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Pre-Processing to Increase the Capacity of SAG Mill Circuits

Total Charge Volume-SAG mill % 30.0: 27.3: Power Draw-SAG Mill: kW: 14,696: 14,542: Power Draw-Ball Mills (each) kW: 8211: 8211: Specific Energy-SAG: …

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SINGLE STAGE SAG/AG MILLING DESIGN

SAG mill (4% ball charge, 90% Nc) A cross between AG and SAG for average competency, abrasive ores. Typically operated in RSA on Witwatersrand Gold Ore Driefontein (Underground), Kloof, Jacobina 6 SAG mill with recycle crusher (8 – 15% ball charge) Competent ores, better suited to coarse grind sizes. High aspect mills are …

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Ball Mill Charge

The ball charge and ore charge volume is a variable, subject to what is the target for that operation. The type of mill also is a factor as if it is an overflow mill (subject to the diameter of the discharge port) is usually up to about 40-45%. If it is a grate discharge you will have more flexibility of the total charge.

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Simulation of overflow ball mill discharge and trommel flow using

For the DEM s etup of the ball charge, the mill chamber is initially filled with a 34% volumetric fill of ball sizes ranging from 32 – 65 mm. The full ball size d istribution is given in Table 3.

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A method to predict shape and trajectory of charge in industrial mills

The tumbling ball charge was photographed with a high-speed camera. Measurements from the photographs were made of the angular displacement of the toe, toe departure, shoulder and charge impact point. ... On account of liner profile change, the AG mill was then converted to a SAG mill by addition of 5% (v/v) balls. Section snippets …

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SAGDesign Mill Throughput Calculation Tool | PDF | Mill …

SAGDesign Mill Throughput Calculation SAGDesign™ Methodology AG-SAG- Ball Mill Grinding Circuit Throughput Forecasting. Remarks Base Case example: ... Operating Conditions %Critical Mill Speed %Total %Steel Speed rpm Charge Load SAG Mill 75 9.93 26 10 Ball Mill 75 12.39 35. Mill Specification Qty Size Installed Power Allowance …

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How to calculate ball/sag mill charge level?

To participate in the 911Metallurgist Forums, be sure to JOIN & LOGIN; Use Add New Topic to ask a New Question/Discussion about Grinding.; OR Select a Topic that Interests you.; Use Add Reply = to Reply/Participate in a Topic/Discussion (most frequent). Using Add Reply allows you to Attach Images or PDF files and provide a more complete input.; Use …

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SAG mill ball charge determination and its influence on mill drive

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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Modelling SAG milling power and specific energy

Scw = solid concentration by weight fraction in the SAG mill feed; Jb = balls charge (bulk fraction of the SAG mill volume); N/Nc = fraction of the SAG mill critical …

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Choosing the Right Motors for your Mills

–SAG mills: 20% v/v ball charge, 30% v/v filling and 78% critical speed with worn liners –Ball mills: 36% v/v filling and 78% critical speed with worn liners. Step 1: Mill overload power •SAG mill, use a Tent Diagram to identify the design requirements •Example, SG=4.0 38'Ø × 19' EGL SAG

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How Mill Load/Charge is Estimated

Sag mills in the gold and copper operations would vary from 6%- 15% and are normally grate discharge types in most cases the densities of the slurry in the mill is over 65% and that goes for ball mills also. Off course you have a upper limit or the balls will "float" out. Higher densities allow better grind and increase residence time in the mill.

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Predicting liner wear of ball mills using discrete element method …

A ball mill is a standard equipment which is mainly used to grind materials in process industries. Liners are the essential parts of a mill. They are used to protect the shell and lift the charge in mill's operation. ... fill level, lifter height and mill speed for a generic SAG mill. The charge shape and location are characterised by the ...

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AG/SAG mill acoustic emissions characterisation under different

In a typical AG/SAG mill operation, the charge, consisting of ore, water, and grinding media (usually steel balls) ... As the lifter height increases, there is a potential of the mill charge, especially ball charge to be projected beyond the toe angle and strike the mill liner/lifters. This condition in practice could potentially accelerate ...

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Optimizing Performance of SABC Comminution Circuit of the …

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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SAG Mill Grinding Circuit Design

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SAG-MILL Ball charge

maximum ball size should be checked against existing formulae, such as Bond's ball size recommendation. Hard ores are best ground with high ball charge levels and high mill speeds. Soft ores are best ground with lower ball charge levels and lower mill speeds. Media quality is rarely a problem if you are buying from a reputable ball vendor.

