The Modelling Of Scrubbers and AG Mills, When to Use Them

"One of the workhorses of the minerals industry is the autogenous grinding (AG) mill and its derivative the semi-autogenous (SAG) mill. These are relatively well understood, but not so Scrubbers. Scrubbers are mechanically of the same appearance/function, so what is the difference between an AG mill and a scrubber? When, or under what conditions should a scrubber be used and when should an AG mill be used? Can the processes within be mathematically modelled?In the past decades, the minerals industry has focused most of its attention on the modelling of unit processes such as cone crushers, HPGR’s, AG/SAG mills and ball mills within conventional processing circuits. Less attention has been placed on the modelling of scrubbers. This paper reviews the difference between scrubber and AG mill modelling, highlighting some of the similarities, with a view to confident comminution circuit designs.Engineering practitioners should be comfortable with these circuit designs and not shy away from considering AG mills for both small and large scale plants. AG mills can treat both harder or softer ore and scrubbers are for only softer ores. This paper differentiates scrubber and AG mill modelling in a similar way that overflow ball mills and grate discharge ball mills are analysed. Smaller scrubbers (600 kW) are suited to small scale soft ore (100-300 t/h) operations. Larger scrubbers up to 2,500 kW have the capability of very high throughput, in excess of 1,750 t/h with soft fine feed ore. AG mills are scalable up to 28 MW and are capable of treating harder ores at rates exceeding 2,000 to 4,500 t/h. Observations are that the specific energy requirements for the mill grinding duty is wide and varied. This is to a large degree the crux of the matter in sizing, as well as, differentiating, scrubbers from AG mills.INTRODUCTIONAG milling is a mature technology that has been used in minerals processing applications for more than 100 years. In the last 50 years, harder metalliferous ores have seen the introduction of steel balls to assist in the grinding/milling action. Tumbling mills used in such a configuration are called semiautogenous mills (SAG). The greater minerals industry is no newcomer to the use of fully autogenous (AG) mills. Perhaps scrubbers are. What is the difference? When should a scrubber be used versus an AG mill? How are they mathematically modelled?"