BAI,I,MII,I,

Lunrpanies andqurliq control ldorutodes lhroughout dtc rofld. 1\e\itsnrd h\ tl. hundfur rAeb\ ccnrcnt 0f all ofc Thedigital cornterindicales the counldo$n endit I lt".l]r hc usd In (. rul,rtift lhr grindrhr||h .l-., slrul'nff rlrcdrfLrr dri\r ilr mrlu.lrncmn)fattcnti0n thistimejs notreouired. durins A jogingbltlon is lhc drun ior beding md urloadirg. A rlr.tnudljog is possible posilioning fofpfecise lrolidcd to positioo

StandardFeatures
. .\ll ballmilk comenandard$ithooe{4 5 lb. ch.ugc 0f lon hdls.ifon slmd, fcccivingtm pm. lUldhmd screen . lil cir-sl ifon dru l

l'ii

Models

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220 \bll,Jph.60 oclc . Modell95-i1 110,'120. 1th.60crcle . l\ odel J9t 5I\ ll0,220!.1ph,50qclc

F.C. BOND BICO BALL MILL The F.C. Bond Ball Mill is a smalluniversallaboratorymill usedin calculatingthe grindability of all ores. GRINDASILITY IS TIM NUMBER OF NET GRAMS OF SCREENIJNDERSZE PRODUCEDPERREVOLUTION. This Ball Mill canbe usedcontinuouslyor it canbe usedfor any numbq ofrcvolutions, accoding to the type of grind desired. For instance, the Frcd C. Bond GrindabiliryTestswre 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 approKimately 20,125 grams. 700 CC ofminus 6 mesh,stagecrushed, dry feedwas usedandthe circulationload maintaindconstantat 250%by adjustingthe numberof revolutionsfor eachgrinding period.

BALL CHARGE DETERMINATION Because ofvaxiationsin ball size,no exactnumberofballs ofeach sizecanbe specified. The ball chargeis prepared by startingwith 285 balls, consistingof approximately equalweights ofvarioussizeballs. These sizes include:3/4 incbrT18irrch,1 inch,1-114 inchand 1-112 inch.....about400 gramsofeach size.With 285 balls alwayspresent, someballs ofone size are removedard replacedwith the next sizeof largeror smallerballs. This is continueduntil the total rveightis at closeto 20,125gramsaspossible,making the last adjustment with the smallestsizeof balls. Do not removeall the balls of any one size. Oncea suitablegrinding chargeis prepared from onegradeofballs, count andnote the number ofballs of each size. gradecanbe started Otherbatches ofthe same using this count,andfirther adjustedif necessary.It is IMPORTANT to ietain the "one for one" rutio while adjustingthe final weight to maintainthe DroDer ball count. continued. ..

OPERATINGINSTRUCTIONS

Coruectthepowetsupply to thecontol box.Wircsarcprotuding for easy aonnection. Makesuleall circuitbreake$ arcof to avoidsevre electicalshock. Thismachine is equipped $r'ith anautomatic counter.To setthecountr, press thebutton to thedesired numbr ofrcvolutions.Theswitchhastwo positions, use,and "RUN" for normal positiotr (for emptyns), "JOG"to movethodrumto a desired To loadthedrum,"JOG"thc drumAsning until it faces upwaid.Rsrnove thecoverand gasket,Insertthesample atrd ball charge into thedrum.Replace thgasket andcovr. Setthe youdesirc numbcr ofrevolutions onthecounter andstartthemotorby pushing thestrrt contol. Themachine will stopautomatically whentle number ofrevolutions is reached. Again, usthe"JOG"buttonto positio[theopening of thedrumupwadtowards theceiling. Now, remove.the coveratrdgaskot.Agai!. 'JOG"theopening of thedrumtowards pan thereceiving sothesample andballscandischarye iltto thereccivilgpan.

F. c. BONDBALL MILL CEARGE Wefird thatthequestion ofcolrert bsll chargc arises oftuandis still yerydebatable. Backin 1960, Mr. Bondhimselfrecommended thc chargc dcscribed; 43batle - 1-ll2 inch (1.45) 67balls - 1-ll4 iuch (1.17) 10balls - 1 inch (1.00) 7l balls - 3/4inch (.75) 94balls - 5/8inch (.61) 285BALLS Total wt. =rDx.44.5lbs. Mr. Bondhimsclfadmittcd tllat it is verydifrcult to spwifr a givennumber ofballs of each weight,andin oul mostreceni conglondlncr with Mr. Bon4 halcoDtrladd a chsrge excluding the5/8 ittch(.61)balls. Becausc ofthis, Bico Inc.o(pcrimrntdlycame up with thc followingfigurefor a cbrrge: 25balls - 1-ll2 inah(1.50) 39balls - l-1l4 inch(1.25) 60 balls- I itrch0.00) 68balls - 7/8inch(.875) ( .75) 93balb- 3/4inc.h 285b&llr Totrt wL = apr.44.5lbs. Weirclude scveral exta ballsof cachsizesothattbecharge caubmanipulatd to result gm in the20,125 totaln'it! 285ba!s.

BICO INc; F. C. BONDBALL.MIL,LSPARE PARTS PLEASESPECTtrY SERIAL NUMEERWEEN ORI'f,RING (.ATAI.OG # BM-I BM-2 BM.3 BM4N BM-9 BM-I2 BM-134 BM-138 BM-13C BM.13D BM.I4DO 8M.15 BM-23 BM-26 BM-294 BM.298 BM-32 NN-SCf,r?ITON (Pleasc DruD,with Shaffs speciSSA.I) Covcr Haagsr Tablewith Legs Pillow Block Asbstos Gasks,t 50IIz Dgital Comter/Jogging Swibh 60 Ilz Digitsl CounlF4ogging Sfitclt CouDter Brackct Courtlr hror Paowith Ss'reca ard Rccaivitrg Palt ChEgeofBaUs ChainCuard = 29 inchcs Chain, onclagth link foi 60I{Z opaetiod Connecting Offsctlink for 50IZ opcrdion ShaftKey I trS/I(G

n3/52
1lt5 13/6 109/50 tl.4 .3t.1

9t4 50n2 31t.5

u.4
ll.4 t/.4

*** Sprockets arcavsilable andquoted uponrcqucat. (S/Ned IU rcquired).

1 . T OT URN DRUI I B Y }IA ND. N - _ 2 . T UR E ND O F S HA E T W T H WRENCH, (-r, o i T o R c 0 v E R B E HT ND c o NT RO L P ANEL )

o8it'fi'88l'J'AiPufl Fo "'lRed8$.
AND NANDLE PUtLIOIiARDS YOU.

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4 LOWE P B U_TO\S

N ' I URN -O S E T N L I , lB E R

A BO V E EA C H . _ S E T S WIT C H ON R UN. - PRESS SIART BUTTONf / I AC H I N EW I L L S H U T OF F A F T E R NUN4BER 0F TURNS COMPLETE. , TO J O G N 4 AC H l N E ' I. P .'T S WITCH ON JOG. 2. KEEP PRESSING I ST AR T BU T T ON 0 N A N D OF F U NTIL DESIRED POSlTl0N- .' lS REA C H E D,

WIRI}.IG DIAGRAM T'\]R BAI,L MILL 50 cYcl,a 220 \DLT

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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. .hd .:.mpl6 of ..t.ut.tion5. siv. to r.ti.l.r {ith r hor..xt.niive.xpl.nrtio.

by FREDC. BOND

Ih.ory is coDerred with tle relarion- of one-balf the surfacearea, and thc new crack tensth is r\OMMINUTION aDd rbc product particle sik \-. ship betw.en eoergt iDpr.tt proportionar ro 1I 1/i - lt\/j . nade from s eivcn fed 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 <iiameter h 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 producd by crubhing or grirding is direclly proporlio.al to feed passes is dcsisnated as F, and the work input iD kilotb. useful work input. Thc surfac area of a totr of prrticlcs watt bours per sbort to! is ttl. The basicThird Th.o.y eqnaof uDiform diamctrd is proportional to 1/d, and according to RFnNolR thc usful work input pcr ton is also to wi t0 wi proponioual to I /d. Hos'cver, tbc measured surfacc encrgy of the nc*, surface ara produccd is only a veiy 6ma[ fr!c'. . ( 1) ? \/F \/ 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 comparameterwhich expre$es rhe resistanc of tbe aDd Srinding. Nearly all of thc rcquircd drgy input ap- mrnunob ftatrial to crushins and CrindiDs.Numericaly rhe work pcars a3 heat dtr thc particLs arc brokeb. The sccondthcory (1885)is tbat of K1cK.:H. ltald 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 equi val enr to about o? p.r. ; nl paF of tbe pa icles conccrncd.Whcrc I is the diametq of the pasi n8 100 mi crons. sing 200 mcsb. When any three of rhe quaDrities in Eqoation fecd paniclcs and p is thc diam.ter oI the product panicles, (l) are known, the fourrh can bc fourjd by transposing rhc tho reduciion ratio Rr is J/p Accordios to KICK, tbc work equation.Useful forms are showd in (ta) and (tb) belowj idput lcquird pcl totr is proportioml to Iog Rrllog 2. Siucc neiter theory agrecawith commercial qushiDg and tl to grindiDa rsult!, the author devcloped thc Third Thcory in . . {la) 1951-r According to this theory, tbe work iDput h proportional to tb trlw crack tip length Foduced iD particle | to wi\/F \' braka8c,and aqualsthe work represnted ....0b) by thc product \ w1 / F - t o wil mitrus that reprcsented by the feed. Ir particles of similar 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 homoseneous 10 size reduction, its }l,i value will cootinu. constanrfor all size reduction stages. I R.prinr.d Fton Brilirhchemical Enpineednp

Fig.2. Expon.itidl size dituibutio, ttlot al ote with naturul gtuin size between1OO ond l5O nesll. E posute tatio Er: 0.30, P = 80 per cent pasine 4nO nicrcns. Oack lenetll equals Cr = 24.4 cnlcc ol solid.

