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

Scope : The Media Charge_MBWT_SAG 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 / 138326442.xls.ms_office

4/6/2013 / 12:47 PM

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 an eventual plant application. Gray background cells contain the results of the corresponding formulas there defined and are protected to avoid any accidental editing. When using the Data_Analyis worksheet. As a practical evaluation criterion. The above expression creates the need for a theoretical representation of the Mill Power Draw and how each component of the mill charge (balls. in any given application. kdE is expected to be more insensitive than k d to variations in mill operating conditions (that may affect Pb and/or W b). 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.xls. will be the one that exhibits the lowest value of the wear rate constant k dE. different Test Groups of balls must be analyzed in separate copies of this master worksheet. As a guide to new users. After recovery. rocks and slurry) contribute to this power demand. 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. the Linear Wear Rate Constant kd for each ball may be computed from the simple expression : kd = (dR . Version 2. The weight loss experienced by each marked ball may then be extrapolated to its expected performance . mm/(kWh/ton)]..in terms of wear resistance (durability) . after a predetermined number of operating hours (ttest). The underlying theoretical claim is that grinding balls will wear faster in a more energy intensive environment. every relevant cell in the worksheets has brief inserted comments that render the whole computation process self-explanatory. In the above theoretical framework. The simple Hogg and Fuerstenau model serves such purpose well (see Spreadsheet Mill Power_SAG Mills).ms_office 4/6/2013 / 12:47 PM . By direct analogy to mineral particle breakage kinetics. Therefore. it is postulated that an even more representative and scaleable quality indicator is the Energy Specific Wear Rate Constant [kdE.. Moly-Cop Tools / 138326442.Moly-Cop Tools.0 About the Media Charge_MBWT_SAG Mills Spreadsheet . Test_Design or Data_Analysis worksheets.dF)/ttest where dF represents the final diameter of the ball upon recovery. it should be then accepted that the top quality grinding media.

94 Lift Angle.75 2223. hrs 78.344 1. m2/m3 (app) Total Charge Area. Diameter Eff.7 Ball Recharge Rate gr/kWh (gross) gr/kWh (balls) 65. ton/m3 Ore Feedrate. Length Mill Speed ft ft % Critical 35.0942 Moly-Cop Tools / 138326442. ton/m3 Slurry Density.977 3.0) DETERMINATION OF WEAR RATE CONSTANTS Special Case : SAG MILLS Remarks Base Case Example Mill Dimensions and Operating Conditions Eff.79 140.222 Mill Charge Weight.093 4. (°) 45.00 76.8 36.6 tons/month 443 3. ton/m3 Balls Density.% 28.142 3.84 % Solids in the Mill Ore Density.55 gr/ton 300.00 Balls Interstitial Filling.0 50.% Slurry Filling. kW 5.952 0.0 hr/month 662 Power. m3 129.63 125.ms_office 4/6/2013 / 12:47 PM . mm Scrap Size. ton/hr ton/day Energy.00 2.286 6. m2 Purge Time.83 1709 788 Charge Filling.00 130.00 Charge Volume.00 % Utilization 92.4 49.491 9.80 2.Moly-Cop Tools TM (Version 2.00 17. tons Ball O´size Interstitial Charge Rocks Slurry 215. mm/[kWh(balls)/ton(balls)] mm/hr Kg/hr 668. mm Spec.813 Balls Rocks Slurry Net Total % Losses Gross Total MWh/month Apparent Density ton/m3 3.xls.01 Wear Rate Constants.01 7.00 rpm 9.00 60. kWh/ton (ore) Make-up Ball Size.% 10.33 62. Area.00 10.

