Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Jef'e de ProHectos
Centro de lnvestigacion Minera
MCTHLURGICO ( INGEMMET )
EDICICn
Llm1Tt1a~
UNIDAD O E CAPACITAC ION
(
X~AA~ COnSULT~ X
---------·------- - - - - - - .. -------------------- ---------------------
V .....1!!1.. ,.,..n~l 11 . . . V
-
INSTITUTO GEOLOGICO MINERO Y METALURGJCO
SECTOR ENERGIA Y MINAS
Upidad de Capacitación
SECTOR EIIIERGIA Y MIIIIAS
PROGRAMA
DE
INAUGURACION
AUSPIC:WI: .
'
n ¡¡ tl'a1 Y CM'IM P* WMIJE '
Jli&BM M'' 1 ,, DE
11 ' • l • • 1 ;,...
Unidad de Capacitación
ll&fiiEf Jr. •••lt ler •Ht• 211- Julo larla lt. 111 '28'! Ttlf. J112U
ti••- ....
•
1" Himno Nacional del Perú
·Le.,.lttalllento • la Cart•
Geoi.S,I~ ..clonel •Tr-.jo de C.mpo
•Pro.peccl&\ y [Xplor•c.16n ·lnv. . tlpciorA• 1M
tNnere labon~torlo
·Doc~ntacl6n tientf-
fiu• y Tec:rtol6glca "" 8anc;o .k Da tos.
PIIIOPOR.C f ONA : laJ espec.lalldldes •
C.Oiogla, "Inerte y -
Nelahirtl•
)
DISCUR30 IEL ING. llliS A. SANalEZ BAZAlAR VICE MINISTRO DE MINAS
----------------------------------------~-----------------------
p8L ~STERIQ~~~-~-~~--: __ 1!_DE~Q--1~~~--=--g~_!.P
,,
illSCURSO r:EL ING. MARIO SAMAME BOGGIO PRESIDENTE IEL CONSEJO
-----------------------.1------ --------------
DI~Cl'IVO !!:!:_~J.~!;A :J:!iA~gQ!:!..!!_~-~pj(~~-=
INl'ERNACIONALE'l - 11 IE JLIO 1988 - C. I. P.
----------------------------------------------------
Muchas gracias
~rsg~2-~~-IN§:_~-§~-~~~-~~~2 -~~~~-~~Y:
TIVO DEL INGEMMET EN lA INAWURACION DE lDS SEMINARIOS INTER
•
Tab 1a 1.- Ensayos Batch de'"Mól i~nda Seca e.n Molinos
d~ Di versos Diámetros (1 )·~ .;u
;
2.0 ...
. \o Diámetro
.Q Molino
en
L.
~ 1. 5 o 30"
w
Q¡
'O_ o 15"
oUl o 10~
.~
¿
:=t-
u-
1.0
""'o~
~~
VI~ o
W- . . ' o
o
E
:J
VI 1 Molienda Batch Seca
e
o
(.) 0.5 1
Alimen tación: Calcita
100%-101/< o
·o~
0.0 .
• 200~---- ~~-----~ ~
300 -~--400 500
~~~-600----~---
700 ----
800
Tamaño P80 ,Micrones
a 1 ( 1}
donde :
n = exponente
En el limite·, cuando 6d
++ o .•
dE
d(d+)
.- k
(d+)n
( 2)
de don de. por inte grac ión se desp rend e .:
n-1 n-1
E =
k
Tñ=T> r e~) (d7-) ] .• si n '1 1
( 3)
.c.c..l6n de
"La. eneJt.g.la. upec .l6-l c.a. c.on.6iun.lda. en .ta. Jt.edu
c.lana.l a.
.ta.ma.ño de u.n .6ó!.i..do e4 dDt.ec..:t.a.men.te p-'!.opo:t.
ta. nu.eva. .6u.peJt.6.lc..le e.6pec.l6.i..c.a. c.Jt.ea.da.".
e de
Ana lític ame nte •. la ley de Ritt ing er se desp rend
1~ Ecu ació n . 3, para el caso esp ecia l n = 2 :
( 4)
E =
d+ correspo~
defi nien do además que el tamaño car acte ríst ico
cial
de a aque l tamaño de par tícu la con área sup erfi
•
equivalente al promedio aritm~tico ·de las ~reas del con-
junto de partículas presentes en la carga.
( S)
. / '
En su forma anali tica, la ley de Bond se despre nde
igualm ente de la Ecuac ión 3, para el caso espec ial
n = 3/2 :
-
E = 2k [
1
( 6)
defini endo adémás que los tama~os carac terfst icos d+ y do+
corres ponde n a los tamañ os d 80 del produ cto (P 80 ) i de la
alimentació~ (F 80 ), respec tivam ente. Por conve nienc ia,
Bond espec ificó :
2k = 10 W¡ { 7)
E = 10 W¡ [ 1 1
J
( 8)
2.0 .
Diámetro
Molino /0
o
.
·e;,
.._ o 30"
Qj
e c. 15"
lJJ 1.5 t
01_ o·
~
'Q(f) o 10" 1 k ·867.
o:I:
.!.l 1-
.
...._
.......