Fig.3. Crack lensth plot l,on Iable l-ton 80 pet cent passi'1g lN micro$ 10 80 pet c.nt pdsire lm , ctohs lot all wLues oJ e,posute ruIio Er.

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 Fo. instance, certain mat rills havc a narural grain size, aDd thcir ryi values will be larg.r bclow that siz. than abovc it. A loosely cementcd sandstoDeof 4S-mesh silic-a graiDs will hav a larger ryi for a product nith broken parricles finer product. than 48 meshthatr for a coarser The etrciency of the rductio! machinc may also influencc thc operating work indx. For iostanci, a ball mill EriDdirgan ore from 80 p.r cent-l4 meshto 80 per cent100 meeh will have a lowcr opratins t/t value with 1.5-in. 3-iD.balls. srindins balls tban witl oversize A material may havc an tudacel grain size resultins from some prefrential siziry action which chatrses its natural size distributioa. Undersiz. s.indine bals can have this effect. I-aboratory.determinations of th. work index sbow the rcsiltance to breakagc at the rize rangc tcsled, and aly variatior in thc }'/; valDes in tests at diffcreDt product sizcs shows that the malerial is not homogencous to size reduction. For thi! reason laboratory testr should preferably be made at or near tbe product size required iD commercial 8Imortr& The opratiry work iDdexfrorn transposcd Equation (la) can bc calculated from size rduction in commercial plants to compare the plaat fficiency wiih laboratory test results, to compa& efrciencies of tb diferent plaDt siz reductiotr stases, or to .ompare thc efrcincies of difierent plants treatins limilar materials. The work index is particularly vahiablin prdictingthe sizeand capacityof Dewinstallations. Tablo IIIA in tle appendix Iists the averag work ind.x values of 82 difireni materials. Three PrinciDles CommiDutiod phenomeDahave recently been redacted into tkee pitrciples,rwhich ar usefrnsuidesfor the consideration of all crushingaDd grinding data. The FiBr Priuctr'le statesthat, since energy irput is necessary for siz. feduction, all fccd particles of finite siu have a certain .oar8y register,or enrgy level. which must be added to tbe enqgy iEput during crusbina or Srinding to obtain tbe enrgyregistei of the product.All statements of th energyutilized in comminutionmust satisfythis condi ene.gy input = enrgy r.gistcr of product - energy rgisterof feed. Th. Third Theory work index Equation (l) fo ows this principle, with tbe energy register equal to the total sp.ciffc energy input io kwh per short tod. The lrork index t/i is rhe energyreSjst.r lo 80 per c.trt pdssing100 miclotrs. If tbe enersy which has becn expended in preparing the fced particlesis Deslcted in analysioscomminution data. tbe first principle has beeo violated.aDd applicationof tbe calculated rsult to difierent feed and product sizes eill be The Second Ptinciple statesthat the useful.work input in crushing and edndine is propoitioDal to the length of tb. nw crack tips produced.In ordinarycrushiosand gdnding, rock particlesabsorbstrain energyand a. deformed uDder compression or sbearuntil the weakest flaw in the particle faih wjth.he formatioo of a crack tip. Tbis minute chanse of shapecauses othercrack lips to form at orberweak flaws, and lhe particle bleaks, releasingthe bulk of tbe shaitr energy as heat.The strain energyrequned to break is proporlional to fte lengtb of the crack tips formed, since the additional energy requircd to xtend the crack tips 10 b.eaka8e is suppliedby the flow of the sunoundingresidert stEitr ene.gyto the crack tips. Since the crack tip lenglh is proportional to tbe square root of the new su.face area produced,tbe specincwork input requiredk i.versely proportionalto the sqLrare root of the p.oducl particle diameter minus that of the feed

diameter,as shown in the work index Equation (1). C{ushiog aDd sriDdins machines are csrdtialtydeviccsfor the .onversiotr of m.chanicat encrgy into strain energy inro heat, uoder conditions which proftote material brcakag.. The enrgy register as uscd herein r.preseDts the specific cnergy rvhich has passed tbroush th material as strain enrcy, and iDcludes heat losses and loss.s due to fricriolr and other causs. It does aot correspond.to the eoergy cont.ni of thc material. The Third Pinciple deals wirh thc relatiooship of particle flaws to mat.rial breakas.. A flaw is defined as atry structual weakn.ss in a particlc which rnay dcvelop iaro a dack tp undc! straid. Flavs ar. slways presDt in brittle materials and may causc wide Erialions in thc brcakinq sLrcD8lh! of apparntlysimilar pardcler. The *cakest flaw iD a particle determines its breaking strength in crushing and Srindi!8. It also cortrols rbe number of particlcs produced by br*kage. Particles with the weakest flaw8 brcak most easiiy and produce thc larsest product particlcs. Ho*ever, they arc not necessadly easier ro grind ro a givcn producr size rcquiriEg severatstages oI brealagethan are pafljcles of rhe samesize \,\bose weatcsL The Third Principle states that the weakcst flaw in a particle der.rmines ils breaking srrengtbbul Dot its work index. Tbe work iodex is conkoU.d by t-be av.rsse 6aw srructurc Lbrougbour lhc Drre size rangc restcd. work index variadons ar dificreni p.oduct sjze, rcsutr from flaw concentratioft or shorlages ai rbose sizes,usually causcd by natural grain siz$. Evaluation ot Particle Size Dirt.ibution The usual ltandard screen scaleconsistsof a seriesof \ievs with square openinesdifrerins by y'i. based upon dre 200-meshsieve oDcbiDgof 74.: microDs. There are 25,400miclors in an inch. A scrcenanalysissize distribution of a crushedor sround product consisr!of a tistins of the pr cent weighr passingor retaired on each si.ve in thc Tbere is probabb a defi tr laq qbicb soreras rbe resltar si zedi .Lri buri on of crusbed or grouodproducrsr b owever , Done of the proposed laws bas bcen generatly accepred as Sizdistribution analyses of crushedand sround products are commonly plotted on los-log paper with (]) the per cenr passing as ordinatc and the parricle diaDeter (r) in microns as absci$a. Such plots of complete samples usuatly sbow a fairly straisbt lioe for rbe firer particle size ratrge which begins to curve in tbe coarser sizes and often aDproaches tao8trcy witb tb I00 per cebt passiogIiDe ar rhe rop oI tbe plot. Tbe size 80 per cenr passes may b. Iound from the curved portion of the plot for use in the work index Equation (l). Wben rbc straigbt lower porrion of lbe plo(ed line is extctrd.dat ils slope ,. ir iDrercepLe rhe 100per ceor passitrg Iine at i.& microns. It follows a po,e. law deffned by th G^rEs-C^r.rD1N-ScAUfiM l.rN equation,t s,hich is

J , : r0 0 1 . : l

'"

(2J

From this equation the surfacearea Jc in cm, per gram of cubical plrticles of density p, with 100 per cent passing tro microDsand slope d lo a grind linit o{ ai mrcronsn: 60.000 d f/k.^ \r-' I rr . . . . ( 3) p,/.roo(t_o) j ai /' L\ The grind limit ai hls lecently been assigDed the valu. of 0.1micron,6equivalent to 1000 Angstrom unirs. This is abolt 200 tjmes th unit spacelatlice of quartz and otber rock forning minerals. The slopr is often about 0.5, but may approach unity.

-3-

Crushins or srinding io closed circuii Foduces less fin.s than oped-circuit opcratiofl, and causes d to rDcreas Renoval of nnes beforc rcductioDhas the same.ffect As a material is eJound fiDer, its value of d often apPears lo However, The loA'log sizedistributionplot is donveDient. the usual curvature in its upper patt itrdicates that the actual size distiibution law is of the expooentialtvpc with a variable exponen!,ralher tbao of th! po*er type witl tbe constant exponentd. ExDonential Size Distribution Plots A metbod of plottios has bc.d developedwith yiclds size distribution lides that arc apparently quite straight for homogeneous materials-! They follow the expon.ntial

crack lcngth Cr of any !8ular qushcd or ground product sizc can be fo'rd grapbically wbeo i$ 80 pc| ceot passiDg P and crposD.e ratio Er arc known frotd atr xponentral sizE distdbution plot. On tbe first shcet tbc Cr valucs for P = I microD ar. plotted otr tbe lcft-hand iidc, and thc vatues for P : r0 microns arc plottcd on the dght-hatd side. Each pair of points is connectcdby a straisbt linc marked with its E value, ard intermediate lincs catr be drawn using a logarithmic rulc. The lecond sbcet is made by plottins values for P: 10 on the left-band sidc abd P : 100 on tbe rishnhand side, and so on for the 3t of lix charts, which cov.r the ltire operating size langc.
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93.0

