

Diameter, ft 35.30 Grate ScreenLenght, ft 15.00 5 10

Speed, % Critical 78.00 76200 13335 Charge Level, % 26.00 0.070 0.017

Balls Filling, % 10.00 0.70 0.90

⊕⊕⊕⊕

⊕⊕⊕⊕

∅∅∅∅

1

2

Complex Circuit Simulation ... SABC-1Complex Circuit Simulation ... SABC-1

D50/D Circ. m % - 200# in psi 10.19 Load, %

Mill Discharge (Guess) 2.367 29.66 (Actual) 2.367

(Delta) 0.000

89 Water, m3/hr

475 2.00 # of Mills

Balls Filling, % 10.00 0.70 0.90 % Solids (slurry) 76.00 3.00 4.00

App. Density, ton/m3 3.331 % Solids 72.79 Gross kW 10093 % - 100# 21.26

kWh/ton 10.09 T80 6112 m3/hr 731

Mesh Opening Fresh Crushed CrushedFeed Pebbles 1 Pebbles 2

1 12" 304800 100.00 100.00 100.00 m3/hr, Water 2 8" 203200 97.60 100.00 100.00

Size Distributions

3 6" 152400 83.93 100.00 100.00 4 4.15" 101600 73.57 100.00 100.00 5 2.95" 76200 67.87 100.00 100.00 6 2.1" 50800 62.82 100.00 100.00 7 1.48" 38100 58.97 100.00 100.00 8 1.05" 26670 53.78 98.07 98.07 9 0.742" 18850 49.78 90.24 90.24

10 0.525" 13335 42.74 61.50 61.50 11 0.371" 9423 38.32 48.04 48.04 12 3 6680 34.00 31.84 31.84 13 4 4699 29.28 23.55 23.55 14 6 3327 25.65 18.08 18.08 15 8 2362 22.57 14.32 14.32 16 10 1651 20.19 11.53 11.53 17 14 1168 18.16 9.20 9.20 18 20 833 16.79 7.80 7.80 19 28 589 15.65 6.65 6.65 20 35 417 14.66 5.74 5.74 21 48 295 13.79 5.06 5.06 22 65 208 12.84 4.43 4.43 23 100 147 12.01 3.96 3.96 24 150 104 11.12 3.50 3.50 25 200 74 10.28 3.10 3.10

19.00 Diameter, ft 24.00 Lenght, ft 76.00 Speed, % Critical 38.00 Charge Level, % 38.00 Balls Filling, %

% Solids 60.01 72.00 % Solids (slurry) m3/hr 1723 5.395 App. Density, ton/m3

4631 Gross kW 9.26 kWh/ton

Current Min/Max RemarksSAG Power, kW 10093 11500 OKPebbles, ton/hr 369 400 OKBM Power, kW 4631 3730 KOProduct Size, P80 167.0 185.0 OKPump Capacity, P*Q 17554 30000 OKTotal Water, m3/hr 1470 2000 OK

PROCESS RESTRICTIONS

� In conjunction with other unit operation models, such as Conventional Ball Milling, Hydroclassification, Screening and Crushing, the referred SAG model can be applied, with Moly-Cop Tools, to represent fairly complex circuit arrangements.

Page 13: Sag Moly Cop

1189 ton/hr, Fresh FeedMesh # 1 131488 F80

Opening 304800 2.90 % Moisture By-Pass 0.000 D50/Ds 1.00 1

m 100.00 Upper 0 ton/hrSplit 0.00

Mesh # 1 1Opening 304800 Lower 0 ton/hrBy-Pass 0.000 0.00 % of FeedD50/Ds 1.00 2.90 % Moisture

m 100.00 2

61.50 % - 1/2"

2

F80 131488 % - 1.5" 58.97

Water, m3/hr 271

Diameter, ft 35.30 Grate ScreenLenght, ft 15.00 5 10 Mesh #

Speed, % Critical 78.00 76200 13335 Opening Charge Level, % 26.00 0.070 0.017 By-Pass

