Ball Mill (Perfect Mixing, Dynamic)
Description
This article describes a dynamic implementation of the Perfect Mixing ball mill model outlined by Napier-Munn et al. (1996).[1]
The dynamic version uses the same underlying theory and structure as the steady-state Perfect Mixing ball mill model. For a full description of the steady-state model, see Ball Mill (Perfect Mixing).
Model theory
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Excel
The Perfect Mixing ball mill model is not implemented in Excel in dynamic form for practical purposes. Excel is not an ideal platform for dynamic simulation and SysCAD (or similar) is preferred.
The dynamic model is, however, included in Excel in a run-to-steady-state mode where all feed and input parameters are fixed and time steps are progressed until the computed load and discharge stabilises.
This mode is useful for extracting separated and functions from steady-state data such as plant surveys or other model calibrations (including the steady-state Perfect Mixing ball mill model).
The run-to-steady-state dynamic Perfect Mixing ball mill model may be invoked from the Excel formula bar with the following function call:
=mdUnit_BallMill_PerfectMixingRiDi(Parameters as Range, Size as Range, MillFeed as Range, OreSG As Range, Appearance as Range, WorkIndexSim as Range, RKnotPositions as Range, RKnotsOrig as Range, Classification as Range)
Invoking the function with no arguments will print Help text associated with the model, including a link to this page.
Inputs
The required inputs are defined below in matrix notation with elements corresponding to cells in Excel row () x column () format:
where:
- is the mill (belly) length
- is angle between the cone end surface and the vertical direction (degrees)
- is the diameter of the discharge trunnion (m)
- is the ball charge volume fraction (often ) (v/v)
- is the void fill fraction, the volumetric fraction of grinding media interstitial void space occupied by slurry (v/v)
- is the Specific Gravity or density of the ball media (excluding void space) (- or t/m3)
- is the mass flow feed rate of liquids into the mill (t/h)
- is the Specific Gravity or density of liquids in the feed (- or t/m3)
- is the method used to defined the classification-by-size to discharge, 0 = User-defined partition or 1 = Leung method
- is discharge configuration, 0 = Grate discharge, 1 = Overflow discharge at trunnion height, 2 = Overflow discharge at user-defined slurry filling volume
- is the user-specified slurry filling volume at which overflow commences (if ) (m3)
- is the number of ore types
- is the number of breakage rate per discharge rate knots
- is feed mass flow rate (t/h)
- is Specific Gravity or density (- or t/m3)
Results
The results are displayed in Excel as an array corresponding to the matrix notation below:
where:
- is the flow rate of pulp into the mill (m3/h)
- is the total volume inside the mill, calculated as the sum of a cylinder and two frustums (m3)
- is the rotational rate of the mill (rpm)
- is the number of time steps required to reach steady-state
- is the size of the discretised time step calculated by the model, (s)
- is the total mass of ore in the mill at steady-state (t)
- is the mass of liquids in the mill at steady-state (t)
- is the mass of balls in the mill at steady-state (t)
- is the volume of slurry in the mill at steady-state (m3)
- is the maximum volume of slurry that can occupy the charge void space before forming a slurry pool (m3)
- is the maximum volume of slurry in the mill before trunnion overflow commences (m3)
- is the discharge mass flow rate of liquids from the mill (t/h)
- is product mass flow rate (t/h)
- is the mass of solids in the mill (t)
Example
The images below show the selection of input arrays and output results in the Excel interface.
SysCAD
The SysCAD interface for Dynamic mode is described below. For steady-state, see Ball Mill (Perfect Mixing).
MD_Mill page
The first tab page in the access window will have this name.
Tag (Long/Short) | Input / Display | Description/Calculated Variables/Options |
---|---|---|
Tag | Display | This name tag may be modified with the change tag option. |
Condition | Display | OK if no errors/warnings, otherwise lists errors/warnings. |
ConditionCount | Display | The current number of errors/warnings. If condition is OK, returns 0. |
GeneralDescription / GenDesc | Display | This is an automatically generated description for the unit. If the user has entered text in the 'EqpDesc' field on the Info tab (see below), this will be displayed here.