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10.65 16.39 r9,t6

r.76 6.60 1,37

r.r7 2,47 7.96

0.495 0.915 r.r35

when the crack 1cn81h C/ bas beenfou!d,'the suface of equivalert cubesi! sq. cm pr cc of solidsis 2 Crt. The WTGNLR surfacearea Sp in sq. cm/8ram is .pproxjmately qual to the BL rNE air rlermeabilitysutfaceto thc as tbc loglog plot, but it power This plot is not as convenieDt : (rl)tr'r. or 0.92, S, has several advantages.The first is that the 80 per cent pass_ The 80 per cent passinasizeP io microDshas the folowins size P can be found with l.ss errot from P:100/v", ing approximate relationship to ibe Bun{E and W^GNER wbere w is rhe value of Xr at the base line 20. or Another advantage is lhe delineation of natural /2o,Jm\' 3.drr rog induced grain sizes.As the size distribution liDe proceeds sr / loop a curved the finer sievesizes, ':\ 6tErF up the chart apptoaching to the riSbt of the indicatedslraight lide shows a grain size and losP:2 los (203m/al):8.56-2.15 Ios (s,) .. .. (54) deffciencv. culminating at the natual gain size where lle parallel 10the straiShllidc. The compensaling lvork lndex from LaboBtory Test loop becomes etain siz. excessis sho\r,n by the return of t1le loop to the Equations havc been derived for findin8 thc work index staisht li'e. II laboratory determinatioft of the work Pt from several types of labomtory crusbability aod index are made at th difierent sieve sizes, th los' t/t as describedbelow. sriodability tests,T ialues will iDcrease as the srain deficiencv sircs approach a( rhe graiD .rcecs sizes rbe Darural grain si7e,aDddecrease where the loop relurns to the straightlinePiecesof brok.n rock passiosa 3-in. lquar end ret'ined The natural srain size in ores usually corespotrds to tbe on a 2-in. squarear. mounted betweentwo opposingequ3l unlockirg or min.ral liberation lize to $hich the ore must 30lb weight! \vhich swins on wheels. when the wheels are be sround before concenkation.The exponential method released on oppositesides th vr.islts strike simultaneously of plouins tle size distribution furnishes a vciv good of tbe measured smallestdimosionof the rcck. The heisht indicarion o{ the unlocking siz. wben tbe amount of the of fall is successively inoeased until tbe rock breaks.Tbe mine.al to b concentrated is 1arge. This is Particulartv imlact crusbing str.nglh in fool-pounds per inch of rock hue of iron ores, and the .xponntial plots sbow clcarlv thickne$ is desisdated as C, and Ss is the specific eravity. the different unlocking properties of autoSenous and The work index is found ftom the averageof 10 brcaks, conventional grinds. Much additional information can be oblained from tbis Wi: z . s g Cls e ...(6) c ra c kl e n g tbval ues.6 r\ D eot 5ia dis r db u o n p l o t,i n c l u d i n S re s l s a l 6 0 )o u l .s i n P Ur l ;l he ball m ; llB r i n d a b i l i ty P er mi l l Rod Mill Gtihdability Test revolution. tbe joules required to produce I cm of new The feed is crushedto -}in., and 1250cc packed in a breakage with graduated crack length in material of homogeneous cylindcr are weiSbed, screen analysed, and Sround specificgravity ss is approximatelyri s8/l l. dry in closdcircuit witb l0O per cent circulatingload iD a ratio Er is relaled to b in lhe exponential l2in. dia. by 24in. long tilting rod nrill with a wave-type The exDosure size distribulion Equation (6) as follows, where Er : X&/ lining and revolution counter,rundiog at 46 rpm. The erinding chargeconsists of six I.25 in. dia. and lwo 1.75in. dia. 2 - l.3ol El neel rods 21in. Long and weigbing 33,380grams. ....(4b) to c b ---1 Fj at tbe miu ends, it i! In order to eqDaiizesegregation of single fotated level for eisht revolutions,then lilted up 5' for oDe Tbe data ;n Table I can be llotted on six sheets dow n 5" fof anol he. revol ul i on, and ret ur ned cyc leloglog pape .l o ma k ea s e to f c h a .l sfro m whi ch rhe .evol ul i on,

X1 reDr.s.nts lt, thc nergy rcgistcr in kwh/toD divided bv the ;ork index fi/i at tbe 80 pcr ccnt passingbale IiDe where v = 20. The per cent cumulative retained v is 10o - y, 6 is th 100 - ) interccpt,and I is the slope. On semi-log paper I is measuredon the vertical logaritbmic scale, and X is on tbe horizotrtal linear scale. Diasonal slfaiqbr Iine5are drasD raoiating from lhe upper lelt-!and each mesh size or rbe corn;r of lne cbarr, {hich represedr bori zoD l al th e 8 0 p e r c e n l p a s s i n g . 2 " c ' eens ( , le an d c ro s s b a s eline. f a. h di a E o n alli re r.l re s e o tsa m e s bs i 4 l eni rg sieve wilh an openingof Pr microns, and cro$s rbe base lo/y'P,. The disgonal lin.s can be assisned line at /: various Desh sizes,-with the proper rclationshiP between

?!?.0 n0.0 t9r-9 t15.2

Surtace Ara C.lculations of Ground Produ.t3 Approximatc surfac areas in sq. cm p.r gram of cquivalent cubes for loglog size dislribution plots can be calcuIated ftom Equatior (3), usins a srind limit Zi of

to levcl lor eiSht rcvolutions cootiruously throushout ach grinding pcriod. Tcsts ar made at all m$h sizEs frotu 4 to 65 F.sb. At tbe cdd ol each srindiDg pcriod thc mill is discharsed by riltiDg downwad at 45" for 30 rciolutioos, and the product is screocd oD si.vcs of the m$h si.zetesl.d. Thc sieYeundcrsiz! is wi8!.d, and frcsh unsesrcsated fced i. addcd to thc oversiz. ro make its total wciSbt cqual to tbat of thc t250cc origitraly charaed into thc mi[. This is retumed of ivol tions to the mill and sround for the Nnb.r calcu.latcd to sive a circulating load equal to the weient of tho ncw fced addcd. Thc stinding period cycl8 are coD' tinucd until thc nct srams of sicve undersize produccd pet tvolutioD rcrchcs equilibrium atd reversd its diretio! of iocrcasc or dccrca3.. Ther the undelsiz! product ard circ lating load are scrccn analy!d, aod tbc averagc of the Iast thrce net Stams pd revolution (G/p) is tbe rod mil Sriodabilily. Wlere F is thc sizc i! nicrons which 80 pcr ceat of the oe* rod mill fed passcs,and Pr is thc oFning of the sievc siz. lestcd in rnicrons. theD the rod mill wo.k index ryi is calculatcd from tbe fonowing revised (1960) cquation : l 0\ /1 0 .,.,(n wi: 62lt P , \ or3 y tc ry )o 6 ' b ) | \vr-^ --/--l vrl

710.75-id. bals, and94 0 6f in balls ia. bslls,l0 l-in. balls, with a slculatd surfac! at@ of 842 sq. in. below28 mcsh.Altr the Tcstsarc madcai all si.vc sizes tust gdodirs pcriod of lm rvolutions,tbc mill i! dudped, out, and tbe 700cc of matcrial th. ball cbarseis screeoed is sdeDcd on sivesof thc mcsh siz. testod,with coafict protccting sicv.s if ncc.ssary.Tbc undersizcis \rci8bd, atrdf.erh unscgresatcd f..d is adddto thc ovcrsizcto bring its wcight bact to that of the original charS!. Thctr it is rcturded on to the bals in the mill and SrouDdfor the numbrof revolutiodsalculatedto goduce a 250pr ccnt circulatins load, dumped aod te:croeo.d. Thc Dumb.r of revolutionsrcquired is calcrllatcdAom th. rcsults of thc pr.vious pcriod to ptoduccsievcuod4sizc cqualto I /3.5 of the total charscio thc mill. Tho g ndiog p.riod cyclcs arc contiNcd utrtil thq oct grams of sicve undrsizeproduccd pcr mill rcvolution reach.s cquilibdum ard rcv.tscs it! dhcction of incrcas. or dlcrcas.. Th.d the uddc$izc product and circulAting and thc avcragr of thc last tbrce load arc a.recnanalyscd, trct grads per revolu.ion (Cbp) is tbc bal rnin grindability. Wbcn F is the size in microm which 80 lcI c.nt of thc P is thc micro$ which 80 pcl c.at ncw ball lDi fe.d passs, of the last cycle si.vc undcrsizc pfoduc! pass.s, ad Pr is thc openingitr micronsof the sivc sizc &stcd, thcn thc Tbis r/i valuc shouldconform wltb the motor outprit ball mill *ork iodex ryt is cdculatcd from thc folowirs Dow.r to ao av.ragc overflowrod mill of 8ft iolerior !.visd (1960).quation : thc $.1 in op.n circuit.For dry sdndiDg diamercr Erindins /r 0 l0 \ BL wlrcrc D is the nil work input sbouldbe multiplied by 1.30. ....(8\ wi _ 44.SttpJa.t' / lcbe\o l--7=- -.1 ' wf \ / r/ diamet.r iftide thc liDing h fet, tbc work input shouldbe Th! averag valuc of P at 100 mh is 114 microF, rt multiplicdby (6/D)o' Ball Mi Gtindabiliry T.'t Th. standardfccd is prepardby stagcdushios to all passinsa 6 mesb sicve, but fiocr fed cao bc uscd whn nccssary. It i! screcnanalys.d and Packedby shakiDsi! a 1om-cc graduatedcylinder, and the weisbt of 700cc is placed in thc mill andsrounddry at 250pcr centcirculatins load.The nill is l2ir. x l2io. wilh toundcdcor.ers,ald for a 4in. x 8 in. hand hole door a shootb lioios excpt counler aadrunsat ?0rpm It hasa rcvolution for cbarging. The erindingcharseconshtsof 285 iroo balls weiShing balls, 67 l.l7' grams. of about43 1.45_in. It consisls 20,125
150 m.sh i. is 76 microns, at m0 mesh ii is 50, ad at 325 mlsh it is 26.7. These v&lues of P arc to b uLd in Equatiotr (8) wher P cannot be found from siza dkEibutioD

The ryi yaluc from Equalion (8) should codorn with the motor output powcr to atr average overflo{, bal mill of 8 ft intcdor diameter SrindiDg wt iu closcd circuil Fot dry srindins tbc work input should no.maly be muliblicd by 1.30.However. bal coatinS ard packiug can incrcasc thc work input in dry Sxindilg. Wbere D is the mill diametrimid. the lining jn ft, lh. wort inpul sbouldbe multiplicd by (8/D)".

