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AG and SAG Mill Circuit Selection and Design by Simulation

The document summarizes a method for simulating autogenous (AG) and semi-autogenous (SAG) grinding mill performance using a mathematical model developed by the Julius Kruttschnitt Mineral Research Centre (JKMRC). The model typically requires pilot mill data but recent research has developed correlations between grinding rates and mill operating conditions as well as between mill feed size and ore breakage characteristics, allowing the model to predict mill performance and evaluate circuit designs without pilot testing. The document provides details on the model structure and equations used to relate operating conditions to grinding rates.

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0% found this document useful (0 votes)
287 views22 pages

AG and SAG Mill Circuit Selection and Design by Simulation

The document summarizes a method for simulating autogenous (AG) and semi-autogenous (SAG) grinding mill performance using a mathematical model developed by the Julius Kruttschnitt Mineral Research Centre (JKMRC). The model typically requires pilot mill data but recent research has developed correlations between grinding rates and mill operating conditions as well as between mill feed size and ore breakage characteristics, allowing the model to predict mill performance and evaluate circuit designs without pilot testing. The document provides details on the model structure and equations used to relate operating conditions to grinding rates.

Uploaded by

bob2341
Copyright
© © All Rights Reserved
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Page 769

MINING AND MINERAL PROCESS ENGINEERING, UBC


Vancouver, 6. C. Canada
-

AG AND SAG MILL CIRCUIT SELECTION AND DESIGN BY


SIMULATION

Dr. S Morrell' and Dr. R D Morrison2


1- Manager - Comminution Research, 2- Manager, JKTech
Julius Kruttschnitt Mineral Research Centre
Isles Road, Indooroopilly, Brisbane, Australia

SUMMARY
The JKMRC AGISAG model typically requires a full scale plant or
pilot mill survey combined with ore breakage testing to generate a
set of grinding rates. However recent research using a large data
base of pilot and full scale milling tests has lead to the develop-
ment of a correlation between model grinding rates and mill oper-
ating conditions. A further correlation between mill feed sizing
and ore breakage characteristics has also been developed. These
two correlations now allow mill performance to be predicted for a
wide range of mill sizes and operating conditions. Hence the
model can be used to evaluate optimisation strategies in existing
plants and to investigate (and compare) grinding circuit configura-
tions at the pre-feasibility stage thus reducing the cost of pilot test-
ing. A comparison of this design method vs actual measured
performance including power is provided for a range of AGISAG
mills and product sizes. The model is also used to describe in de-
tail the effects of changing operating conditions.
Using these correlations the effects of changing operating condi-
tions are considered in detail.
Page 770
INTRODUCTION
Pilot-scale testwork based on a 6' x 2' mill is arguably still the
most reliable method for predicting full scale autogenous (AG)
and semi-autogenous (SAG) grinding mill behaviour when treating
a given ore. However, the cost of a detailed pilot-mill programme
both in terms of providing sufficient sample material as well as the
hire of the plant can be prohibitive. Deposits with highly variable
ore types are a particular problem as pilot testing of the different
ore types greatly escalates the cost of the testwork programme.
The use of mathematical modelling and simulation based on labo-
ratory ore characterisation can help reduce the cost of the pilot
test programme. This can be achieved by both narrowing the
choice of the most likely successful processing routes at the pre-
feasibility stage and providing realistic pilot plant throughput tar-
gets, as well as augmenting a pilot test programme on a bulk
sample with a number of simulations based on satellite drill core
samples. In cases where pilot-scale testwork is not possible,
simulations referenced against a large industrial data base signifi-
cantly reduces the risk of not piloting. The added advantages of
the simulation route are in its versatility, its ability to simulate the
entire comminution circuit and the ease with which combinations
of circuit designs, operating conditions and ore types can be
evaluated on a throughput, power utilisation and product size ba-
sis.
For 25 years the Julius Kruttschnitt Mineral Research Centre
(JKMRC) has been conducting applied research on AGISAG mill-
ing. During this time it has collected a large volume of data from
pilot and full size AGISAG mill grinding circuits as well as develop-
ing a number of ore characterisation tests with which to develop
and validate its mathematical models. This paper describes some
of the developments in the AGISAG model together with some ex-
amples of its use, with particular reference to the design of green-
field circuits.

