DESIGN OF THE KUBAKA GRINDING CIRCUIT USING SPI AND BOND

By
John Starkey, President, Starkey & Associates Grinding Design and Process Engineering,
and Graham Holmes, Manager of Mineral Processing, Kaerner Metals E & !"
Pa#er to $e #resented at the !anadian Mineral Processors !onference
in %tta&a %', Jan(ary )*, )++,
1
ABSTRACT
-he Kinross K($aka Pro.ect is a gold mine located in the /(ssian 0ar East" -he grinding
circ(it, com#rised of a 1", m diameter 2 )"34 m long SAG mill and a 4", m diameter 2 *"* m
long secondary $all mill in closed circ(it &ith cyclones, &as $(ilt (sing SAG Po&er 5nde2
and Bond Ball Mill 6ork 5nde2 testing to determine the grinding energy re7(irements"
E2tremely cold climatic conditions and the need to kee# heated s#ace and ca#ital costs to a
minim(m, dictated a grinding circ(it &ith no in8circ(it cr(sher and no coneyors e2ternal to
the mill" High energy re7(irements for $oth the SAG mill and the $all mill &ere correctly
#redicted and hae allo&ed grinding #rod(ction tonnage forecasts to $e met" Design test data
and #rod(ction res(lts are gien"
INTRODUCTION
5n ,99* Day 5nternational !anada, no& Kaerner Metals E & !, &as commissioned as the
Engineer and Pro.ect Manager for the %molon Gold Mining !om#any, to design and
constr(ct a gold e2traction #lant for the K($aka gold de#osit, located in the /(ssian 0ar East"
-his de#osit had $een st(died e2tensiely in /(ssia d(ring the e2#loration #hase and a
0easi$ility St(dy &as com#leted in ,99: $y Kil$orn &ho isited the site t&ice d(ring that
year to ins#ect facilities and to take metall(rgical test sam#les" More sam#les &ere taken in
,99* to check ore hardness aria$ility, as #art of the final design #rogram $y Day"
-he client;s o$.ectie in designing the K($aka grinding circ(it &as to achiee design tonnage
at all times, een &hen milling the hardest ore <ones in the de#osit" Since the sam#les taken
in ,99: &ere taken as com#osite sam#les, it &as necessary to take additional sam#les in ,99*
to determine the e2tent of the aria$ility" Si2 sam#les &ere sent to !anada for SAG Po&er
5nde2 =SP5> testing" 0ie of these &ere com$ined as a com#osite o#en #it sam#le, &hile the
si2th sam#le &as taken from the site adits as a com#osite sam#le to re#resent (ndergo(nd
ore" -hese t&o com#osite sam#les &ere tested to determine the MacPherson A(togeno(s
6ork 5nde2 for com#arison &ith the SP5 al(es"
A second design o$.ectie &as to meet f(ll #rod(ction &itho(t (sing an in8circ(it #e$$le
cr(sher for critical si<e material in the SAG mill $eca(se the 0easi$ility St(dy had indicated
that this co(ld $e a #ro$lem" Day;s design team &as a&are that the SP5 test had $een
deelo#ed $y Minnoe2 -echnologies 5nc" to determine s#ecific energy in SAG milling
&itho(t cr(shing, so Minnoe2 &as asked to do SP5 tests on the si2 aaila$le sam#les"
-his #a#er deals &ith the grinding test&ork, and the grinding circ(it design and selection of
grinding mills that res(lted from this test&ork"
-est&ork &as #erformed $y A"/ MacPherson !ons(ltants ?td" as #art of a larger #rogram at
Ha<en /esearch 5nc", and $y Minnoe2 -echnologies 5nc" MacPherson@Ha<en did the
MacPherson A(togeno(s 6ork 5nde2 =A6i> tests, the Bond 5m#act 6i test, the Bond /od
Mill 6ork 5nde2 =/M 6i> tests, and the Bond Ball Mill 6ork 5nde2 =BM 6i> tests" -he
SAG Po&er 5nde2 =SP5> tests &ere done at Minnoe2 -echnologies 5nc" in -oronto"
-he MacPherson A(togeno(s test is done in an ,A8inch diameter dry, air8s&e#t Aerofall style
mill, $y contin(o(sly feeding ore that has $een cr(shed to ,++ B #assing ,")* inches" -he
final #rod(ct from this test is a##ro2imately A+ B #assing :++ microns and the s#ecific
2
energy cons(med is calc(lated as an o#erating &ork inde2 (sing Bond e7(ations" -he
res(lting &ork inde2 is then ad.(sted to a commercially correlated A6i al(e $y A"/"
MacPherson !ons(ltants" -here is only one MacPherson mill in e2istence, located in Ha<en
/eseach 5nc";s facility in Dener !%"
-he Bond tests are ind(stry standard tests that can $e #erformed in any commercial ore
testing la$oratory that has the re7(ired e7(i#ment" 5n this case these tests &ere done at Ha<en
/esearch"
-he SP5 test is done on ) kg sam#les of ore cr(shed to ,++ B #assing +"3* inches in a ,)8inch
diameter Starkey SAG mill" -he time re7(ired to grind the sam#le to A+ B #assing ,+8mesh
=,3++ microns> is the SP5 al(e in min(tes" -he s#ecific energy is calc(lated from e7(ations
deried from commercial $enchmark testing" -hese energy e7(ations re7(ire in#(t of the SP5
min(tes from the test and the desired SAG #rod(ct si<e e2#ressed as -
A+
&here -ransfer Si<e
-
A+
refers to the SAG #rod(ct si<e in microns transferred to the $all mill circ(it"
-he design #roced(re chosen $y Day (sed the SP5 and Bond Ball Mill 6ork 5nde2 al(es to
select the re7(ired s#ecific energy for $oth the SAG mill and the $all mill" -he other tests
&ere (sed for com#arison and to confirm the chosen res(lt" -hen, since (sed e7(i#ment &as
aaila$le in client inentory, Day chose those mills that most closely matched the re7(ired
d(ty"
PRODUCTION OBJECTIVES
-he goals for the ne& grinding circ(it &ere clear and are s(mmari<ed $elo&" -he ,,3*+ t@d
ca#acity &as to $e the minim(m &hen treating hard ore &ith no #e$$le cr(sher"
Summary of Productio O!"#cti$#%

