Work

Heterarchical comminution model for SAG mills

Year: 2025

Type: article

Abstract: Semi-autogenous grinding (SAG) mills are commonly used in the mineral processing industry to effectively grind large particles into finer ones suitable for further processing. Despite their effectiveness in comminution, these mills are highly inefficient in terms of energy consumption. Understanding this inefficiency using population-balance models is challenging, as those are not informed by granular interactions and physics involving the interplay of crushing, segregation, and mixing. Conversely, using discrete-element simulation models to study SAG mills is also limited in scope since at any given time these mills can contain eight orders of magnitude more particles than those models can handle. Here, we address these challenges by developing a new comminution approach based on heterarchy. Expanding upon the previously developed heterarchical model for comminution in rotary mills, we incorporate the dynamics of grinding media consisting of steel balls, offering a comprehensive understanding of comminution within a SAG mill. Employing this new comminution model, we further analyse the effect of the different mill operating parameters — mill speed, fill fraction, and ball-to-charge ratio — on the comminution behaviour. This model brings us one step closer to understanding energy consumption in SAG mills.

Source: Minerals Engineering

DOI: 10.1016/j.mineng.2025.109563

Authors: Mukesh Singh Bisht, François Guillard, Paul Shelley, Benjy Marks, Itai Einav

Institution: The University of Sydney

Language: English

Topic: Mineral Processing and Grinding

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Responsible consumption and production

Open Access status: hybrid

Estimated APC paid: $4,220