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Grinding Business Line

Andrew Wilkinson
Metso TR Seminar
27 April 2012
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Metso grinding mills world wide

York (PA) USA


Product Center

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Grinding mill sales in % USD$ world wide 2007
Representing 88,2 % of 2007 market

Metso 41,6 %
FLS 37 %
Krupp 1,4 %
Outotec 9,9 %
Citic 3,8 %
Others 6,3 %

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Size reduction mechanisms

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Size reduction is required to liberate the
minerals of interest to recover them selectively
Ore Textures Require Different Grinding Strategies / Stages to liberate minerals

Coarse Grind Reqd Medium Grind Reqd Fine Grind Reqd

Massive Sulphide Net Texture Disseminated


Texture

Pyrrhotite (Waste) Ni Mineral


Copper Mineral Serpentine (Waste)

Scale of pictures: each square represents rock 3.5mm x 3.5mm

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Particle Liberation where economic mineral is
coloured red

Barren Locked Middling Liberated

Scale: particle images are from +53 or +75um size fractions

A typical Mineral Processing Plant will be designed to maximize the


recovery of minerals of interest / limited by the constraints of capital and
operating costs and required concentrate grade

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Typical Ball Mill Components
Main
Gear Guard Lining Bearing Trommel

Gear

Shell

Discharge
Feed Chute
Chute
Jacking
Cradle
Motor

Inching
Head Drive
Reducer
Clutch
Pinion Bearings

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Milling circuits
Wet
Conventional (traditional) milling circuit

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The fine art of milling Grinding Mills
Basics

Wet grinding
Dry grinding
Open circuit
Closed circuit
Batch

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The fine art of milling Grinding Mills
Wet grinding

Material ground as a slurry


Percent solids by weight (60 to 80%)
Dependent on subsequent process
Requires less power compared to dry
Media and liners consumption higher than dry
Eliminates formation of dust

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The fine art of milling Grinding Mills
Dry grinding

Ground in a dry state


Material less than 1% H20
Dependent on subsequent process
Requires 1.3 times power as wet
Media and liners consumption less than wet
Requires dust collection system

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The fine art of milling Grinding Mills
Open circuit

One pass through mill


Average 1.4 to 1.5 more power over closed circuit
Broad product distribution
Less control compared to closed circuit

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The fine art of milling Grinding Mills
Closed circuit

Mill discharge is fed to a sizing device with oversize returning to


the mill

Oversize returning is called circulating load


Less kW per unit ground vs. open circuit
Product top size control
Used in both wet and dry milling

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The fine art of milling Grinding Mills
Batch

Material retained for batch-wise charging and discharging


Specialty applications

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The fine art of milling Grinding Mills
Discharge arrangements

Overflow mills
Grate or diaphragm mills
Peripheral discharge mills

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Performance profiles - Grinding mills

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AG/SAG Mills

Application
- Primary grinding

Types
- Wet
- Dry Airswept

1,8 m. to 13,4 m. diameters


7 kW To 30MW

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40 ft. Shell

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Pebble Mill Grinding

Secondary grinding
Grinds product from primary grinding step, which is
normally; Rod Mill, AG-Mill or SAG Mill Grinding
Grinding media (Pebbles) consists of screened out
fractions of the ore itself, synthetic pebbles or
Grate discharge
manufactured Al2O3. 50-90 mm in size, sometimes larger
Grate discharge
Lower charge and pulp density than Ball Mill Grinding
Pebble Mills are larger than Ball Mills running at the same
horse power draw
Pebble consumption normally between 5-20% of the ore
quantity
Speed: 75-85% of critical
No metal contamination

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Rod Mills

1,5m to 4,5m diameters


55 to 1500 kW

Overflow
Application
- 5mm to 0,5mm product
Types
End peripheral
- Wet trunnion overflow
discharge - Dry peripheral discharge
- Dry center discharge

Center peripheral
discharge

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Ball Mills

Tumbling mill

Overflow Steel media

1,2m to 8m dia

1,5 kW To 15,5 MW
Grate discharge

Minus 15mm feed

Minus 0,5 mm to micron


sized products

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SALA Rubber Roller (SRR) Mills

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PROP&EST DEPT
PRESENTATION OCT.
2007 D.SHAFFER
Typical dry grinding
& air classifier system
(Medium to fine products)

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Rendering By: George Geesey


Metso Mill Types

AG (Autogenous Mill)
Pebble Mill
SAG (Semi Autogenous Mill)
Rod Mill
Ball Mill
SRR Mill (Sala Rubber Roller Mill)
Hardinge Conical Ball Mill
Vertimill
SMD (Stirred Media Detritor)
VBM
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THANKS FOR YOUR ATTENTION

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