t&d A$ai'a!i'ity t&( SAG F##d Tra%f#r Product
Si)# F
*+
Si)# T
*+
Si)# P
*+

,,3*+ 9+ B A,"+ ,*+ mm ,,)++ *:

SA,P-E SE-ECTION AND GRINDING TEST RESU-TS
Sam#le selection has al&ays $een the key to designing a s(ccessf(l mineral #rocessing #lant"
A good deal of effort &as taken to ens(re the selection of meaningf(l sam#les" -hree
se#arate cam#aigns &ere carried o(t to inestigate the grinding characteristics of K($aka ore
=and the cyanide leach for #recio(s metals recoery>"
-he first #rogram incl(ded three sam#les taken d(ring the A#ril ,99: Kil$orn isit" -&o
sam#les &ere from (ndergro(nd adits &hile the third and largest sam#le &as taken from the
o#en #it" A com#osite &as made to re#resent these : sam#les as !om#osite C," -he second
#rogram incl(ded a single com#osite sam#le =C)> taken d(ring the A(g(st ,99: Kil$orn isit"
-he third lot of 1 sam#les &as taken in ,99* as #art of Day;s design confirmation &ork to
meas(re ore hardness aria$ility (sing SAG Po&er 5nde2 testing" All 1 of these sam#les &ere
3
tested indiid(ally $y Minnoe2 to determine the SP5 al(es" 0ie of these sam#les &ere
from the o#en #it and &ere later com$ined as com#osite C,, &hile the si2th &as an
(ndergro(nd com#osite sam#le C)" -hese t&o com#osite sam#les &ere then tested $y
MacPherson !ons(ltants to determine the A(togeno(s 6ork 5nde2"
-he com#lete list of sam#les taken and made8(# as com#osites is gien $elo& in -a$le ,"
Ta!'# . / -i%t of Sam0'#% T#%t#d
No1 Id#tificatio ad D#%cri0tio

, Dndergro(nd
) Dndergro(nd
: %#en Pit
4E 9: !om#osite C,
* 9: !om#osite C)
1EE 9* %#en Pit !om#osite C,
3 %#en Pit
A %#en Pit
9 %#en Pit
,+ %#en Pit
,, %#en Pit
,) 9* DG Sam#le JF3:4
'otesG E Denotes a com#osite sam#le made from sam#les ,, ) and : in this list"
EE Denotes a com#osite sam#le made from sam#les 3 to ,, incl(sie"
/es(lts of all the grinding tests done on these sam#les are #resented $elo& in -a$le )"
Ta!'# 2 / Gridi3 T#%t R#%u't%
No1 Bod Bod B, 4i ,acP(#r%o SPI ,io$#5 SAG
of R, 4i 2++ .++ Corr#ct#d ,iut#% S0#c1 E#r3y
Sam0'# .6 m#%( m#%( m#%( A4i to T
*+
7.2++
84(&t 84(&t 84(&t 84(&t Ca'c1 84(&t