MODEL STRUCTURE
In its original form the JKMRC AGISAG mill model utilises the
concept that breakage within a mill is dependent upon specific
breakage energy. This in turn is related to the mill dimension and
a grinding medium size which is a characteristic of the ball charge
(if any) and rock charge (Leung et al 1987).
Page 771
The relationship between specific breakage energy and the prog-
eny size distribution is provided by laboratory impact and tumbling
tests which are carried out on the ore(s) in question. These gen-
erate breakage parameters which relate to the high energy (im-
pact) and low energy (abrasion) size reduction processes which
are believed to take place in AGISAG mills.
Transport of slurry through the mill is described by a function
which relates the hold-up of slurry, grate design, grate open area
and mill speed to the volumetric discharge rate through the grate
(Morrell and Stephenson, 1996):

J - k 0.5 - 1 . 2 5 ~ - 0 . 5 + 0 . 6 7 ~ 1 0 . 2 5
P- Q Y
where
J, = fractional slurry hold-up
D = mill diameter (m)
y = mean relative radial position of the grate apertures

where
ai = open area of all holes at a radial position ri
=
r, radius of mill inside the liners.
A = total area of the grate apertures (m2)
Q, = fraction of critical speed
Q = volumetric flowrate out of the mill (m3lhr)

Classification by the grate is related to the effective grate aperture


by a simplified classification function. For illustrative purposes a
conceptual view of the model is shown in Figure 1.
One of the limitations of the original model, particularly from a de-
sign viewpoint is that it contains a fixed breakage rate distribution,
which must be back-calculated from existing plant data. How-
ever, it is clear from the many industrial and pilot data that have
been examined that the breakage rate distribution varies consid-
erably with factors such as ball load, mill speed and feed size
(Morrell & Morrison, 1989; Morrell et al, 1995).
Page 772

new feed + breakage discharge


fi pi

high
energy

Figure 1: Conceptual View of JKMRC AGlSAG Mill Model

What is therefore needed is a relationship between operating con-


ditions and the breakage rate distribution.
Breakage Rate Distribution
To determine what the relationship was between operating condi-
tions and the breakage rate distribution systematic changes in the
breakage rate distributions within the JKMRC's pilot mill data
base (Mutambo, 1993) were looked for. These results were aug-
mented with results from full scale mill data in cases where the pi-
lot mill data base contained little or no variation in the parameter
of interest eg. mill speed. To indicate the extent of the pilot mill
data base, Table 1 summarises its details.

Table 1: Pilot Mill Data Base Details


Range
New Feed F,, (mm) 35-140
Ball load (%) 0-12
Recycle load (%) 0-500
No. different ores 16
No. tests 52
Page 773
The breakage rate distribution is described within the model using
cubic splines (Ahlberg, 1967). This gives rise to five breakage
rate values each of which relate to a particular particle size and
which together characterise the entire breakage rate distribution.
The five particle sizes chosen are 0.25, 4, 16, 44 and 128mm
which have associated with them breakage rates which are la-
belled R1, R2, R3, R4 and R5 respectively (Figure 2).

