Chapter 10

STATE OF THE ART I N THE MODELING AND DESIGN

OF AUTOGENOUS AND SAG MILLS

L. G. Austin

Mineral Processing Section

The Pennsylvania S t a t e U n i v e r s i t y
U n i v e r s i t y Park, PA 16802

ABSTRACT

The paper summarizes t h e c u r r e n t s t a t e of development of

s i m u l a t i o n models f o r SAG and FAG m i l l s , and g i v e s t h e r e s u l t s of
r e c e n t i n v e s t i g a t i o n s of t h e p h y s i c a l processes o c c u r r i n g i n
autogenous g r i n d i n g . The breakage process i s t r e a t e d a s t h e sum of
t h r e e r e g i o n s of breakage a c t i o n s : normal breakage caused by
nipping of p a r t i c l e s between media ( s t e e l b a l l s o r pebbles);
abnormal breakage caused when t h e p a r t i c l e o r lump i s t o o b i g i n
r e l a t i o n t o t h e media t o be r e a d i l y nipped; self-breakage r e s u l t i n g
from t h e chipping f r a c t u r e and a b r a s i o n of t h e tumbling a c t i o n of
rock lumps. Each r e g i o n of breakage a c t i o n has a s s o c i a t e d s p e c i f i c
r a t e s of breakage and primary progeny fragment d i s t r i b u t i o n s .
 CHALLENGES IN MINERAL PROCESSING

INTRODUCTION

Although t h e use of s i m u l a t i o n models f o r t h e d e s i g n of b a l l

m i l l s h a s advanced s i g n i f i c a n t l y i n r e c e n t y e a r s , ( I ) p r o g r e s s h a s
been slow i n a p p l y i n g t h e concepts of s p e c i f i c r a t e s of breakage and
primary breakage d i s t r i b u t i o n s i n t h e c o n s t r u c t i o n of s i m u l a t i o n
models (2-4) f o r semi-autogenous (SAG) and fully-autogenous (FAG)
mills. T h i s i s l a r g e l y because t h e p h y s i c a l p r o c e s s e s of breakage
o c c u r r i n g i n t h e s e m i l l s a r e more complex t h a n t h o s e i n b a l l m i l l s .
S e v e r a l r e c e n t p a p e r s by Austin and co-workers (5-9) have i n v e s t i -
g a t e d c e r t a i n a s p e c t s of t h i s problem.

I n t h i s p a p e r , t h e c u r r e n t s t a t e of model development w i l l be
summarized a s s e e n by t h e a u t h o r and t h e n an approximate s i m p l i -
f i e d form of t h e models w i l l be used t o compare t h e performance of a
t y p i c a l SAG m i l l d e s i g n (L/D = 0.5) w i t h t h a t of a r e p r e s e n t a t i v e
FAG m i l l (LID = 2 ) . It i s assumed t h a t t h e r e a d e r i s f a m i l i a r w i t h
(1)
t h e concepts and symbolism of c o n s t r u c t i o n of m i l l models.

MILL MODELS

SAG M i l l Model

The Basic Mass Balance. It i s assumed t h a t t h i s t y p e of m i l l

approximates t o a f u l l y mixed r e a c t o r where t h e g r a t e a c t s l i k e a
s i z e c l a s s i f i e r t o prevent large material leaving the m i l l . The
simple concept of r e s i d e n c e time d i s t r i b u t i o n l o s e s meaning i n such
a system because t h e r e s i d e n c e time i s determined by t h e r a t e s of
breakage of f e e d m a t e r i a l t o l e s s t h a n t h e g r a t e s i z e , s o i t i s a
complex f u n c t i o n of t h e f e e d s i z e d i s t r i b u t i o n and s p e c i f i c r a t e s of
breakage. However, i t i s s t i l l convenient t o d e f i n e a mean
r e s i d e n c e time by s o l i d hold-up W d i v i d e d by s o l i d f e e d r a t e ,
7 = W/F. The b a s i c mass b a l a n c e i s simple t o w r i t e :
 MODELING AND DESIGN OF AUTOGENOUS AND SAG MILLS