, ,3", ,*", 88 88 88 88
) ,4"* ,:"A 88 88 88 88
: ,A") ,*"* 88 88 88 88
4 ,A"+ ,*"+ 88 ,3"4 88 88
* ,3", ,*"* 88 )+"* 88 88
1 ,1") ,3"1 ,4"A ,4"9 88 88
3 88 88 88 88 *A 3"*
A 88 88 88 88 ,,* ,)"9
9 88 88 88 88 ,*) ,1"4
,+ 88 88 88 88 ,)+ ,:"4
,, 88 88 88 88 ,)+ ,:"4
,) ,3"+ ,3"A ,1") ,*"3 9) ,+"3
Average 16.9 15.8 15.5 17.1 110 12.4
Median 17.2 15.5 15.5 16.6 118 13.1
4
SP5 min(tes in -a$le ) &ere conerted to s#ecific SAG energy $y calc(lation, (sing the
e7(ation in the Minnoe2 SP5 /e#ort for K($aka" -he design team .(dged these al(es to $e
conseratie $eca(se SP5 $enchmark cali$ration $eyond 1+ min(tes had not $een com#leted"
=S($se7(ent &ork $y Minnoe2 has confirmed this to $e the case>" -he res(lts gien in
-a$le ) &ere e2tra#olated $y e2tending the SP5 range of the e7(ation to incl(de ,*) min(tes,
the hardest sam#le tested"
Gra#h , #lots SAG Mill S#ecific Energy Haria$ility Hs Distri$(tion B of %re /esere
-onnes, and is taken from data in -a$le )" Each sam#le &as assigned e7(al &eight
re#resentation &ith res#ect to the tonnes of minea$le ore in the reseres, to a##ro2imate the
distri$(tion B"
Graph 1 - Kubaka, SAG kWh/t Variability Vs Dist. % of Ore Toes
0
10
20
30
40
50
60
70
80
90
100
0 2 4 6 8 10 12 14 16 18
Spe!ifi! SAG "er#y to Gri$ to T%& 1'&& (i!ros, kWh/t
)
u
(
.

D
i
s
t
.