_
U .S::
l'i?: 1.0
lll,y_
w_ ~/
o 1 LEY DE RITTINGER
E
~ 1 / Molienda Batch
.. .Seca
e
o·
u 0.5 1
/ Alimentación: Calcita
/o 100%-10#
a
2.0
Diámetro
Molino
o
•
.Q o 30"
01 ·,
ti; o 15"
e:
LJJ·
(!)
o 10"
"O-
8V)
·- ¿
.........
~ü "".
(!).C.
0..3:
tYJ~ · LEY. DE KICK
o~.:
E Molie~ ·Batch Seca
::J .....da
g)
o· Alimentación: Calcita
u
100% -10#
•
2.0 •
Diámetro
Molino
o /0
.01
....(\1 o 30"
e 1.5 o 15H
w
(\1
"0- o 10".
81/) L\ 10 w1 =80.
·- :4
!!::;1-
u -
(\J.C
1.0
fir~
w_
o 1 7 LEY DE BOND
E
:J
1/)
e 1 / Molienda Batch Seca
o 0.5 1
u /
Alimentación: Calcita
o 100%-104/:
•
Sin embargo, para la evaluación de alternativas
operacionales con fines optimizantes, la relación_de
Bond - con una precisión estimada en ~ 20 ~ - ha demos-
trado ser claramente insatisfactoria. Ello debido a
que, a pesar de reconocer la estrecha relación existente
entre consumo especifico de energía y tamaño de producto,
es dem~siado global en su descripción del proceso. Asf
po.r ejemplo, la ley de Bond no considera el importante
rol que le c~be al a9ua en sistemas de molienda hGmeda,
operando en circuito cerrado con- hidrocitlones; donde
.
la eficiencia .de i!stos últimos como clasificadores (y
por ende, la eficiencia del sistema global} es fuerteme~
te dependiente de la cantidad especifica de agua dosifi-
cada al circuito. Tampoco es p~sible, ~ partir de la
Ecuación 8 propuesta por Bond, o en ~u defecto cual-
quiera de las anteriores, predecir la razón de carga ci~
culante a desarrollar por el sistema, cuyo importante
impacto sobre el comportamiento operacional del circuito
no puede ser ignorado.
ALLIS-<:llA.l..MERS CORPORATION
Grinding is mos1: !requen tly done in ro- '!'be interior sur!ace ,of grinding
tating drums ul:ili:in g loose grinding milla exposed to grinding media
media, lifted , by the rotal:ion of the and/or the . materia l being grouod
drum, to break the ores in various com- are protecte d froa wear and corro-
bination s of impact, attritio n and sien by rubber, metall1 e, a combi-
abrasion to produce the specifie d pro- nat1on of rubber and mecallic , or
duce. Grinding media can be the ore non-met allic wear resistan t mater-
itself (aul:ogenou~ grinding -- primary ials.
and aeconda ry), natural or manufac turad
non-met allic media (pebble milling) or il. Drives
manufac turad metallic media -- steel
rods, steel or iron balls. Ec:onomics at the time of plant de-
sign and mill purchase deter:in e
This eha?~er will discuss general mill the drive to be used.
desi¡n and the speci!ie design and ap-
plicatio u of tne followi~g types of The simplest drive is the low
speed synchr~noua mocor wíth
tumbling grinding mills.
speeds in the range of 150 to 250
Overflow Rod Mills Figure l RP~ c:oonected to the mill pinion-
Peripne ral Discharg e Rod Mills shaft by either an air clutch or
Figures 2 and 3 flexible coupl1ng . _
-1:-
Gr1nd1ng mills essent1ally draw speed range, if power factor cor-
constant power, thus are well rection is not required induct1on
su1tecl for-use of syuc:hronous lllo- motors can be used; S quirrel cage
tors with power factor correction when there is no restriction on
capabilit1es as drive motors. A inrush current; slip ring when a
net of approximately 120 to 130% slow start and low inrush current
of running torque is Tequirecl to is required. A!r c:lutch~s can al-
cascacle the- c:harge in these mills. so be used to ease starting prob-
The pull in torque is about 130 to lems with squirrel eage motors.
140% with the pullout torque to
keep the motor in-step (in-phase) ln some areas of the world induc-
generally in excess of 150%. tion motors and starters are less
expensive than synchronous motors
When mills are startecl across- at a sacrifiee of motor efficiency
the-line the s::arting and pull-in and power fac:or cor=ection.
torques result in inrush curren~s
exceeding 600% which result in Dual drives, that is two pinions
possibly _high voltage drops. !o driving one gear mounted on the
cleliver 130% starting torque to mill, can become economical for
the mill the IUOtor design must ball mills drawing more than ~500
take 1nto accotint the maximum an- to 4000 horsepowér (2600 to 3000
ticipated voltage drop. Motor kilowatts). At this time, single
torque dec:reases , as the decimal pinioa drives with rat1ngs of 6000
fraction of the voltage available horsepower is a prac~i~~l limit.
squared. 'E.g., a motor ratee! 160%
starting torque with a '10: system Further developmen~s of the low
voltage drop will deliver 160% x frequency, low speed synchronous
(100%-10%)2 or 129.6% torque to_ ~Uot:ors with the roeor moun::ed on
lOO the mill shell or an extension of
its output shaft. the m.ill trunnions could improve
the cost pioture for these "gear-
When it is not possible oT prac:ti- less drives", making them practi-
c:al to sta'rt a fully loaded syn- c:al for large ball mills.