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Difference Between Sag Mill vs Ball Mill

The ball charge of a SAG mill is about 29% to 30%. By friction and influence of tumbling balls inside rotating cylinder grinds the raw material to the required fineness. The internal machinery of ball mill grinds the raw …

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CALCULATION OF THE REQUIRED SEMIAUTOGENOUS …

the existing techniques of sizing SAG mill power, Bond work in-dexes and their applicability to calculating autogenous/semiau-togenous mills. Finally, the authors give a comparative analysis ... to the detailed accounting of ball charge motion. The Introduction gives a description of the proposed approxi-mation of ball charge position in a ...

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WO2007110466A1

In the present invention a method, apparatus and computer program are presented, with which the amount of balls among ore material contained in a grinding mill is estimated as a percentage by volume of the total volume of the mill. Preferably, the invention relates to semi-autogenous mills. In the invention, an expanded Kalman filter is used to estimate …

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What is the difference between a SAG mill and ball 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%. [6] [7] The largest SAG mill is 42′ (12.8m) in diameter, powered by a 28 MW (38,000 HP) motor. [8] A SAG mill with a 44 ...

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Pre-Processing to Increase the Capacity of SAG Mill Circuits

The specific energy value (7.4 kWh/t) obtained of both SAG-5 and SAG-6 tests were interpreted as equivalent to an increased ball charge and mill rotating speed. Both changes were thus beneficial to the SAG mill performance compared with the SAG-2 test performance (7.8 kWh/t), where both ball charge and mill speed were relatively low.

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Improving Energy Efficiency Via Optimized Charge Motion and …

@article{osti_922135, title = {Improving Energy Efficiency Via Optimized Charge Motion and Slurry Flow in Plant Scale Sag Mills}, author = {Rajamani, Raj K}, abstractNote = {A research team from the University of Utah is working to make inroads into saving energy in these SAG mills. In 2003, Industries of the Future Program of the …

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Modelling SAG Milling Power and Specific Energy Consumption

inside the mill and it is composed of balls, ore and water. The ball charge is a function of the bulk fraction of the SAG mill volume (Jb) occupied by balls; the ore retained in the mill is the result of the volumetric filling which depends on the ore size distribution (spe-cially the % +600 and the % 600 +100), on the rotational speed (N/Nc)

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SAG

Through an innovative manufacturing process we've produced a ball with greater impact resistance and reduced spalling compared to the standard SAG ball, ready to perform in the highest impact SAG milling environments. PRODUCT SPECIFICATIONS. SIZE: SAG milling grinding media are available in sizes from 4.0" to 6.5" or 105 mm to 160 mm.

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INFERENTIAL MEASUREMENT OF SAG MILL …

semiautogenous grinding (SAG) mills and is the fourth paper in a series of five papers on Inferential Measurement of SAG Mill Parameters. The development of the inferential measurement models of SAG mill discharge and feed streams and mill rock and ball charge levels, detailed earlier in the series, is summarised.

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SAG Mill Ball Size Evaluator | Evaluation Factors | Calculate …

Lets calculate/select/pick a new ball for your SAG mill. Now, lets suppose you have a SAG Mill and Ball Mill that are not drawing full kW Power. 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.

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Molycop NG is Here!

Operators of high-impact SAG mills require tougher SAG balls. The volumetric ball/charge ratio (impact severity) in the mill dramatically affects ball consumption rates in SAG milling. Molycop has noticed the trend among customers to increase this ratio. The potential of the new Molycop NG balls to reduce total media …

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SAG Mill Grinding Circuit Design

SAG circuits may employ low to relatively high ball charges (ranging from 2% to 22%, expressed as volumetric mill filling) to augment autogenous media. Higher ball charges shift the breakage mode away from attrition and abrasion breakage toward impact breakage; as a result, AG milling produces a finer grind than SAG milling for a given ore …

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An improved method for grinding mill filling

1. Introduction. Mill filling has a dominant effect on grinding mill performance (Apelt, Asprey and Thornhill, 2001), and therefore, its accurate measurement is vital for modelling grinding mill performance.Measuring filling is also necessary to estimate the composition of the load for mill modelling: rock and slurry for AG mills; rock, balls and …

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Research on performance of a laboratory-scale SAG mill based …

Mishra and Rajamani [[2], [3], [4]] first studied the charging behavior and the rule of energy consumption of the ball mill based on 2D DEM in 1992. Cleary et al. [5] studied the effect of ball mill rotational rate on charge behavior and mill power, and in 2001, Cleary et al. [6] first applied 3D DEM to calculate the operating power of a SAG mill.

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