Research highlights DEM used to simulate the dynamics of ball motion in an industrial scale ball mill. Energy distributions with progressively worn lifter geometry profiles were simulated. A basic wear model based on detailed DEM output data is proposed. DEM simulated energy data was utilised to predict breakage rates of fine particles. A …
A mill lining is a customized wear part. Identifying the appropriate type of lining and design is vital for optimizing mill throughput and total grinding costs, including costs for energy, grinding media and maintenance.
The increasingly thick centrifuged layer causes the intensity to decline even more for the lower fill levels. 7. Effect of lifter shape Sacal liners are used because of the high wear rates occurring within the mills. This wear occurs most strongly on the protruding lifter bars, reducing the lifter heights and their face angles over time.
While the mill is being operated at a reduced speed at the start and end of the liner life, the mill feed rate set point must also be lower as shown in Figure 5a. ... McBride, A T and Powell, M S, 2006. A structured approach to modelling SAG mill liner wear – Numerical modeling of liner evolution, in Proceedings International Autogenous and ...
To achieve this goal, it is important that the actual liner wear is known. The wear can be measured from inside the mill but this requires a costly production stop. A method to detect wear during operation is therefore desirable →1. 01 Monitoring the liner wear in high-throughput grinding equipment is critical if process uptime is to be ...
Change in liner shape and wear rates for five steps of wear evolution over the liner life cycle for the Hicom 110 mill, (left) predicted wear rate with the liner surface from the start of the step shaded by the predicted abrasion rate, and (right) evolved liner shape at the end of the step shaded by the cumulative wear depth (with red ...
A numerical framework to predict the three-dimensional evolution of the liner profile within a rotating industrial SAG mill is presented. The need to understand the manner in which the lifter profile develops is emphasised by comparing two discrete element method (DEM) simulations with measured new (i.e. unworn) and worn lifter profiles. The DEM informs …
Mill component wear rate can be predicted with machine learning and simulation. • Wear profile of lifters in real large-scale mills can be determined by small …
Mill Liner Wear > Monitor wear rates at frequent intervals- mechanical gauge > Electronic measuring devices are also available- Scanalyse > Liners could last 18 months so this is a slow optimisation process > Monitor cracks, damage bolts, pegging, broken balls, steel scats Source: Growth Steel Group Library (2013)
The wear rate on rubber mill liners (in fact most if not all types of liners) is a function of ore type and PSD, media type and size distribution, mill filling level, speed and operational up-time. I am not aware of a universal formulation to calculate expected wear life. Typically in wet mineral ball mills we see a life time of 2 years (under ...
This paper presents an analysis of 3D simulation of a grinding mill carried out using the EDEM software package customised to predict the rate of wear of lifter …
The proposed method could provide the liner wear profile and liner weight at any given operating time with a good accuracy (±2.5%). 3. It was found that at the Sarcheshmeh new concentration plant the wear profile of the SAG mill along the liner length is not uniform. The difference in wear at specific location on the liner width could …
In a Ball Mill (particularly) the wear rate or wear life of Rubber depends much on the Ball Size/Diameter used in that mill. The grinding media size which itself is much of a function of the ore/material …
A simplified breakage rate model is developed as a tool to correlate liner profile to mill performance.The combination of the prediction of liner profile and grinding rate shows promise to provide ...
The relationship between rate of wear of the metal surfaces and the ball charge in the mill is shown by the data of Gross, plotted in Fig. 8.9. This curve is seen to be, very roughly, of the same form as that of …
The greater the hardness of the material, the faster the wear rate of the ball mill liner and steel balls, which may cause equipment damage or even safety accidents in severe cases. In addition, the wear of the ball mill liner is also related to the steel balls. The size and quantity of the steel balls will affect the service life of the ball ...
• Face angle drives the liner wear rate – Once the lifter face angle reaches a critical angle, wear rates accelerate (YELLOW REGION): due to the change in the relative friction angle between the contacting surfaces et al –Applying mill control to account for liner wear on the Cadia 40ft mill, SAG 2015
This resulted accelerated wear rate throughout a shell liner campaign (Hong et al., 2016, Shaeri et al., 2012). A wear rate metric, in terms of millimeter thickness worn per service day, was also calculated for each sensor, and results are shown in Fig. 8 b. Comparing the averaged wear rate for three segments (FE, MID and DE), MID segment shell ...
Under normal operating conditions, the wear life of SAG mill liners can be estimated by the material wear rate. Studies have indicated that more than 95% of equipment wear in mineral processing occurs in the grinding stage, estimated at up to 700-g/ton of ore feed (Hawk & Wilson, 2001) . ...
The numerical calculation method is used to analyze the wear of the liner of the general structure of a semi-autogenous mill in the axial direction, and the non-uniform wear of each area of the ...
This characteristic of ball media wear rate vs the bond index was investigate at part of the AMIRA P9L project 1996-1999. It was found the systems dominated by corrosive wear mechanisms (ie: mild steel media) had wear rate in the 100-159g/kwh range and the systems that did not have corrosive wear mechanisms (Cr media or non-corrosive ores) …
Application of the proposed method in a 9.75 × 4.88 m SAG mill indicated that the liner wear profile along the liner length was non-uniform and the highest wear occurred between 1.25 m and 2.75 m ...
Understanding how your linings wear has a direct impact on the performance of your grinding mill. 's wear management solutions extend liner life cycles, optimize throughput and uptime and empower …
One way to estimate this screw liner wear is monitoring the power draw of the mills and another tool that could be used is DEM simulations to estimate the liner wearing (Esteves et al. 2018). ...
A mill' steel liner wear rate and total useful operating life is a function of its hardness (mostly). Here is a chart displaying Liner Hardness on the Brinell Scale as a function of the tonnage of ore/rock milled/processed. Not showed here is the impact a mill's RPM has on the liner's wear rate. Comminution and Energy Consumption: By ...
High–low double wave ball mill liners – These are a refinement of the wave liner, Figure 5. This was applied to Cadia Hill Gold Mine through evaluation of their existing wear profile and wear rate, and provided a more consistent wear profile through the liners working life.
There are many different designs and styles of ball mill liners. As with grinding balls local economics and ultimately operating costs determine the best design and material to use. The initial set of liners is rarely the final design selected. Based upon individual experience, mill superintendents develop preferences for liner designs. The …
Boost mill productivity and improve processing performance by understanding your mill liner wear with mill liner profiling and 3D scanning from FL.
Fig. 5 shows the total wear rate on the liners of the mill. Clearly, wear rate increases with increasing shape indices. That is to say, more angular particles cause larger wear, which is in line with the experimental results reported by other researchers [5].Moreover, with increasing shape indices, the increasing rate of the total wear rate …
's wear management solutions extend liner life cycles, optimize throughput and uptime and empower better decision making with accurate wear reports and thorough analysis and wear forecasts. Furthermore, …
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