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Model Predictive Control for SAG Milling in Minerals Processing Steven J. McGarel, Rockwell Automation Introduction SAG and ball mills are generally accepted as the largest power consumers in a mining and mineral processing operation and can be 80% of total electrical energy consumed at a specific power consumption of around 20kWh/ton.
operating at 90% of its maximum power. The combined power draw of the SAG mill and ball mill was 8658 kW, which caused partial overgrinding. From experience in processing plants outside of China, the power rating of the ball mill should be higher than that of the SAG mill [5]. The pebble crusher had an overpowered configuration.
Benchmarking: SAG Mill Power Draw Meadowbank. Muteb, P. Allaire, J., Meadowbank Mine Process Plant Throughput Increase, Proceedings of the Canadian Mineral Processors Annual General Meeting, Ottawa, Canada, January 2013. Power reported "at the DCS". DCS Power, kW Ball/Mill filling
An overview of the selection and design of mill liners was published ... Development of models relating charge shape and power draw to SAG mill operating parameters and their use in devising mill ...
History. The SAG mill model by proposed by Leonard Austin (1990) was largely based on modifications of earlier tumbling mill models by Hogg Fuerstenau and F. Bond. The model uses a kineticpotential energy balance to describe the power draw of a mill charge. Many geometric components of the earlier models were fit to empirical relationships measured by Austin.
on. The operating power draw of the mill and, consequently, the motor torque consumed will vary during mill operation as the operating parameters vary. The SAG mill power draw model of Austin (using the calibration by Doll, 2013) is used to predict
A further explanation is required to explain the importance of designing the SAG mill chamber to draw required power at optimum operating conditions of 75% critical speed and less than 30% by volume load. Recent studies in the threefoot diameter SAG mill are instructive. The following graph shows the relevant facts as Figure 2.
Comminution alone can account for 60% of mine electrical power load and more than 35% of the operation’s greenhouse gas emissions [23]. Case 1 In this example, a company operates 26 mines with 19 of the 26 using SAG (semiautogenous grinding) and Ball mills, with power capabilities of up to 12,000 kW [24].
Two new SAG milling models are developed in this work, able to predict power or specific energy consumption, including the usual design variables such as mill size; balls charge level, solids concentration in the SAG mill feed and % of critical speed, but adding a .
SAG mill power draw models using techniques of Austin and Morrell, Ball mill power draw models using techniques of Morrell and . The combination of a database capable of tracking thousands of grindability test results with models that can run hundreds of samples per second make the grindability models ideal for geometallurgy.
Parametric models, created as a best fit to the DEM mill data, are used to relate these charge shape characteristics and the power draw to these operating parameters. They also allow inverse prediction of the fill level and lifter height (or wear state) from measurements of the charge structure and the mill .
predictions made by two published mill power draw models for SAG mills (Austin''s SAG model and Morrell''s Cmodel). A third model (Hogg and Fuerstenau) is fit to each survey and the principal fitting parameter is tabulated. Power measurement The nature of electrical and mechanical networks is that power is lost to various types of inefficiency as
INCREASING SAG MILL CAPACITY AT THE COPPER MOUNTAIN MINE THROUGH THE ADDITION OF A PRECRUSHING CIRCUIT. ... SAG Power Draw, kW Date SAG Power Draw kW (Daily) ... Figure 10 Ball Mill power draw . Plant throughput rates were not much improved into 2012, so it was decided to collect a larger number of
The discovery of excess mill pooling in the SAG mill prompted a review of the "pumping" capacity of the SAG mill. The excess slurry pool inhibited grinding and caused unnecessary power draw on the mill with the internally recirculating slurry. Crash stop inspections (Figure 2) of the mill interior
Nov 25, 2015· SAG power draw survey tabulation This LibreOffice spreadsheet contains the raw data used to create Table 1 and Table 2 of the paper "An updated data set for SAG mill power model calibration", presented at IMPC 2016 in Quebec City, Canada in September, 2016.
SAG mills • Determination of your SAG mill''s power draw characteristics. • SAG Mill Steel Charge Estimation tool provides an estimate of the percent steel in the charge of your SAG mill based on the power draw and the total charge volume. • Ball impact energy chart to determine the impact energy of balls as a function of mill diameters.
SAG power draw survey tabulation This LibreOffice spreadsheet contains the raw data used to create Table 1 and Table 2 of the paper "An updated data set for SAG mill power model calibration", presented at IMPC 2016 in Quebec City, Canada in September, 2016.
Mill Power Draw Model Bibliography. Mill power draw models are used to predict the usable power draw that a particular mill will generate. The three SAG mill models are benchmarked and reviewed in: Doll,, A comparison of SAG mill power models, Procemin 2013; Austin SAG Model. The Austin SAG model was published in: Austin,
Mill Power Draw Models. The mill power draw models are used to predict how much power will be consumed by a particular type of mill, mill geometry and set of mill operating conditions. This power is transferred to the ore and used to predict the throughput when combined with the specific energy consumption models.
Which power model is the most efficient to predict the correct power consumption in sag mill with change in process variables?I have developed a few dynamic simulators for different mineral/metal processing plants. Prediction of correct sag mill power consumption with a change in ore hardness, solid
Modelling SAG milling power and specific energy consumption including the feed percentage of intermediate size particles ... ables with the dependent variables SAG mill power and specific energy, to assure models with fixed parameters. ... a significant portion of the power draw.
For the mill with higher mill load and lower speed, the power draw of the mill differed slightly for the different lifters with the same face angles of 20o. Rail lifter drew higher mill power and lower power for HiLo lifter. The HiLo lifter relatively indicated improvement in the energy efficiency of the mill approximately 22%.
Grinding mills: how to accurately predict their power draw. ... In total 76 data sets were generated covering the power draws of ball, SAG and AG mills in the range 7 7900 kW. ...
The no load power is a measure of some of the power losses in the gears, bearings and electrical components and is the gross power draw of the mill when empty, obtained either during commissioning of the mill or when ground out for a mill reline. Morrell [13] developed an empirical expression for the no load power draw of ball, SAG and AG mills as
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