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By F. Charette

The paper reviews recent investigations of the impact of corrosion on the performance of both plain and coated Swellex rock bolts. It addresses the problems associated with estimating and predicting corrosion rates of friction bolts, and based on field data it suggests an empirical relationship to predict corrosion rates. A review of the necessary qualities for a protective coating leads to recent experience with coated Swellex bolts that suggest that they can contribute to extending the useful life of Swellex bolts in potentially corrosive environments.

May 1, 2004

"The application of telerobotics to mining is currently being introduced into production systems around the world. Mining companies in Canada, Sweden, South Africa, and Australia have tended to lead the international charge to this form of technology for mining. While this introduction is taking place, a few basic questions have yet to be answered. How many machines can a single operator run? How many types of machines can a single operator run?A Canadian Research Chair in Robotics and Mine Automation has been established at Laurentian University to investigate these questions and many more through a series of experiments in a telerobotics laboratory that connects Laurentian teleoperation workstations to model mining machines at Cambrian College’s eDome. The laboratory supports many experiments allowing researchers to physically run multiple robot scenarios differing the numbers and types of machines at one quarter scale. Further experiments are being designed to investigate the potential for managing time delays in telerobotics. This paper describes the laboratory, experiments, and some preliminary results."

Jan 1, 2005

By A. G. Doll

"Multi-stage crushing plants, including high pressure grinding roll (HPGR) circuits, require more materials handling equipment than SAG and ball mill circuits. A temptation exists to neglect the energy consumption of materials handling when doing desktop comparisons of HPGR versus SAG milling circuits because estimation of materials handling power requirements can demand significant general arrangement drafting that is not available when performing preliminary scoping or ""desktop"" studies.The largest component of materials handling power is consumed by conveyors when lifting material between stages of crushing, meaning that a simple potential energy model can be used to evaluate conveying specific power consumption. This potential energy consumption for conveying can then be factored to provide overall materials handling specific energy consumption suitable for desktop studies of HPGR and other multi-stage crushing circuits. The technique also permits different crushing circuit flowsheets to be evaluated, at a preliminary level, by simply counting the number of times a conveyor must ""lift"" ore from ground level up to a bin or other equipment mounted up high.INTRODUCTIONTrade-off studies of multi-stage crushing plants involving high pressure grinding rolls (HPGRs) versus semi-autogenous grinding (SAG) mill circuits typically focus on the operating cost savings of crushing plants versus the capital cost savings of SAG mill plants. Very high-level (or desktop) studies of this type do not include a great deal of engineering work, meaning that the details (and costs) of ancillary systems are often not captured when doing the comparisons. The more complicated nature of the multistage crushing plants means there are more ancillary systems than a SAG mill plant, risking a skewed analysis of the operating costs, benefiting the HPGR option.One of the ancillary systems that may be overlooked is the more complicated conveying systems inherent in multi-stage crushing plants. Due to the mass of material being handled in large mining operations, these conveyors become a significant portion of the operating costs. A simple way to estimate the specific energy consumption of conveying systems without requiring engineering drawings and a site layout would allow high-level studies to capture this operating cost."

Jan 1, 2015

By Gianni Bartolacci, Patrice Nadeau, Szatvanyi. Gerard, Carl Duchesne, Claude Chrétien