%

o
f

O
r
e

T
o

e
s
-he al(e selected for SAG gross s#ecific energy of ,:"A K&h@t, $ased on the data aaila$le,
a##ro2imately re#resented the to# 7(artile of hardness aria$ility &hen grinding from 0
A+
,*+
mm to -
A+
,)++ microns" 5t &as also o$sered from the data that the oerall aria$ility in
s#ecific SAG energy to grind K($aka ore from 0
A+
,*+ mm to -
A+
,)++ microns, &o(ld range
from 3 to a##ro2imately ,1 k6h@t for the hardest ore =$ased on the original e7(ation>"
More acc(rate energy estimates are no& aaila$le for hard ores" -he ma2im(m energy, for
the hardest SP5 res(lt, &o(ld no& $e slightly less than the design al(e chosen" 5n any case,
the difference &o(ld not hae $een eno(gh to change the recommended SAG mill #o&er or
si<e" Since the intention &as to design for the hardest ore tested, it is concl(ded that the
design goal &as achieed $y selecting the gross s#ecific energy al(e of ,:"A k6h@t for the
K($aka SAG mill"
5
DESIGN CRITERIA
-he a$oe res(lts re#resent the $asic ore hardness meas(rements that &ere made" Bond
6ork 5ndices =BM 6i> and the MacPherson A(togeno(s 6ork 5nde2 =A6i> &ere (sed to
calc(late s#ecific energy re7(irements to accom#lish the desired si<e red(ctions" -hese
al(es for s#ecific energy =6> in k6h@t are an estimate of the #inion #o&er re7(ired to grind
the ore and e2cl(de electrical and mechanical losses in the motor and drie train" S(ch losses
can ary from ) to ,+ B de#ending on the ty#e of drie and motor" -hat in t(rn can im#act
heaily on the oerall electrical #o&er factor for the #lant" Gross energy re7(irements
calc(lated from &ork inde2 meas(rements, &ere estimated $y MacPherson !ons(ltants and
A" Sto.sic, an inde#endent Mineral Engineering !ons(ltant, (sing a com$ined drie loss in
the order of A B, a relatiely safe and conseratie n(m$er"
As re#orted in the SAG 91 Proceedings, the SAG mill energy re7(irements deried from SP5
testing are in a significantly different form in that they are $ased on gross SAG mill #o&er
meas(red at the meter, and therefore incl(de the drie train" -his is #ractical $eca(se the
ma.ority of large mill dries (se a synchrono(s motor=s> direct co(#led to the #inion=s>" 5t is
estimated that the electrical@mechanical efficiency loss for this ty#e of drie is in the order of
1 B" -his factor sho(ld $e ad.(sted if dries &ith different efficiencies are (sed" -he initial
SP5 cali$ration &ork, as #resented at SAG 91, &as (sed for the K($aka #ro.ect"
SAG ,i'' D#%i3
-here are many &ays c(rrently (sed to design a SAG grinding circ(it" -echni7(es ary from
continent to continent and from designer to designer" 5t &as Day;s intention not to eal(ate
these #roced(res $(t sim#ly to create the $est design in the conte2t of the time re7(ired to do
$ack8(# testing and to minimi<e the cost of s(ch testing" Gien the remote location of the
#ro.ect site, a f(ll scale #ilot test &as not an o#tion"
-he SAG Po&er 5nde2 -est #rogram offered the $est com$ination of timing, 7(ality and
#rice" /es(lts &ere e2#ected to $e conseratie $eca(se initial SP5 cali$ration &ork had .(st
$een com#leted and the res(lts &ere kno&n to $e alid (# to SP5 al(es of 1+ min(tes" -here
&ere also strong indications that the emerging transfer si<e corrected e7(ation &o(ld gie a
realistic order of magnit(de estimate of the energy to grind harder ores to SAG #rod(ct si<es
finer than ,+ mesh" -his s(ited K($aka $eca(se finer transfer si<es &ere $eing considered"
-he attractie feat(re of the SP5 test &as that it is $ased on the meas(rement of time re7(ired
to red(ce the test sam#le to A+ B #assing ,+ mesh and (ses $enchmark cali$ration e7(ations
to estimate the energy re7(ired for grinding to ,+ mesh and finer si<es" -he definition of
energy to achiee a s#ecific si<e is a f(ndamental conce#t introd(ced $y Bond for $all mill
grinding and has $een integrated into the SAG Po&er 5nde2 for semi8a(togeno(s grinding"
A s(mmary of the SAG mill s#ecific energy recommendations deried from the grinding
test&ork, is #resented $elo& in -a$le :" Design inter#retations for the SAG mill, &ere
offered $y MacPherson !ons(ltants, A" Sto.sic, and Day;s design team and are also incl(ded
in -a$le :"
6
Ta!'# 9 / SAG ,i'' S0#cific E#r3y R#comm#datio%
Co%u'tat Corr#ct#d SAG ,i'' Piio Po:#r Gro%% T
*+
A4i N#t E#r3y 84 HP HP
84(&t 84(&t

MacPherson ,99: )+"* ,,",3 9+* ,),4 ,:,9E :++
MacPherson ,99* ,A"A ,+":1 A:9 ,,)* ,)):E :++
Sto.sic ,)"A ,+:3 ,:9+ ,*++E :++
Day from Minnoe2 SP5 ,:"AEE ,499 ,)++
Fine SAG Grind Option
Day from SP5 & Bond I ,3"AEE ,9:: :++

'otes -a$le :G E /ecommended making allo&ance in the layo(t to add a #e$$le
cr(sher
EE Ma2im(m gross s#ecific SAG mill energy &hen meas(red at the meter
-he a$oe data clearly sho&s the different choices that &ere offered in deciding &hat #o&er
to select for the K($aka SAG mill and in #redicting the res(lting transfer si<e that
corres#onded &ith the #o&er selection" -he ariation can $e e2#lained $y noting that Day
(sed #o&er for hardest ores as the design $asis &hile the other methods (sed aerage #o&er"
-o define the energy difference $et&een ,)++ and :++ micron #rod(cts, calc(lation of the
s#ecific energy needed in a grinding mill to grind from ,)++ microns to :++ microns (sing a
Bond BM 6i of ,*"* k6h@t, sho&s an energy re7(irement of a##ro2imately 4 k6h@t" 5t &as
therefore decided to (se the design transfer si<e -
A+
of ,)++ microns and to incl(de this
re7(ired #o&er in the $all mill design"
!om#aring the alternaties, Day;s design &as $ased on SAG grinding alone &ith no #e$$le
cr(sher and a transfer si<e -
A+
in the order of ,)++ microns" 5n this regard it &as Day;s
o#inion that a transfer si<e of :++ microns co(ld $e achieed $(t oer 4++ HP of e2tra SAG
#o&er and a finer screen =&ith I , mm o#enings> &o(ld hae $een needed"
A s(mmary of the SAG Mill Design !riteria recommended $y Day is gien in -a$le 4"
Ta!'# 6 / Summary of SAG ,i'' D#%i3 Crit#ria
It#m Va'u#

