Ore mill mill series

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Overview
FLS AG and SAG mills deliver high throughput ore grinding with impressive energy efficiency, helping you maximise mineral recovery and reduce total cost of ownership. Advanced process control systems, digital tools and specially engineered mill liners are provided to increase uptime and productivity.

Key benefits of AG and SAG mills

• Proven technology supported by lifecycle services — Semi-Autogenous Grinding (SAG) and Autogenous Grinding (AG) mills are offered with lifecycle services from installation and commissioning to process optimisation and maintenance, including smart mill liner packages, load optimisation and advanced process control.
• Range of sizes enables flexible use — Fuller-Traylor SAG/AG mills range in diameter from 4.3 m to 12.2 m and can be configured for open or closed circuit operations, with discharge options such as trommel or vibrating screens (trommel screens supplied up to 6.0 m diameter for high-throughput applications).
• Digital tools enhance performance — LoadIQ smart sensor technology combined with ECS/ProcessExpert advanced process control automates responses to mill conditions, improves ore reduction and energy efficiency, and increases operator productivity.

Our AG and SAG mills

• SAG Mill — Semi-Autogenous Grinding mills use grinding balls and the ore itself to reduce particle size. They are suitable for hard, abrasive ores (gold, copper, iron) and typically used for primary or intermediate grinding. They provide large throughput, robust performance and low power consumption per tonne.
• AG Mill — Autogenous Grinding mills use the tumbling motion of ore (rock-on-rock) to achieve grinding. AG mills are ideal for coarse grinding, featuring simpler operation, reduced wear challenges, lower maintenance costs and less downtime due to elimination of grinding media in many cases. AG and SAG mills can be configured as single-stage units operating in closed circuit to produce finer product sizes.

Design aspects

• Support Method: trunnion-supported or shell-supported.
• Drive Train: high speed with reducer, low speed direct coupled, or gearless (wrap-around motor). Geared solutions can be single or dual pinion with references up to 10,000 kW per pinion.
• Main Bearings: hydrostatic or hydrodynamic; sleeve or multi-pad (self-aligning).

Add-ons and optimisation features

• Mill liners — Armour™ mill liners to increase uptime and improve grinding efficiency.
• LoadIQ™ — smart sensor technology to optimise mill loading and increase throughput by 3–6%.
• Smart liner package — specialist lifecycle service package to extend liner life and reduce power consumption.
• ECS™/ProcessExpert — advanced process control system to optimise mill performance automatically.
• Composite and low‑carbon liner options — lighter, faster to install liners supporting safety, circularity and reduced manufacturing CO2 emissions (Armour™ low-carbon liners).

Downloads (titles only)

• Service datasheet: Gearless SAG and Ball Mills or gear pinion drive (PDF)
• Product datasheet: Upgrade your SAG mill feed chute seal (PDF)
• Product datasheet: SAG liner support and optimisation - FLS Mill Service (PDF)
• Case study: How an issue with SAG mill dischargers became a nine-year-and-counting collaboration (PDF)

Technical specifications

• Diameter range: 4.3 m to 12.2 m.
• Drive power: up to 28,000 kW (reference maximum).
• SAG mill ball charge: typically 6–15% ball charge for semi-autogenous operation.
• Discharge configurations: trommel screen or vibrating screen; trommel diameters supplied up to 6.0 m for high throughput.
• Operation modes: open circuit (feeding downstream grinding) or closed circuit (single-stage fine product generation).
• Support options: trunnion-supported or shell-supported designs.
• Drive train options: high-speed with reducer, low-speed direct coupled, gearless wrap-around motor; single or dual pinion geared solutions (up to ~10,000 kW per pinion).
• Main bearing options: hydrostatic or hydrodynamic; sleeve or multi-pad self-aligning bearings.
• Advanced control and digital add-ons: LoadIQ™ (smart sensors), ECS™/ProcessExpert (advanced process control), smart liner and liner profiling/scanning services.
• Liner options: Armour™ liners, composite mill liners, low‑carbon liner manufacturing for reduced CO2 emissions; tailored liner packages for extended life and improved efficiency.