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    Choosing The Right Motors For Your Mills: Alex Doll and Derek Barratt

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    avca65
    This document discusses choosing the right motors for mills. It outlines a 4 step process: 1) determine maximum mill overload power, 2) benchmark motor power needs, 3) choose from gearless, synchronous or induction motor types based on power and efficiency needs, 4) select an optimal motor speed. It provides examples of applying this process to a case study of a South American iron ore project with one SAG mill and two ball mills. The conclusion is to size mills for nominal throughput and motors to handle potential overload conditions.

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    Choosing The Right Motors For Your Mills: Alex Doll and Derek Barratt

    Uploaded by

    avca65
    33 views16 pages
    This document discusses choosing the right motors for mills. It outlines a 4 step process: 1) determine maximum mill overload power, 2) benchmark motor power needs, 3) choose from gearless, synchronous or induction motor types based on power and efficiency needs, 4) select an optimal motor speed. It provides examples of applying this process to a case study of a South American iron ore project with one SAG mill and two ball mills. The conclusion is to size mills for nominal throughput and motors to handle potential overload conditions.

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    ALEX DOLL

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    This document discusses choosing the right motors for mills. It outlines a 4 step process: 1) determine maximum mill overload power, 2) benchmark motor power needs, 3) choose from gearless, synchronous or induction motor types based on power and efficiency needs, 4) select an optimal motor speed. It provides examples of applying this process to a case study of a South American iron ore project with one SAG mill and two ball mills. The conclusion is to size mills for nominal throughput and motors to handle potential overload conditions.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    33 views16 pages

    Choosing The Right Motors For Your Mills: Alex Doll and Derek Barratt

    Uploaded by

    avca65
    This document discusses choosing the right motors for mills. It outlines a 4 step process: 1) determine maximum mill overload power, 2) benchmark motor power needs, 3) choose from gearless, synchronous or induction motor types based on power and efficiency needs, 4) select an optimal motor speed. It provides examples of applying this process to a case study of a South American iron ore project with one SAG mill and two ball mills. The conclusion is to size mills for nominal throughput and motors to handle potential overload conditions.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 16

    Choosing the Right Motors for your Mills

    Alex Doll and Derek Barratt DJB Consultants, Inc., Canada

    Overview of Mill Selection


    Grinding testwork to characterise the project's oretypes Characterise hardness variability or load grinding results into block model Select mill sizes to achieve a desired throughput (or select a throughput based on desired mill sizes) Select motor(s) to fit the mills

    Step 1: Mill overload power


    Determine a set of operating conditions that reflects the maximum overloaded condition that the mill should be able to handle:
    SAG mills: 20% v/v ball charge, 30% v/v filling and 78% critical speed with worn liners Ball mills: 36% v/v filling and 78% critical speed with worn liners

    Step 1: Mill overload power


    SAG mill, use a Tent Diagram to identify the design requirements Example, SG=4.0 38' 19' EGL SAG Requires 21.5 MW at mill shell

    Benchmarking Power

    Step 2: Power measured where?


    The process conditions reflect power delivered to the mill shell The motor power reflects the motor output Motors with pinions and reducers must allow mechanical losses
    makes the motor bigger to produce the same shell power

    Step 3: Which Type?


    Three commonly used mill motor types:
    Gearless drives
    largest size, up to 28 MW highest efficiency

    Synchronous with pinion


    one or two pinion configuration, up to 15.6 MW

    Induction motor with speed reducer


    one or two pinion configuration cheapest capital, but poorest electric efficiency

    Step 3: Which Type?


    Electrical efficiency
    Gearless is highest Induction is lowest
    CCV/Transformer Input 0.98 0.99 0.99

    Motor Input

    Directly affects operating costs


    inefficient motors consume more Gearless power Synchronous
    Induction

    0.97

    0.96

    0.96

    Motor Output

    1.0

    0.985

    0.97

    Mill Shell

    Step 3: Which Type?


    Gearless is always variable-speed Synchronous and induction are normally fixed-speed
    Can be made variable speed by adding more equipment and sacrificing electrical efficiency In almost all cases, variable speed is costeffective for SAG mills Variable speed for ball mills depends on the particular project and ore

    Step 4: Select Speed


    The rated speed of a motor is nominated by the engineer The torque output of a motor is constant up to the rated speed The power output of a motor is constant above the rates speed
    (More on speed in the case study)

    Case Study
    South American iron-ore project Variability in ore density 60,000 tonnes/day on 75% of samples Single line
    1 SAG, 38' 19' EGL 2 ball mills, 22' 38' EGL

    Case Study: Nominal operation

    Case Study, Design Speed


    78% of critical 75% of critical

    Case Study, 21.5 MW SAG


    Density 4.0 t/m Density 3.17 t/m

    Case Study, Liners


    (based on change in mill volume, does not consider charge motion)

    Worn (75 mm)

    New (150 mm)

    Conclusion
    Size grinding mills for nominal operating conditions (throughput targets) Size motors for overload conditions that may reasonably be encountered
    High ball charge, volumetric filling High density ore Worn liners

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