00 60.0 0.00 Mill Power. Marked Balls.06 0.977 3.25 Sample Size.00 76.61 23. kW 5.61 Recovery Rate. with one full-turn inching of the mill Recovery Recovery Exposed Exposed Marked Balls Target.87 0.491 9. m3 129.286 Balls Rocks Slurry Net Total % Losses Gross Total Apparent Density ton/m3 3.0 0.344 1.79 140.84 Charge Filling.63 0.34 w/ Grind-out w/o Grind-out Option 2. (°) 45.77 Same as Option 1. Length Mill Speed ft ft % Critical 35. tons Ball O´size Interstitial Charge Rocks Slurry 215.09418 265 Charge Volume.ms_office 4/6/2013 / 12:47 PM .xls. ton/m3 Balls Density.05 1.0 48. ft 28.12 1.00 Balls Interstitial Filling. ton/m3 Initial Ball Size.% Slurry Filling.55 with Grind-out without Grind-out Free Height Above Charge. NTOT 20 44 w/ Grind-out w/o Grind-out Required Labor Man-hrs Inspectors 23 4 30 5 Moly-Cop Tools / 138326442. Ball Picking over Exposed Mill Charge Surface Recovery Recovery Exposed Exposed Marked Balls Target.00 Lift Angle.44 5 119.10 1. % Wear Rate Estimates. m-hours/m2 0.01 7.0 100.00 rpm 9.80 2.% 10. ton/m3 Slurry Density.142 3. NTOT (Minimum Number of Marked Balls per Group) Option 1.12 Available Recovery Hours 8. mm Final Ball Size. mm/[KWH(balls)/ton(balls)] mm/hr TEST DURATION. Ball Layers. Degrees 101.94 Mill Charge Weight. Ball Layers. Concentration. Area.952 0.% 28.0 Required Labor Man-hrs Inspectors 11 2 13 3 SAMPLE SIZE.76 0.75 125. m2 # Balls/m2 # Balls/m3 # Balls # 5 91.8 3. mm Weight Loss. hrs 78. Area.94 5 51.04 1.222 % Solids in the Mill Ore Density.17 139.0 0. Marked Balls.0 0.00 2. m2 # Balls/m2 # Balls/m3 # Balls # 5 42. Concentration.Moly-Cop Tools TM (Version 2. Sample Size.00 10. NTOT 43 100 Kidney Angle.0) Practical Guidelines for MARKED BALL WEAR TEST DESIGN Remarks Base Case Example Mill Dimensions and Operating Conditions Eff.00 17.33 62. Diameter Eff.

kW 4.2 0..00 17. ton/m3 Slurry Density.4 121. gr 13998.11 Moly-Cop Tools / 138326442.00 9.244 1.49 277.456 COMPARATIVE PERFORMANCE 265 590 2648 177 125 51 Sp. m3 129.0 14105.0991 0.1 150.4 151.75 7.11 4.3 150.4 61.0 mm/hr Wear Rate Constant mm/(KWH/ton) 0.1 124.75 Charge Volume. ton/m3 .36) Group B : Alternative Product Initial Weight.1006 0.8 122.01 7. kWh/ton (net) Ball Consumption.074 Test Media (Projected) 4. gr/ton . Length Mill Speed Charge Balls Interstitial ft ft % Critical Filling. ton/m3 Balls Density.446 9.545 4. mm Scrap Size.4 7444.138 3. % 150. tons Ball O´size Interstitial Charge Rocks Slurry 215.1007 0.49 300.0) MARKED BALL WEAR TEST RESULTS Remarks Base Case Example Mill Dimensions and Operating Conditions (Actual Average for the MBWT) Eff.80 2.1030 4.39 0.0 Initial Size.33 62.1065 0. gr/kWh (net) . gr 7808.222 % Solids in the Mill Ore Density.Test Group Operational Records during MBWT : Test Duration.0 13702.55 Host Charge (Actual) 4.6 0.Moly-Cop Tools TM (Version 2.00 2.0 668.3 Mill Power.59 0.1 Final Weight. ktons Energy Cons. tons Make-up Ball Size.1030 0.7 124. mm Ball Group Identification : TAG # B03 B10 B16 B23 B34 B38 78.3 7755.609 4.% Slurry Filling.94 Mill Charge Weight. Energy.xls.00 60.678 3.9 7879. of Variation.5 Final Size. mm 151.988 3.582 Average Std.5 7364.% 35.0 150.289 4.ms_office 4/6/2013 / 12:47 PM .1059 4.8 598. mm 124. Coeff. Diameter Eff.0 13721.00 10.977 Balls Rocks Slurry Net Total % Losses Gross Total Apparent Density ton/m3 3.0032 3.00 76. mm/hr mm/(KWH/ton) % Better (9.456 0. (°) 43.Host Charge . MWh (net) Balls Charged. Dev.1051 0.% Filling.79 140.0 13780.355 4.0 13810.6 0.4 122.00 28.354 4. hrs Ore Processed.0942 4. kg/hr WR Constant.7 67.8 7322.5 150.00 Lift Angle.