0eed Si<e, 0
A+
,*+ mm
-ransfer Si<e, -
A+
,)++ microns
!a#acity A,"+ t@h of hardest ore
Aaila$ility 9+ B
Aerage -hro(gh#(t ,3*+ t@d
S#ecific Energy ,:"A k6h@t Gross =Direct from SP5 testing>
Motor Po&er ,,,9 k6 or ,*++ HP
Serice 0actor S(fficient to o#erate at ,*++ HP =Minim(m ,"+*>
7
Ba'' ,i'' D#%i3
-he selection of $all mill design criteria &as m(ch more straight8for&ard than for the SAG
mill" Bond &ork inde2 testing (sing a )++ mesh closing screen &as done on 3 sam#les as
listed a$oe" -he median hardness for these sam#les &as ,*"* k6h@t and that is the al(e
chosen $y Day for $all mill design" -he ario(s design inter#retations for the $all mill are
gien in -a$le * $elo&"
Ta!'# ; / Ba'' ,i'' S0#cific E#r3y R#comm#datio% U%i3 Bod
Co%u'tat B, Ba'' ,i'' Piio Po:#r Gro%% T
*+
P
*+
4i N#t E#r3y 84 HP HP
84(&t 84(&t

MacPherson ,99: ,*"* ,)"+: 934 ,:+1 ,4)+ :++ *:
MacPherson ,99* ,1"1 ,:"): ,+3) ,4:3 ,*1) :++ *:
Sto.sic ,1"1 ,:"9+ ,,)1 ,*+9 ,1,1 :++ *:
Day ,*"* ,*"91E ,)9: ,3:: ,A:1 ,,)++ *:
'oteG E 5ncl(des 4 k6h@t of energy re7(ired to accommodate the coarse $all mill feed
-he Day s#ecific energy calc(lations incl(ded Bond correction factors for the #rod(ct $eing
finer than 3+ microns and for the mill diameter $eing larger than A ft" =A ,:"* ft" diameter $all
mill &as (ltimately chosen>"
A s(mmary of the K($aka Ball Mill Design !riteria recommended $y Day is gien $elo& as
-a$le 1"
Ta!'# < / Ba'' ,i'' D#%i3 Crit#ria
It#m Va'u#

0eed Si<e, 0A+ ,)++ microns
Prod(ct Si<e, PA+ *: microns
!a#acity A,"+ t@h of hardest ore
Aaila$ility 9+ B
Aerage -hro(gh#(t ,,3*+ t@d
S#ecific Energy ,*"91 k6h@t 'et =!alc(lated from Bond>"
,1"9) k6h@t Gross
Motor Po&er ,:19 k6 or ,A:1 HP
Serice 0actor S(fficient to o#erate at ,A:1 HP dra&
8
Summary +f T(# Gridi3 Circuit D#%i3
-he o$.ectie for the grinding circ(it design &as to achiee A, tonnes #er ho(r thro(gh#(t
&hen milling the hardest ores in the mine" -he si2 sam#les chosen for SP5 testing &ere not
eno(gh to say &ith confidence that the hardest ores had $een sam#led" Ho&eer, it &as noted
that the original sam#ling done in ,99: sho&ed that o#en #it ore &as harder than the
(ndergro(nd sam#le" By inference therefore one might concl(de that it &as essential to
#roide #o&er to grind the hard ore initially $eca(se if the SAG mill &as (nder si<ed and
(nder #o&ered, a cr(sher co(ld hae $een added $(t not in time to treat the hardest ores"
-his co(ld hae res(lted in a significant red(ction in cash flo& early in the #ro.ect;s life"
6hen a SAG grinding circ(it fails to meet thro(gh#(t #redictions, (ndetected ore hardness
ariance is (s(ally inoled" -he design team therefore decided to o$tain SP5 test data on
hardness ariance and to (se the res(lting design $eca(se it had the greatest chance for
s(ccess $y #roiding eno(gh #o&er on the SAG mill to grind the hardest ores" 5n retros#ect,
the (se of SP5 technology &as an e2cellent choice een tho(gh hard ore cali$rations had not
$een finished at Minnoe2" By e2tra#olation $eyond the #roen SP5 cali$ration range and $y
e2ercising good .(dgment in (sing the res(lting data, Day;s design team &as a$le to
correctly #redict the ma2im(m s#ecific energy that the SAG mill &o(ld re7(ire"
-he oerall grinding s#ecific energy re7(irements are s(mmari<ed in -a$le 3" -he data is
taken from -a$les : and * a$oe"
Ta!'# = / Tota' Gridi3 Circuit S0#cific E#r3y
Co%u'tat N#t E#r3y 84(&t Gro%% Po:#r> HP T
*+
SAG B, Tota' SAG B, Tota'

