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BallMill Optimum Process Manual PDF
BallMill Optimum Process Manual PDF
StandardFeatures
. .\ll ballmilk comenandard$ithooe{4 5 lb.
ch.ugc0f lon hdls.ifon slmd, fcccivingtm
lUldhmd screenpm.
. lil cir-slifon dru l
Models
l'ii ilqi so
220\bll,Jph.60 oclc
. Modell95-i1
110,'120.1th.60crcle
. l\ odelJ9t 5I\
ll0,220!.1ph,50qclc
F.C. BOND BICO BALL MILL
This Ball Mill canbe usedcontinuouslyor it canbe usedfor any numbq ofrcvolutions,
accoding to the type of grind desired. For instance,the Frcd C. Bond GrindabiliryTestsw€re
madein the Bico Mill rurmingat 70 revolutionsper minute,with a chargeof285 iron balls
rangingin sizefrom 3/4 inch to 1-1l2 inch in diameter,andweighing approKimately20,125
grams. 700 CC ofminus 6 mesh,stagecrushed,dry feedwas usedandthe circulationload
maintain€dconstantat 250%by adjustingthe numberof revolutionsfor eachgrinding period.
continued...
OPERATINGINSTRUCTIONS
*** Sprockets
arcavsilableandquoteduponrcqucat.(S/Ned IU rcquired).
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F ts . L 8 + i n . H l d to c o n e crush.t l or
t.ttidtt ctushirs ol SemnTa@zite ote
(speculat henatite). ( unboldt
Mi^iry Co., Humboldt, Michisan.)
CRUSHING&
GRINDING
CALCUTATIONS
PART I
lh. .rlehing .nd Srindinr of or.., ro.kr ri.l mii.rk k .n indusrri.l proc.$ of sr.rr inpori:nc.. Sp.ci.li!.d
enSin€.fin! khowl.d3. ir r.quir.d fo. ihe rolution of pr.ctidl probl.n! in p.nicl. ii1. r.ducrioh, rnd
c odif ic . t io. oI r hi! k no* l. dg . h r 3 h . r d l / b c i l n . T h . p r . . . n r p . p . r i , . n r t t e m p t t o . $ c m b t . r h i r h ty
.ond.n!.d summ.ry of th. princip.l crl.!l.tion d.thodr whi.h th. .urhor h.s found us.ful, R.f.r.nc.r 1r.
siv€. to r.ti.l.r {ith r hor..xt.niive.xpl.nrtio. .hd .:.mpl6 of ..t.ut.tion5.
by FREDC. BOND
r\OMMINUTION Ih.ory is coDerred with tle relarion- of one-balf the surfacearea, and thc new crack tensth is
\-. ship betw.en eoergt iDpr.ttaDd rbc product particle sik proportionar ro 1I 1/i - lt\/j .
nade from s eivcn f€ed sizc. It continues to be a rich ficld For practical calculationsrhe size in microns which 80
per cent passesis selccted as tbe criterion of particle siz€.
Tb. oldest therry (1867) is fiat of RrrrINoEA,LBnd it still The <iiameterh microns which 80 per ccnt of tbe producl
bas adhcr.nts. He srat.d that tbc arca of the n.w surfac€ passesis dcsipat.d as P, the siz! which 80 pcr cent of the
produ€cd by crubhing or grirding is direclly proporlio.al to feed passesis dcsisnatedas F, and the work input iD
kilo-
tb. useful work input. Thc surfac€ area of a totr of prrticlcs watt bours per sbort to! is ttl. The basicThird Th.o.y eqna-
of uDiform diamct€rd is proportional to 1/d, and accord-
ing to RFnNolR thc us€ful work input pcr ton is also
proponioual to I /d. Hos'cver, tbc measured surfacc encrgy to wi t0 wi
of the nc*, surface ar€a produccd is only a veiy 6ma[ fr!c- \/ ? \/F '. . ( 1)
tion of thc ordcr of l/10cr0 of the energy iaput actually
required to producc tbat surface h commercial crushjna wbere ryt is tlre work index. Tbe work index is the com-
parameterwhich expre$es rhe resistanc€of tbe
aDd Srinding. Nearly all of thc rcquircd €d€rgy input ap- mrnunob
pcars a3 heat dt€r thc particLs arc brokeb. ftat€rial to crushins and CrindiDs.Numericaly rhe work
The sccondthcory (1885)is tbat of K1cK.:H. ltal€d that iDdex is the kwh per shorr ton required ro feduce Ibe
lhe work requircd is proportioDal to the rcdultioo in volume mateial from theoreticallyinfinite feed siz! to 80 pcr cenr
of tbe pa icles conccrncd.Whcrc I is the diametq of the pasi n8 100 mi crons.equi val enr to about o? p.r. ; nl paF
fecd paniclcs and p is thc diam.ter oI the product panicles, sing 200 mcsb. When any three of rhe quaDritiesin Eqoation
(l) are known, the fourrh can bc fourjd by transposingrhc
tho reduciion ratio Rr is J/p Accordios to KICK, tbc work
idput lcquir€d pcl totr is proportioml to Iog Rrllog 2. equation.Useful forms are showd in (ta) and (tb) belowj
Siucc neiter theory agrecawith commercial qushiDg and tl to
grindiDa r€sult!, the author devcloped thc Third Thcory in . . {la)
1951-rAccording to this theory, tbe work iDput h propor-
tional to tb€ trlw crack tip length Foduced iD particle
br€aka8c,and aqualsthe work repres€ntedby thc product - | to wi\/F \' ....0b)
mitrus that reprcsentedby the feed. Ir particles of similar
\ w1 / F - t o wil
shape,thc @ck rjp length is €quivalentto the sqrare root Tbe sork input in
Ioules or wa {econds per gram equals
D.rann.n(. ArG-Chrdqs If th€ naterial is homoseneous10 size reduction, its }l,i
value will cootinu. constanrfor all size reduction stages.
