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Modelling SAG milling power and specific energy The ball charge is a function of the bulk fraction of the SAG mill volume (Jb) occupied by balls the ore retained in the mill is the result of the volumetric filling which depends on the ore size distribution (specially the +6″ and the −6″ +1″) on the rotationalN Nc Chat Online
Recommended ball filling percentage for sag mill Balls Used In Sag Mills Whats the difference between sag mill and ball mill 2020 5 27sag mills grinding media includes some large and hard rocks filled rate of 9 20 sag mill grind ores through impact attrition abrasion forces in practice for a given ore and equal processing conditions the ag milling has a finer grind than
Figure 2: SAG Mill Crash Stop on 10 8 2003 Crash Stop 2 March 3 2004 Please refer to Figures 3 5 This crash stop was done on severely SAG mill limiting ore that typically averaged 360 390 dry tph In comparison the worst case SAG mill limiting ore type throughput is 8 160 dry tons per day (340 dtph)
Feed ore with a top size of up to 200 mm (8 in ) and water enter the feed end of a SAG mill through a feed chute the ore is milled in the shell and milled product exits through grates and pulp lifters at the discharge end (Fig 1)
Feb 01 2012 The power draw of the mill was set at 2300 kW to provide mill filling of at least 20 depending on the ore hardness At this operating condition (i e mill power draw of 2300 kW) the effect of power draw of exhaust fan on the product size was investigated over a period of two months ( Fig 8 )
All autogenous (AG) and semi autogenous (SAG) mills in use today are operated with water and ore fed to the mill in a or less fixed ratio The water forms a slurry with the fine ore particles This slurry is much efficient than air at transporting ore progeny and finished product (sufficiently comminuted particles) out of the mill Slurry
Depending on the mill size the SAG mills draws between 2 MW and 17 MW The product from the SAG mill is further reduced in size using pebble crushers and ball mills Hence typical gold or copper ore requires between 2 0 and 7 5 kWh per ton of energy to reduce the particle size
Operational Trends (Start up to 1 5 hours) Slide 8 LDL = purple Toe = yellow Outlet fill level = blue Inlet fill level = red Shell fill level = green • Three plots show mill filling slowly over 1 5 hour period (left to right) • Fill levels increase as expected and LDL begins to drop as mill becomes full
Do one for each ore If you need than 9 then add another Interface to another side of the SAG Mill (still touching one of the ME devices) and stock the other ores ME Chests make pretty good sub net storage and for manually filling things (setting partitions Matter Cannon Color Applicator etc)
A gold processing plant I visited recently valued their SAG mill downtime at US$ 130 000 per hour so extending the life and availability of mill liners is crucial to them The reduced damage improves the mills’ availability and minimises the downtime This can translate to literally millions tonnes of ore
Fuller Sag Mill Description: SAG mill 18' diameter x 10 1 2' long manufactured by Fuller rubber lined driven by 1500 HP 4160 volt 1192 RPM continuous motor 5010 frame thru Moventas gear reducer 4 5:1 gear ratio 264 4 output RPM mfg C001338
(EGL) SAG mill driven by a 24 000 kW gearless drive The SAG mill feeds two FLSmidth ball mills each 26 ft in diameter 40 ft long (EGL) each driven by a 16 400 kW drive The SAG mill is one of the largest volumetric capacity SAG mills in the world and represented the first 40 ft SAG mill in Peru (Garcia Villanueva 2013 [1])
Failure analysis of the old SAG mill shell liners Since the commissioning of φ 9 15 5 03 semi autogenous mill in Baima concentrator the operation rate is only about 55 due to the irregular damage and replacement of mill liners which seriously affects the economic benefits
Figure 2: SAG Mill Crash Stop on 10 8 2003 Crash Stop 2 – March 3 2004 Please refer to Figures 3 5 This crash stop was done on severely SAG mill limiting ore that typically averaged 360 390 dry tph In comparison the worst case SAG mill limiting ore type throughput is 8 160 dry tons per day (340 dtph)
A representative SAG mill charge was used with a rock top size of 122 mm and the bottom size resolved in the DEM model chosen to be 6 mm so that 90 per cent of the charge was correctly represented in the model The fill level was 39 per cent with a ball load of 5 per cent giving around 425 000 particles
