User talk:Alex Doll

Not sure what to do with this benchmarking data yet, but I'll record it here so I can find it in the future

Ball and liner wear benchmarking

Ben Burger, Luis Vargas, Hamer Arevalo, Sergio Vicuna, Jim Seidel, Walter Valery, Alex Jankovic, Roberto Valle and Eduardo Nozawa, YANACOCHA GOLD SINGLE STAGE SAG MILL DESIGN, OPERATION, AND OPTIMIZATION, SAG 2011

Single-stage SAG mill, reported with slurry pooling

• New liner effective thickness: 7.7 inches (half-worn 5.5 inches)
• Ball charge: 19% v/v (18-20%)
• total charge: 22.5% v/v (20%-25%)
• grate open area 12%; wear rate 0.6 mm/day (rubber)
• Operating work index 23.0 - 25.2 metric
• Ball consumption: 3 kg/t (2-3.5 kg/t) or 0.16 g/kWh
• Bond predicted ball mill ball consumption: 0.13 kg/kWh; actual ~ predicted
• Bond predicted ball mill liner consumption: 9.5 g/kWh
• Shell liners life of 6 months; assume 3" thick at end of life. 5 g/kWh wear (+ 3 g/kWh scrapped)
• Grate wear: 0.06 g/kWh steel; 0.02 g/kWh rubbber

• Laboratory testwork:
  • Bond abrasion index: 0.5 (0.467-0.555)
  • DWi 3.45 kWh/m³
  • Mia 12.3
  • A: 82.8; b: 0.88; A×b: 72.9
  • t_a: 0.75
  • density: 2.52 t/m³

SAG liner wear benchmarking

Orford, I., Larsen, C., Cooper, M., Renaud, M. & Strah, L Brunswick Mine SAG Liner Design & Wear, CMP 2003

• SAG liner wear 2.6 g/kWh
• liners typically replaced with 50% steel remaining
• Ai not given, but assume 0.3 for a massive sulphide
• Bond ball mill liner wear estimate: 8.1 g/kWh
• SAG wear is less than half the Bond BM prediction.

Ball wear benchmarking

Larsen, C., Cooper, M., & Trusiak, A. Design and Operation of Brunswick's AG/SAG Circuit, SAG 2001

• Operating work index: 11.5 kWh/t
• SAG operating with 4% ball charge (originally was AG)
• SAG 4" ball wear rate: 0.12 kg/t (10.4 g/kWh)
• BM 24 mm slug wear: 0.91 kg/t (80 g/kWh)
• Assume Ai of 0.3, BM ball wear rate prediction: 105 g/kWh

The parallel RM/BM plant has same operating work index, but following wear:

• Rods 0.39 kg/t
• 38 mm balls: 0.72 kg/t
• 25 mm slugs: 0.94 kg/t

Since Wi_O is the same for both, the SABC ball wear is half the RM-BM combined steel wear.

Ball Mill Ball wear benchmarking

Villanueva, F., Ibañez, L., & Barratt, D. Los Pelambres Concentrator Operative Experience, SAG 2001

• BM Operating work index: 15.9 kWh/t (14.4 kWh/st)
• Laboratory ball mill work index: 12.1 kWh/t (11.0 kWh/st)
• T₈₀: 2.5 - 3.0 mm (raw measurement)
• BM specific energy consumption: 11.9 kWh/t
• BM ball wear: 315 g/t