j
Fig.4.Scalpedleed conection plot. Scalpedleed with 80 pel
cent passine 7900 niuo^s (F = 79OO).Y = 29 pet cent,
80 - Y/2 = 65.5 per cent. Slope = | t2. Catected leed
size Fc = 12,0m thictons.
MESH
MESII
CRAC KLENG TH PLO T S C A LP ETE
D E OC OR R E C TION
P LOT
-l -
Howevcr, beterogeneoDs structures in rock diameter,as shown in the work index Equation (1). C{ush-
Fo. instance, certain mat rills havc a narural grain size, aDd iog aDd sriDdins machines are csr€dtialtydeviccsfor the
thcir ryi values will be larg.r bclow that siz. than abovc it. .onversiotr of m.chanicat encrgy into strain energy inro
A loosely cementcd sandstoDeof 4S-mesh silic-a graiDs will heat, uoder conditions which proftote material brcakag..
hav€ a larger ryi for a product nith broken parricles finer The en€rgy register as uscd herein r.preseDts the specific
than 48 meshthatr for a coarserproduct. cnergy rvhich has passed tbroush th€ material as strain
The etrciency of the r€ductio! machinc may also in- en€rcy, and iDcludes heat losses and loss.s due to fricriolr
fluencc thc operating work ind€x. For iostanci, a ball mill and other causs. It does aot correspond.to the eoergy
EriDdirgan ore from 80 p.r cent-l4 meshto 80 per cent- cont.ni of thc material.
100 meeh will have a lowcr op€ratins t/t value with 1.5-in. The Third Pinciple deals wirh thc relatiooship of particle
srindins balls tban witl oversize3-iD.balls. flaws to mat.rial breakas.. A flaw is defined as atry struc-
A material may havc an tudacel grain size resultins from tual weakn.ss in a particlc which rnay dcvelop iaro a dack
some pref€rential siziry action which chatrses its natural tp undc! straid. Flavs ar. slways pres€Dt in brittle
size distributioa. Undersiz. s.indine bals can have this materials and may causc wide Erialions in thc brcakinq
effect. sLrcD8lh!of appar€ntlysimilar pardcler.
I-aboratory.determinationsof th. work index sbow the The *cakest flaw iD a particle determines its breaking
rcsiltance to breakagc at the rize rangc tcsled, and aly strength in crushing and Srindi!8. It also cortrols rbe num-
variatior in thc }'/; valDes in tests at diffcreDt product sizcs ber of particlcs produced by br*kage. Particles with the
shows that the malerial is not homogencous to size reduc- weakest flaw8 brcak most easiiy and produce thc larsest
tion. For thi! reason laboratory testr should preferably be product particlcs. Ho*ever, they arc not necessadly easier
made at or near tbe product size required iD commercial ro grind ro a givcn producr size rcquiriEg severatstagesoI
8Imortr& brealagethan are pafljcles of rhe samesize \,\boseweatcsL
The op€ratiry work iDdexfrorn transposcdEquation (la)
can bc calculated from size r€duction in commercial plants The Third Principle states that the weakcst flaw in a
to compare the plaat €fficiency wiih laboratory test results, particle der.rmines ils breaking srrengtbbul Dot its work
to compa& efrciencies of tb€ diferent plaDt siz€ reductiotr index. Tbe work iodex is conkoU.d by t-be av.rsse 6aw
stases, or to .ompare thc efrci€ncies of difierent plants srructurc Lbrougbour lhc €Drre size rangc restcd. work
treatins limilar materials. The work index is particularly index variadons ar dificreni p.oduct sjze, rcsutr from flaw
vahiabl€in pr€dictingthe sizeand capacityof Dewinstalla- concentratioft or shorlages ai rbose sizes,usually causcd by
tions. Tablo IIIA in tle appendix Iists the averag€ work natural grain siz$.
ind.x values of 82 difi€reni materials.