p : (2s,4M) (osr)(0.042i fatus which allow telease urder excsriv. pressure. This + 0.40) ....00) $ith the is contrasted erinding, which is accomplhhedby The product siz.s of cone crushers, with their flat clushto sravity and other forcesof ing conesand ielatively higb spccds,arc conrroltedpriDcifrcc rnotion itr response unconnectcd media such as rods, balls,rock piecs aEd patly by tbe close sidc setting. Wherc Crs is the ctose side pcbblca. setting of the cone crusher in incbca at thc bottom of tbe Frec mcdia grindins hssscvcralinhcrent advantages over crushins chamber, as commonly d.temircd by passiog fixed nedh crushing,and as reductionmachinlry increases a pie.c of lead though the crusher, sod Ecc is tte eccenrric in sizc and strength largcr particlcs bccomc amonableto tbrow in inches at the bottorh of thc crushing cor, thc Srindingwbich could forncrly b rcducedonly by crushing. product size P is found from Cass in point aie tlo devclopmnt of large periphcraldis(25,400) (C$) (7,s..) (0.027r + 0.70) chargerod miUs and autogcDous srindios mills. Hos,ever, .. ..o l ) (1Ecc- 2css\ tl comnercial Foductio! of pa icl.s larger than about If the matcrial is very slabby, tbe vstu. of p mav bc * in. i! sti a crushinspfocese. Gushing is uually doft &y itr sveralstages with small somewhatlarar than tbai irdicated by Equatioru (10) and rducdon rstios ranging fron 3 to 6 in each stage.The (ll). These equations are useful wh.n scrccu analyssoI mschin$ usd includcr gtratory sushers, jaw crulhcrs lhe crusher products are not available. Ooth singlc and doubl togglc),$uhiDs.rolls, and impact clushcrs,hammcriills or pulvcrators.It is donc with botb Scalpetl Feed to Crushett and natural fcds,in staSes 3c.ncd vith scrccnsbctwceD The Third Theory equations rcquire a '.Datur.al" feeal cach stagcto rcmovc und.rsiz,as w.1l as in open circuit containioS tho Datural finesproducedin the prviousreducand in closedcircuii witb lcrccls. tior stagcs.When fioes are removed from tbe fed, the Excssivo moistu, ffn$, or both, id the feed can cause relationshipbetwen F aod P is alrered.In most crushing packing in the cr$her, r$ulting in a deqeasein capacily, installations wbere fines smauer rhan the crushcr dischargo incrcaseio power dmw4 and increasc in the croshingplanr opening are removed from the feed by screenhg, thc work work index.This is usuallyrcmedicdby screening out more input per ton of original feed is not matcrislly decreascd, ffncs aheadof the crushr. exceptas the removal of fines prev.ns rb abnorrnal conCrushcrmoror sizcsare usuauylimited to protectrhe dition of packidg in the clusher.It has beDfound satisfaccrushersaSainst br.aka8e.For the samereasanuncrushable tory to djsregardthe scalpiDg operatioD,and to co$idcr th6 pieces of metal lre usually removed from thefeedmagnetic- feed to the screen or grizzly as equivalenr f.ed ro the ally, or thc crusher is designed to open up and let tben crusher.This is pleferable in most cascswbre the Brizzty
separaling size aDd hou.ly tonnaserhrough are nor kno*n

crusbers wilh steep crushiDs cones are coDrrollcd priDcipally by the opetr side settins of tbe crusher. Wb.rc O$ is rhe opeDside stting of thc crusherin incbcs at the bottom of Crurhing Crushing is acc.mplishedby contactwith metal or other the crushingchamber, the 80 pcr ceDrpassingsizc P of tho fton E4uarion (10). surlacer maintaineditr a ffxed position or in a risidly con- crusherproduciin micronsis calculated I i!. cquals 25.400 microns. path, straincd motion althoughmany dusbcrs bave safety

H adercv e Gtindability Ratins capacilycaDbe estiluted from lhe crushcrsetting,.ccentric Whcre Itd rcpr.s.nts the Hardgrov! grindability ratina,r' throw and work index of the material thc equivalcntwt edndins work index is found from I The product sizsof jaw crusher! aad primary Srraroly

. (e)

Ctuther PtoductSizes product size whicb80 pcf cent passes The crusber at full

H,){ever, in some insiances where much of the fineg i,ren removed the cor.ectjon for scalpedfeeo musr o

mad.. This is done empirically by using that incrcascd normal fed sizc Fc which is equivalcnt io s,ork input per ton to the 80 pcr cent passing size F of lhc scalped fed. siz dhtribution tin. oflhe scalp.d fe.d The per cent passing is ploltcd oD logJog paper. A liDe wilh thc normal slope of 1:2 is drawn through the E0 pe. ccdt passingpoint a to ih intersectionr. with the size wbich 5 pcr cent of tbe scalpedfccd passes;a parallel line is drawn through the point with co-ordinates F, (80 - Ycl2), and its tute6ection with the 80 per ceritpassingline givesthc value of Fc. WheE pieccsall of onc diamcler of.J microns ar fed to a crushcr the equilal.nt 80 pr cnt lassing sizc F. b lhat of a Third Thcory siz. disrribution liac with an exposur mtio E of 0.05 and the sarn. crack leaStbas the panicles fed.' The crack IeDSth in cmlcc is Ct = 173| \la. T],neFc valucs arc lisred in Table II. When the fced codsists of parliclcs of several different diameters d withou! fines, the equivalentcorrcclcd feed size Fc can b computcd as the wcigbtcd averas. of thc ditraent sizes d, r^rLF rr-l{urldr r0 F cdr Pstut si:.-.il,ro,pm(r4 dr d u!(mr
itr cm/c.-ltl'/r, r, slots - 0.11609 V,'

ton sround should bc mrdtiplied by (D /8)trr to find the work index flom Equation (la). FinenestAdjustnenl Expcrietrce bas shosE that .xtremcly finc g!indi!8 requires additional etrergyirput bcyoDdthat iDdicatedby tbe work index Equation (1). Thcrc arc scvqral po$ible rcasonsfor ihis, including: (a) The ball size! cuslomarily employcd arc too large for xtremely fiDe particlcr. (b) In finc gridiDs thc closcd-circuit classification is usually .ith.r iDefrcictrt or absent. (c) In dry srindiog of fitre particlcs th amount of ball coating ranses fron iDcipient 10 complct.. Ball coaling cushions rhe metal contact! and d.cr.ases sriodins efficiency. (d) In wet sdnding a thick viscous pulp can caule ball cusbiooing and dcrcase grindiDs efrciency. (e) The production of particlcs sma.Id than thc grind limit ti of 0.1 rnicron involves breakas. across thc uDflawed space lattice, aDd requir.s seveml times as mucb enerSy iDput as thc customary brcakag alonS planesof lattice displaccrDcnt-6 CoNidcrableamounts of traos-srind-liDit particlc! may bc produc.d in ultra-fin grinding. Wh.n tbe prodoct sizc P is Icssthan 70 micronsthe work input I/ as calculatedfron laboratory testsis nultiplicd by tbe followiog empirical adjustmcot factor ,t! which

P + 10.3 L145P
The fine product lactor rl was dcrived for the frne dry to dry srinalinsdown srindins of cmentclinker, and applies to valuesof 15 or less-For wet fine gdndirg,,{r should " a maximum value of 5havc Conversly, thc plant opcratins work index ftorn Equation (la) sbould be dividcd by 11 and by (8/D)tr, for dtuect compari\ob sirh tbe laboratory work index lti.

'

Gri n ding Corcction lor Feed and Products Closed-circuit grinding and complex grinding circuits and separationquipment are which include coDcentration best analysedby consid.dng each circuit as an inlegraled grinding the unit consislsof tbe mill unit. In closed-circuit and the classifier, with a single feed to the mill or classifier and a singleclassifier undersizcproduct. Calculationsfrom the mill discbar8e and circulatiDgload are usually unsatisfactory because the harder fraction of the material accuhuIates.and the circulating load has an unknown hiSherq,ork index than the new feed. If lhe closedcircuit includ.s concentrating equipment such as magnetic separatorswhich reject a taiUng,the product of the ItindinS circuit is a calunde.size and the separaculatedcompositcof the classifier lnalysed for this tor tailirg, which should always be screen Calculationsinvolvjns urnatural feed from which part or all oi the nnes have been removed should be avoided lvhenever calculationsof inlesraled ci.cuits can be subslituted. However. the empirical mcthods describedunde. ''Scalped Feed to Crushere" can be used when necesa.y

Prcper Grindins M.dia Sizes Th siz of tbe griDding rn.dia is one of the pridcipal factors afecting th efrciency and apaciry of tumblingtypc gridios milh. It is bcst determirdfor any particolsr iDstallation by lengrhy comparative plant tesb with carcfully kept records. Howevcr, a mcthod of calculating the propcr sizes,basedupon coffcct theoreticalprincipl$ and tcstcd by experince, can bc very llpful, particutarly in nw The gcneral principle of selection should be that th proper size of th. make-up srindins n.dia is the siz. which will just brcak the larsestfeed particlcs.If tbe media is too will be.cduccd, and larse, the Dumberof breakinsconlacts ihe x&emefines mad by each coniacr will be\incrased. If rhe media is too smal, there will be \yastedconlactsof s foic. insufrcientto brcak the particle! contacted. ln eitber casethe srinding efficiency wil be reduced,but the rse of undersirc media is usually more harmful lhan the use of Let , = F = 7i C3 = sc = D = K = make-up ball, rod, or pebble diameterin inches; sizein microns80 p.r ceot of the new feed passs; work iodex at thc fecd sizeF; f.action of mill critical specd; specific8rality of material being ground; mill diamere.in fect insideliners; an empirical.xpericnceconslant.