"Combustion is used throughout the mineral processing industry to produce steam in boilers, to dry concentrates in rotary dryers, and to apply heat treatments in pyrometallurgical furnaces. Tight combustion control is very important in latter type of furnace since the combustion conditions directly affect final ore quality. However, achieving tight combustion control is not straightforward since most of the flames encountered in industry are turbulent non-premixed flames, they are affected by several unmeasured disturbances and are often produced by burning several types of fuel simultaneously, some of them coming from other parts of the plant. A novel method is proposed in this paper to improve process and product quality control as well as to optimize the combustion conditions based on digital flame color images. Multivariate Image Analysis and Regression is to used extract the flame color characteristics from images to predict the solids discharge temperature of an industrial rotary kiln. It is shown that this method yield extremely good 10 minutes ahead forecast of the temperature and should lead to a substantial reduction in product quality variability as well as in fuel consumption.INTRODUCTIONFuel-fired furnaces are often used in the mineral processing industry for various purposes, such as for the production of steam (utility boiler), in conjunction with rotary dryers to dry mineral concentrates or in pyrometallurgical processes for induration, roasting, and so forth. These furnaces are necessary in the supply chain from the mine to the metals, but their operating costs are constantly rising due to the fluctuations in fuel prices. Moreover, these processes are now targeted by the Kyoto Protocol since they are energy intensive and they produce significant amounts of CO2 and other pollutants such CO, NOx and SO2. To achieve both a reduction in operating costs (i.e. fuel consumption) and in pollutant emissions while maintaining or improving product quality, one needs to have a very good control of the combustion process."

Jan 1, 2005

By B. K. Gorain

"Mining of low grade deposits along with the necessity to design and operate process plants requiring high throughputs presents unique metallurgical environmental and sustainability challenges that need to be addressed to reduce project risks, improve project economics and to sustain the profitability of operations over the life-of-mine.Some of the key challenges include poor recovery of valuables and concentrate quality issues due to complex mineralogy and high ore variability, water scarcity and quality issues, high energy costs, complex environmental issues including tailings management, high capital and operating costs, worldwide constraints on resource availability, complicated regulations in emerging economies, changing demographics of mining operations with ever-changing cultural or community issues and the urgent need for a better assessment of project viability to reflect the dynamics of present mining scenario. Developing breakthrough solutions to these problems is the key to success of any new project and maintaining profitability of a mining operation. An integrated multi-disciplinary approach to problem solving is crucial along with the need for a more lateral thinking, strategic partnerships and collaboration involving the right players. This paper presents some of the key findings based on experiences from a large number of challenging projects and operations focused on solving complex metallurgical problems.IntroductionThere is a plethora of challenges in developing new ore bodies. The metallurgical complexity of these deposits has increased significantly due to the need for mining lower grade ores along with the presence of deleterious elements that have environmental and processing implications. In addition, many of the mining projects are capital intensive due to high throughput requirements to be economical along with the need for building infrastructure due to remote locations, while operating costs steadily increase due to high reagent, energy and labour costs, increased state royalties and community obligations, to name a few of the key factors. There is also scarcity of water in many regions requiring the use of sea water or brackish water, which has both environmental and metallurgical implications. The shortage of qualified technical manpower adds significantly to the woes of many mining companies. Considering these multiplicity of challenges, it has become imperative for many mining companies to be innovative in addressing these issues."

Jan 1, 2015

By Donald Strickland, Peter Kresin, Dave Hall

"Have your parents or grandparents ever tried to share with you their wisdom and you ignored it because it did not relate to you‘? I have been ignorant and inevitably grew older and wished I had listened. The result: learning the hard way. As British Astronomer Fred Hoyle once said. “It is the true nature of mankind to learn from mistakes not from example.“ Hopefully we will continue to learn from the examples shared by our fellow mineral processors in these conference proceedings. It is the intent of this paper to share wisdom from the Musselwhite Mine that you may apply to your own operation.This paper is divided into three sections:1. Feasibility3. Operation3 . DesignKey points of the Feasibility and Design stages are summarized. followed by an analysis of actual operating statistics. An attempt is made to relate these statistics back to the feasibility and design with emphasis on areas of success and those with potential for improvement."

