Difference between revisions of "Benchmarking: Ball Mill Power Draw Models"

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(→‎Benchmarking: Ball Mill Power Draw - Meadowbank)
(→‎Benchmarking: Ball Mill Power Draw - Collahuasi)
 
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Line 13: Line 13:
 
! Pulp %solids,<br>w/w
  
! Pulp %solids,<br>w/w
 
! Morrell SAG Model,<br>kW at input / ''shell''
  
! Morrell SAG Model,<br>kW at input / ''shell''
−
! Nordberg Model,<br>kW at input / ''shell''
 +
! Nordberg Model,<br>no density correction<br>kW at input / ''shell''
  +
! Nordberg Model,<br>density correction<br>kW at input / ''shell''
 
|-
  
|-
 
| Survey 1
  
| Survey 1
 
| '''3,864'''
  
| '''3,864'''
  +
| <del>66.7</del> 68.4 <sup>&dagger;</sup>
−
| 68.3
  
 
| 38.7
  
| 38.7
 
| 72.0
  
| 72.0
−
| '''3,933''' / ''3,776''
 +
| '''3,798''' / ''3,798''
−
| '''3,592''' / ''3,345''
 +
| '''3,619''' / ''3,370''
  +
| '''3,894''' / ''3,626''
 
|}
  
|}
   
 
* Morrell model predicts 2% high
  
* Morrell model predicts 2% high
−
* Nordberg model predicts 7% low
 +
* Nordberg model predicts 7% low with no density correction and 0.8% high with density correction.
   
 
[[Benchmarking: Fimiston Ball Mills|See details of benchmarking]]
  
[[Benchmarking: Fimiston Ball Mills|See details of benchmarking]]
Line 32: Line 34:
   
 
* ''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.
−  
−
The ball mill design given as:
  
−
* Diameter inside shell: 18 ft
  
−
* Length (assumed to be flange-to-flange length): 29 ft
  
−
* Effective grinding length: 28.5 ft (using rule-of-thumb half-foot basis)
  
−
* Motor size: 6,000 horsepower (4,474 kW)
  
−
* Overflow mill with synchronous motor assumed
  
−  
−
The operating conditions of the May 2012 survey, including the pre-crushing circuit given as:
  
−
* Mill speed 14.19 rpm (75% critical)
  
−
* Volumetric filling 30.6% v/v
  
−
* Ball charge 30.6% v/v
  
−
* Ore density 2.93 kg/L
  
−
* Grindability: A&times;b 38.6; Wi<sub>BM</sub> 10.9 kWh/t
  
−  
−
Liners assumed to be an effective thickness of 3 inches. DCS power is assumed to be indicated (mill power measurements &times; 0.985 pinion &times; 0.96 motor eff equals power "at mill shell"). Model power measurements are shown "at DCS".
  
−  
 
{| class="wikitable" border="1"
  
{| class="wikitable" border="1"
 
|-
  
|-
Line 56: Line 41:
 
! Morrell Model, kW
  
! Morrell Model, kW
 
! Nordberg model, kW
  
! Nordberg model, kW
  +
no density correction
  +
! Nordberg model, kW
  +
density correction
 
|-
  
|-
 
| May 2012
  
| May 2012
Line 61: Line 49:
 
| 30.6% v/v
  
| 30.6% v/v
 
| 4,765 (+9.3%)
  
| 4,765 (+9.3%)
−
| 4,423 (+1.9%)
 +
| 4,426 (+1.9%)
  +
| 4,753 (+9.5%)
  +
|}
  +
  +
[[Benchmarking: Meadowbank ball mill model|See details of benchmarking]]
  +
  +
==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.
  +
{| class="wikitable" border="1"
  +
|-
  +
!
  +
! 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: Santa Rita ball mill model|See details of benchmarking]]
  +
  +
==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 &ndash; I-42
  +
  +
{| class="wikitable" border="1"
  +
|-
  +
!
  +
! 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.
   
−
[[Bibliography: Meadowbank ball mill model|See details of benchmarking]]
 +
[[Benchmarking: Collahuasi ball mill model|See details of benchmarking]]

Latest revision as of 16:57, 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 66.7 68.4 † 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.

See details of benchmarking

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%)

See details of benchmarking

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%)

See details of benchmarking

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.

See details of benchmarking

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