Evaluation ot Particle Size Dirt.ibution
Three PrinciDles The usual ltandard screen scaleconsistsof a seriesof
CommiDutiod phenomeDahave recently been redacted into \ievs with square openinesdifrerins by y'i. based upon
tkee pitrciples,rwhich ar€ usefrnsuidesfor the considera- dre 200-meshsieve oDcbiDgof 74.: microDs. There are
tion of all crushingaDd grinding data. 25,400miclors in an inch. A scrcenanalysissize distribu-
The FiBr Priuctr'le statesthat, since energy irput is neces- tion of a crushedor sround product consisr!of a tistins of
sary for siz. feduction, all fccd particles of finite siu have the p€r cent weighr passingor retaired on each si.ve in thc
a certain .oar8y register,or en€rgy level. which must be
added to tbe enqgy iEput during crusbina or Srinding to Tbere is probabb a defi tr laq qbicb soreras rbe resltar
obtain tbe en€rgyregistei of the product.All statementsof si zedi .Lri buri onof crusbedor grouodproducrsrb owever ,
th€ energyutilized in comminutionmust satisfythis condi Done of the proposed laws bas bcen generatly accepred as
ene.gy input = en€rgy r.gistcr of product - energy Siz€distribution analysesof crushedand sround products
r€gisterof feed. are commonly plotted on los-log paper with (]) the per
Th. Third Theory work index Equation (l) fo ows this cenr passing as ordinatc and the parricle diaDeter (r) in
principle, with tbe energy register equal to the total sp.ciffc microns as absci$a. Such plots of complete samples usuatly
energy input io kwh per short tod. The lrork index t/i is sbow a fairly straisbt lioe for rbe firer particle size ratrge
rhe energyreSjst.r lo 80 per c.trt pdssing100 miclotrs. which begins to curve in tbe coarser sizes and often aD-
If tbe enersy which has becn expended in preparing the proachestao8trcy witb tb€ I00 per cebt passiogIiDe ar rhe
fced particlesis Desl€ctedin analysioscomminution data. rop oI tbe plot. Tbe size 80 per cenr passesmay b. Iound
tbe first principle has beeo violated.aDd applicationof tbe from the curved portion of the plot for use in the work
calculated r€sult to difierent feed and product sizes eill be index Equation (l).
Wben rbc straigbt lower porrion of lbe plo(ed line is
The Second Ptinciple statesthat the useful.work input in extctrd.dat ils slope ,. ir iDrercepLe
rhe 100per ceor passitrg
crushing and edndine is propoitioDal to the length of tb. Iine at i.& microns. It follows a po,e. law deffned by th€
n€w crack tips produced.In ordinarycrushiosand gdnding, G^rEs-C^r.rD1N-ScAUfiMl.rN equation,t s,hich is
rock particlesabsorbstrain energyand a.€ deformed uDder
compressionor sbearuntil the weakestflaw in the particle J , : r0 0 1 . : l (2J
faih wjth.he formatioo of a crack tip. Tbis minute chanse '"
of shapecausesothercrack lips to form at orberweak flaws, From this equation the surfacearea Jc in cm, per gram
and lhe particle bleaks, releasingthe bulk of tbe shaitr of cubical plrticles of density p, with 100 per cent passing
energy as heat.The strain energyrequned to break is pro- tro microDsand slope d lo a grind linit o{ ai mrcronsn:
porlional to fte lengtb of the crack tips formed, since the
additional energy requircd to €xtend the crack tips 10 60.000d f/k.^ \r-' I
rr . . . . ( 3)
b.eaka8eis suppliedby the flow of the sunoundingresidert p,/.roo(t_o)L\ ai /' j
stEitr ene.gyto the crack tips. The grind limit ai hls lecently been assigDedthe valu. of
Since the crack tip lenglh is proportional to tbe square 0.1micron,6equivalent to 1000 Angstrom unirs. This is
root of the new su.face area produced,tbe specincwork abolt 200 tjmes th€ unit spacelatlice of quartz and otber
input requiredk i.versely proportionalto the sqLrareroot rock forning minerals.
of the p.oducl particle diameter minus that of the feed The slop€r is often about 0.5, but may approach unity.
-3-
Crushins or srinding io closed circuii Foduces less fin.s crack lcngth Cr of any !€8ular qushcd or ground product
than oped-circuit opcratiofl, and causes d to rDcreas€ can be fo'rd grapbically wbeo i$ 80 pc| ceot passiDgsizc
Renoval of nnes beforc rcductioDhas the same.ffect As a P and crposD.e ratio Er arc known frotd atr €xponentral
material is eJound fiDer, its value of d often apPears lo sizE distdbution plot. On tbe first shcet tbc Cr valucs for
P = I microD ar. plotted otr tbe lcft-hand iidc, and thc
The loA'log sizedistributionplot is donveDient.However, vatues for P : r0 microns arc plottcd on the dght-hatd
the usual curvature in its upper patt itrdicates that the side. Each pair of points is connectcdby a straisbt linc
actual size distiibution law is of the expooentialtvpc with marked with its E value, ard intermediate lincs catr be
a variable exponen!,ralher tbao of th! po*er type witl drawn using a logarithmic rulc. The lecond sbcet is made
tbe constant exponentd. by plottins values for P: 10 on the left-band sidc abd
P : 100 on tbe rishnhand side, and so on for the 3€t of lix
ExDonential Size Distribution Plots charts, which cov.r the €ltire operating size langc.
A metbod of plottios has bc.d developedwith yiclds size T DI:E I--4'..1 Larh vd!6 lor PldiD. cr (.DFu
distribution lides that arc apparently quite straight for
homogeneous materials-! They follow the expon.ntial t6iso l0@ 10,@0 l0o,00o I
P + 10.3
L145P
The fine product lactor rl was dcrived for the frne dry
srindins of c€mentclinker, and appliesto dry srinalinsdown
to valuesof 15 or less-For wet fine gdndirg,,{r should
" a maximum value of 5-
havc
Convers€ly,thc plant opcratins work index ftorn Equa-
tion (la) sbould be dividcd by 11 and by (8/D)tr, for dtuect
compari\ob sirh tbe laboratory work index lti.