where p is the fraction of mill product in size class i; fi is

i
fraction of feed in size class i; Si is the specific rate of
breakage of size i material; b is the fraction of material broken
isj
from size class j which appears in size class i; w is the fraction
i
of hold-up of size class i; and n is the total number of size
intervals.
There is evidence that material less than the grate size
undergoes classification as it passes through the grate (see later).
Therefore, the system is treated as shown in Figure 1, with material
rejected by the grate thrown back into the mill charge with an
equivalent internal circulation ration of C'. Since F' = (l+C1)F,
the mass balance of the apparent mill feed is

where the value of c is the fraction of size i material returned to

i
the mill. The value of C' is defined by

Applying Eq. [I] to this system using w = gives

i i
i- 1

The equation is readily converted to the closed circuit form.

 CHALLENQES IN MINERAL PROCESSING

------------
I GRATE
'ION

L-----------J
OVERALL M I L L

FIGURE 1. I l l u s t r a t i o n of g r a t e c l a s s i f i c a t i o n treatment a s an e x i t
classifier.

The hold-up i n t h e m i l l of s i z e s l e s s than t h e g r a t e opening

depends on t h e e a s e w i t h which s l u r r y flows from t h e m i l l : t h e l e v e l
must i n c r e a s e i n o r d e r t o permit s l u r r y t o flow out a t a h i g h e r
rate. Thus, t h e system i s only p r e c i s e l y defined i f a mass t r a n s -
p o r t r e l a t i o n i s used. The e m p i r i c a l f u n c t i o n

where f i s t h e f r a c t i o n a l f i l l i n g of t h e m i l l by s l u r r y , w i t h
s
s l u r r y defined by s i z e s l e s s than t h e g r a t e opening w i l l be used.
F i s a volume flow r a t e and Nm i s an e m p i r i c a l c o n s t a n t . I n terms
v
of t h e hold-up of m a t e r i a l of s i z e s l e s s than g r a t e opening i n a
m i l l of e f f e c t i v e volume V,
3

where C i s t h e volume f r a c t i o n of s o l i d i n t h e s l u r r y ; P S i s t h e
s
t r u e d e n s i t y of t h e s o l i d ; and i i s t h e i n t e r v a l number correspond-
g
i n g t o t h e g r a t e s i z e . The v a l u e of Fvo i s a s t a n d a r d flow r a t e
which g i v e s a s t a n d a r d f i l l i n g of fso. Fvo i s expected ( l o ) t o be
 MODELING AND DESIGN OF AUTOGENOUS AND SAG MILLS

r e l a t e d t o m i l l s i z e by

where 4c i s f r a c t i o n of c r i t i c a l speed and A i s t h e f r a c t i o n of

g
m i l l c r o s s - s e c t i o n which i s open g r a t e a r e a . The simultaneous
s o l u t i o n of Eq. [ 4 ] , [ 5 ] and 161 g i v e s

f CpV 1INm
W
T =(- 1 1
FvoPsCs wcgwk
n

For given v a l u e s of f
1' b i , J j
.
,S and c t h e r e i s only one v a l u e of
i
T

which w i l l s a t i s f y b o t h Eq. [ 3 ] and [ 7 ] .

