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WhitepaperDecember 11th, 2023

Enhancing AG Mill Performance: Collaborative Optimization, Innovative Design, and Digital Tools

Bradken’s innovative design, advanced simulations, and digital tools achieve a remarkable 9.5% throughput increase and 2.5% energy reduction for the customer.

Unlocking peak performance in mineral processing through collaborative journey optimizing customers AG Mill. Bradken’s innovative design, advanced simulations, and digital tools achieve a remarkable 9.5% throughput increase and 2.5% energy reduction for the customer.

Overview

The optimization project, targeting ⌀32-ft x 13-ft AG Mill, comprised a collaborative approach. The initial assessment identified challenges in the existing radial design, leading to the proposal of a Bradken Vortex discharge system. Advanced simulations, such as DEM-SPH simulations, were employed to compare three concepts: radial pulp lifters, Vortex pulp lifters, and a half-row Vortex design. The results showed that the half-row Vortex design achieved maximized chamber intake with minimal backflow.

Solution

The shell design was optimized, addressing factors like transfer size and throughput. Grate revisions proposed increased open area and reduced slot size to control product size. Digital tools, including machine learning models, tracked and reported key metrics identified to improve mill optmisation.

Results

Optimization efforts significantly improved AG mill performance. The final design, featuring a half-row double-wide Bradken Vortex discharge system, yielded a 9.5% throughput increase and a 2.5% reduction in overall circuit energy consumption. The collaborative and iterative optimization process successfully met the customers production goals, showcasing advanced liner design, modeling, material selection, and digital tools. This methodology holds potential for enhancing design optimization in similar mineral processing circuits.

Results summary

  • AG mill performance significantly improved.
  • 9.5% throughput increase, 2.5% energy reduction.
  • Collaborative process met Freeport Bagdad's productivity goals.
  • howcased advanced liner design, modeling, material.
  • Digital tools utilized in successful optimization.

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