'
Prcper Grindins M.dia Sizes
Th€ siz€ of tbe griDding rn.dia is one of the pridcipal
factors afecting th€ efrciency and €apaciry of tumbling-
typc gridios milh. It is bcst determir€dfor any particolsr
iDstallation by lengrhy comparative plant tesb with carcfully
kept records. Howevcr, a mcthod of calculating the propcr
Gri n ding sizes,basedupon coffcct theoreticalprincipl$ and tcstcd
Corcction lor Feed and Products by experi€nce, can bc very l€lpful, particutarly in n€w
Closed-circuit grinding and complex grinding circuits
which include coDcentrationand separation€quipment are The gcneral principle of selection should be that th€
proper size of th. make-up srindins n.dia is the siz. which
best analysedby consid.dng each circuit as an inlegraled
unit. In closed-circuitgrinding the unit consislsof tbe mill will just brcak the larsestfeed particlcs.If tbe media is too
and the classifier,with a single feed to the mill or classifier larse, the Dumberof breakinsconlactswill be.cduccd, and
and a singleclassifierundersizcproduct. Calculationsfrom ihe €x&emefines mad€ by each coniacr will be\incr€ased.
the mill discbar8eand circulatiDgload are usually unsatis- If rhe media is too smal, there will be \yastedconlactsof s
factory becausethe harder fraction of the material accuhu- foic. insufrcientto brcak the particle! contacted.ln eitber
Iates.and the circulating load has an unknown hiSherq,ork casethe srinding efficiencywil be reduced,but the rse of
index than the new feed. If lhe closedcircuit includ.s con- undersirc media is usually more harmful lhan the use of
centrating equipment such as magnetic separatorswhich
reject a taiUng,the product of the ItindinS circuit is a cal- Let , = make-up ball, rod, or pebble diameterin inches;
culatedcompositcof the classifierunde.sizeand the separa- F = sizein microns80 p.r ceot of the new feed pass€s;
tor tailirg, which should always be screenlnalysed for this 7i work iodex at thc fecd sizeF;
-
C3 = f.action of mill critical specd;
Calculationsinvolvjns urnatural feed from which part sc = specific8rality of material being ground;
or all oi the nnes have been removed should be avoided D = mill diamere.in fect insideliners;
lvhenever calculationsof inlesraled ci.cuits can be sub- K = an empirical.xpericnceconslant.
slituted. However. the empirical mcthods describedunde.
''Scalped Feed to Crushere" can be used when necesa.y
In o.dinary ball mill opcration f-in. steelballs will€fiec-
when E r . naingr e r\ a rc ma d e In o .m c l l . .0 1 .n rous. lively crind averasesiliceousore with 80 per cent passing
p i l ot - plantm ill of d i a fre te rD , tb e g ro s sp o w e r i n prt per l mm. of * i l h F:1000mi crons or about 16 mesh.I t
follows theor€tically,r aod i! coDfirmed by experiencc, that largediamcte. mills draw rnore power with large ball sizes.
2-in. balh are suitabl. fo! 4-mrn feed- 3-in. balls for 9-mm Ball rationins. whicb is tbe regular addition of dcfilite
particl$, .tc. Th. batl size should vary as the squarc root propofiioos of balls of djfferent sizes,may be used when a
of the paniclc size to be broken. is intermediatebetweetrtwo commercialbau sizcs,or wher!
From tbeo.etical considerationss the proper make-up size an unusualsizedistribution of the fccd requAesthe addition
a of steelor cast iron batls is found fron of some smaller balls with lhose of the calculrtcd sizc ,.
r,s,
Fip. l. Fouteen
86-ht ba nius
istallei! at So then
Petu CopPer CotP.'s
corcentotor, foque'
palo, P.tu, griu.Iing
30,ffiO tons ol coP'
P A RT II
CRUSHTNG AND
GRINDTNG GALGUTATIONS
Th. concludinsp.rt of thi. rrtlcl. i5 conc.rn.d with r nuhb'r of h'toR rfi'di" th' gindina
J"..'i ."iiriiit..t such r5 th. rhdion or nill volufr. occ!pi'd bv th' trind-
i;;-;;:;.,.h. or rods dd b.rk b b. 6nt.in.d in . mirr, {"r
"q"lpn.nt.
qu.ntni; or mill
'nd
;;"ndin!;.diun,.id mlll tP..d in le/ms of th. critic.l tP..d. Th. .ff.cti of hill dhh't'r' or
;ownw;rd rlltt.sc ol b.tl .hrrg.. rrtio ov.Eiz.:f"d. uPon P'rtormrn" Powcr
'nd 'on{hts
don rre d'(us.d, oP.n-.ncuit multitliatio^ frcloB rrc liv.n ror.onrcrtlng clor'o{rrc!E
work v.t{.s to the oP.n_circuit vrlu.r .nd. 6n.llt. .o'r.ctiq r.cio6 lN'n ror worx
'r'
i'a.i *rirtion' *hicli .rit. wh.i l.boBtory srind.birit/ ind ioP.<t cruthinl t'ris 8iv'
diF.r.nt wort Ind.x v.lu.t.