Jan 1, 1999

"Gravity concentration remains the main separation method for fine iron ore and is used extensively for treating various minerals. Gravity concentration methods separate minerals of different specific gravity by their relative movement in response to gravity and one or more other forces, the latter often being the resistance to motion offered by a viscous fluid, such as water or air (Wills, 2006).Spirals concentrators are one of the gravity concentration equipment used for beneficiation of minerals. Spirals are typically used for processing of fine minerals (-1mm) size fraction. The main operating variables for a spiral concentrator are the feed rate, the solids concentration, the wash water addition and the position of the cutters or splitters used to separate the tailings, middling and concentrate streams (Sadeghi, Bazin & Renaud, 2014).The aim of this study is to investigate the effect of feed rate, solids concentration and wash water on grade and recovery on iron ore material. The Multotec SC20HC/7 WW spiral was used for the experimental test work. The spiral was tested at varying solids concentration and feed rate. The wash water rate was also varied to establish the best washing rate. The splitter positions were kept constant. Optimization of these variables is expected to provide optimum conditions for a good compromise between grade and recovery.INTRODUCTIONSpiral concentrators are simple low energy consuming devices that separate minerals mainly on the basis of density. Spirals are widely used in mineral processing as a method for preconcentration and have proven to be metallurgically efficient and cost effective.Spirals have a wide application, they are used in iron ore processing, coal, gold, chromites, mineral sands, glass sands, and in soil cleaning.Separation on a spiral is achieved through a combination of forces that act on particles as they move down the trough of the spiral. The main forces known to act on the particle on a spiral are the gravitational forces, centrifugal force, hydrodynamic drag, and lift and friction forces (Kapur & Meloy, 1998). Apart from the forces acting on a spiral, the properties of the slurry flowing on a spiral including, solids concentration, feed rate and wash water also plays an important role in the separation on the spiral.The relationship between separation efficiency and feed rate was shown to be linear, with a decrease in efficiency at higher flow rates. Previous work on flow profile by Holland - Batt (1990) indicated that any increase in the feed rate to a spiral results in a greater part of the additional flow volume reporting to the outside of the trough. The flow on the outside of the trough becomes energized and consequence to that the heavy particles find it hard to settle and escape this region to the inner region. This effect has a high impact on recovery of heavy minerals, since any increase in volumetric flow on the spiral is not made available for recovery in the inner region of the spiral."

Jan 1, 2015

By R. Tyreman, G. Ritson

"The Red Lake Mine is situated in Balmer Township, Red Lake area in northwestern Ontario. It is an underground mine that has been in production since 1948. The property was originally known as the Dickensen Mine and was shut down in 1996.A feasibility study was carried out in 1998 and it was determined that a new mill should be constructed with a throughput rate of 600 stpd. The life-of-mine average gold grade was projected to be 1.35 oz/t with gold predominantly associated with arsenopyrite and pyrite. Metallurgical testwork indicated that the optimal flowsheet for gold recovery would include an autoclave for oxidation with a carbon circuit for adsorption. To limit capital cost and establish cashflow, the mill was constructed without an autoclave. The recovery by gravity and cyanidation was projected to be 83%. A flotation plant was constructed at the tail end of the circuit to recover the additional gold associated with sulphides from the leach circuit tailings. This material is being stockpiled onsite for future oxidation treatment.Detailed engineering was started in early 1999 and the first gold was poured in August 2000. One feature of the project was the use of Contact Lake equipment from Cameco’s Contact Lake project. The entire mill was purchased and equipment re-used where possible. The capital cost for the process facilities was C$3 1.5 million."

Jan 1, 2001

By Simon D. Handelsman

?Artisanalmining ?Application of human energy (e.g. pick & shovel) directly to produce minerals ?majority no technical skills and lack adequate working tools ?Small-scale mining ?Application of modern technology for limited scale mineral production Significance of ArtisanalMining ?15 million people in artisanaland small scale gold mining ?55 developing countries ?Use of mercury damages health of 100 million people

