OPTIMAL GRINDING SOLUTION THROUGH LINER DESIGN

By B. K. Roy

Tegas Glossary of Software

State of the art liner selection and mill modeling software

JK SimMet: INPUT VARIABLES: Material properties: Feed rate, BWI, feed sizing, product sizing, feed B.D & Equipment properties: Mill Diameter, Mill Length, Installed power/power draw, ball load, Trunnion diameter, Ball size, Fraction of Critical speed, etc. PROCEDURE: Through Mass balancing, Model fitting and Simulation exercises. OUTPUT: Simulated, optimized grinding circuit parameters LINKAGE: MILL POWER TegaSoft: INPUT VARIABLES: MILL CHARACTERISTICS: Mill Size, No of rows in the shell, RPM, LINER CHARACTERISTICS: Lifter width, lifter height, face angle of L.B, Plate thickness, No of rows. PROCESS CHARACTERISTICS: Charge volume, type( Ball+ore), size distribution and proportion. PROCEDURE: DEM based mathematical modelling. OUTPUT: Power draw, Impact spectra, Packing characteristics, charge dynamics.

CASE STUDY: I
OPTIMIZATION OF AG MILL LINER(26X10)

TARGET:
Optimization of AG Mill power draw , mill throughput & Liner life. Concerns: Mill Power Draw & throughput will remain same as existing (1800 Kw) in spite of that AG Mill has provision for higher capacity ( Available power 2460 Kw). Low liner life which is around 3000 hrs. Ball path trajectory will not be better.

Existing rubber shell liner.

Tega rubber lining keeping the profile same as existing. Hi-Lo : 250-460 YTS/250-250 YTS & P120. Mill Effective diameter: 7419 mm.

Existing Liner Profile:

Power & Impact Spectra with Existing Liner :

Visualization of charge motion with Existing Liner:

Proposed Tega rubber shell liner.

Solution for capacity improvement: Tega rubber lining: 300-500 Lifters in alternate rows with metal reinforced shell plate PM 140. Mill Effective diameter: 7515 mm. Power draw will be improved to 1985 Kw. ( Avg). No charge packing so improved charge motion & grinding. Capacity will improved by 9.3 %.

Tega Liner Profile:

Power & Impact Spectra with Existing Liner :

Visualization of charge motion with Existing Liner:

Tega Rubber Liner for Optimum Mill Throughput:

Benefits:
Power draw increased to 1980 Kw from 1800 Kw. Capacity improve by 9.7%. Additional revenue generation due to 112,000 tons of additional grinding/Mill. Liner life will be 6000 Hrs +. So 1 shutdown/ Year as compared to 3 to 4 shutdowns/ Year presently. Savings of production hour: 96 hrs/Year/Mill.

CASE STUDY-III

OPTIMAL GRINDING PERFORMANCE OF BALL MILLS AT PELLETIZATION PLANT-BRAZIL

OBJECTIVE
TO BE ABLE TO PROPOSE ALTERNATE SELECTION IN BALL MILL LINERS FOR : IMPROVED CAPACITY IMPROVED LINER LIFE

OPERATING PARAMETER

BALL MILL: 5.2MX10.6M LG ORE TYPE: IRON ORE TYPE OF DISCHARGE= OVERFLOW INSTALLED POWER = 4500W GRINDING MEDIA TOP SIZE = 30MM MILL SPEED = 12.9 RPM THROUGHPUT = 250-300 TPH FEED SIZE(K80) = 1.2MM PRODUCT SIZE(K80) = -45 MICRONS BOND WORK INDEX = 12 KWH/T CHARGE VOLUME = 35% CIRCULATING LOAD= 200% POWER DRAW= 3500-3600 KW

COMPARISON OF LINER PROFILE: 5M5B

TEGA SELECTION:( 40R) 140-110 BLS, P-50 EFFECTIVE DIAMETER WITH EXISTING LINERS = 4998.8MM EFFECTIVE DIAMETER WITH TEGA LINERS = 5072.0MM EXTRA CAPACITY GENERATED BY TEGA LINERS = 3.8 %

Advantage of TEGA design liners

With time as the liners wear out, the bar and plate tends to retain its profile shape as compared to the double wave design. Hence the level of productivity can be retained for a longer duration. In case of double wave profile, the edge of the liners only wears out and hence the profile loses its shape with wear. A representative sketch is shown below for reference. The actual pattern of wear and its effect on capacity can be confirmed with regular wear measurement plots to be taken at site Aluminum reinforced lifters are easy to install. This means less downtime during installation and replacement, resulting in increased availability. Leak proof fastening system reduces risk of flushing behind lining and eliminate leakage , resulting in better protection of mill body from corrosion. TEGA liners are designed to utilize the maximum wearable rubber, providing better economy and minimum scrap generation.

