About the Bond_Mill Sizing Spreadsheet ...

Scope :
The Bond_Mill Sizing spreadsheet was designed to determine the most appropriate mill dimensions and operating
conditions for a given grinding task (known ore properties plus desired mill throughput and feed and product sizes), based
on the traditional Bond's Law and the Hogg & Fuersteneau Power Model (see Mill Power_Ball Mills spreadsheet for
further details on such model).
Theoretical Framework :
Undoubtedly, the extensive work of Fred C. Bond ("The Third Theory of Comminution", AIME Trans.,Vol. 193, p. 484,
1952. Also in Mining Engineering, May 1952) has been widely recognized as a very significant contribution to a first
understanding of the operational response of conventional ball mills in various grinding circuits. His Third Theory or
"Law" of Comminution has become the most traditionally accepted framework for the evaluation of existing grinding
operations as well as the design of new installations :
E = 10 Wi (1/P801/2 1/F801/2)

where :
E
F80
P80
Wi

=
=
=
=

Specific Energy Consumption, kWh/ton ground.

80% passing size in the Fresh Ore Feed Stream, microns.
80% passing size in the Final Ground Product, microns.
Bond's Work Index, indicative of the hardness of the ore, kWh/ton.

The Bond's Law so allows, as a first approach, to estimate the energy demand (kWh) required to grind each ton of ore.
Such Specific Energy Consumption determines in turns the Capacity of the grinding section, by the expression :
M = P/E
where :
M
P

= Fresh Ore Throughput (not including Circulating Load), ton/hr.

= Net Mill Power Demand, kW.

Bond's Work Index may be estimated directly from operational data (whenever available) from back-calculation of the first
equation above. In such case is denoted as the Operational Work Index :
Wio = E / 10 (1/P801/2 1/F801/2)
Data Input :
All data required by the calculation routine must be defined in each corresponding unprotected Turquesa background cell
of the here attached Data File worksheet. blue background cells contain the results of the corresponding formulas there
defined and are protected to avoid any accidental editing.
In order to match the Power Demand (from Bond's Law) with the Power Availability (from Hogg & Fuersteneau's Model)
a Goal Seek algorithm must be implemented, as indicated at the bottom of the Data File worksheet.

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ermine the most appropriate mill dimensions and operating

s plus desired mill throughput and feed and product sizes), based
neau Power Model (see Mill Power_Ball Mills spreadsheet for

Third Theory of Comminution", AIME Trans.,Vol. 193, p. 484,

widely recognized as a very significant contribution to a first
al ball mills in various grinding circuits. His Third Theory or
ally accepted framework for the evaluation of existing grinding
1/F801/2)

n ground.
ed Stream, microns.
Product, microns.
ardness of the ore, kWh/ton.

te the energy demand (kWh) required to grind each ton of ore.

ns the Capacity of the grinding section, by the expression :

Circulating Load), ton/hr.

ational data (whenever available) from back-calculation of the first

onal Work Index :

1/2

1/F801/2)

ed in each corresponding unprotected Turquesa background cell

und cells contain the results of the corresponding formulas there
g.

) with the Power Availability (from Hogg & Fuersteneau's Model)

ed at the bottom of the Data File worksheet.

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Moly-Cop Tools

TM

BOND'S LAW APPLICATION

Conventional Ball Mill Sizing
Remarks

Base Case Example

GRINDING TASK :
Ore Work Index, kWh/ton (metric)
Feed Size, F80, microns
Product Size, P80, microns
Design Throughput, ton/hr

13.00
9795
150.0
800.00

Specific Energy, kWh/ton

Net Power Requirement, kW
Number of Mills for the Task
Net kW / Mill

MILL DESIGN PARAMETERS AND OPERATING CONDITIONS :

Diameter
ft
18.50

Length
ft
22.00
L/D
1.19

% Solids in the Mill

Ore Density, ton/m3
Slurry Density, ton/m3
Balls Density, ton/m3

Mill Speed
% Critical
72.00
rpm
12.82

Charge
Filling,%
38.00

72.00
2.80
1.86
7.75

Power, kW
3348
0
536
3885
10.0
4316

Balls
Overfilling
Slurry
Net Total
% Losses
Gross Total

Mill Charge Weight, tons

Ball
Slurry
Charge
Interstitial
above Balls
296.48
47.48
0.00

Apparent
Density
ton/m3
5.395

Balls
Interstitial
Filling,%
Slurry Filling,%
38.00
100.00

Charge
Volume,
m3
63.76

9.30
7441
2
3720

Lift
Angle, ()
35.00

Power Oversize, %

HYDROCYCLONES CLUSTER : (Preliminary Sizing)

# Cyclones
per Mill
4

Cyclone
Diameter, in
26.00

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Feed
% Solids
62.00

Circulating
Load, %
250.0

ton/hr
per Cyclone
350.0

m3/hr
per Cyclone
339.5

Pressure
Loss, psi
11.21

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