May 1, 2006

By Richard Mcivor, Largo Albert

"Inco Limited has operated aluminum mine shaft conveyances since 1968. Aluminum conveyances are used where the hoisting in system requires lightweight conveyances to maintain the hoist rope safety factors and mine hoist rope pulls as dictated by government regulations. Inco Ltd. currently has 20 skips (including spares) operating in the Ontario Division mines. The main problems encountered are with galvanic corrosion between dissimilar metals and metal fatigue. This paper will highlight some of the problems encountered and illustrate methods utilized to overcome the problems and improve the conveyances performance.IntroductionAluminum mine shaft conveyances have been in use at Inco Limited's various Sudbury district mines since 1968. All of the conveyances currently in use are skips used for hoisting mine ore and rock. Inco had an aluminum quick change Kimberley-type skip and cage in operation at its Totten Mine in the early 1970s, but this mine is no longer in operation and no further comment will be made.The primary reason why aluminum conveyances are chosen over conventional steel conveyances is because of their light weight. Typically an aluminum conveyance will weigh about 60% to 70% of a steel conveyance of similar design. The lighter weight conveyances will allow higher payloads to be used and still maintain the statutory hoist rope factors of safety. It must be remembered that increasing the payload will increase the power required to raise the load and the hoist will have to have the necessary horsepower for the increased payload or the system will be overloaded.The front dump (Rola-chute) skips are of the bail-less design, i.e. the box structure also supports the load and has the shaft guide shoes attached directly to the side of the box structure. The Copper Cliff North Mine and South Mine skips have a joint in the centre of the conveyance and are installed in the shaft in two sections and connected with pins. This feature allows very long (42 ft) skips to be used in areas where a one-piece bail-type conveyance could not be installed. It is not practical to make sectionalized bail-type conveyances"

Jan 1, 1988

By A. Sinha, N. K. Babar, H. R. Kalihari, A. K. Chakraborty, M. R. Saharan, C. P. N. Pathak

A case study is presented on the optimization of cable bolting patterns in cut-and-fill stopes at the Chikla Mine, MOIL, India. Rock mass characterization, using Bieniawski’s RMR and Barton’s Q, indicated that the stopes lie in the “no supports required” to “spot bolting required” support categories. In contrast, the current practice of cable bolting in a 2.0 m by 2.0 m grid pattern for stope widths less than 12 m displays different results. Numerical modelling results are in line with the rock mass characterization study. It can be affirmed, as well, that no cable is carrying rock loads greater than 5 t. This fact is derived from observational behaviour of the crown pillar of an experimental stope with open stoping operations and hanging cables in the cut-and-fill stopes of the mine. An increase in the cable bolting grid spacing is, hence, recommended for implementation by mine management, based on the study described in subsequent sections. It is also suggested that the mine adopt the open stoping method, provided results of a rock mechanics instrumentation program in an experimental stope with a cable bolting grid of 2.5 m square are favourable.

Jan 1, 2007

By G. Barbery

"Particle composition distribution is an essential feature of materials processed by physical separation methods. The amenability to segregate a feed material in a concentrate and a tailings stream depends to a large extent on what is called usually the ""liberation"" of the various mineral phases that are present in an ore. In fact the energy consumed in crushing and grinding has the major justification of producing particles that are as close as possible to monominerallic. Monophasic particles are able to reveal physical differences in mineral properties that make their separation possible. For many years, various authors have insisted on the concept of liberation, without noting that, in practice, it can be a pure concept which does not lead to measurements or predictions. The present paper insists on the concept of particle composition distribution, in which the complete distribution is the information to be obtained, and not the ""liberation·· of various phases, just like for particle size distribution, the complete distribution is an objective commonly desired, and not one or two values representing the coarse or fine fraction.2. NOTATIONS-EQUATIONSFor the purpose of the paper, a particle will be characterized by its volume Vp, and its volumetric composition with respect to a mineral of interest, which will be given the notation ""O"". All the other minerals present will be called ""1"". This notation does not imply that the particles are biphasic, but that we are interested in the composition of particles with respect to one phase only. The volumetric composition will be given the sybol m:"

