SAG mill operators adjust speed, ball charge, and feed rate using experience and shift-to-shift handover notes because the relationship between feed ore hardness, mill load, cyclone overflow P80, and specific energy consumption is never modeled across a full shift sequence. Bond Work Index measurements from the lab arrive hours after the ore has already been processed. Energy bills for comminution can exceed 50% of total site power consumption, but the operating envelope that maximizes tonnes per kWh is never formally defined - it is approximated and re-approximated each shift.
Built For
Process Metallurgist optimizing SAG and ball mill circuits across a 45,000 tpd concentrator with variable ore hardness and mineralogy
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Process / Plant Engineer
Optimizes SAG and ball mill operating parameters to maximize throughput per kWh across variable ore hardness conditions.
Mine Geologist / Grade Control
Provides ore hardness domain predictions from the geological model to enable proactive comminution parameter adjustments before hard ore reaches the mill.
Mine Planner / Operations
Adjusts ore blend sequencing from stockpile and ROM to manage feed hardness variability and maintain mill throughput targets.
Lumina correlates SAG mill feed hardness indices, ball charge level, motor draw, bearing pressure, cyclone overflow particle size, and downstream recovery against energy consumption to identify the operating conditions that maximize throughput per kWh without sacrificing flotation feed quality.
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I see a consistent -12% variance between Block Model estimates and Plant Recovery for material from Pit B. This suggests high dilution during blasting.
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