autogenous grinding & semi autogenous grinding circuits

autogenous grinding & semi autogenous grinding circuits

Size reduction is the most expensive operation in most mills. Crushing and grinding usually require the greatest portion of capital costs and often make up 60-70 percent of total mill operating costs as shown in Figure 1. Selection of the proper crushing and grinding method must, therefore, be done with great care to be sure that the best circuit is chosen.

Autogenous grinding is favored when the ore is quite competent and a fine grind is required. Semi-autogenous grinding is applied when fine crushing could cause severe problems or when ore is variable in hardness or competency.

Figure 2 shows a typical conventional crushing-grinding circuit with three stages of crushing followed by ball mills or rod mill-ball mill combination. This flowsheet is typical of many mills that have been built throughout the world. Figure 3 shows a typical semi-autogenous (SAG) circuit with feed coming directly from a primary crusher, and the semi-autogenous mill product going to the separation process. Many similar semiautogenous circuits are built today because they are simple and flexible, lend themselves readily to high tonnages and usually are lower in capital cost and lower in operating cost. With some ores, it is possible to send mine-run ore directly to the semiautogenous mill so that the primary crusher can be eliminated.

An autogenous or semiautogenous circuit, as the name implies, uses the ore itself to assist in the grinding process. In this type of circuit, the ore must be competent so large chunks of ore can be used to grind smaller chunks of ore.

If ore alone is used then the circuit is autogenous but if balls are added to supplement the charge, then the circuit is termed semiautogenous . Ore competency is not always a binding criterion to break up large pieces and wash away cementing material. Autogenous and semi-autogenous mills have been very successful on relatively soft uranium ores where the values are frequently found in the material that cements the sandstone grains together.

When an ore is hard and competent, there is always the possibility that it would make good pebbles which could be used for fine grinding media. Different methods that have been tried using combinations of autogenous, semi-autogenous, pebble and/or ball mills. The flowsheets shown are typical of the properties listed but a specific property may be using a slight modification of the method depicted.

In autogenous and semi-autogenous grinding, where all or most of the grinding media is also the material to be ground, those fixed conditions do not exist, so the media itself becomes a variable that must be evaluated.

The first question that we at Allis-Chalmers ask about the feasible application of primary autogenous or semi-autogenous grinding mills concerns the quantity and the competency to be media of media-sized ore in the feed. These are the first factors to be appraised, since if there is not enough media-sized ore and/or if the media-sized ore will not perform as media in an autogenous or semi-autogenous mill, autogonous grinding probably would not be feasible.

To study the competency of ore as media, Allis-Chalmers developed a test procedure and a device in which to run the test, which were described in 1963. The test charge consists of ten pieces of dry ore in each size fraction, weighed, beginning with 6- x 6- ending with 4- x 4. This total of fifty pieces of ore are put into a 6 x 1 closed drum tester as shown in Figure 1. The tester is then run for 500 revolutions after which it is emptied. The number of survivors in each size fraction down to 2- x 2 are counted and weighed. A screen analysis down to 3 mesh is also made. Bond Impact, grindability tests, and abrasion index tests are also run on the sample. Rod mill grindability tests for Work Index are run at 10 or 14 mesh, and ball mill Work Index tests are run at the desired grind if finer than 28 mesh. All the data obtained is evaluated and one or more of the following recommendations made:

To date, Allis-Chalmers has not made a recommendation to use primary autogenous or semi-autogenous mills based upon media competency test results alone. The most frequent recommendation, based on tests made to date, has been to proceed to pilot plant testing.

Professor Marcus Digre in his book on autogenous grinding discusses grinding action in autogenous mills as different from the action in rod and ball mills. He confirms the observation that in autogenous grinding the breakage is principally along grain boundaries and around hard size fractions with little trans-granular breakage. In autogenous grinding, there appears to be more abrasion or attrition grinding and less impact grinding than in rod and ball milling.

Many of the early autogenous grinding installations in the United States and Canada were used to grind iron ores. Generally the results showed the final product contained less fines (the screen analysis as plotted on log-log paper had a steeper slope) than the products from circuits using more conventional media. This led to the statement that autogenous grinding produces less extreme fines than conventional grinding.