Jan 1, 1986

By J. Chlopas, D. J. Barratt, M. V. Sharp

"This paper describes the modifications made to the Fox Mine copper concentrate bin in order to obtain a continuous flow condition. The design of these modifications is based on test results obtained on Fox Mine concentrate using the flow factor testing machine in the research facilities of Cominco at Trail, B.C.The original design consisted of a cylindrical steel bin on a concrete slab with two slot-discharge openings. Based on predictions of the maximum mass flow hopper angle for conical and wedge shaped hoppers for the concentrate on various potential bin lining materials, Ultra-High Molecular Weight (UHMW) Polymer was selected as a liner.Using the recommended angles for conical and wedge shaped hoppers, the profile of the bin base was changed to suit the existing slot openings.The initial method of fastening the liner resulted in failure of the connections. Subsequent modification to the zinc concentrate bin fastener system proved satisfactory and it has now been in operation for over one year without any separation of the lining material.Utilization of flow testing procedures on concentrate samples has demonstrated that proper design of storage bins or hoppers to achieve continuous flow can be incorporated into the design of new plants."

Jan 1, 1978

By J. E. Sepulveda, R. Morrow

"The Linear Wear Theory provides a reliable framework for the assessment of grinding media performance at full scale. This theory can be applied for analyzing grinding media consumption rates in any given grinding operation as well as the evaluation of alternative grinding media products, based on actual operational data, correcting for conditions like ore hardness, feed and product sizes, mill power and circuit throughput; all of them unrelated to the grinding media intrinsic quality attributes. A series of Moly-Cop Tools 3.0 applications have been developed to facilitate the calculations involved. Moly-Cop Tools 3.0 is available, free of charge, to all interested parties through the corresponding author.INTRODUCTION Mineral grinding circuit operators recognize the significance of grinding media (balls) consumption on the cost structure of any full scale grinding facility. The effective cost associated with this essential consumable depends on two factors: delivered price and durability (quality) of the grinding media. When evaluating alternative grinding media varieties, there is a well accepted evaluation criterion by which a given media type is considered to be “cost-effective” when its unit application cost – normally expressed in $/ton of ore ground – is shown to be lower than that of a nominal reference condition: Grinding Media Cost = Ball Price x Ball Consumption (1) ($ /ton ground) ($/ton balls) (ton balls/ton ground) Under this criterion, an alternative, higher-price grinding media product could be “cost-effective” if its associated consumption rate is sufficiently lower than the reference media, enough to yield a lower grinding cost, as dictated by Equation 1. For the proper application of the above criterion, evaluators must rely on representative indicators of grinding media quality, ideally independent of most mill operating conditions. In each particular case, ball price is always a known component; however, it is not so evident how media performance (quality) differences amongst alternative product types could be assessed with a reasonable degree of accuracy and precision."

Jan 1, 2014

By Richard P. Reiff

"The Facility for Accelerated Service Testing (FAST) program has been involved in numerous rail wear tests since its inception in 1976. A number of specialized tools have been developed to aid in assessing specific performance parameters including gauge face wear, head height loss, metal flow, head area loss, hardness, and welded rail end batter. The layout of a test site, including position in curve, number of measurements per rail, and train operation must be properly controlled/monitored to provide valid wear comparisons.This paper will provide an overview of the above-mentioned tools and techniques. In addition, a summary of recent test results from FAST, including information on head hardened rail investigations, will be provided. A set of guidelines for establishing a revenue service field test site will also be provided to aid users in performing evaluations of their own.IntroductionBackground of Rail Wear Testing at FASTThe Facility for Accelerated Service Testing (FAST) located at the Transportation Test Center, (TIC), Pueblo, Colorado has been involved with testing of rail since program initiation in 1976. A huge data base of rail wear information has been gathered from FAST operations under a variety of rail metallurgies, lubrication conditions, and measurement techniques. Attempts at obtaining meaningful rail wear information from early (1976-1978) FAST rail wear data was hampered by two main factors: (I) measurement techniques were insufficiently accurate for the amounts of wear being experienced, and (2) the lubrication was not sufficiently controlled to obtain uniform conditions for a sufficient measurement time period.Subsequent test periods were operated with improved measurement techniques and controls that ensured statistically valid data. The policies and conditions that permit accurate rail wear assessment will be reviewed and outlined in this paper, along with some specific TIC and field examples that will allow the user to improve the accuracy of a field rail test on their own operating property."