Balls Filling, % 10.00 0.70 0.90 D50/D

⊕⊕⊕⊕

⊕⊕⊕⊕

∅∅∅∅

∅∅∅∅1

2

Simulation N° 0 Remarks

371 ton/hr Base Case Example31.19 % of Feed

2.90 % Moisture Ore Density, ton/m3 2.80

61.50 % - 1/2"

Split 0 ton/hr 1189 ton/hr (all mills)0.00 0.00 % of Feed 40.00 % Solids

62.52 % - 100#270.0 P80

# of Cyclones 4.00 357 d50cDiameter 26.00 0.260 Bpf

Height 78.00 0.273 BpwInlet 10.00

Opening Vortex 10.00 82.66 % SolidsApex 5.00

Circ.

Complex Circuit Simulation ... SABC-2Complex Circuit Simulation ... SABC-2

Balls Filling, % 10.00 0.70 0.90 D50/D % Solids (slurry) 76.00 3.00 4.00 m

App. Density, ton/m3 3.331 % Solids 73.45 Gross kW 10093 % - 100# 25.85

kWh/ton 8.49 T80 5052 m3/hr 588

Mesh Opening Fresh Crushed CrushedFeed Pebbles 1 Pebbles 2

1 12" 304800 100.00 100.00 100.00 m3/hr, Water 391 2 8" 203200 97.60 100.00 100.00

Size Distributions

Circ.% - 200# in psi 13.51 Load, %

Mill Discharge (Guess) 2.688 16.08 (Actual) 2.688

(Delta) 0.000

353 Water, m3/hr

2.00 # of Mills3 6" 152400 83.93 100.00 100.00 4 4.15" 101600 73.57 100.00 100.00 5 2.95" 76200 67.87 100.00 100.00 6 2.1" 50800 62.82 100.00 100.00 7 1.48" 38100 58.97 100.00 100.00 8 1.05" 26670 53.78 98.07 98.07 9 0.742" 18850 49.78 90.24 90.24

10 0.525" 13335 42.74 61.50 61.50 11 0.371" 9423 38.32 48.04 48.04 12 3 6680 34.00 31.84 31.84 13 4 4699 29.28 23.55 23.55 14 6 3327 25.65 18.08 18.08 15 8 2362 22.57 14.32 14.32 16 10 1651 20.19 11.53 11.53 17 14 1168 18.16 9.20 9.20 18 20 833 16.79 7.80 7.80 19 28 589 15.65 6.65 6.65 20 35 417 14.66 5.74 5.74 21 48 295 13.79 5.06 5.06 22 65 208 12.84 4.43 4.43 23 100 147 12.01 3.96 3.96 24 150 104 11.12 3.50 3.50 25 200 74 10.28 3.10 3.10

19.00 Diameter, ft 24.00 Lenght, ft 76.00 Speed, % Critical 38.00 Charge Level, % 38.00 Balls Filling, %

% Solids 64.12 72.00 % Solids (slurry) m3/hr 2009 5.395 App. Density, ton/m3

4631 Gross kW 7.79 kWh/ton

Current Min/Max RemarksSAG Power, kW 10093 11500 OKPebbles, ton/hr 371 400 OKBM Power, kW 4631 3730 KOProduct Size, P80 270.0 185 KOPump Capacity, P*Q 27155 30000 OKTotal Water, m3/hr 1759 2000 OK

PROCESS RESTRICTIONS

� In conjunction with other unit operation models, such as Conventional Ball Milling, Hydroclassification, Screening and Crushing, the referred SAG model can be applied, with Moly-Cop Tools, to represent fairly complex circuit arrangements.

