CHAPTER 4 t ORE COMMINUTION MEASUREMENT TECHNIQUES

Comments on the SMC Test

• 3DUDPHWHUVIURPWKH60&7HVWDUHJRRGIRUSUHGLFWLQJWKHVSHFLÀFHQHUJ\UHTXLUHPHQW
for a range of comminution devices including conventional crushers, high-pressure
grinding rolls and tumbling mills. The range of devices where the parameters
from this ore characterisation test can be applied is wider than any other known
comminution test.
• The A and B parameters can be used for predicting AG/SAG milling characteristics
of an ore using JKSimMet, provided the ore is brittle and does not experience much
plastic deformation before breaking. Since the test uses the same device as the JK
Drop Weight Test the problems that related to ore characterisation tests using the
JK Drop Weight Test apply to the SMC Test. The methodology for the latter is a
VLPSOLÀHGYHUVLRQRIWKHIRUPHU
• 7KH 6&6( YDOXH GLVFXVVHG LQ WKH 'URS :HLJKW 7HVW VHFWLRQ LV DOVR FDOFXODWHG DQG
reported with SMC Test results.
• The methodology and analysis performed to extract the parameters used in predicting
VSHFLÀFHQHUJ\IRUPRVWRIWKHRUHFKDUDFWHULVDWLRQWHVWVLQFRPPLQXWLRQKDYHEHHQ
published, but how the Mia, Mic, Mih, Mib and DWi are obtained from SMC Test data
is yet to be reported in literature. Functions such as f(Ar) and g(x), as well as the
constants a, b, c, d and e, are proprietary to Citic SMC Process Technology.
• Companies that have used the SMC Test to design comminution circuits have
indicated that the comminution energy requirements estimated from test work
results are reasonably close to that found in the designed operating plant. This is
not surprising, since SMC established a large database of operating comminution
circuits to develop and validate the equation. SMC Test estimates are considered
reliable.

SPI® TEST
SPI stands for SAG Power Index. The SPI test is the commercial name given by the
0LQQRY(;7HFKQRORJLHVFRPSDQ\WRDODERUDWRU\RUHKDUGQHVVFKDUDFWHULVDWLRQWHVWWKH
procedure for which was originally developed by John Starkey.
The procedure involves the use of a 300 mm diameter, 100 mm long laboratory mill
loaded with 25 mm steel balls, as seen in Figure 4.6. Two kilograms of feed material are
crushed to -19 mm (P80 is approximately 12.5 mm) and ground in the mill until a product
P80 of 1.7 mm is obtained. The time in minutes to reach this point is the SPI.
The SPI parameter is used in conjunction with the following equation to predict the
VSHFLÀFHQHUJ\RI6$*PLOOV 'REE\%HQQHWWDQG&RVLFN 
n.
SAG (kWh/t) = K. (SPI/T 800.5) fsag (7)

where:
T80 is a rock size parameter
fsag is the submodel that incorporates effects such as feed size and pebble crushing
This is an empirical equation that predicts power used by a SAG mill from laboratory
data. SPI is determined experimentally. It is the proprietary nature of all these constants
WKDW PDNH WKH SURFHGXUH GLIÀFXOW WR XQGHUVWDQG KRZHYHU OLNH 0RUUHOO·V SURFHGXUH

Comminution Handbook | Spectrum Series 21 53

 CHAPTER 4 t ORE COMMINUTION MEASUREMENT TECHNIQUES

FIG 4.6 – SPI® test mill (image courtesy SGS).

it must be mentioned because it is widely used. The description here is kept to a

minimum. The submodel fsag and the equation contain 21 constants, enabling the equation
to be applied to AG and SAG mills working under several conditions. These constants
are proprietary to the Swiss company SGS (Société Générale de Surveillance), which
DFTXLUHG0LQQRY(;7HFKQRORJLHVLQ2YHU63,WHVWVKDYHEHHQFRQGXFWHG
making it as popular as the SMC Test.

