Effects of slurry rheology and ball coating
on abrasive wear and the grinding rate
of quartzite
J.N.Orlich and I. Iwasaki
Abstract - The effect of slurry rheology and ball
coating characteristics on the abrasive wear of grind-
ing media and the rate of grinding were studied using
-10 mesh quartzite in laboratory marked ball wear
tests. Pulp viscosity was found to be closely related
with both the thickness and physical characteristics of
the coating affecting abrasive wear. The packing
density of particles at the ball surface was the primary
determinant of wear while the grinding rate was more
dependent on viscosity and thus the ball coating thick-
ness. The optimum grinding rate was achieved when
the coating thickness was about twice the largest
particle size.
Introduction
The consumption of grinding media in rod and ball
milling represents a major operating cost to the
minerals industry, amounting to approximately 900,000
tons of steel annually (Committee on Comminution
and Energy Consumption, 1981). Both corrosion and
abrasion are thought to play major roles in the wear of
grinding media; however, the majority of the research
in this area has been devoted to the contributions of
corrosion. While the estimates vary, it has generally
been shown that abrasion is still the major factor
affecting media wear.
Recent research conducted at the Mineral Resources
Research Center (Iwasaki et al., 1984) has shown that
percent solids of a magnetic taconite pulp significantly
affected abrasive wear and the grinding rate. Earlier,
EUimpel (1982, 1983) showed that the use of viscosity
modifying chemicals can have a significant effect on
grinding under proper conditions. Thus, the slurry
rheology is a major factor affecting abrasive wear and
the rate of grinding.
The effects of pulp density on grinding efficiency
have been explained by various authors (Clarke and
Kitchener, 1968; EUimpel, 1982; Meloy and Crabtree,
1967; Pryor, 1965) in terms of the ability of the slurry
to coat the grinding media, which provides a convenient
means of visualizing the physical relationship between
the slurry and the grinding media. A simple laboratory
procedure (Iwasaki et al., 1984) has recently been
developed that provides a means of quantifying the
ball coating tendencies for laboratory study.
The purpose of this investigation was to study the
effects of slurry viscosity and ball coating characteris-
tics on abrasive wear and the rate of grinding by
varying pulp density, the size distribution of the solids,
and addition of a viscosity modifying chemical.
J.N. Orlich, member SME, is a sales engineer at Eriez
Magnetics, Erie, PA. I. Iwesekl, member SME, is a professor
at the Mineral Resources Research Center, University of
Minnesota, Minneapolis, MN. SME-MMP nonmeeting paper
85-643. Manuscript August 1985. Discussion of this paper
must be submitted, in duplicate, prior to April 30, 1987.
32 FEBRUARY 1987
Experimental
A 203-mm Abbe porcelain grinding mill was used
with a ball charge consisting of 126 mild steel balls
having a nominal diameter of 25.4 mm, 15 of which
were marked. The mill was charged with 1150 g of - 10
mesh quartzite and was rotated a t 69 revolutions per
minute (rpm), or 73.5% of critical speed. In order to
study abrasive wear only, all tests were conducted in
a nitrogen atmosphere by purging the charged mill
with nitrogen through a 12.7-mmhole in the end of the
mill immediately before sealing. The distilled water
was also deoxygenated by bubbling with nitrogen for
10 to 15 minutes. General ~roceduresfor cleaning and
weighing the marked ballsare given elsewhere (Ferez
and Moore, 1982) .
For the measurements of pulp viscosity, a Brookfield
RVT rotational viscometer with a tee-bar spindle was
chosen. The standard Brookfield tee-bar (helipath)
spindle set, consisting of six spindles each with two
bars of varying length, was used together with a
modified 12-bar version (Underwood, 1976). To mini-
mize the potential of particle settling, a special sample
cell was devised that circulated the sample upward
through a 76-mm-diam cylindrical measurement zone
by means of a peristaltic pump. The measurement cell
was enclosed in an outer casing through which con-
stant-temperature water was circulated to provide
temperature control at 35OC. Calibration was conduct-