1000 :

-
r

i
s
100 -
9 I07
a
m
m
X
?2
m
1 -
0 0 1 10 100 1000
Size (mm)

Figure 2: Characterisation of the Breakage Rate Distribution


These rate curves exhibit a characteristic shape. The coarser (R5
and R4) rates relate to abrasive breakage while the finer rates R1
and R2 exhibit similar characteristics to those of coarse ball mill-
ing, ie. predominantly impact breakage. The pronounced dip in
the rates at R3 is associated with the critical size which may limit
mill throughput by building up to excessive levels. Typically it is in
the 25-75mm range and varies with particular combinations of
feed sizing, breakage characteristics and the magnitude of the
breakage energy developed in the mill.
To determine the relationship between operating conditions and
the breakage rate distribution, the breakage rates R1-R5 were re-
gressed against operating conditions. The resultant equations
were of the following form:
Page 774
Ln ( R I ) = (k,, + kl2Ln(R2) - kl3Ln(R3) + J, (k14- k15F,) - D,)ISb (2)

Ln (R3) = S,, (k,, + k,, Ln(R4) -k,, R,) IS, (4)

where
S, = rpm scaling factor
= Ln (simulated mill rpm123.6)
S, = fraction of critical speed scaling factor
= simulated mill fraction of critical speed10.75
D, = ball diameter scaling factor
= Ln (simulated ball diameterl90)
J, = % of total mill volume occupied by balls and associated voids
R, = recycle ratio
- (tph recycled material -20+4mm)
(tph new feed) + (tph recycled material -20+4mm)
F,, = 80% passing size of new feed (mm)
k, = regression coefficients

The regression coefficients for equations (2) - (6) are given in Ta-
ble 2 and are based on the JKMRC's current data base. As more
data are collected and our understanding of the various factors in-
creases these coefficients are likely to be modified.
It can be seen from the equations that the finer size rates are
functions of the rates of the coarser sizes. Hence R1 is a function
of R2 and R3 etc. The rates can be considered as falling into 2
groups which represent the grinding media and product size frac-
tions.
Page 775
Table 2: Rearession Coefficients

Hence the grinding media group contains the rates R4 and R5


(related to particles >30mm) the magnitude of which affect the
throughput. The product group incorporates rates R1, R2 and R3
(related to particles < 30mm) and the magnitude of these affects
the final product size. It is of particular note that the rates are in-
terrelated in a complex manner and are best understood by plot-
ting the entire breakage rate distribution.
Effect of Ball Load
The effect of changing ball load on the breakage rate distribution
is illustrated in Figure 3.

10000

1000

-
-
f
m
loo
F
m
m
X
"r 10
E

1
0 1 10 100 1000
Size (mm)

Figure 3: Effect of Ball Load on Breakage Rate Distribution


Page 776
The resulting relationship is as expected in that by increasing the
ball load the breakage rates increase at coarser sizes but reduce
at finer sizes. This has the effect of predicting higher throughputs
at coarser grinds as the ball load is increased. However, it is
commonplace to operate at too high a ball charge often because
of historical experience with softer, oxidised surface ore. As the
ore becomes harder it may well be able to replace balls as grind-
ing media for more power effective operation.
Effect of Feed Size (F,,)
The effect of F, was found to be the most difficult one to evaluate
as it interacted with the ball charge level. At relatively high ball
charges (10% or more) high Fs, were detrimental as evidenced
by the reduction in the breakage rates illustrated in Figure 4.

10000

1000

-
L.

f 100
w
3
w
a
m
X
10
m
e

1
0 1 10 100 1000

Size fmm)

Figure 4: Effect of F,, on Breakage Rate Distribution (sag mill)


However in the case of autogenous grinding the pattern is differ-
ent. In this case a higher F, promotes breakage in the coarser
size fractions (Figure 5). This is to be expected when it is consid-
ered that in autogenous milling large rocks are required to break
ore in the R5 size range (128mm).
Page 777

1000 -

100 -
A

-
f
i% 10 -
%
E!
m

1-
0 1 10 100 1000
Size (mm)

Figure 5: Effect of F,, on Breakage Rate Distribution (ag -


mill)