A More Complex Mass Balance. The problem w i t h t h e simple mass

balance given above i s t h a t i t c o n s i d e r s o v e r a l l f i r s t - o r d e r S
i
v a l u e s , whereas t h e r e i s t h e p o s s i b i l i t y of a s u b s t a n t i a l component
of a b r a s i o n i n a d d i t i o n t o normal breakage p r o c e s s e s , and a b r a s i o n
f o l l o w s a d i f f e r e n t s e t of laws than breakage. Thus, Austin and
Menacho (11) have formulated t h e o v e r a l l balance on s i z e i a s 'Rate
of s i z e i m a t e r i a l out = ( r a t e of s i z e i m a t e r i a l i n ) + ( n e t r a t e of
m a t e r i a l wearing i n t o s i z e i by a b r a s i o n of rounded pebbles through
t h e upper and lower l i m i t s of s i z e i n t e r v a l i ) - ( r a t e of l o s s of
fragments by a b r a s i o n of pebbles i n s i z e i n t e r v a l i ) + (rate or
production of s i z e i m a t e r i a l from t h e products of a b r a s i o n of
larger sizes) - ( r a t e of production of s i z e i m a t e r i a l by f r a c t u r e )
+ ( r a t e of production of s i z e i m a t e r i a l from t h e products of
f r a c t u r e breakage of l a r g e r s i z e s ) '.
Considering a b r a s i o n according t o a l i n e a r wear law i t i s r e a d i l y
shown ( 7 s 1 2 ) t h a t t h e n e t r a t e of i n c r e a s e of mass due t o pebbles of
e q u i v a l e n t r a d i u s r wearing i n and out of a d i f f e r e n t i a l s i z e
2 2
element d r i s W K ( ~P / d r ) d r , where P i s t h e cumulative mass f r a c t i o n
s i z e d i s t r i b u t i o n of hold-up W and K i s t h e l i n e a r wear r a t e (LIT).
S i m i l a r l y , t h e mass l o s s from t h e i n t e r v a l s i s ( 3 ~ / r ) ( d P / d r ) d r .
178 CHALLENGES IN MINERAL PROCESSING

I n c o r p o r a t i n g t h e s e w i t h t h e u s u a l f i r s t - o r d e r mass-rate balance due

t o f r a c t u r e gives

where a i s t h e f r a c t i o n of m a t e r i a l abraded from s i z e j which

ij
appears i n s i z e i n t e r v a l i.

The value of K i s not n e c e s s a r i l y constant over a wide s i z e range

b u t i t can be assumed t h a t i t i s approximately c o n s t a n t w i t h i n a
size interval; Ki i s t h u s defined a s t h e mean v a l u e of K for
particle sizes 2 r <xi' Then

i
Also, by d e f i n i t i o n j (dP/dr)dr = wi, s o i t i s convenient t o d e f i n e
- by t h e product of some f a c t o r a and t h e upper s i z e
a mean value r
i
of s i e v e s i z e i , Fi =
i
and make t h e reasonable approximation
-
r ~d e r. i v a t i v e d ~ / d ris approxi-
( ~ / r ()d ~ / d r ) d r;~ ~ w ~ /The
1+1
mated by (dP/dr)i ;w ~ - ~ / ( x ~ - ~ z- w x i~- l)/ ~ i - l (1-R), g i v i n g

where R i s t h e r a t i o of lower t o upper s i e v e s i z e of t h e s i z e

interval (=JZ).

I t i s convenient t o d e f i n e t h e s p e c i f i c r a t e of l o s s of m a t e r i a l
by a b r a s i o n t o fragments a s a f r a c t i o n of t h e s p e c i f i c r a t e of
 MODELING AND DESIGN OF AUTOGENOUS AND SAG MILLS 179

f r a c t u r e ; l e t t i n g yi = ( ~ K ~ / ~ x ~ R ~ - p' u) t/t isn~g , o/3(1-R) = K , and

s e t t i n g p i = w gives a s before
i

t o be used i n p l a c e of Eq. [ 3 ] i f a b r a s i o n p r o c e s s e s a r e
significant. The s i z e d i s t r i b u t i o n of t h e product stream from t h e
g r a t e c l a s s i f i c a t i o n is then given by p = (wi) ( l + c l ) (1-ci). For
i
c l o s e d c i r c u i t t h e v a l u e s of f a r e r e a d i l y r e p l a c e d i n terms of
i
make-up f e e d gi u s i n g t h e s parameters f o r t h e e x t e r n a l c l a s s i f i e r .
i

