Using DEM to model ore breakage within a pilot scale SAG mill

The best accepted method for design of autogenous and semi-autogenous (AG/SAG) mills is to carry out pilot scale test work using a 1.8 m diameter by 0.6 m long pilot scale test mill. The load in such a mill typically contains 250,000-450,000 particles larger than 6 mm, allowing correct representation of more than 90% of the charge in Discrete Element Method (DEM) simulations. Most AG/SAG mills use discharge grate slots which are 15 mm or more in width. The mass in each size fraction usually decreases rapidly below grate size. This scale of DEM model is now within the possible range of standard workstations running an efficient DEM code. This paper describes various ways of extracting collision data front the DEM model and translating it into breakage estimates. Account is taken of the different breakage mechanisms (impact and abrasion) and of the specific impact histories of the particles in order to assess the breakage rates for various size fractions in the mills. At some future time, the integration of smoothed particle hydrodynamics with DEM will allow for the inclusion of slurry within the pilot mill simulation. (C) 2004 Elsevier Ltd. All rights reserved.

Influence of explosive energy on the strength of the rock fragments and SAG mill throughput

Extensive in-situ testings has shown that blast fragmentation influences the performance of downstream processes in a mine, and as a consequence, the profit of the whole operation can be greatly improved through optimised fragmentation. Other unit operations like excavation, crushing and grinding can all be assisted by altering the blast-induced fragmentation. Experimental studies have indicated that a change in blasting practice would not only influence fragmentation but fragment strength as well. The strength of the fragments produced in a blast is clearly important to the performance of the crushing and grinding circuit as it affects the energy required to break the feed to a target product size. In order to validate the effect of blasting on fragment strength several lumps of granite were blasted, under controlled conditions, using three very different explosive products. The resulting fragments were subjected to standard comminution ore characterisation tests. Obtained comminution parameters were then used to simulate the performance of a SAG mill. Modelling results indicate that changes in post blast residual rock fragment strength significantly influences the performance of the SAG mill, producing up to a 20% increase in throughput. (c) 2004 Elsevier Ltd. All rights reserved.

Slurry flow in mills with TCPL - An efficient pulp lifter for ag/sag mills

The difficulties associated with slurry transportation in autogenous (ag) and semi-autogenous (sag) grinding mills have become more apparent in recent years with the increasing trend to build larger diameter mills for grinding high tonnages. This is particularly noticeable when ag/sag mills are run in closed circuit with classifiers such as fine screens/cyclones. Extensive test work carried out on slurry removal mechanism in grate discharge mills (ag/sag) has shown that the conventional pulp lifters (radial and curved) have inherent drawbacks. They allow short-circuiting of the slurry from pulp lifters into the grinding chamber leading to slurry pool formation. Slurry pool absorbs part of the impact thus inhibiting the grinding process. Twin Chamber Pulp Lifter (TCPL) - an efficient design of pulp lifter developed by the authors overcomes the inherent drawbacks of the conventional pulp lifters. Extensive testing in both laboratory and pilot scale mills has shown that the TCPL completely blocks the flow-back process, thus allowing the mill to operate close to their design flow capacity. The TCPL performance is also found to be independent of variations in charge volume and grate design, whereas they significantly affect the performance of conventional pulp lifters (radial and curved). (c) 2006 Elsevier B.V. All rights reserved.

Modelling comminution patterns within a pilot scale AG/SAG mill

The patterns of rock comminution within tumbling mills, as well as the nature of forces, are of significant practical importance. Discrete element modelling (DEM) has been used to analyse the pattern of specific energy applied to rock, in terms of spatial distribution within a pilot AG/SAG mill. We also analysed in some detail the nature of the forces, which may result in rock comminution. In order to examine the distribution of energy applied within the mill, the DEM models were compared with measured particle mass losses, in small scale AG and SAG mill experiments. The intensity of contact stresses was estimated using the Hertz theory of elastic contacts. The results indicate that in the case of the AG mill, the highest intensity stresses and strains are likely to occur deep within the charge, and close to the base. This effect is probably more pronounced for large AG mills. In the SAG mill case, the impacts of the steel balls on the surface of the charge are likely to be the most potent. In both cases, the spatial pattern of medium-to-high energy collisions is affected by the rotational speed of the mill. Based on an assumed damage threshold for rock, in terms of specific energy introduced per single collision, the spatial pattern of productive collisions within each charge was estimated and compared with rates of mass loss. We also investigated the nature of the comminution process within AG vs. SAG mill, in order to explain the observed differences in energy utilisation efficiency, between two types of milling. All experiments were performed using a laboratory scale mill of 1.19 m diameter and 0.31 m length, equipped with 14 square section lifters of height 40 mm. (C) 2006 Elsevier Ltd. All rights reserved.