As the F,, increases, this will typically result in more coarse rocks
in the charge able to break R5-size ore and hence R5 will in-
crease. In SAG mills running with higher ball charges, the rock
component of the grinding media plays a lesser role in dictating
the breakage rate and contributes more to the rock 'burden' which
has to be ground down. Feeds with higher Fs ,' and hence more
coarse feed rocks, can thus be expected to reduce the breakage
rate. Caution needs to be exercised, however, as it has been
found that the F, is not always a good indication of the feed size
distribution. This is particularly noticeable with autogenous mills
whose performance may fluctuate considerably yet maintain a
reasonably constant F., In such cases the distribution changes
systematically with performance and that typically higher propor-
tions of 25-50mm material in the feed result in lower feedrates, ie.
less sub-grate size material is present in the feed and more near
size material has to be broken.
In green-field design situations the question always arises as to
what the expected AGISAG mill feed size distribution will be.
Page 778
In the majority of existing installations the AGISAG mill is fed with
prirnary crushed material, though rom or secondary crushed feed
is used in some plants (Nelson et al, 1996; Needham & Folland,
1994). From the JKMRC data base the most popular gap setting
in circuits using primary crushing only is of the order of 150mm
(closed side setting) though in some cases up to 200mm is used.
Crusher manufactures' grading curves typically give a P,, of
180mm for a 150mm css. However, for base metal and gold op-
erations this appears to be an unrealistic estimate. Figure 6
shows the Fs,' from over 100 mill feed sizings for 30 different
mills which have been conducted by the JKMRC.

25-50 50-1 00 100-150 150-200 200-250


FSO (mm)

Figure 6: Histogram of AGISAG Mill Feed F,,'s


The modal F, is 75mm and is clearly much lower than the
180mrn determined from crusher manufacturers' data. The dis-
crepancy has to do with the origins of manufacturers' data which
typically derive from quarry applications and may be based on
scalped feed to the crusher. Quarry operations endeavour to
minimise the amount of fines produced and hence blasting prac-
tice reflects this requirement. The resultant coarse prirnary
crusher feed therefore results in a coarse crusher product. In
base metal and gold operations relatively large amounts of fines
are produced and hence the primary crusher circuit product is
typically much finer. To illustrate this effect Figure 7 shows a run-
of-mine (ie. uncrushed) size distribution from a gold operation
which was determined by sizing approximately 85 tonnes of ore.
Page 779

100

.F
I0
s
v@

1
z
4
4
1 2 0
8
9
0
0
z
Size (mm)

Figure 7: ROM Size Distribution for a Gold Plant

It can be seen that even in its uncrushed form the F, is only


154mm and close to 20% of this material is already -I mm. By us-
ing the AndersenNVhiten crusher model (Andersen, 1989) it is
possible to simulate the effect of crushing such a feed in a primary
crusher set at 150mm (css). If the crusher feed is first scalped at
150mm the crusher would reduce the oversize to a P,, of 150mm
ie. more in line with the crusher manufacturer's grading curves.
On combining the crusher product with the scalper undersize an
overall product P, of 100mm is obtained ie. in line with the data in
Figure 6.
For a given css, variations in the P,, will result from differences in
ore hardness as well as variations in the blast (McKee, Chitombo
& Morrell, 1995).
Page 780
It has been found that the F, data correlate with the abrasion pa-
rameter (fa) which is a hardness indicator obtained from the
SAGIAG mill laboratory tumbling test. Regression analysis of the
data yielded the relationship:

F, =71.3 - 28.4 Ln (t,) (7)

A plot of the ta parameter vs primary crusher product (AGISAG


F), is shown in Figure 8.

