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RANDOL 99 GOLD & SILVER FORUM CONFERENCE AND EXHIBITION

OPTIMIZING SAG MILL PRODUCT SIZE IN SAG MILL - BALL MILL CIRCUITS

Author: Ivan C. Machado, M.Sc., P.Eng., PE

1 INTRODUCTION
In full autogenous grinding (FAG Mills) the ore itself determines almost exclusively the product size that will be produced, as opposed to conventional steel-media grinding where the product size can be engineered by changing media size, feed size, feed rate, classifier cutpoint size, etc. SAG Mills are in the middle of the way, since they offer some room to engineer their product size by properly defining some critical process variables, such as feed size, ball charge and size, mill charge and speed. SAG Mill product P80 values are typically in the range of 500 m (35 US mesh) to 2000 m (10 US mesh). Whenever it is possible to determine an optimum value for the SAG Mill product P80 value (which will be the Ball Mill fresh feed F80 value), the Engineer should define the process variables that will yield a SAG product size as close as possible to the optimum calculated P80 value. In general, a coarser SAG product will draw less power from the SAG Mill and more power from the Ball Mill, and conversely, a finer SAG product will draw more power from the SAG Mill and less power from the Ball Mill. Metal consumption analyses also have to be taken into consideration, for they typically account for 30% to 45% of the total grinding cost. This presentation addresses the issue of defining an optimum SAG Mill product size (X=P80), during the design phase of the SAG and Ball milling circuits, from a general perspective, i.e., the SAG product size that will lead to an overall SAG Mill - Ball Mill performance optimization. Bonds Third Law approach is used, as well as the SPI (SAG Power Index), and also the generally accepted equations and Engineering Practice currently utilized to design SAG Mill Ball Mill circuits.

2 APPROACH
Bonds third theory of comminution is used in order to establish a first estimate for the total fragmentation power draw associated with the entire grinding section under study, encompassing both the SAG milling and Ball milling circuits. The Work Index value used for this first estimate is the Overall Work Index (Wi*), herein defined as the largest value amongst the Bond Ball Mill Wi (WiB), Bond Rod Mill Wi (WiR), Impact Index (WiI), and the SAG Power Index (SPI), all of them expressed in kWh/st. Therefore, the following equation is used to determine a first estimate, in kW, of the total power (TKW) required by the entire grinding section (SAG and Ball Mills): TKW = (10) . (Wi*) . (FR ) . [(P80) -1/2 - (F80) -1/2)] Where: FR is the design feed rate being processed by the Grinding Section, in STPH, P80 is the 80% passing size, in m, of the final product of the Ball milling circuit (typically the solids fraction of a cyclone overflow stream), and F80 is the 80% passing size, in m, of the fresh feed to the SAG Mill. [Eq 01]

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A conventional mathematical approach to split the above equation into a sum of two portions, one for the SAG milling circuit, and one for the Ball milling circuit, the two segments using X (in m) to represent the SAG circuit product 80% passing size, and then trying to minimize power draw (TKW in kW) seems not to apply, as indicated by equation 3 below: TKW = {(10) . (SPI) . (FR) . [(X) -1/2 - (F80) -1/2]} + {(10) . (WiB) . (FR) . [(P80) -1/2 - (X) -1/2]} [Eq 02] (TKW)/X = [(5) . (FR) . (WiB - SPI)]/X3/2 [Eq 03]

Equation 03 indicates that no finite value of X will zero the partial derivative (TKW) / X, and thereby no mathematical extreme value (maximum or minimum) of the power draw exists in connection with whatsoever critical value of X (SAG milling circuit product 80% passing size). However, a very pragmatic and proven approach may be used instead: grinding practice has shown that the closer to a 50% / 50% total power split between the SAG milling and the Ball milling circuits, the better the overall performance of the grinding plant will be, from both the energy and metal consumption perspectives. This 50% / 50% energy split substantiates the basis of the approach that will be used to optimize X, i.e., the SAG Mill 80% passing product size, in m.

3 METHODOLOGY
The optimizing methodology consists of determining X, based on the SAG Mill calculations and on 50% of the first pass calculation for the total power (TKW) required by the entire grinding section (SAG and Ball Mills), in kW. This variable will be denoted as Xs. Similarly, a value of X will be determined based on the Ball milling calculations, and also based on 50% of the first pass calculation for the total power (TKW), in kW. This variable will be denoted as Xb. A conciliation procedure aiming at determining an optimum value (Xo), in the range between Xs and Xb will then take place, simultaneously with an analysis of what impacts may be occurring with the design of both the SAG and the Ball milling circuits. This method offers the unequivocal advantage to allow for a continual engineering judgment along with the manipulation of the several equations involved. Calculation of X from the SAG milling circuit perspective: (TKW)/2 = (10) . (SPI) . (FR) . [(Xs) 1/2 - (F80) 1/2] Thus: Xs = {[(F80) 1/2 + (TKW) / [(20) . (SPI) . (FR)]} -2 [Eq 05] [Eq 04]

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 Calculation of X from the Ball milling circuit perspective: (TKW/2) = (10) . (WiB) . (FR) . [(P80) 1/2 - (Xb) 1/2] Thus: Xb = {[(P80) 1/2 - (TKW)/[(20) . (WiB) . (FR)]} 2 [Eq 07] [Eq 06]

After Xs and Xb are calculated an iterative process to determine the best value for X (SAG Mill Optimum 80% passing size = Xo) is then undertaken by back calculating and balancing the total calculated power (TKW), making use of a spreadsheet, and most importantly, of good engineering judgment. The following example illustrates the proposed method. The values assumed for the several variables are very close to an existing 12.5 million metric tonnes per year project.