chronous motor ac:ross-the-line it
is possible to utili;e the motor'a Critical speed, whic:h is the speed
pull-out torque :o start the mill, at whieh the c:entrifugal force is
By using a clutch, normally an air suf!ieiently large to cause a
clutch, between the motor and the small particle to adhere to the
mill, the motor is brought up to shell liners for the full revolu-
synchronous speed before the tion of the mill. Critic:al speed
clutch is energizad. lf the motor ia determinad from the follo~~ng:
has an adequate amount (175% or
greater) of pull-out torque the N.= 42.305 D-o-a (1)
pull-out torque starts the mill
without major disruptiona of the
electrical system. Where D is mill diameter inside
liners specified in oeters.
Since the energy ralease at 1ni-
tial eascade of the mill charge is N0 is critical speed in RPl!.
an inverse funct1on of accelera-
tion time, a minimum acceleration When D is specified in feet:
time of 6 to 10 seconda or more is
reeommended to prevent damage to
the mill or the e~ill: foundation. N,= 76.63 D .o_o (l,a.)
-2-
in =ill desig n. It can be deter - A rod mill is a tumbl ing m:f.ll in
=ined by the follow ing eithe r as which rods are.th e grind ing media .
meter $ per minut e or as feet per See Figur es 1, 2 and 3.
minut e.
Rod mills are usual ly used in wet
J.ir• = ;.: DN (2) grind ing appli catio ns. For~ the
~iner coars e grind s wet overfl ow
where (Figu re l) rod mills are used and
for tlle coars er .grind s eente r pe-
Np • Perip heral speed riphe ral disch arge rod mills .(Fig-
D • Diame ter insid e liner s ure 3) are used. The latte r case
N • M1ll speed in rpm being for produ cts where a mini.mum
of extrem e fines are desire d auch
as for speci ficati on sand. ·
To relate critic al speed and pe-
riphe ral speed as mill diame ters Dry grind ing in rod mills .is gen-
1ncre ase, the averag e· recommended erally not recommended. Dry 111a t~
speed as perce nt of critic al speed rial flowa póorl y and cause s r.od.
decre asesa s shown in table I. swell ing which leads to.rod break -
These are guide lines for initi al age and rod tang ling. Dry rod
plant desig n. Actua.l speed s may mills are used fo'r speci al a,ppli -
diffe r from these to suit speci fic eation s such as grind ing ~oke
ore and economic condi tions that breez e in iron ore sint11 ring
apply to the speci fic plant . plant s for grind ing eemen t clink er
(an energ y saver but high capit al
II. ROD M!U.S cost) . Dry grind ing rod mills are·
usual ly desig ned for end per1p her-
'When grind ing to a coars e produ ce al diseh arge (Figu re 2) but ean be
size .in the range of aox passin g cente r perip heral discll arge (Fig-
2.0 ~ to 80% passin g O.S mm ure 3). Excep t in cases such as
(some times finer) rod E.lls are cemen t clink er dry rod mills. are
norma lly used. The feed size can ineff ieien t power wise and subje c:
be as coars e as 80% passin g 20 mm to mecha nical probl~s parti eular -
and as fine as 80% passin g 4 mm. ly rod tangl ing.
Table I
Average ~ of Critic al Speed
-~-
-·
t ••• v •
•
•
~ ~
•
~
•
• ~
•
..' ...
'•
~
,.~·
~
~
"' ••
. ~
••
Table II
Rod Milling Coke Breeze
Table III
Rod Mi11 Diameter- Rod Length
5.03 '
16.5 6.29 20.6 7.04. 23.1
-6-
Table IV
1'11ninun1!od Spec:ific:ations·
PHYSICAL REQUIREMENTS
Rods shoul d also have ·the foll~ng physic:al requir~nts:
• Rods are to be spec:i al ccmmerci al strai ghten ed.
• Rods are to be hot sawed to le~h where mill
(stee H facil ities ~rmit. tf hot sawing is
not poss ible, use an abras ive cutti ng wheel
or machine cut both ends to prope r lengt h.
• A11 grind ing mill rods should be lSZ 11111 (6
i nches) sho_rter in 1ength than the worki ng
lengt h of tne rod mrtll.
The fee<t eDCls of roda vear ia.co a taper ed vear aa.ci aceua ulatio a. of
loa.g ~apere<! •apea r-sba ped• pro- brokea. roda reduc es the bulk dea.-
file • while the dheh er¡e ends aity of the eill ehar¡ e, arul chus
wear ia.co more of a eoa.ie al shape . eill pove r.
Appro ximac ely the eiddl e tvo
third s of the roci lea.gt h evea. tual- The roci ehar¡ e bv.lk · ciea.s ity given
ly vears ia.to aa. ellip tieal ahape d ia. Tabla V esa. be uaeci· to deter -
seetio a.. Smal l p~eees of broke n mine the pover a _roci aUl vith a
roda eaa. aeeua ulace in the eill vonl -iu ebarg e llbov.lci draw.
befar e beiD¡ ~aehar¡eci.
