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Operation Analysis of a SAG Mill under Different Conditions Based on DEM and Breakage Energy Method

Author

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  • Qiyue Xie

    (School of Electrical & Information Engineering, Changsha University of Science & Technology, Changsha 410114, China)

  • Caifengyao Zhong

    (School of Energy and Power Engineering, Changsha University of Science & Technology, Changsha 410114, China)

  • Daifei Liu

    (School of Electrical & Information Engineering, Changsha University of Science & Technology, Changsha 410114, China)

  • Qiang Fu

    (School of Electrical & Information Engineering, Changsha University of Science & Technology, Changsha 410114, China)

  • Xiaoli Wang

    (School of Automation, Central South University, Changsha 410083, China)

  • Zhongli Shen

    (School of Electrical & Information Engineering, Changsha University of Science & Technology, Changsha 410114, China)

Abstract

As one of the machines widely used in mining, a semi-autogenous grinding (SAG) mill can significantly improve the roughing efficiency of rock. But the SAG mill still faces the obstacles of significant energy consumption and empirical operation parameters. In order to obtain the optimal operation parameters of a SAG mill, in this paper, the discrete element method (DEM) is used to simulate the breakage process of the particles by controlling three parameters, i.e., the mill speed ratio, the mill fill level ratio, and the steel ball ratio. This method simulates the particles size, mill power, and qualified particles quality of crushed particle, which reveal the grinding strength and energy consumption of the SAG mill. In this paper, the grinding changes of a SAG mill under different parameter conditions are explored. Firstly, an experiment on the influence of a single parameter change on the mill’s operation is set up, and then the influence of three parameter changes on the mill’s operation is analyzed. These changes are characterized by particle size and mill power. Simulation results under the ∅ 5250 × 500 mm mill model show that the mill operates with the optimal effect when the mill is under the condition of 80% critical speed and 15% fill level; the power of the mill does not increase linearly with an increase in the mill speed ratio, but will decrease after 85% of the critical speed, and finally increase again; the optimal steel ball ratio in the SAG mill depends on the simulation time (mill actual working time) and the limitation of the rated power. The mill speed, fill level ratio, and steel ball ratio can significantly affect mill operation, and our conclusions can provide a reference for an actual situation.

Suggested Citation

  • Qiyue Xie & Caifengyao Zhong & Daifei Liu & Qiang Fu & Xiaoli Wang & Zhongli Shen, 2020. "Operation Analysis of a SAG Mill under Different Conditions Based on DEM and Breakage Energy Method," Energies, MDPI, vol. 13(20), pages 1-13, October.
  • Handle: RePEc:gam:jeners:v:13:y:2020:i:20:p:5247-:d:425472
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    References listed on IDEAS

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    1. Yan Bai & Fang He, 2015. "Modeling on the Effect of Coal Loads on Kinetic Energy of Balls for Ball Mills," Energies, MDPI, vol. 8(7), pages 1-22, July.
    2. Yi Liu & Zhaosheng Yu & Jiecheng Yang & Carl Wassgren & Jennifer Sinclair Curtis & Yu Guo, 2020. "Discrete Element Method Investigation of Binary Granular Flows with Different Particle Shapes," Energies, MDPI, vol. 13(7), pages 1-25, April.
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