In o.dinary ball mill opcration f-in. steelballs willfiecwhen 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 theortically,r aod i! coDfirmed by experiencc, that 2-in. balh are suitabl. fo! 4-mrn feed- 3-in. balls for 9-mm particl$, .tc. Th. batl size should vary as the squarc root of the paniclc size to be broken. From tbeo.etical considerationss the proper make-up size a of steelor cast iron batls is found fron

largediamcte. mills draw rnore power with large ball sizes. Ball rationins. whicb is tbe regular addition of dcfilite propofiioos of balls of djfferent sizes, may be used when a is intermediate betweetr two commercialbau sizcs,or wher! an unusualsizedistribution of the fccd requAes the addition of some smaller balls with lhose of the calculrtcd sizc ,. For Rod MilLs From theoreticalcolsidelarions, the proper diamcter B of mak-up steelgrinding rods i! found from:

": \"/ \rmc" /r-l

/r\I /

ssr.t/i\r

. ...0 2)

Th empirical coastaot.K is found by expericDce to be 350 for wei sriDdirs and 335 for dry srindiDs. The comrncrcialsizc ncar.st to t h ordinarily sclect.d for ibe make-upball siz. However, when B is less than I id., it E|ay be cconomicalto sclect a largcr ball size for the3ercasons:(1) the cost pr ton of the smaler ballsis (2) lcsswearis obtained increased; from th smallerballs before they are di$harsed fron th mill; (3) the smaller balls may plue thc gratesof diapbrasm discharge mills; (4)
syn h o l i l d E q u d onNo'

when the reduction ratio R/ = r/P is lessthan 8, the calculatedvalue ofB should bc increased by 1in. For Pebble and Rockled MilLr Pebblesfcd to pebble mills, and the ruck fed to autogenous rnils wbere tbe large pieces srind the smaller particles, are selected 10 have the same weight as steel balls suitablefor the sameseNice.Wben B is tbe proper make-up b8ll sizc accordinsto Equation (12),theDthe proper lebble or srinding rock sizeof speific gravity Ss is A x 0.8/58)+. Size Distribution oJ Gdndiry Media All types of grinding mcdia commonly wear down to sizEs sufncientlysmall to discharsefrom tbe mill with the material beins ground. However, in someiod mills broken and worn rods are removed manually. It has beendelerminedtha! a film of metal of udit thicknes is worn from any siz ball in a mill in the samesrinding time. If the weighl loss is periodically replaced as make-up balh of size a, th. ball chaige reachesac equilibrium size disributioo which extendsdown to almost the ball sizedischarged from the mill. Tbis equilibriun sizedistributioD follows the equation . . . . ( 14) whe.e ) is the percentageof the lotal equilibrium cbarge passins any size r. Equatior (14) presumably holds for srindins rods and pebblesas weil as balis. In order to obtain consislent perfolmancein wet srirding mills, the initial media charseshould be made up from the several sizesavailableto besimilar to lhe equilibrium charse defined by Equatioo (14). This cao.be approximated by drawing on loglog paper the srraight per ccnt passinA lide witb a slope of 3.8 tbrough 100per cent passingsize8. The initial chargecorDposition is detclminedby mdking the poids midway betwen the ball or rod sizesto be used. ff ball rationirs i! to be used,tbe initial chargc should be proportioned betweenthe two ball sizesfed. In commercialrod mills no rod sizssmaller than 2+ in. should be used in tbe initial charge.In commercial ball milk (he minimLm si/e used is commonly I iD. In dry-grinding milh the metal wear rate is so much less than in wet milh tbat two years or more may b. required to rcach equilibrium, aod the initial chargcaD be proportioned lo fit the mill feed without referenceto the equiliThe weisht. volume, and surface area of steel balls or rods of diamelrt inchescan be foudd from Tabte III.

ro0\r lm cr v,

et l--wig

.,.. (13)

Ftu D'dridiBri.nr hcror. Rod hnl rdiu$m.dr rrcror -R' rdiBh.nt Bd onl Rr rrcror. rbiD. {ifac. ao jn rq cn/srh. E$o!.ntirl !ir. dndbudon o.6ddi. F L b g g in cb .im Dld c' ul hi n'nmsrb' &r 6r dturdiB rord/100

4, 3 . l ,

Tour cack ldrlh</d. rad. orcon6,B'o ' -dshr cyda Fi. m'nnc in rR. on. '.njsr6chr P.r edr or dnchlrF rasine riz. ,. F.dtl. th6w df c;shq in i.cb6. F.ri rzFnikrcci0 Fenrpekr lqrivrrmr 3iz .. &,rp.! f..n. PdcmrolD4f.!dDaliJa!i'P16 tuj.e!$rF !; hil n.- red. P.r.d'

n ,+n

lra{d3rctr eirdbilily

,,

Kilovat! Kilof,d! l43rh

s to! ol bdk, id tm of rcd!. ol !n incio! in tei.

Pq.4lpuiainhilldjtch'ie' [email protected]&ni4inb.hB. Producr!i!F n...o 30 tsr@t pn*i si.v.o!ai4inmjclot'FA-cah&bj]ny, Fd.rroo '.p or nilr 'o rocr di:.b!re

n,r+

4P

Ps dr opti-uE

of ov6ir

rrsid

!iz. P. n.it.

ro.t nill r.dldjon

Pdcot'ai4i!claliid@rRproducl'

Yt.

Fflcdon or nill varud. b.low dischrrce work indcr: kwhjon wort rdd: rwbhod 30 Fr @r'o ro D@dud 5;..

r,s,

Fouteen l. Fip. nius ba 86-ht 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' gindina Th. concludinsp.rt of thi. rrtlcl. i5 conc.rn.d with r nuhb'r of h'toR rfi'di" such r5 th. rhdion or nill volufr. occ!pi'd bv th' trindJ"..'i ."iiriiit..t or mill "q"lpn.nt. qu.ntni; or rods dd b.rk b b. 6nt.in.d in . mirr, {"r i;;-;;:;.,.h. 'nd mlll tP..d in le/ms of th. critic.l tP..d. Th. .ff.cti of hill dhh't'r' or ;;"ndin!;.diun,.id uPon rrtio ov.Eiz.:f"d. Powcr ol b.tl .hrrg.. P'rtormrn" ;ownw;rd rlltt.sc 'on{hts 'nd don rre d'(us.d, oP.n-.ncuit multitliatio^ frcloB rrc liv.n ror.onrcrtlng clor'o{rrc!E r.cio6 lN'n ror worx work v.t{.s to the oP.n_circuit vrlu.r .nd. 6n.llt. .o'r.ctiq 'r' i'a.i *rirtion' *hicli .rit. wh.i l.boBtory srind.birit/ ind ioP.<t cruthinl t'ris 8iv' v.lu.t. Ind.x diF.r.nt wort

Dl

FRE D

C.

g O ND

realor the m6tal savine! resultinS frorn the usc of hard M6t3l Wcar altoy mil lirings or mcdia arc usualy Srcater id drf iten 6itr8le r f,ETAL $.ar is us'rally lbo s'-.ond largeqt griDditrg, is conventiooal Itindins, aod io wcr Srindingttan in wet lVl **'r. thc "i i*i"l"ti*' il mav lpproacb or iii'-ai'g 'ven "cerd Ab.arion Tcat DOWCrCOSL ' wlcralwcar is commonlv .xpre$edin lb/ton susbcd or Abrasion tits to indicatc mtal wcar ar6 madc a3 ald sizs paniclcaof the rnrttrirl aod ;; fced Eoduct folows: o 4O0 i*r"toDs slams of -l + rl"".ii". coDsumP' m'tal drutn for 15nin Th' bv erprcsliDs in a rotAtiry Ested ar; to be Dlaccd climinalcd -iiii. are indcx L work '-in, parb: can be iop.llcr it rotating wom a rapidy rcjtcd thousb drun sbowrs thc rock Go ,, nltWl" iucludios pcr and toD at 632tpm metal coDsumed lotatd pourds of it. The imPcller within contained tu i.on ott i". crPoscd paddl 2 !q. in. with kwh/ion x i[. stccl the consistsofa3 1x + crusbedor eroud and a\ to wcar, machiDedof SAB 4325 stcl hardeDdto 50O scrapped of nelat botb wom awav-abd Tbe pounds of tbc ore and lhc Brircll. The gram! of weislt lost bv thc pad{ c after im' tte abEsivncss *.'i-"Le tuti"" of rcck for 15min. batchcs 400-8ram ot rt" IDetal Th averagi v'lues froE pactinglour Juccessive t."itta""o -itt "trnsi6o rt-to of mils witb ordharv miU--liriDg'srDd iach ii called the abrasion irdcx and dcsienat.d $ ,ti ors' The combinedproduct of the four ls_min. pcrioal!i! sctccD "-irie" eFindingEcdia, grinding w.t a largprangEof siliceous it avra8es 80 per cent passins13'250micron$ aoalysed; allov si.els and cbet irom csrl bc of sDecial Paddles Bd Rod Milt TlPc rlaabrasive r.sEd with a sdtrdard Faterialto detcrmiDc balls 0.14 ro d s 0 2 1 M c dia: lb/ k l 9 h of the metals. tiv wcar raqistance 0.020 O.oAi LiniDg: lb/twh T\a av.raeaAi values of some tvpical materialsfron aboul oo' averages drv io wesr SritrdiDg Th. nctal 125 tests artlsted iD Table IIA in tho lppndix. A ftm Howcver' rnatedal ."ve*l tnal ot wlt ItiDdiDS tbe same cofielation with actual wcsr ratsin rushcrssDdeEiodhg * U" mat.rials Srouod dry are sofi'r aid less mils hasDot becdmadeasyet; however, it is apparcutthat q'ct io drv coatios Batl srioding -r"" Ii-#iu. rl* tlo'. gr-'a in Table IIA ar! mucb sho$n abrasion index vadations the can reduc. tbe metal wal still turlher' expccLd iD tho ts.tal to be than tle wriations sreatcr re\ulLs i! wct wear SriDdiDg Wcff over taf of tl. nelal tbat anv obscrved It is machines. wear rates in cornmercial from lbe'ctivc nasetrt metal ftom conosion, or dissolutjoo hdei and tl abrasioE work index correlation b.twen tbe tb's For produced in tbe mill l"J""es iont.uattv bcids is vc.y slight Prelimirary indications ate that ir wet srndins thc pourds of bals pr kwh equals(li + 1) dividcd bv a

t'ffi"F*,"F,*"+H'[+"t:r#':#.1"ji{;T|i"#tTJ &".df"':i'i i r,iLTr:!.1*';5;