COMPARATIVE EVALUATION STUDY OF TEGA LINERS vs DOUBLE WAVE TYPE LINERS AT NIBRASCO- V The following four parameters have been considered for evaluating the performance of the liners: Throughput ( tons/hr) BLAINE ( specific surface area generated: cm2/gm) Specific energy consumption (kwh/t) The operating life of the liners will also have to be taken into account.

FOR EVALUATING THE PERFORMANCE WE HAVE TAKEN TWO APPROACHES. APPROACH-I: One approach of evaluating the performance could be comparing the performance of the three mills at NIBRASCO V( 5M5A,5M5B,5M5C) for the same given period of time. In doing so, the data for the three mills for the period April 2006 to October 2006 have been compared.
5M5A SPCIFIC ENERGY CONSUMPTIO N 14.4 15.9 14.5 15.1 14.8 14.3 14.1 14.7 5M5B SPCIFIC ENERGY CONSUMPTIO N 16 16.2 14.1 15.6 15.1 14.1 13.3 14.9 5M5C SPCIFIC ENERGY CONSUMPTIO N 15.3 16 15.2 15.5 16.5 14.8 13.9 15.3

MONTH-YEAR APRIL-2OO6 MAY-2OO6 JUNE-2OO6 JULY-2OO6 AUGUST-2OO6 SEPT-2OO6 OCT-2OO6 AVERAGE

TPH (t/h) 271 248 264 257 265 274 276 265. 0

BLAINE (cm2/gm) 1721 1737 1735 1684 1720 1706 1655 1708.3

TPH (t/h) 258 246 264 262 273 285 312 271.4

BLAINE (cm2/gm ) 1688 1756 1735 1687 1771 1807 1731 1739.3

TPH (t/h) 262 246 262 257 250 274 279 261.4

BLAINE (cm2/gm ) 1702 1728 1710 1632 1669 1725 1728 1699.1

VARIATION OF PRODUCTIVITY
5M5A 5M5B( TEGA) 5M5C

TONS/HOUR

400 300 200 100 0

APRIL2OO6 MAY2OO6 JUNE2OO6 JULY2OO6 AUGU ST2OO6 SEPT2OO6 OCT2OO6

MONTH( YEAR)

COMMENTS: THE AVERAGE THROUGHPUT (TPH) OF 5M5B IS 2.4% HIGHER THAN 5M5A AND 3.8% HIGHER THAN 5M5C MILL FOR THE PERIOD INDICATED. THE THROUGHPUT WITH TEGA DESIGN LINERS INCREASES GRADUALLY WITH TIME TILL IT ATTAINS ITS MAXIMUM. THE ABOVE FACT WAS EMPHASISED BY TEGA AS A TYPICAL CHACTERISTIC OF ITS BAR AND PLATE LINER DESIGN.

VARIATION OF BLAINE
5M5A 1850
BLAINE( cm2/gm)

5M5B( TEGA)

5M5C

1800 1750 1700 1650 1600 1550 1500 APRIL2OO6 MAY2OO6 JUNE2OO6 JULY2OO6 AUGUST2OO6 SEPT2OO6 OCT2OO6

MONTH (YEAR)

COMMENT: THE AVERAGE BLAINE NO (cm2/gm) MEASURED FOR 5M5B MILL WITH TEGA DESIGN LINER 1.8% HIGHER THAN THAT OF 5M5A MILL AND 2.36% HIGHER THAN THAT OF 5M5C MILL. THIS INDICATES THAT WITH TEGA DESIGN LINERS THERE IS MORE CASCADING EFFECT OF THE CHARGE, WHICH IS DESIRABLE FOR FINE GRINDING APPLICATION.

