MILL EFFICIENCY
SAG Mill Success—Start with the Basics
New products and techniques proliferate for maintaining and improving mill performance,
but careful planning at installation may be the most effective tool of all
SAG mills are often flexible enough to accomplish the same size reduction provided by two or three stages of crush-for grinding circuit design, either in com-
ing and screening, a rod mill, and some or all of ttie work of a ball mill.
With units available in ratings up to
35,000 hp, capable of supporting a
grinding line that can output more than
100,000 mt/d, SAG milis have played a
steadily growing role in mineral process-
ing. To get an idea of the extent to
which this technology has been accept-
ed by the mining industry, it's only nec-
essary to look at a brief sampling of
recent contract awards from major mill
suppliers.
• FFE Minerals Brazil was awarded a
contract to supply a 26 x 16-ft,
6,500-hp SAG m i l l - a s well as a 21 x
32.5-ft, 9,600-'hp ball mill—for
CVRD's Paragominas bauxite mine in
northern Brazil.
• Metso Minerals provided a 5,400-kW
SAG mill along with technical services,
spare parts and supervisory services for
erection and commissioning to Kun-
ming Iron and Steel Group Co. Ltd
(KISCO) for its Dahongshan mine in
Yunnan province, China, Delivery was
completed in the second quarter of
2006. Metso Minerals more recently
48 E&MJ • MARCH 2007
flexibility and the ability to cope effi-
ciently with large ore variations.
announced that it wili supply grinding
and flotation equipment to the Gaisky
copper mine of Ural Mining and Metal-
lurgical Co. The order, valued at more
than €20 million, will be completed by
the end of 2007 and comprises two
5,000 kW SAG mills, two 4,100-kW
ball mills and 17 RCS (Reactor Cell
System) flotation cells, complemented
by installation and commissioning sup-
port services.
Wedgetail Exploration purchased a
SAG mill from Thyssen Krupp Engi-
neering Polysius Division for installa-
tion at its Nullagine gold project in
Western Australia. The mill, which
measures 6.1 m in diameter by 7 m
long, is powered by a 3,500-kW drive.
Outokumpu Technology was selected to
provide a 32-ft-diameter, 20-ft-long
SAG mill with 12,000 kW of installed
power to First Quantum Minerals'
Frontier project in the Democratic
Republic of Congo, The trunnion-sup-
ported mill features variable speed
capability, allowing greater production
The Frontier mil! is notable because it
tiighlights an approach toward over-com-
ing what may be SAG technology's major
challenge—ioad stabilization and con-
trol. A credible argument can be made
that the flexibility offered by SAG mills
may also be their greatest weakness; A
mill that is touted to be capable of grind-
ing anything that is fed to it, might there-
fore be fed a mix of everything—ranging
from vastly different chunk sizes to vari-
able rock hardness. Feed variations such
as this, as well as over or underloading a
mill, can result in less-than-optimum
performance and make it difficult to
achieve satisfactory mill control. In fact,
at least in part because of the attention
that must be given to the care and feed-
ing of SAG mills, producers have begun
to look increasingly favorably at high-
pressure grinding rolls as a viable option
bination with SAG mills or as a replace-
ment, particularly when dealing with low-
grade, abrasive ore.
There are a number of laboratory and
software tools that can provide both pre-
and post-installation solutions to SAG
mill power and feed problems. As an
example, Dawson Metallurgical Labora-
tories, based in Salt Lake City, Utah,
USA, in association with the SAG Design
Consulting Group, offers SAGDESIGN
test work and consulting. The SAGDE-
SIGN test is performed with a specially
designed laboratory SAG mill and uses 7-
to 9-kg (depending on ore specific gravi-
ty) of - 3 8 mm ore. The SAG product is
then used as feed to a Bond ball mill
work index test. The results can be used
to determine or confirm SAG (or AG) and
ball mill energy requirements. Other
engineering and laboratory firms offer
similar services.
Variable Drive - Mill Efficiency
According to Outokumpu Technology, the
advanced technology utilized in the
Frontier mill's Hyper SER Drive ensures
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that the mill can operate efficiently both
above and below the synchronous speed
of the motor, thus allowing better man-
agement of variable feed rate and feed
competency. The design also is claimed
to facilitate optimized handling of any
short- or long-term variations in ore.