Bulk
1he lieoa ity ia· varia ble • subje ce co
-7-
Table V
Bulle Density Worn-In Rod Charges
Bulle Density
KG Per·Cubic Meter Lbs Per Cubic Foot
New Rods 6247 390.
Worn-ln Charge
Mi l1 Di ameter
Meters Feet
0.91-1.83 3-6 5847 355
1.83-Z. 74 6-9 5756 360
2.74-3.66 9-12 5606 350
3.66-4.57 12_-l5 5446 340
cara given a rod charle (~culling• Heavy duty single wave "shell li-
cut broken and thill roda), aruS ex- nera c:ast of either aUoy stt~el.
perieDce i.nc!icates 'lllill c!iAeter (manganesa steel. ·1s not rec~
also has a11 effect on b~ de11sity mendec!) cr wear resistant alloye4
of the vorn-in charge. ·The larpr. cast iron are most frequently uaed
tbe diameter of the red 111111 the in rod milla. the o<Íl\IJIIber· ;· óf
len practica! ·c\J.lling• of .the lifters to the circle ·_.ls- usually
charge bec0111es, tllus mqte brolcen. equal to appro>Q.mati\+Y'' ~.-6 O 1n·
and wcrn roda in-. the charge reduc- •eters (fo-: D in feet divide 6.6 0'.
ing the bulk density of the by 3.3). These.-linen have 65 mi
charge. (2.5-) to 90 mm (3.5~) bighwaves
Red milla normally carry a ril<l above 65 m111 to 75 - · (3H) lin~rs.
charge from 35 to 40% of mill vol- Rubber backing can be used lHÚloféeli
ume. They can carry up to a 45% the uners and shell . to: .Í>~7oteee
charge. The limita on charge · the shell from washing and,:l)ort"Q-
level are: keeping tbe feed end sion. However, Witb rubber _ bac:\t~
trunnion open so feed will go into ing cara must be taken wil::h the-
the mill and keeping the rod liner bolt speci.h.c:ations .and'
charge low encugh so roda will not seale-: assembly to assd,:e the 11-..
work inte the discharge end erun- cera will stay tight arut not .move_
nion cpening, where they can tip on the shell. This create_s 1-e.í!Í<Y
and cause red tangling• line-: bolts and causes ···the bólt.
boles in the shell to wear inco 'ilil'
Rod mills are normally fed by elongated ;hape~ ··'' ·
spoul: feeders as shown in Figure
4. !o get the proper flow of feed !here are modific:ations such as
into the mill a minimum head of the cwo piece liner -l!fter design
1.5 meters (5 feet) is required that can be used instead of the
above the mill center line to :he single wave line=. Rubbe-: shell
bottom of the feed hopper to which line-:s have been successfully ap-
che feeder is attached. plied in the smaller diameter rod
-8-
milla running at slow speeds. in using wear resistant cast iron
Wben uaing rubber liners cara muse end linera. Rubber liners can be
be given to using good quality used with eaution as they can be
rods aud culling brokan and thin subjee~ to damage from the sharp
roda from the charge. Rubber li- anda on worn roda. txeept when
nera can belp reduca the noisa
levsl.emanating from a rod mill.
using rubber liners there should
be a rubber baeJc.ing between the
head l!ners and the heads. tnd
-
tnd line.rs ara ge.ne.rally a thie!c., l.!ne.rs ahould be smocth .wi th no
a110oth liner case of alloy sceel. waves or lifters as these can dis-
bpscting frlllll the rod eharge., rupt red action and cause rod
wbich has a lateral 1110vement in tangling.
the mill, re.quires great eaution
-10-
Table Vl lists many cf the ecmmcn eui t ball mill aud when the same
size red milla ¡iving' speed, load- diameter mills can ,be used mechan-
in¡ and pcver data. The P,aver is ieally, i t is feasible eo make the
in horsepcwer ,at the mill piuicn- two Silla into one multi-
shaft. Fcr differeut length red eo;;.partment mill. These mills are
milla pover varie• diréctly as red feund wet ¡rindin¡ cement raw ma-
length. For differenee between new terial and are also used fer
and vcrn linera increase pcwer ¡rinding bauxite in a caustie se-
draw by 6%, and adjust fcr bulk lutiou. The ealculaticns relative
deusit1 per Table V. te the red eompartmelu: , ,are: the
same as for a separata ,roe! mill.
Since it is harder te r~place roda
The red ecmpar:ment cf a rod-ball the time intervsl between adding
ecmpartmented mill, aee Figure 6, new rada is a month er ,~re, some
is the same as an overflow rod additienal reserve must be added
mill. ~~en wet rod milling a non- te allov the red c0111paruent to
abrasiva mineral or material te pe,rferm its vcrl< at a , lewer than
prepare,feed for a wet open eir- normal (40%), red c:,harge.,
-n:..