FAG M i l l Model

The FAG m i l l model i s e s s e n t i a l l y i d e n t i c a l t o t h e SAG m i l l model

given a s Eq. [ 8 ] except t h a t i t i s a p p l i e d a s an e q u i v a l e n t s e r i e s
of r e a c t o r s ( 8 y 9 ) w i t h v a r i o u s d e g r e e s of r e c y c l e of t h e m a t e r i a l
r e j e c t e d back t o t h e m i l l by t h e g r a t e , a s i n d i c a t e d i n Figure 2 . A
g r a t e c l a s s i f i c a t i o n a c t i o n i s necessary t o r e t a i n t h e pebbles i n
the m i l l . Of c o u r s e , t h e c a l c u l a t i o n of t h e e f f e c t i v e o v e r a l l Si

GRATE
CLASSIFICATION
r--------------------
I
I MILL I MILL 2 MILL m
F
fl
I
I
"I, I
TI
- '"1'2
r2
----- '"I, m
rm
I
I ec
,4
I elCm
sC' '
C
I
L--------------------------J
OVERALL MlLL

FIGURE 2. Reactors-in-series formulation f o r a FAG m i l l w i t h g r a t e

classification.
180 CHALLENGES IN MINERAL PROCESSING

values will not include a term for breakage by balls. In addition,

the mass transport constant k will correspond to that for a long
m
LID ball mill and not a short SAG mill.

CALCULATION OF S AND B VALUES

Breakage By Balls and Pebbles

In order to allow for different ball and pebbles sizes in the

mill, the values of specific rates of breakage of smaller sizes by
impact from media were calculated from the equations developed for
ball mills. The relations between the specific rates of breakage
determined using a single ball size in a laboratory test mill of
diameter DT and those for a mixture of balls in a larger mill of
diameter D are

Sn = 0

with

where A=O for SAG milling; A=O for D<3.81 m and = 0.2 for D>3.81 m
for ball milling or long L/D FAG milling.
The subscript T denotes conditions in the test mill, and mk is
the mass fraction of the kth size class of balls in the full-scale
mill: No, N1, N2, N3 are empirical exponents based on experience
with ball mills. The value of U is the fractional interstitial
 MODELING AND DESIGN OF AUTOQENOUSAND SAG MILLS

f i l l i n g of t h e media voids by p a r t i c l e s and J i s t h e f r a c t i o n a l

f i l l i n g of t h e m i l l by media. The v a l u e s used f o r t h e exponents
were N =0.5, N =0.2, N =1.0 and N =1.0, and t h e cushioning f a c t o r c
1 2 3 0
was taken a s 1.3.

The cumulative primary progeny fragment d i s t r i b u t i o n s (B ) for

i,j
normal breakage by a s i n g l e s i z e of b a l l of c l a s s k have been found
t o be f i t t e d by t h e e m p i r i c a l f u n c t i o n

a s i l l u s t r a t e d i n Figure 3. For comparison purposes, t h e o v e r a l l

B value f o r a mixture of b a l l s can be c a l c u l a t e d from
i3 j

Figure 4 i l l u s t r a t e s t h e decrease of breakage r a t e s a s t h e

p a r t i c l e s become t o o l a r g e t o be nipped properly by t h e b a l l s . In
Region 2, t h e breakage of t h e m a t e r i a l i n a batch r a t e t e s t becomes
n o n - f i r s t o r d e r (abnormal) because i t c o n s i s t s of a mixture of
normal f r a c t u r e caused by a d i r e c t impact and chipping caused by a
glancing, l e s s v i o l e n t impact. Figure 3 shows t h e v a r i a t i o n of
o v e r a l l B v a l u e s a s p a r t i c l e s i z e i n c r e a s e s with r e s p e c t t o t h e b a l l
size. I t i s c l e a r t h a t chipping becomes more important a s t h e s i z e
increases.