Variable speed offers optimized trajecto-
ry for the charge during mill operation,
minimizing unnecessary wear of the mill
lining, according to Oskar Gustavson,
Outokumpu Technology's global technol-
ogy manager for grinding. "The beauty of
this customized system is that it is
designed for optimal operation and can
cope with pretty much anything. This is
critical, especially at remote sites which
can be prey to challenging situations
such as voltage variations and thus
unavoidable downtime. The Hyper SER
Drive can transfer to fixed speed mode
during under-voltages, then transfer
back to variable speed when the supply
voltage stabilizes, ensuring no costly mill
stops occur."
SAG mill breakdowns are costly
events for producers. As an example,
early in 2006, Cia. Minera Doiia Ines de
Collahuasi had to make temporary repairs
on the drive on the iargest and newest of
its three SAG mills at the Collahuasi cop-
per mine in northern Chile, and then in
mid-January 2007, finally began full
replacement of the motor stator on the
Metsc Minerals helped Anglo American's Lisheen mine improve mill uptime by developing SAG mill linings that can Mountain, Nevada, USA, with another
be replaced without halting production.
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21-MW gearless drive for the 40-ft-diam-
eter mill. The company expected the mill
to be out of action for approximately 65
days, representing about 30,000 mt of
lost output.
The need to monitor and control
these mills has led to the growth of a
significant sub-sector in mineral pro-
cessing technology and product devel-
opment. For example, the technical pro-
gram for SAG 2 0 0 6 - t h e 4th Inter-
national Conference on Autogenous and
Semiautogenous Grinding, held in
Vancouver, B.C., in September 2006,
listed roughly 100 papers devoted to
research, product development, main-
tenance and operation of this type of
grinding equipment.
Products for the care and feeding of
SAG mills range from preventive main-
tenance-oriented items such as Eriez
Manufacturing Co.'s SAG mill ball sepa-
rator, which employs magnets to remove
worn/broken media from mills before the
tramp iron can cause problems down-
stream; to real-time monitoring devices
such as Metso Minerals' Electric Ear,
which listens to the sound level generat-
ed by a SAG mill and provides an indica-
tion of load conditions within the mill.
The Electric Ear can warn the operator of
a low load level that might result in liner
damage, or an overload condition that
could interrupt production.
Facing the risk of losing a significant
amount of production in case of mill fail-
ure or downtime, producers are constant-
ly on the lookout for new products and
methods that have the potential for
improving mill reliability and availability.
Metso Minerals, for example, helped
Anglo American's Lisheen mine in
Ireland improve mill uptime by develop-
ing SAG mill linings that can be replaced
without halting production of zinc and
lead concentrates {E<6M./, "Sectional Mill
Lining Helps Keep Lisheen at Full
Production," Sept. 2006). The resulting
design, according to Metso, provides
optimum performance while enabling the
linings to be quickly replaced during
scheduled shutdowns.
Lisheen opened in 1999 and pro-
duces some 300,000 mt/y of zinc con-
centrates and 40,000 mt/y of lead con-
centrates. Material is crushed under-
ground, stockpiled and then conveyed to
a 6.1 X 4.1-m SAG mill. It is powered by
a 2.3-MW motor and runs with 8%-12%
of the mill's voiume filled with 125-mm-
diameter steel grinding balls. Incoming
ore varies in zinc and lead levels and
hardness. The SAG mill therefore oper-
ates at variable speeds.
Normally, it would take about 60
hours to replace the mill's entire lining in
a single job—too long for a monthly shut-
down. A cooperative effort between
Metso and a mine task group was able to
develop an approach that optimizes the
life of the linings and staggers the work
so that replacement of the feed, central
and discharge sections of the mill's liner
are timed so that they need replacing in
different months. End sections take
about 15 hours to fit while the central
section takes 36. Maximum life is gained
from each section by monitoring the rate
of wear and carrying out the replacement
only when it becomes necessary.
As mills grow larger, so do their sup-
port components. To illustrate, Eaton
Corp.'s Airflex division recently developed
what is claimed to be the world's largest
air activated drum-style clutch for use
with grinding mills. The Airflex 76VC
measures 8 ft (2.4 m) in diameter and is
capable of transmitting 7.3 million Ib-in.
of torque with 9,500 hp at 200 rpm.
Three of the units were shipped to a
Newmont Gold project near Battle
order in the works for a customer in Chile.