If this field is blank, then SysCAD will display the unit class ID. |
Requirements | ||
On | CheckBox | This enables the unit. If this box is not checked, then the material will pass straight through the mill with no change to the size distribution. |
NumParallelUnits | Input | The number of parallel, identical units to simulate:
|
Method | Fixed Discharge | The discharge particle size distribution is user defined. Different distributions can be used for different solids. |
AG/SAG (Variable Rates) | The Variable Rates AG/SAG mill model is used to determine the mill product size distribution. Different parameters can be used for different solids. | |
Rod Mill (Lynch) | The Lynch rod mill model is used to determine the mill product size distribution. Different parameters can be used for different solids. | |
Ball (Perfect Mixing) | The Perfect Mixing ball mill model (steady-state or dynamic) is used to determine the mill product size distribution. Different parameters can be used for different solids. | |
Stirred (Perfect Mixing) | The Perfect Mixing stirred mill model (steady-state or dynamic) is used to determine the mill product size distribution. Different parameters can be used for different solids. | |
Mill (Herbst-Fuerstenau) | The Herbst-Fuerstenau model is used to determine the mill product size distribution. Different parameters can be used for different solids. | |
PowerModels | CheckBox | Show alternative mill power model calculations on the Power page. |
MediaTrajectory | CheckBox | Show mill media rolling, sliding and free flight trajectory computations on the MediaTraj page. |
OverfillingIndicator | CheckBox | Show overflow ball mill slurry volume, residence time, and overfilling evaluation on Overfilling page. |
MediaStrings | CheckBox | Show media size distributions at recharge equilibrium on the MediaStrings page. |
Options | ||
ShowQFeed | CheckBox | QFeed and associated tab pages (eg Sp) will become visible, showing the properties of the combined feed stream. |
ShowQProd | CheckBox | QProd and associated tab pages (eg Sp) will become visible, showing the properties of the products. |
SizeForPassingFracCalc | Input | Size fraction for % Passing calculation. The size fraction input here will be shown in the Stream Summary section. |
FracForPassingSizeCalc | Input | Fraction passing for Size calculation. The fraction input here will be shown in the Stream Summary section. |
Stream Summary | ||
MassFlow / Qm | Display | The total mass flow in each stream. |
SolidMassFlow / SQm | Display | The Solids mass flow in each stream. |
LiquidMassFlow / LQm | Display | The Liquid mass flow in each stream. |
VolFlow / Qv | Display | The total Volume flow in each stream. |
Temperature / T | Display | The Temperature of each stream. |
Density / Rho | Display | The Density of each stream. |
SolidFrac / Sf | Display | The Solid Fraction in each stream. |
LiquidFrac / Lf | Display | The Liquid Fraction in each stream. |
Passing | Display | The mass fraction passing the user-specified size (in the field SizeForPassingFracCalc) in each stream. |
Passes | Display | The user-specified (in the field FracForPassesSizeCalc) fraction of material in each stream will pass this size fraction. |
Mill page
The Mill page is used to specify the input parameters for the mill model.
Tag (Long/Short) | Input / Display | Description/Calculated Variables/Options |
---|---|---|
PerfectMixing | ||
HelpLink | Opens a link to this page using the system default web browser. Note: Internet access is required. | |
Mode | Steady State |
|
Dynamic | The dynamic Perfect Mixing ball mill model described here is used to determine the mill product size distribution. Different parameters can be used for different solids. | |
MinSubSteps | Input | The user-specified minimum number of internal models steps taken per SysCAD step. |
SubSteps | Display | The actual number of internal models steps taken per SysCAD step. May be affected by breakage/discharge rates or the user-specified MinSubSteps parameter. |
DischargeType | Grate | The ball mill is configured with a grate discharge. |
Overflow | The ball mill is configured with an overflow discharge. The maximum slurry volume in the mill before overflowing the trunnion is calculated by the model. | |
Overflow (User) | The ball mill is configured with an overflow discharge. The user specifies the maximum slurry volume before overflow. | |
Ball | ||
MediaStringsP50 | CheckBox |
|
Diameter | Input | The inside liner diameter of the original and simulated ball mills. |
BellyLength | Input | The inside liner belly length of the simulated ball mill, excluding cones. |
ConeAngle | Input | Angle of the feed and discharge end cones, measured as positive displacement from the vertical direction. |
TrunnionDiameter | Input | The inside liner trunnion diameter of the simulated ball mill. |
LoadFrac | Input | The volumetric load fraction of the original and simulated ball mills. |
FracCS | Input | The fraction critical speed of the original and simulated ball mills. |
WorkIndex | Input | Bond Ball Work Index of ore in the original mill. |
BallSize | Input | Characteristic diameter of balls in original and simulated ball mills. |
MaxBreakageRateFactor / K | Input | Parameter relating ball size and the size at which the breakage rate per discharge rate is maximum. |
RFunction | ||
NumSplineKnots | Input | Number of spline knots for the function. |
Size | Input | Spline knot size positions. |
Ln(R) | Input | Values of at each spline knot position. |
Power | ||
BallVolume | Input | Volumetric fraction of mill occupied by balls and voids. |
VoidFillFraction | Input | Volumetric fraction of void space between balls occupied by slurry. |
BallSG | Input | Specific Gravity or density of ball media. |
Results | ||
MillVolume | Display | Volume inside mill, including cones. |
MillSpeed | Display | Rotational speed of simulated mill. |
Ore page
This page is used to define the comminution properties of SysCAD species with the size distribution quality in the project.