Dl FRE D C. g O ND
M6t3l Wcar realor the m6tal savine! resultinS frorn the usc of hard
6itr8le iten altoy mil lirings or mcdia arc usualy Srcater id drf
r f,ETAL $.ar is us'rally lbo s'-.ond largeqt griDditrg,
lVl **'r. is conventiooalItindins, aod io wcr Srindingttan in wet
"i i*i"l"ti*' il mav lpproacb or thc
iii'-ai'g 'ven "cerd Ab.arion Tcat
DOWCrCOSL
' wlcralwcar is commonlv.xpre$edin lb/ton susbcd or Abrasion t€its to indicatc m€tal wcar ar6 madc a3
rl"".ii". i*r"toDs ;; fced aod Eoduct siz€s ald folows: o 4O0slams of -l + paniclcaof the rnrttrirl
-iiii.
L work indcx are climinalcd bv erprcsliDs m'tal coDsumP' to be Ested ar; Dlaccd in a rotAtiry drutn for 15nin Th'
wom parb: it can be '-in,
a rapidy rotatingiop.llcr
Go ,, nltWl" iucludios rcj€€tcd drun sbow€rs thc rock thousb
ott i". i.on tu pourds of metal coDsumed pcr toD contained within it. The imPcller lotat€d at 632tpm and
crusbedor eroud and the kwh/ion consistsofa3 x 1x + i[. stcclpaddl€ with 2 !q. in. crPoscd
Tbe pounds of nelat botb wom awav-abd scrapped a\ to wcar, machiDed of SAB 4325 st€cl hardeD€d to 50O
*.'i-"Le tuti"" tte abEsiv€ncss of tbc ore and lhc Brircll. The gram! of weislt lost bv thc pad{ c after im'
t."itta""o -ittot rt" IDetal Th€ averagi v'lues froE pactinglour Juccessive 400-8rambatchcsof rcck for 15min.
"trnsi6o rt-to of mils witb ordharv miU--liriDg'srDd iach ii called the abrasion irdcx and dcsienat.d $ ,ti
or€s' The combinedproduct of the four ls_min. pcrioal!i! sctccD
eFindingEcdia, grinding w.t a largprangEof siliceous
"-irie"
aoalysed;it av€ra8es80 per cent passins13'250micron$
Milt TlPc Rod Bd Paddlesof sDecialallov si.els and cbet irom csrl bc
0 2 1 ro d s 0.14 balls r.sEd with a sdtrdardabrasiveFaterialto detcrmiDc r€la-
M c dia: lb/ k l 9 h
LiniDg: lb/twh O.oAi 0.020 tiv€ wcar raqistance of the metals.
wesr io drv SritrdiDg averages aboul oo€' T\a av.raeaAi values of some tvpical materialsfron
Th. nctal 125 tests artlsted iD Table IIA in tho lpp€ndix. A ftm
."ve*l tnal ot wlt ItiDdiDS tbe same rnatedal Howcver'
cofielation with actual wcsr rat€sin €rushcrssDdeEiodhg
* U" mat.rials Srouod dry are sofi'r aid less mils hasDot becdmadeasyet; however,it is apparcutthat
-r""
Ii-#iu. rl* tlo'. gr-'a q'ct Batl coatios io drv srioding
the abrasionindex vadationssho$n in Table IIA ar! mucb
can reduc. tbe metal w€al still turlher' sreatcr than tle wriations to be expccLd iD tho ts.tal
Wcff over taf of tl. nelal wear i! wct SriDdiDg re\ulLs
metal wear rates in cornmercialmachines.It is obscrvedtbat anv
ftom conosion, or dissolutjoofrom lbe'ctivc nasetrt correlation b.twe€n tbe work index and tl€ abrasioEhdei
l"J""es iont.uattv bcids produced in tbe mill For tb's
is vc.y slight
Prelimirary indications ate that ir wet srndins thc
t'ffi"F*,"F,*"+H'[+"t:r#':#.1"ji{;T|i"#tTJ
&".df"':i'i
i r,iLTr:!.1*';5;
pourds of bals p€r kwh equals(li + 1) dividcd bv a
- 9-
Dumberwhich ransesfrom 6 to 9, atrd Iid€r w€ar iE about speedis about 77 pd cent of criticat: for wct rod milh ii h
onc-cishth of bal wear. For wet rcd mills the divisor about 70 per ceDt of critical. Somewhat slower spe.ds arc
rang$ from 4 to 6, and liner w.ar is about one-s€vmthof often found to b6 more e4onomical.
rod w.ar. Wear in dry srindins t about onc-scvlrih of Dry-grindins mills atrd pebble mills usualty operare at
wet Brindins.Thc .veragc metal wear in cnshirs is rougbly about lbc same sleed! as wct mith! nith the maxiDum less
comparabl. to the liner wear in wet srioding. lirnited thaD iD wet mills-
Laboratory sludies hav€ showo that or thc iising side of
Volume of Grinding CharSe th6 mil each circular row of gritrdirg ba s slips dowqward
Tbc ftactior /p of thc total iot€rior mill volum€ occupied tilb lespect to the next o!te. row it restsupon, tbus causiog
grindina in tbis portion of the mi . A similar dippase
(1t, somc
by llc srirdins charsc can be foutrd by Equation obs€rvcd in rod Eills.