MacPherson ,99: ,,") ,)"+ ):") ,:,9 ,4)+ )3:9 :++
MacPherson ,99* ,+"4 ,:") ):"1 ,)): ,*1) )3A* :++
Sto.sic ,)"A ,:"9 )1"3 ,*++ ,1,1 :,,1 :++
Da$y D#%i3 .91+? .<1+ 2@1+ .6@@ .*9< 999; .2++
Day =alternate> I,1"AE 88 )9"+ ,9:: ,4+) :::* :++
E net J gross@,"+1
MacPherson;s recommended total #o&er &as )3A* HP" Sto.sic recommended a##ro2imately
:,++ HP &hile Day recommended :::* HP for the com$ined SAG mill and $all mill #o&er"
Sto.sic;s &ork confirmed that in his o#inion the mills chosen $y Day &o(ld do the .o$ as
s(mmari<ed in -a$le 3 a$oe" He also o$sered that the $all mill &o(ld only dra& a$o(t
,1++ HP at a mill s#eed of 3* B of critical and that this &o(ld $e s(fficient to achiee the
desired grind &itho(t tr(nnion modifications, as long as the SAG mill #rod(ct =transferred
material> &as A+ B #assing :++ microns"
Day;s assessment of re7(ired SAG #o&er to achiee design tonnage &as higher than Sto.sic
and MacPherson for the same transfer si<e" -his &as #artly the res(lt of Day (sing
ma2im(m hardness &hile the latter t&o (sed aerage hardness, &here these meas(rements
relate to indiid(al sam#les tested in one case, Hs com#osites in the others" -he remaining
9
difference &as d(e to the conseratie energy assessment in the Minnoe2 e7(ations that
re7(ired additional cali$ration &ork at the hardness leels that occ(r in the K($aka de#osit"
EAUIP,ENT SE-ECTION
5n order to kee# ca#ital costs to a minim(m, the client &anted the design team to select (sed
grinding mills since there &as a reasona$le selection of s(ch mills aaila$le &ithin their o&n
s#here of infl(ence" -he mills chosen &ere &ell s(ited to the d(ty as sho&n in ta$le A $elo&"
Ta!'# * / Gridi3 ,i''% S#'#ct#d From C'i#t I$#tory
,i'' Dia1 - EG- ,otor S0##d St##' E%t1 Gro%%
Ft1 Ft1 Ft1 HP B Crit1 -oad B HP Dra:

