Mineral Processing
S. Kolahi; M. Jahani Chegeni
Abstract
The number of lifters of mill shell liners, mill rotation speed, and filling percentage of grinding media are three of the most important parameters influencing the charge behavior and the trajectory of ball motion inside the SAG mills, and consequently, their performance. In this paper, the milling ...
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The number of lifters of mill shell liners, mill rotation speed, and filling percentage of grinding media are three of the most important parameters influencing the charge behavior and the trajectory of ball motion inside the SAG mills, and consequently, their performance. In this paper, the milling operation of pilot-scale SAG mills using the discrete element method (DEM) is investigated. First, a pilot-scale SAG mill with dimensions of 3.0 m × 1.5 m with no lifter is simulated. Then by adding, respectively, one, two, four, eight, sixteen, and thirty-two rectangle lifter(s), six other independent simulations are performed. The effects of the number of lifters on the two new parameters introduced by the authors, i.e. ‘head height’ and ‘impact zone length’ as well as on creation of cascading, cataracting, and centrifuging motions for balls at two different mill speeds, i.e. 70% and 80% of its critical speed (NC), are evaluated. Also in order to validate the simulation results, a laboratory-scale SAG mill is simulated. The results obtained indicate that the optimum number of lifters for pilot-scale SAG mills is between 16 and 32 lifters with medium thickness. Liners with the number of lifters in this range require less mill speed to create cataract motions. However, liners with the number of lifters less than this range require a higher mill speed. Also liners with the number of lifters beyond this range require less mill speed, and can cause centrifugal motions in the balls. Comparison of the simulations related to the laboratory-scale SAG mill with experimental results demonstrates a good agreement, which validates the DEM simulations and the software used.
Mineral Processing
M. Jahani Chegeni; S. Kolahi
Abstract
The shell liner type, rotation speed, and ball filling percent are the key factors influencing the charge behavior inside the SAG mills, and consequently, their performance. In this work, the milling operation of industrial SAG mills is investigated using the Discrete Element Method (DEM). First, an ...
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The shell liner type, rotation speed, and ball filling percent are the key factors influencing the charge behavior inside the SAG mills, and consequently, their performance. In this work, the milling operation of industrial SAG mills is investigated using the Discrete Element Method (DEM). First, an industrial SAG mill with dimensions of 9.50 m × 4.42 m that has a Smooth-type liner is simulated. Then by changing the liner types, i.e. Wave, Rib, Ship-lap, Lorain, Osborn, and Step liners, six other independent simulations are performed. In order to investigate the impact mechanism and improve the mill performance, two new parameters called ‘head height’ and ‘impact zone length’ are introduced. Then the effects of the mill shell liner type on those parameters at two different mill speeds, i.e. 70% and 80% of its critical speed (CS), are evaluated. Also for validation of the simulation results, a laboratory-scale SAG mill with dimensions of 57.3 cm × 16.0 cm is simulated. The results obtained indicate that the Osborn liner, due to the angularity of its lifters and their proper number and thickness, performs best because it increases both parameters more than the other liners. Thus this liner is recommended as the best and optimal liner in this research work and is suggested for installation inside the industrial SAG mills. Also the Wave liner, due to its specific geometrical shape and its wavy lifters as well as their low number and inadequate thickness, provides the lowest charge ‘head height’. Therefore, it is not recommended to install this liner inside the industrial SAG mills. Meanwhile, comparison of the simulations related to the laboratory-scale SAG mill with the experimental results demonstrates a good agreement that validates the DEM simulations and the software used.