Page 14: Sag Moly Cop

Current Operational Trends inCurrent Operational Trends inCurrent Operational Trends inCurrent Operational Trends inSEMIAUTOGENOUS GRINDINGSEMIAUTOGENOUS GRINDINGSEMIAUTOGENOUS GRINDINGSEMIAUTOGENOUS GRINDING

Page 15: Sag Moly Cop

200

400

600

800

1000

1200

Mill

Thr

ough

put,

ton/

hr5000

10000

15000

20000

25000

30000

Mill

Pow

er D

raw

, kW

22% Total Filling 26% Total Filling 30% Total Filling

Effect of % BALLS IN THE CHARGE

Effect of % BALLS IN THE CHARGE

� D = 36’φφφφL = 15’Vel. = 78% Crit.

SimulatedConditions

Max. Power

0

200

0 5 10 15 20

% Balls

Mill

Thr

ough

put,

ton/

hr

0

5000 Mill

Pow

er D

raw

, kW

Vel. = 78% Crit.% Solids = 76%F80 = 131448 micronsGrate = 0.5”Screen = 0.5”Ball Size = 5”Circuit Type = SABC-1

� One of the first “diversions” from Fully Autogenous Grindingwas the addition of large diameter balls with the purpose of increasing mill power draw and so providing extra grinding capacity, giving rise to the so-called Semi Autogenous option.

� Under any circumstances, Operators must be alert not to exceed the design Maximum Power of the mill motor and drive mechanism.

Page 16: Sag Moly Cop

200

400

600

800

1000

1200

Mill

Thr

ough

put,

ton/

hr5000

10000

15000

20000

25000

30000

Mill

Pow

er D

raw

, kW

22% Total Filling 26% Total Filling 30% Total Filling

Effect of % BALLS IN THE CHARGE

Effect of % BALLS IN THE CHARGE

� D = 36’φφφφL = 15’Vel. = 78% Crit.

SimulatedConditions

Max. Power

0

200

0 5 10 15 20

% Balls

Mill

Thr

ough

put,

ton/

hr

0

5000 Mill

Pow

er D

raw

, kW

Vel. = 78% Crit.% Solids = 76%F80 = 131448 micronsGrate = 0.5”Screen = 0.5”Ball Size = 5”Circuit Type = SABC-1

� Even at the same mill power draw, balls would be more effective than rocks to convert the available power into actual grinding, thanks to their higher density and spherical shape.

Page 17: Sag Moly Cop

11.5

12.0

12.5

13.0

13.5

14.0

kWh/

ton

200

400

600

800

1000

1200

Mill

Thr

ough

put,

tph

22% Total Filling 26% Total Filling

Effect of % BALLS IN THE CHARGE

Effect of % BALLS IN THE CHARGE

� D = 36’φφφφL = 15’Vel. = 78% Crit.

SimulatedConditions

11.0

11.5

2.0 3.0 4.0 5.0

Apparent Charge Density, ton/m 3

0

200 Mill

Thr

ough

put,

tph

26% Total Filling 30% Total Filling

� In some cases, it is possible to identify an Apparent Charge Density (determined by the balls/rocks ratio) that minimizes the overall Specific Energy requirement.

� If the feed contains large rocks – that essentially must grind themselves – we must assure that these large rocks get to absorb the necessary proportion of the total available energy, so the overall process can achieve optimal performance.

Vel. = 78% Crit.% Solids = 76%F80 = 131448 micronsGrate = 0.5”Screen = 0.5”Ball Size = 5”Circuit Type = SABC-1

Page 18: Sag Moly Cop

11.5

12.0

12.5

13.0

13.5

14.0

kWh/

ton

200

400

600

800

1000

1200

Mill

Thr

ough

put,

tph

22% Total Filling 26% Total Filling

Effect of % BALLS IN THE CHARGE

Effect of % BALLS IN THE CHARGE

� D = 36’φφφφL = 15’Vel. = 78% Crit.

SimulatedConditions

11.0

11.5

2.0 3.0 4.0 5.0

Apparent Charge Density, ton/m 3

0

200 Mill

Thr

ough

put,

tph

26% Total Filling 30% Total Filling

� However, regardless of this ideal Apparent Charge Densitythat would optimize the energy efficiency (kWh/ton) of the process, the overall effectiveness (mill throughput) of the operation is always achieved at higher balls/rocks ratios, up to the limit imposed by the available motor and drive power.

