Benchmarking: Ball Mill Power Draw Models: Difference between revisions
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! Pulp %solids,<br>w/w |
! Pulp %solids,<br>w/w |
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! Morrell SAG Model,<br>kW at input / ''shell'' |
! Morrell SAG Model,<br>kW at input / ''shell'' |
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! Nordberg Model,<br>kW at input / ''shell'' |
! Nordberg Model,<br>no density correction<br>kW at input / ''shell'' |
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! Nordberg Model,<br>density correction<br>kW at input / ''shell'' |
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|- |
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| Survey 1 |
| Survey 1 |
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| '''3,864''' |
| '''3,864''' |
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| <del>66.7</del> 68.4 <sup>†</sup> |
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| 68.3 |
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| 38.7 |
| 38.7 |
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| 72.0 |
| 72.0 |
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| '''3, |
| '''3,798''' / ''3,798'' |
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| '''3, |
| '''3,619''' / ''3,370'' |
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| '''3,894''' / ''3,626'' |
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* Morrell model predicts 2% high |
* Morrell model predicts 2% high |
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* Nordberg model predicts 7% low |
* Nordberg model predicts 7% low with no density correction and 0.8% high with density correction. |
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[[Benchmarking: Fimiston Ball Mills|See details of benchmarking]] |
[[Benchmarking: Fimiston Ball Mills|See details of benchmarking]] |
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* ''Muteb, P. & Allaire, J.'', '''Meadowbank Mine Process Plant Throughput Increase''', Proceedings of the Canadian Mineral Processors Annual General Meeting, Ottawa, Canada, January 2013. |
* ''Muteb, P. & Allaire, J.'', '''Meadowbank Mine Process Plant Throughput Increase''', Proceedings of the Canadian Mineral Processors Annual General Meeting, Ottawa, Canada, January 2013. |
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The ball mill design given as: |
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* Diameter inside shell: 18 ft |
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* Length (assumed to be flange-to-flange length): 29 ft |
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* Effective grinding length: 28.5 ft (using rule-of-thumb half-foot basis) |
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* Motor size: 6,000 horsepower (4,474 kW) |
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* Overflow mill with synchronous motor assumed |
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The operating conditions of the May 2012 survey, including the pre-crushing circuit given as: |
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* Mill speed 14.19 rpm (75% critical) |
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* Volumetric filling 30.6% v/v |
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* Ball charge 30.6% v/v |
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* Ore density 2.93 kg/L |
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* Grindability: A×b 38.6; Wi<sub>BM</sub> 10.9 kWh/t |
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Liners assumed to be an effective thickness of 3 inches. DCS power is assumed to be indicated (mill power measurements × 0.985 pinion × 0.96 motor eff equals power "at mill shell"). Model power measurements are shown "at DCS". |
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{| class="wikitable" border="1" |
{| class="wikitable" border="1" |
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|- |
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| Line 56: | Line 41: | ||
! Morrell Model, kW |
! Morrell Model, kW |
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! Nordberg model, kW |
! Nordberg model, kW |
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no density correction |
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! Nordberg model, kW |
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density correction |
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|- |
|- |
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| May 2012 |
| May 2012 |
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| Line 61: | Line 49: | ||
| 30.6% v/v |
| 30.6% v/v |
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| 4,765 (+9.3%) |
| 4,765 (+9.3%) |
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| 4, |
| 4,426 (+1.9%) |
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| 4,753 (+9.5%) |
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|} |
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[[Benchmarking: Meadowbank ball mill model|See details of benchmarking]] |
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==Benchmarking: Ball Mill Power Draw - Santa Rita== |
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* ''Latchireddi, S. & Faria, E.'', '''Achievement of High Energy Efficiency in Grinding Mills at Santa Rita''', Proceedings of the Canadian Mineral Processors Annual General Meeting, Ottawa, Canada, January 2013. |
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* ''Faria, E. & Latchireddi, S.'', '''Commissioning and Operation of Milling Circuit at Santa Rita Nickel Operation''', Paper #137: Proceedings of the International Autogenous Grinding, Semiautogenous Grinding and High Pressure Grinding Roll Technology Conference, Vancouver, Canada, September 2011. |
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{| class="wikitable" border="1" |
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|- |
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! |
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! DCS Power, kW |
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! Mill filling |
