AG and SAG Mill Circuit Selection and Design by Simulation
AG and SAG Mill Circuit Selection and Design by Simulation
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)
high
energy
1000 :
-
r
i
s
100 -
9 I07
a
m
m
X
?2
m
1 -
0 0 1 10 100 1000
Size (mm)
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
10000
1000
-
-
f
m
loo
F
m
m
X
"r 10
E
1
0 1 10 100 1000
Size (mm)
10000
1000
-
L.
f 100
w
3
w
a
m
X
10
m
e
1
0 1 10 100 1000
Size fmm)
1000 -
100 -
A
-
f
i% 10 -
%
E!
m
1-
0 1 10 100 1000
Size (mm)
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.
100
.F
I0
s
v@
1
z
4
4
1 2 0
8
9
0
0
z
Size (mm)
100
m
.,-
e
4l
4l
n
CL
10
:
-
+
n r
m
a
5
U
1
.O1 .I 1 10 100 1000
Size (mm)
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)
1-
1
0El33
- 1 5 g
S
Size (mm)
loOD -
100 -
3-
a,
i
2 10 -
I I
113 DUE
1
-
-
9
0
1
0
d
r
0 S
Size (rnm)
10000-
8000-
6000-
t
Ih
a
0
1 4000-
L
2000-
0 -
0 2000 4000 6000 8000 I0000
MN - predicted
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
Between Fragmentation in Mining and Communition Circuit
Throughput. Minerals Engineering, 8, No. 11, pp.1266-1274.
Morrell, S. 1996. Power Draw of Wet Tumbling Mills and its Re-
lationship to Charge Dynamics. Part I: A Continuum Approach to
Mathematical Modelling of Mill Power Draw. Trans. Instn.
Min.Metall, 105, C43-53.
Morrell S & Stephenson 1, 1996. Slurry Discharge Capacity of
Autogenous and Semi-autogenous Mills and the Effect of Grate
Design. Int J. Miner, Process. (In press).
Morrell S, Finch W M, Kojovic T, Delboni H, Jr. 1995. Modelling
and Simulation of Large Diameter Autogenous and Semi-
Autogenous Mills. Int. J. Miner. Process. (In press).
Morrell S & Morrison R D,1989. Ore Charge, Ball Load and Mate-
rial Flow Effects on an Energy Based SAG Mill Model. Presented
SAG 1989, University of British Columbia. Editors. Mular & Agar.
Mutambo. J, 1993. Further Development of an Autogenous and
Semi-autogenous Mill Model. M. Eng Sci. Thesis. Uni of Qld.
Needham T M & Folland G.V. 1994. Grinding Circuit Expansion
at Kidston Gold Mine. Presented at SME Annual Meeting, Albu-
querque, New Mexico. February 14 -17.