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Moly-Cop Tools, Version 2.0 About the Media Charge_MBWT_Ball Mills Spreadsheet ...

Scope : The Media Charge_MBWT_Ball Mills spreadsheet provides specific guidelines for the design, execution and data interpretation of a Marked Ball Wear Test (MBWT), as a standard procedure for the evaluation of alternative varieties of grinding media to be utilized in conventional and semiautogenous mineral grinding tumbling mills.

Theoretical Framework : The most widely accepted mathematical description of the gradual consumption process experienced by a grinding ball inside a tumbling mill is known as the Linear Wear Theory, by which the mass rate of consumption of a grinding ball is described as directly proportional to the surface area exposed by such ball to the various wear mechanisms (abrasion and/or corrosion) active in the mill charge environment : Wt = d(mb)/d(t) = - km Ab where : Wt mb Ab km = mass wear rate, kg/hr = ball weight, kg; after t hours of being charged into the mill. = exposed ball area, m 2 = mass wear rate constant, kg/hr/m 2.

Equivalently, taking into account the geometry of the grinding body (sphere or cylinder), one obtains : d(d)/d(t) = - 2 km / rb = - kd where : d rb kd = size (diameter) of the grinding ball, mm; after t hours of being charged into the mill. = grinding ball density, ton/m 3 = wear rate constant, mm/hr.

If kd is to remain unaffected by the extent of wear; that is, k d is not a function of the current ball size d - a condition satisfied by most grinding media varieties and normally referred to as Linear Wear Kinetics - the above expression may be simply integrated to obtain : d = dR - kd t where dR represents the initial size of the balls. For any given grinding media variety, the constant k d becomes an indicator of its relative quality, as compared to other alternative products.

Moly-Cop Tools / 138325796.xls.ms_office

4/6/2013 / 12:41 PM

Data Input : All data required for the calculation must be defined in each corresponding unprotected white background cell of the here attached Wear Rate_Host Charge. As a practical evaluation criterion. As a guide to new an eventual plant application. a MBWT consists of weighing and tagging a limited number of balls (Test Group) – of the type (or types) under consideration – charging them into the selected industrial test mill and recovering as many of them as possible.dF)/ttest where dF represents the final diameter of the ball upon recovery. rocks and slurry) contribute to this power demand.ms_office 4/6/2013 / 12:41 PM . By direct analogy to mineral particle breakage kinetics. The weight loss experienced by each marked ball may then be extrapolated to its expected performance . Test_Design or Data_Analysis worksheets. Therefore. The simple Hogg and Fuerstenau model serves such purpose well (see Spreadsheet Mill Power_Ball Mills). The above expression creates the need for a theoretical representation of the Mill Power Draw and how each component of the mill charge (balls. it is postulated that an even more representative and scaleable quality indicator is the Energy Specific Wear Rate Constant [kdE. The underlying theoretical claim is that grinding balls will wear faster in a more energy intensive environment.xls.Moly-Cop Tools. after a predetermined number of operating hours (ttest).in terms of wear resistance (durability) . it should be then accepted that the top quality grinding media. When using the Data_Analyis worksheet. in any given application. different Test Groups of balls must be analyzed in separate copies of this master worksheet. will be the one that exhibits the lowest value of the wear rate constant k dE. kdE is expected to be more insensitive than k d to variations in mill operating conditions (that may affect Pb and/or W b).. every relevant cell in the worksheets has brief inserted comments that render the whole computation process self-explanatory. the Linear Wear Rate Constant kd for each ball may be computed from the simple expression : kd = (dR . Gray background cells contain the results of the corresponding formulas there defined and are protected to avoid any accidental editing.. After recovery. mm/(kWh/ton)]. defined through the expression : kd = kdE (Pb/Wb) / 1000 where the ratio (Pb/W b) corresponds to the contribution (Pb) of every ton of balls in the charge (W b) to the total power draw (Pnet) of the mill. In the above theoretical framework. Moly-Cop Tools / 138325796. Version 2.0 About the Media Charge_MBWT_Ball Mills Spreadsheet .

48 0.% 38.0 hr/month 698 Power.00 2.82 % Solids in the Mill Ore Density.76 Wear Rate Constants.% Slurry Filling.00 Balls Interstitial Filling. Area.007 0. mm Spec. ton/m3 Slurry Density.xls.76 Lift Angle. mm Scrap Size.00 4.0114 Moly-Cop Tools / 138325796.0 Ball Recharge Rate gr/kWh (gross) gr/kWh (balls) 41.014 Balls Overfilling Slurry Net Total % Losses Gross Total MWh/month Apparent Density ton/m3 5.0 tons/month 126 1. kW 3.0 9.00 72.00 rpm 12.312 10. ton/m3 Ore Feedrate.86 7.50 22.0) DETERMINATION OF WEAR RATE CONSTANTS Special Case : BALL MILLS Remarks Base Case Example Mill Dimensions and Operating Conditions Eff.00 100.00 Charge Volume.% 38.538 Charge Filling. ton/m3 Balls Density.ms_office 4/6/2013 / 12:41 PM .0 63. mm/[kWh(balls)/ton(balls)] mm/hr Kg/hr 180.395 Mill Charge Weight.348 0 536 3.316 3.00 gr/ton 450. m3 63.Moly-Cop Tools TM (Version 2. m2/m3 (app) Total Charge Area. (°) 35.0 12. tons Ball Slurry Charge Interstitial above Balls 296.885 10.70 53. Length Mill Speed ft ft % Critical 18.78 4067 5. hrs 72.79 75.48 47.80 1.75 400. m2 Purge Time. kWh/ton (ore) Make-up Ball Size. ton/hr ton/day Energy. Diameter Eff.00 % Utilization 97.

