BAI,I,MII,I,

andqurliq controlldorutodeslhroughout
dtc rofld.
1\e\itsnrd h\ tl. hundfur rAeb\ ccnrcntLunrpanies
the counldo$nendit
I lt".l]r hc usd In (. rul,rtift lhr grindrhr||h0f all ofc Thedigitalcornterindicales
.l-., slrul'nff rlrcdrfLrrdri\r ilr mrlu.lrncmn)fattcnti0n
durinsthistimejs notreouired.
A jogingbltlon is
positioo
possible
to
lhc
drun
ior
beding
md
urloadirg.
A
rlr.tnudljog
is
posilioning
fofpfecise
lrolidcd

StandardFeatures
. .\ll ballmilk comenandard$ithooe{4 5 lb.
ch.ugc0f lon hdls.ifon slmd, fcccivingtm
lUldhmd screenpm.
. lil cir-sl
ifon dru l

Models

l'ii

ilqi so

220\bll,Jph.60
oclc
. Modell95-i1
110,'120.
1th.60crcle
. l\ odelJ9t 5I\
ll0,220!.1ph,50qclc

F.C. BOND BICO BALL MILL

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 approKimately20,125
grams. 700 CC ofminus 6 mesh,stagecrushed,dry feedwas usedandthe circulationload
maintaindconstantat 250%by adjustingthe numberof revolutionsfor eachgrinding period.

BALL CHARGE DETERMINATION

Becauseofvaxiationsin ball size,no exactnumberofballs ofeach sizecanbe specified.
The ball chargeis preparedby startingwith 285 balls, consistingof approximatelyequalweights
ofvarioussizeballs. Thesesizesinclude:3/4 incbrT18irrch,1 inch,1-114inchand 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 adjustmentwith the smallestsizeof balls. Do not removeall the balls of any one size.
Oncea suitablegrinding chargeis preparedfrom onegradeofballs, count andnote the number
ofballs of eachsize.
Otherbatchesofthe samegradecanbe startedusing this count,andfirther adjustedif
necessary.It is IMPORTANT to ietain the "one for one" rutio while adjustingthe final weight
to maintainthe DroDerball count.
continued...

OPERATINGINSTRUCTIONS

Coruectthepowetsupplyto thecontol box.Wircsarcprotuding for easyaonnection.

Makesuleall circuitbreake$arcof to avoidsevreelecticalshock.
Thismachineis equipped$r'ithanautomatic
counter.To setthecountr,pressthebutton
to thedesirednumbrofrcvolutions.Theswitchhastwo positions,"RUN" for normaluse,and
"JOG"to movethodrumto a desiredpositiotr(for emptyns),
To loadthedrum,"JOG"thc drumAsning until it facesupwaid.Rsrnovethecoverand
gasket,Insertthesampleatrdball chargeinto thedrum.Replacethgasketandcovr. Setthe
numbcrofrevolutionsyoudesirconthecounterandstartthemotorby pushingthestrrt contol.
Themachinewill stopautomatically
whentle numberofrevolutionsis reached.Again,
usthe"JOG"buttonto positio[theopeningof thedrumupwadtowardstheceiling. Now,
remove.the
coveratrdgaskot.Agai!. 'JOG"theopeningof thedrumtowardsthereceivingpan
sothesampleandballscandischarye
iltto thereccivilgpan.

F. c. BONDBALL MILL CEARGE

Wefird thatthequestionofcolrert bsll chargcarisesoftuandis still yerydebatable.
Backin 1960,Mr. Bondhimselfrecommended
thc chargcdcscribed;
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 Totalwt. =rDx.44.5lbs.
Mr. Bondhimsclfadmittcdtllat it is verydifrcult to spwifr a givennumberofballs of
eachweight,andin oul mostreceniconglondlncr with Mr. Bon4 halcoDtrladd
a chsrge
excludingthe5/8 ittch(.61)balls. Becausc
ofthis, Bico Inc.o(pcrimrntdlycameup 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)
93balb- 3/4inc.h( .75)
285b&llr Totrt wL = apr.44.5lbs.
Weirclude scveralexta ballsof cachsizesothattbechargecaubmanipulatd
to result
gm
in the20,125 totaln'it! 285ba!s.

