Minerals Engineering 17 (2004) 891–896

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The Magotteaux Mill
: investigating the effect of grinding media

on pulp chemistry and flotation performance
a,*
C.J. Greet , G.L. Small b, Philippe Steinier a, S.R. Grano b

a
Magotteaux Australia, West Perth 6005, Australia
b
Ian Wark Research Institute, Mason Lakes 5095, Australia
Available online Received 18 August 2003; accepted 3 March 2004

Abstract
Many laboratory studies are completed each year exploring the flotation response of old and new ore sources. Most pay little
attention to the impact grinding media has on down stream processing or even attempt to match the laboratory grinding chemistry
to comparable plant data. The Magotteaux Mill
, described in this paper, allows the user to measure, monitor and control the pulp
chemical conditions during grinding. This ultimately means that it is now possible to prepare ore samples in the laboratory that have
the same properties as those in the plant (i.e. particle size distribution and pulp chemistry).
 2004 Elsevier Ltd. All rights reserved.

Keywords: Grinding; Redox reactions; Froth flotation; On-line analysis

1. Introduction grinding media and sulphide minerals (for example,

The key to a successful separation in mineral pro-
cessing is the preparation of particles with adequate
liberation under the correct pulp chemical conditions.
Therefore, improving the efficiency of the comminution
process is paramount to this success, but this is not re-
stricted to size reduction alone. At Magotteaux it is
recognised that while high chrome grinding media offers
advantages in reduced media wear, translating to re-
duced operating costs, this saving is frequently not en-
ough to off-set the higher grinding media cost.
Additional improvements to the process are required,
and it is believed that high chrome grinding media may
provide these in the form of pulp chemical changes
which may improve metallurgical performance when
compared to traditional forged grinding media.
2. Background
A considerable volume of work exists in the literature
examining the electrochemical interactions between
* of oxidised iron species as measured using and
Corresponding author. Present address: Suite 4, 83 Havelock
Street, West Perth WA6005, Australia. Tel.: +61-8-9322-3255; fax:
+61-8-9322-3007.
E-mail address: christopher.greet@magotteaux.com (C.J. Greet).
0892-6875/$ - see front matter  2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mineng.2004.03.003
Iwasaki et al., 1983; Natarajan and Iwasaki, 1984;
Yelloji Rao and Natarajan, 1989a,b). Broadly, most
sulphide minerals are more noble than the grinding
media used during comminution, therefore a galvanic
couple between the media and the sulphide mineral(s)
exists, which increases the corrosion rate of the grinding
media. The corrosion products of the grinding media,
iron oxy-hydroxide species, invariably precipitate on to
the surfaces of the sulphide minerals thereby affecting
their floatability (Johnson, 2002).
These previous investigations were completed using
controlled, laboratory conditions, which are remote
from actual plant practice. More recently Cullinan et al.
(1999) completed laboratory experiments examining the
effect of different ferrous based grinding media on ga-
lena flotation performance in the lead circuit of the
Mount Isa mines lead/zinc concentrator. While this
work did not mimic plant conditions, it showed that the
maximum lead recovery and the galena flotation rate
constant of fine ()10 lm) galena was significantly in-
creased when the ore was ground using high chrome
grinding media when compared to forged media. An
increased surface concentration of hydrophilic layers
EDTA extraction technique (Rumball and Richmond,
1996; Cullinan et al., 1999; Greet and Smart, 2002) on
fine galena was a likely reason for their diminished
892
flotation behaviour, when forged grinding media was
employed.
Cullinan (1999) completed more fundamental work
examining the effect of the grinding environment on
galena flotation. In these tests, 100 g of galena were
ground in different mills: mild steel mill using forged
high carbon low alloy steel balls; a stainless steel mill
using high chrome white iron balls; and a ceramic mill
using ceramic balls. The resultant recovery versus time
curves are provided in Fig. 1, and illustrate that the
galena recovery increased markedly as the media type
changed from forged to high chrome, to ceramic. The
increased galena flotation was attributed to a reduction
in the oxidised iron levels in the pulp, as measured using
an EDTA extraction technique.
To further test this observation, galena was ground in
a ceramic mill with varying amounts of iron powder
added to determine its effect on the galena flotation
performance (Cullinan, 1999). These tests (Fig. 2) sug-
gested strongly that the addition of iron had a detri-
mental effect on galena flotation.
These results suggest that the iron debris from tra-
ditional forged grinding media can have a significant
deleterious effect on the flotation performance of fine
()10 lm) galena. By changing the media type to an inert
material (i.e. ceramic grinding media) the galena flota-
tion response can be markedly improved. It is postulated
that similar effects would be noted for other sulphide
minerals.
Magotteaux Australia Proprietary Limited through
the Ian Wark Research Institute have completed further
laboratory scale work investigating the effect of high
chrome grinding media on pulp chemistry and sub-
sequent flotation on a number of other sulphide min-
erals. Invariably changing the grinding media type from
forged to high chrome produced a shift to less reducing
pulp conditions and a positive change in the flotation
100.0
80.0
Mass recovery, %
60.0
40.0
20.0
0.0
0.0
Fig. 1. Mass recovery versus time curves for rougher flotation tests completed on 100 g of Rapid Bay galena ground to a P50 of 9 lm using forged,
high chrome, and ceramic media. The tests were completed in demineralised water (pH 7), and employed 1000 g per tonne of sodium ethyl xanthate
collector.
C.J. Greet et al. / Minerals Engineering 17 (2004) 891–896
response. A typical example of the improvement in the
flotation performance is illustrated in Fig. 3 (Ward and
Grano, 1999). These data indicated that when high
chrome grinding media was substituted for forged media
when grinding a refractory gold ore, the pulp chemistry
shifted to more oxidising conditions. This shift was
accompanied by a reduction in the EDTA extractable
iron levels in the pulp, and an improvement in the flo-
tation performance. That is, at 85% gold recovery, the
gold grade was increased from 282 g/t for the forged
media up to 328 g/t for the 21% chrome grinding media.
Thus, there is ample evidence to suggest that a change
in grinding media type will have an influence on the pulp
chemistry of the system, which will change the flotation
behaviour of the sulphide minerals present.
3. Driving force behind the current research
These observations have lead to renewed vigour
within Magotteaux in terms of promoting high chrome
grinding media as an alternative to conventional high
alloy, low carbon steel variety. Magotteaux realise the
potential benefits their media has to the mining industry,
and the value of providing a more integrated, scientific
approach to media selection. Therefore, Magotteaux
Australia Proprietary Limited and Ian Wark Research
Institute have formed a partnership to investigate the
mechanisms by which high chrome grinding media can
improve metallurgical response and reduce reagent
consumption within operating concentrators.
However, the emphasis of this current work is con-
siderably different from the earlier work. That is, in the
past much of the work has not used plant-operating
conditions during testing, which has lead to a suspicion
of laboratory results. The driving force behind this work
is an attempt to match the laboratory conditions to
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0
Time, minutes
Forged media High chrome media Ceramic media
 C.J. Greet et al. / Minerals Engineering 17 (2004) 891–896 893

