common operating issues in comminution circuits by https://padlet.com/metcelerate/Common_issues_comminution Explore the list of common comminution problems provided and choose one or more of these issues that you would like to focus our tutorial discussions on. You can include any more detailed description of the problem, its causes, potential solutions, or its impact on the process. If you know of any comminution problems that aren't listed, feel free to add them to the discussion! Double click on the Padlet screen to add your comments. en-us 2024-10-03 00:03:27 UTC 2025-10-01 14:07:23 UTC hello@padlet.com common operating issues in comminution circuits: DianaDrinkwater https://padlet.com/metcelerate/Common_issues_comminution/wish/3151142714

  • Ball mill recirculating loads

  • Grind size control

  • Overgrinding/sliming

  • Plant feed variations (size, feed rate)

  • Managing variable ore blends (hardness, rheology)

  • Mill charge level control

  • Sampling difficulties

  • Liner wear

  • Estimating liner condition

  • Differences in design vs actual capacity

  • Ore texture

  • Milling competent ores

  • Tramp material in crushers

    • ]]>     2024-10-03 00:47:34 UTC https://padlet.com/metcelerate/Common_issues_comminution/wish/3151142714     Difference in design vs actual capacity https://padlet.com/metcelerate/Common_issues_comminution/wish/3612824877 issues with significant difference between design SAG circuit capacity and actual performance were discussed in a 2015 paper by Ausenco (Paul Staples) at the SAG conference.



    ]]>     2025-10-01 05:55:30 UTC https://padlet.com/metcelerate/Common_issues_comminution/wish/3612824877     Grind Size Control https://padlet.com/metcelerate/Common_issues_comminution/wish/3612830958 At PT Freeport Indonesia, a common challenge in the comminution circuit arises when tonnage increases, often leading to coarser grind size from the ball mills. This negatively impacts flotation performance, potentially reducing mineral recovery.


    To mitigate this, metallurgists typically:

    • Ensure ball charge is on target, especially under high load conditions in SAG and ball mills.

    • Monitor and maintain ball mill power draw within optimal range.

    • Verify that cyclone clusters are operating properly, with no signs of roping.

    • Adjust water addition to maintain appropriate density to flotation.

    • Confirm reliability of AMDEL readings for grind size and density control.

    ]]>     2025-10-01 06:00:17 UTC https://padlet.com/metcelerate/Common_issues_comminution/wish/3612830958     Lack of a deep understanding https://padlet.com/metcelerate/Common_issues_comminution/wish/3612833859 Since I am engaged in modeling and simulating processes, all these issues are not particularly relevant to me. The main problem lies in the lack of a deep understanding of comminution circuits.

    ]]>     2025-10-01 06:02:35 UTC https://padlet.com/metcelerate/Common_issues_comminution/wish/3612833859     Inaccurate charge estimatation in Ball Mill https://padlet.com/metcelerate/Common_issues_comminution/wish/3612833919 We used to have an issue in inaccurate charge of a ball mill. We used to calculate the estimation of the ball mill charge using last consumption based on the past inspection and based on the assumption of 1 bucket of balls is 4 tons. But unfortunately, the bucket is not exactly 4 tons and also some ore changes might change the grinding balls consumption inside the mills, therefore the ball charge estimation that we did earlier was inaccurate

    ]]>     2025-10-01 06:02:39 UTC https://padlet.com/metcelerate/Common_issues_comminution/wish/3612833919     Crusher Liner Wear https://padlet.com/metcelerate/Common_issues_comminution/wish/3613524419 We are using Cone Crusher MP1250 as our secondary crusher. Our target for mantle & bowl liner lifetime is 8 weeks, we're struggle to reach this target lifetime. Some observations and preliminary assumptions:


    - Crusher rarely runs with choke feed conditions, causing more direct impact of ore to liner - mainly due to low feed supply from mine.

    - Crusher capacity too big for current feeding capability - review equipment design

    - Foreign materials comes inside the crusher, sometimes could be rebar or other metals that passed through belt magnet / metal detector.

    - Uneven feeding, might need to modify chute position.

    - Monitor CSS (Close Side Setting) to maintain crusher product and efficiency.


    ]]>     2025-10-01 14:07:22 UTC https://padlet.com/metcelerate/Common_issues_comminution/wish/3613524419