BICO INc; F. C. BONDBALL.MIL,LSPARE PARTS

PLEASESPECTtrYSERIAL 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
DruD,with Shaffs(PleascspeciSSA.I)
Covcr
Haagsr
Tablewith Legs
Pillow Block
AsbstosGasks,t
50IIz Dgital Comter/Jogging
Swibh
60 Ilz Digitsl CounlF4oggingSfitclt
CouDter
Brackct
Courtlr hror
Paowith Ss'reca
ard RccaivitrgPalt
ChEgeofBaUs
ChainCuard
Chain,onclagth= 29 inchcs
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
arcavsilableandquoteduponrcqucat.(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 ,oi 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$.
ANDPUtLIOIiARDS
NANDLE
YOU.

amzz

! , P ESS ;H ESE

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

tt6f

u)A6M ,t1|

oP6.'S

It

coprrec'f Eb

ZASETS ILe.

Coaole{,
lo{Ep TLe PAES'T l,/t+L4E
IS RE/\CHED THE COU|J|EL U.LL
OPEZAT' THE /ZE.LA,? cR I *DD sroP

lhe

ni o7oA-

THE Joe auTFa,tJ

PI.STBLES 'tt1F- ztJT6 zLo ck

CD '|{cY
As
c ttara

W]RING DIAGR.AMTOR BAI,], MII

220 VOLT
50 cYclB

r3

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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
\-. ship betw.en eoergt iDpr.ttaDd rbc product particle sik
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 <iiameterh microns which 80 per ccnt of tbe producl
bas adhcr.nts. He srat.d that tbc arca of the n.w surfac passesis dcsipat.d as P, the siz! which 80 pcr cent of the
producd by crubhing or grirding is direclly proporlio.al to feed passesis dcsisnatedas 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 resistancof 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
to about o? p.r. ; nl paF
of tbe pa icles conccrncd.Whcrc I is the diametq of the pasi n8 100 mi crons.equi val enr
sing
200
mcsb.
When
any
three
of
rhe quaDritiesin Eqoation
fecd paniclcs and p is thc diam.ter oI the product panicles,
(l) are known, the fourrh can bc fourjd by transposingrhc
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-rAccording to this theory, tbe work iDput h proportional to tb trlw crack tip length Foduced iD particle
| to wi\/F \'
braka8c,and aqualsthe work represntedby thc product
....0b)
\ w1 / F - t o wil
mitrus that reprcsentedby 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 homoseneous10 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 between1OOond 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'1glN 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
than 48 meshthatr for a coarserproduct.
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.
srindins balls tban witl oversize3-iD.balls.
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.determinationsof 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 transposcdEquation (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 statementsof
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 Deslctedin 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
compressionor sbearuntil the weakestflaw in the particle
faih wjth.he formatioo of a crack tip. Tbis minute chanse
of shapecausesothercrack 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.eaka8eis 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 sqLrareroot
of the p.oducl particle diameter minus that of the feed

-3-

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 severatstagesoI
brealagethan are pafljcles of rhe samesize \,\boseweatcsL
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$.
Evaluation ot Particle Size Dirt.ibution
The usual ltandard screen scaleconsistsof a seriesof
\ievs with square openinesdifrerins by y'i. based upon
dre 200-meshsieve oDcbiDgof 74.: microDs. There are
25,400miclors in an inch. A scrcenanalysissize distribution of a crushedor sround product consisr!of a tistins of
the pr cent weighr passingor retaired on each si.ve in thc
Tbere is probabb a defi tr laq qbicb soreras rbe resltar
si zedi .Lri buri onof crusbedor grouodproducrsrb owever ,
Done of the proposed laws bas bcen generatly accepred as
Sizdistribution analysesof crushedand sround products
are commonly plotted on los-log paper with (]) the per
cenr passing as ordinatc and the parricle diaDeter (r) in
microns as absci$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 aDproachestao8trcy witb tb I00 per cebt passiogIiDe ar rhe
rop oI tbe plot. Tbe size 80 per cenr passesmay 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-ScAUfiMl.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:
60.000d f/k.^ \r-'
I
rr
. . . . ( 3)
p,/.roo(t_o)L\ ai /'
j
The grind limit ai hls lecently been assigDedthe 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.

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
The loA'log sizedistributionplot is donveDient.However,
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

Y =]rn-v=bte'=blt0A x
Ax = loeb -1oeY

. . . (4 )
.... (44)

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
corn;r of lne cbarr, {hich represedreach mesh size or rbe
. 2 " c ' eens ( , le an d c ro s sth e 8 0 p e r c e n l p a s s i n gbori zoD l al
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

crack lcngth Cr of any !8ular qushcd or ground product

can be fo'rd grapbically wbeo i$ 80 pc| ceot passiDgsizc
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.
T DI:E I--4'..1

Larh

vd!6

l0@

t6iso

ol0

lor PldiD.