m2 # Balls/m2 # Balls/m3 # Balls # 5 37.007 0.% 38.04 SAMPLE SIZE. Marked Balls.86 7.01 Kidney Angle.48 Free Height Above Charge.0 1.79 Recovery Rate.13 1. tons Ball Slurry Charge Interstitial above Balls 296.82 Charge Filling.80 1.00 Mill Power.25 Sample Size. % Wear Rate Estimates. mm Final Ball Size.0 0.06 1.01138 1319 Charge Volume.76 Mill Charge Weight.00 47.17 0. with one full-turn inching of the mill Recovery Recovery Exposed Exposed Marked Balls Target.00 rpm 12.0 Required Labor Man-hrs Inspectors 9 2 Option 2.75 75. ton/m3 Balls Density.00 100.348 0 536 3.75 Sample Size.395 % Solids in the Mill Ore Density.% Slurry Filling.ms_office 4/6/2013 / 12:41 PM . Diameter Eff. Ball Layers. ton/m3 Slurry Density. NTOT 48 Required Labor Man-hrs Inspectors 22 4 Moly-Cop Tools / 138325796.316 Balls Rocks Slurry Net Total % Losses Gross Total Apparent Density ton/m3 5.8 1. hrs 72. NTOT 114 Available Recovery Hours 8.00 Lift Angle.00 Balls Interstitial Filling. Ball Layers. kW 3. m-hours/m2 0.885 10. Degrees 158.Moly-Cop Tools TM (Version 2. ft 11.00 72.50 22. NTOT (Minimum Number of Marked Balls per Group) Option 1.0 60.0 48. m2 # Balls/m2 # Balls/m3 # Balls # 5 89. Ball Picking over Exposed Mill Charge Surface Recovery Recovery Exposed Exposed Marked Balls Target.38 0. Length Mill Speed ft ft % Critical 18. Concentration. Same as Option 1. Area. mm/[KWH(balls)/ton(balls)] mm/hr TEST DURATION.xls. Area. (°) 35. m3 63. ton/m3 Initial Ball Size. Marked Balls. Concentration. mm Weight Loss.00 2.% 38.0) Practical Guidelines for MARKED BALL WEAR TEST DESIGN Remarks Base Case Example Mill Dimensions and Operating Conditions Eff.00 4.48 0.

885 Balls Rocks Slurry Net Total % Losses Gross Total Apparent Density ton/m3 5. gr/ton . kW 3.Test Group Operational Records during MBWT : Test Duration..% Slurry Filling. gr/kWh (net) . kWh/ton (net) Ball Consumption. ktons Energy Cons.0129 1.0 1744.0131 0.496 10.3 Final Weight.00 rpm 12.395 % Solids in the Mill Ore Density.3 57.0 764.7 mm/hr Wear Rate Constant mm/(KWH/ton) 0.277 1. of Variation.98 0.0 782.44) Group B : Alternative Product Initial Weight.0) MARKED BALL WEAR TEST RESULTS Remarks Base Case Example Mill Dimensions and Operating Conditions (Actual Average for the MBWT) Eff.285 1.38 453. tons Make-up Ball Size.0130 0. hrs Ore Processed.276 COMPARATIVE PERFORMANCE 1365 565 5302 256 75 12 Sp. m3 63.Host Charge .00 38.00 38.74 0.76 Mill Charge Weight.5 204.0 1659.% Filling. (°) 31.8 57.7 57. Dev.276 0.80 1.9 75. MWh (net) Balls Charged. mm/hr mm/(kWh/ton) % Better (9.82 Lift Angle.48 0. gr 1811.0 731.00 72.Moly-Cop Tools TM (Version 2.% 18.00 100.0119 1.75 Charge Volume.1 48. tons Ball O´size Interstitial Charge Rocks Slurry 296.00 3.ms_office 4/6/2013 / 12:41 PM .5 57. Energy.264 1.0131 0.009 0.0 1702.0130 0. Diameter Eff.0 1732.xls. mm Ball Group Identification : TAG # B03 B10 B16 B23 B34 B38 72.70 1. kg/hr WR Constant.0 780.6 74.5 74.38 548.70 Moly-Cop Tools / 138325796.0130 1.166 Test Media (Projected) 9.0 1753.00 2. mm 76.0130 0.2 75.00 47.3 0.3 187. mm 58.4 0.0 777.0 Final Size. Length Mill Speed Charge Balls Interstitial ft ft % Critical Filling.50 22.5 0. ton/m3 Balls Density.86 7. Coeff.267 Average Std. % 75.7 58. ton/m3 .75 7.0 Initial Size.279 1. ton/m3 Slurry Density.1 Mill Power.48 Host Charge (Actual) 9.6 56. gr 821.4 75.0001 0.285 1.0129 0.013 0 483 3. mm Scrap Size.