Model predictive control on a SAG mill and ball mills The solution for the SAG Mill is an adaptive controller which controls mill load using direct mill weight measurement or …
Hard ore, when not identified in mine production planning, can cause the selection of a SAG mill which is too small, resulting in losses in tonnage and metal …
A SAG mill, or semi-autogenous grinding mill, operates on the principle of autogenous or self-grinding. It uses a combination of ore and grinding media to break down larger rocks into smaller pieces. Understanding the working principles of a SAG mill is crucial for anyone involved in the mining industry.
Figure 1 shows a range of M4A SAG feed size distributions compared with an M1 feed size distribution. It is clear that the M1 material fragments very finely in the blast -producing about 70% minus ...
The JKMRC has been studying and modelling industrial AG and SAG mills for over 40 years, but the ability to simulate the effects of blending hard and soft components on mill performance remains ...
Considering the continuous increase in production costs and resource optimization, more than a strategic objective has become imperative in the copper mining industry. In the search to improve the …
A SAG mill, or semi-autogenous grinding mill, is a type of machine used in mining and mineral processing operations. It uses the crushing and grinding action of rocks to reduce materials such as copper ore into smaller pieces for further processing. Unlike traditional mills that rely on steel balls or other media to break down materials, SAG ...
Semiautogenous-single stage. These circuits are not a good choice for many orebodies because it is not logical to expect one machine to be as efficient on 150 mm ore as it is on 100 micron ore. Semi …
The optimization aimed to estimate SAG mill throughput for soft and hard components based on the breakage model parameters (A and b) from the fitted curves while VMF varies at 25.501±0.3%.
... This control software integrates model-based constraint optimization and decoupling control technology to overcome the variations of feed ore composition and particle size, so as to...
operational relative-hardness. We applied the proposed methodology on two SAG mill datasets, of one year period each. Results show accuracies above 80% on both SAG …
Semi-autogenous grinding (SAG) occurs in tumbling mills which use both large ore particles and steel balls for grinding. Grinding is the most energy intensive mineral processing unit operation and ...
Abstract and Figures. The new practice of applying full pre-crushing of SAG mill feed to substantially increase throughput is challenged as retrogressive and inefficient at a time the industry ...
• Critical size is a term used to describe coarse ore that builds up in a SAG mill. It is hard. But the reason it builds up is that the mill does not have enough power …
The difficulty of stabilizing SAG mill load limits the effectiveness of feedback control approaches. Control is particularly difficult during periods when the feed ore is either unusually hard or ...
In this study, the relationship between acoustic emissions and hardness of different rock types (model quartz, model calcite, and real iron ore) coupled with binary mix ratios of model quartz and iron ore (1:3, 1:1 and 3:1) was investigated in a laboratory-based AG/SAG mill. The acoustic emission response and sensitivity of the mill were ...
Secondary crushing or pre-crushing of the ore before SAG mills has been integrated in the circuit in order to increase the throughput while maintaining the grind. The pre-crushing option selected ...
In this case, mill speed is the primary manipulated variable used to control mill load. While there is no generic control strategy for SAG milling there is a considerable amount of reusable engineering. In contrast to an expert or black box system, the control loop approach was built using standard blocks, connected as shown.
SAG Mill Advanced Process Control and Optimization Using BrainWave MPC (A. Kheradmand) 11:30 11:45 Paper 11 Optimizing Energy and Throughput for HPGR: A Case Study for Copper Mountain Mine (G. Pamparana) 11:30 11:45 Paper 11 Mine to Mill the next phase – incorporating Soft Sensors and Data Analytics (P. Madrid)
The JKMRC has been studying and modelling industrial AG and SAG mills for over 40 years, but the ability to simulate the effects of blending hard and soft components on mill performance remains quite limited.In an effort to quantify these effects for modelling purposes, a series of laboratory, pilot scale and full scale tests, using multi-component …
This is achieved by using two stockpiles of limited capacity, to classify ore as hard or soft, depending on its expected grindability (Fig. 3). The SAG mill will draw from one of the two stockpiles at will to minimize the energy cost. If one of the stocks is emptied, the ore from the other stockpile is …
Based on experience, mill-liner designs have moved toward more open-shell lifter spacing, increased pulp lifter volumetric capacity, and a grate design to facilitate maximizing both pebble-crushing circuit utilization and SAG mill capacity. As a guideline, mill throughput is maximized with shell lifters between ratios of 2.5:1 and 5.0:1.
