An Investigation on Effect of Shell Liner Type on Performance of Industrial SAG Mills Using DEM

The shell liner type, rotation speed, and ball filling percent are the key factors influencing the charge behavior inside the SAG mills, and consequently, their performance. In this work, the milling operation of industrial SAG mills is investigated using the Discrete Element Method (DEM). First, an industrial SAG mill with dimensions of 9.50 m × 4.42 m that has a Smooth-type liner is simulated. Then by changing the liner types, i.e. Wave, Rib, Ship-lap, Lorain, Osborn, and Step liners, six other independent simulations are performed. In order to investigate the impact mechanism and improve the mill performance, two new parameters called ‘head height’ and ‘impact zone length’ are introduced. Then the effects of the mill shell liner type on those parameters at two different mill speeds, i.e. 70% and 80% of its critical speed (CS), are evaluated. Also for validation of the simulation results, a laboratory-scale SAG mill with dimensions of 57.3 cm × 16.0 cm is simulated. The results obtained indicate that the Osborn liner, due to the angularity of its lifters and their proper number and thickness, performs best because it increases both parameters more than the other liners. Thus this liner is recommended as the best and optimal liner in this research work and is suggested for installation inside the industrial SAG mills. Also the Wave liner, due to its specific geometrical shape and its wavy lifters as well as their low number and inadequate thickness, provides the lowest charge ‘head height’. Therefore, it is not recommended to install this liner inside the industrial SAG mills. Meanwhile, comparison of the simulations related to the laboratory-scale SAG mill with the experimental results demonstrates a good agreement that validates the DEM simulations and the software used.