VARIATION OF SPECIFIC ENERGY CONSUMPTION

5M5A 18 16 14 12 10 8 6 4 2 0 APRIL2OO6 MAY2OO6 JUNE2OO6 JULY2OO6 AUGU ST2OO6 SEPT2OO6 OCT2OO6
SPECIFIC ENERGY CONSUMPTION ( KWHR/TON)

5M5B (TEGA)

5M5C

MONTH ( YEAR)

COMMENT: THE AVERAGE SPECIFIC ENERGY CONSUMPTION (KWH/T) FOR 5M5B IS 1.3 % HIGHER THAN 5M5A MILL AND 2.6% LOWER THAN 5M5C MILL.

APPROACH II: The second approach is comparing the performance of only 5M5B Mill with Bar and Plate design (Tega) and Double wave type of liners. For this we have considered the performance of the 5M5B Mill for the 1st seven months ( i.e April-2006 to Oct 2006) since the installation of new Bar and Plate design liners and corresponding 1st seven months ( June 2005 to Dec 2005) since the previously installed double wave type of liner in the same 5M5B mill.
5M5B( TEGA DESIGN) 5M5B( DOUBLE WAVE DESIGN)

MONTH-SINCE INSTALLATION MONTH 1 MONTH 2 MONTH 3 MONTH 4 MONTH 5 MONTH 6 MONTH 7 AVERAGE

TPH (t/h) 258 246 264 262 273 285 312 271.4

BLAINE (cm2/gm) 1688 1756 1735 1687 1771 1807 1731 1739.3

SPCIFIC ENERGY CONSUMPTION 16 16.2 14.1 15.6 15.1 14.1 13.3 14.9

TPH (t/h) 261 244 271 257 278 240 252 257.6

BLAINE (cm2/gm) 1747 1740 1728 1722 1705 1859 1887 1769.7

SPCIFIC ENERGY CONSUMPTION 14.2 15.8 14.8 15.6 15.6 16.8 15.9 15.5

COMPARISON OF TPH
5M5B(TEGA) 350 300 250
TPH( T/HR)

5M5B (DOUBLE WAVE)

200 150 100 50 0 1 2 3 4 5 6 7 MONTHS( FROM DATE OF INSTALLATION)

COMMENTS: THE AVERAGE THROUGHPUT (T/Hr) OF 5M5B MILL WITH TEGA DESIGN BAR AND PLATE DESIGN IS 5.35% HIGHER THAN WITH DOUBLE WAVE TYPE LINERS.

COMPARISON OF BLAINE
TEGA DESIGN 1950 1900 1850 1800 1750 1700 1650 1600 1550 MONTH MONTH MONTH MONTH MONTH MONTH MONTH 1 2 3 4 5 6 7 MONTH DOUBLE WAVE DEGIGN

COMMENT: THE AVERAGE BLAINE MEASURED WITH BAR AND PLATE DESIGN IS 1.7% LOWER THAN THAT WITH DOUBLE WAVE LINERS.

BLAINE ( CM2/GM)

COMPARISON OF SPECIFIC POWER CONSUMPTION

5M5B(TEGA) 18
SPECIFIC POWER CONSUMPTION( KWH/T)

5M5B(DOUBLE WAVE)

16 14 12 10 8 6 4 2 0 1 2 3 4 5 6 7 MONTHS( FROM DATE OF INSTALLATION)

COMMENTS: THE AVERAGE SPECIFIC ENERGY CONSUMPTION ( kwh/t) WITH DOUBLE WAVE TYPE OF LINER IS 4.0% HIGHERTHAN THAT OF BAR AND PLATE DESIGN.

COMMENTS: Approach-II is more representative in nature for comparing the performance if there has not been any appreciable change in the ore characteristics since the last double wave type of liners were installed in 5M5B in May 2005. FROM THE ANALYSIS IN APPROACH-II, THE FOLLOWING HAVE BEEN OBSERVED: THROUGHPUT ( TONS/ HOUR): TEGA DESIGN BAR AND PLATE DESIGN HAS 5.35% HIGHER PRODUCTIVITY THAN DOUBLE WAVE TYPE LINERS. BLAINE (cm2/ gm): THE AVERAGE BLAINE FOR TEGA BAR AND PLATE DESIGN IS MARGINALLY LOWER (1.7%) THAN DOUBLE WAVE TYPE LINERS. BUT THE BLAINE HAS BEEN IMPROVING OVER THE PAST MONTHS AND AT PRESENT IT IS BETTER THAN ANY OTHER MILLS AT NIBRASCO V. SPECIFIC ENERGY CONSUMPTION (kwh/t): THE AVERAGE SPECIFIC ENERGY CONSUMPTION WITH TEGA BAR AND PLATE DESIGN IS 4.0% LESS THAN THAT WITH DOUBLE WAVE TYPE DESIGN LINERS.

