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Conference Proceedings

Mill Operators Conference Proceeding 2026

Conference Proceedings

Mill Operators Conference Proceeding 2026

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SAG milling – the benefits of bigger balls

Semi-autogenous grinding (SAG) milling circuits are almost always associated with high throughput mining operations with aggressive production targets. The main role of the SAG mill is to achieve and maintain the desired feed rate while the role of the ball milling circuit is to achieve and maintain the target product size. While there are a few industrial levers available to make it easier to maintain the desired feed rate, the simplest change is to increase the SAG mill ball top size. In the SAG milling environment, rock breakage rates can be increased by using larger grinding media. The improvement can be usually measured using the throughput rate, pebble production rate, and specific energy consumption. Larger diameter (and therefore heavier) balls will result in a greater kinetic energy per impact, meaning that they can break larger and harder rocks more effectively, thus reducing the accumulation of the critical size materials. Large balls may also cause a finer particle size distribution per impact that smaller balls on the same size rocks, leading to accelerated fine particle production. While it is true that there are fewer balls per unit volume and thus less frequent impacting events than that smaller diameter balls, it is also true that there are still an enormous number of balls tumbling within the mill. The key benefits include unlocking a wider operational range thus improve consistency and reducing ball consumption. Larger grinding media on the SAG mill could also lead to slower mill speed and/or lower ball load to maintain the fresh feed rate. There are some case studies briefly explain in the presentation that show the benefits of larger media on milling performance and media consumption. This paper provides valuable insight into optimising SAG milling performance with bigger balls; there is an extensive list of benefits with very few risks, especially on the liners.
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  • Published: 2026
  • Pages: 16
  • PDF Size: 0.812 Mb.
  • Unique ID: P-05660-G7Y5N4

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