Increasing The Grinding Efficiency Of Gol-E-Gohar Iron Ore And Sarcheshmeh Copper Complex Sag Mills With Changing Liner Design By Discrete Element Method (Dem)

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GHASEMI ALIREZA; MALEKI MOGHADDAM MOSTAFA; Razi Erfan; BANISI SAMAD

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Journal: IRANIAN JOURNAL OF MINING ENGINEERING (IRJME) Year:2018 | Volume:13 | Issue:40 Page(s): 46-59

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Title

Increasing The Grinding Efficiency Of Gol-E-Gohar Iron Ore And Sarcheshmeh Copper Complex Sag Mills With Changing Liner Design By Discrete Element Method (Dem)

Author(s)

GHASEMI ALIREZA | MALEKI MOGHADDAM MOSTAFA | Razi Erfan | BANISI SAMAD | Issue Writer Certificate

Keywords

TerajectoryQ1

SAG millQ1

Discrete Element Method (DEM)Q1

Model millQ1

KMPCDEMQ1

Abstract

At Gol-E-Gohar iron ore concentration plant and Sarcheshmeh copper complex, SAG mills are used with the diameter of 9 and 10 meters and length of 2 and 4. 9 meters, respectively. Monitoring the operation in these two plants indicated that the tonnage of the mill at Gol-E-Gohar was lower than the nominal value with large variations and the Sarcheshmeh mill experienced liner breakages which in turn increased the non-scheduled shutdowns. In order to overcome these difficulties and to increase the performance, the charge trajectory, which is an important parameter, was studied in these two mills. To simulate the charge trajectory KMPCDEM software was used, which has been developed based on discrete element method (DEM). The results of simulations using two different liner designs were verified with a Model mill of 1-m diameter and 22-cm length. The comparison indicated that inthe worst case the difference between the shoulder and toe positions of the simulated and measured charges was found to be less than 4 degrees which was not considered significant given the experimental error of the test. Once the accuracy of the simulation was verified, it was used to simulate the charge trajectory in the two industrial SAG mills. The simulations showed that unlike the expectation, cataracting particles do not impact toe, they rather they hit shell liners. In order to solve this problem, various liner designs at the plant operating conditions were simulated with the objective of reaching a state where the falling charge impacts the toe region. To achieve such a goal, for Gol-E-Gohar SAG mill the release angle was increased from 7 to 30 degrees and for the mill at Sarcheshmeh, the number of lifters was decreased from 60 to 40 and the release angle increased from 15 to 30 degrees. The proposed liner designs were constructed and installed in the industrial SAG mills where their performances were monitored during a period of twenty months. At Gole-E-Gohar, the feed rate increased by 17% and its variation reduced by 31% which indicats more stable operation. At Sarcheshmeh, the average number of broken liners decreased from 4. 2 to 1 and the variation of feed rate decreased by 30%. The promising results of liner change in the last few years resulted in replacement of old liners in the SAG mills of the two plants with the proposed liners.

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APA: Copy

GHASEMI, ALIREZA, MALEKI MOGHADDAM, MOSTAFA, Razi, Erfan, & BANISI, SAMAD. (2018). Increasing The Grinding Efficiency Of Gol-E-Gohar Iron Ore And Sarcheshmeh Copper Complex Sag Mills With Changing Liner Design By Discrete Element Method (Dem). IRANIAN JOURNAL OF MINING ENGINEERING (IRJME), 13(40 ), 46-59. SID. https://sid.ir/paper/117038/en

Vancouver: Copy

GHASEMI ALIREZA, MALEKI MOGHADDAM MOSTAFA, Razi Erfan, BANISI SAMAD. Increasing The Grinding Efficiency Of Gol-E-Gohar Iron Ore And Sarcheshmeh Copper Complex Sag Mills With Changing Liner Design By Discrete Element Method (Dem). IRANIAN JOURNAL OF MINING ENGINEERING (IRJME)[Internet]. 2018;13(40 ):46-59. Available from: https://sid.ir/paper/117038/en

IEEE: Copy

ALIREZA GHASEMI, MOSTAFA MALEKI MOGHADDAM, Erfan Razi, and SAMAD BANISI, “Increasing The Grinding Efficiency Of Gol-E-Gohar Iron Ore And Sarcheshmeh Copper Complex Sag Mills With Changing Liner Design By Discrete Element Method (Dem),” IRANIAN JOURNAL OF MINING ENGINEERING (IRJME), vol. 13, no. 40 , pp. 46–59, 2018, [Online]. Available: https://sid.ir/paper/117038/en

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