More and more autogenous grinding installations have been made for non-ferrous ores, particularly low grade copper ores. These ores usually do not have well-defined grain structure as found in many iron ores, and this statement has not proven correct. Some of these non-ferrous ores, when ground in autogenous mills, have produced an excess of fines and a greater surface area than with conventional grinding. An explanation for this could be that the production of fines is a function of the grain structure of the ore being ground.

The fact that the product from autogenous grinding is different from that produced by conventional grinding is the second major factor requiring testing, when studying the feasibility of using autogenous grinding. (There are few, if any, ores that will not grind in an autogenous mill.) The key questions are:

In conventional grinding, the size of product can be changed by changing media size, feed size, feed rate, classifier cut size, etc. The grinding circuit responds to these changes. In autogenous grinding, the ore says how it wants to be ground and the product size that it will produce, and does not change in response to the same factors. With some ores there are two possible products from an autogenous grinding circuit a coarse product or a fine product. With other ores, there may only be one product. In autogenous grinding, one way to change the product size is to switch to semi-autogenous grinding which will give a coarser product than autogenous grinding and usually at less power consumption per ton. The Cleveland-Cliffs Iron Company referred to this in their paper on autogenous grinding. The Union Corporation in a paper on the reduction works at the Kinross Mine gives some data on grinding mill performance with and without grinding balls being used as supplemental media.

Pilot plant testing is required to determine how the ore wants to grind and the effect on the product size and power requirements by using autogenous and/or semi-autogenous grinding. To date it is only through continuous flow pilot plant testing that these factors can be established. In studying the breakage characteristics of the ore, the possibility of stage grinding using either secondary autogenous mills, such as used by The Cleveland-Cliffs Iron Company at the Empire and Sherman Mines and Pickands Mather at the Griffith Mine, or secondary ball mills such as used by Pickands Mathers Savage River Mine, Cyprus Pima Mines, Island Copper, Bolidens Aitik Mine, and Lornex, can also be investigated in a pilot plant test. Another possibility to be tested is the use of a cone crusher in the primary mill closed circuit arrangement. Crushing the coarse circulating load, which can be a critical size, as described by Pickands Mather and Newmont Mining, can also be tested in the pilot plant.

In conjunction with pilot plant testing, there should be either pilot plant facilities or at least bench scale facilities to test the suitability of the product for the next processing step. Either test facilities or data should be available to compare this with the product from a conventional grinding circuit.

McDermott, Lipovetz and Peterson of Pickands Mather in their paper The Dollars and Sense of Autogenous Grinding describe the testing they did to develop an autogenous grinding circuit for a taconite ore processing plant. Bassarear and Sorstokke of Cyprus Pima reviewed the test work they performed to develop their semi-autogenous ball mill grinding circuit. Many other papers on autogenous and semi-autogenous grinding also discuss the pilot plant and bench scale testing done to prove grinding circuits.

Recent developments in the design of concentration plants have reflected the increased recognition that has been given to the economic and metallurgical advantages of autogenous grinding. This has manifested itself in the increasing adoption of primary autogenous grinding in iron ore beneficiation plants in North America.

a. Primary autogenous mills which process directly the total discharge of primary crushers (usually set at 6 to 10 open side setting). Under some circumstances and for certain types of ore, small ball charges (usually less than 5% of the mill volume, but sometimes up to 10%) may be used with advantage to complement the natural rock grinding media forming inside the mills. b. Intermediate autogenous mills (or intermediate pebble mills) which process a fine crushed product (minus 5/8 to minus 1) obtained from an intermediate crushing plant. The grinding media in these mills are rock pebbles of suitable size (3 to 6) screened out of the intermediate crushing circuit. c. Secondary autogenous mills (or secondary pebble mills) which process a coarse ground product. (4 to 14 mesh; or, finer) obtained from rod mills or from primary or intermediate autogenous mills. Grinding media in these mills are rock pebbles of suitable size (1- to 3-) bled off from primary autogenous mills or screened out of intermediate crushing circuits.