- 9-

loose rods 3901band silica pbbles 1001b.Measuemcnts of thc weisht of steel ba s contain.d in a cubic foot. bor are usually lccs than 2901b becau. of thc incrascdvoid sprce at th sids of the box, and tbc wielt coatained decreas.s as tbc ball siz idocas$. For accurat! ocasurcof the contaiocr lhouLl bc at mentsthe smallcstdimeDsioE least 20 times that of tbe largest ball. Brokn balls caD reduccth. spccificweight to 2801b/cu.ft, and b.okcr rcds to 3401b.Thc spedfic weisht of both ball add md charges caD also bc rcducedby a content of hard particles of the material bciog ground. Tons of new balls 7b cotrtaiod io a min ar. found approximately from Equation(tO, atrd lons of rew rods (17). ?/ from EquatioD

speedis about 77 pd cent of criticat: for wct rod milh ii h about 70 per ceDt of critical. Somewhat slower spe.ds arc often found to b6 more e4onomical. Dry-grindins mills atrd pebble mills usualty operare at about lbc same sleed! as wct mith! nith the maxiDum less lirnited thaD iD wet millsLaboratory sludies hav showo that or thc iising side of th6 mil each circular row of gritrdirg ba s slips dowqward Volume of Grinding CharSe to the next o!te. row it restsupon, tbus causiog Tbc ftactior /p of thc total iotrior mill volum occupied tilb lespect grindina in tbis portion of the mi . A similar dippase somc (1t, by llc srirdins charsc can be foutrd by Equation is Dot obsrvcd in rod Eills. whereD is the insidc diaractcraDal O b thc \rtical distaocc At spccds faster than 60 per ccnt of critical the srnaller griDditrg do$n from th iDlide top of the Ini[ to thc lcvcled or rods in e Sdnding charac tcDd to concsnEatc qritb balls at the charS!: O should bc the &vcragof masu.crDents 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 ccrE of th cbargc. Advanvp = 1.r3 ....0 t tagc is t.kea of ftis iD ball mill6 AP - r.26 to movc the smalld balls loward th dischargc end of thc milt by spiral liftcrs Aailina Tho weighi of the srindiDgcbrs catrbe calculatcdftod towerd the mill diacharge; or by rnaking thc mil sh D, Izp, atrd thc inside leDstb of the mi[. Loosroudd balls wilhout b!akagcweigh 290lb/cu, ft, sli8hdy conicd, with the smallest diamctcr at thc dischargc Smal-diameter mils arc cornlnodly opcratd at somcwhat highcr fractions of tbeir critical sp.lds than are lars mills, indicatirg tlat the proper mill sp.ed h itrtermediare between a constant fraction of criticsl spced and a coDsrant pcdpheml speed. An approximat empirical cqurioD for tbo maximum praticalrpm of wer bal mills, designared as

Dumberwhich ransesfrom 6 to 9, atrd Iidr war iE about onc-cishth of bal wear. For wet rcd mills the divisor rang$ from 4 to 6, and liner w.ar is about one-svmthof rod w.ar. Wear in dry srindins t about onc-scvlrih of wet Brindins.Thc .veragc metal wear in cnshirs is rougbly comparabl. to the liner wear in wet srioding.

No = 51 - At)los D

. . .. (20)

....00 . ...07) Tt = Vp D'L16.8 approximately A charseof Brindirs balls contaiDs 40 per cenl of void space,aDd rods in lirar contact contaiu 20 per cent voids. Broker orc coDtainsapproximately 40 pr ceatvoid space, andweighs 100lb/cu.ft multipliedby its specificsravity ovcr 2.65.At 80 pcr ccnt soli& or morc rhe voids iD a grinding charsof stcel balls caDcortaiE 14 pcr cent of the batl wcight iD ore multiplicd by S8/2.65.A rod chargowith the rods in liaear contactcan co aiD 7 per cen. of (hc rod *eigbt. Howcvr, botb bals and rods arc commonly fored apart in the mill atrd may coDtainmore ore thao tlese miEim m amounts. Tbe pr ccDt solids containedin th pulp within a wct Brindins mill is ordiaarily more tban that mtering and Icaviry tb mill, siDce thc flater fows tbroughthc mill fastcr tlar the havierparticl.s of ore. This diference is iocreased in 8ra.eand pedpheraldischarsmilb-

Criticel Mill speed Tho theoreticalcritical spcedNc h rpm b the speedat \rhich a particle of Do diameteragainstthe mil linins witb no slippaso s?ouldcentrifus!. It is found from Fauation (18), itr fcct. Powe. pr Ton of c.indlng Media c,hercD is th intcriormill diamctcr The powerinput required ia tumblins mitlsis calcutated Nc = 76.61\fd .. . 0 8 ) from tbe power requircd pcr ton of srindins media uuder The ftactioD Cr of the critical speed rcprcscnted by alry tbe mill operating coDditioDs. It vari.s wirh the ftaction bil rpm is found from Equatiotr(19). Zp of the mill volume occupied by the srirdins charge,tb x rpm x y'b Cr=0.01305 .... (19) fractio! Cr of the critical spccd, rod tbc iDrerior mill
Tumblins mills are usually d$ign.d to rcvolve at a con(21)sivcs Equatioo th. mil input kW pcr ron of stsnt fractioD of th critical speed.Incrcascd specd iocrases grinding nelv rods in -(r/, cotrvenlional power wet Srirding ovdflow draught,but also increases the the mill .apacity ard metal war and mainteDaDce cost per ton Sround.For con- lod mills. Kvr=Dt4(6.3-s.4vdcs . .. .(21) ventional wct grindiog ball mills more than 8 ft in diameter, *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 Dractical mill tbe actualpower d.awn by as much as l0 per ceDt.

Effed of Mill Diam6t.s At a consiantvolume fraction t/p the massof rhe grindilg cbarSevarics as D'. At a coostantfraction Cr of the critical sped the pcripheralspeed variesas v5. It follo*s rhat tbc powr input to a conventional tumblios mill theor.tically variesas the interior diametcrto tbe 2.5Dower. Meaqurements bav. shown rharlbc wer6n. srirdi;g mitl capacity varies as D'.. Thc diamcter expoDeatincreaslr sliSltly in mils opcrated under bish impact condirions. Theoretically, iho maximum expon.nt under reductioo ertirelyby inpact is 3.0. Mealulemdrts haye aho sbown that tbc power inpur expooentactually vadcs as Dar. The decrease from tbe theoreticBl 2.5 cr(poDent probably result! ftom energyfrom tbe falling bals or rods beiss tsansferred back ro th mifl she on its do$n-8oing side.The actualdjametercxponent per lon of grindins nedia is 0.4 insradof th thcoretical 0.5. Tho difideDce betweenthe two observeddiameter exponentsof 2.6 aDd2.4 is 0.2,yJbichis the expon.nt dfiling the mechanical advantag.of larsdiametermilb. Mechanical emciencyircreascsas thc inrerior mil diarneterto rhe 0.2pow.r, aBdtbe kwh/ton requiredto sdnd d.creases in the samcratio. Sitrcethe standards'ork iDdcxis basedon rDillsof I ft intrior dhmeter, rhc computed kwh/ron (I/) by EqDatior(1) for any min of D fr interior diametershould be multiplied by (8/D)'t

- 10-

4 f,
I

,r/ -r i

!\

i..

C LA S S IFIE R P E R FOR I{ ANCL

-----------TLoi-

* E Ei: :

Fig. 2. TOP: Classifiet perlorma ce plot. 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.

E[ = i:

oN - %cuM \ovERs,zE

- [ -'"

3i<'

\--as

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. 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

;*
W. 7 O a | <r h / S H o R Tl O N

Efict of Reduction Ratios Th vertical componctrt of thc motioD of a particle of no The reducrionratio Rr is the ratio of the size of the rew diamc.r a8ainst thc lining of a bal mill at griticd spccd prod ct, or F/P Witb of tbe final scalp.d to that mill fced colrEsponds to frce v.rtical oscillation*ith h: l2D, znd pa.ticularly s$iIccd, FclP should bc used. Rod mills arc tive to u avourablercduction ratios, atrd if F/P is smatlcr (,'/) than about 12 or larser thatr abouf 20 the twh/tor Fed If Rto represenhtbe opti- Ef,ect of Overiize required fo! grinding increases. Fced particlq which are too lars. for thc grinding ballt mum rod oill reduction ratio, its approximate value is or rods 10 brcak are sradually worn down ir the mill r,itl (25) a considerable lossof srindif,g eficieocy.If rhe mill product Rto=8+5LlD - 11 '

Whcn the actualreduction latio.Rf is much smal.r or Equation (22) sives.Krr, the mil irpur kW per ton of srindiEgballs for coaventionalw.t-gdnditrg ball mills using larger thanRro, the work input P from E4uation (l) 3hould of thc mill bo multiplied by the cmpirical adjBtmcnt factor 1,, wher. makc-up balls lar8cr than about oDe-eighticth A'=r+2(RtR0)'1300 ....(26) Kt tb * 2.8DLt(3.2 |Ztrw, .... Qz) - 3 v p) Cdr - o.1 pcdpheral Sinc dischargcrod mills havc los, reduction For dry-grinding smtc discbargcmils Xn, should bc ratios, thcy Dormallyr.quirc an incrcasciD P. Ba[ rdills arc lcssEeruitiveto changes in reduction ratio multiplied by 1.08. If Od rprcscnt! &c vcrtical distaDccin feet ftom thc ttad rod mills. Ho$cvcr, whm R/ b.lomes le$ thar about point, then 3, particularly in 1befDe srirdins of concentsat$,7 frorn insidetop of thc mil to th. lowast discharse ' Vpd= t.r3 - r.26 (l) should be nultiplicd by the cmpiric{l adjultBquation ....Q3) AdlD mcntfactorlt, where wheret/pd is llc fractior of the intdior mill volume below zX(R!- 1.351 + 2.& dischargclcvcl. For a full lowlevl gtat discbary. Vpd ....Q' --' 20(Rr- 1.35) equal!0.029.For welgrindins srate |nd low-leycl discbargp . l, . O.4O - VDdI ny nlrD m'rls. rnurupry Free Verticll Orcillatlon l, + 2l l. A body id fre vrtical oscilation fals from it! highast posilion under tbe influcncc of gravity and tu stopp.d SlumD Coffection Lars+diametq ball mills fed with small rnak&up balls lorcibly by atr equal deccleraiion; it is thctr acc.l.ratcd downwardslippagcof the upwad at tb! samelate and r.acbcs tba samchiSh.st poriof xce+livc lose power becausc a sinplc barmonicmotion ovcl a bal chalsc or the siDSsid. of tbe'milt, and this lo$ of tioD asbcfor.. It dcscdbs powd inult dcreas.!tho min capacity.An cmpiricsl slump vertical distanccof ,fi inchcs with .prr cycl.! pcr minut!, subtraction quantity Sr is computedfor wet overnow and ....(28) satc ball rnills by Bqu&tion(24),to bc subFact d from the is madcfor vtct K)r, vdue of Equation(22).No subEaction 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 orcillafrom Xr, is tbec-quartersof Sr asfound by F4uatiotr (2t, tion caNesthc amplitudc i to incr.aic. whcr , is the dianeter of tbc make-upballs fd in inch.s. Tho power occasary to maiDtainfrc vcrticd oicillation 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)