Tag (Long/Short) | Input / Display | Description/Calculated Variables/Options |
---|---|---|
Appearance | ||
DefaultAppearance | Sets all species to the the default Broadbent-Callcott Appearance function. | |
OreSpecific | CheckBox |
|
Appearance | Input | User-specified Appearance function data for all species with size distribution property. |
WorkIndex | ||
WorkIndex.Sim | Input | Bond Ball Work Index data for all species with size distribution property. |
RiDi page
This page displays the scaling factors and breakage rate per discharge rate for each size interval computed by the Perfect Mixing model.
Tag (Long/Short) | Input / Display | Description/Calculated Variables/Options |
---|---|---|
Scaling | ||
Diameter | Display | Value of the mill diameter factor for rate scaling. |
LoadFraction | Display | Value of the load fraction factor for rate scaling. |
FracCS | Display | Value of the fraction critical speed factor for rate scaling. |
WorkIndex | Display | Value of the Work Index factor of each ore species for rate scaling. |
Rates | ||
Size | Display | Size of each interval in internal mesh series. |
MeanSize | Display | Geometric mean size of each interval in internal mesh series. |
R | Display | Value of breakage rate, , for each size interval, for each ore species. |
C | Display | Value of classification function, , for each size interval. |
D | Display | Value of discharge rate, , for each size interval. |
Load page
This page displays information about the balls, solids and liquids that currently comprise the mill load.
Tag (Long/Short) | Input / Display | Description/Calculated Variables/Options |
---|---|---|
Filling | ||
SLCapacity / SLVtCap | Input / Display | The maximum volume of slurry the mill can contain before overflow. |
SLCharge / SLVtCharge | Display | Only appears if DischargeType is 'Overflow'. The maximum volume of slurry that can fill the charge void space. |
SLVolume / SLVt | Display | The total volume of slurry currently in the mill. |
SLLevel / SLLvl | Display | The current slurry volume (SLVolume) as a fraction of the maximum slurry volume before overflow (SLCapacity). |
Load | ||
SolidMass / SMt | Display | The mass of solids with the SysCAD size distribution property currently in the mill. |
LiquidMass / LMt | Display | The mass of liquids plus solids without the SysCAD size distribution property currently in the mill. |
BallMass / BMt | Display | The mass of ball media in the mill. |
Size | Display | Size of each interval in internal mesh series. |
MeanSize | Display | Geometric mean size of each interval in internal mesh series. |
Load | Display | The mass of solids with the SysCAD size distribution property currently in the mill, by size and species. |
Content, Sp, Ec, Sz and MSz pages
These pages display the standard SysCAD Material Content, Species Content and Size pages for the current mill load
Power page
This optional page displays the inputs and results for alternative mill power models. The page is only visible if PowerModels is selected on the MD_Mill page.
Tag (Long/Short) | Input / Display | Description/Calculated Variables/Options |
---|---|---|
Power | ||
HildenPowell | CheckBox | Shows inputs and results for tumbling mill power calculations using the Hilden and Powell method. |
MediaStrings page
This page displays the inputs and results for grinding mill media string calculations. The page is only visible if MediaStrings is selected on the MD_Mill page.
MediaTraj page
This page displays the inputs and results for tumbling mill media trajectory calculations. The page is only visible if MediaTrajectory is selected on the MD_Mill page.
Overfilling page
This page displays the inputs and results for overflow discharge mill overfilling calculations. The page is only visible if OverfillingIndicator is selected on the MD_Mill page.
About page
This page is provides product and licensing information about the Met Dynamics Models SysCAD Add-On.
Tag (Long/Short) | Input / Display | Description/Calculated Variables/Options |
---|---|---|
About | ||
HelpLink | Opens a link to the Installation and Licensing page using the system default web browser. Note: Internet access is required. | |
Information | Copies Product and License information to the Windows clipboard. | |
Product | ||
Name | Display | Met Dynamics software product name |
Version | Display | Met Dynamics software product version number. |
BuildDate | Display | Build date and time of the Met Dynamics Models SysCAD Add-On. |
License | ||
File | This is used to locate a Met Dynamics software license file. | |
Location | Display | Type of Met Dynamics software license or file name and path of license file. |
SiteCode | Display | Unique machine identifier for license authorisation. |
ReqdAuth | Display | Authorisation level required, MD-SysCAD Full or MD-SysCAD Runtime. |
Status | Display | License status, LICENSE_OK indicates a valid license, other messages report licensing errors. |
IssuedTo | Display | Only visible if Met Dynamics license file is used. Name of organisation/seat the license is authorised to. |
ExpiryDate | Display | Only visible if Met Dynamics license file is used. License expiry date. |
DaysLeft | Display | Only visible if Met Dynamics license file is used. Days left before the license expires. |
See also
References
- ↑ Napier-Munn, T.J., Morrell, S., Morrison, R.D. and Kojovic, T., 1996. Mineral comminution circuits: their operation and optimisation. Julius Kruttschnitt Mineral Research Centre, Indooroopilly, QLD.