Vel. = 78% Crit.% Solids = 76%F80 = 131448 micronsGrate = 0.5”Screen = 0.5”Ball Size = 5”Circuit Type = SABC-1

Page 19: Sag Moly Cop

1000

1050

1100

1150

1200

1250

Mill

Thr

ough

put,

ton/

hr

Screen Opening = 1/2 inch Screen Opening = 3/4 inch

Effect of DISCHARGE GRATE OPENING

Effect of DISCHARGE GRATE OPENING

� D = 36’φφφφL = 15’Vel. = 78% Crit.

SimulatedConditions

950

1000

0.0 1.0 2.0 3.0

Grate Opening, inches

Mill

Thr

ough

put,

ton/

hrVel. = 78% Crit.% Solids = 76%F80 = 131448 microns% Filling = 28%% Balls = 16%Ball Size = 5”Circuit Type = SABC-1

� Another source of “diversion” of SAG milling technology has been the empirical confirmation that removing and crushing larger and larger pebbles (by opening the discharge grate slots) invariably translates into substantially improved mill grinding capacity.

� In plain words … it is like “the SAG mill is asking help from the Crushers”.

Page 20: Sag Moly Cop

12001400160018002000220024002600280030003200

ton/

hr

SABC-1 SABC-1 plus +6 inch Crushing SABC-1 plus 6x2 inch Crushing

Effect of FRESH FEED SIZE DISTRIBUTION

Effect of FRESH FEED SIZE DISTRIBUTION

� D = 36’φφφφL = 17’Vel. = 76% Crit.% Solids = 78%

SimulatedConditions

21%21%

600800

10001200

20 30 40 50 60 70 80 90 100

% - 2" in SAG Mill Feed

Vel. = 76% Crit.% Solids = 78%% Filling = 28%% Balls = 12%Grate = 2”Ball Size = 5”Circuit Type = SABC-1

� It has been repeatedly demonstrated in actual operational practice that “getting rid of the rocks” ahead of the SAG mill brings substantial throughput benefits, raising questions about the effective contribution of such rocks to the overall grinding process.

� Taken from: J. E. Sepúlveda, “A SIMULATION ANALYSIS OF THE NET EFFECT OF FEED PARTICLE SIZE DISTRIBUTION ON SAG MILL PERFORMANCE”, Jan D. Miller Symposium, SME-AIME Annual Meeting, 2005.

Page 21: Sag Moly Cop

2400

2500

2600

2700

2800

2900

3000

ton/

hr

SAG 1 SAG 2

Effect of Feed Size THE PELAMBRES CASE

Effect of Feed Size THE PELAMBRES CASE

21%21%

� D = 36’φφφφL = 17’Vel. = 76% Crit.% Solids = 78%

OperatingConditions

2200

2300

2400

40 45 50 55 60 65

% - 1.25" in SAG Mill Feed

� Actual data in support of the previous statement was provided by the PELAMBRES (Chile) operation, back in 2001, in the context of their “mine-to-mill” approach.

� Taken from: R. Palomo, Moly-Cop 2001: IX Mineral Processing Symposium.

Vel. = 76% Crit.% Solids = 78%% Filling = 23%% Balls = 15%Grate = 2”Ball Size = 5”Circuit Type = SABC-1

Page 22: Sag Moly Cop

Effect of Feed SizeTHE COPPERTON CASE

Effect of Feed SizeTHE COPPERTON CASE

10001100120013001400150016001700180019002000

ton/

hr

Lines 1 - 3 Line 4

(*) D. King (2005), SME-AIME Annual Meeting

800900

1000

30 35 40 45 50 55 60

% - Fines in SAG Mill Feed (*)