Equations [9] and [ l o ] were used f o r both b a l l s and pebbles, with

t h e v a l u e s of t h e c h a r a c t e r i s t i c parameters aT and uT a d j u s t e d by

d e n s i t y pebbles, pp
aT pebbles = aT b a l l s x d e n s i t y b a l l s , PB

PT pebbles = PT x P /P
P B
 CHALLENGES IN MINERAL PROCESSING

RELATIVE SIZE, XI / xi

FIGURE 3 . T y p i c a l v a r i a t i o n of t h e breakage d i s t r i b u t i o n v a l u e s f o r
l a r g e p a r t i c l e s . Dry b a t c h g r i n d i n g of q u a r t z i n a 0.6 m
diameter m i l l (U=0.5, J ~ 0 . 2 , 26.4 mm d i a m e t e r b a l l s ,
4 = 75% of c r i t i c a l speedy.
C

The v a l u e of J t o b e used i n Eq. [lot] i s based on t h e t o t a l

media f i l l i n g which d e f i n e s how media tumbles i n t h e m i l l , t h a t i s ,
i t must be t h e sum of f i l l i n g by b a l l s and p e b b l e s , J = J +J
B P'
C a l c u l a t i o n of breakage due t o b a l l s u s i n g t h i s J would o n l y b e
v a l i d i f a l l t h e media were s t e e l , s o t h e v a l u e i s c o r r e c t e d by t h e
f a c t o r of f r a c t i o n a l volume J B / J , S(B) = (JB/J) C t S ( d k ) i .
i
S i m i l a r l y , S ( P ) I = ( J p / J ) Cw S ( x ) where w is t h e mass f r a c t i o n of
j j i j
p e b b l e s of s i z e i n t e r v a l j i n t h e tumbling charge. It i s assumed
t h a t a l l rock l a r g e r than t h e g r a t e s i z e , p l u s b a l l s , c o n t r i b u t e s t o
t h e media f i l l i n g l e v e l of t h e m i l l .
 MODELING AND DESIGN OF AUTOGENOUS AND SAG MILLS 183

S I E V E SIZE, mm

FIGURE 4. Typical shape for the sum specific rate of breakage in

SAG.

The term exp[-c(U-UT)] in Eq. [lot] represents the decrease of

specific breakage rates when the media void spaces are overfilled.
This effect states that excessive powder in the media cushions the
breakage action on the powder. It seems reasonable that the
cushioning action depends on the media size, that is, a 10 mm
diameter lump will be media to small sizes but should be counted in
the cushioning powder for pebbles of 100 m diameter. Using the
~eymont('~) voidage b) factors a simple method of defining powder
is that all material of size less than 0.125 of the media size is
considered to be powder. This corresponds to a voidage factor of
size iwith respect to media size k of 0.5. Then the term in Eq.
[ 10c 1 becomes exp [-c (Uk-UT) 1, since the effective value of U depends
on the media size being considered.

Self-Breakage
As particle size is increased the particles are not nipped by
tumbling balls. However, they eventually become big enough to break
by the impact of their own fall, in the stream of tumbling rock and
balls. Then the breakage rates increase with increased lump size
 CHALLENGES IN MINERAL PROCESSING

due t o t h e increased impact f o r c e , g i v i n g Region 3 of Figure 4. The

t r a n s i t i o n from Region 2 t o Region 3 is obtained by simple a d d i t i o n ,
S . = S(B) + S ( P ) . + S ( S ) . where S(B)i and S(P)i a r e breakage due t o
1 i 1 1
nipping by b a l l s and pebbles (which become s m a l l a t l a r g e s i z e s ) ,
and S(S)i has been termed self-breakage. The v a l u e s of S(S)i appear
a l s o t o follow a power f u n c t i o n

where as i s s m a l l e r than t h e corresponding f o r media, s o t h a t S(S)i

is n e g l i g i b l e f o r small p a r t i c l e s i z e s .