whereD is the insidc diaractcraDalO b thc \€rtical distaocc is Dot
griDditrg At spccds faster than 60 per ccnt of critical the srnaller
do$n from th€ iDlide top of the Ini[ to thc lcvcled
balls or rods in e Sdnding charac tcDd to concsnEatc qritb
charS!: O should bc the &vcrag€of m€asu.crDents at the
the pulp nea! ih. IiDiDg of a cylin&icrl mill, ard lhe larg.r
contr. and borh .d3 0f thc mi[. media lre displaccd roward the of th€ cbargc. Advan-
vp = 1.r3- r.26AP ....0 t tagc is t.kea of ftis iD ball mill6ccrE€
to movc the smalld balls
Tho weighi of the srindiDgcbrs€ catrbe calculatcdftod loward th€ dischargc end of thc milt by spiral liftcrs Aailina
D, Izp, atrd thc inside leDstb of the mi[. towerd the mill diacharge; or by rnaking thc mil sh€
Loos€roudd balls wilhout b!€akagcweigh 290lb/cu, ft, sli8hdy conicd, with the smallest diamctcr at thc dischargc
loose rods 3901band silica pbbles 1001b.Measuemcnts
of thc weisht of steel ba s contain.d in a cubic foot. bor Smal-diameter mils arc cornlnodly opcratd at somc-
are usually lccs than 2901b becau. of thc incr€ascdvoid what highcr fractions of tbeir critical sp.lds than are lars€
sprce at th€ sid€s of the box, and tbc w€ielt coatained mills, indicatirg tlat the proper mill sp.ed h itrtermediare
decreas.sas tbc ball siz€ idocas$. For accurat! ocasurc- between a constant fraction of criticsl spced and a coDsrant
mentsthe smallcstdimeDsioEof the contaiocr lhouLl bc at pcdpheml speed. An approximat€ empirical cqurioD for
least 20 times that of tbe largest ball. Brok€n balls caD tbo maximum pra€ticalrpm of wer bal mills, designaredas
reduccth. spccificweight to 2801b/cu.ft, and b.okcr rcds
to 3401b.Thc spedfic weisht of both ball add md charges No = 51 - At)losD . . .. (20)
caD also bc rcducedby a content of hard particles of the
material bciog ground. Effed of Mill Diam6t€.s
Tons of new balls 7b cotrtaio€d io a min ar. found At a consiantvolume fraction t/p the massof rhe grind-
approximately from Equation(tO, atrd lons of rew rods ilg cbarSevarics as D'. At a coostantfraction Cr of the
?/ from EquatioD(17). critical sped the pcripheralspeedvariesas v5. It follo*s
....00 rhat tbc pow€r input to a conventional tumblios mill
Tt = Vp D'L16.8 . ...07) theor.tically variesas the interior diametcrto tbe 2.5Dower.
Meaqurements bav. shownrharlbc wer6n. srirdi;g mitl
A charseof Brindirs balls contaiDsapproximately40 capacity varies as D'.. Thc diamcter expoDeatincreaslr
per cenl of void space,aDd rods in lir€ar contact contaiu sliSltly in mils opcrated under bish impact condirions.
20 per cent voids. Broker orc coDtainsapproximately 40 Theoretically, iho maximum expon.nt under reductioo
p€r ceatvoid space,andweighs100lb/cu.ft multipliedby ertirelyby inpact is 3.0.
its specificsravity ovcr 2.65.At 80 pcr ccnt soli& or morc Mealulemdrts haye aho sbown that tbc power inpur
rhe voids iD a grinding chars€of stcel balls caDcortaiE 14 expooentactually vadcs as Dar. The decreasefrom tbe
pcr cent of the batl wcight iD ore multiplicd by S8/2.65.A theoreticBl2.5 cr(poDentprobably result! ftom energyfrom
rod chargowith the rods in liaear contactcan co aiD 7 per tbe falling bals or rods beiss tsansferredback ro th€ mifl
cen. of (hc rod *eigbt. Howcv€r, botb bals and rods arc she on its do$n-8oing side.The actualdjametercxponent
commonly for€ed apart in the mill atrd may coDtainmore per lon of grindins nedia is 0.4 insr€adof th€ thcoretical
ore thao tlese miEim m amounts. 0.5.
Tbe p€r ccDt solids containedin th€ pulp within a wct Tho difideDce betweenthe two observeddiameter ex-
Brindins mill is ordiaarily more tban that mtering and ponentsof 2.6 aDd2.4 is 0.2,yJbichis the expon.nt d€filing
Icaviry tb€ mill, siDcethc flater fows tbroughthc mill fastcr the mechanicaladvantag.of lars€diametermilb. Mechani-
tlar the h€avierparticl.s of ore. This diference is io- cal emciencyircreascsas thc inrerior mil diarneterto rhe
creasedin 8ra.eand pedpheraldischars€milb- 0.2pow.r, aBdtbe kwh/ton requiredto sdnd d.creasesin
the samcratio. Sitrcethe standards'ork iDdcxis basedon
Criticel Mill speed rDillsof I ft int€rior dhmeter, rhc computedkwh/ron (I/)
Tho theoreticalcritical spcedNc h rpm b the speedat by EqDatior(1) for any min of D fr interior diametershould
\rhich a particle of Do diameteragainstthe mil linins witb be multiplied by (8/D)'t
no slippaso s?ouldcentrifus!. It is found from Fauation
(18),c,hercD is th€ intcriormill diamctcritr fcct. Powe. p€r Ton of c.indlng Media
Nc = 76.61\fd .. . 0 8 ) The powerinput requiredia tumblinsmitlsis calcutated
from tbe power requircd pcr ton of srindins media uuder
The ftactioD Cr of the critical speed rcprcscnted by alry tbe mill operating
bil rpm is found from Equatiotr(19).