•• •
-12-
Table VI
Rod 11111 f>ower at Hlll Plnlonshaft (llorsepower)
Rod Rod Bulk _ Rod Charge WetghC~------- ~~Hin l'oiier-- ~-uh- {DI
Rod !LID 1Hlll Speed 1
1111 1 Htll lenglh · Oenslty lnslde
Olame ter length (l) Rod · Hetrlc Tonnes ShOrt lons 1- Volumetrlc New
Cbarge lVOlumetrlc_ loadl.!!lJ 't Volumetrlc Loadl.!!lJ Load In..,..._ Ltners
J-!--J.-!.LI-!!--1 ft H Ft. RPH l CS FPH ~g¡m• ilb/rt• ~ 4U 4s-- 35 •fll 4S ~ ~~~¡-lL._l!
0.91 J.O 1.22 4 1.01 3.5 1.4 36.1 14.5 284 5847 365 1.0 1.13 1.27 1.1 1.25 1.4 1 8 8 0.76 2.5
1.22 4.0 1.83 6 1.68 s.s 1.57 30.6 74.7 336 5847 365 2.25 2.56 2.9 2.48 2.84 3.2 23 25 26 1.07 3.5
1.52 5.0 2.44 8 2.29 7.5 1,67 25.7 71.2 363 564t 365 6,91 7.95 8.09 7.62 8.76 9.8 57 61 64 1.37 4.5
1.83 6.0 3.05 1.0 2.90 9.5 1.73 23.1 10.1 399 5847 365 13.1 15.0 16,8 14.4 16.5 18.5 114 122 128 1.68 s.s
2.13 7.0 3._35 11 3.20 10.5 1.62 21.0 69.9 428 5766 360 20.0 22.8 25.6 22.0 25.1 28.2 181 194 204 1.98 6,5
1
~ 2.44 8.0 3.66 12 3.51 11.5 1,53 19.4 69.3 457 57~~ 360 29.0 33.2 .37,4 32.0 36.6 41.2 275 295 310 2.29 7.5
...., 2.59 8,5 3,66 12 3.51 11.5 1.44 18.-7 69.0 410 5766 360 33.0 31.1 u.s .36.4 41.6 46.8 318 341 359 2,44 8.0
1 2.14 9.0 3.66 12 l.lil 11.5 1.38 17,9 67.5 470 5766 360 36.0 41.1 45.5 39.7 45.3 50.1 344 369 386 2.55 8.35
2.89 9.5 3.96 13 3.81 12,5 1.41 17.4 67,6 483 5606 350 42.7 48.8 54.9 47.1 53.8 60.5 416 446 .410 2.70 8.85
3.05 10.0 4.21 14 4.11 13.5 1.~4 16.8 67,0 493 5606 350 51.5 59.0 63.8 56.8 65.0 70.3 507 544 572 2.85 9.35
3.20 10.5 4.57 15 4.42 14.5 1.47 16.2 66.4 501 5606 350 61.4 70.1 78.9 67,7 77.3 87.0 609 653 687 3.00 9.85
3.35 11.0 4.08 16 4.72 15.5 1.5.0 15.9 66.8 517 5606 350 72.5 82.8 93,5 79.9 91.1 103 735 788 829 3.15 10.35
3.51 11.5 4.88 16 4.12 15.5 1.43 15,5 66,6 528 5606 350 79,7 90.7 103 87.8 tOO 113 819 878 924 3,31 10.85
3.66 12.0 4.88 16 4.72 15.5 1.31 15.1 66,4 538 5606 350 8?.7 99.8 112 91.1 110. 123 906 -ní 1023 3.'46 11.35
3,81 12.5 5.49 18 5.34 17.5 1,48 14.7 66.0 547 5446 340 104 119 134 115 131 . 148 1093 ~1?~ 1234 3.61 11.85
3,96 ll.O 5.79 19 5•64 18.5 1.so 14.3 65.6 sss 5446 340 120 137 154 132 151 110 1264 1356 1426 3.76 12.35
4.12 13.5 5.19 19 5_.64 18.5 1.44 14.0 65.5 565 5446 340 IJO 148 166 143 163 183 1385 1486 1562 3.92 12.85
4.21 14.0 6.10 20 S.94 19.5 1.46 13,6 64.9 570 5446 HO 147 169 190 162 166 209 1580 1695 1783 4.07 13.35
4.42 14.5 6.10 20 5.94 19.5 1.41 13.3 64.6 579 5446 340 159 181 204 175 200 225 1.115 1840 1935 4.22 13.85
4.57 15.0 6.10 20 5.94 19,5 1,36 13.0 64.3 566 5446 340 111 194 219 188 214 241 1853 1988 2091 4.37 14.35
.\ r.
'·-
7be varioua rod mill manufacture ra .which are considerad to be non·
bave d1fferent equat1ons for de- abrasive, where rollar mills (F1g·
ter=in1ng tbe power rod milla ure 7) can be more econ0111ic:ally
draw, but all come close to the used. A ball m1ll 1s a tumbling
sama ealeulated power draw, aa · aill 1n wh1c:h metallic: balls or
given in !able VI. spec1al shapes are the grinding
tDecU,•, se e Figures ~ and 9.
I U. liALL MIU.S
__
-
.
... _
-14-
•
..... ..
••
•• •
.
~
•
•:• '~:
•• ••
4 ••
• •• •
:..
···" .
•
---.-:;-:--
•
f'tUUHt:. ~. u1aonragm (\.;frateJ t.JISCn!lr;e .csau Mm. ury \,;lnncmg 1 y pe.