MARCH 2007 • E&MJ 49
 MILL EFFICIENCY
The Airfle* 76VC drum-style clutch was designed to
handle the largest grinding mills currently available,
Johnson Industries, which has
offices in Canada and the U.K., says its
TL series toggle lever caliper brakes are
the largest known spring applied,
hydraulic released caliper brakes in the
world and are well-suited to accommo-
date very high braking torque require-
ments in applications such as SAG or
ball mill installations. Features include
a stackable design allowing 1 to 4
Mill Installation: Getting to the
Heart of the Matter
Peter Nilsson, installation manager-
Grinding Division for Outokumpu Tech-
nology Australia, who recently compiled
some useful recommendations for planning
basic mill installation. His suggestions are
based on the concept that the millmg/gnnd-
ing area is traditionally known as "the heart
of the plant." So, when it comes to prepar-
50 E&MJ • MARCH 2007
calipers to be mounted in a common
frame and spring force compensation by
toggle mechanism resulting in constant
braking torque. Caliper shoes are
attached with stainless steel shoe pins
that incorporate countersunk lubricating
holes, tapped pm-pulling holes, and a
pin retention groove. Caiiper levers
incorporate a unique toggle mechanism
to compensate for spring force and
ensure constant braking torque. The
system is powered by a hydraulic power
unit incorporating a manifold fitted with
valves to accommodate brake set,
creeping and inching modes.
Focusing on Installation
With all the tools available for optimizing
SAG mill performance, it might be possi-
ble to overlook what could be the most
important element of all in achieving
successful long-term performance: a
careful, accurate and well-planned
installation sequence. The trend toward
installation of large, gearless drive mills
amplifies the importance of this opera-
tion. At SAG 2 0 0 1 , Doug Farnell and
Stephen Thompson, both principals in
Farnell-Thompson Applied Technologies,
Montreal, Canada, presented a paper
titled Coordination of Mill. Motor and
ing the installation of a plant's "heart," a
great deal of planning is required. The fol-
lowing information outlines some common-
sense steps and pointers which are crucial
to this planning process.
Step 1-Preparing the method statement.
Safety aspects, especially how to handle
large components, must be the primary
consideration when planning any large
Plant Engineering for Large Gearless Mill
Projects. In their words, "The successful
execution of a geariess drive mill project
requires that the mill vendor, motor ven-
dor and piant engineer coordinate their
design efforts to a much greater degree
than has been the case for most tradi-
tional grinding mill projects. This coordi-
nation is critical to the design of the
three major elements of the system—the
mill, the motor and the foundation—so
as to end up with a system that can be
assembled, commissioned, and operated
with as few surprises as possible,"
The authors divide the necessary
tasks into three main c a t e g o r i e s -
basic design, operating and control
logic design, and installation coordi-
nation—and focus mainly on basic
design elements such as coordination
of interfacing geometry/layout; struc-
tural design/analysis of mill, motor
and foundation; static and dynamic
stability analysis of the overall system;
and coordination of services such as
water, oil, air and power. Although
they recommend against assigning
technical responsibility for overall
design of the motor, mill and founda-
tion to any one specific entity, they do
offer specific guidelines for improving
mill installation. If you can look through
a particular installation job with all its
peculiarities and challenges (be it a
shell- or trunnion-mounted bearing mill,
or a mill on riding rings mounted on the
shell) and can clearly envisage how you
are going to site rig all the components,
you are in effect, mentally forming your
method statement which you will have to
produce to the engineer at some stage.
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 MILL EFFICIENCY

the technical coordination required to
achieve a successful installation. These
include:
• Joint review by mill and motor supplier
of foundation requirements, mainten-
ance access and clearances, and
installation planning prior to submis-
sion to the project engineer;
Early exchange of data between mill
and motor suppliers so that foundation
drawings from both refiect the same
geometry;
Improving the timeliness of the system
studies such that there is the oppor-
tunity to make any necessary design
changes prior to fabrication;
"Closing the loop" involving the mill vendor,
motor vendor, plant engineer, and owner on
control l(^ic implementation through joint
review of the final PLC logic; and
Improved planning of the installation
sequence, particularly in the area of
motor alignment vs. bearing adjustment
so as to avoid repeating any tasks.

This, in turn, helps with organizing the
speciai equipment you need to take when
building the various possible configura-
tions of custom built grinding mills.
Step 2-Preparing the schedule. Once you
have written down your method state-
ment, preparation of the activity sched-
ule is the next task. It is advisable to sep-
arate all the different tasks into groups.
One method would be to group tasks
according to how the various sections of
the mill itself are assembled. Once you
have an overview of issues like timeline,
resources, personnel and tools, you are
better prepared to ensure full efficiency
with the workforce during the installa-
tion. Another benefit of a well-prepared
activity schedule is that it then doubles
as a progress report of the job itself dur-
ing the actual installation.