SAGDESIGN™ TEST
7KH6$*'HVLJQWHVWZDVFUHDWHGVSHFLÀFDOO\IRUWKHVL]LQJRIQHZ6$*DQGEDOOPLOOV
UHIHU WR )LJXUH   7KH WHVW ÀUVW PHDVXUHV WKH 6$* SLQLRQ HQHUJ\ QHHGHG WR JULQG
ore from 80 per cent passing 152 mm to 80 per cent passing 1.7 mm as WSDT in kWh/t.
The second stage of the test measures the Bond Ball Mill Work Index on SAG ground
ore, Sd-BWi in kWh/t. SAGDesign ore feed is prepared from a minimum of 10 kg of
split or whole diamond drill core pieces or run-of-mine ore, by stage-crushing the ore
in a jaw crusher to 80 per cent passing 19 mm. The crushed ore is then ground in a
SAGDesign SAG mill (489 mm inside diameter × 163 mm effective grinding length) that
operates with parameters similar to commercial SAG mills (26 per cent total charge with
11 per cent steel load, 15 per cent ore load and rotation at 76 per cent of critical speed).
The calculated cumulative mill revolutions to 80 per cent passing 1.7 mm is used
WRJHWKHUZLWKWKHPDVVRIWKH6$*PLOOFKDUJHWRFRPSXWHWKH6$*PLOOVSHFLÀFSLQLRQ
energy. The process to determine the revolutions is done in cycles, with the minus
PPPDWHULDO ÀQHV UHPRYHGIURPWKHPLOODIWHUHDFKF\FOHXSWRSHUFHQWSDVVLQJ
PP$IWHUWKHÀUVWJULQGLQJWDUJHWLVUHDFKHG WKDWLVSHUFHQWSDVVLQJPP 
ERWKWKHÀQHDQGFRDUVHPDWHULDOVDUHUHWXUQHGWRWKHPLOOIRUWKHUHPDLQGHURIWKH6$*
mill-grinding cycles to reach the 80 per cent passing 1.7 mm test end point.
In industrial practice, few if any SAG mills create a product of exactly 80 per cent
passing 1.7 mm. In order to modify this product size to the exact size required for the

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 CHAPTER 4 t ORE COMMINUTION MEASUREMENT TECHNIQUES

FIG 4.7 – SAGDesign mill (image courtesy Starkey & Associates Inc).

design, an energy factor is added or subtracted from the SAGDesign test result. This
factor is calculated using the results of the Bond Ball Mill Work Index Test conducted
as part of the SAGDesign test on SAG ground ore and is a function of the size deviation
from 1.7 mm. Factors can also be applied to model alternative mill feed sizes and/or
pebble crushing.
The 1.7 mm closing screen for the SAG test was chosen because it is close to the feed
size F80 used in a Bond Ball Mill Work Index test and matches the coarse transfer size
T80, which is often over 2 mm in large plants. In this way SAG mill energy and ball mill
energy are measured accurately.
The SAGDesign test has some potential advantages over the SPI test in that the feed
size is coarser and arguably better, indicating that the impact of critical size on SAG mill-
VSHFLÀFHQHUJ\LVFRQVLGHUHGZKLOHWKHIHHGPDVV NJ DOORZVD%RQG%DOO0LOO:RUN
Index test to be conducted on the SAG test mill product. The SAGDesign test is available
from 11 laboratories around the world. A list is provided on the Starkey & Associates Inc
website.2 SAGDesign technology is open and is patented by Outotec.

SAG variability test

An abbreviated version of the SAGDesign test is the SAG variability test (SVT), intended
for use in geometallurgical throughput study applications. The procedure of the test
LVLGHQWLFDOWRWKHIXOO6$*'HVLJQWHVWH[FHSWWKDWLWLVVWRSSHGDIWHUWKHÀUVWJULQGLQJ
target of 60 per cent passing 1.7 mm is reached. In practice the SVT test is stopped after

