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Tenova Bateman Mills

(SAG, AG, Rod, Ball)


Optimal solutions for Comminution

TENOVA is a worldwide supplier of advanced technologies, products and engineering services for the
iron & steel and mining industries.

TENOVA BATEMAN MILLS


Tenova TAKRAF has been actively supplying mills into the
mining industry since 1922.
We offer a full range of mills suited to the minerals industry.
SAG & AG mills - up to 11.6 m (38) diameter.
Ball mills - up to 7.9 m (26) diameter.
Rod mills - up to 4.5 m (15) diameter.
All mill designs are proven in the field and are backed by
FEA if required.
Tenova Bateman mills are designed to global standards or
to meet client specific requirements.

Tenova Mining & Minerals is a total integrated solutions provider to the global mining, bulk materials handling and
minerals beneficiation and processing sectors, offering innovative technological solutions and full process and
commodity knowledge across the mining industry value chain.

Tenova TAKRAF is a key supplier of equipment and systems for open pit mining and bulk handling, having provided
hundreds of complete systems, as well as individual machines to clients all over the world. Comminution systems for
milling and crushing requirements in mining and mineral processing are based on a track record dating back to the
1920s. Air pollution control, specialised handling equipment, and technology for the cement and fly ash industries and
pneumatic conveying, ensure selection of optimal processing options. A comprehensive after sales service is provided.
Bateman Engineered Technologies (previously part of the Bateman Engineering Group) is now trading as Tenova TAKRAF.
Tenova TAKRAF designs comminution systems for coal mining and preparation, industrial minerals, mining and
processing and other non-metallic mining and processing systems. Crushing systems include in-pit, primary, secondary,
tertiary and quaternary crushing systems. An extensive size reduction database from a significant number of
installations is used to recommend crusher models and sizes.
Tenova TAKRAF has the services of a world authority in semi-autogenous grinding (SAG) and is experienced in design
and construction of large autogenous grinding (AG) and SAG circuits. It has many rod and ball milling references.

MILL CONFIGURATIONS
Drives
Mills can be designed to operate using either
synchronous low speed motors driving the pinion
through a clutch system, or
asynchronous motors driving the pinion through a
reducer.
Motors can be WRIM or slip-ring type and can be offered
with an electronic variable speed controller if required.
Discharge Configuration
Grate discharge is normally used in AG, SAG and
some Ball Mill applications.
This screen grate installed near the discharge end of the
mill has slots to allow material to pass through. It
incorporates pulp lifters to assist with slurry discharge.
The grate and pulp lifters act in a similar way to a pump
in drawing material from the mill.
A discharge trunnion is typically used in ball mills
Overflow discharge allows for natural overflow of slurry

through the trunnion, caused by a gradient designed into


the trunnion inserts. The discharge trunnion insert is
normally fitted with a reverse scroll to help keep larger
ore particles and steel balls in the mill.
Lubrication
Tenova Bateman mills are trunnion supported and use
either hydrodynamic or hydrostatic lubrication depending
on design requirements.
Bearings are of proven design and include 120 enclosed
self-aligning rocker white metal bearings for the
hydrodynamic lube systems and bronze bushings for the
hydrostatic option.
Lubrication systems are designed in-house, while we will
use any recognised lube system that the client may
request.
The gear set is designed in accordance with AGMAstandard practice, with protection provided by triple
labyrinth seals on the girth gear cover. A FARVAL or
equivalent gear spray lube system is used.

STANDARD MILL RANGES


SAG MILL STANDARD RANGE
MOTOR POWER NO. OF
MAX (kW)
PINIONS

190
375
600
950
1,300
2,250
2,600
3,350
4,100
5,600
5,600
6,700
8,200
9,700
10,450
11,950
11,950
14,900

1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2

D
(feet)

MILL DIMENSIONS
L
EGL
(feet)
(feet)

12
14
16
18
20
22
24
26
28
28
30
32
32
32
34
34
36
36

5
6
7
8
8
10
10
10
10
14
12
14
14
16
15
17
15
19

4
5
6
6.75
6.75
8.5
8.5
8.5
8.5
12.5
10.5
12.5
12.5
14.5
13.25
15.25
13.25
17.25

D
(m)

MILL DIMENSIONS
L
(m)

EGL
(m)

