M10,000 IsaMill™ Whyalla Field Trial
Azitec participated in a short M10,000 IsaMill™ field trial at Whyalla to assess disc performance in magnetite iron ore processing. The trial followed laboratory M4 testing and formed part of Azitec’s broader R&D program to investigate whether grinding efficiency benefits could be conserved across different mineral types. Field data showed strong alignment with laboratory IsaMill™ M4 test results, while highlighting the complexity of comparing site and laboratory data.
About this Project
Challenge
Magnetite processing requires efficient fine grinding to achieve suitable product quality and liberation. The challenge was to assess disc performance in a full-scale M10,000 IsaMill™ environment while accounting for changing site conditions, including throughput, density, feed sizing, bypass behaviour and product size variation.
Solution
Azitec and Global Met Tech reviewed site operating data, laboratory results, signature plot comparisons, shell wear observations, thermal images and disc wear inspections. The analysis considered throughput, power draw, specific grinding energy, product sizing and operating conditions to better understand trial performance.
Outcome
The field trial showed very good alignment with laboratory IsaMill™ M4 testing. Analysis indicated reduced specific grinding energy during the Azitec trial period, including a 14.3% decrease in energy requirements when using 3.5mm media compared with 5.0mm media. Increased throughput was observed during the comparison period, with no significant increase in shell wear reported. Further field work is currently on hold.
Key Metrics
- M10,000 IsaMill™ magnetite field trial
- Conducted at Whyalla, South Australia
- Strong alignment with IsaMill™ M4 laboratory testing
- 3% decrease in energy requirements identified
- Increased throughput observed
- No significant increase in shell wear reported
- Further optimisation opportunities identified
- Further field work currently on hold
Related Projects
Grinding Efficiency Across Mineral Types
Controlled IsaMill™ M4 testing showed Azitec discs delivered an average 20.8% efficiency advantage across silica, magnetite, zinc, copper and gold samples.
IsaMill™ Monitoring During Disc Upgrades
Azitec combines thermal imaging with 24/7 Oscillot vibration sensing to identify abnormal mill behaviour and support faster, more informed operational response.
M3000 IsaMill™ Efficiency Upgrade
Azitec disc technology helped improve grinding efficiency while managing disc usage and extending critical component wear life in a gold processing UFG mill.