ed using standard viscosity fluids obtained from
Brookfield Engineering Laboratories Inc., Stoughton,
MA. Spindles were selected for each individual slurry
to give instrument readings a s close a s possible to the
desired range of 5% to 100% of full scale.
As the Brookfield viscometer with the tee-bar spindle
does not provide actual shear stress and shear rate
data, relative viscosity estimates and the general
rheological behavior were obtained using the instru-
ment readings (proportional to shear stress) and
spindle rotational speed (proportional to shear rate).
For the purposes of this investigation, the "true"
relative viscosity as defined by the tangent to the rpm
vs. viscometer reading curve was utilized.
Experimental results
Effect of percent solids and slurry rheology
The easiest and most practical means of changing
the rheological characteristics of a mineral slurry is
by variation of either the pulp density (percent solids)
or the size distribution of the solids. The use of
viscosity modifying chemicals has also been shown to
be effective (Klimpel, 1982, 1983). Percent solids
variation in batch grinding may be achieved by one of
two possible methods: either maintain constant slurry
volume and allow charge weight to change, or hold the
charge weight constant, varying volume filling. In
general, the first method is preferable since grinding
MINERALS AND METALLURGICAL PROCESSING
in this manner more closely simulates grinding in an
overflow ball mill (Katzer, Klimpel, and Sewell, 1981).
However, it has been demonstrated over a wide range
of volume filling (20% to 140% of void volume) that
grinding media wear does not change appreciably
compared to the effects of percent solids (Iwasaki
et al., 1984). Therefore, the constant charge weight
method was selected because the intended range of
percent solids, and thus void volume, was relatively
narrow and the analysis of the results is greatly
simplified.
Variation of the size distribution of the solids can be
accomplished by either varying the time of grind or by
altering the size distribution of the feed to the batch
tests. The latter was accomplished by the addition of
varying amounts of CaCO, precipitates (Calcium
Carbonate Precipitated Chalk, Fisher Scientific Co. ) ,
maintaining a constant void volume filling for a given
percent solids. CaCO, was selected because it was
known to produce pseudoplastic suspensions, similar
to quartzite, with relatively small additions and was
used by previous investigators in a similar study
(Clarke and Kitchener, 1968).
Viscosity curves showing relative viscosity versus
viscometer spindle speed are presented in Fig. 1 for
various percent solids and grinding times. Pseudo-
plastic nature of the quartzite slurries is indicated by
the reduction in viscosity with increasing rate of shear
(i.e., shear thinning). At 60% solids, viscosity is seen
to increase directly with grinding time over the entire
range of spindle speed. A similar relationship was
obtained for 70% solids between 15 and 30 minutes.
However, the viscosity curves at 30 and 60 minutes of
grinding virtually coincided. The manner in which
these curves tend to parallel one another indicates that
viscosity variations due to percent solids or particle
size distribution may be characterized equally well a t
any given spindle speed (shear rate). In subsequent
discussions, therefore, viscosity is generally quoted at
the intermediate speed of 7.5 rpm, a s the lower rpm
data was less accurate and some of the high spindle
speed results were erroneous due to the effects of
turbulence.
The effect of pulp density, size distribution of solids,
and viscosity modifiers on abrasive wear and grinding
rate, as indicated by percent - 325 mesh, are presented
in Fig. 2. As percent solids increased from 50% to 70%
(solid line), media wear decreased continuously from
59.3 to 44.0 mg/ball. Additions of up to 200 and 175 g
of CaCO, precipitates a t 50% and 60% solids, respec-
tively (dashed lines), resulted in some further decrease
in wear due to the effects of viscosity (see the viscosity
values in parentheses). The use of 0.5 kg/t Dow 4272
viscosity reducing agent at 60% and 70% solids showed
very little effect on media wear. The rate of grinding,
also presented in Fig. 2, is seen to be maximized a t
