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

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.

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 optimization.

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 customer's 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.