2. http://sagdesign.com/home/worldwide-lab-locater

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 CHAPTER 4 t ORE COMMINUTION MEASUREMENT TECHNIQUES

three cycles. From this data, the results of a completed SAGDesign test can be predicted.
7KLVUHVXOWLVGHÀQHGDV:SVT and is reported in kWh/t to grind from 80 per cent passing
152 mm to 80 per cent passing 1.7 mm.
This test is intended to provide a cost-effective solution for high volumes of samples
for SAG grinding test work. It also has the advantage that SVT samples can be retrieved
from storage so the remainder of the SAGDesign test procedure can be completed later
on the same sample. This allows process engineers to make an informed decision on
selecting the most appropriate samples for further testing in cases where maximum
accuracy is required on key samples for the project.
$ VXPPDU\ RI WKH YDULDEOH GHÀQLWLRQV UHOHYDQW WR 6$*'HVLJQ DQG 6$* YDULDELOLW\
testing is given below:
F80 80 per cent passing feed size (μm)
T80 80 per cent passing transfer size between the SAG and ball mill (μm)
P80  SHUFHQWSDVVLQJÀQDOSURGXFWVL]H —P
WSDT SAG grindability from F80 = 152.4 mm to T80 = 1700 μm from SAGDesign test
work (kWh/t)
WSVT predicted SAG grindability from F80 = 152.4 mm to T80 = 1700 μm from SAG
variability test work (kWh/t)
Sd-BWi Bond Ball Mill Work Index on SAG ground ore (kWh/t)
(*/  HIIHFWLYHJULQGLQJOHQJWK
WSAG  6$*SLQLRQHQHUJ\IURPVSHFLÀHGF80 to T80 (kWh/t)
WBM  EDOOPLOOSLQLRQHQHUJ\IURPVSHFLÀHGT80 to P80 (kWh/t)
Wtot total pinion energy from F80 to P80 (kWh/t)
6*  RUHVSHFLÀFJUDYLW\

COMPRESSION TEST
7KHPRVWHIÀFLHQWPHWKRGWREUHDNSDUWLFOHVLQWHUPVRIHQHUJ\XWLOLVDWLRQLVWRFRPSUHVV
the particle bed between two plates (Schonert, 1982). Breakage by compression occurs
in vertical roller mills, which have been used since 1900 and in high-pressure grinding
rolls, which were patented in 1982.
In the piston and die test for compression grindability seen in Figure 4.8 (Otte, 1988),
QDUURZVL]HG IUDFWLRQV DUH SUHSDUHG DQG FRPSUHVVHG WR D À[HG UDQJH RI GLIIHUHQW
pressures. Particles in the bed start moving through the voids, then breakage occurs and
this continues until the desired force is reached. The change in the height of the material
bed (displacement) during the test is recorded.
From the force-displacement graph the energy levels corresponding to displacement
are calculated from the following equation:

#
h2
W = f (h) dh (8)
h1

where:
W is work
h is displacement
f is force

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FIG 4.8 – Piston and die compression tester (image courtesy Hakan Dundar).
Size distributions of the compressed materials are determined by sieve analysis and
the energy–particle size distribution (PSD) relationship can be obtained for the material.
This is used to calculate the PSD for a given energy level.

BOND WORK INDEX VALUES (BOND, 1953)

7KH %RQG %DOO 0LOO :RUN ,QGH[ LV WKH ROGHVW DQG PRVW FRPPRQ IRUP RI GHÀQLQJ WKH
resistance to breakage in terms of energy consumption (kWh/t). An indicative list of
values is given for various materials in Table 4.4. The actual Bond Work Index values for

TABLE 4.4
A selection of Bond Work Index values (Metso, 2012).
Material Value Material Value Material Value
Andesite 18.25 Fluorspar 8.91 Oil shale 15.84
Barite 4.73 Gabbro 18.45 Phosphate rock 9.92
Basalt 17.10 Glass 12.31 Potash ore 8.05
Bauxite 8.78 Gneiss 20.13 Pyrite ore 8.93
Cement clinker 13.45 Gold ore 14.93 Pyrrhotite ore 9.57
Cement raw material 10.51 Granite 15.13 Quartz 13.57
Clay 6.30 Graphite 43.56 Quartzite 9.58
Coal 13.00 Gravel 16.06 Rutile ore 12.68
Coke 15.13 Gypsum rock 6.73 Shale 15.87
Copper ore 12.72 Hematite 12.84 Silica sand 14.10
Diorite 20.90 Lead ore 11.90 Silicon carbide 25.87
Dolomite 11.27 Lead-zinc ore 10.93 Slag 10.24
Emery 56.70 Limestone 12.74 Spodumene ore 10.37
Feldspar 10.80 Magnetite 9.97 Syenite 13.13
Ferro-chrome 7.64 Manganese ore 12.20 Taconite 14.61
Ferro-manganese 8.30 Magnesite 11.13 Tin ore 10.90
Ferro-silicon 10.01 Molybdenum 12.80 Titanium ore 12.33
Flint 26.16 Nickel ore 13.65 Zinc ore 11.56

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DSDUWLFXODUPDWHULDOFDQEHTXLWHZLGHO\GLVWULEXWHGVRWKHYDOXHIRUDVSHFLÀFPDWHULDO
must be determined by experiment.