Nov 30 2012 Mill size 4 6 x 16 5 m L D ratio Mill drive the ball charge filling and estimate the power consumption at mill shaft detailed ore filling to power consumption in ball mills – Grinding Mill China
Filling in the mill and not related to total mill filling Discharge through an individual opening on the grate is driven by the factors of ore filling radial position and the size of the aperture The results indicate that 1 18 mm is approximately the size below which particles
Additionally the SAG mill ball load could not be set up optimally for treating the harder ores because the ore could just as readily change to easy milling material which when treated with a
Mill fills up with ore or grinds down The lower limits of the normal filling The operation of AG SAG mills is sensitive to mill filling therefore developing grindcurves to relate mill
SAG mills are employed in plants where the ore is not suited to grinding such as mill filling ball load and the percentage solids of the mill slurry critical size build up problems RoM
Step 1: Mill overload power •Determine a set of operating conditions that reflects the maximum “overloaded” condition that the mill should be able to handle: –SAG mills: 20 v v ball charge 30 v v filling and 78 critical speed with worn liners –Ball mills: 36 v v filling
SAG mills tumble mainly ore but they use up to 15 volume of steel balls to assist The Operating Principle Of The Ball Mill The model was originally developed using a data base of 76 operating mills to In SAG mills the total filling relates to the combined rock and ball
• A 6 1 km Overland Conveyor discharging ore to a 360 000 tonnes Mill Coarse Ore Stockpile • 2 x 36’ x 19’ ABB Svedala Gearless Motor Drive 13 4MW SAG Mills • 4 x 20’ x 33 5’ Svedala 7 400 kW Ball Mills • 4 x MP1000 750 kW Pebble Crushers • 4 x clusters of 26” WEIR Cavex Cyclones
Crash stop The mill filling should be measured at a minimum of 3 points along the mill Excess of slurry could also be estimated To get rid of pulp and rocks in the charge a mill grind out (no ore feed) of 10 to 20 minutes is also performed before mill inspection or relining The complete grind out is required to obtain the accurate ball load
The three jobs lined up for the Kaltech teams were all performed with worker safety as their primary objective while continuing the trend of efficiency and job completion before the planned deadline their initiative to replace the liners on our SAG mill feed chute was appreciated beyond words or the setting of the ore charge level for
SAG and AG Mills operate by lifting ore grinding media and dropping it on the operating bed of the mill charge High impacts from lifting ore and media promote impact breakage which is the primary mechanism for size reduction in the mill Via the use of sophisticated instruments and software we closely monitor the mill impact location to boost
Mines (WA) 36ft SAG mill the number of Outer Head Liners was reduced from 36 to 18 pieces and in doing so reduced the time to replace them by 9 hours at a cost downtime saving of about U$25 000 per hour In this case the liners sections are 3 5 t each For smaller mills the liners have to be handled and installed manually so smaller blocks with
Jan 01 2016 The AG SAG mills generally receive ore directly from the crushing plants with alternative arrangements made to receive ore from a stockpile In rare cases the feed is directly from the mine Schematic diagrams of a typical semi autogenous mill with large D L ratio and a square mill are illustrated in Figure 9 1 Figure 9 2
Issue as it affects ore loss dilution as well as geotechnical (filling the berms) requirements • The circuit may be limited by crusher SAG mill or ball mill Morrell’s power modelling is used to evaluate the comminution circuit performance
Was surprising that the Bond Rod Mill Wi average was 11 3 kWh t Since the ore is unusually soft the Rod Mill Wi is probably irrelevant in determining required power for the SAG mill Drop Weight Tests Drop Weight tests were done at Hazen and analyzed by Contract Support Services Inc Table 4: Summary of 6 JKTech Drop Weight Tests
2 1 SAG mill model The particles fed to the mill are ground in the milling chamber and subsequently downloaded into the discharge zone where according to a classification probability they are either returned to the milling chamber for further grinding or become part of the mill output stream