60% solids. The addition of CaCO, precipitates resulted
in a continuous decrease in percent - 325 mesh a t the
lower percent solids. At 60% solids the viscosity
modifier led to a slight decrease in the grinding rate,
while at 70% solids, percent - 325 mesh increased.
To further evaluate the contributions of viscosity,
Fig. 3 was constructed showing relative viscosity a s
the abscissa rather than percent solids. Similar to
Fig. 2, media wear is seen to decrease continuously
with increasing viscosity a s percent solids increased;
however, increased viscosity due to CaCO, additions
showed slightly higher wear a t the same viscosity. At
70% solids, the use of 0.5 kg/t viscosity modifier did
result in a significant reduction in viscosity, but
despite the magnitude of this change, there was
MINERALS AND METALLURGICAL PROCESSING
relatively little effect on media wear. Neither media
wear nor viscosity were greatly affected by the
viscosity modifier a t 60% solids. This may suggest that
it is the percent solids or the packing density of the
particles that is the primary determinant of wear.
A 70% Solids
6O0lOSolids
60 q)n. Gripd tiye
't
L..
...
101 1
lo0 10' lo2
SPINDLE SPEED - RPM
Fig. 1- Slurry viscosity as a function of spindle speed at
different percent solids and grinding time
In terms of the rate of grinding, Fig. 3 shows that a s
percent solids increased, the percent - 325 mesh was
maximized a t approximately 60% (192 mPa.s vis-
cosity). With increasing viscosity due to CaCO, pre-
cipitates, the grinding rate decreased continuously.
The use of the viscosity modifier produced results
similar to those obtained by percent solids variation
at the same viscosity. Therefore, the grinding rate
appears to be more sensitive to viscosity.
Effects of ball coating
Ball coating characteristics were determined using
the method reported previously (Iwasaki et al., 1985)
for quartzite slurries of various percent solids, CaCO,
additions, and grinding times and are summarized in
Table 1. With increasing percent solids, the thickness
of the ball coating is seen to increase together with the
percent solids of the coating. I t is interesting to note
that only a t the highest density (70% solids) was the
percent solids of the coating the same as the bulk of the
slurry. Table 1 also shows a similar relationship with
increasing additions of CaCO, and increasing grinding
time. Further examination of the data in Table 1
indicates that there is a good correlation between
grindhg time, viscosity, and ball coating. This will be
discussed in more detail later.
The effects of ball coating on media wear are
summarized in Table 2. With increasing percent
solids, media wear is seen to decrease with increasing
coating thickness. A similar trend is evident with
FEBRUARY 1987 33
increasing additions of CaCO, precipitates. However, radially attached bars, the tee-bar spindle has the
with the viscosity modifier a t 70% solids, the wear rate advantage of having no areas for particles to settle and
decreased somewhat despite a significant decrease in is not as susceptible to slippage. However, because of
coating thickness. the absence of a well defined shearing gap, exact shear
rates cannot be calculated; thus, only relative viscos-
ity data can be determined.
Various means of evaluating the effects of slurry
50% Solids rheology on the process of grinding in tumbling mills
6O0/0 Solids
have been utilized. Early investigators concentrated
on variation of the characteristics of the liquid media,
such a s glycerine (Clarke and Kitchener, 1068;
Schweyer, 1942), corn syrup (Hockings, Volin, and
- - Due to CaCOj Mular, 1965), and calcium carbonate precipitates
(Clarke and Kitchener, 1968). While these efforts did
produce some valuable information, because actual
slurry viscosity a t any time during grinding is affected
by other factors such as particle size distribution and
shear rate (as well a s other liquid properties - density
and surface tension), it has become increasingly
apparent that the viscosity of the slurry itself needs
to be considered. Recent work by Klimpel and co-
workers (1982, 1983) has successfully demonstrated
the analysis of the effects of slurry density on grinding
rates by characterization of the slurry after grinding.

