Moly-Cop Tools, Version 3.

0
About the Media Charge_Level Spreadsheet ...

Scope :

The Media Charge_Level spreadsheet was designed to help in the calculation of the Fractional Apparent
Charge Level in any given mill, on the basis of the mill geometry and direct measurements or observations of
such mill interior.

Theoretical Framework :

There at least two possible ways to procede with the calculations in reference :

Method 1 : Free Height.

Consists of taking direct measurements of the Average Free Height (h) inside the mill (the distance from the
charge level up to the highest point in the mill shell). Replicate measurements are strongly recommended to
account for level variations along and across the mill.

If f represents the center angle created by the two radius pointing at the opposing lateral extremes of the top
charge surface, then from the geometry of the mill, the following relationships apply :

f = (360/p) arcsin [ 2 (h/D) (D/h - 1)0.5 ] , in degrees

J = (f/360) - (4/p) (h/D) (h/D - 1/2) (D/h -1)0.5

where D represents the effective internal mill diameter (inside liners) and J represents the fractional apparent
charge level, including all interstitial voids. D and h must be expressed in the same measuring units.

Method 2 : Cord Length.

Consists of measuring the cord length S across the exposed charge surface, to then compute :

h = [ D + ( D2 - S2)0.5 ] /2

Then, J may be calculated as above.

Method 3 : Number of Exposed Lifters.

Consists of counting the number of exposed lifter bars (NL) (i. e. not hidden by the charge) and compare this value
with the total number of lifter bars (NTOT) of the particular liner design in reference, to compute :

f = 360 [ 1 - NL / NTOT ] , in degrees

h = (D/2) [ 1 + ( 1 - sin2(f/2) )0.5 ]

Then, J may be calculated as above.

Moly-Cop Tools / 369968665.xlsx 10/27/2017 / 21:42:59

Moly-Cop Tools / 369968665.xlsx 10/27/2017 / 21:42:59
 Moly-Cop Tools, Version 3.0
About the Media Charge_Level Spreadsheet ...

Data Input :

All data required by the model must be defined in each corresponding unprotected white background cell of the
here attached Method 1 or Method 2 worksheets. Gray background cells contain the results of the
corresponding formulas there defined and are protected to avoid any accidental editing.

New Moly-Cop Tools users are invited to explore the brief comments inserted in each relevant cell, rendering the
whole utilization of the worksheets sel-explanatory.

Moly-Cop Tools / 369968665.xlsx 10/27/2017 / 21:42:59

Moly-Cop Tools / 369968665.xlsx 10/27/2017 / 21:42:59
 Moly-Cop Tools TM
(Version 3.0)
DETERMINATION OF CHARGE LEVEL IN A MILL
by Measuring Free Height Above the Charge

Remarks : Ball Mill # 4

Effective Mill Diameter, 18.50 ft 60

% Filling
5.64 m
Effective Mill Length 24.00 ft 50
7.32 m
40
Average Measurements of 30
Free Height (h) : 10.32 ft
3.15 m 20
10
0
Angle f, degrees 166.66 0.50 0.60 0.70 0.80 0.90 1.00
Charge Level, % 42.62 h/D Ratio

Moly-Cop Tools / 369968665.xlsx 10/27/2017 / 21:42:59

 Moly-Cop Tools TM
(Version 3.0)
DETERMINATION OF CHARGE LEVEL IN A MILL
by Measuring Cord Length across the Charge

Remarks : Ball Mill # 4

Effective Mill Diameter, 18.50 ft 60

% Filling
5.64 m
Effective Mill Length 24.00 ft 50
7.32 m
40
Average Measurements of 30
Cords (S) : 18.04 ft
5.50 m 20
10
Equivalent Free Height 11.29 ft
0
Angle f, degrees 154.52 0.50 0.60 0.70 0.80 0.90 1.00
Charge Level, % 36.08 h/D Ratio

Moly-Cop Tools / 369968665.xlsx 10/27/2017 / 21:43:00

 Moly-Cop Tools TM
(Version 3.0)
DETERMINATION OF CHARGE LEVEL IN A MILL
by Counting the Exposed Lifter Bars

Remarks : SAG Mill # 1

Eff. Mill Diameter 35.50 60

% Filling
Total # Lifter Rows 72.00
Lifter Rows Exposed 44.00 50
Fraction Exposed 0.61
40
30
20
10
Angle f, degrees 140.00
Height (h) Above 23.82 0
Charge Level, % 28.66 0.50 0.60 0.70 0.80 0.90 1.00
h/D Ratio

Moly-Cop Tools / 369968665.xlsx 10/27/2017 / 21:43:00