Figure 8: Association Between ta Parameter and AGISAG Mill


F80

Scatter is obviously apparent though much of this can be ex-


plained by natural variations in crusher feed size distributions. To
illustrate this Table 3 shows the results from repeat primary
crusher product sizings from three different mines each crushing
a nominally homogenous ore with a css of 150mm. The ores
were chosen to give a wide range of t, values. The observed
mean Fs, as well as their standard deviations are shown, to-
gether with the predicted F,, using equation (7). It can be seen
that the higher t, values coincide with the finer crusher products.
The standard deviation is similar in each case being approxi-
mately 10% of the css. This gives rise to a 95% confidence inter-
val of approximately i 30mm, which is in line with the scatter in
Figure 8.
Page 781

Table 3: Observed vs Predicted AGlSAG FEosfor Different


Ore Type
ta No. Sur- Mean S.D. Pa, Predicted
VeYS Pa0 (mm) Pa0 (mm)
(mm)
0.36 9 113 15 100
0.68 5 92 17 82
1.5 12 57 17 59

Equation 7 was derived from crushers with closed settings of ap-


proximately 150mm. It can be extended to larger gap settings as
follows:

F, (mrn) = (css - 78.7 - 28.4 In (f))


s.d. = 0.1 css.

To test the validity of equation 8, 4 repeat surveys were con-


ducted on a primary crusher with a nominal css of 200rnm. The ta
parameter for the ore was 0.44. The survey results are shown in
Table 4 together with the predicted F,, using equation 8. Rea-
sonably close agreement was obtained.

Table 4: Observed and Predicted Crusher P,,'s


Observed Predicted
INO. Surveys I 4 I - I
css (mm) 200 -
Mean F,,(mm) 157 145

In a design scenario therefore, equation 8 is used to determine a


likely F, which in turn is used in the breakage rate equations
(2)-(6).
Having chosen a F, for the AGlSAG mill feed the question still
arises as to what size distribution should be used.
Page 782
Once again this will be influenced by blasting practice and ore
type. To assist with this choice grading curves are extracted from
the JKMRC data base to represent the ore in question, based on
its hardness. Typical curves representing a coarselhard ore, and
a finelsoft ore are shown in Figure 9.

100

m
.,-
e
4l
4l
n
CL

10
:
-
+
n r

m
a
5
U

1
.O1 .I 1 10 100 1000
Size (mm)

Figure 9: Typical AGlSAG mill feed sizings

The majority of the size distributions in the data base fell in be-
tween these curves.
Effect of Recycle Load
Recycle loads broadly fall into 2 categories viz.:
1. coarse recycles from trammels, vibrating screens and recycle
crushers which typically comprise only -20 + 4mm material
and have Ps,' of the order of 8 - 12mm,
2. fine recycles from hydrocyclones and DSM screens which are
predominantly - 4mm material and have P,s' of the order of
0.2 - 0.5mm.
It has been found that the amount of recycled material in the -20 +
4mm size range is inversely related to the amount of breakage
that this material is subjected to.
Page 783
This can be explained if one considers that these rocks are bro-
ken by coarser rocks and balls whose frequency does not appre-
ciably change with changes in recycle load. However as the
amount of recycled -20 + 4mm rock increases, the amount of this
size material in the load will increase. As the breakage rate in a
given size class is related to the ratio of the number of coarser
rocks and balls to the number of rocks in the given size class,
then increasing the -20 + 4mm recycle will result in a drop in the
breakage rate in this size range (R3 size = 16mm). The changes
in the breakage rate distribution as the coarser recycle increases
is illustrated in Figure 10. Interestingly, recycle of fine material ie.
-4mm did not correlate with any of the breakage rates. This may
be related to the breakage mode of this material which is believed
to be dominated by attrition.