coDditioDs.It vari.s wirh the ftaction
Zp of the mill volume occupiedby the srirdins charge,tb€
Cr=0.01305x rpm x y'b .... (19) fractio! Cr of the critical spccd, rod tbc iDrerior mill
Tumblins mills are usually d$ign.d to rcvolve at a con-
stsnt fractioD of th€ critical speed.Incrcascd specd iocr€ases Equatioo(21)sivcs th. mil input kW pcr ron of
the mill .apacity ard power draught,but also increasesthe nelv grindingrods in -(r/,
cotrvenlionalwet Srirding ovdflow
metal w€ar and mainteDaDce cost per ton Sround.For con- lod mills.
ventional wct grindiog ball mills more than 8 ft in diameter, Kvr=Dt4(6.3-s.4vdcs . .. .(21)
*ilh peripherallifters and a ball chargeof more than 30 per An accumulalion of broken rods in thc mill can reduce
cent of the ioterior mi1l volume.the maximum Dracticalmill tbe actualpower d.awn by as much as l0 per ceDt.
- 10-
4 !\ C LA S S IFIE RP E R FOR I{ ANCL
-----------TLoi-
,r/ -ri i.. \
f, oN
- %cuM
I * E Ei: \ovERs,zE
Fig. 2.
E[ = i: \
: 3i<' \
TOP: Classifiet perlorma ce plot. - -[ -'" \--as
Ov.tsize per ceat .am. ok plott?d against und.6ize
D.t ce Dasinz. InrcB..tior showt E3 p.r .enl
ildsifi.t Zfrci.icr anl t6s nkrcas pa iaE eze.
S 3l vA R ,A l ,oN s- PLor
BOTTOM: Coftection lor wolk indet variations. ; ;*
Gtindabiliry TestFWi = 14.4 at 14 mesh.
Wi: 1O.4a, 2$ nesh. W. 7 O a | <r h / S H o R Tl O N
Gind in ball ni| lrcn 80 pet cent pasins 1m0
miooAs to 80 p?t ceht passinelN nicrons.\'lit =
10.9,Wit:r4.4i lrcn Esuatioi (42)W=7.O8 kwh
Equation (22) sives.Krr, the mil irpur kW per ton of Whcn the actualreductionlatio.Rf is much smal.r or
srindiEgballs for coaventionalw.t-gdnditrg ball mills using larger thanRro, the work input P from E4uation (l) 3hould
makc-up balls lar8cr than about oDe-eighticthof thc mill bo multiplied by the cmpirical adjBtmcnt factor 1,, wher.
A'=r+2(Rt- R0)'1300 ....(26)
Kt tb * 2.8DLt(3.2- 3 v p) Cdr - o.1|Ztrw, .... Qz) Sinc€ pcdpheral dischargcrod mills havc los, reduction
For dry-grinding smtc discbargcmils Xn, should bc ratios, thcy Dormallyr.quirc an incrcasciD P.
multiplied by 1.08. Ba[ rdills arc lcssEeruitiveto changesin reduction ratio
If Od r€prcscnt! &c vcrtical distaDccin feet ftom thc ttad rod mills. Ho$cvcr, whm R/ b.lomes le$ thar about
insidetop of thc mil to th. lowast discharsepoint, then 3, particularly in 1befDe srirdins of concentsat$,7 frorn
' Vpd= t.r3 - r.26 ....Q3) Bquation (l) should be nultiplicd by the cmpiric{l adjult-
AdlD
mcntfactorlt, where
wheret/pd is llc fractior of the intdior mill volume below
dischargclcvcl. For a full lowlev€l gtat discbary. Vpd zX(R!- 1.351+ 2.&
--' ....Q'
equal!0.029.For welgrindins srate |nd low-leycl discbargp 20(Rr- 1.35)
. l, . O.4O- VDdI
m'rls.rnurupry nlrD -ny
l, + 2l l. Free Verticll Orcillatlon
A body id fre€ v€rtical oscilation fals from it! highast
SlumD Coffection posilion under tbe influcncc of gravity and tu stopp.d
Lars+diametq ball mills fed with small rnak&up balls lorcibly by atr equal deccleraiion; it is thctr acc.l.ratcd
lose power becauscof €xce+livcdownwardslippagcof the upwad at tb! samelate and r.acbcs tba samchiSh.st pori-
bal chalsc or the siDSsid. of tbe'milt, and this lo$ of tioD asbcfor.. It dcscdb€sa sinplc barmonicmotion ovcl a
powd inult d€creas.!tho min capacity.An cmpiricsl slump vertical distanccof ,fi inchcs with .prr cycl.! pcr minut!,
subtraction quantity Sr is computedfor wet overnow and
satc ball rnills by Bqu&tion(24),to bc subFact d from the ....(28)
K)r, vdue of Equation(22).No subEactionis madcfor vtct The critical frequencyof vibrating bodic! is calculst d
ball milts with , < 8 or for dry ball mills with D < 10.For fiom Equation (28)i as tbe cpn (oi rpro) dccrc*cs below
dry mils with D > 10 thc slump quantity to be subtrastcd thc critical, th€ tcndcncy to mai sio frcc vdtlcal orcilla-
from Xr, is tbec-quartersof Sr asfound by F4uatiotr (2t, tion caNesthc amplitudc i to incr.aic.