- t"":(i#

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 cotrsumed in tle two lin6 cross h thc partirg size, aod the pcr ceot fine erindirg increases. The decrease in capacity caulcalby passiDgat tbc cro3sirg poiDt is the per cetrt cmciency of the overeize erirding media is aot as pronouncedas that caused When Fo reprcscDts the maximum 80 pe. cdt passing feed siz. in microns wbich does not appreciably decreas th. erinding efrcicocy (is not oversire) nith tle ball or rod siz! calculatedfrom Equation (12) or (13), aDd the rrork index is 13, Fo is about 4000 foi ordinary ball mils and 30,000 for rod mills. Pernta8e Circulating Load In .losed-circuit reductioD the per cnr circularing load (100 C0 is 100 tnnes the ratio of the weisht of separator oversizc returning to the rcductioD machire io tbe weieht of the new feed enterins tbe circuit h the same time P: Fp = Dp : Rp : When microns 80 pr ceot o[ scparatorundcrsize passes. per cent of new fecd passiDssiz, P. per cent of iDacbine discharse passirg size P. per ceDt of separator oversizc passing sizc p. tbe new feed enters the re.luction machinc

The work input Il/ for oversiz! feed (F> Fo) is calculated

y'(l3VD4 Forba mirsro : ao,m Forrodmills fo = 30,000 ,/(3)twi

. .. . (30) ....131\

wi w- lto P L\/

10wil I Rr+(W i- T (F - Fo\lFo \/F I L

. ... (32\

The quaDtities (37) aDd (38) caD be requircd in EquarioDs Tbe gdnd differeDiial Gd evaluates the diferen@ h the deteimioed fron loglog or exponenrialplots of complere particlc sizcsof the concentrate and tailing when griDdisg size distribution aDallses. However, rh sdeen adalyses for rnineral unlockiDg and cotrcentration by flotatioD or by evailablemay not permi! detclminatior of thesequanrities, cravity. An inqeased grind difierential can b of mal'or and C/ must be calculatedfrom the old equationslrbascd importancein such srindils cjrcuits. passing?00 meshor any otie. availahlc on the perceDtages Whcre P is tbe 80 per cent passidssize in microns of tle fe6d ao concenr.ation, Cp is tbe 80 pe! cent passingsize of If . represents the per cent of tbe classifi.r fine producr tho concentrate, and Cw is the per ceDtweight qf the coo- passing 200 mesh. r is the per cenr of rhe classifier coarse cenrrate divided by rbe f4d, the griod difierentkF is product passing ahe same sizc, and m is tbe pcr ceot of thc mill dischargcpassiDg the samesize,thcn whcn tbc Dcwf.ed P (150- Cr) - 50 cp .... (33) ente$ the erinding mill P (5o-Cwr+50Cp A typical copper flotatiotr plant has a sriDd differeDtial of 1.34.Any chansein thc sinding circuit $fhich would iDdcase tbe Srind diferential *ould resott iu relarively coarser srindins of lhe g3trgue.and should favourably afiect costs,recoveryand gladc.rr WbcE makibg rwo grinds to 80 per ceot passio8a giveo product size P, witb the tust srind diferential c4 larger than thc secoDdsrind diferential GdL the relative IbechaDi, cal efrciencyof the filst srind to the secondis:

Grind Difrerential

Cr: (8 0 -Dd l(Dp * Rp \ Whcnthenewfeedenters theseparator c t : (8 o -F p )l(Dp _ Rp )

ct = (c - m)l(m _ t)

. .. . (39)

When tho new feed enters rhe classifier, and ld r.pteseors tbo per cent of tlc new feed passine 200 rncsh,thcD

c t = (c -t " )t (n -t )

. ... (()}

Ary other suitablesc.eensize may be subsrituted. Howev.r, tbe Cl values calculaled from dn.r.nt scleer siz.s usually show a wide variatioo. and tbe mesh size at whicb the circulating load is calculated should be sp.aiffd.

Per Cent new Classifler Feed to Closod-circuit Mlll Rer. En:./r + f91' , l) - l9,r , l) ....,r, When a rod mill in open circuit discharges ro a cls$ifi.r a \Gdr.l 1l \Gd,+ tJ

ff the recession faclor R/ is tb number of standard y', screo scalcspacs between sizeP and sizeCp, then

in closed circuit with a bal mill, rh. per ceDt of thc rod mill discharse which enlrs the ball miI as scalpd ncw feed

RJ: (toEP - losCd ltoc,/1

P:c PQ)l
N

,'*-l

Closed-circuit Versus ODen-circqit Eell Mill Grinding The listed work index valuesapply to ball rnills srindiDs wt in closedcircuit. For dry sriDdiDsitr closedcircuit, the work input Z should be multiplied by 1.30. _to open-circuit The conversion eilher wet or Srinding, Clairifler Performance dry, is dode by multiplyinstbe closed-circuit work input In closed"circuit reduction tbe efficiencyaDd tlc sparaG ,y by aE open-cilcuit multiplicatior factor. Itr tbis coDDecins size,cut poitrt or lartins size of tbe classifieror screen tion the circulatirg load Cl shoutdbc uoity or grcater. are important. The efrciency is commoDly exprssedas This factor varies wjth rhe refercncpe! ccnt passilg! I0{ minus the per ceDtof finished nalerial or "unders" in or tbe per cent passiog at which tbc opcr- and closcdthe ove.sizeleturned to the rnill or crusher, a! a cenau circuitsrindinsafe compared. For iosratrce, iJ rhe.efereoce percentpassing is 95,tbernuttiplication factorwil be much The paldns size h defioed as the size at which the per largertbatrat 80 pr ceDt passitrg. th.t 95 ff it is required cent "unders" in tbe separatorovenize equalsthe per cent pe. ceot of tbe productpasles 200 meshtbe change fron "overs" in the separator lndersize. The separator lnder- closed circuit to opencircui!wil requirca muhgreater size per cent passing,and the separatorove.size per ceil increase in powerthanif ir is required thar80 pe. centpass cumulalivo relained on, are plorld as smooth cu.ves on 200nrcsh, or aay otherspecified mesh size. -i2-

Tbc g nd difereolial cd can be calculated from the rec$sioD factor Rl aDd thc p.r cent weigbt of the conceutral C}? by substituting the value of P ftoln Equation (3O inlo Bquatioo (33). Th Schuhmann sloped oflhe heavierconcentrat.is commodly greatertban that of the lighter taitings.

fc" or rod mi discharyel [% pn , lm-% Enl passiog parrirgsi.. I I r0o -r tmc/ I ..., (41)

Som. apFoximatc opcD-.ircuit multiplication factoft for vario'rs r.ferencc percentag.spassingare lisred below in Table IV. They follow an exponeniial function.
TASLE IV

'lo 80 90 92 95 98

50 60

1 .0 3 5 t.0 5 t.l 0 1 .2 0 1.4'0 1.46 1 .5 7 1 .7 0

on th. same samplc at difer.nt producr lizes. Tbis corEplicates the calculatior of the work iDput rcquird (p) in kwl/ton from Equation (l), which is !s.n with rbc dcsir.d capa.ity to fnd thc required rDoror and mil siz!. Who this bappens thc various work iddci values ar. plotted vcnically as orditra!$ on lo8-lo8 papr against tbc 80 per cent passing size as abscissdc,and the poin& arc connccted by stlaight linca which arc cxtcrided horizoDralty to the edg.s of rb pap.r. Tbe 80 pcl cear pa.gsiDg sizcs ol Sriodability l.st ploducts are fourd by divjding rbc r.r.cn opeDin$ Pl in Eicrons by log 20 (1.301),or by the valucs sivn folowing Equation (8) for fine bal miI tcsts. Thc 80 pcr cent passing sizo is 1.5 iD. for rhe impac! cruhitrg The work indcx values at tl. dcsignat.d 80 pc! cerr !assing product size P a l fced sizc F arc found from ihe plot and dcsiguated as tri and ,t/i. Thctr thc work irpul ry is fouDd from F,quation (42) as givon below: lO W t0 wi, , 10\wit - wt,, _.

tbat laboratory rcd mil and ball mi gdndability tesis and impact crustiDg teEts sive dificrDtwork index (7r1 values Appendix
syEb.F rn E{ur.ion No. t
,6 R.d nil nr drutuar Brll birr i' rdBdot rerd. f.cror.

Correctionfor Work Index Variations When aDor. has mtural grainsizes, it sometimes happrs

*-@-

-J--

....to r t

s.buhDrm miftd 100 d q. I4idt o, bin uEnd in fct. !q !.'t' P!.ti.. b @l]l dn:hq., 9e hu bilitrd b En.

ole.

rlrim.udr4 116 in e, h/{b. r$oo.nri:r $E dBdbnuon ad6ddL Pd sr qmr.rN lordroo. Middr 30 E ar otdol16frr. b!q. rmr h.k iddh<n/c. !ruliono|diltc!i.i.d!Dej. O@ sid. corhr 3.triu b D.h6. Ps dr *.irhr olcoDHhk D fd_ P.r ar Furi,r b .r!.16s 6no ,rcd(r cyrA ro ohur.in fG vdial ofirrrion. P4 ed ol dncnu.. !ain! Ex'ffilj'|olqDccrrtio' u P,

,d
,N

nr .