O Kec=.OS

0 Rec= l

1-
1
0
- 0
8 !
Sue (mm)

Figure 10: Effect of Recycle Load on Breakage Rate


Effect of Speed
The breakage rate is related to the number of size reduction
events per particle, per unit time and is hence a frequency.
Page 784
This in turn must be related to the frequency with which the mill
rotates (rpm). A scaling factor is therefore applied to account for
changes in the rotational rate. For a given fraction of critical
speed the rpm decreases with mill and hence this scal-
ing factor will also change with mill diameter. All else being equal,
therefore, a larger diameter mill will have a lower breakage rate
than a smaller unit. However it is pointed out that the JKMRC
model inherently scales on the basis of breakage energy which it
relates to mill diameter. Therefore, whereas a larger diameter mill
will have a lower breakage rate it will have a higher breakage en-
ergy.
In a given mill as the rpm changes, apart from the rotational rate,
the shape of the grinding charge will also change in line with the
fraction of critical speed (Morrell, 1996). Typically as the fraction
of critical speed increases the charge is subjected to increased lift
and hence impact breakage is enhanced. It is at the expense of
attrition breakage which is normally associated with cascading
motion and which is prevalent at lower speeds. To account for
these effects a further scaling factor is applied which is based on
the fraction of critical speed. Figure 11 illustrates the predicted
changes in the breakage rate distribution as speed is changed.

1-
1
0El33
- 1 5 g
S
Size (mm)

Figure 11: Predicted Effect of Changing Speed on the Break-


age Rate Distribution
Page 785
Effect of Ball Size
No significant dependence of the breakage rates on ball size was
found in the pilot mill database. The sag model does account for
ball size changes in terms of the energy provided during impact.
It does this by changing the mean grinding media-size, which in
turn changes the 'energy level' of the mill. This 'energy-level' term
is used to determine the specific energy of impact. As the ball
size is increased, therefore, the specific energy increases and
hence for a given impact event a finer product size distribution oc-
curs. However, as the ball size is increased the number of grind-
ing media per tonne of charge will decrease. As the breakage
rate is related to the number of impacts provided by the grinding
media then a reduction in the breakage rate may be expected to
occur. To account for this a ball scaling factor is used. Figure 12
illustrates the effect of the ball size correction factor on the break-
age rate distribution.

loOD -

100 -
3-
a,

i
2 10 -

I I
113 DUE

1
-
-
9
0
1
0
d
r
0 S
Size (rnm)

Figure 12: Predicted Effect of Changing Ball Size

It should be emphasised that it is usually argued that a coarser


ball size will give a higher throughput but with a coarser grind.
Page 786
In practice, experiments with full scale mills are sometimes incon-
clusive and mill operators see little or no effect when ball size is
experimented with. This may be due to the counter-effect of re-
duced numbers of balls providing higher breakage energies when
increasing ball size. The model predicts such a response by in-
creasing the breakage energy and reducing the breakage rate. In
some instances the one effect may outweigh the other, in which
case a response will be noted. Over some ranges of ball sizes,
however, little or no effect will be seen.

PREDICTING AGISAG MILL PERFORMANCE


To determine the accuracy of the model in a design situation the
performance of a number of full scale AGISAG mills which have
been surveyed by the JKMRC was predicted, based solely on
laboratory impact breakage and tumbling test results, coupled
with mill design data. Details of the mills are given in Table 5. In
each case the breakage rate distribution was determined using
equations 2-6. The slurry hold-up - flowrate relationship was then
calculated using equation 1. Using the measured feedrate and
feed size distribution, the model was then used to predict both the
mass of ore and water in the mill as well as the product size distri-
bution. The simulated mass of ore and water in the mill was then
used to predict the mill power using the JKMRC power draw
model (Morrell, 1996). The observed and predicted power draws
and associated 95% confidence intervals, and product size distri-
butions as described by the P, and P, are given in Figures 13
and 14 respectively.
It can be seen from Figure 13 that the observed and predicted
power draws are well matched in most cases. One or two in-
stances are apparent where the predictions are not quite as good
as would be hoped. These are associated with autogenous op-
erations where in practice it was found that even though the F,
remained constant, very large changes in mill performance were
observed. This was due to the effect of feed size distribution for
which the model only partly accounts. Figure 14 indicates that the
product size distribution trends are followed reasonably well
though scatter is apparent in the data. It is emphasised that these
results are based solely on the breakage of rock samples of <50
kg. Where pilot data are available equations 2-6 can be fitted to
generate a model which will predict full scale mill performance
with an even higher degree of accuracy.
Page 787