SPLIT HOPKINSON PRESSURE BAR TEST

Split Hopkinson pressure bars (SHPB) are used to conduct ballistic impact experiments
and obtain precise measurements of material load response at high strain rates. Bertram
Hopkinson originally put forward the technique in 1914 to measure stress pulses in
EDUV +RSNLQVRQ   :KLOH KH LV FUHGLWHG ZLWK WKH LGHD LW ZDV ODWHU PRGLÀHG E\
Kolsky in 1949 to two bars in series (hence the name Split Hopkinson bar) that could
be used to measure stress and strain. The stress-time responses of ductile materials (for
example, metals) can be used to characterise their strength by conventional engineering
parameters such as yield stress and Young’s modulus.3 The SHPB device can also be
applied to ore-breakage testing by characterising the behaviour via a rock mechanics
approach.
In its simplest from, the SHPB consists of some form of launcher such as a gas gun, an
impactor known as a striker, and two bars in a series usually made out of rigid steel with
a specimen loaded in between them. The bars are mounted in a rigid framework and are
restricted from movement, except in the longitudinal direction where they move freely
DORQJEXVKLQJVRUEHDULQJV)LJXUHVKRZVDSLFWXUHDQGVLPSOLÀHGVFKHPDWLFRIWKH
arrangement as set up at the Blast Impact and Survivability Research Unit (BISRU) at the
University of Cape Town.

FIG 4.9 – Picture and schematic of Hopkinson bar apparatus (image courtesy Aubrey Mainza).

:KHQWKHODXQFKHULVÀUHGWKHVWULNHUVKRRWVRXWRIWKHEDUUHODQGLPSDFWVDJDLQVWWKH
IDFHRIWKHÀUVWEDUFDOOHGWKHLQFLGHQWEDUJHQHUDWLQJDORQJLWXGLQDOVWUHVVZDYHWKDW
propagates along it. When it interacts with the specimen, a portion of this wave follows

3. Young’s modulus is a standard characterisation parameter that describes the elastic properties of a solid
undergoing tension or compression in only one direction.

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WKURXJKWRWKHVHFRQGURGNQRZQDVWKHWUDQVPLWWHUEDUZKLOHWKHUHPDLQGHULVUHÁHFWHG
back along the incident bar. Both bars are mounted with strain gauges, illustrated in red
in the Figure 4.9 schematic. These output voltage signals are recorded through electronic
DPSOLÀHUVZKLFKDUHGLUHFWO\SURSRUWLRQDOWRWKHLQVWDQWDQHRXVVWUHVVDWWKHLUSRVLWLRQ
These signals can be captured and recorded over the entire loading duration by
computer and used to accurately resolve force to fracture, incident strain energy and
the fraction of this energy absorbed by the specimen during impact. For specimens of
known dimensions, deformation characteristics can be calculated, and through imaging
techniques, crack initiation and propagation can also be studied (Gross and Seelig, 2007).
SHPB is normally used to characterise material behaviour at high strain rates, so while
conventional strength tests normally apply to quasistatic-type loading environments,
this data can apply to dynamic environments. This is useful in the case of ballistic
impacts such as the design of Kevlar jackets for the military, but in comminution it is
not directly used for equipment design. In comminution, the usefulness of the SHPB is
in determining fracture criteria such as probability of fracture, cumulative damage and
strain energy of fracture. The work by Bearman, Briggs and Kojovic (1997) also suggests
that the values of Young’s modulus correlate well with parameters such as fracture
toughness (KIC), which is used in rock mechanics.