100.0

80.0

Mass recovery, %
60.0

40.0

20.0

0.0
0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0

Time, minutes
0.0 g Fe added 0.2 g Fe added 1.5 g Fe added

Fig. 2. Mass recovery versus time curves for rougher flotation tests completed on 100 g of Rapid Bay galena ground to a P50 of 9 lm using ceramic
media. The tests were completed in demineralised water (pH 7), and employed 1000 g per tonne of sodium ethyl xanthate collector. The iron was
added during grinding.

Fig. 3. Pulp chemical data and gold grade/recovery curves for laboratory rougher flotation tests conducted on a refractory gold ore ground using
forged and high chrome grinding media.

those recorded for the plant. In doing this, it is antici-
pated that the flotation performance in the laboratory
will more closely resemble that achieved in the plant.
This will lead to a more direct means of scaling-up po-
tential improvements.
To achieve this match a new laboratory grinding mill,
the Magotteaux Mill
, has been developed.
then manipulate the laboratory grinding, using the
Magotteaux Mill
, to reproduce these values in the
laboratory. It is then anticipated that having matched
the specific parameters the flotation response in the
plant and the laboratory can be correlated.
The strategy adopted to achieve the desired outcomes
is to:

• determine the plant cyclone overflow size distribu-

4. Research philosophy and strategy tion, the pulp chemical conditions (i.e. Eh, pH, dis-
solved oxygen, oxygen demand, and EDTA
There is a need to correlate the physical and chemical extractable iron) through the grinding and flotation
conditions generated during laboratory grinding with circuits, and the flotation behaviour of the plant
those routinely observed in plant milling circuits. (i.e. metallurgical survey);
The research philosophy behind this work is therefore • collect a bulk sample of the plant feed at the time of
based on measuring specific parameters in the plant, the plant survey;
894 C.J. Greet et al. / Minerals Engineering 17 (2004) 891–896
• determine the laboratory flotation response of the
plant cyclone overflow at the time of the plant survey;
• use the bulk sample to calibrate the Magotteaux
Mill
, using the current grinding media, to obtain
the same product size distribution as the plant cy-
clone overflow and the pulp chemical conditions as
the plant grinding mill discharge; and
• determine the laboratory flotation response of the
Magotteaux Mill
discharge.
These steps are illustrated in Fig. 4.
It is anticipated that the results obtained from this
work will show that the flotation response of the labo-
ratory tests completed on the plant cyclone overflow and
the Magotteaux Mill
discharge will be the same. Fur-
ther, the link between the laboratory flotation response
and the plant flotation behaviour will be established by
comparing the flotation results from the laboratory tests
completed on the plant cyclone overflow and metallur-
gical survey completed on the plant. With this link
established the scaling factor between the laboratory
and the plant can be developed.
Once the various parameters have been matched, it is
intended that various grades of high chrome grinding
media can be substituted for the current grinding media
type during laboratory grinding using the Magotteaux
Mill
. It is anticipated that the tests completed using the
Magotteaux Mill
employing high chrome grinding
media will clearly demonstrate any changes in the pulp
chemistry and the flotation response when compared to
tests prepared using the current media type. Further,
from these laboratory tests an estimate of the benefits to
the process of using high chrome grinding media can be
made.
The cost of performing plant trials to investigate the
benefits of high chrome grinding media is, in many
cased, prohibitive. It is suggested that this approach will
provide a robust laboratory methodology that: firstly
Reagents
Laboratory grinding
Reagents
Laboratory conditioning
Laboratory flotation
Fig. 4. Test strategy.
provides a link between the laboratory and the plant
using the existing grinding media; and secondly inves-
tigates changes to the pulp chemistry and metallurgical
outcome when high chrome grinding media is substi-