It is interesting to note that mill configurations vary between wide limits. In South Africa wet grate discharge mills having a nominal ratio of length to diameter slightly larger than 1 (16/12 = 1. 33 and 14/12 = 1.17.

In North America, with wet primary mills, the practice has been to use low or high level grate discharge or peripheral discharge and a nominal ratio of length to diameter relatively close to 1/3. Ores ground have ranged in power requirements from 2-3 Hph/lt for an 8 14 mesh grind up to 20 30 Hph/lt for a 48 65 mesh grind.

Where dry grinding has been adopted, Aerofall Mills have been exclusively used. They are characterized by a length that varies little, ranging from nearly 5 6 for 17 mills and not exceeding 6 for the largest ones. This corresponds to nominal ratios of length to diameter that decrease from around 1/3 for the smaller mills to less than for the larger mills. The grinding characteristics of the ores processed have varied from 2-3 Hph/lt for a 10 20 mesh grind up to 15 20 Hph/lt for a 65 mesh grind.

From the standpoint of operating costs, it is to be expected that liner wear, and, where a small ball charge is used, ball wear would be higher in wet grinding than in dry grinding. On the other hand, the frequent necessity to dry the mill feed and to provide adequate dust collection would weigh against dry grinding. Moreover, it is to be expected that the cost of dry classification would be higher than for wet classification.

In most cases as matters stand today, only adequate testing and comprehensive cost and metallurgical comparisons can establish a sound and reliable basis for the determination of the most efficient and economic method of primary grinding.

As a matter of fact, there is evidence that for some types of ores, dry and wet autogenous grinding are characterized by differences that may, in certain cases, represent an essential consideration from a metallurgical standpoint. The major points of difference that seem to have been established in this respect are:

a. For fine grained ores, a finer product can be obtained in a single stage of wet primary grinding than in a dry grinding circuit. b. Wet primary grinding has a tendency to produce more slimes than dry grinding. c. Dry primary grinding gives the, possibility of obtaining higher grade concentrates at a coarser size than wet grinding. d. With dry grinding, it is easier and less costly to provide for storage of the primary ground product prior to subsequent processing, in cases where it is important to do so. e. Wet autogenous mills can have their grates fitted with slots of suitable size making it possible to set, as desired, the top size of the product discharged from the mill.

One major characteristic of primary autogenous concentrators is the relative simplicity of their overall plant flowsheet. Where in conventional rod and ball mill plants there are usually 3 to 4 stages of crushing followed by 1 to 3 stages of grinding, depending on ore fineness and hardness, primary autogenous plants require only one stage of crushing followed by 1 to 2 stages of grinding. It is even reasonable to expect that with the development of suitable designs for primary grinding mills of increasing diameters, these mills will be able to directly process run of mine ore, suitably fragmented to keep the size of the largest pieces within reasonable limits.

There is no basic difference in the design and layout of a primary crushing plant, whether it delivers ore to an autogenous or a conventional concentrator, except in the fact that in the former case it need not include more than a single stage of crushing.

With the size of ore to be handled and the capacities involved, which are usually of the order of 2000 ltph or more, primary gyratory crushers are mostly used, with mantle diameters of 7 feet or more and feed openings of 54 or more. In these sizes, no grizzlies are required ahead of the gyratory crusher, and very compact and economic layouts can be adopted for the crushing plant, incorporating a dumping pocket above the crusher, a discharge box underneath it feeding an apron feeder which delivers the crushed ore to the primary conveyor belt. For the capacities considered, 72 or 84 apron feeders and 48 to 60 belt conveyors are usually used.

Primary grinding mills almost always operate in closed circuit. Even when they are used for coarse grinding, the fineness of the primary ground product is seldom coarser than 8-10 mesh. The discharge of wet primary mills, as determined by the openings in their grates may contain fractions as coarse as 3/8 to , if no pebble slots are provided, and as coarse as 2- to 3- if pebbles are extracted. Consequently, trommels and vibrating screens are used on the discharge of wet primary mills to separate oversize fractions which are almost always recirculated back to the mill feed end. The screen undersize constitutes the primary circuit final product when the grind required is not finer than 10 to 14 mesh.