212.0

93.0

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

36.6
1r.r
32.1

cr (.DFu

10,@0 l0o,00o I

10.65

r.76

r.r7

0.495

16.39
r9,t6

6.60
1,37

2,47
7.96

0.915
r.r35

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

when the crack 1cn81hC/ bas beenfou!d,'the suface of

equivalert cubesi! sq. cm pr cc of solidsis 2 Crt.
The WTGNLRsurfacearea Sp in sq. cm/8ram is .pproxjmately
qual to the BL rNE air rlermeabilitysutfaceto thc
This plot is not as convenieDtas tbc loglog plot, but it power 0.92, or S, : (rl)tr'r.
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.
Another advantage is lhe delineation of natural or
/2o,Jm\' 3.drr rog
induced grain sizes.As the size distribution liDe proceeds
sr /
loop
':\
6tErF
up the chart apptoachingthe finer sievesizes,a curved
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
loop becomesparallel 10the straiShllidc. The compensaling lvork lndex from LaboBtory Test
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
sriodability tests,Tas describedbelow.
ialues will iDcrease as the srain deficiencv sircs approach
rbe Darural grain si7e,aDddecreasea( rhe graiD .rcecs sizes
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 $hich the ore must 30lb weight! \vhich swins on wheels. when the wheels are
be sround before concenkation.The exponential method releasedth vr.islts strike simultaneouslyon oppositesides
of plouins tle size distribution furnishes a vciv good of tbe measuredsmallestdimosionof the rcck. The heisht
indicarion o{ the unlocking siz. wben tbe amount of the of fall is successively
inoeased until tbe rock breaks.Tbe
mine.al to b concentrated is 1arge. This is Particulartv
imlact crusbing str.nglh in fool-pounds per inch of rock
hue of iron ores, and the .xponntial plots sbow clcarlv thickne$ 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)
r\ D eot 5ia dis r db u o n p l o t,i n c l u d i n Sc ra c kl e n g tbval ues.6
l ;l he ball m ; llB r i n d a b i l i tyre s l sa l 6 0 )o u l .s i n P UrP 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
crack length in material of homogeneousbreakage with graduatedcylindcr are weiSbed,screenanalysed,and Sround
specificgravity ss is approximatelyri s8/l l.
dry in closdcircuit witb l0O per cent circulatingload iD a
The exDosureratio Er is relaled to b in lhe exponential l2in. dia. by 24in. long tilting rod nrill with a wave-type
size distribulion Equation (6) as follows, where Er : X&/
lining and revolution counter,rundiog at 46 rpm. The erinding chargeconsistsof 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
In order to eqDaiizesegregationat tbe miu ends, it i!
Tbe data ;n Table I can be llotted on six sheetsof single fotated level for eisht revolutions,then lilted up 5' for oDe
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,dow n 5" fof anol he. revol ul i on,and ret ur ned

ia. bslls,l0 l-in. balls,710.75-id.bals, and94 0 6f in balls

with a slculatd surfac! at@ of 842 sq. in.
Tcstsarc madcai all si.vc sizesbelow28 mcsh.Altr the
tust gdodirs pcriod of lm rvolutions,tbc mill i! dudped,
th. ball cbarseis screeoedout, and tbe 700cc of matcrial
is sdeDcdon 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$izc product and circulAting
load arc a.recnanalyscd,and thc avcragr of thc last tbrce
trct grads per revolu.ion (Cbp) is tbc bal rnin grindability.
Wbcn F is the size in microm which 80 lcI c.nt of thc
P is thc micro$ 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 :
diamercrErindins$.1 in op.n circuit.For dry sdndiDgthc
/r 0
l0 \
BLl--7=
- -.1
work input sbouldbe multiplied by 1.30.wlrcrc D is the nil
....(8\
wi _ 44.SttpJa.t'
/ lcbe\o
'
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'

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-^ --/--lvrl

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
placedin thc mill andsrounddry at 250pcr centcirculatins
load.The nill is l2ir. x l2io. wilh toundcdcor.ers,ald
a shootb lioios excptfor a 4in. x 8 in. hand hole door
It hasa rcvolutioncounleraadrunsat ?0rpm
for cbarging.
The erindingcharseconshtsof 285 iroo balls weiShing
balls,67 l.l7'
of about43 1.45_in.
20,125grams.It consisls

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)".

