Moly-Cop Tools, Version 2.

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About the Media Charge_Optimal Ball Size Spreadsheet ...

Scope :

The Media Charge_Optimal Ball Size spreadsheet was designed to estimate the ideal make-up ball size to any given
grinding application, on the basis of the empirical correlations independently proposed by Ettore Azzaroni and Allis
Chalmers. In the normal case that such ideal ball size is not commercially available, this spreadsheet also allows for the
design of a mix recharge policy (maximum 2 different make-up sizes) with the same ideal ball charge area.

Theoretical Framework :

In a first attempt to provide an answer as to what would be the ideal size (diameter) of balls to be continuously recharged
to any given grinding mill - in order to achieve maximum performance out of such mill - the following two (amongst others)
independent empirical correlations have been proposed in the literature :

Ettore Azzaroni's Formula : (3rd ARMCO-Chile Symposium, Nov. 10-14, 1980)

dB* = 4.5 F800.263 ( r s Wi )0.4 / (N D)0.25

Allis Chalmers' Formula : (Mineral Processing Plant Design, Chapter 12, SME of AIME, 1980)

dB* = 1.354 (F80)0.5 [ r s Wi / (Nc D0.5) ]1/3

where :

dB* = Ideal Make-up Ball Size, mm

F80 = 80% Passing Size in the Fresh Feed Stream, microns
rs = Ore Density, ton/m 3
Wi = Bond's Work Index of the ore, kWh/ton (metric)
N = Rotational Mill Speed, rpm
Nc = Rotational Mill Speed, as a percentage of the Mill Critical Speed.
D = Effective Mill Diameter, feet.

For further background references on this sort of calculations, see Moly-Cop Tools spreadsheet Media Charge_Strings.

Data Input :

All input data required must be defined in each corresponding unprotected white background cell of the here attached
Optimal Ball Size worksheet. Gray background cells contain the results of the corresponding formulas there defined
and are protected to avoid any accidental editing.

New Moly-Cop Tools users are invited to explore the brief inserted comments in the most relevant cells, rendering the
use of the attached worksheet self-explanatory.

Moly-Cop Tools / 403725709.xls 12/04/2018 / 02:33:13

Moly-Cop Tools / 403725709.xls 12/04/2018 / 02:33:13
 Moly-Cop Tools TM
(Version 2.0)
OPTIMAL MAKE-UP BALL SIZE

Remarks : Base Case Example.

Mill Dimensions and Operating Conditions :

Eff. Diameter, ft 18.50 Eff. Diameter, m 5.64

Eff. Length, ft 22.00 Eff. Length, m 6.71
% Critical Speed 72.00 Mill Speed, rpm 12.82
Ball Dens., ton/m3 (app) 4.65 Mill Volume, m3 167.79
Ball Filling, % (app) 38.00 Charge Weight, tons 296.22
Scrap Size, in 0.50

Ore Properties :
Ore Density Work Index Feed Size, F80
ton/m3 kWh/ton (metric) microns
2.80 13.00 9795

RECOMMENDED OPTIMAL BALL SIZE :

AZZARONI's Formula :

Optimal Ball Size, in 2.87 String Area, m2/m3 65.60

, mm 73

ALLIS CHALMERS' Formula :

Optimal Ball Size, in 2.58 String Area, m2/m3 72.72

, mm 66

Moly-Cop Tools / 403725709.xls 12/04/2018 / 02:33:13

 Moly-Cop Tools TM
(Version 2.0)
BALL CHARGE COMPOSITION AT EQUILIBRIUM

Remarks : Base Case Example.

Mill Dimensions and Operating Conditions :

Eff. Diameter, ft 18.50 Eff. Diameter, m 5.64

Eff. Length, ft 22.00 Eff. Length, m 6.71
% Critical Speed 72.00 Mill Speed, rpm 12.82
Ball Dens., ton/m3 (app) 4.65 Mill Volume, m3 167.79
Ball Filling, % (app) 38.00 Charge Weight, tons 296.22
Scrap Size, in 0.50

Balanced Charge : Overall

String 1 String 2 Charge Area
Top Size, in 3.00 2.00 Indicated Mix
Specific Area, m2/m3 62.75 93.38 65.60
Recharge Policy, % 86.74 13.26 Target Value
Mill Charge Content, % 90.68 9.32 65.60
Excess Area 0.00

Balanced Charge,
Ball Size, in % Passing % Passing % Retained
3.0 100.00 100.00 27.73
2.5 48.19 100.00 35.01
2.0 19.69 100.00 22.02
1.5 6.18 31.37 11.51
1.0 1.16 5.88 3.41
0.5 0.00 0.00 0.32
0.5 0.00 0.00 0.00
0.5 0.00 0.00 0.00

Weight, tons 268.63 27.60 296.22

Volume, m3 (app) 57.82 5.94 63.76
Area, m2 3628 555 4183
# Balls per ton 1860 5666 2214

Moly-Cop Tools / 403725709.xls 12/04/2018 / 02:33:13