I
I I
60 70 80 50% Solids
%SOLIDS (including CaC03)

Fig. 2 - Percent solids vs. abrasion wear and percent - 325 C3

mesh at 60-minute grind showing the effects of viscosity z
difference. Numbers in parentheses indicate viscosity in
mPa s..
CaC03 removed before screening by dissolution with HCI.

Discussion
Determination of the rheological properties of a
mineral slurry is a complex matter due to various
factors such a s nonideal rheological behavior, particle
settling tendencies, and possible problems associated
with particle migration away from viscometer shear-
ing surfaces. Consequently, rheological measurements
are used mainly for trend or relative comparison
purposes, and a s yet, no standard equipment or
procedures have been universally accepted.
The three most commonly used instruments for the
rheological characterization of mineral slurries are
consistometers (DeVaney and Shelton, 1940), rota-
tional viscometers (Underwood, 1976; McKennel, 1960; 8 R E L A T I V E VISCOSITY - mPa-s (7.5RPM)
Tucker, 1982), and pipeline rheometers (Pouska and
Link, 1981). Of these, the rotational viscometers Fig. 3 - Viscosity vs. erosive wear and percent - 325 mesh
provide the best overall performance giving quick, showing the effectsof percent sollds not related to viscosity.
reproducible results under a variety of slurry condi- Numbers in parentheses indicate % solids of pulps.
tions and particle sizes. The most popular of the
rotational viscometer spindle geometries is concentric
cylinders, which have the advantage of providing well Effect of percent solids and viscosity
defined shearing conditions. However, due to potential
problems of particle settling on top of the spindle Experimental results presented herein have shown
(Underwood, 1976),as well as coarse particles slipping the abrasive wear of grinding media in quartzite
on the cylindrical surfaces (Hansford, Levy, and slurries to be significantly affected by pulp density.
Dekock, 1976), a tee-bar spindle has also been used Over the range of 60% to 70% solids, wear was found to
(Underwood, 1976). Consisting of a central shaft with decrease continuously with increasing percent solids.

34 FEBRUARY 1987 MINERALS AND METALLURGICAL PROCESSING

Recent test work conducted a t MRRC (Iwasaki et al., with CaCO, additions showed pH values in the area of
1984) showed similar results using magnetic taconite 9.0. Since a t this pH CaCO, surfaces are positively
over the range of 80% to 80% solids, see Table 1. The charged while quartzite is negatively charged, there is
grinding rate, indicated by percent -325 mesh, in- a possibility of heterocoagulation and flocculation,
creased with increasing percent solids, reached a which may have specific effects on media wear and
maximum, then decreased, which also is in agreement the grinding rate. Another alternative, as indicated by
with the literature (Katzer et al., 1981; Klimpel, 1982, the numbers in parentheses in Fig. 3,is that a t a given
1983;Tucker, 1982). viscosity the generally lower percent solids and thus
lower particle packing density results in higher wear
and lower grinding rates. Finally, another factor that
Table 1 - Summary of Ball Coatlng Results may need to be considered is the influence of yield
values and their effects on ball coating. To study this
Welght Thickness % Sollde Vlecoelty effect further, an improved experimental procedure
Sample (0) (rm) on Ball (7.5 rprn)
is required to define accurate yieldwalues.
Effect of Percent Solids (at 60 mln grind)
While slurry viscosity is known to increase with
45% solids 0.06 64 36 - increasing percent solids, it cannot be concluded that
50% solids 0.1 1 98 42 42
60% solids 0.21 127 54 192 the influence of pulp density changes on media wear
65% solids 0.25 127 61 - and grinding are due solely to these viscosity changes.
70% solids 1.32 507 70 2359
The results of viscosity changes a t a given pulp density
Effect of Grinding Time through the use of a viscosity reducing chemical has
60% sollds: shown that the media wear rate is not greatly affected
15 min grind
30 min grind
by changes in viscosity. Therefore, as percent solids
60 min grind increases, it is more likely that the packing density of
70% solids: the particles on the ball surface determines media
15 min grind wear more than viscosity.
30 mln grind The results of reduced viscosity by chemical addi-
60 min grlnd
tives on the rate of grinding, on the other hand, agrees
Additions of CaC03 Preclpitates
well with the results of pulp density variations, indicat-
to 60% Solids Quartzite (const. vol, 60 min grind)
ing that the viscosity component of these density
g CaCO3 Overall Thlckneee % Sollde Vlecosity changes is more important to grinding than media
Addad % Sollde (rrn) on Ball (7.5 rprn)
25 60.8 204 60.2 427
wear.
50 61.6 420 60.3 570
175 65.4 1728 65.8 1769
Effect of ball coating
Laboratory data has been presented that suggests a
Variation of grinding time has shown that the size link between ball coating theory and slurry viscosity.
distribution of the solids significantly affected viscos- To further explore this relationship, coating and
ity; however, the contribution of particle size effects viscosity data from Table 2 has been plotted in Fig. 4
to viscosity was diminished as slurry density increased. together with similar data for taconite. With 60
Therefore, a s percent solids increased, slurry density minutes of grinding, the changes in size distribution
became the primary determinant of viscosity. This (max. 8.8% - 325 mesh) had relatively little effect, and
conclusion is substantiated by Fig. 2 where the effects a close correlation between viscosity and ball coating
of CaCO, additions, and thus viscosity, on grinding is evident. The close agreement between quartzite
media wear were shown to become less significant (specific gravity 2.66) and taconite (specific gravity
with increasing percent solids. 3.33) also indicates that this same relationship may
Figures 2 and 3 have shown that the addition of apply to other minerals as well.
CaCO, as a viscosity modifier produces results that With shorter grinding times, the relationship between
deviate from the viscosity results due to changing ball coating and viscosity shifts to heavier coatings in
percent solids. Several possible reasons may be the low viscosity range. This shift occurs only a t low
suggested for these discrepancies. Quartzite slurries viscosity because it is in this range that viscosity is

