[2S ror COMMINUTION THEORY TO DEFINE A NUMERICAL DESCRIPTION OF THE SIZE REDUCTION IN RELATION TO THE ENERGY CONSUMPTION + MATERIAL GRINDABILITY MUST BE DETERMINED. + SIZE REDUCTION REQUIREMENTS MUST BE DEFINED + SEPARATOR CIRCUIT MUST BE EVALUATED [2SEmorn DETERMINATION OF GRINDABILITY Mill kW Production [t/hr] Grindability kWh/t = + kWh/t IS INFLUENCED BY: ~ Material components ~ Product fineness ~ Grinding system ~ Equipment efficiency Se ae ee[2S oom COMMINUTION THEORIES A. RITTINGER’S LAW: (1867) ~ Work New Surface Area Created (11) E=Cx)— \D, D,) B. KICK’S LAW: (1885) © Work « Reduction in Volume D,) E=Cxlog| | (D,} (C. BOND'S THIRD THEORY: (1951) = Work» New Crack Tip Lenath Produced fi. 1 [2S bmn DETERMINATION OF REQUIRED MILL POWER CONSUMPTION BONDS THEORY: CALCULATION OF EXPECTED POWER CONSUMPTION TO ACHIEVE A CERTAIN SIZE REDUCTION BASED ON A SPECIFIC RAW MATERIAL, PRODUCT RESIDUE, AND MILL CIRCUIT kwh 1 1oxCx x[wy mt Tin wd constant 80% Passing Size in Mill Product, ym 80% Passing Size in Mil Feed, jum ond Work Index[2S oom DETERMINATION OF MILL POWER CONSUMPTION CHC, xO) xO, xO, xC,x Cy x, G 1.3 correction for dry grinding G correction for open circuit grinding G correction for mill giameter efficiency G correction for oversized feed G correction for scalped feed Ce correction for fine grinding (>80%-74ym) Cy = correction for high eff. separators[2S Baemorn DETERMINATION OF GRINDABILITY: M301 1122 kW Grindability kWh/st = ———————__—_ 131 Production [st/hr] Grindability = 8.6 kWhist @mee = 9.4 kWhimt @ mee Grindability = 8.6 kWhimt mill shaft 95% motor eff 96% gear loss l2sm EXAMPLE: BM 301 (w]e) josex| --z|| kwh/mt 8.6 kWwh/mt c 0.8 Peo 100 pm Feo 19000 um[2S iismorn 100 [as |—2s1 |—200 | 110 |—ts tas jasResat0mens |_ ye 154m 208s um |e % 4 RESIDUE ON San 30 |—as 1 “0 GRESDUEON EACH IEE SER EXAMPLE: BM 301 [kWh W, /|10xCx t i L mt oll Fr Poo i kWaymt 8.6 kWh/mt c 08 (Peg) 0S on Fe) °5 0.00726 Ww, Bond Work Index = 11.6[2SBsmiorm Reference Tables: Log table and Material Work Index Tate War aor Cinier Tae [infeed [ines Chay 788 Coal 72.58 Gyprureck [2.29 Limestone re] Shale “a7 Sim sad 73.14 Sana Sene [art Granulted Slap [1340 + TO QUANTIFY THE ENERGY REQUIREMENT TO ATTAIN A SPECIFIC SIZE REDUCTION OF & MATERIAL + IN GENERAL + ASA FIRST ORDER PROCESS Kick n= 1.0 gE ox". Bond n= 15 ax Rittinger n= 2.0 Beer E=W,xCopy ¥ [log[R, ]-log IR, ](2S mom OPEN CIRCUIT GRINDING DETERMINATION OF GRINDABILITY E, = W x[log(Ro) - log(Rf)] W=W, xCoy (2S Emon Reference Tables: Log table and Material Work Index retained | Logiveret) | [Material Werk indox Op = 770 | [elinkor 1487 a CC | 10 700 Sey LBs Coal 1258 18 118 | [erpcimreck [02 18 126 | [Limestone FA 20 1.30 ‘Shale 18.07, 25 140__ || Sica sand 184 Send Stone rai Granulated Sag [1340(EST morn Example: What is Expected Power Consumption at 30% retained on 200 mesh (75um) Ry = 100% Typical for Raw meal Es = W, x Cayx log (RO/RF) Es = 11.65 x 1.67 x [log(100) — log(30)] Es = 11.65 x 1.67 x [2.00 - 1.48] Es = 10.12 kWhimt [2S mom GRINDING TO DIFFERENT RESIDUES Log(R,) ~Log(R2) * Log(R,) - Log(R,) a E, = KNOWN SPECIFIC POWER CONSUMPTION E, = SPECIFIC POWER CONSUMPTION AT NEW R + W = GRINDING CONSTANT Ry = RESIDUE OF THE FEED MATERIALS RF = RESIDUE OF THE KNOWN PRODUCT + Ry = RESIOUE OF THE NEW PRODUCT(ES morn Reference Tables: Log table and Material Work Index % retained Log(Yeret) = Clinker 44.87 8 0.90 18 1.26 Limestone | 41.22 a aa re rvetoumtee en: ey Example: What is Expected Power Consumption when changing from 30% retained to 20% retained on 200 mesh (75um) R, = 100% typically _g, LoglR» 2" LogIR 0) og(R 2) og(R ,) a0 X (2.00-1.3)/(2,00-1.48) Es = 10.12 x 1.35 Es = 13.66 kWh/mt[2Seeorm DETERMINATION OF MILL POWER REQUIREMENT + POTENTIAL MILL CAPACITY IS & FUNCTION OF THE PHYSICAL DIMENSIONS OF THE MILL, BALL CHARGE, LINERS, ETC. AND MATERIAL GRINDABILITY