Abstract. Towards the development of an improved and more efficient online monitoring system in an industrial AG/SAG grinding mill, the present study employs a laboratory-based AG/SAG mill and acoustic sensor to investigate the acoustic characteristics of different mill operating conditions. Specifically, mill operating …
the hard ore in the critical particle size range cannot be effectively processed by SAG mills. The critical particle size of the ore can be between 20–70 mm, according to the SAG pa‐ ... and Raw Ore from a SAG Mill ... [12] implemented a dynamic AG/SAG model to control a pebble crusher and ...
MODEL PREDICTIVE CONTROL OF SAG WEIGHT. The MPC controller was installed to control the SAG mill weight, the belt weight in the ore feed system, and the SAG mill sound emissions. A diagram of the control strategy is shown in Figure 3. Figure 3 – SAG mill MPC control strategy The MPC SAG weight controller includes measured …
Semi-autogenous grinding mills play a critical role in the processing stage of many mining operations. They are also one of the most intensive energy consumers of the entire process. Current forecasting techniques of energy consumption base their inferences on feeding ore mineralogical features, SAG dimensions, and operational variables. …
zones. Ore is considered to be soft when it requires less than 10 kWh/t to grind from F80 152 mm in a SAG mill, to a T80 of 1.7 mm. Hard ore requires more than …
SAG mills are currently the technology of choice in hard rock milling operations for reducing primary-crushed ore to ball mill feed. In recent years, the trend has been towards larger-sized SAG mills with diameters of 10.4 m (34 ft) and above, with the largest being 12.2 m (40 ft) in diameter and drawing 20 to 22 MW (Jones, 2006).
Tracking the mill performance showed that the mill power consumption decreased from 9.49 to 6.63 kWh/t (a nearly 30% reduction), P80 of the mill product decreased from 611 to 355μm, and the mill ...
A control strategy has been implemented on a large variable-speed SAG mill at MMG's Century Zinc operation in Australia in which the mill speed has been manipulated variable to control mill load ...
Ore hardness plays a critical role in comminution circuits. Ore hardness is usually characterized at sample support in order to populate geometallurgical block models. However, the required...
The solution: Measure. Control. And profit. BrainWave SAG mill is a unique control package using patented model-based predictive adaptive control technology. It is well known within the mining industry that efective grinding in a SAG mill depends largely on the loading of the mill. A mill con-taining too much material does not allow for ...
In this paper, we use a series of DEM simulations to explore how the energy utilization and the collisional environment within a SAG mill changes with operating conditions, specifically the mill speed, the lifter height, the fill level and the charge composition (in terms of volumetric ratio of rocks to balls).
AG and SAG mills are now the primary unit operation for the majority of large grinding circuits, and form the basis for a variety of circuit configurations. SAG circuits are common in the industry based on: High single-line capacities (leading to capital efficiency) The ability to mill a broad range of ore types in various …. Read more.
The hours, days or weeks needed to get a mill back on line are often filled with tense periods of trouble-shooting and scrambling to locate and acquire needed parts, and the characteristics that make SAG mills such robust performers — powerful drives, massive components and capacity to carry a thousand tons or more of ore and grinding balls ...
SAG mills are the mill of choice for most major mining operations. They are some of the largest mills around – and are constantly getting bigger with the largest ones presently having a diameter ...