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1

Modelling the power draw of tumbling mills : a comprehensive review

Golpayegani Mohammad Hasan, Rezai Bahram

Physicochemical Problems of Mineral Processing

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2022

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Vol. 58, iss. 4

art. no. 151600

EN

Optimizing power consumption in grinding, the most consumed stage in the mining industry, plays an influential role in reducing operating costs. Obtaining an efficient model to predict tumbling mills' power consumption accurately took the attention of researchers, mineral processing engineers, and tumbling mill manufacturers. This article comprehensively reviews the published mill power models and the most critical studies on this topic since 1919. Furthermore, the employed approaches for modelling the tumbling mills' power draw, the incorporated parameters into the developed models, the models' performances in predicting the industrial mills' power draw, and the potential gaps in the available literature are discussed. Moreover, based on the shortages identified in this review, some recommendations have been made to enhance the modelling mill power draw.

2

Improvement of the accuracy of Hogg and Fuerstenau's model in predicting the power draw of ball mills based on determining the grinding media’s dynamic voidage

Golpayegani Mohammad Hasan, Rezai Bahram

Physicochemical Problems of Mineral Processing

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2022

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Vol. 58, iss. 6

art. no. 153380

EN

In the development of tumbling mills' power models, the voidage of grinding media is assumed to be static and equal to 40%. While the grinding media’s voidage is dynamic; and hence is varied by changing the operating parameters. In this paper, to improve the Hogg and Fuerstenau model's accuracy in predicting the ball mills' power draw, the grinding media's static and dynamic voidage was studied for Bond's proposed ball size distributions (BSD) for the ball mills' first filling. To this end, by scaling down balls to one-tenth of actual size, developing a novel method to measure the dynamic voidage, and employing the three-level factorial method, a separate empirical model was developed for determining the dynamic voidage of each Bond's BSD with respect to mill's fractional filling and rotating speed. Moreover, using the multiple regression method, a general empirical model was derived to determine the dynamic voidage of each supposed BSD based on calculating the mean absolute deviation of balls diameter (MAD). Results indicated that grinding media's dynamic voidage increases with an increase in rotating speed and a decrease in fractional filling and balls diameter's MAD. The maximum and minimum static and dynamic voidage occurred for the seventh and first Bond's BSDs. By employing an industrial database and analyzing the mean absolute percentage error (MAPE) of predicted ball mills' power draw, it was found that the Hogg and Fuerstenau model's accuracy enhances by calculating the load's bulk density based on the grinding media's dynamic voidage.

3

Calculation of the power draw of dry multi-compartment ball mills

Erdem A. S., Ergün S. L., Benzer A. H.

Physicochemical Problems of Mineral Processing

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2004

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Vol. 38

221-230

EN

In this paper, a new approach for the calculation of the power draw of cement grinding ball mills is proposed. For this purpose, cement grinding circuit data including the operational and design parameters were collected from 14 industrial ball mills, ranging in diameters from 3.2 to 4.8 m. The ball loads within the mills were measured by different methods proposed in the literature and power draw of each mill were calculated. The results showed that power draw of the cement mills could accurately be predicted by the method proposed in this study.

PL

W pracy zaproponowano nowe podejście do problemu kalkulacji zużycia energii przez młyny kulowe pracujące "na sucho", stosowane do otrzymywania cementu. Dla realizacji tego zamierzenia, zgromadzone zostały dane operacyjne i projektowe z 14 instalacji przemysłowych, które zawierają młyny kulowe o średnicy w przedziale od 3,2 do 4,8 m. Załadunek kulami każdego młyna został zmierzony przy wykorzystaniu różnych metod, proponowanych w literaturze. Zużycie energii przez każdy z badanych młynów, zostało wyliczone. Otrzymane wyniki wskazują, ze zużycie energii przez młyny do produkcji cementu można dokładnie przewidzieć stosując metodę zaproponowana w pracy.