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)

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
surlacer maintaineditr a ffxed position or in a risidly con- crusherproduciin micronsis calculatedfton E4uarion (10).
straincd motion path, althoughmany dusbcrs bave safety I i!. cquals 25.400microns.

p : (2s,4M)(osr)(0.042i+ 0.40) ....00)

fatus which allow teleaseurder excsriv. pressure.This
$ith
the
is contrasted
erinding, which is accomplhhedby
The product siz.s of cone crushers,with their flat clushfrcc rnotion itr responseto sravity and other forcesof ing conesand ielatively higb spccds,arc conrroltedpriDciunconnectcd
media such as rods, balls,rock piecsaEd patly by tbe close sidc setting. Wherc Crs is the ctose side
pcbblca.
setting of the cone crusher in incbca at thc bottom of tbe
Frec mcdia grindins hssscvcralinhcrent advantagesover crushins chamber, as commonly d.temircd by passiog
fixed nedh crushing,and as reductionmachinlry increases a pie.c of lead though the crusher, sod Ecc is tte eccenrric
in sizc and strength largcr particlcs bccomc amonableto tbrow in inches at the bottorh of thc crushing cor, thc
Srindingwbich could forncrly b rcducedonly by crushing. product size P is found from
Cassin point aie tlo devclopmntof large periphcraldis(25,400)(C$) (7,s..) (0.027r + 0.70)
chargerod miUs and autogcDoussrindios 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 sveralstageswith 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),$uhiDs.rolls, and impact
clushcrs,hammcriills or pulvcrators.It is donc with botb Scalpetl Feed to Crushett
3c.ncdand natural fcds,in staSesvith scrccnsbctwceD The Third Theory equations rcquire a '.Datur.al" feeal
cach stagcto rcmovc und.rsiz,as w.1l as in open circuit containioStho Daturalfinesproducedin the prviousreducand in closedcircuii witb lcrccls.
tior stagcs.When fioes are removed from tbe fed, the
Excssivomoistu, ffn$, 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 increascin the croshingplanr opening are removed from the feed by screenhg, thc work
work index.This is usuallyrcmedicdby screeningout 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 satisfaccrushersaSainstbr.aka8e.For the samereasanuncrushable tory to djsregardthe scalpiDgoperatioD,and to co$idcr th6
piecesof metallre usuallyremovedfrom thefeedmagnetic- feed to the screen or grizzly as equivalenr f.ed ro the
ally, or thc crusheris designed
to open up and let tben crusher.This is pleferable in most cascswbre the Brizzty
separalingsize aDd hou.ly tonnaserhrough are nor kno*n

Ctuther PtoductSizes
The crusberproductsizewhicb80 pcf cent passes
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.
The per cent passingsiz dhtribution tin. oflhe scalp.d fe.d
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-ordinatesF, (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
srindins of cmentclinker, and appliesto dry srinalinsdown
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
which include coDcentrationand separationquipment are
best analysedby consid.dng each circuit as an inlegraled
unit. In closed-circuitgrinding the unit consislsof tbe mill
and the classifier,with a single feed to the mill or classifier
and a singleclassifierundersizcproduct. Calculationsfrom
the mill discbar8eand circulatiDgload are usually unsatisfactory becausethe 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 calculatedcompositcof the classifierunde.sizeand the separator tailirg, which should always be screenlnalysed for this
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
larse, the Dumberof breakinsconlactswill be.cduccd, and
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 efficiencywil 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

ssr.t/i\r

/r\I /

. ...0 2)

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

Th empirical coastaot.K is found by expericDceto 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 obtainedfrom th smallerballs
increased;
before they are di$harsed fron th mill; (3) the smaller
balls may plue thc gratesof diapbrasm dischargemills; (4)
syn h o l i l d E q u d onNo'

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.

P.r.d'

rad.
orcon6,B'o
'
-dshr
cyda Fi. m'nnc in rR.
on.
'.njsr6chr
P.r edr or dnchlrF rasine riz. ,.
F.dtl.

n ,+n

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.

lra{d3rctr eirdbilily

,,

Kilovat!
Kilof,d!
l43rh

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

incio!

in tei.

Pq.4lpuiainhilldjtch'ie'

4P

n,r+

o@id.cruh.r&ni4inb.hB.
Producr!i!F n...o 30 tsr@t pn*i
si.v.o!ai4inmjclot'FA-cah&bj]ny,
Fd.rroo

Ps dr

'.p

or nilr

of ov6ir

opti-uE

'o

rrsid

ro.t nill r.dldjon

rocr

di:.b!re

!iz. P.
n.it.