BIBLIOGRAPHY
ASTM International, 2012. D409/D409M-12 – Standard test method for the grindability of coal
using the Hardgrove machine method.
Bailey, C W, 2012. JKTech Laboratory Services Bond Rod Mill Index Test.
Bearman, R A, Briggs, C A and Kojovic, T, 1997. The application of rock mechanics parameters to
the prediction of comminution behaviour, Minerals Engineering, 10(3):255–264.
Bond, F C, 1953. Work Indexes tabulated, Mining Engineering, 5:315–316.
Bond, F C, 1961. Crushing and grinding calculations, British Chemical Engineering, 6:378–391.
Bond, F C, 1963. Metal Wear in Crushing and Grinding (Allis Chalmers Publication 07P1701).
Dobby, G, Bennett, C and Cosick, G, 2001. Advances in SAG circuit design and simulation applied
to the mine block model, in Proceedings SAG 2001, pp 221–234, Vancouver.
Engineering Toolbox, 2015. Brinell Hardness Number [online]. Available from: <http://www.
engineeringtoolbox.com/bhn-brinell-hardness-number-d_1365.html> [Accessed: 21 May
2015].
Gross, D and Seelig, T, 2007. Fracture Mechanics, with an Introduction to Micromechanics (Springer-
Verlag: Berlin).
Hopkinson, B, 1914. A method for measuring the pressure produced in the detonation of high
explosives or by the impact of bullets, Philosophical Transactions of the Royal Society, 213:437–456.
Kolsky, H, 1949. An investigation of the mechanical properties of materials at very high rates of
loading, Philosophical Proc Phys Soc London, B62:676.
Levin, J, 1989. The Bond standard grindability test and a proposal for a standard grindability test
IRUÀQHPDWHULDOVJ SAIMM, 89(1):13–21.
McKen, A and Williams, S, 2005. An overview of the small-scale tests available to characterize ore
grindability for design purposes, SGS Minerals Technical Bulletin, 2005–06.
Metso, 2012. Basics in Mineral Processing Handbook HGV3(6DQGJUHQ%%HUJOLQGDQG60RGLJK 
pp 3–24.

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 CHAPTER 4 t ORE COMMINUTION MEASUREMENT TECHNIQUES

Morrell, S, 2004a. An alternative energy-size relationship to that proposed by Bond for the design
and optimisation of grinding circuits, International Journal of Mineral Processing, 74(1–4):133–
141.
Morrell,6E3UHGLFWLQJWKHVSHFLÀFHQHUJ\RIDXWRJHQRXVDQGVHPLDXWRJHQRXVPLOOVIURP
small diameter drill core samples, Minerals Engineering, 17(3):447–451.
Morrell, 6  3UHGLFWLQJ WKH RYHUDOO VSHFLÀF HQHUJ\ UHTXLUHPHQW RI FUXVKLQJ KLJK SUHVVXUH
grinding roll and tumbling mill circuits, Minerals Engineering, 22(6):544–549.
Napier-Munn, T J, Morrell, S, Morrison, R and Kojovic, T, 1996. Mineral Comminution Circuits –
Their Operation and Optimisation (Julius Kruttschnitt Mineral Research Centre: Brisbane).
Otte, O, 1988. Polycom high pressure grinding principles and industrial application, in Proceedings
Third AusIMM Mill Operators’ Conference, pp 131–136 (The Australasian Institute of Mining and
Metallurgy: Melbourne).
Rowland Jr, C A and Kjos, D M, 1980. Rod and ball mills, chapter 12, in Mineral Processing Plant
Design (eds: A L Mular and R B Bhappu), second edition (Society for Mining, Metallurgy, and
([SORUDWLRQ/LWWOHWRQ 
Schonert,.0HWKRGRIÀQHDQGYHU\ÀQHFRPPLQXWLRQRIPDWHULDOVKDYLQJEULWWOHEHKDYLRXU
US patent 4357287, 2 November.
Society for Mining, Metallurgy, and Exploration, 1983. Mill design and grinding performance of
ODUJHEDOOPLOOV,DQG,,SUHVHQWHGWR60(²$,0()DOO0HHWLQJ6DOW/DNH&LW\2FWREHU
Whiten, W J and Kavetzky, A, 1984. Studies on scale-up of ball mills, Minerals and Metallurgical
Processing, May, pp 23–28.

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 HOME

Chapter 5

TUMBLING MILLS
Alban Lynch

INTRODUCTION
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FDQDIIHFWEDOOPLOOSHUIRUPDQFH

FIG 5.1 – An Outotec single-compartment tumbling ball mill (left; image courtesy Outotec) and
the breakage mechanisms that operate in it (right; image courtesy the Cement Grinding Office).