Table 5: Mill details


Circuit Diameter AGISAG
(m)
closed circuit; DSM screens 7.05 I SAG
closed circuit; DSM screens 7.73 I SAG I
open circuit 1 5.08 1 SAG I
closed circuit; Cyclones 4.35 I SAG
lclosed circuit; Cyclones 3.9 I SAG I
lclosed circuit; recycle crusher 1 4.05 1 SAG I
lclosed circ.; screen; 94mm balls 1 9.56 1 SAG I
lclosed circ.; screen; 120mm balls 1 9.56 1 --
SAG
-

closed circuit; recycle crusher 6.49 AG


recycle crusher in by-pass 6.49 AG
open circuit; high density ore 7.1 1 AG
lopen circuit; low density ore 1 7.11 1 AG I
closed circuit; cyclones 6.5 SAG
open circuit 6.5 SAG
open circuit 6.51 AG
lclosed circuit; cyclones 1 5.88 1 AG I
lclosed circuit; cyclones 1 9.4 1 AG I
lclosed circuit; trommel 1 9.5 1 AG I
Scaling Between Operating Conditions.
If a set of rates have been measured by plant survey and the ore
breakage characteristics determined using the JKMRC's test
methods, equations (2) - (6) can be used to estimate the effect of
variations in ball load, mill speed etc. In this way optimisation
strategies can be evaluated without recourse to costly and time
consuming trial and error methods. JK breakage characterisation
tests which include the more recently developed drop weight test,
can be used on particles up to 90mm which provides an indication
of ore competence at larger particle sizes.
Page 788

10000-

8000-

6000-
t
Ih
a
0

1 4000-
L
2000-

0 -
0 2000 4000 6000 8000 I0000

MN - predicted

Figure 13: Observed vs Predicted Power Draw

Figure 14: Observed vs Predicted Product Size Distributions


Page 789
These tests have become an accepted technique over the last
decade with test facilities available at five laboratories world wide.
The data base of breakage tests now covers more than 500 ore
types. It should be noted that this technique only applies to mate-
rials which do break. It is not useful for "plastic" ores or those
which change rapidly in water.
Using AGlSAG Product Size Distributions
The simulation model predicts a complete product size distribu-
tion. This line is almost never parallel with the feed size distribu-
tion. Hence traditional power methods based on product F80s
are not valid. As these products typically contain more finished
product that would be expected for a similar ball mill product, cal-
culations based on P80 can be excessively conservative. If the
circuit target product size is known, a simulated classifier can be
used to remove this "extra" product and provide a realistic esti-
mate of the effective feed sizing (and feed rate) to the next stage
of size reduction.

CONCLUSIONS
A method has been developed for estimating grinding rates for the
JK AGISAG mill model over a wide range of operating conditions.
This allows the model to be used to aid in the design of AGlSAG
mill circuits based solely on laboratory breakage tests and/or in
conjunction with pilot mill data. Its application is seen to be for
pre-feasibility studies, for limiting the size and cost of pilot mill pro-
grammes, designing full scale plants in conjunction with pilot mill
results, and reducing risk when designing plants without pilot
data.

REFERENCES
Ahlberg J H, Nilson, E N & Walsh, J L, 1967. The Theory of
Splines and Their Applications. Mathematics in Science and En-
gineering, 38, Academic Press, New York and London
Andersen J S, 1989. Development of a Cone Crusher Model.
M.Eng.Sc Thesis, University of Queensland.
Leung. K, Morrison R D & Whiten W J, 1987. 1987. An Energy
Based Ore Specific Model for Autogenous and Semi-autogenous
Grinding Mills. Copper 87, Santiago Chile.
Page 790

REFERENCES (cont'd)
McKee D J, Chitombo G P & Morrell S, 1995. The Relationship
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