4 EXAMPLE
It is assumed that testwork carried out by a reputable institution on representative samples yielded the following results: Ball Mill Bond Work Index: WiB Rod Mill Bond Work Index: WiR Impact Bond Impact Index: WiI SAG Power Index: SPI = = = = 12.1 kWh/st 10.5 kWh/st 7.9 kWh/st 13.2 kWh/st = Wi* by definition: highest Wi value.)

The Grinding Plant design feed rate is FR = 1774 STPH. The SAG Mill will operate in closed circuit with a Trommel Screen, a 20% to 50% circulating load being anticipated. Preliminary calculations indicated two (2) Ball Mills operating in closed circuit with Cyclones, a 300% circulating load being forecast. Cyclones also perform a scalping function, and therefore are the process pieces of equipment that are fed with the SAG Mill product pulp. F80 value to the SAG Mill = 4 = 101,600 m P80 value from SAG Mill = Xo (to be determined) P80 value from Ball Mills = 100 US mesh = 150 m (Grinding Plant Product, i.e. Cyclones overflow) Estimate of total required power (TKW): From Equation 01: TKW = (10) . (13.2) . (1774 ) . [(150) Hence:
-1/2

- (101,600)

1/2

] 18,385 kW.

From equation 5: Xs = {[(101,600) 1/2 + (18,385)/[(20).(13.2).(1774)]} 2 = 556 m - SAG Mill perspective.

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From equation 7: Xb = {[(150) 1/2 - (18,385)/[(20).(12.1).(1774)]} 2 = 663 m - Ball Mill perspective."

The optimum value (Xo) should lie between 556 m and 663 m. A more fine-tuned calculation for the Ball Mills power draw follows, using X = 610 m, i.e. the average value in connection with the above range. Two amongst the eight Bond/Rowland efficiency/inefficiency factors apply: EF3 = 0.914 (Diameter Efficiency Factor), since a fairly accurate pre-sizing of each of the two Ball Mills led to an 18.40 ft IL mill diameter, therefore bigger than 12.5 ft, and EF7 =1.0479 (Ball Mill-Low Rate of Reduction Factor; Rate of Reduction = 610/150 4, hence less than 6.) EF3 = (8/12.5) 0.2 = 0.914, where 12.5 ft is the maximum applicable diameter, and EF7 = [2 . (4.066 - 1.350) + 0.260] / [2 . (4.066 - 1.350)] = 1.0479, where 4.066 is the Rate of Reduction. Thus, the calculated power draw (PB) for each Ball Mill for an 80% passing feed size X = 610 m is: PB = (10 ). (12.10) . (1774/2) . [(150) -1/2 - (610) -1/2] . (0.914) . (1.0479) = 4,231 kW. For X = 600 m, PB = 4,197 kW. The total Ball milling section power draw would consequently vary from 8,394 kW (2 x 4,197 kW) for X = 600 m, to 8,462 kW (2 x 4,231 kW) for X = 610 m. A calculation for the SAG Mill power draw (PS) for X = 610 m follows. It is noteworthy that the SPI index has been conceived to include the SAG Mill overall inefficiency factor. PS = (10) . (13.2) . (1774) . [(610) -1/2 - (101,600) -1/2] = 8,746 kW. X = 600 m would yield a PS of 8,825 kW. Therefore, a value slightly higher than 610 m for X will lead to the SAG/Ball power draw split of 50% / 50%: X = 600 m: SAG/Ball = 8,825 kW / 8,394 = 1.0513 ( = 5.1%) X = 610 m: SAG/Ball = 8,746 kW / 8,462 = 1.0335 ( = 3.4%) With help of a spreadsheet it is easily determined that X = 630 m will correspond to a total SAG Mill section and Ball Mill section calculated power draw of approximately 8,595 kW (11,521 HP). Assuming 95% efficiency for the motor/transmission system of the Ball Mill, a total installed power of 12,127 HP would be required, since the design feed rate has been used for the calculations. Typically two (2) 6,500 HP nameplate motors (one for each Ball Mill) would be specified. Assuming 92% efficiency for the motor/transmission system of the SAG Mill, and an additional 10% safety factor, a 14,000 HP nameplate motor would be envisioned.
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Hence, even though the determined optimum SAG Mill product 80% passing size value X o = 630 m corresponds to about the same calculated power draw for both the SAG milling and Ball milling sections, the actual total installed power is typically higher for the SAG Mill.

5 CONCLUSION
Comminution circuits correspond to the most costly operations in the context of mineral processing in general. This holds very especially true for gold projects, where large throughputs have been one of the most important factors to make production feasible "via--vis" the currently depressed price of this commodity. Also, as a general rule, higher grade ores amenable to "pulp" concentration methods (CIL, CIP), as opposed to "solution" Heap Leach CIC or Merrill-Crowe plants, are becoming -- again as a general rule -- increasingly more attractive, mainly when the associated capital and operating costs can be creatively minimized by the Engineer. In this scenario the performance optimization of typically large SAG Mill/Ball Mills plants has become a weighty item to make projects viable. A method to optimize the SAG Mill product design P80 value (Transition Size) has been presented in this paper, based on the proven benefits of balancing the power draw between the SAG milling and the Ball milling sections.

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