Pdcot'ai4i!claliid@rRproducl'

Yt.

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 intermediatebetweetrtwo commercialbau sizcs,or wher!
an unusualsizedistribution of the fccd requAesthe 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:

et l--wig

ro0\r lm cr v,

when the reduction ratio R/ = r/P is lessthan 8, the calculatedvalue ofB should bc increasedby 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
sizEssufncientlysmall 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 sizedischargedfrom 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 consislentperfolmancein wet srirding
mills, the initial media charseshould be made up from the
severalsizesavailableto 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 chargecorDpositionis 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.

Fflcdon or nill varud. b.low dischrrce

work indcr: kwhjon
wort

rdd:

rwbhod

.,.. (13)

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 $.ar is us'rally lbo s'-.ond largeqt
griDditrg,
is conventiooalItindins, aod io wcr Srindingttan in wet
lVl
**'r.
thc
"i i*i"l"ti*'
il mav lpproacb or
iii'-ai'g
'ven "cerd
Ab.arion Tcat
DOWCrCOSL
' wlcralwcar is commonlv.xpre$edin lb/ton susbcd or
Abrasion tits to indicatc mtal wcar ar6 madc a3
ald
sizs
paniclcaof the rnrttrirl
aod
;;
fced
Eoduct
folows: o 4O0slams of -l +
i*r"toDs
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
it
rotatingiop.llcr
wom
a
rapidy
rcjtcd
thousb
drun
sbowrs
thc
rock
Go ,, nltWl" iucludios
pcr
toD
at 632tpm and
metal
coDsumed
lotatd
pourds
of
it.
The
imPcller
within
contained
tu
i.on
ott i".
paddl
2 !q. in. crPoscd
with
kwh/ion
x
i[.
stccl
the
consistsofa3
1x
+
crusbedor eroud and
a\
to 50O
scrapped
hardeDd
wom
awav-abd
4325
stcl
of
botb
to
wcar,
machiDed
SAB
pounds
nelat
of
Tbe
of tbc ore and lhc Brircll. The gram! of weislt lost bv thc pad{ c after im'
tte abEsivncss
*.'i-"Le
tuti""
400-8rambatchcsof rcck for 15min.
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
aoalysed;it avra8es80 per cent passins13'250micron$
Paddlesof sDecialallov si.els and cbet irom csrl bc
Bd
Rod
Milt TlPc
rlar.sEd
with a sdtrdardabrasiveFaterialto 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
the abrasionindex vadationssho$n in Table IIA ar! mucb
can reduc. tbe metal wal still turlher'
sreatcr than tle wriations to be expccLd iD tho ts.tal
re\ulLs
i!
wct
wear
SriDdiDg
Wcff over taf of tl. nelal
wear
rates in cornmercialmachines.It is obscrvedtbat anv
metal
ftom conosion, or dissolutjoofrom lbe'ctivc nasetrt
correlation
b.twen tbe work index and tl abrasioEhdei
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-

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.

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
obsrvcd in rod Eills.
whereD is the insidc diaractcraDalO b thc \rtical distaocc is Dot
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
balls
in e Sdnding charac tcDd to concsnEatc qritb
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
of th cbargc. Advanvp = 1.r3- r.26AP
....0 t tagc is t.kea of ftis iD ball mill6ccrE
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

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.sas tbc ball siz idocas$. For accurat! ocasurcmentsthe smallcstdimeDsioEof the contaiocr lhouLl bc at
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
?/ from EquatioD(17).

....00
. ...07)
Tt = Vp D'L16.8
A charseof Brindirs balls contaiDsapproximately40
per cenl of void space,aDd rods in lirar contact contaiu
20 per cent voids. Broker orc coDtainsapproximately 40
pr ceatvoid space,andweighs100lb/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, siDcethc flater fows tbroughthc mill fastcr
tlar the havierparticl.s of ore. This diference is iocreasedin 8ra.eand pedpheraldischarsmilb-

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, designaredas

No = 51 - At)losD

. . .. (20)