Prediction of slurry transport in SAG mills using SPH fluid flow in a dynamic DEM based porous media

DEM modelling of the motion of coarse fractions of the charge inside SAG mills has now been well established for more than a decade. In these models the effect of slurry has broadly been ignored due to its complexity. Smoothed particle hydrodynamics (SPH) provides a particle based method for modelling complex free surface fluid flows and is well suited to modelling fluid flow in mills. Previous modelling has demonstrated the powerful ability of SPH to capture dynamic fluid flow effects such as lifters crashing into slurry pools, fluid draining from lifters, flow through grates and pulp lifter discharge. However, all these examples were limited by the ability to model only the slurry in the mill without the charge. In this paper, we represent the charge as a dynamic porous media through which the SPH fluid is then able to flow. The porous media properties (specifically the spatial distribution of porosity and velocity) are predicted by time averaging the mill charge predicted using a large scale DEM model. This allows prediction of transient and steady state slurry distributions in the mill and allows its variation with operating parameters, slurry viscosity and slurry volume, to be explored. (C) 2006 Published by Elsevier Ltd.

Archaeological Identification and Significance of ÉSAG (Agricultural Storage Pits) at Kaman-Kalehöyük, Central Anatolia

Evidence for the presence of storage pits described in Hittite texts by the Sumerogram "ÉSAG" is presented from Kaman-Kalehöyük, a multi-period tell site in central Turkey occupied during the second and first millennia BC. Small earthen pits matching the description of "ÉSAG" were part of the normal suite of domestic installations at the site throughout the period. Similar to pits seen across western Eurasia, they were probably used to store seed corn or seed for trade. Large earthen pits (>7m in diameter) were also present that matched the description of the "ÉSAG" form, and in some cases contained archaeological cereal remains. Evidence from Kaman shows "ÉSAG" were part of Anatolian life for at least 4,000 years and suggests that the term was generic for lined, earthen storage pits. The presence of so many small pits at Kaman-Kalehöyük showed that it was an agricultural production site for much of its existence. The appearance of the large pits, confined to the Hittite period, reflects centralised control of grain supply, probably by the Hittite Kingdom, and fits a pattern seen at other sites in the region during the second millennium BC. /// Hitit metinlerinde Sumerogram "ÉSAG" ile tanimlanan depo çukurlarinin varliğina dair kanit, Orta Anadolu'da M.Ö. İkinci ve Birinci binde iskan edilmiş çok dönemli bir yerleşim alani olan Kaman-Kalehöyük'ten taninmaktadir. Küçük toprak çukurlar "ÉSAG" in tanimlamasina uygun olarak bu dönem süresince normal ev düzeninin bir parçasi olarak karşimiza çikmiştir. Çukurlar, Bati Avrasya'daki benzer çukurlar gibi olasilikla ticaret maksadi ile misir tohumu ya da tohum muhafaza etmişlerdir. "ÉSAG" formunun tanimina uyan büyük toprak çukurlara (çapi 7m. den büyük) rağmen bunlarin tahil depolama ile ilgili bağlantilari tam olarak belirlenmemiştir. Kaman'daki delil, "ÉSAG" in en az 4,000 yildir Anadolu yaşaminin bir parçasi olduğunu ve bu sözcüğün sivanmiş toprak çukurlar için kullanildiğini işaret etmektedir. Kaman-Kalehöyük'te ele geçen birçok küçük çukur, yerleşimin varliğini sürdürdüǧü sürecin büyük bir bölümünde zirai üretim yapildiğini göstermektedir. Hitit Döneminde büyük çukurlarin ortaya çikmasi muhtemelen Hitit Kralliği tarafindan gerçekleştirilen tahil tedarikinin merkezi kontrolünü yansitmakta ve M.Ö. İkinci binde bu bölgedeki diğer yerleşim alanlarinda görülen şekle uymaktadir.