!i.E

oFlt8

i! E 6od-A,{

sidlb0rry,

n.*. ts

Rdlton

rdr

tdra

6!n6trt rizo P.

Dd

x"
iq, ", "

E4uj'd.oltEofrlBd|ed. Pq 60r ol-!.r fe! puiq j' Eiu r* nijr oi'r sindrbjliry gild.bir a-c, y A-c! rir,. r..d &. @ ar8/ s@s/

F_61 nd., 9t -!Ero r.d EjI nihdid |40 !u.!. 4r 6/ttu, l.ll r m! dbs.cdo! ouurxv. & 6 pg arp. w|@.udre Pa @ FEdd p|!n$_b

or o6i:.JlBi4

cl.t i6a co!ru DtbdEr, b.ro' rron @!. o Eldd.i:a d&cbrs.

l-d c9nJ.peiq lan R.d

of Dix $rltd

wo'k iutsr h trvb F wd( rndd: lwlhd worr brl: twnhd

,,
'b $r: erF rh ds6 d .F

arindi4mni..j.mfutrnt.

P.i 6r @d.ds F.lr.n d uv riz.. 6rots or li:. dndb!!i@ I& wort bcd r6E DIo. r Dodud riz worr. I!d.: r@ iro' ri fd dF F, ".

b. que TABLE llr_^ h.do!

r F4u.u@ (a, o3), (3e, Dd raa) re I'd'r Td RTIB ,to" ^ of l in' y I j!

bor d4r'yh by .b. ruuoi

.T',*ji

l'}l'"#*,

,rnicl.'

Tb. Eod

rirr"r rr,zso- 13 _

l 3l o,?s

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 decrease ir capacity causdby passingat the crossiDA point is the per cent emciencyof the griodine media is not as pronounc.d ss that caused ove.size When Fa represeots the maximum 80 per cent passirs Percentage Ci.culating Load feed size in rnidols which does not appreciably deqease ID closed{ilcuit reduction the per ccDr cicularira lord tbc grirdiDg efrcicncy (is not oversiE) with the ball or rod (100 c/) is 10O times the latio of the wcighl of separaror size calculatedfrom Equation (12) or (13), and thc work oveftize returning to the reduction machine ro rhe weight index is 13, Fo is about 4000 for ordidary ba mills and of tbe new fed Dtering rhe circuit io the same time 30,000 for rod mills. por ballmitbro = a0o0 y'057fr .,.. G0) P : microDs 80 pcr ceDt of scparator undcrsizc passes. Forrod mills Fo:30,m0 \/G)m ..,.(3t) Fp : per ccnt of new fced passing sizc P. The work input 7 for oversizc feed (F > Fo) is calculated Dp : pe! cent of machincdischarsc passinssiz! p. Rp = p.r cent of scpararor passinssizeP. ovcrsize when the new feed eDters thc reduction machine , , , l g w _ g w tl IR .(w i _ rt6 _ F o\fof

" : L,/F

^/F J

l------------o--

. . . , (3 2 )

CI=180-Dp)l(Dp-Rp) rflLen the trew feedeDters the separator ct=(8o-Fdl(,p_Rpt

Tbe qDaDrities rquiredia Eauations(3, and (38) cau !c determined from log-1og o. exponential plo& of completc size distribution analyses. However, the s$een analyses availablemay not permit det.rmioation of rhesequantiries, and C/ must be calculatedfrom the old equationltr bas.d on the percentages passing 2-00mesh or any otner availablc

Grind Difrerential
The grind differential Cd eaaluatcs the difcrdce iD the particle sizes of tbe conceDtrate and lailing when grindiDg for minral unlocking and concenbationby nobtion or by gravity. Ao increased srind diferential can be of major importancein such grindins circuits. wlere P is the 80 per cen! passiDs sizeiD microns of the fecd to concentration, Cp js tbe 80 pcr cent passingsiz of lhe concenrare,and C19is the per cent weighr of the conceatrate divided by thc fc.d, tb. grind difierentialu is P (lJo - Cw) - 50 Cp

If . represents the per cenr of the classifier fine producr passing200 m$b, r is tle p.r cenr of the classifiercoarse product passiDg tbe samesize,and u is the pcr crnt of ttc mill discharg. passiog lbe samesize, thctr 1,hcn the ncw fcd .... (31) enterstbe srinding milt P(50-C,)+50CP C I= (c-' 1:.)l @ -t) .. . . (39) A iypical copper flolation plant has a eritrd differeDtial of 1.34.ADy chaDse in tle srindins circuit which would inwhen thc new fecd oterN tbc classifier, and t rep.escnts creasc tle sdnd difier.ntial would result in rclalively aheper cent of the new feed palsing 200 mesh, then coaner sdoding of tbe 8atr8ue, aDd should favourably a6ect cr: (c _ l(n _ t) .. . . (40) costs,recovely and grade.ll Aoy other suitable scrcen sizemay bc substitutcal. How, Wbeo makiog ttro griod! ro 80 per ceol passinga eivn ever.tbe C/ valuescolculared ftom ditrerenr scr.o sizes product siz P, witl tbe first grind difierential cdr lalsr thaD tb lecond Srind differ.ntial Gd,, tbe relative mcchatri- usually show a widc vadatioD,and the ma3hsize at which thc circulatiDs loadis calculated should be specified. cal efrciencyof the first grjDd to the secoDd is:

t------;;,----;: Rcr.E tr - J,-(# )-(Fl

;--

Per Cent new Clersille. Feedto Closed-<lrcuit Mill . tt4) When a rod rnill iD open circuit discbarscs to a classificr cncuir sith a ball mill. tb. DerceDtof th. rod in closed mill discharswhich entcrsthe ball mifas lcalDednew feld

ff the recession factor Rl is the numbq oI slardard y'z screnscalespaces betweensize P and size Cp, tlten

Rt = (los P - loscdllos\/2 nt P :cP Q)1

The sriDd ditr rential Gd caD b. calculated from tbe rcssion factor Rl and the per cent weisht of tbe coocentrate Cw by substitutinstbe value of P from Equation (36) ioto Equation (33). Tbc Schbmann slope of tbe heavierconc.Dtrate is com' monly graicr than that of the lighter tailings.

,loo orrod min discharsel l%En , tm % Eff.l '*-L passins paningsL" I L lm -r - 100cr I .... (41)

Closed.circuit Versus ODen-circuit Ball Mill Grinding The listed work index valuesapply to bau rni s Sridditrg wet in closedcircuit. For dry gritrditrgi! closedcircuit, th. rvorkinput tY should bc muiiiplicd by 1.30. Th conversion'to open,circuit gdnding,cirber wct or Classifir Pe.formance dry, is don by multiplyitrs the closBd-circuir $ork input Io closed-circuit r.duction th eficieocy and the separan Irl by an open-cncuitmultiplication factor. In tbis comecitrg size,cut point or parting size of the classifieror sdeen liofl ihe circulating load Cl should be uniry or greatcr. are impo(ant. Tte efficiency is commonty expressedas This factor varieswitb the rcference pcr cedt passing, 100minus the per cent of fiDishedmaterial or "uDders" in or the per cent pasibS ar whicb the opcd- atrd closcdlbe oversia returnd to the mill or crusber, aL a cqraro ci-cuitgrindidg arecompared. For iostaoce, if the referelce is 95,1he multiplication ler centpassing factorwill b. Eucb Thc parlinS size is defined as tbe size at wbich the per targer than at 80 pr cent palsing. If it is rcquird thar 95 cent "urders'' in the separato.oversizeequak the per cenr per cent of the productp:sses 200meshthe chanae from "overs" itr the separatof undersize.The separalor undei- clos.d circuit to opencircuirwill requirea much greaicr jn powertbanjf it is required size pe. cent passingiand the separaroroversizeper cent incrcase that 80 per centpass cumulative retained on, are plotted as smooth cu.ves on lO0 incsh, or any othersDecified mesb sjz. -.,2,

cluijon

$ouid b. ucd i. "Dt

it't .h. .wrry

@rr hdd

vd!.!

br T9E of Mrbrtrl' L,Ed tuE ro ,!*r6c - idrrulioE, |hs d! indMdut

vdliod

bd*&

6{cld!

i! rry

z's4 id
r19 2.69 r6,30 9 27 r.76 2,66

r0.r3

5 1 7 9

2,5. 2.1r 2.73 3.00 16.16

2.15 r J.r 3

19

2.36

P. ltrnEr. !Krn, FrIMtd.

j.r,rD!.rr

di

aulb.t.runtrktnd4

Bzttin. ! BoRrM, B. B. "Mcr$ri!3 rh. RdaliE Abrasiv.n.s , Pr .Id Oufr,

' Bo^D. F. a. lllni, Th.ory ol Caanian. oa', /.t u r }1[1y 1952. tlrt 4a1t Mhin. EBtLnl^t, 'Bom, F. c. 'ThG PriDcirls ol corhirution , E '8.!D, 'l'inqer4 F. C. 'ConFE.rim o' rh. Thi'd Tn.ory .

Itud.,

tetl, "DoNo. F. c. 'I^@t\I Mry

Ind Gftdidg cr,c,rhioon. cdadian vnht 107, r66tz ttn'. t9s1, M!rh.6rh! or C(fq D4rnir. Dr.sr", rnd se, 6, r. i6 (\'r.y) s.c. 19, F. r02 @il.y)

of CoDmiDurid I , A.IM.F. T..l'.

Edttboo\ ot Mhtd ot Mk?o,

'BoND, l. C. 'sundnd G.irdrbil sie s.l.lo!! r9s3". ,r.r.M.E. T,@,. !953. tll. 592. Minins En.in..ri4.

' T^ao^Nt. EnAb..k

^sTM

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