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 pcripheralspeedvariesas v5. It follo*s
rhat tbc powr input to a conventional tumblios mill
theor.tically variesas the interior diametcrto tbe 2.5Dower.
Meaqurements
bav. shownrharlbc 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 decreasefrom tbe
theoreticBl2.5 cr(poDentprobably result! ftom energyfrom
tbe falling bals or rods beiss tsansferredback 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 mechanicaladvantag.of larsdiametermilb. Mechanical emciencyircreascsas thc inrerior mil diarneterto rhe
0.2pow.r, aBdtbe kwh/ton requiredto sdnd d.creasesin
the samcratio. Sitrcethe standards'ork iDdcxis basedon
rDillsof I ft intrior dhmeter, rhc computedkwh/ron (I/)
by EqDatior(1) for any min of D fr interior diametershould
be multiplied by (8/D)'t

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),c,hercD is th intcriormill diamctcritr fcct.
Powe. pr Ton of c.indlng Media
The powerinput requiredia tumblinsmitlsis 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 occupiedby the srirdins charge,tb
Cr=0.01305x rpm x y'b
.... (19) fractio! Cr of the critical spccd, rod tbc iDrerior mill
Tumblins mills are usually d$ign.d to rcvolve at a conEquatioo(21)sivcs
th. mil input kW pcr ron of
stsnt fractioD of th critical speed.Incrcascd specd iocrases
grindingrods in -(r/,
nelv
cotrvenlional
power
wet Srirding ovdflow
draught,but also increasesthe
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 Dracticalmill tbe actualpower d.awn by as much as l0 per ceDt.

- 10-

4
f,
I

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.

,r/ -ri

!\

i..

* E Ei:

E[ = i:

3i<'

- -[ -'"

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

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

oN
- %cuM
\ovERs,zE

\--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

Whcn the actualreductionlatio.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
makc-up balls lar8cr than about oDe-eighticthof thc mill bo multiplied by the cmpirical adjBtmcnt factor 1,, wher.
A'=r+2(RtR0)'1300
....(26)
Kt tb * 2.8DLt(3.2- 3 v p) Cdr - o.1|Ztrw, .... Qz)
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 changesin 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
3, particularly in 1befDe srirdins of concentsat$,7 frorn
insidetop of thc mil to th. lowast discharsepoint, then
' Vpd= t.r3 - r.26
(l) should be nultiplicd by the cmpiric{l adjultBquation
....Q3)
AdlD
mcntfactorlt, where
wheret/pd is llc fractior of the intdior mill volume below
zX(R!- 1.351+ 2.&
dischargclcvcl. For a full lowlevl gtat discbary. Vpd
....Q'
--'
20(Rr- 1.35)
equal!0.029.For welgrindins srate |nd low-leycl discbargp
.
l, . O.4O
- VDdI
nlrD -ny
m'rls.rnurupry
Free Verticll Orcillatlon
l, +
2l
l.
A body id fre vrtical oscilation fals from it! highast
posilion
under tbe influcncc of gravity and tu stopp.d
SlumD Coffection
Lars+diametq ball mills fed with small rnak&up balls lorcibly by atr equal deccleraiion; it is thctr acc.l.ratcd
lose power becauscof xce+livcdownwardslippagcof the upwad at tb! samelate and r.acbcs tba samchiSh.st poribal chalsc or the siDSsid. of tbe'milt, and this lo$ of tioD asbcfor.. It dcscdbsa sinplc barmonicmotion ovcl a
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
K)r, vdue of Equation(22).No subEactionis madcfor vtct
The critical frequencyof vibrating bodic! is calculst d
ball milts with , < 8 or for dry ball mills with D < 10.For fiom Equation (28)i as tbe cpn (oi rpro) dccrc*cs below
dry mils with D > 10 thc slump quantity to be subtrastcd thc critical, th tcndcncy to mai sio frcc vdtlcal 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 occasaryto 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)

"":(i#- t-

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 considerablelossof srindif,g eficieocy.If rhe mill product
Rto=8+5LlD
- 11 '

is coarsc,the loss in milt capacity can b. quite large; ir tho same linear or logarithmic gsph shect. Thc poiqr *herc
dereasesas the proporlior of the lotal work cotrsumedin tle two lin6 cross h thc partirg size, aod the pcr ceot
fine erindirg increases.The decreasein capacity caulcalby passiDgat tbc cro3sirg poiDt is the per cetrt cmciency of the
overeizeerirding media is aot as pronouncedas that caused
When Fo reprcscDtsthe 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
30,000for rod mills.

Forba mirsro : ao,my'(l3VD4

Forrodmillsfo = 30,000
,/(3)twi

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

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

P:
Fp =
Dp :
Rp :
When

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

wi
w- lto P
L\/

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

\/F I L

microns 80 pr ceot o[ scparatorundcrsizepasses.