whcr€ , is the dianeter of tbc make-upballs f€d in inch.s. Tho power o€ccasaryto maiDtainfrc€ vcrticd oicillation
"":(i#- t-
is direcdy proportionalto thc pcriod of os.ilatiod (l/cpn)
,.,.Q4) aod to y'n. Wbere-Kvo is the kilowatts n!.cssary to mair.
tain a ton massin frec vcrti.al oscillation.thctr
Kvo = 328lcpn = l.tt li ... (29)
Efi€ct of Reduction Ratios
The reducrionratio Rr is the ratio of the size of the rew Th€ vertical componctrt of thc motioD of a particle of no
mill fced to that of tbe final prod ct, or F/P Witb scalp.d diamc.€r a8ainst thc lining of a bal mill at griticd spccd
Iccd, FclP should bc used. Rod mills arc pa.ticularly s€$i- colrEsponds to frce v.rtical oscillation*ith h: l2D, znd
tive to u avourablercduction ratios, atrd if F/P is smatlcr
than about 12 or larser thatr abouf 20 the twh/tor (,'/)
required fo! grinding increases. If Rto represenhtbe opti- Ef,ect of Overiize F€ed
mum rod oill reduction ratio, its approximate value is Fced particlq which are too lars. for thc grinding ballt
or rods 10 brcak are sradually worn down ir the mill r,itl
Rto=8+5LlD (25) a considerablelossof srindif,g eficieocy.If rhe mill product
- 11 '
is coarsc,the loss in milt capacity can b. quite large; ir tho same linear or logarithmic gsph shect. Thc poiqr *herc
dereasesas the proporlior of the lotal work cotrsumedin tle two lin6 cross h thc partirg size, aod the pcr ceot
fine erindirg increases.The decreasein capacity caulcalby passiDgat tbc cro3sirg poiDt is the per cetrt cmciency of the
overeizeerirding media is aot as pronouncedas that caused
En:./r
Rer. a
+ f91', l) - l9,r, l) ....,r,
-
Per Cent new Classifler Feed to Closod-circuit Mlll
When a rod mill in open circuit discharges ro a cls$ifi.r
\Gdr.l 1l \Gd,+ tJ
ff the recessionfaclor R/ is tb€ number of standard y', in closed circuit with a bal mill, rh. per ceDt of thc rod
scr€eoscalcspac€s betweensizeP and sizeCp, then mill discharse which enl€rs the ball miI as scalp€d ncw feed
-i2-
Som. apFoximatc opcD-.ircuit multiplication factoft for on th. same samplc at difer.nt producr lizes. Tbis corE-
vario'rs r.ferencc percentag.spassingare lisred below in plicates the calculatior of the work iDput rcquir€d (p) in
Table IV. They follow an exponeniial function. kwl/ton from Equation (l), which is !s.n with rbc dcsir.d
capa.ity to fnd thc required rDoror and mil siz!.
TASLE IV Wh€o this bappens thc various work iddci values ar.
plotted vcnically as orditra!$ on lo8-lo8 pap€r against tbc
80 per cent passing size as abscissdc,and the poin& arc
connccted by stlaight linca which arc cxtcrided horizoDralty
50 1 .0 3 5 to the edg.s of rb€ pap.r. Tbe 80 pcl cear pa.gsiDgsizcs ol
60 t.0 5 Sriodability l.st ploducts are fourd by divjding rbc r.r.cn
'lo t.l 0 opeDin$ Pl in Eicrons by log 20 (1.301),or by the valucs
80 1 .2 0
90 1.4'0 siv€n folowing Equation (8) for fine bal miI tcsts. Thc
92 1.46 80 pcr cent passing sizo is 1.5 iD. for rhe impac! cruhitrg
95 1 .5 7
98 1 .7 0 The work indcx values at tl. dcsignat.d 80 pc! cerr !ass-
ing product size P a l fced sizc F arc found from ihe
plot and dcsiguated as tri and ,t/i. Thctr thc work irpul
Correctionfor Work Index Variations ry is fouDd from F,quation (42) as givon below:
WhenaDor. hasmtural grainsizes,
it sometimes
happ€rs
tbat laboratoryrcd mil and ball mi gdndabilitytesisand _. lO W t0 wi, , 10\wit - wt,,
*-@- -J-- ....to r t
impact crustiDg teEtssive dificr€Dtwork index (7r1 values
-
Appendix
- 13 _
is coarsc,tbe loss in mill capacity can be quitc largc; ir Lhe same lirear or logaritlmic Sraph sheet. The point wb.re
decrcases as thE proporlion of the totll work consumedin ihe two lioes crolc is the parting sizc, and th. per cent
fine srinding iocrcascs.The decreaseir capacity caus€dby passingat the crossiDApoint is the per cent emciencyof the
ove.sizegriodine media is not as pronounc.d ss that caused
-.,2,
br T9E of Mrbrtrl'
cluijon $ouid b. ucd i. it't .h. .wrry @rr hdd vd!.! L,Ed tuE ro ,!*r6c - idrrulioE, |hs d! indMdut vdliod bd*& 6{cld! i! rry
"Dt
z's4
id r19 2.69
r6,30
9 r.76
27 2,66 r0.r3
5 2,5.
1 2.1r
16.16
7 2.73
9 3.00
1 2.15
r J.r 3
19 2.36
- 14 -