SAG Mill )+ 9 3"* ,*++ 3, ,) ,41+
Ball Mill ,:"* ,A ,3"* ,9*+ 11 :4 ,44+
c@& )38tooth #inion instead of )4 K 3* :4 ,34+
c@& smaller diameter tr(nnion K 3* :9 ,A:*
-he SAG mill selected &as ery close to the d(ty s#ecified in the design criteria" -he shell
and motor si<e &ere &ell matched so there &as no need to ad.(st the drie com#onents or to
change any of the ma.or feat(res of the mill"
-he $all mill selected &as (n(s(al in that it had a large diameter tr(nnion and a motor that
&as larger than the ca#acity of the shell to dra& #o&er" 5t &as in fact a mill that had
originally $een designed for rod mill d(ty" -he mill s#eed &as therefore increased from 11 B
of critical s#eed to 3* B, $y re#lacing the )48tooth #inion &ith a )38tooth one" Altho(gh the
large diameter tr(nnion &ill not allo& the mill to dra& design #o&er it &as felt that since the
motor #o&er and the shell;s a$ility to dra& re7(ired #o&er &ith a smaller tr(nnion &ere
com#ati$le &ith the design criteria, it &o(ld $e acce#ta$le to start (# &itho(t modifying the
discharge tr(nnion arrangement"
P-ANT RESU-TS
-he follo&ing data in -a$le 9 &as s($mitted $y Kinross staff at the K($aka site and
re#resents a 18month aerage #lant res(lt for the #eriod March to A(g(st )+++ incl(sie"
Plant data is gien in the middle col(mn" %ther data deried or calc(lated from the #lant data
has $een com#ared to the original design criteria and hardness meas(rements in -a$le ,+"
-he data in ta$les 9 and ,+ demonstrates that the K($aka grinding circ(it has e2ceeded
design #rod(ction oer the last 1 months $y a$o(t )3B $ased on aerage ho(rly #rod(ction"
-he K($aka mill has also met or e2ceeded design tonnage since start (# in ,993" 5t has not
$een necessary to add an in8circ(it #e$$le cr(sher $eca(se the hardest ores hae $een
#rocessed &ith no #ro$lem"
-he difference $et&een the median indicated SAG s#ecific energy of ,:", k6h@t, and the
ma2im(m of ,1": k6h@t, re#resents a difference of a##ro2imately )4 B in the SAG mill
energy or ,+ B oerall" -his difference &o(ld $e smaller (sing c(rrent SP5 cali$ration data"
10
%ther factors contri$(ting to the high #rod(ction rates achieed are disc(ssed $elo&"
Ta!'# @ / P'at Data
It#m Data R#mar8%
R#0ort#d

-onnes milled 4:A,):*
%#erating time ho(rs 4,)4*"1 ,A4 days
%#erating -ime Percent 91",
Aerage SAG 0eed t@h ,+:")
-onnes milled@day ):A,
Aerage SAG HP ,4A+
Aerage BM HP ,*,*
SAG 0eed 0
A+
, mm ,:+
SAG Discharge -
A+
, microns ,+++
!irc(it Prod(ct P
A+
, microns 1*
SAG S#eed, r#m ,)"* 3, B !ritical
Ball Mill S#eed, r#m ,1"+ 3* B !ritical
SAG Steel ?oading B Hol(me ,) 8 ,4
SAG -otal ?oading B Hol(me )* 8 )3
BM Ball ?oading B Hol(me :) 8 :4
SAG Discharge B Solids 34 8 31
BM Discharge B Solids 13 8 1A
Cy!one"
'o" of ,* 5nch Diam" !yclones *
!yclone 0eed, B Solids 43 8 4A
!yclone %@0, B Solids )* 8 )1
!yclone D@0, B Solids 13 8 1A
Stee! Con"#$ption
*L Balls, kg@t +"9
)L Balls, kg@t ,")
Ta!'# .+ / Data Com0ari%o> Actua' P'at V% D#%i3
It#m Actua' Ra3# D#%i3 Actua'&D#%i3
R#0ort#d B

Aerage SAG 0eed, t@h ,+:") 94 to ,+A t@h A,"+ ,)3
-onnes @day ):A, ,3*+ ,:1
%#erating -ime, B 91", 9+ ,+3
Aerage SAG Po&er, k6 ,,+4 ,,,9 99
Gross SAG S#ecific Energy, k6h@t ,+"3 ,+") to ,,"3 ,:"A 3A
Aerage BM Po&er, k6 ,,:+ ,A:* 1)
Gross BM S#ecific Energy, k6h@t ,,"+ ,+"* to ,)"+ ,1"9 1*
SAG 0eed 0
A+
, mm ,:+ ,*+ A3
SAG Discharge -
A+
, microns ,+++ ,)++ A:
!irc(it Prod(ct P
A+
, microns 1* *: ,):
Bond 6i, !alc(lated, k6h@t ,)"+ =%#erating, 6io> ,*"* 33

