New approach for load level

estimation in SAG mills using a

sensor system and optimization
algorithm
Hernn Robles, Tania Ledezma and Javier Inostroza
New Electromagnetic Technologies On-Site
Netos S.A., Chile
Luis Vinnett, Waldo Valderrama and Jorge Pontt
Universidad Tcnica Federico Santa Mara, Chile
 Contents
Introduction
Methodology
Multi-sensor system
Optimization algorithm

Results and discussion

Conclusions
 Introduction
Knowing the filling level of load within the SAG mill

Benefits Optimization
Process Control
Processed tonnage
Power draw
Lining and grinding media
wear
 Introduction
Sensor and instrumentation development for
estimating the filling level within a mill
Sound
MONSAG
Vibrations (Pontt et al., 1997)

Load cells
SAGAnalyzer
Bearing pressure (Magne et al., 2005)

Electrical measurements
Sensomag
Invasive sensor (Keshav et al., 2011)
 Introduction
Use of a set of variables that account for
changes in the dynamics of the load
Power draw
Affected by the filling level and Power
composition of the load Bearing draw
pressure
Bearing pressure
Indicator of the direction of Load
change of the filling level position

Load position
Spatial information of the internal
load
Load filling level
Multi-sensor system

Instrumentation on-site (Hardware)

Phenomenological and empirical models (Software)

Phenomenological and empirical
models
LINING WEAR

SHOULDER S

JB
JC

POWER DRAW

BEARING PRESSURE
TOE T
 Lining wear model
Lining monitoring data

DM t m D0 2 kL more t treline
D0 : diameter of the mill with new lining
kL : lining wear rate
ore: solid tonnage (raw feed).
(t - treline): time since the mill is relined
Phenomenological and empirical
models
LINING WEAR

SHOULDER S

JB
JC

POWER DRAW

BEARING PRESSURE
TOE T
 Ball filling level model
Ball diameter

DB t , t R , i m DB0 kD t t R , i

nBalls t R , 1 nBalls t R , 2 nBalls t R , n

(Magne & Valderrama, 1999)

B t
DB t , t R , 1 DB t , t R , 2 DB t , t R , n D t , t slot size
B R, i

VBalls t
JB t
V 1 B
Phenomenological and empirical
models
LINING WEAR

SHOULDER S

JB
JC

POWER DRAW

BEARING PRESSURE
TOE T
 Power draw and load position
models
Morrells models (1993)

PGross =PNL PNet

PNL f1 DM , LM , C
PNet =k Pcone +Pcylinder f 2 DM , LM , C , L , T , S
T f3 J C , C , S f 4 J C , C
Phenomenological and empirical
models
LINING WEAR

SHOULDER S

JB
JC

POWER DRAW

BEARING PRESSURE
TOE T
 Bearing pressure model
Purpose
Avoid over-filling effect on power draw
Direction of change
5400
Information Balls, JB

Bearing pressure, kPa

Total, JC
5225
Grind out
Crash stop 5050

4875
PreskPa JB JC JB
4700
10 20 30 40
Filling level, %
 onMilL system

Fitting parameters
Mill geometry Optimization algorithm
DCS data
Vibration
Power draw model
measurements Bearing pressure model
Recharge of balls Load position models
Lining wear data

Total filling level JC

Ball filling level JB
 Ball filling level comparison
25
Model
Grind out
20
JB [%]

15

10
0 75 150 225 300
Time [days]

Test onMilL estimated JB, % Grind out JB, %

1 19.99 19.55
2 21.73 22.12
3 19.89 18.93
4 20.32 19.55
5 19.36 19.55
6 17.96 18.60
7 15.81 17.80
Power draw and bearing pressure
estimation
Correlation coefficients greater than 0.8 for both variables
16500
Model
Power draw [kW]

DCS

13750

11000
0 50 100 150 200 250
Time [hour]
5600
Bearing pressure [kPa]

Model
DCS
5300

5000
0 50 100 150 200 250
Time [hour]
 Filling level estimation
38x22 SAG mill
50
Total, JC
Ball, JB
Filling level [%]

40

30

20

10
0 50 100 150 200 250
Time [hour]
 Results
Four industrial tests, > 5000 data.
Continuous operations without maintenance stops.
The sampling rate, 1 Sa/min

Set JB, % JC, % Power draw, Bearing pressure, Speed, Feed tonnage,
kW kPa rpm tph
1 21.1 23.63.9 162971022 5209138 9.850.12 4289437
2 21.4 26.03.0 16702450 530963 9.740.06 5086345
3 18.5 28.94.3 13435732 529768 9.140.34 5762451
4 18.5 38.32.7 15363770 539235 9.340.27 5885490
 Conclusions
Ball filling level in a SAG mill (38x22) showed the best fit with an
apparent ball wear rate of 46.5 m/h. Only one test presented more
than 1% of difference regarding the actual ball filling level measured in
grind out operations.

The proposed algorithm was able to successfully forecast the power

draw and bearing pressure, with almost all correlation coefficients
greater than 0.8 for both variables.

The estimated total filling levels were in good agreement with the
typical JB and JC values observed during the grind out and crash stop
procedures. The estimated JB and JC values were also in good
agreement with operational control of the main variables such as feed
tonnage, ball filling level, rotation speed, bearing pressure and power
draw.
New approach for load level
estimation in SAG mills using a
sensor system and optimization
algorithm
Hernn Robles, Tania Ledezma and Javier Inostroza
New Electromagnetic Technologies On-Site
Netos S.A., Chile
Luis Vinnett, Waldo Valderrama and Jorge Pontt
Universidad Tcnica Federico Santa Mara, Chile