Jan 1, 1988

By D. D. Tannant

An experimental and numerical study was conducted on the geomechanical behaviour of oil sands during penetration tests in which a steel wedge with an apex angle of either 20 degrees or 30 degrees was forced into compacted oil sands. The boundary conditions simulated in the laboratory tests are similar to shovel penetration into oil sands. The objective of the laboratory tests was to measure the force required to push a steel wedge into compacted oil sands. A wedge penetration test differs from conventional triaxial tests in that much more shear is generated. The laboratory data was needed to improve calibration of micro-mechanical input parameters for a two-dimensional discrete element model of oil sands constructed with Particle Flow Code (PFC). Initial model calibration was performed with triaxial test data and then a PFC model of the wedge penetration test was constructed. The measured force-displacement behaviour of the steel wedge was compared with PFC modelling results. It was found that different combinations of PFC particle and bond parameters could equally well replicate the laboratory triaxial compression data for bitumen-rich oil sands. When the wedge model was run, it was found that the resulting force required to penetrate the wedge into the oil sands was about four to six times higher than that measured. This clearly indicates that further research is required to improve the predictive capability of PFC models of oil sands.

Jan 1, 2002

By W. J. González

"With the increasing demand for minerals, technologies to maximize mineral recovery are paramount to a mine’s economic success. Many mining process waters have the potential to form calcium-based inorganic scales, which inhibit effective mineral recovery. Often, the solution to inhibit these deposits is the implementation of a chemical antiscalant program. This paper examines the application of a fouling analyzer to continuously monitor the formation of inorganic scale in mining process streams. The fouling data can be used to compare antiscalant programs and to optimize antiscalant feedrates. Case studies validate the ability of this technology to help optimize mineral recovery processes.INTRODUCTION The mining industry uses significant quantities of water. From quarrying, to crushing, to flotation, leaching, and refining, water is often the integral motive force to move slurries, separate or agglomerate fines, and extract and purify minerals. As well, water is used in a number of ancillary applications at mines, including dust suppression, gas scrubbing, and utility processes such as boiler, cooling, and waste water operations. For many processes, the quality of water being used is inconsequential. However, for certain processes, such as flotation, leaching, and desorption / stripping, water quality plays a key role in the ability of the operation to economically recover the target minerals. Dissolved solids such as calcium and magnesium salts can concentrate in process waters, exceed their solubility limits, and precipitate as scale on metal surfaces such as feed and transfer pumps, piping, and equipment. Some of the more common scales that form in mining operations include calcium carbonate (CaCO3, or calcite) and calcium sulfate (CaSO4, or gypsum), and to a lesser extent, calcium and magnesium silicate compounds. Any scale that deposits in a process stream will negatively impact mineral recovery, and increase the operational costs of the mine site. Whether it is acid washing a scaled heat exchanger in a carbon strip at a gold operation, replacing plugged emitter tubes in a leaching operation, or hydroblasting process lines in a scrubber unit, there are costs associated with labor, cleaning chemicals, repairs, and replacement parts. These costs pale in comparison to the potential costs of downtime and lost production, should the scale deposits occur in a process that is critical to the recovery of the target mineral."