- -

Table 2 - Summary of Ball Coating Effects on Wear and Grinding Efficiency at 60 Min Grinding
Slze -325 Ball Coatlng
Wear Rate Modulus meoh Vol. Thlckneee Sollds Ratlo
Sample % Sollds rnglball k, Frn % rnL (urn) % Thickneeelk
Quartzite

Taconite'

60% solids quartzite

+25g CaC03 (4% solids)
+ 508 CaC03 (8% solids)
+ 175g CaC03 (20% solids)
60% solids + 0.5 kg11
grinding aid
70% solids + 0.5 kglt
grindlng aid

Taconite data from lwasaki et al., 1984.

The low wear rate at 50% solids is altributed to the very high void volume lilling of 200%.

MINERALS AND METALLURGICAL PROCESSING FEBRUARY 1987 35

most sensitive to grinding time (coarser size distribu-
tions and larger particles) as was demonstrated in
Fig. 1.
Conversely, changes in the fine end of the particle
size distribution due to CaCO, precipitate additions
resulted in an increase in the coating thickness a t
higher viscosities. A possible reason for this may be a
greater sensitivity of ball coating to extremely fine
particles. This may require further study.
v, lo'
lo0
u- lo1 102 lo3 104
RELATIVE VISCOSITY - mP0.s (7.5RPM)
Fig. 4 - Relationship between ball coating thickness and
viscosity as a function of grinding time
Abrasive wear has been shown to decrease with
thicker ball coatings; however, dven the relatively
large coating increases due to CaCO, additions, the
reductions in wear were significantly less than would
have been anticipated based on ball coating changes
due to percent solids. In other words, the same coating
thickness of a higher percent solids slurry would result
in greater reductions in wear. Thus, the percent solids
or the packing density of the slurry that coats the
grinding balls, a s well a s the thickness of the coating,
affected the ability of the slurry to shield the balls
from abrasive wear. This point is also emphasized by
the very small change in wear shown for a 70% solids
slurry treated with 0.5 kg/t viscosity modifier despite
a significant drop in viscosity and ball coating thick-
ness. The importance of the physical characteristics of
the coating is also indicated by the higher wear rates
obtained with the harder quartzite slurries compared
to taconite.
The abilitv of a slurrv to shield articles from
grinding canWberepresented by the r a t k of the coating
thickness to the largest particle size present in the
slurry. An estimate-was obtained for relative com-
parison purposes from the size modulus, or the hypo-
thetical maximum size in the Schuhmann eauation, of
the final ground solids. This data, shown in ?able 2, is
plotted against percent -325 mesh in Fig. 5, which
gives an excellent illustration of the effects of ball
coating on grinding efficiency. A certain degree of
coating, on the order of twice the size modulus, was
required for optimum grinding with reduced efficiency
beyond that point due to cushioning.
Conclusions
The abrasive wear of grinding media was strongly
influenced by pulp density through both viscosity and
the physical shielding of the ball surface. Viscosity
changes due to factors such as size distribution and
36 FEBRUARY 1987
50% Solids
6 0 % "
A 70% "
+80°/o "
0 60% Sol + Vi;~c.Mociifier
A 70% Sol +
5 10 15 20 25 30
RATIO O F COATING THICKNESS/SIZE MODULUS
Fig. 5 - Effect of ball coating thickness relative to the largest
particle size on percent - 325 mesh for quartzite and taconite
viscosity modifying chemicals also affected wear, but
to a much lesser degree than percent solids. The
packing density of particles at the ball surface affected