_,.:;_
!be feed to dry · ¡riading hall grinding ball mills use spout
milla must be dry containing lesa feeders (see Figu·re. 4) with air
tball. l% aioisture by weight. There seals. A rule-of~thumb for det•r-
is a loes in efficiency when the mining the air required for dust
feef ~oatains sufficient mdisture eontrol 1s:
to slow down the flow rate or Closed Circuit 5.5 cubic
,- cause eoating of the grinding meters per hour pe_r horse-
media and/or mill liners. Dryin¡ power of mill power •.
can be.aeeomplished in one of the
followin¡ ways: Open Circ:uit $.0 cubic:
meters per bour per horse-
A. Separata dryer-rotary-fluo- power of mill power.
solids, etc. Being free of the limits imposed
on rod milla by the rods, ball
B. Drying in the mill by drawing mills bave more variations in
hot gases througb the mill length todiameter x;atios, ranging
with a partial or total air from slightly less than l:l eo
sweeping. some greater than 2:1. !here are
no fiXed rules on the proper L/D
c. cOmbinad dryer aad hall mill ratio& to use as these vary witb
with the dryer being the the circuit used, ore type, feed
firsc eompartment: and the size and overall gr1nd1ng require-
hall mill 1:he secoQii compare- ments. Tabla VIl gives some rough
ment. The hall mill compare- guide lines showing, based upon
menl: 1s a ir swept: beca use p&st experience, the general L/D
gases from the deyer are ratios used in the application of
pulled through it. hall mills.
D. Drying in the air separator Depending upon the sin of make-up
where the feed goes to the balls usad, adversa hall segrega-
sir separator. Bot gases are tion, that is large balls going to
dr&VIl through the air separa- the discbarge ead and small balls
tor drying the new feed. to the feed end, can oecur as the
Drying also oecurs in the · L/D becomes larger. !bis begins
bucket elevator usad to con- to occur as the make-up hall size
vey the mill dischar¡e, wbicb 1s largar tban 65 111111 (2.5").
is hot, and the new feed to
tbe air •!parator. Grinding balls <:an be made of
forged or case steel or cast iron.
Except for fully a ir swept mills, !he quality dependa upon the
dry grindin¡ hall mills are sup- source of supply. While not al-
plied with low le•el discharge di- ways true, frequently the better
aphragms (Figure 10). With air quality balls are forged steel.
swept and part1al sir swept milla, Generally balls are spherical but
the sir volume and velocity Will they · can he 1n various cylindri-
be tbat required to carry the cal, C:onical or other irregular
coarsest particle a1~e desired sbapes. Balls vary considerably
from the m1ll. ClassificaUon to in h&rdness with soft balls ·having
close the mill eircuit is usad, Brinnell bardnesses in the range
therefore the largest part1cle to of 350 to 450, and the hard balls
be swept from the mill will be have bardnesses·in excess of 700.
larger than the desired product A rule-of-thumb subject to argu-
si:e. Diaphragm discharge mills ment is: "the harder the ball the
will requ1re a suff1c1ent a1r draw better its life" (provided it is
to keep tbe mill under negativa not too brittle and breaks or be-
pressure to prevent dust from comes too highly polished and too
leaking from the mill around the smootb to nip the material being
feeder and discharge ho~sing. Dry ground).
-16-
l.ocal economic s anol tbe apecific
grinding applic.t ion general ly are
tbe daci4ing faé::ors :l.n aa1eci:in g
· polnon s~d havin¡ as.
to U a.urface s, vb:l.ch
alightly co.acave.
-nf-- &
C!ÍIIií -.,
e.,:tdeno'\1 .t.
tbe tlalls to usa. the llalla .•1...- 'brokaa b&1l.ll :1.8 founcl 1iban pS.ec.M
iJt& elle 1-n operatin & coat .and flf llalla are beiiiC dhchá1'g ed,
best parforaa nce are ganerall y se- SOIH as •it'l:ula r cU.aes, _.... as
. lécted. Tilia· Med aot ba tbe low- .hal.f r.oulltla, • - cnscetK sbapad •
. .t prLced llalla .avallall ia ur tbe l':l.ecea ltf 1oil0r:ll or· -brolr.en .· 'balls
aaas f:I.Yiq tlle 1-st vear rata, Witll llo14a. iD tño• tMLcau poor
llv.r can be a. -Pfoa. iM · berveea qual:l.ry 'balls Vith ...a ~~uaions
tba tilOe:R1'-·· aotl./or blov boles and/ot hollow
Qfttera .·
lalls ahou14 lle soli4 v:l.th a rea-
aoli.ably \11Úfom . har4uu throu¡h For ul.Clala d:.¡ tba po,..r th&t a
tbe entin ball. .. they abould wear .• li&U. alll Vill cnv, for¡e.l ned
in a relat1.ve ly· 1111>Uom patterÍl. .. all4 G.K ateel balJ.s ara ass..,..d
Aa :1.114ieator of soo4 Wl -.ar ia · to tllll!p 4646 ~lomas per c\lbic:
Wbaa tbe votu 'balla d.Ücbar¡ in& . .ter (HO pouzuSa pal' callic foot)
frQI tbe aill are aroUIId 16 - Vida case 1roa llalla weighin ¡ 416!1
(stt•) or IINl~r u a:l.ae SII04 ara - pet .3 (260 pc:t) • . ' .