tuted into the grinding circuit. It is further believed that
this strategy will provide an excellent screening proce-
dure that will yield valuable information about the
‘‘best’’ grinding media for the operation. This should
focus pilot plant and plant trials on only the most
promising of grinding media types.
5. Diagnostic tool
Early in the project, it was recognised that the design
and selection of an appropriate laboratory mill would be
vital in achieving the desired outcomes. Therefore, the
Magotteaux Mill
(Fig. 5) was designed. The key
capabilities of this laboratory mill are the ability to:
• vary the rotational speed of the mill;
• accept different diameter mills;
• control the temperature;
• control the pulp chemistry during grinding;
• inject gases;
• inject reagents; and
• continuously monitor the system during grinding.
This unique capability of being able to measure and
monitor the pulp chemical conditions during grinding is
the key to understanding and improving the impact of
particle preparation on flotation performance.
6. Results
While there is still a long way to go, with many
technical challenges, the Magotteaux Mill
has enabled
Ore
Process water Reagents
Plant grinding circuit
Plant cyclone overflow
Reagents
Plant flotation
Key points for matching
 C.J. Greet et al. / Minerals Engineering 17 (2004) 891–896 895

Fig. 5. Schematic representation of the Magotteaux Mill
.

Table 1
Summary of parameters matched between Magotteaux Mill
discharge and the plant cyclone overflow
Parameter Laboratory Plant Difference Criteria Valid
BMD FF BMD FF BMD FF
Size distribution
P80 170 170 0 ±3 lm Yes
% )38 lm 47 45 2 ±5% Yes

Pulp chemistry
pH 6.8 7.1 6.8 7.1 0 0 ±0.2 Yes
Eh, mV (SHE) )125 250 )125 250 0 0 ±10 mV Yes
DO, ppm <1 3 <1 3 0 0 ±1 ppm Yes
EDTA Fe 0.8 0.8 0 ±0.1% Yes

Flotation
Au recovery (%) 79 80 1 ±3% Yes
S recovery (%) 82 79 3 ±3% Yes
Note: BMD refers to ball mill discharge for the Magotteaux Mill
in the laboratory, and ball mill discharge in the plant; and FF refers to flotation
feed which is the conditioned feed in the laboratory and the cyclone overflow in the plant.

32.0 response) between the laboratory mill discharge and the

plant cyclone overflow has been achieved (Table 1 and
28.0
Fig. 6). Further, it has been demonstrated that it is
Sulphur grade, %

possible to vary one parameter to determine what is

24.0
required to achieve the targets set from the plant char-
20.0
acterisation phase of the work, and to establish how
these changes impact the other parameters measured.
16.0

12.0
20.0 40.0 60.0 80.0 100.0
7. Conclusions
Sulphur recovery, %
Plant cyclone overflow Magotteaux Mill discharge A new approach, investigating the impact of grinding
media on flotation response has been developed. The
Fig. 6. Sulphur grade/recovery curves for laboratory rougher flotation
new strategy will enable a correlation between the plant
tests completed on the plant cyclone overflow and the Magotteaux
Mill
discharge. and the laboratory to be established.
The tool to achieve this is the Magotteaux Mill
,
which allows the pulp chemistry during grinding to be
progress to be made. That is, by using the Magotteaux monitored.
Mill
on a similar refractory gold ore to that presented Manipulation of the various parameters in the Ma-
in Fig. 3, matching of the three key parameters (product gotteaux Mill
resulted in matching the size distribu-
size distribution, pulp chemical conditions and flotation tion, pulp chemistry and flotation response of the plant
896 C.J. Greet et al. / Minerals Engineering 17 (2004) 891–896
cyclone overflow with the laboratory mill discharge for a
refractory gold ore.
8. Future work
The objective is to complete further work on other
ore types to validate the Magotteaux Mill
. Once the
validation process is complete various grades of high
chrome grinding media will be substituted for the forged
media to determine the impact of those media types on
the pulp chemistry and flotation response.
Finally, the link between the laboratory and the plant
must be established.
Acknowledgements
The authors wish to thank Magotteaux Limited for
giving permission to publish this paper.
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