Step 3-Selecting the right crew. In today's
marketplace where there are acute short-
ages in qualified technical staff, ensuring
you have the right crew for the job has
never been more difficult. The trades-
people you select must have heavy fitting
experience and be trained in use of all the
different technical equipment aspects of
the jobs tasks. For example, both the use
of laser alignment for the drive train and
also ultrasonic bolt micrometers for meas-
uring the elongation of critical fasteners
are mandatory standards today.
The people you select for the handling
and rigging must have heavy lifting experi-
ence and preferably have worked in a sim-
ilar industry for at least some 10 years.
Many lOG-ton section lifts are becoming
commonplace these days as processing
plants become larger, so there are pitfalls
awaiting the inexperienced.
Step 4-Selecting the right tools. Selecting
the right tools sounds easy enough-but this
can be a minefield to the inexperienced!
The list can be mind-boggling; an experi-
enced provider's "toolkit" can cost
$300,000-$400,000. Items could include
temporary power generator, specially
designed lifting equipment, computerized
laser alignment equipment, a hydraulic
torque multiplier for the large critical fas-
teners and temporary oil lube systems for
floating the mill dunng construction as the
main operational equipment is usually still
being installed and without mains power.
The correct clamping force on structur-
al mill bolts is vital as these bolts are
designed to last the lifetime of a mill, so
choosing the right tool is crucial. An ultra-
sonic bolt micrometer, for example, meas-
ures the elongation of a bolt much more
accurately than just measuring the torque.

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www.e-mj.com MARCH 2007 • E&MJ 51

 MILL EFFICIENCY
Apart from ensuring a supplier has an
adequate toolkit, there are other tooling
issues to also consider. All rigging equip-
ment and specially designed attachments,
for example, must be certified for use and
the certification must be up-to-date. Items
such as slings must be checked and regis-
tered before sending to the project.
Step 5-Planning your delivery timeline. In
order for the installation to flow smoothly,
component delivery to site must be such
that it arrives to compliment the progress of
the installation. This avoids congestions and
double handling. The weights and size of
components means crane reach and practi-
cable working space adjacent to the mill
installation are usually at a premium.
Some pointers to consider-Depending on
a project's location—the tropics or a dusty
desert environment—a lot of large tarpau-
lins are needed to protect the machined
items from rust corrosion or contamination
while the machine is being erected. Some
large mills take 12-14 weeks to build and
rust/dust prevention is an ongoing task
that has to be monitored through the
whole erection of the mill.
the latest BAC
Fies advisory service
available in Australia
BAC SYSTEMS Pty Umited
193-195 Power Street
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9832 2777 Fax: (021 9675 3645
52 E&MJ • MARCH 2007
During the main mechanical erection it
makes good sense to involve the operational
and maintenance staff as much as you pos-
sibly can. Usually the various components
are already exposed, thus enabling 'hands
on' visual explanations, This is important
not only for smooth day-to-day operation but
also when it comes to choosing long term
critical maintenance spares other than com-
missioning and first 12-month run spares.
Site operators and maintenance crews will
feel more comfortable with the machine if
they are involved from the beginning of the
mill erection. It is human nature for people
to look after a machine better if the correct
operational aspects are understood.
Commissioning is very important for
compiling all electrical settings and actual
starting reference trend data for monitored
components, including the mechanicals.
The mill charge is normally increased grad-
ually to full load over some days. The drive
train sometimes has to be reset to suit the
hot alignment and dynamic conditions
experienced by the mill as load is gradual-
ly increased. Site mill staff should keep
handy and retain copies of all final full load
starting data settings for reference against
what were new as built data readings.
Ask now for
catalogue!^
and overseas
"Housekeeping" on mills is aiso very
important and cannot be overlooked. This is
especially the case for those who operate in
a wet area and, in the case of SAG mills, usu-
ally a messy area. It's a well-known milling
fact that when housekeeping has been ongo-
ing, there are far less instrument and
mechanical problems. Care, however, should
be taken when hosing down around any bear-
ings. Operators should be made aware of
what can and cannot be hosed down.
There are many hundreds of different
things to look out for when planning and
building large heavy machinery. These can
range from the day scabbling of latent con-
crete float starts, through to final paint and
punch lists. The best advice, when it comes
to planning the erection of a large mill, is to
get advice from an experienced professional
who can either assist in the project planning
or manage the mill erection completely-
either on a stage-by-stage basis, or from start
to finish. After all, a plant's "heart" is key to
optimum performance in a plant. And if poor
planning and/or lack of experience in certain
issues resuits in poor performance, time wast-
ing or, worse still, regular breakdowns, this is
something which is not only easily avoided
but also makes very sound economic sense,
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