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

Cr: (8 0 -Dd l(Dp * Rp \

Whcnthenewfeedenterstheseparator
c t : (8 o -F p )l(Dp _ Rp )

. ... (32\

Grind Difrerential

The quaDtitiesrequircd in EquarioDs(37) aDd (38) caD be

Tbe gdnd differeDiial Gd evaluates the diferen@ h the deteimioed fron loglog or exponenrialplots of complere
particlc sizcsof the concentrateand 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
cenrratedivided by rbe f4d, the griod difierentkF is
product passing ahe same sizc, and m is tbe pcr ceot of thc
mill dischargcpassiDgthe samesize,thcn whcn tbc Dcwf.ed
P (150- Cr) - 50 cp
.... (33) ente$ the erinding mill
P (5o-Cwr+50Cp

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

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:

. .. . (39)

When tho new feed enters rhe classifier, and ld r.pteseors

tbo per cent of tlc new feed passine200 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)
, l) ....,r,
- l9,r
When a rod mill in open circuit discharges ro a cls$ifi.r
a
\Gdr.l 1l
\Gd,+ tJ

ff the recessionfaclor R/ is tb number of standard y',

screoscalcspacs
betweensizeP 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

,'*-l

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 Schuhmannsloped oflhe heavierconcentrat.is commodly greatertban that of the lighter taitings.

fc" or rod mi discharyel [% pn , lm-% Enl

passiogparrirgsi.. I I r0o -r
tmc/
I
..., (41)

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 shouldbe multipliedby 1.30.
_to open-circuit
The conversion
Srinding,eilher wet or
Clairifler Performance
dry, is dode by multiplyinstbe closed-circuit
work input
In closed"circuitreduction 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 passiogat 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 ceDtpassitrg.
ff it is requiredth.t 95
cent "unders" in tbe separatorovenize equalsthe per cent pe. ceot of tbe productpasles200 meshtbe changefron
"overs" in the separator lndersize. The separator lnder- closedcircuit to opencircui! wil requirca muhgreater
size per cent passing,and the separatorove.size per ceil increase
in powerthanif ir is requiredthar80 pe. centpass
cumulalivo relained on, are plorld as smooth cu.ves on 200nrcsh,or aay otherspecified
meshsize.
-i2-

Som. apFoximatc opcD-.ircuit multiplication factoft for

vario'rs r.ferencc percentag.spassingare lisred below in
Table IV. They follow an exponeniial
function.

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.gsiDgsizcs 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

TASLE IV

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

'lo
80
90
92
95
98

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,,
_.

Correctionfor Work Index Variations

WhenaDor. hasmtural grainsizes,
it sometimes
happrs

tbat laboratoryrcd mil and ball mi gdndabilitytesisand

impact crustiDg teEtssive dificrDtwork index (7r1 values

*-@-

-J--

....to r t

Appendix
syEb.F rn E{ur.ion No. t
,6

R.d nil nr drutuar

Brll birr i' rdBdot

s.buhDrm miftd
100 d q.
I4idt o, bin uEnd in fct.

rerd.
f.cror.

!q !.'t' P!.ti.. b @l]l dn:hq.,

9e hu bilitrd b En.

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.

n.*. ts

x"

P4 ed ol dncnu.. !ain!

P,

,d

nr .

,N

Rdlton

Pq 60r ol-!.r fe! puiq

j' Eiu r*

$r: erF

nijr

sindrbjliry

R.d

oi'r

gild.bir

rir,.

Pa @

r..d

FEdd

a-c,

&.

ar8/

y A-c!

s@s/

rh

ds6

rdr

tdra

sidlb0rry,

6!n6trt

p|!n$_b

cl.t i6a co!ru DtbdEr,

of Dix $rltd

wo'k iutsr h trvb F

wd( rndd: lwlhd
worr brl:

twnhd

b.ro'

d&cbrs.

rron @!.
o Eldd.i:a

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, ".

d .F
b. que
TABLE llr_^

r F4u.u@ (a, o3), (3e, Dd raa) re

h.do!

.T',*ji

I'd'r Td RTIB
,to"

l'}l'"#*,

bor d4r'yh by .b. ruuoi

of l in' y I j!

,rnicl.'

Tb. Eod

rirr"r rr,zso- 13 _

Dd

rizo P.

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

arindi4mni..j.mfutrnt.