The e m p i r i c a l equation used t o allow f o r t h e e f f e c t of media

f i l l i n g on self-breakage i s

Since breakage i s p r o p o r t i o n a l t o SJ, t h i s g i v e s a maximum r a t e of

breakage a t J=0.4. When a f r a c t i o n of t h e media i s s t e e l b a l l s i t
seems l o g i c a l t h a t t h e rock i n t h e tumbling stream w i l l r e c e i v e a
p r o p o r t i o n a t e f r a c t i o n of h e a v i e r impacts. Therefore, t h e breakage
r a t e s were c o r r e c t e d by

S(SIi = (JBpB+JPpp)/JPpp [I71

Thus, although t h e breakage r a t e of a given s i z e of tumbling rock is

termed self-breakage i t i s accepted t h a t t h e s i z e and d e n s i t y of t h e
r e s t of t h e charge h a s an i n f l u e n c e on t h i s breakage.

It i s expected t h a t t h e s p e c i f i c r a t e s of self-breakage w i l l
s c a l e w i t h m i l l diameter i n e s s e n t i a l l y t h e same way a s breakage by
b a l l s a s i n Eq. [lo]. Combining equations g i v e s
 MODELING AND DESIGN OF AUTOGENOUS AND SAG MILLS 185

where (DIDT) -
D<3.81 m
C =
S1 N A
(3.81/~~)~1(~/3.81)1- -
D>3.81 m

where cs is the cushioning factor for self-breakage.

Problems in Applying the Model

Figures 5 and 6 illustrate two of the major problems involved in

0 EXPERIMENTAL
- SIMULATED
10 1 I I I I I I
0 5 10 15 20 25 30 35

GRINDING T I M E , min

FIGURE 5. Determination of combined rate of breakage-chipping for

63x53 mm fresh quartz feed with no accumulation of fines
(D=0.6 m, J=0.2, 4 =70% of critical speed).
 CHALLENGES IN MINERAL PROCESSING

-
-
I 1 1 1 1 1 1 1 1
I 1 1 1 1 1 1 1 1
-
-
-
-

-
-
AGED

-
-
-
-
/ A -
FEED SIZE, m m
-
-
45 x 38 -
A 53 x 45 -
QUARTZ
0 63x53
-
- -
- -
- -
I I II I I I I I 1111 I I I 1 1 1111 I I I 1 1 1 j i -

0.001 0.0 I 0.1 I

RELATIVE PARTICLE SIZE, XI /xi

FIGURE 6. B values from fully-autogenous batch grinding tests in

0.6 m mill (J=0.30, U=O,$ -0.7).

applying the model to the simulation of the performance of a SAG

mill. First, the kinetics of self-breakage are strongly non-first
order, with a rapid breakage of fresh feed followed by a much slower
overall breakage of the stronger remaining material. This
slow-breaking material forms the rounded pebbles of autogenous
grinding. This non-first order effect must be incorporated into the
kinetic model ('I. Second, there are different B values
corresponding to the different specific breakage rates of fresh feed
and the persistent slow-breaking (aged) material.
Third, experimental tests show that smaller sizes cushion the
self-breakage of larger sizes and larger sizes increase the specific
breakage rates of smaller sizes. Although there is no problem in
writing equations to allow for the interaction of any size with all
other sizes, from a breakage point of view, the amount of
 MODELING AND DESIGN OF AUTOGENOUS AND SAG MILLS 187

e x p e r i m e n t a l work n e c e s s a r y t o e l u c i d a t e t h e laws governing t h e s e

i n t e r a c t i o n s i s l a r g e , and h a s n o t y e t been performed.

