The SAG mill makes-up balls not as big as possible. The geoding diameter and the complementary rhythm shall be determined in combination with maximum grinding particle size, ore hardness, grinding diameter, mill liners state, critical rate of rotation and current ball rate of breakage.
i. Grinding balls determine impact energy and fragmentation capacity
The SAG mill uses both ore and grinding balles as a grinding medium. With an increase in the diameter of grinding balls, the impact of individual grinding balls is higher and better suited to deal with large, hard ore; but oversized grinding balls can also reduce the number of media in a unit volume and reduce the exposure to grinding of fine particles.
Therefore, the grinding diameter should serve target particle size and throughput rather than being determined directly by the mill specifications or the usual size of the supplier.
Focusing on checking five profiles when determining the diameter of grinding balls
It is recommended that the following data be collected before the selection and that at least one full run cycle be covered:
- Maximum and P80 caloric: The larger the size of the block, the greater the need for sufficient shock energy.
- Hardness and corrosivity of ore: Hard ore, strong corrosive ore, need to balance shock resilience with grinding.
- Mill diameter, effective volume and rotation: determine the geoding ball tracks, the altitude of the drop and the physical impact environment.
- Ballloads and mills state: low ballloads, increased bar wear or change in spacing change the effective sports of grinding balls.
- The material resilience, hard gradients and operating conditions should be checked first when the abnormally high rate of the ball breakage is recorded in the ball breakage, out-of-roll bars and grinding media records.
iii. Griding balls diameter matches ball holster, mill liners, speed transfer requires a connection
Replacement of the grinding ball diameter alone may shift the problem to the millliners wear, drain capacity or power utilization factor. Physical modifications usually require simultaneous review of the ball load, the ratio of make-up balls, grinding speed and lift strips.
For example, when the ball load increases, the grinder power and the frequency of collisions change; when the mills are not able to upgrade, the ball cannot produce an effective fall; and excessive turn-off can cause the medium to become centrifuges and reduce the effective impact. Therefore, the Grinding Balls programme should be validated with the mill operational parameters.
IV. TESTING THE TRANSPORT ON THE HOLDING
It is recommended that the current grinding balles be retained as a benchmark to be compared with the best possible alignment of the target of the mineral, operation and product particle size. Not only compare unit prices or short-term media consumption, but also record:
- Ton of mineral medium consumption and catch-up cycle
- P80/Scientific and particle fluctuations
- Time throughput, power and unit energy consumption
- Ball breakage, un-of-roll balls, clean-up and abnormal stoppages
- Mills wear and tear, plyboard state, downstream effects
Concluding remarks: looking at the drawing limits before determining the diameter
The SAG grinder is not separated from the generic answers. It is recommended that the collection of mineral and mill data be completed and that the scale, retroactive field tests be used to validate the ball path, material, weight transition and catch ratio. For overseas projects, the delivery period, secure stocks and emergency replenishment capacity should also be assessed simultaneously.
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