SAG mill optimization insights by

measuring inside the mill

Paul Shelley, Ignacio Molina and Dimitrios
Patsikatheodorou
 Technical importance of the project

≈ 36% of Global
Mining Operations

• With the aim to improve energy efficiency

numerous eminent researchers, from Bond (early
50’s) to Morrell (today) have developed models
describing particle breakage energy in ball mills and
attempted to align this directly to mill power.
• Interestingly, all the studies rely upon empirical
findings with a base in laboratory projects, and they
suffer from the inability to accurately measure mill
dynamics from inside an industrial scale.
 Technical importance of the project

≈ 36% of Global
Mining Operations

• A further attempt to measure inside the mill was

detailed by Martins et al (2006). A ball sensor was
successfully trialed in a laboratory scale mill but it
could not be used in a real-mill situation
• Our project has successfully secured in-ball
measurement from within an operating mill. We are
now analysing that data to improve mill optimization
modelling and, separately, to improve on-site
decision making
 Practical importance of the project
• The best approach to date to predict the charge in a
mill is by using Discrete Element Method (DEM) based
simulations.
• DEM uses modelling theory in an attempt to provide
practical advice to mill managers, but taking into
account the limitations of these non-dynamic
simulations
• The standard practice in real life is to maximize mill
power for mill throughput. This ‘cover-all’ approach
ignores the variability of the complex system.
• The measurement of mill variables from inside the
mill that directly indicate efficiency, combined with
increasing the visibility of these measures, could
align the thinking of the theorists and the
practitioners.

Measurements, in real time, from inside the mill might be a game changer
 Industry importance of the project
• In our industry supply of metals is becoming a
fundamental problem and miners want clever spends that
trigger step change:
 The virtual mine
 Automation and remote operations centres
 The internet of things
 Big data or ‘Smart data’
 LEAN in mining
 Suppliers with the customers can articulate innovative
solutions that reduce cost are emerging as winners

A sensor system that improves theoretical modelling and provides results

that can be seen live in real time can facilitate skills and decision making
of met plant teams …….. The possibility of more from less is improved!!!!
Project methodology
Project methodology
SAG media and Bolt sensors
generates data that is
captured in real time:
 Temperature
 Impact measurement
 Impact count
 Project results
Operational Conditions:
 Mineral: Gold
 Equipment: SAG Mill
 Diameter: ≈ 26 (ft)
 GM: 125 & 94 (mm)

Ball sensors captured in

real time (1 day):
 Peak G – Force
 Temperature
 Impact count

7,000 strikes 7,000 strikes

 Project results

Rod sensors captured in 2 day: • The data can compare external measures with
 Temperature (Red) the sensor variable outputs. Some of the
 Impact count (White) comparisons try to connect phenomenon such
 Orientation (Blue) as temperature rise, impact and mill power.
Creating real value for stakeholders
Creating real value for stakeholders

Ambition: Reduced extraordinary wear events

• Consumable wear is an undesirable outcome

of the milling process. Consumable wear is
the result of periods of ‘routine wear’ and
periods of extraordinary wear events.
Creating real value for stakeholders
Ambition: Improved operator decisions

Mill operating variables

Report#1: The current state Report#2: The stabilized state

Real time
visibility

Improved
decision
making
Report#3: The improved state
 Conclusions
• The commercialization project has proven that a sensor
system can deliver real time measurement from inside an
operating mill.
• The system is robust and reliable and has passed the proof of
concept stage.
• Initial results can connect mill events and operating SCADA
measurement directly to changes in the measured variables. It
works!.
• A triangulation of results model is proposed that has the
possibility of quantifying real value creation for stakeholders.
• The system has the potential to contribute to the industry by
facilitating on-the-job learnings of the inside of the mill and
the external mill factors.
• The trials and the quantification of benefit model continue at
the Westgold sites.
 Next steps
• Increase the technology of the sensor system to include
trajectory measurement.
• Algorithm development that supports AI and machine learning.
• Design experiments to use real time measures in various DEM
simulations.
• Connect real time measurement and mill events to confirm the
stakeholder benefit model.
• Secure more collaboration partners to ensure the system
results are generalizable.
SAG mill optimization insights by
measuring inside the mill
Paul Shelley, Ignacio Molina and Dimitrios
Patsikatheodorou
 Back - up
Throughput Throughput (Future: Constant Power Draw )
0.010 0.010
Current 442 t/h Current 442 t/h
0.008 0.008
Stabilised 483 t/h Stabilised 483 t/h
Improved 530 t/h
Probability

Probability
0.006 0.006

0.004 0.004

0.002 0.002

0.000 0.000
0 200 400 600 800 1000 0 200 400 600 800 1000
Throughput (t/h) Throughput (t/h)

Power Power (Future: Constant Throughput)

0.010 0.010
Current 1416 kW Current 1416 kW
0.008 0.008
Stabiised 1383 kW Stabilised 1383 kW
Probability

Improved 1325 kW

Probability
0.006 0.006

0.004 0.004

0.002 0.002

0.000 0.000
0 500 1000 1500 2000 2500 0 500 1000 1500 2000 2500
Power (kW) Power (kW)
 Back - up
Reduced wear events
& Improved decisions
Back - up
Operational Condition  Correlation  Action Plan