:
!
t>
"-.A-.1 .U 111~
-17-
Table VII
Ball Mill LID Ratio - Application General Guidelines
.. • ~
Tv"" of G"lnd1ng · Fped ~ Pa<sino Si:e Too Bo11 Siro l /!) ~atto
100
- .
'
.
-
.. ..
/
..,__.
1
, ...........
a:
·w
/
V 1
3:
o11.
90
v
/
-
~
~
:E
80
/
/
.- 1
1
""o 70 1 1
~ í7
150
.•. i .
1
• • • •
io 25 30 35 40 45 .SO. . 55 '
60
% OF MIU. VOLUME OCCUPIED BYBAU. OA PEBBLE CHARGE
~~;11
~
• Q
a
a
~
,;, .
t •~v9 ~
1·o y
" -·
'
~
:,;¡
• ~
~
~
.¡
•
"" "
' o
¡
y ~
y
:;
;;;
"~
y
~
~
-
.,--
~ ' 9
.,Y' y~ il
..• i
•• ....
FIGURE 12, Singte Scoop Feeder witll 6all Cllarg'"g Drum. (Ooub!e Scoop is ava•lableJ.
-19-
..:
e
.,.¡
..,
... "" -- w
,
. - ..,
.
-
<1 y
,¡
"'
..J ,¡
-
•
-.j
.J
,J
.¡
-
•
.;
J .J.
.¡ J
J
.1
"' "' J
.- .1 ..;
l
FIGURE 13. Orum Feeder.
-20 -
Maka-up grincUng balls are fed to in the mill pover draw until
the mill as required through the the waves'wea r in and the
mill feeder with t:.he mHl in oper- balla can nest betveea the
ation. !alls may fee~ ~ireetly lifters, ' . When · liners, and
through a spout, but should ~ be
fed into a seoop box beeause of
poaaible jamming and serious mill double vave liners i~ parti-
damage. Seoop feeders usually cular, wear with circumfer en-
bave a central ball feed pipe or a tial ¡rooves, sl1ppi~¡ of che
s~~~&ll 'ball charging ctrum to aecom-
·char¡e U 1nd1cated , and tbts
plish tbts. varu o'f accelerat ed vear.
When the toP. aize ball is
There are many different designa saaller tban 6S aaa (2.5") and
and stylas of ball mill liners. aill speecl 1a lesa than 72%
As w1 th ¡r1nding balls local eeo- ot ,eritical vesr ·resistant
nomies and ultimatel y operatin¡ case irons can be used. For
coses determine the bese desi¡n otber eoadition s alloyed case
and material to use.· Tbe 1nitial ateel is 'i:ecOIIIDended_.
aet of linar• is raraly the final
design selacted. iaaed upon .indi- llubbér linera are well suited
vidual axperienc: a, aill superin- to tMs saae area and not
'tandaata develop preferanc ea for only reduce operating c:osts
linar desi¡na. The following 1s but eaa reduce noiáe levels.
¡iven aa a ¡uide for tbe in1tial ~- to the teaperatu re of the
set of linera. feed and the heat generated
ill.¡rind1n g aoin¡ into the
féed,· the teaperatu res in dry
crindin¡ aills are too hi¡h
to allow the use of rubber
A. For 65 mm (2.5") and saaller linera.
top abe balls for cut metal ·
linera use donble vave liners
with the number of lifters to
B. · ·· · Single vaYa linera a re . ree
aendecl for ~er size balls
=-
the c:irc:le approxtma tely 13.1 ( 60 ~~~a/2'. S" alld largar) • The
D in .. ters (for D in feet ~be~ of the lifters to the
divide 13.1 D by 3.3). Wave c1rcle equals •P?l'oz~tely
hei¡ht fr0111 40 to 65 mm (1- .6.6 D :l.n asterá. (for D in
5/8-:' 1;0 2-l/2") above the li- feét clLvide 6,6 D by 3.3).
nar tbiclmesa , linar thick- t'ba l1ners a.h fro.: SÓ to 65
nesa ts froa 40 to 50 mm (l- ma tbick (2" to 2.i3") with
5/8• éo 2"). ~ubber linera che vavea fr011 60 to 75 u
of the · integral aíolded desi¡n (2.5" to 3") above the 11-
follov tbe east metal design. ners. Tbe replaceab 1e lifter
If Uaing ~ replaceab le bar desi¡n aacle of either
lifterb. r design in either 111etal or rubber ia. about the
an.al or rubher the numbar of &&lile clesip propcl rUons can
Hfter. should be about .be Qed. There éoul4 be a
3.3 D in·aetera (for D is loils 1n po114!r vi th 't'uf>ber 11-
in .feet divide 3.3 D by ners of up, to 10% •.... 'llubber
. 3.3) with the 1ifter hei¡ht
above the linera about twice
liners az:e · . .Ot tR~ed
wh'fln :be lial:l Íli&e : 1s largar
the Uaer tbicka.ess •. than 75 mí. ·
:
The u1a of double .vave li- lec:ause of t~ impactin¡ ' trom
nera, particula rly vben using e be lar& e bal,ls, singla vave
50 a (2") or laqer bella, 11ners for ball aills are
aay show a losa of S% or so usually ~~~ade froa alloyed
---~--
-21-
steel or specia l wear resist- tegr&l. radial riba or 111 th
ant alloyed c_ast, iroaa. Be- replace able lifters or vith
cause of tbe difficu lty of both.
