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To verify the new power draw approach, detailed surveys of the 14 ball mill circuits at 6 different plants were carried out The ball mills sampled in this study are ranging in diameters from 32 m to 48 m Design and operational parameters of the ball mills sampled are given in Table 1 Table 1

Ball Mill Design/Power Calculation

Ball Mill Power Calculation Example #1 A wet grinding ball mill in closed circuit is to be fed 100 TPH of a material with a work index of 15 and a size distribution of 80% passing ¼ inch (6350 microns) The required product size distribution is to be 80% passing 100 mesh (149 microns)

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Ball Mill Design/Power Calculation The basic parameters used in ball mill design (power calculations), rod mill or any tumbling mill sizing are; material to be ground, characteristics, Bond Work Index, bulk density, specific density, desired mill tonnage capacity DTPH, operating % solids or pulp density, feed size as F80 and maximum

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AG/SAG mills in the data base are up to 40ft in diameter and ball mills are up to 26ft in diameter The measured gross power draws from these mills are plotted against the model predictions in Figure 1 As indicated by this data base the accuracy of the model (1 standard deviation) is 46%

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As the ball wear rate depends directly on the surface of the media charge, a small variation in power will lead to an important increase of wear rate The risk of underloading or overloading the mill is an additional factor A direct measurement of the ball level in the mill, more accurate than power readings, as well as a control of it, is

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Ball & race Mill Hammer mill, beater mill or fan mill Dominating Principal Attrition Crushing Impact 15 Tube mill Slow speed mills(10-20rpm) 16 BOWL MILL MPS MILL Medium speed 40-70 rpm 17 X - frequency of power supply 50 cycles In USA ’x’ means 60 cycles

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Figure 84 The effect of mill speed on the power drawn by a rotating mill The liner profile and the stickiness of the pulp in the mill can have a significant effect on the actual critical velocity Mills usually operate in the range 65 - 82% of critical but values as high as 90% are sometimes used

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GROSS POWER CALCULATOR - SMC Testing

GROSS POWER CALCULATOR General calculations by the user If the mill has cone ends the model automatically calculates the volume of the Predicted Power Draw (kW) Ball mills AG/SAG Mills smctesting 5 Figure 2 – Overflow Discharge Mill Figure 3 - Grate discharge mill

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