The Moly-Cop NG -  A new generation in Grinding Media

After considerable in-house and in-field testing Moly-Cop has developed a superior, high performance SAG ball - “Moly-Cop NG”.   The ball is manufactured using an innovative, proprietary manufacturing process that has resulted in a tougher SAG Ball, with higher impact and spalling resistance.

Trials to date have resulted in a significantly lower ball consumption range for medium to high impact milling environments

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Milling Evolution

Why the Need to Develop a new SAG Ball?

Newer SAG mills are becoming larger and many mills are being operated more aggressively to maximize throughput.  Traditional SAG grinding media, when used in these environments can experience higher levels of breakage and spalling.  Operators of high-impact SAG mills require tougher SAG balls.

The volumetric ball/charge ratio (impact severity) in the mill dramatically affects ball consumption rates in SAG milling.  The potential of the new NG balls to reduce total media consumption may range from 10-15% in lower impact mill environments up to 20-25% in higher impact mill environments, by virtually eliminating the breakage and spalling components of total ball consumption.

Moly-Cop Has Conducted an Extensive R&D Effort

Over a three year period, Moly-Cop undertook a comprehensive effort to develop a SAG ball with greater wear performance and toughness for High-Impact SAG mills.  Specialised manufacturing processes and micro-alloy combinations have been developed to produce the New Generation SAG ball.

Extensive internal testing and multiple successful field tests have confirmed unprecedented levels of product toughness which has resulted in high impact resistance and lower spalling rates.

Investment in New Manufacturing Capabilities

Selected Moly-Cop facilities in the Americas underwent considerable investment in order to install the new Moly-Cop NG manufacturing technology.

The Moly-Cop NG ball is now available in the Americas.

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Case Study A

The Customer
  • Large copper mining operation in northern Chile
  • A single 36’ x 19’ SAG mill, recharging 5.5” balls
The Trial

The site has a single SAG milling line. The Reference Period
(Pre-Purge) was undertaken between November 2013 and
May 11, 2014.  The Evaluation Period (Post-Purge) was
defined between July 15, 2014 and November, 15 2014.
During the latter period, the Moly-Cop NG product was
charged to the mill.

The Results

The Moly-Cop NG product observed an estimated
reduction in ball consumption of 26.1% when compared
to the consumption of the competitor’s product during the
pre-purge period.

Click here to read the full case study

Case Study C

The Customer

Large copper mining operation in northern Chile
Two parallel 36’ x 17’ SAG mills, recharging 5.5” balls

The Trial

The fact that the selected site has two side by side SAG mills, provided a perfect opportunity to run a comparative trial.  The trial commenced in March 2014 in the SAG 2 line, while the competitor was maintained in the SAG 1 line.  

The Results

The results of the trial have been very conclusive, observing an estimated ball consumption reduction of 18.6%, when compared to the consumption of the competitor’s product in SAG 1.  It is worth highlighting that SAG 2 has historically demonstrated higher ball consumption rates, due to ore stockpile segregation.  Careful observation of the ball cores (scats) being rejected by the mill proved there was almost no evidence of ball breakage.  The usual ball ‘clinking’ typically heard when inspecting the mill charge after a grind-out was virtually eliminated.

Click here to read the full case study

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