AN APPROXIMATE MODEL

Because of t h e problems d i s c u s s e d i n t h e p r e v i o u s s e c t i o n , an
approximate model was c o n s t r u c t e d by u s i n g s p e c i f i c r a t e s of
s e l f - b r e a k a g e b a c k - c a l c u l a t e d from p i l o t - s c a l e SAG m i l l t e s t s (8) .
Best e s t i m a t e s ( g u e s s e s ) were made f o r a l l o t h e r unknown f a c t o r s ,
and t h e s i m u l a t i o n model used t o p r e d i c t t h e c a p a c i t y of a f u l l -
s c a l e pan-cake t y p e m i l l a s a f u n c t i o n of b a l l l o a d . The m i l l power
was c a l c u l a t e d u s i n g t h e e q u a t i o n proposed by A u s t i n ( 1 4 ) , which
g i v e s r e s u l t s s i m i l a r t o t h o s e quoted by Tanaka and Tanaka ( I 5 ) f o r
a m i l l d e s i g n e d by M.P.S.I. I n c . , York, PA, w i t h a nominal c h a r g e
l o a d i n g of J=0.25.
F i g u r e s 7 and 8 show t h e r e s u l t s . F i g u r e 9 shows t h e s i z e
d i s t r i b u t i o n s p r e d i c t e d by t h e model f o r o p e r a t i o n a t 8% b a l l l o a d
and f o r f u l l y - a u t o g e n o u s o p e r a t i o n . F i g u r e 10 shows t h a t t h e e f f e c t
of t h e b a l l s i s t o i n c r e a s e t h e s p e c i f i c r a t e s of breakage of t h e
l a r g e r s i z e s , w h i l e F i g u r e 9 shows t h a t t h e consequence i s t h a t t h e
f r a c t i o n of m i l l c h a r g e i n t h e s i z e r e g i o n of 20 mm t o 60 mm i s t h u s
reduced.
 0 4 8 12 16
PERCENT MILL FILLING. J PERCENT B A L L L O A D

FIGURE 7 . Variation of predicted capacity FIGURE 8 . Optimum capacity and s p e c i f i c

with f i l l i n g and b a l l load f o r grinding energy with b a l l load
nominal 28 f e e t diameter a t t o t a l f i l l i n g of 25%m i l l
by 14 f e e t long SAG m i l l . volume ( s e e Fig. 7 ) .
 MODELING AND DESIGN OF AUTOGENOUS AND SAG MILLS 189

S l Z E INTERVAL i AND SlZE

FIGURE 9. Simulated size distributions for FAG mill and SAG mill
with 8% ball load.
 CHALLENGES IN MINERAL PROCESSING

5.0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 , 1 1 1 1 1 1 1 -
- -

- -

- -

1.0 -
-
-
-
-

AUTOGENOUS

0.05 -
- / / -
/
- SELF BREAKAGE -
I 0 0 pm I mm 10 mm IOOmm

I I I I I I I I I I I I I I I I I I I I I I I
2 4 2 3 2 2 2 1 2 0 1 9 I 8 17161514 131211 10 9 8 7 6 5 4 3 2 1

S l Z E I N T E R V A L i AND SlZE

FIGURE 10. Simulated specific rates of breakage for conditions of

Figure 9.
 MODELING AND DESIGN OF AUTOGENOUS AND SAG MILLS

DISCUSSION OF RESULTS
It is clear that the ore studied was a coherent ore which would be
suitable for FAG grinding since it leads to a mill charge with
sufficient large rounded pebbles to be equivalent to a ball mill
(with lower density of media, of course). Although the specific
rates of breakage of these large lumps are relatively low, requiring
larger mill volume as compared to ball milling, the chipping-
abrasion process produces a high proportion of fines which
compensates for the low breakage rates to give specific grinding
energies and circuit products comparable to more conventional
crushing-grinding circuits. However, the use of 6 volume X of ball
charge and a total fractional mill charge of 25 volume X gives a
substantial increase in capacity (from 305 tph to 400 tph) over FAG
milling in the large mill, with a significantly finer circuit
product (approximately 32% minus 400 mesh versus 33%) and somewhat
lower circulating load.

There remains substantial work to be done to improve the model to

a level of accuracy sufficient for utility. The use of average
specific rates of self-breakage is not as satisfactory as the use of
equations representing a fast-slow breakage process. The current
method of entry of B values is not satisfactory. The lack of
precise relations to describe the variation of S and B values with
mill conditions and the interactions with other sizes prevents the
development of simple laboratory tests to predict the values from a
small amount of laboratory work. The results are sensitive to the
level of slurry in the mill, but the calculation of this level by
mass transport relations is based on entirely inadequate
information. The model at the moment does not include the effect of
ball diameter on self-breakage.

