About the Media Charge_Level Spreadsheet ...

Scope :

The Media Charge_Level spreadsheet was designed to help in the calculation of the Fractional Apparent Charge Level
in any given mill, on the basis of the mill geometry and direct measurements or observations of such mill interior.


Theoretical Framework :

There at least two possible ways to procede with the calculations in reference :

Method 1 :

Consists of taking direct measurements of the Average Free Height (h) inside the mill (the distance from the charge level
up to the highest point in the mill shell). Replicate measurements are strongly recommended to account for level variations
along and across the mill.

If f represents the center angle created by the two radius pointing at the opposing lateral extremes of the top charge
surface, then from the geometry of the mill, the following relationships apply :

f = (360/p) arcsin [ 2 (h/D) (D/h - 1)
0.5
] , in degrees

J = (f/360) - (4/p) (h/D) (h/D - 1/2) (D/h -1)
0.5


where D represents the effective internal mill diameter (inside liners) and J represents the fractional apparent charge level,
including all interstitial voids. D and h must be expressed in the same measuring units.

Method 2 :

Consists of counting the number of exposed lifter bars (N
L
) (i. e. not hidden by the charge) and compare this value with
the total number of lifter bars (N
TOT
) of the particular liner design in reference, to compute :

f = 360 [ 1 - N
L
/ N
TOT
] , in degrees

h = (D/2) [ 1 + ( 1 - sin
2
(f/2) )
0.5
]

Then, J may be calculated as above.


Data Input :

All data required by the model must be defined in each corresponding unprotected white background cell of the here
attached Method 1 or Method 2 worksheets. Gray background cells contain the results of the corresponding formulas
there defined and are protected to avoid any accidental editing.

New Moly-Cop Tools users are invited to explore the brief comments inserted in each relevant cell, rendering the whole
utilization of the worksheets sel-explanatory.
Moly-Cop Tools / 227540937.xls.ms_office 5/9/2014 / 10:06 PM
Moly-Cop Tools / 227540937.xls.ms_office 5/9/2014 / 10:06 PM
Moly-Cop Tools
TM
Remarks :
Effective Mill Diameter 18.50
Average Measurements of
Free Height (h) : 11.00
Angle f, degrees 158.19
Charge Level, % 38.03
by Measuring Free Height Above the Charge
DETERMINATION OF CHARGE LEVEL IN A MILL
Ball Mill # 4
0
10
20
30
40
50
60
0.50 0.60 0.70 0.80 0.90 1.00
%

F
i
l
l
i
n
g

h/D Ratio
Moly-Cop Tools / 227540937.xls.ms_office 5/9/2014 / 10:06 PM
Moly-Cop Tools
TM
Remarks :
Eff. Mill Diameter 35.50
Total # Lifter Rows 72.00
Lifter Rows Exposed 44.00
Fraction Exposed 0.61
Angle f, degrees 140.00
Height (h) Above 23.82
Charge Level, % 28.66
DETERMINATION OF CHARGE LEVEL IN A MILL
by Counting the Exposed Lifter Bars
SAG Mill # 1
0
10
20
30
40
50
60
0.50 0.60 0.70 0.80 0.90 1.00
%

F
i
l
l
i
n
g

h/D Ratio
Moly-Cop Tools / 227540937.xls.ms_office 5/9/2014 / 10:06 PM