WORKSHOP DE MOLIENDA SAG 2001 16, 17 y 18 de Mayo - Vifia del Mar - CHILE CENTRO TECNOLOGICO DE MOLIENDA SAG y SISTEMAS ELECTRICOS UNIVERSIDAD TECNICA FEDERICO SANTA MARIA UNIVERSIDAD DE SANTIAGO DE CHILE Methodologies for the Optimization of SAG Mill Internals John A. Herbst ‘Svedala Optimization Services PO Box 2568 Kealakekua, HI 96750 USA Voice: 808-324-6100 Fax: 808-324-6304 E-mail: john.herbst@svedala-sos.com and Lawrence Nordell Conveyor Dynamics, Inc. 1111 West Holly Street Bellingham, WA 98225 USA Voice: 360-671-2200 Fax: 360-671-8450 E-mail: nordell@conveyor-dynamics.comMethodologies for the Optimization of SAG Mill Internals by John A. Herbst ‘Svedala Optimization Services and Lawrence Nordell Conveyor Dynamics, Inc. Abstract Anew set of High Fidelity Simulation tools is opening doors to optimization of SAG mill internals, ie., liners, lifters, grates and balis. The current paper introduces the key components of HFS (DEM, CFD, FEM breakage) and the validation of the associated models. A methodology is presented which uses these tools to do internals selection based on mill throughput and weer criteria. Introduction In the past SAG internals selection has been based on engineering rules- of-thumb. Very recently 2D charge motion simulators have been used as a “physics-based” qualitative guide to selection of lifter profiles while taking into account operating conditions such as mill speed, and ball/ore filling (Rajamani and Mishra, 1996). In the last year or two a new set of tools referred to here as HFS tools has. been created. The 3D tools are the most interesting and valuable, because they produce the highest accuracy (Herbst, 2000; Nordell, 2001). Svedala Optimization Services and Conveyor Dynamics, Inc. recently formed an alliance to validate and ultimately to use this technology for SAG mill optimization. Some examples of high fidelity model predictions that have been developed are shown in Figures 1 and 2. Figure 1a shows a snapshot of ball and particle motion in a small SAG mill operated at 79% of critical speed.Figure 1. Simulation of charge motion, balls and particles and the associated lifter deflections predicted and measured with @ strain gauge in lifter bar (Svedala Continuous Charge Measurement System) Figure 1b shows measured deflections in a lifter bar instrumented with a strain gauge as it rotates inside the mill and the corresponding HFS predictions based on calculated tangential forces converted to deflections. A comparison of measured and predicted values shows that the HF Simulations are extremely accurate even at the “microscopic” level. Figure 2a shows a snapshot of ball-particle and slurry motion in a large SAG mill operated at 75% of critical speed. Figure 2. Simulation of charge motion, bails and particles and the associated lifter wear profile predicted and measured with a feeler gauge. Figure 2b shows the profile determined for one lifter using a feeler gauge Measurement and the profile predicted from HFS normal and tangential force calculations and Finnie's equation (Finnie, 1972). Once again a comparison ofthe predicted and measured profiles shows that the HFS accuracy is quite remarkable. Methodologies and Applications A combination of HFS tools and Svedala experience has lead to a benefit oriented approach to liner lifter design which is based on an analysis of wear and throughput. ‘The major steps in the methodology are as follows: 1) Specify Mill Dimensions and Operating Variables 2) Calibrate HFS Models 3) Use Svedala HFS to Optimize Profiles fro Target Mill 4) Verify Performance ‘Step one involves the determination of physical variables (lengths, widths, masses, etc). Step two involves measurement of ore breakage properties and specification of reference liner wear rates. Illustrations of the type of activities that occur during the last two steps are shown in Figures 3,4,5 and Table 1. Figure 3. Predictions of wear profiles for unidirectional ‘and bi-directional miling in a large SAG mill Figure 3 shows simulated wear profiles at various stages in the life of two ‘SAG belly lifters (each of which has the same initial mass) one designed for unidirectional milling (3a) and one designed for bi-directional milling (3b). Figure 4 shows a comparison of calculated mill power (4a) and energy available for impact breakage (4b) in the mill at each stage for unidirectional and bi-directional cases.Bidreciona! |b ~ “Bidrectonal Unisiectonal Figure 4. Relative power draw and impact breakage energy dissipation for unidirectional and bi-directional miling. Ina similar manner total wear and comminution efficiency at each stage can be estimated to allow an optimal selection which takes into account ball size distribution and filing, ore size distribution and filling, and mill speed. Figure 5 shows that the HFS methodology allows consideration of the design of the pan lifter and grate system to minimize internal recycle of product size material in the case for unidirectional milling, E— roduction 92% Grate Recycle 5% Figure 5. Effect of pan lifter and grate system Pa REDGe $6 {design on internal recycle for uniirectional miling, Figure 6 shows the results of a simulation search for the best combination of lifter spacing and release angle for a bi-directional milling system.Figure 6. HFS Response surface search for optimum number of lifters and release angle. 62. Objective function is predicted liner lifter wear. 6b. Objective function is predicted mil throughput. Finally Table 1 shows an example of results obtained in the last, Le., Performance Evaluation, step. The challenge here is to “measure” the increase in mill throughput which results from a recommended change in mill internals. The evaluation procedure must be capable of “factoring out’ the effect of other variables such as ore variations and operating levels. In this case a specially designed regression package, MillSat, was used to analyze historical data collected prior to and after installation of a recommended lifter profile. In this case, F; and Fz denote the average feedrates for old and new design respectively while E; and E2 denote the energy consumptions for the old and new lifter designs. Table 1. Comparison of throughputs for two liter designs: Relative Throughput __ Relative Energy (FeFiVFiX100___ (Ex E:)/EsX100 Uncorrected 3.5% 6.5% Corrected for feed size only 6.5% =10.6% Corrected for feed size and operating conditions 11.0% =13.8% Corrected to identical product size 32% 5.9% The bottom one of this analysis is that the new profile would allow a throughput increase of 11% (with 14% less energy consumption) for the same feed and operating conditions, however, the product is coarser. When corrected to the same fineness the true improvement was 3.2% (with 5.9% less energy consumption).Conclusions This paper has presented a methodology offered by Svedala for optimal design of mill internals. This methodology is based on validated High Fidelity Simulation tools including 3D Discrete Element Modeling, Computational Fluid Dynamics and Finite Element Breakage Code. It has been demonstrated that this methodology allows best designs to be identified based on both predicted wear life and mill throughput. Finally, a statistical technique is invoked to determine whether predicted performance improvements are in fact achieved in the plant. References Finnie, |., Some observations on the erosion of ductile metals, Wear, 1972, 19, 81-20. Herbst, J.A., Model-based decision making for mineral processing — A maturing technology, Control 2000, 187-200. Nordell, L.K., SAG and ball mill comminution rate and power analysis using 3-D discrete element method (DEM) to accounting for particie shape, size range and fluid rheology, Comminution 01, 2001, Rajamani, R.K. & Mishra, B.K., Dynamics of ball and rock charge in sag mills, Proc., SAG 1996.