Page 23: Sag Moly Cop

Effect ofCIRCUIT CONFIGURATION

Effect ofCIRCUIT CONFIGURATION

100012001400160018002000220024002600280030003200

ton/

hr

DSAG SABC-1 SABC-1 plus +6 inch Crushing SABC-1 plus 6x2 inch Crushing SABC-2

� D = 36’φφφφL = 17’Vel. = 76% Crit.% Solids = 78%

SimulatedConditions

600800

1000

20 30 40 50 60 70 80 90 100

% - 2" in SAG Mill Feed

� The grinding capacity of any given circuit improves as its configuration evolves from DSAG to SABC-1 to SABC-2; that is, as the SAG mill contributes less and less to the overall grinding task!

� Also, as the larger feed rocks get to be pre-crushed, the Ideal Apparent Charge Density quickly approaches values close to the limiting maximum value corresponding to just ‘balls plus slurry’ (~5 ton/m3); that is, Conventional Grinding.

Vel. = 76% Crit.% Solids = 78%% Filling = 28%% Balls = 12%Grate = 2”Ball Size = 5”Circuit Type = SABC-1

Page 24: Sag Moly Cop

Effect of Balls/Rocks RatioIDEAL APPARENT CHARGE DENSITY

Effect of Balls/Rocks RatioIDEAL APPARENT CHARGE DENSITY

� D = 36’φφφφL = 17’

SimulatedConditions

0

2000

4000

6000

8000

10000

12000

kW (Net)

Total

Balls

Rocks

Slurry

� As Total Mill Filling is increased (by the addition of large or mid size rocks), at constant Ball Filling, the Total Mill Power Draw increases, but the Net Power absorbed by the Ballsactually decreases.

� If one is to accept that rocks are less effective than balls as grinding media (not to say, totally ineffective), then Mill Throughput will be higher at lower Total Filling levels.

� This empirical finding has led operators to run at fairly low Total Filling (below 24%) and relatively high (up to 20%) Ball Filling levels.

L = 17’Vel. = 70% Crit.% Solids = 78%% Balls = 12%Grate = 0.5”Ball Size = 5”Circuit Type = DSAG

0

14 16 18 20 22 24 26 28 30 32 34 36 38

Total Mill Filling, %

Page 25: Sag Moly Cop

Meanwhile ... Has theIDEAL MAKE-UP BALL SIZE

also been evolving?

Meanwhile ... Has theIDEAL MAKE-UP BALL SIZE

also been evolving?

� With the advent of the new century, SAG mill operators have been consistently 1200

1400

1600

1800

2000

2200

2400

Mill

Thr

ough

put,

ton/

hr

F80, mm

27

56

been consistently realizing the clear advantages of using larger and larger balls, regardless of the ore feed particle size.

800

1000

1200

3.5 4 4.5 5 5.5 6 6.5 7 7.5

Make-up Ball Size, inches

Mill

Thr

ough

put,

ton/

hr

120

131

� For every ‘grinding task’, there is an Ideal Make-up Ball Sizethat maximizes mill throughput.

� Quite often, this Ideal Make-up Ball Size turns out to be larger than the largest commercially available ball size and increases consistently for coarser and coarser feeds.

Page 26: Sag Moly Cop

4.8

5.0

5.2

5.4

5.6

Ave

. SA

G B

all S

ize,

inch

es

Meanwhile ... Has theIDEAL MAKE-UP BALL SIZE

also been evolving?

Meanwhile ... Has theIDEAL MAKE-UP BALL SIZE

also been evolving?

� It should be noted that this trend of increasing make-up

4.0

4.2

4.4

4.6

'90 '92 '94 '96 '98 '00 '02 '04 '06 '08

Ave

. SA

G B

all S

ize,

inch

esincreasing make-up ball sizes has not yet been offset by the concurrent trend of feeding the mills with finer and finer particles.

� Based on Historical Sales Records of Moly-Cop Chile S. A.

Page 27: Sag Moly Cop

So ...HOW ARE THEY RUNNING TODAY?