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 CHAPTER 5 t TUMBLING MILLS

TABLE 5.1
The effects of design and operating variables on ball mill performance.
Design/operating variable Effect on ball mill variables
Mill diameter Capacity, feed size, power draw
Mill length Capacity, power draw
Ball load Capacity, power draw
Ball size and distribution Size reduction
Solids per cent Discharge rate, size reduction, power draw

BALL MILLS FOR CEMENT

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 CHAPTER 5 t TUMBLING MILLS

FIG 5.2 – Examples of two-compartment Polysius mills for grinding cement clinkers –
conventional mill (left) and double rotator mill (right; images courtesy Polysius).

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FIG 5.3 – Size reduction through a two-compartment cement mill (image courtesy Hakan Dundar).

FIG 5.4 – Centre diaphragm (image courtesy Christian Pfeiffer Beckum).

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 CHAPTER 5 t TUMBLING MILLS

TABLE 5.2
Size ranges of grinding balls in two compartments in a cement clinker mill.
Ball size (mm) 17 20 25 30 40 50 60 70 80 90
Compartment 1 (%) 5–15 20–25 20–30 20–25 15–20
Compartment 2 (%) 10–30 20–45 10–25 15–20 5–10 5–10

TABLE 5.3
Sizes of ball mills for grinding cement clinker. Mills may have one or two compartments.
KHD Humboldt FLSmidth Polysius PSP CITIC
Wedag Engineering
Mill diameter (m) 3.0–5.8 3.8–5.8 3.4–5.4 3.4–5.4 2.4–5.8
Mill length (m) 10.0–19.0 13.0–17.0 10.1–17.0 11.0–17.0 9.0–19.0
Installed power (kW) 1100–11 500 2570–9560 1600–7800 1600–7500 900–11 500

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64 Comminution Handbook | Spectrum Series 21

 CHAPTER 5 t TUMBLING MILLS

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Sizes and capacities of ball/tube mills for pulverising coal (data from Metso: Babcock Riley).
Operating characteristic Values
Mill diameter (m) 3.8–5.5
Mill length (m) 5.8–8.2
Motor maximum (kW) 820–2760
Throughput (mt/h) 42–141

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FIG 5.5 – Double-ended ball/tube mill for grinding coal (image courtesy Foster Wheeler Global Power Group).

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TABLE 5.5
Increase in the size and power of ball mills during the 20th century.
Year 1909 1912 1927 1940 1963 1970 1990 1997 2012
Diameter (m) 1.2 1.9 2.4 3.0 3.9 5.6 6.1 7.3 8.5
Length (m) 2.1 2.3 2.4 2.8 5.5 6.4 9.3 10.5 13.4
kW 11 41 168 447 1491 3169 5593 10 440 22 000

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66 Comminution Handbook | Spectrum Series 21

 CHAPTER 5 t TUMBLING MILLS

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TABLE 5.6
Typical stream sizings in a ball mill/cyclone circuit.
Size (mm) Circuit feed Ball mill discharge Cyclone underflow Cyclone overflow
2.36 98.8 98.6 98.5 100
1.18 78.6 96.3 91.5 100
0.60 52.3 90.9 82.2 100
0.30 38.6 76.6 65.3 98.9
0.15 29.9 47.3 35.8 91.3
0.075 23.9 25.4 16.3 72.2
0.038 19.2 16.3 9.9 53.8
Tonnes per hour 110 592 592 110
Solids (%) 95.6 69.4 72.9 34.3

FIG 5.6 – Diagram of the circuit used to gather the data in Table 5.6 (image courtesy Hakan Dundar).

TABLE 5.7
Sizes and motor powers of large ball mills.
Metso Polysius Outotec FLSmidth CITIC
Diameter (m) 7.9 7.3 8.5 8.2 7.9
Length (m) 12.5 12.5 13.4 13.1 13.6
Installed power (MW) 15.0 13.3 22.0 18.6 17.0

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68 Comminution Handbook | Spectrum Series 21

 CHAPTER 5 t TUMBLING MILLS

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FIG 5.7 – A semi-autogenous grinding (SAG) mill (left; image courtesy FLSmidth) and
a typical SAG mill/ball mill circuit (right; image courtesy Hakan Dundar).