3.66
4.27
4.88
5.49
6.10
6.71
7.32
7.92
8.53
8.53
9.14
9.75
9.75
9.75
10.36
10.36
10.97
10.97

1.52
1.83
2.13
2.44
2.44
3.05
3.05
3.05
3.05
4.27
3.66
4.27
4.27
4.88
4.57
5.18
4.57
5.79

1.22
1.52
1.83
2.06
2.06
2.59
2.59
2.59
2.59
3.81
3.20
3.81
3.81
4.42
4.04
4.65
4.04
5.26

BALL MILL STANDARD RANGE (ALL SINGLE PINION)


MOTOR POWER
MAX (kW)

55
0
90
150
225
275
300
350
375
525
750
950
1,120
1,300
1,500
1,680
1,875
3,000
3,750
4,100
4,500
6,750

D
(feet)

MILL DIMENSIONS
L
(feet)

EGL
(feet)

D
(m)

MILL DIMENSIONS
L
(m)

EGL
(m)

5
6
6
7
8
8
8
9
9
10
11
12
13
13
14
14
15
16.5
16.5
17
18
20

8
6
8
9
10
12
14
12
14
15
17
18
17
19
18
20
19
24
30
33
30
32

7.5
5.5
7.5
8.5
9.5
11.5
13.5
11.5
13.5
14.5
16.5
17.5
16.5
18.5
17.5
19.5
18.5
23.5
29.5
32.5
28.5
33

1.52
1.83
1.83
2.13
2.44
2.44
2.44
2.74
2.74
3.05
3.35
3.51
3.96
3.96
4.27
4.27
4.57
5.03
5.03
5.03
5.49
6.10

2.44
1.83
2.44
2.74
3.05
3.66
4.27
3.66
4.27
4.57
5.18
5.49
5.18
5.79
5.49
6.10
5.79
7.32
9.14
10.06
9.14
9.75

2.29
1.68
2.29
2.59
2.90
3.51
4.11
3.51
4.11
4.42
5.03
5.33
5.03
5.64
5.33
5.94
5.64
7.16
8.99
9.91
8.69
10.06

BASIC MILL APPLICATION DATA


The Third Theory of Grinding, published by Fred C. Bond
of Allis Chalmers in 1952, for calculating crusher and
grinding mill power requirements permits
rapid, accurate power calculation,
evaluation of circuit efficiency, and
selection of the most economically sized comminution
machines.
The Third Theory, also known as the Bond Formula, was
based upon data compiled and correlated from several
thousand laboratory tests and was confirmed in the field
from operating data, gathered over a period of more than
40 years. The results revealed that
the quantity of size reduction is proportional to the
work required to accomplish that reduction.
each material has a definite Work Index (Wi).
each mill size has a definite rated power.
The Bond Formula yields the work required to reduce a
material, of known Work Index, from an infinitely large size
to the desired product size, less the work required to
reduce the same material to its present (partially reduced)
feed size from an infinite size.
The resultant work (W), measured in kilowatt-hours per
ton, indicates the overall energy requirement to reduce
the material, of known Work Index, from present Feed size
to the desired Product size.
(10 Wi) (10 Wi)
W=
P
F
Where W = Work in kilowatt-hours/ton
Wi = Work index of material as derived from
laboratory tests or empirical data
P = 80 % passing point of product screen
analysis in microns
F = 80 % passing point of feed screen
analysis in microns
Actual Grinding Mill Power is
kW = (W) (EF)
(EF) = Efficiency Factor (Total) for special
material and circuit requirements
(combined product of EF factors below)

Efficiency Correlation Factors (EF)


EF1 Dry Grinding (rod and ball mills) 1.3
EF2 Open Circuit (ball mill only) 1.04 to 1.7 (average: 1.2)
EF3 Diameter Factor (rod and ball mills) Not normally
used
EF4 Oversize Feed (rod and ball mills) Use 1.0 except
when Wi exceeds 14.0 and/or F exceeds
16,000 microns (rod) or 4,000 microns (ball)*
EF5 Fineness (ball mill only when P is below
70 microns)
(P+10.3)
(1.145 P)
EF6 Reduction Ratio (rod mill) 1.0 when Rr is between
10 and 20*
EF7 Reduction Ratio (ball mill) 1.0 when Rr exceeds
5.0*
EF8
Feed
Preparation
Open circuit crusher (rod mill only)
1.4
Open circuit crusher (rod ball circuit) 1.2
Closed circuit crusher (rod mill only) 1.2
Closed circuit crusher (rod ball circuit) 1.0
*NOTE: if outside above limitations or if rod mill (only) feed
is scalped, consult the manufacturer.
For other factors that need to be considered, consult the
mill designer.
Indemnity. Notwithstanding any application data and /
or formulas provided in this brochure, final design and
technical specifications of any particular piece of
equipment should be obtained from Tenova TAKRAF.