So ...HOW ARE THEY RUNNING TODAY?

Mill Mill Ball Total Ball F80 ChargeFacility Diameter, Length, Filling, Filling, Size, Size, D ensity, Circuit Type

ft ft % % in mm ton/m 3

Chuquicamata 32 15 15.0 28.0 5.0 120 3.75 SABC-1 Andina 36 15 14.0 30.0 5.0 76 3.54 SABC-2 Teniente SAG 1 36 15 14.0 33.0 5.0 170 3.46 SABC-2 Teniente SAG 2 38 22 15.0 31.0 5.0 100 3.64 SABC- 2 Collahuasi 32 15 12.0 25.0 5.0 152 3.56 SABC-1 MEL Laguna Seca 38 20 19.0 26.0 5.5 80 4.37 SABC-1 MEL Los Colorados SAG 1 28 14 13.0 23.0 5.0 80 3.88 SABC-1

� Data obtained from direct interviews to the listed operations.

MEL Los Colorados SAG 1 28 14 13.0 23.0 5.0 80 3.88 SABC-1 MEL Los Colorados SAG 2 28 14 13.0 23.0 5.0 80 3.88 SABC-1 MEL Los Colorados SAG 3 36 19 15.0 23.0 5.0 80 4.14 SABC-1 Candelaria 36 15 17.5 31.0 5.5 128 3.95 SABC-2 Mantos de Oro 28 14 14.0 30.0 6.0 64 3.52 Precrush ing Pelambres 36 17 19.5 30.0 5.5 90 4.10 Precrushing El Soldado 34 17 14.0 25.0 5.0 117 3.83 SAC Los Bronces SAG 1 28 14 17.0 30.0 5.0 60 3.88 Prec rushing Los Bronces SAG 2 34 17 17.0 30.0 5.0 60 3.88 Prec rushing

Page 28: Sag Moly Cop

120

140

160

180

200

F80

Siz

e, m

m

Chuquicamata Andina Teniente Collahuasi Escondida Candelaria

So ...HOW ARE THEY RUNNING TODAY?

So ...HOW ARE THEY RUNNING TODAY?

Too manyballs!

FAGFAG

40

60

80

100

2.8 3.0 3.2 3.4 3.6 3.8 4.0 4.2 4.4 4.6 4.8

Charge Density, ton/m 3

F80

Siz

e, m

m

Candelaria MDO Pelambres Anglo

� Data obtained from direct interviews to the listed operations.

Not enoughballs!

BAGBAG

Page 29: Sag Moly Cop

�� It is very likely that many of It is very likely that many of It is very likely that many of It is very likely that many of It is very likely that many of It is very likely that many of It is very likely that many of It is very likely that many of

the members of this audience the members of this audience the members of this audience the members of this audience the members of this audience the members of this audience the members of this audience the members of this audience

would would would would would would would would notnotnotnotnotnotnotnot share with me the share with me the share with me the share with me the share with me the share with me the share with me the share with me the

‘rightfulness’‘rightfulness’‘rightfulness’‘rightfulness’‘rightfulness’‘rightfulness’‘rightfulness’‘rightfulness’ of all of my of all of my of all of my of all of my of all of my of all of my of all of my of all of my

todays statements.todays statements.todays statements.todays statements.todays statements.todays statements.todays statements.todays statements.

�� For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just

CONCLUDING REMARK

CONCLUDING REMARK

�� For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just For now, in my defense, I just

wish to express that, in real wish to express that, in real wish to express that, in real wish to express that, in real wish to express that, in real wish to express that, in real wish to express that, in real wish to express that, in real

life ... life ... life ... life ... life ... life ... life ... life ...

nobody is free ofnobody is free ofnobody is free ofnobody is free ofnobody is free ofnobody is free ofnobody is free ofnobody is free of

making mistakes !!!making mistakes !!!making mistakes !!!making mistakes !!!making mistakes !!!making mistakes !!!making mistakes !!!making mistakes !!!


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