the physical ability of the slurry to shield the ball
surface; therefore, both viscosity and packing density
decreased media wear with increasing percent solids.
As percent solids increased, the viscosity effects due to
size distribution were diminished, leaving percent
solids as the primary determinant of viscosib. The
grinding rate was seen to be primarily dependent on
viscosity, lnltially increasing up to a maximum and
then decreasing.
The thickness of the slurry that coats the grinding
media has been shown to be directly related to the
slurry viscosity. Therefore, the changes in abrasive
wear and grinding rates may be explained in terms of
the packing density of the slurry coating the balls and
the coating thickness. Abrasive wear was seen to be
related to both factors, with the physical characteris-
tics of the slurry playing the major role. Grinding was
a function of coating thickness, being optimum when
the thickness was about twice the largest particle
size. W
Acknowledgment
Financial support provided for this project by the US
Department of Energy under Contract DE-FC07-
83ID124.1is gratefully acknowledged.
References
Clarke, B., and Kltchener. J.A., 1968, "The Influence of Pulp Viscosity on Fine
Grinding In a Ball Mill," British Chemlcal Engineerlng. Vol. 13, pp. 991.995.
Committee on Comminutlon and Energy Consumptlon, 1981, Comminution and
Energy ConsumpUon, Natlonal Materials Advlsory Board. National Academy of
Sciences. Washlngton, DC. 283 pp.
DeVaney, F.D.. and Shelton, S.M., 1940, "Properties of Suspensions Mediums for
Float-and-Sink Concentration," RI 3489. U S Bureau of Mlnes.
Hansford. G.S., Levy, C.D., and Dekock. I.W., 1976, "Rheolaglcal Measurements of
Pulps from South Afrlcan Gold Mlnes." South Alrlcan institute 01 Mining 8
Metallurgy, pp. 363-369.
MINERALS AND METALLURGICAL PROCESSING
Hockings, W.A., Volin, M.E., and Mular, A.L., 1965, "Effect of Suspending Fluid on
Batch Mill Grinding," Trans. SME-AIME, Vol. 232, pp. 59-62.
Iwasaki, I., Natarajan, K.A., Riemer, S.C., and Orlich. J.N., 1985, "Effect of Percent
Solids and Mlll Loadlng on Ball Wear in Laboratory Taconite Grinding," Minerals
and Melallurgical Processing, Vol. 2, pp. 185-192.
Katzer, M.. Klimpel, R., and Sewell, J., 1981. "Example of the Laboratory
Characterizatlon of Grinding Aids in the Wet Grinding of Ores," Mining Engineer-
ing. Vol. 33, pp. 2471-2475.
Klimpel, R., 1982, "Laboratory Studies of the Grinding and Rheology of Coal-Water
Slurries," Powder Technology, Voi. 32, pp. 267-277.
Klimpel, R., 1962, 1983, "Slurry Rheology Influence on Perlormance of Minerallcoal
Grinding Circuits," Mining Engineering, Vol. 34, pp. 1665-1668 and Vol. 35,
pp. 136-143.
TECHNICAL NOTE
Effects of air usage on flotation of coal
Introduction
The studies conducted by Laplante and coworkers
(1983,1984)with flotation of galena and quartz,showed
that the rate of flotation reaches a maximum value for
a certain intermediate value of the air flow rate. A
similar, though less pronounced, effect of the air flow
rate on the selectivity was also observed. Luttrell and
coworkers (1985) showed that the size of air bubbles
has a significant effect on both rate and selectivity of
coal flotation. These two studies used flotation tests in
which no froth layer was formed.
This note describes effects of the air flow rate and
bubble size on the rate constant and selectivity of coal
flotation, using a mechanical laboratory machine with
a froth layer allowed to form.
Experimental
A raw, dry ground Illinois coal was used in flotation