In coarse grinding primary circuits (10 14 mesh) the product of the first two collectors is screened. The screen oversize is returned to the mill and its under size, with the underflows of the third stage cyclone and dust collector constitute the primary circuit product. In fine grinding flowsheets, no screening is necessary. Depending on the fineness of grind required, both the vertical separator and intermediate collector underflows or the former only are returned to the mill.

lokomo cone crusher parameters

lokomo cone crusher parameters

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crusher plant | henan deya machinery co., ltd

crusher plant | henan deya machinery co., ltd

A Stone Crushing Plant is one-stop crushing installation, typical materials like limestone, granite, river gravel, basalt, etc., the plant produces different sizes of gravels and sand which can be used for constructions.

Stone Crushing plants may be either fixed or mobile. A stone crushing plant has different stations, primary, secondary, tertiary, etc., where different crushing, selection and transport cycles are done in order to obtain different stone sizes, for fixed plant different stages combines together to form a complete stone crushing plant.

Raw materials are evenly and gradually conveyed into jaw stone crushing equipment for primary crushing via the hopper of vibrating feeder. The crushed stone materials are conveyed to crushing plant by belt conveyor for secondary crushing before they are sent to vibrating screen to be separated. After separating, qualified materials will be taken away as final products, while unqualified materials will be carried back to the stone crushing equipment for re-crushing. Customers can classify final products according to different size ranges, also according to different requirements, final products sizes can be adjusted from the crusher machines.

ball mill | henan deya machinery co., ltd

ball mill | henan deya machinery co., ltd

The quality of the installation is the key to ensure the normal operation of the ball mill. The installation method and sequence for all types of ball mills are roughly the same. To ensure smooth operation of the ball mill and to reduce the risk to the building, the ball mill must be installed on a reinforced concrete foundation of 2.5 to 3 times of its weight. The foundation should be laid on solid soil and should be at least 40-50 cm away from the workshops foundation. Read more

The final stages of comminution are performed in tumbling mills using steel balls as the grinding medium and so designated ball mills. Since balls have a greater surface area per unit weight than rods, they are better suited for fine finishing. The term ball mill is restricted to those having a length to diameter ratio of 1.5 to 1 and less. Ball mills in which the length to diameter ratio is between 3 and 5 are designated tube mills. These are sometimes divided into several longitudinal compartments, each having a different charge composition; the charges can be steel balls or rods, or pebbles, and they are often used dry to grind cement clinker, gypsum, and phosphate. Tube mills having only one compartment and a charge of hard, screened ore particles as the grinding medium are known as pebble mills. They are widely used in the South African gold mines. Since the weight of pebbles per unit volume is 35-55% of that of steel balls, and as the power input is directly proportional to the volume weight of the grinding medium, the power input and capacity of pebble mills are correspondingly lower. Thus in a given grinding circuit, for a certain feed rate, a pebble mill would be much larger than a ball mill, with correspondingly higher operating cost. However, it is claimed that the increment in capital cost can be justified economically by a reduction in operating cost attributed to the lower cost of the grinding medium. This may, however, be partially offset by higher energy cost per tonne of finished product. Read more

Ball mill is key equipment for grinding in mineral processing plant, it is widely used in cement, silicate, new-type building material, refractory material, fertilizer, ore dressing of ferrous metal and non-ferrous metal, glass ceramics etc.There are dry grinding and wet grinding, ball mill can be divided into tabular type and flowing type according to different forms of discharging materials.

The ball mill is a horizontal rotating device transmitted by the outer gear. The materials are transferred to the grinding chamber through the quill shaft. There are ladder liners and ripple liners and different specifications of steel balls in the chamber. The centrifugal force caused by rotation of barrel brings the steel balls to a certain height and impact and grind the materials. The ground materials are discharged through the discharging board thus the grinding process is finished.