IMPLICATIONS: WITH 5.35 % HIGHER PRODUCTIVITY, TEGA DESIGN LINERS WILL MEAN: 0.0535X257.5X24X30X12 = 119026 TONS (APPROX) OF EXTRA PRODUCTION PER ANNUM FOR 5M5B MILL. THIS HIGHER PRODUCTIVITY HAS BEEN ACHIEVED WITH 4.0% LOWER SPECIFIC ENERGY CONSUMPTION. THIS IN EFFECT MEANS ENERGY SAVINGS TO THE TUNE OF 1.40 MILLION kwhr APPROX (UNITS)!! PER ANNUM PER MILL. COST/ FININCIAL IMPLICATIONS: AT THE PRESENT PRICE LEVEL OF USD110/ TON FOR PELLETS, THIS WOULD IMPLY ADDITIONAL REVENUE GENERATION OF USD 13.0 MILLION AND SIMULTANEOUSLY COST SAVING, ON ACCOUNT OF LOWER ENERGY CONSUMPTION, TO THE TUNE OF USD175800 APPROXIMATELY. (Assuming cost of energy at 12.5 cents /unit ). THE ABOVE DATA IS FOR A SINGLE MILL. HENCE THE POTENTIAL BENEFITS (ADDITIONAL REVENUE GENERATION + COST SAVING), CAN BE HUGE CONSIDERING THE FACT THAT CVRD HAS 16 GRINDING MILLS AT VITORIA PELLETIZATION PLANT.

CASE IV: Performance of Primary Ball Mill liners at concentrator in South Africa

Performance of Primary Ball Mill liners

Problems reported: After three months of operation with very low ball charge(18%-14%), some surface cracks or fissures were found in some of the shell lifters. Breakage of quite a lot of grinding media was also observed during the initial run of the liners. Peening of grate plates.

Performance of Primary Ball Mill liners

Design data for the liner selection: Mill Diameter: 5.18M. Mill Length: 8.4M. Mill speed: 75% critical. Mill circuit: Closed. Aperture size of classifier screen:0.6mm. % recirculation load:? Fresh Feed rate: 177MTPH; Motor Rating: 3600KW F80: 100mm P80: 140 micron. BWI: 17.49 Total Charge volume:32% (max) & 24% (min) Maximum size of Ball: 80mm

Performance of Primary Ball Mill liners

Performance of Primary Ball Mill liners

With 18% charge volume & present liner:

Performance of Primary Ball Mill liners

With 24% charge volume with Tega liner

Performance of Primary Ball Mill liners

Root Cause analysis for the high liner wear & ball breakage: Greatly accelerated liner wear due to high-energy impacts on the liner. This can reduce liner life from a year to less than a few months under these excessive stresses, especially when worn to partial thickness. Ball fracture from the high velocity impacts directly onto steel an impulse force which many balls cannot withstand. This results in a loss of top-size grinding media and reduced milling efficiency, plus increased ball addition costs. Due to low charge level, there was ball breakage & the broken balls were not culled out. During liner & charge motion interaction, these broken ball edges caused that type of wear in a few lifters which were in the zone of broken ball concentration.

Performance of Primary Ball Mill

Proposed Remedial measures: Increase charge level to minimum 24% mill filling. F/A of the lifters to made less aggressive. New shell plates of 100mm thickness would have to be provided with the gouged shell lifters to reduce H/A value to 10mm. sh or a new one to be used.

Performance of Primary Ball Mill

Performance of Primary Ball Mill

Performance of Primary Ball Mill

Root Cause of Grate Opening: Inclined Grate subject to ball impact. Low & tapered charge level leading to very less cushion against metal to metal impact. Flow of comparatively ductile material of the grate under repetitive ball impacts causing reduction of the width of the slots.

Performance of Primary Ball Mill

Proposed solution: Actual flow rate of feed , recirculation load & % solids to be measured from site to come to the actual open area requirement in the grate. If possible, charge level to go unto 24% minimum. As EGL is not very important here due to the mill being oversized, Change of the grate from inclined to straight disposition is solicited along with the change the pulp lifters accordingly. Since, low charge level is the fate of the operation, grate should be of metal only to accommodate the required open area.

Thank You.. .. Gracias..