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 CHAPTER 5 t TUMBLING MILLS

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TABLE 5.8
Sizes and motor powers of large autogenous and semi-autogenous grinding mills.
Metso Polysius Outotec FLSmidth CITIC
Maximum diameter (m) 12.8 13.4 12.2 12.2 12.2
Maximum length (m) 7.6 6.8 8.8 7.9 11.0
Maximum power (MW) 28.0 25.4 28.0 22.0 28.0

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 CHAPTER 5 t TUMBLING MILLS

TABLE 5.9
Comparison of rod and ball mill feed and product sizings (WI – Work Index).
Rod mill (2.7 m × 4.1 m, 110 t/h WI-14.6) Ball mill (3.2 m × 4.3 m, 155 t/h WI-9.5)
Size (mm) Feed % passing Product % passing Feed % passing Product % passing
19 100 100 100 100
9.5 64 100 86.1 100
4.75 39.2 100 68.5 99.8
2.35 24.1 100 54.2 99.1
1.18 14.4 98.8 40.7 96
0.60 7.7 52.3 27.7 86.3
0.30 3.2 38.6 16.4 68.3
0.15 1.8 29.9 9.3 49.7
0.075 1.3 23.8 5.8 36.5

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FIG 5.9 – Rotary breaker 3.6 m diameter × 8.2 m long prior to installation of
dust cover guard (image courtesy McLanahan Corporation).

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TABLE 5.10
Capacities of Bradford breakers (McLanahan Corporation).
Breaker Aperture size (mm) and throughput (Mt/h)
Dia × L (m) 38 mm 50 mm 63 mm 76 mm 89 mm 102 mm 127 mm 152 mm 203 mm
2.74 × 5.49 303 409 512 529 544 560 622 699 934
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FIG 5.10 – Rotary scrubbers showing a scrubbing section and an optional

trommel screen (image courtesy McLanahan Corporation).

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 CHAPTER 5 t TUMBLING MILLS

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1. The examples given here are products of Magotteaux, a company located in Belgium with global affiliations.

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 CHAPTER 5 t TUMBLING MILLS

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Comminution Handbook | Spectrum Series 21 75

 CHAPTER 5 t TUMBLING MILLS

Shells
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76 Comminution Handbook | Spectrum Series 21

 CHAPTER 5 t TUMBLING MILLS

BIBLIOGRAPHY
Allen, 7  Particle Size Measurement &KDSPDQ DQG +DOO /RQGRQ 
Austin, / * /XFNLH 3 7 DQG .OLPSHO 5 5  The Process Engineering of Size Reduction: Ball
Milling  S 6RFLHW\ IRU 0LQLQJ 0HWDOOXUJ\ DQG ([SORUDWLRQ DQG WKH $PHULFDQ ,QVWLWXWH RI
0LQLQJ 0HWDOOXUJLFDO DQG 3HWUROHXP (QJLQHHUV 1HZ <RUN 
Beke, %  The Process of Fine Grinding  S $NDGHPLDL .LDGR %XGDSHVW 
Bickle, : + HG   Crushing and Grinding – A Bibliography  S 'HSDUWPHQW IRU 6FLHQWLÀF
DQG ,QGXVWULDO 5HVHDUFK /RQGRQ 
Bond, ) &  7KH WKLUG WKHRU\ RI FRPPLQXWLRQ Trans SME/AIME ²
Digre, 0 HG   Proceedings Autogenous Grinding Seminar, YROXPHV  DQG  7URQGKHLP 0D\
 $VVRFLDWLRQ RI 1RUZHJLDQ 0LQHV 7URQGKHLP 
Gross, -  &UXVKLQJ DQG JULQGLQJ US Bureau of Mines Bulletin 
Gy, 3 0  Sampling of Particulate Materials: Theory and Practice  S (OVHYLHU $PVWHUGDP 
Lowrison, * &  Crushing and Grinding: The Size Reduction of Solid Materials  S %XWWHUZRUWKV
/RQGRQ 
Lynch, $ -  Mineral Crushing and Grinding Circuits: Their Simulation, Optimisation, Design and
Control  S (OVHYLHU $PVWHUGDP 
Wills, % $ DQG 1DSLHU0XQQ 7 -  Mineral Processing Technology VHYHQWK HGLWLRQ %XWWHUZRUWK
+HLQHPDQQ 2[IRUG 

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