11
-he final #lant grind has $een coarser than originally #lanned &ith the #rod(ct P
A+
$eing 1*
instead of *: microns" -his is tho(ght to $e #artly d(e to the large diameter $all mill
discharge tr(nnion that makes it im#ractical to carry a large $all load in the mill" -he res(lt
has $een a red(ction in $all mill #o&er cons(m#tion &hen com#ared to the original design"
Another contri$(tor to lo& #o&er dra& in the $all mill is light density in the mill discharge,
ca(sed $y a density of 13 B solids in the cyclone (nderflo&" Based on Bond e7(ations the
coarse grind is estimated to red(ce energy $y a$o(t ,* B in the $all mill or A B oerall"
Plant $all mill s#ecific energy (sed is :* B less than e2#ected" -his is e7(ialent to a$o(t ,9
B of the oerall design grinding energy" 5t is &orth noting that Bond BM 6i tests at ,++
mesh closing screen &ere done on the t&o ,99* com#osite sam#les" !om#aring these res(lts
&ith )++ mesh Bond res(lts sho&ed that the coarser grind gae a lo&er Bond BM 6i $y )")
k6h@t" -he reason &as attri$(ted to mica in the ore that needs more energy to grind" Based
on #lant res(lts it a##ears that li$eration occ(rs at a coarser grind than design"
-he SAG mill feed &as finer than originally #lanned" -he 0
A+
&as ,:+ mm com#ared to the
design of ,*+ mm" -he difference in re7(ired energy =in the order of * B of SAG mill gross
energy> &as offset $y a slightly finer SAG #rod(ct of ,+++ microns, com#ared to the design
al(e of ,)++ microns" At the same time the SAG mill #o&er cons(m#tion &as ery close to
design" 5t is also a##arent that &hen ma2im(m kno&n hardness ore is enco(ntered, the SAG
mill &ill grind it at design thro(gh#(t"
Any remaining differences $et&een #lant res(lts and design, relate to the SP5 cali$ration (sed
and the deli$erate #roision to install eno(gh SAG mill #o&er to grind the hardest ore"
-he engineering design at K($aka incl(ded a &ay to coneniently sam#le the SAG mill
#rod(ct" -his feat(re allo&ed the #lant transfer si<e to $e easily meas(red" 5n this &ay the
SAG mill o#eration co(ld $e monitored, analysed and controlled to gie acce#ta$le res(lts"
CONC-USIONS AND RECO,,ENDATIONS
-he K($aka grinding circ(it design (sing SP5 and Bond testing &as s(ccessf(l" -his
method is recommended for f(t(re #ro.ects"
-he high thro(gh#(t achieed com#ared to the design, relates to fo(r main things" 5n
order of increasing magnit(de these areG slightly finer feed, minor oerestimation of the
SAG #o&er re7(ired d(e to incom#lete hard ore SP5 cali$ration, coarser final #rod(ct,
and designing for ma2im(m SAG hardness, not aerage"
Si2 SP5 tests &ere done on sam#les from the mine" -he s(ccess of the design directly
relates to the fact that these sam#les a##eared to re#resent some of the hardest ores in the
K($aka de#osit" -his is im#ortant &hen only a fe& sam#les are aaila$le and the f(ll
distri$(tion of hardness ariance is not f(lly defined"
-he definition of SAG s#ecific energy re7(irements to grind the hardest ore allo&ed the
circ(it to $e designed &itho(t an in8circ(it cr(sher" 5t is concl(ded that if the circ(it had
$een designed for aerage or median SAG #o&er instead of ma2im(m, that an in8circ(it
cr(sher may hae $een needed to achiee design thro(gh#(t on hard ores"
Bond Ball Mill 6ork 5nde2 testing at )++8mesh gae conseratie res(lts &hen com#ared
to the #lant #erformance at a similar grind" More detailed st(dy of fines #rod(ction in the
SAG mill #rod(ct &o(ld $e re7(ired to e2#lain this o$seration"
12
ACKNO4-EDGE,ENTS
-he a(thors &ish to thank Kinross Gold !or#oration and Kaerner Metals E & ! for
#ermission to #($lish this #a#er" -he K($aka #lant is the first in the &orld to $e designed
(sing SP5 data for the SAG mill design and the foresight of George Mitchell, the client;s
/esident Metall(rgical Manager, in a(thori<ing the SP5 tests is here$y ackno&ledged"
REFERENCES
A##lication of the Minnoe2 SAG Po&er 5nde2 at 0ie !anadian SAG Plants, $y John
Starkey and Glenn Do$$y" 5nternational A(togeno(s and Semia(togeno(s Grinding
-echnology ,991, Hol(me ,, Page :4*"
Getting More 0rom Drill !ore, Preliminary SAG Design, $y John Starkey, P" Eng"
/andol Gold 0or(m Monterey 93, !onference Proceedings, Page 13"
13