tests. The size distribution and ash content of the
samples are :
Particle size (pm) Weight (%) Ash (%)
+600 4.30 41.7
600/200 43.05 19.0
200/74 22.25 16.0
- 74 30.40 24.0
average 20.8
No. 2 fuel oil with a concentration of 200 g/t of feed
and M.IBC with concentrations of 11,22, and 33 mg/L
of pulp (128, 266, 384 g/t, respectively) were used as
flotation reagents. Tap water with a natural pH of 7.0
to 7.8 was used throughout the tests. No other reagents
were used. The starting concentration of coal in the
pulp was 86 g/L.
A standard flotation machine with the pulp volume
of 5 L was used in experiments. Three different air
flow rates were employed, resulting in three air
escape velocity values of 14, 30, and 70 cm/min. The
air escape velocity (AEV)was calculated a s the ratio
of air flow rate (Q ), to the slurry surface (S,) in the
machine. For a comparison, the upper limit of air
escape velocity values used in commercial size flota-
MINERALS AND METALLURGICAL PROCESSING
McKennel, R., 1960, "The Influence of Viscometrlc Design on Non-Newtonian
Measurements," Analylical Chemislry, Vol. 32, pp. 1458-1463.
Meloy, T.P., and Crabtree, D., 1967, "Surface Tension and Viscosity in Wet
Grinding," Dechema Monographien, Vol. 57, No. 1, pp. 405-526.
Perez, R., and Moore, J.J., 1982, "The Application of the Scanning Electron
Microscope in Determining the Interaction of Abrasion and Corrosion in Mineral
Grinding Media," Microslructural Science, Vol. 11, pp. 207-234.
Pouska, G.A., and Link, J.M., 1961, "Differential Flow Rheometer," Proceedings,
6th International Technical Conference on Slurry Transportation, Las Vegas, NV.
Pryor, E.J., 1965, Mineral Processing, Elsevier, New York, 844 pp.
tion machines is between 70 and 100 cm/min (WEMCO,
1983).
A machine consisting of a generator of fine bubbles
and a separatory column, described elsewhere (Szat-
kowski and Freyberger, 19851, was used for some tests
where bubble size lower than that generated in the
standard machines was required.
Prior to a flotation test, a batch of coal was mixed
with water in the flotation cell for a t least 10 minutes to
ensure that all coal was thoroughly wet. Then the
specified amount of fuel oil was added and the pulp
was conditioned for five minutes. The specified amount
of MIBC was added 15 seconds before the end of
conditioning. After air flow was opened, flotation
products were collected for 0 to 30, 30 to 60, and 60 to
120 second intervals. Content of the combustible
material in samples was determined by subtracting
the ash content from 100%.
A photographic technique was used to determine
initial distributions of bubble size generated by the
flotation machines. Bubbles generated in water con-
taining the prescribed amount of the frother but no
solids were photographed against a black background.
The average diameter and standard deviation were
then calculated for each set of flotation conditions. The
method gives results reproducible within k 5% of the
average bubble size. Table 1 contains information
about the measured bubble size distributions expressed
by the average bubble diameter (Db) and the standard
deviation ( SD ) .
Results and discussion
The general formula for calculating the flotation
selectivity is:
o = recovery of coal/recovery of ash (1)
M. Szatkowskl, member SME. is an instructor., metalluraical
engineering department, ~ i c h i ~ aTechnological
n University,
~~
- - -
Houghton, MI. SME-MMP nonmeeting paper 86-655. Manu-
script June 1986.
FEBRUARY 1987 37