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! Morrell Model, kW |
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! Nordberg model, kW |
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(no density correction) |
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! Nordberg model, kW |
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(density correction) |
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|- |
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| July 2010 |
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| 5085 |
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| 27.5% v/v |
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| 4979 (-2.1%) |
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| 4706 (-8.1%) |
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| 5083 (0.0%) |
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|} |
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[[Benchmarking: Santa Rita ball mill model|See details of benchmarking]] |
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==Benchmarking: Ball Mill Power Draw - Collahuasi== |
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* ''Villouta, R.M.'', '''Collahuasi: After years of operation''', Proceedings of the International Autogenous and Semiautogenous Grinding Technology conference (SAG 2001), Vancouver, Canada, Pages I-31 – I-42 |
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{| class="wikitable" border="1" |
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|- |
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! |
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! DCS Power, kW |
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! Speed, % |
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of critical |
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! Mill filling |
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! Morrell Model, kW |
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! Nordberg model, kW |
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(no density correction) |
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! Nordberg model, kW |
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(density correction) |
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|- |
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| original |
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| 8900 |
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| 74% |
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| 35% v/v |
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| 9044 (+1.6%) |
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| [deduct 5%] 8183 (-8.8%) |
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| [deduct 5%] 8717 (-2.1%) |
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|- |
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| later |
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| 9200 |
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| 78% |
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| 35% v/v |
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| 9655 (+4.9%) |
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| [deduct 5%] 8890 (-3.5%) |
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| [deduct 5%] 9471 (+2.9%) |
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|} |
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All power values relative to DCS. |
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[[ |
[[Benchmarking: Collahuasi ball mill model|See details of benchmarking]] |
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Latest revision as of 15:57, 31 May 2014
Benchmarking: Ball Mill Power Draw - Fimiston
- Nelson, M; Valery, W; Morrell, S, Performance Characteristics and Optimisation of the Fimiston (KCGM) SAG Mill Circuit, Page 233 - 248, SAG 1996 Conference, Vancouver, Canada.
| Survey | Survey Power, kW at input |
Mill speed, %critical |
Total load, %v/v |
Pulp %solids, w/w |
Morrell SAG Model, kW at input / shell |
Nordberg Model, no density correction kW at input / shell |
Nordberg Model, density correction kW at input / shell |
|---|---|---|---|---|---|---|---|
| Survey 1 | 3,864 | 38.7 | 72.0 | 3,798 / 3,798 | 3,619 / 3,370 | 3,894 / 3,626 |
- Morrell model predicts 2% high
- Nordberg model predicts 7% low with no density correction and 0.8% high with density correction.
Benchmarking: Ball 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.
| DCS Power, kW | Mill filling | Morrell Model, kW | Nordberg model, kW
no density correction |
Nordberg model, kW
density correction | |
|---|---|---|---|---|---|
| May 2012 | 4,341 | 30.6% v/v | 4,765 (+9.3%) | 4,426 (+1.9%) | 4,753 (+9.5%) |
Benchmarking: Ball Mill Power Draw - Santa Rita
- Latchireddi, S. & Faria, E., Achievement of High Energy Efficiency in Grinding Mills at Santa Rita, Proceedings of the Canadian Mineral Processors Annual General Meeting, Ottawa, Canada, January 2013.
- Faria, E. & Latchireddi, S., Commissioning and Operation of Milling Circuit at Santa Rita Nickel Operation, Paper #137: Proceedings of the International Autogenous Grinding, Semiautogenous Grinding and High Pressure Grinding Roll Technology Conference, Vancouver, Canada, September 2011.
| DCS Power, kW | Mill filling | Morrell Model, kW | Nordberg model, kW
(no density correction) |
Nordberg model, kW
(density correction) | |
|---|---|---|---|---|---|
| July 2010 | 5085 | 27.5% v/v | 4979 (-2.1%) | 4706 (-8.1%) | 5083 (0.0%) |
Benchmarking: Ball Mill Power Draw - Collahuasi
- Villouta, R.M., Collahuasi: After years of operation, Proceedings of the International Autogenous and Semiautogenous Grinding Technology conference (SAG 2001), Vancouver, Canada, Pages I-31 – I-42
| DCS Power, kW | Speed, %
of critical |
Mill filling | Morrell Model, kW | Nordberg model, kW
(no density correction) |
Nordberg model, kW
(density correction) | |
|---|---|---|---|---|---|---|
| original | 8900 | 74% | 35% v/v | 9044 (+1.6%) | [deduct 5%] 8183 (-8.8%) | [deduct 5%] 8717 (-2.1%) |
| later | 9200 | 78% | 35% v/v | 9655 (+4.9%) | [deduct 5%] 8890 (-3.5%) | [deduct 5%] 9471 (+2.9%) |
All power values relative to DCS.