BASIC INFORMATION REQUIRED


Material Name.
Work Index (from lab test or empirical data).
Feed Size: F obtained from actual screen analysis.
Product Size Desired: P obtained from actual screen
analysis.
Capacity in metric tons per hour.
Is mill feed crushed in open or closed circuit?
Is mill feed prescreened or classified to remove product
size material?
Type of mill and type of circuit desired?
TYPICAL BOND INDEX
Wi
Solids
kWh/t
Andesite
19.5
Barite
5.0
Basalt
19.0
Bauxite
10.0
Cement clinker
15.0
Cement raw material
12.0
Clay
7.0
Coal
14.5
Coke
16.5
Copper Ore
14.0
Diorite
23.0
Dolomite
12.5
Emery
62.5
Feldspar
13.0

Solids
Ferrochrome
Ferromanganese
Ferrosilicon
Flint
Fluorspar
Gabbro
Glass
Gneiss
Gold Ore
Granite
Graphite
Gravel
Hematite
Magnetite

Wi
kWh/t
8.5
9.0
11.0
29.0
10.0
19.5
14.0
22.0
16.5
16.5
48.0
17.5
14.0
11.0

Solids
Taconite
Lead Ore
Lead-Zinc Ore
Limestone
Manganese Ore
Magnesite
Molybedum
Nickel Ore
Oil Shale
Phosphate Rock
Potash Ore
Pyrite Ore
Pyrrhotite Ore
Quartzite

Wi
kWh/t
16.0
13.0
12.0
14.0
14.0
12.5
14.0
15.0
17.5
11.0
9.0
9.5
11.0
11.0

Solids
Quartz
Rutile Ore
Shale
Silica Sand
Silicon Carbide
Slag
Slate
Sodium Silicate
Spodumene Ore
Syenite
Tin Ore
Titanium Ore
Trap Rock
Zinc Ore

Wi
kWh/t
15.0
14.0
17.5
15.5
28.5
11.5
16.0
15.0
11.5
14.5
11.5
14.0
21.5
13.5

These values are typical and should be determined by test work to confirm the Bond Wi before mill power requirements
are finalised.

THEORETICAL SIZE REDUCTION FOR


DIFFERENT GRINDING MILLS

AG

400 mm

SAG

400 mm
50 mm
15 mm

1m

100 mm

75 microns

10 mm

75 microns
ROD

75 microns

BALL

1 mm

20 microns

100 micron

10 micron

1 micron

Tenova TAKRAF

Tenova MINING & MINERALS

Tenova Mining & Minerals (Pty) Ltd


1 Kramer Road
Bedfordview
Johannesburg
PO Box 75996
Gardenview, 2047
South Africa
phone +27 11 201 2300
fax +27 11 455 4547
enquiries.TMM@za.tenovagroup.com

Tenova Mining & Minerals (Pty) Ltd


58 Emerald Parkway Road
Greenstone Hill, Ext 21 1609
PO Box 7737
Johannesburg 2000
South Africa
phone +27 11 899 9111
fax +27 11 899 2302
enquiries.TMM@za.tenovagroup.com

TAKRAF GmbH
Torgauer Strae 336
04347 Leipzig
Germany
phone +49 341 2423 500
fax +49 341 2423 510
sales@takraf.com
Bahnhofstrae 26
01979 Lauchhammer
Germany
phone +49 3574 854 0
fax +49 3574 854 100
service@takraf.com
Tenova S.p.A
Via Albareto, 31
16153 Genoa
Italy
phone +39 010 6054067
fax +39 010 6054710
bulkhandling@it.tenovagroup.com

www.tenovagroup.com
www.bet.bateman.com
TECHINT GROUP
Edition 1 August 2012

MINING & MINERALS