It will be interesting to program the model for removal of

material from the mill contents by pebble ports, followed by
crushing of these sizes, in the size range of 38 mm (1.5 inches) to
 CHALLENGES IN MINERAL PROCESSING

75 (3 inches). At the moment, it is not possible to demonstrate

the effect of using a less coherent ore because the associated
variation of the self-breakage B values is not known: the rapid
breakage of a weak ore is expected to give B values with a smaller
fraction of fines.

ACKNOWLEDGEMENTS

The work was performed under NSF Grant CPE 8303154.

REFERENCES

1. AUSTIN, L.G., KLIMPEL, R.R. and LUCKIE, P.T. Process

Engineering of Size Reduction: Ball Milling. New York, N.Y.,
Society of Mining Engineers of A.I.M.E., 1984, pp. 1-561.

2. STANLEY, G.G. Mechanisms in the autogenous mill and their

mathematical representation. J. SO. ~ f r .Inst. Min. Metal.,
Vol. 75, 4, Nov. 1974, pp. 77-98.

3. GAULT, G.A. Modelling and control of autogenous grinding

circuits. Ph.D. Thesis, University of Queensland, Australia,
1974.

4. VANDERBEEK, J.L., HERBST, J.A., RAJAMANI, K. and HALES, L.

Online estimation of particle size distribution and volumetric
filling in a SAG mill with a view to automatic control.
Presentation, Society of Mining Engineers of A.I.M.E. meeting
in Alburquerque, N.M., Oct. 1985.

5. AUSTIN, L.G., WEYMONT, N.P., PRISBEY, K.A. and HOOVER, M.

Preliminary results on the modeling of autogenous grinding.
Proc. 14th Int. APCOM Conference. Ramani, R.V., The
Pennsylvania State University, P.A., 1976, pp. 207-226.

6. AUSTIN, L.G., WEYMONT, N.P., BARAHONA, C.A. and SURAYANARAYAN,

K. An improved simulation model for semi-autogenous grinding.
Powder Technology, Vol. 47, 3, 1986, pp. 265-283.
7. AUSTIN, L.G., BARAHONA, C.A. and MENACHO, J.M. Fast and slow
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Proc. 1st. World Congress Particle Technology. Leschonski, K.,
Nuremberg, Federal Republic of Germany, April 1986.
 MODELING AND DESIGN OF AUTOGENOUS AND SAG MILLS 193

9. AUSTIN, L.G., MENACHO, J.M. and PEARCY, F.A., A General model

for semi-autogenous and autogenous milling. APCOM 87
Proceedings of the Twentieth International Symposium on the
Application of Computers and Mathmatics in the Mineral
Industries. Volume 2: Metallurgy, Johannesburg, SAIMM, 1987,
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10. ROGERS, R.S.C. and AUSTIN, L.G. Residence time distributions

in ball mills. Particulate Science and Technology, Vol. 2,2,
1984. pp. 193-204.
%
11. AUSTIN, L.G. and CONCHA, F.A. Diseno simulacibn de circuitos
de molienda. To be published.

12. MENACHO, J.M. Some solutions for the kinetics of combined

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1986, pp. 87-95.

13. WEYMONT, N.P. The analysis and simulation of autogenous

grinding systems, Ph.D. Thesis, The Pennsylvania State
University, P.A., 1979.
14. AUSTIN, L.G., A mill power equation for SAG mills, submitted
for publication.
15. TANAKA, T. and TANAKA, K. Design features of a semi-autogenous
grinding mill and a comparison of test mill data with actual
operation data. Santiago, Chile, Centro de Investigaci n Mineva y
Metalurgica, Primer Taller Nacional de Molienda ~ u t o ~ e nde
a
Minerales. Preprint No. 6, Sept. 1983, pp. 1-26.