,,
'b

lan

i! E 6od-A,{

or o6i:.JlBi4

Ex'ffilj'|olqDccrrtio'

l-d c9nJ.peiq

oFlt8

!i.E

E4uj'd.oltEofrlBd|ed.

iq,
", "

ole.

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 decreaseir capacity causdby passingat the crossiDApoint is the per cent emciencyof the
ove.sizegriodine media is not as pronounc.d ss that caused
When Fa represeotsthe 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
30,000for rod mills.
por ballmitbro = a0o0y'057fr
.,.. G0)
P : microDs 80 pcr ceDt of scparator undcrsizc passes.
Forrod millsFo: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 machincdischarscpassinssiz! p.
Rp = p.r cent of scpararorovcrsizepassinssizeP.
g
w
tl
.(w
i
_
rt6
_
F
o\fof
when
the new feed eDters thc reduction machine
,,, lgw _
IR

" : L,/F

^/F J

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

CI=180-Dp)l(Dp-Rp)
rflLen the trew feedeDtersthe separator

. . . , (3 2 )

ct=(8o-Fdl(,p_Rpt

Grind Difrerential
The grind differential Cd eaaluatcsthe 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! passiDssizeiD 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

Tbe qDaDritiesrquiredia 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

If . represents the per cenr of the classifier fine producr

passing200 m$b, r is tle p.r cenr of the classifiercoarse
product passiDgtbe 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 chaDsein tle srindins circuit which would inwhen thc new fecd oterNtbc 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 ditrerenrscr.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 circulatiDsloadis calculated
shouldbe specified.
cal efrciencyof the first grjDd to the secoDdis:

t------;;,----;:
R c r . E- J,-(#
tr
)-(Fl

;--

Cent new Clersille. Feedto Closed-<lrcuit Mill

. tt4)PerWhen
a rod rnill iD open circuit discbarscsto a classificr

ff the recessionfactor Rl is the numbq oI slardard y'z

screnscalespacesbetweensize P and size Cp, tlten

Rt = (losP - 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.Dtrateis com'
monly graicr than that of the lighter tailings.

in closedcncuir sith a ball mill. tb. DerceDtof th. rod

mill discharswhich entcrsthe ball mifas lcalDednew feld

,loo orrod min discharsel l%En , tm % Eff.l

'*-L
passinspaningsL" 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 shouldbc muiiiplicdby 1.30.
Th conversion'toopen,circuitgdnding,cirber wct or
Classifir Pe.formance
dry, is don by multiplyitrs the closBd-circuir$ork input
Io closed-circuitr.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 rcferencepcr 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-cuitgrindidgarecompared.
For iostaoce,
if the referelce
is 95,1hemultiplication
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:sses200meshthe chanaefrom
"overs" itr the separatof undersize.The separalor undei- clos.d circuit to opencircuirwill requirea much greaicr
jn powertbanjf it is requiredthat 80 per centpass
size pe. cent passingiand the separaroroversizeper cent incrcase
cumulative retained on, are plotted as smooth cu.ves on lO0 incsh,or any othersDecified
mesbsjz.
-.,2,

cluijon

$ouid b. ucd i.

it't .h. .wrry

@rr hdd

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

vd!.!

vdliod

6{cld!

bd*&

i! rry

"Dt

z's4
id

r19

2.69
r6,30

9
27

r.76
2,66

2,5.

1
7
9

2.1r
2.73
3.00

2.15

r0.r3

16.16

r J.r 3
19

P. ltrnEr.
!Krn,

j.r,rD!.rr

di

aulb.t.runtrktnd4

! BoRrM,

E
'8.!D,

Bzttin.

FrIMtd.

' 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 ,
'l'inqer4

F. C. 'ConFE.rim

Itud.,

"DoNo. F. c.
'I^@t\I

Mry

rh. RdaliE Abrasiv.n.s

, Pr .Id Oufr,

Ind Gftdidg cr,c,rhioon. cdadian vnht

107, r66tz ttn'.
t9s1,

o' rh. Thi'd Tn.ory .

'BoND, l. C. 'sundnd G.irdrbil

Minins En.in..ri4.

B. B. "Mcr$ri!3

tetl,

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

sie s.l.lo!!
r9s3". ,r.r.M.E. T,@,. !953. tll. 592.

2.36

M!rh.6rh!

Edttboo\ ot Mhtd

' T^ao^Nt. EnAb..k

- 14 -

or C(fq

ot Mk?o,

rnd

D4rnir.

se, 6, r. i6 (\'r.y)

Dr.sr",

s.c. 19, F. r02 @il.y)

^sTM