Pebble mills are similar to ball mills except that the grinding media is closely sized rocks or pebbles.Pebble milling is a form of autogenous milling as no steel media is used in the process however, the type of rocks used are selected more carefully than in convention AG milling.

gyratory crusher liners | flsmidth

gyratory crusher liners | flsmidth

Naturally, you need to protect your equipment to keep it running smoothly and continuously. In order to accomplish that, you demand liners with superior wear life and proven production. Thats precisely what you get with our Gyratory Crusher Liners. You may need something more than simply a Gyratory Crusher Liner. At FLSmidth, we are capable of helping you find the very best solution regardless of your needs. We do so by reviewing your entire process and machine setup.

Crusher operating parameters, liner selection, material selection, plant process review, and customer goals all go into providing our customers with the ideal solutions. If more than one option is available, we offer cost-benefit options to make the decision-making process easier for you.

FLSmidth Gyratory Crusher Liners solutions help enhance the efficiency of your operation and lower your operating expenses. We offer many grades of Gyratory Crusher Liners, enabling you to find the ideal solution.

Using our knowledge as an Original Equipment Manufacturer (OEM), we ensure that the supplied product is correct for your equipment and application. We offer Gyratory Crusher Liners tailored to your needs and manufactured for increased productivity. Here is what sets our Gyratory Crusher Liners apart:

FLSmidth provides sustainable productivity to the global mining and cement industries. We deliver market-leading engineering, equipment and service solutions that enable our customers to improve performance, drive down costs and reduce environmental impact. Our operations span the globe and we are close to 10,200 employees, present in more than 60 countries. In 2020, FLSmidth generated revenue of DKK 16.4 billion. MissionZero is our sustainability ambition towards zero emissions in mining and cement by 2030.

crusher spare parts for jaw, cone &gyratory crusher | qiming machinery

crusher spare parts for jaw, cone &gyratory crusher | qiming machinery

Qiming Machinery is also cooperating with some other foundries to help our customers get their inquiry crusher spare parts. On the other hand, we also stocked large numbers of brands crusher spare parts to a short delivery time.

All Qiming Machinery crusher spare parts are backed by our Quality Guarantee and are shipped only after meeting our rigorous quality standards. We are committed to meeting your replacement parts needs in a professional and efficient manner. Our Customer Support Department is ready to help you with a quote, to check inventory, or simply answer a technical question.

When choosing any type of spare parts for your crusher, think long-term. Qiming Machinerys spare parts help keep your crusher working at peak performance because they are made to fit and function for just that.

Qiming Machinery aftermarket jaw crusher replacement parts are used by crusher operators worldwide and are often specified by many of the worlds most prestigious mining, quarrying, demolition, and recycling operators together with several of the major original equipment manufacturers.

Qiming Machinery aftermarket cone crusher spare parts are used by crusher operators worldwide and are often specified by many of the worlds most prestigious mining, quarrying, demolition, and recycling operators together with several of the major original equipment manufacturers.

Qiming Machinery aftermarket gyratory crusher spare parts are used by crusher operators worldwide and are often specified by many of the worlds most prestigious mining, quarrying, demolition, and recycling operators together with several of the major original equipment manufacturers.

Qiming Machinery is the leading manganese steel, chromium steel, alloy steel, and heat-resisting steel manufacturer in China. We manufacture crusher wear parts, shredder wear parts, mill liners, apron feeder pans, and other wear parts for customers.

rockster blow bars | wear parts for industry | qiming casting

rockster blow bars | wear parts for industry | qiming casting

The company Kormann Rockster Recycler GmbH specializes in the design and production of mobile crushing and screening systems for profitable recycling of asphalt, concrete anddemolition rubble as well as natural stone. The rockster mobile crushers are very popular in the world.Our range of Rocksterblow bars and impact plates are extensive and has variations which consist of manganese, high chrome, martensitic and ceramic to enable JYS crusher partsto offerfor our customers machinery to run in any condition.

Qiming Casting is one of the largest manganese steel, chromium steel, and alloy steel foundry in China. Products include crusher wear parts, Crusher spare parts, mill liners, shredder wear parts, apron feeder pans, and electric rope shovel parts.

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