Jan 1, 2014

By W. Bullen

A hypothetical economic model has been developed for diamond projects in the Canadian Arctic using data from recent exploration and mining projects. The model reflects economic conditions applicable to the diamond mining industry in the Canadian Arctic at the present time. The economic model captures pre-production expenditures, production data, and post-production costs. Before- and after-tax cash flows are derived from the data along with the relevant economic criteria. From the corporate perspective, the model provides guidance concerning the minimum size and/or in situ value per tonne requirements of targets being sought in order to ensure economic success and predict exploration and development expenditures. From the government perspective, the model provides an indication of income and mining tax revenues that can be expected from a particular diamond project. The model shows, on average, diamond projects in the Canadian Arctic are expensive to explore for and develop, but are economically robust under the present conditions. They generate great economic return for mining companies and significant amounts of tax revenue for governments. The fact that diamonds can be transported directly from the minesite by air makes them particularly attractive targets for mining companies that operate in the Canadian Arctic.

Jan 1, 2006

By C. R. Edwards

"The Cigar Lake project will develop the world’s second largest high grade uranium deposit. The Cigar Lake Phase 1 orebody contains approximately 226 million pounds U3O8 at an average grade of 20.7% U3O8. The mine, to be operated by Cameco Corporation, will use a unique water jet boring mining method to cut previously frozen ore. A distinctive ore handling design is required to handle the high grade ore slurry exiting the mining machines. The ore will be crushed and ground underground, with the ore slurry then pumped to surface. Loaded into purpose-designed containers on tractor-trailer units, the ore slurry will be trucked to Cogema Resources Incorporated’s McClean Lake mill. McClean Lake will leach all of the ore. Forty-three percent of the resulting uranium solution will remain at McClean Lake for processing into yellowcake. The other 57% of the uranium solution will be shipped to Cameco’s Rabbit Lake mill for processing into yellowcake there. Detailed design for the Cigar Lake project is now underway. Barring regulatory or market delays, production could start up as soon as early 2005.INTRODUCTIONThe Athabasca Basin in northern Saskatchewan hosts a number of large uranium mining and milling operations, including Cluff Lake, Key Lake, McArthur River, McClean Lake and Rabbit Lake. (Edwards 1988, Edwards 1992, Fielder 1998, Edwards and Oliver 2000, Edwards 2001) The latest project in the Athabasca Basin is the Cigar Lake project."

Jan 1, 2002

By J. E. Sepulveda, R. Morrow

"In full scale mineral grinding operations, the steel balls normally utilized as auxiliary grinding media get to be consumed at different specific rates, as determined by 3 basic mechanisms: abrasion/corrosion (wear), impact ball breakage and impact surface spalling, the latter relating to the removal of rather small pieces of steel coming off the exposed surface of the balls due to repetitive impact with other balls in the charge or the surrounding mill liners. In conventional ball milling applications, the clearly predominant mechanism is gradual wear by abrasion/corrosion. In the case of SAG mills, where the make-up balls may be as large as 6”f diameter, breakage and spalling mechanisms are significant contributors to total ball consumption, although not to the extent of overriding wear mechanisms.Ball wear has been well characterized by the Linear Wear Theory, as presented at the last CMP 2014. Impact breakage has been customarily monitored, at the ball manufacturing site, via Drop Ball Tests (DBT) consisting of repeatedly dropping balls from a standard height and accounting for the number of broken balls and the weight loss (spalling) of the remaining unbroken balls. When properly conducted, DBT’s should provide meaningful indications of the breakage and spalling resistance of large diameter balls. The current publication is focused on the interpretation and projection of DBT results to full industrial scale, taking into account all 3 mechanisms of grinding media consumption in SAG mills.INTRODUCTIONA thorough, quantitative understanding of the independent contribution of all active grinding media consumption mechanisms is of the highest practical relevance, particularly in semiautogenous (SAG) milling operations where ball breakage and spalling can not be ignored or neglected, as it has been normally acceptable for conventional ball milling processes. The high severity impact conditions currently imposed in typical SAG mill environments create serious challenges to the manufacturers and suppliers of large diameter (5”–6”) SAG balls, whose products must be capable of surviving such harsh operational conditions with minimum breakage or spalling."

Jan 1, 2015