balanc:i ng . growtb and wear
W1 th vork hárc!en ing, manga- E. When a grate dischar ge is
Dese steel ia used infre- used, the gratas and wear
quently and then W1th extreme platea are normal ly perpen di-
cara to aiiow for growth. cular to the mill axis vbile
tbe dischar ge pans conform to
Tbere are cases libere double tpe slo~ of the m1ll head.
wave linett bave béen used as '!be gratas and wear plates
repl:aeement liners for single are normal ly 111ade from al- ·
wave linera. !his require s a loye<! wear-r esistan e east
stuc!y of wear pattern a mill steel or rubber. !bey are
power, .capac:ity_&ncl o~rating ribbed to preven t racing and
eosts •. exc:ess ive wear. !be dis-
c:harg~rs. and pana are genar-
c. Classif ying linera bave·be en ally.llla de from either wear-
· used in ball milla to ¡>u:' the resista nt cast iro~ or rub-
largar balls at the feed end ber, or vear-r esistan t fabri-
ancl the smáller llalla at tbe cated steel,
discbar ge ene!. Spiral sbel.l
linera sucb as sbovn . in Fig- Slot pluggin g can be a prob•
ure 9 bave been usad succes s- lem in grate dischar ge mills,
fully, !he spiral ia ati ad- Wbeehe r·ehe grates are made
vancin¡ spiral. of_met al or rubber tbe slots
should have ample · relief
!he sc¡u.are mlll Uner also ·tap.tred toward the · discbar ge
knovn as a classif ying liner side. Total angles 7 to lO
gives a square c:onfig uraeion degrees (3,5 to 5 dagrees per
to the inside of · the· mUl. side) are commonly used.
!here are a series of : .:Pff Metal -gratas oftan bave a
settin¡ circ\llll ferenti& l. rows small leacl-in pocket or re-
vbicb r•tard the movement of ceas which can fill in vith
balls and allow a i!ett,er ma- peened metal ratber tban bave
terial flow ancl filling of . the slot ~eu shut.
the ball c:harge•· There have
been succ:ess es and failure s. With tbe propér combin ation
· W1th thU.ty~ of-liner~ of me.tal 1ntarn als and rubber
It. surface s, rubber gratas bave
does reduce mill vol\lllle and
cause a reducei on .in tbe flexib ility that tend to make
power drawn by the mill. tbem self c:leanin g and yet
In not fail due
some cases a reducti on in to flexing .
pover per tonne has occ:utre<l, Rubber grates cannot be used
1mprov1ng grindin g· efficié rt- in dry grilloding ball mills.
cy, In other cases tbere has
been a corresp onding reduc... F. Except; ~en using rubber 11-
tion in·capa city llith.th e re- ners~ t·he mill surface s are
duction in paver drav. covered With a protect ive
rubber or plast!c materia l to
D. End liners for oall milla proeec t tbe
confo rm to the slope of "tl!tf · surface s from
·. pulp racing and corrosi on.
mill ·heac! &lid can· be m.ac!-e::.,f· Tbis is d·one in wet grinclin g
rubber, alloyec! c:ast suel cir mills. · Sine e: dry grind:!,ng
wear-r esistan t é:an iron•.; To _·:millS get bot due to heat
preven e rac:ing · allod· ~xcessive ·from · grindin g rubber liners
.u-. ....
waar ellod ·liners
¡~ . . . . . .
for 'bai1 · and r.ui;b'ar materi als usually
e:a r f. le ,...,. h «r,
-22-
';' ,,
e··.
~ ;
Table VIII
8~11 Hlll Pv~r at Hi11 Pinlonshaft (ltorsepower)
8 9 8 8
22 25 20 21
41 49 54 45 49
89 9] 10) 86 9Z
10.1 12.3 u.8 11.8 13.5 15.2 lll 145 151 158 115 148 151
18.6 21.0 11.9 29.5 ZJ.I 215 228 231 249 Zl5 2J2 246
1 21.1 21.8 20.4 U.3 26.2 250 266 211 290
r591 ú¡z:••r &:o, so 1t:o,!ó:4 rs:l,SIJ¡:::~ m 210 281
2.14 9.0 2.14 9,0 so 2.0 19.1 75,0 526 23,5 26.9 30.2 25.9 29.6 33.3 312 342 ]56 JI] 41J 348 . 369
"'.t:1 2.09 9.5 2.14 9.0 so
..... - ..... - - -- 2.0 30.1 31.9 29.1 Jl.2 ]1.4 361 390 406 415 411 396 421
- - .19.15
- -- 15.0
-- - 541
... 26.4
32.7 37,3 42.!1 36.0 41,1 46.3 462 491 512 515 59] 499 SlO
36.1 H.4 46.5 ]9,9 4S;li 51.2 519 ssz 515 692 661 561 596
u.o 49.2 55.4 4l.4 54.2 61.0 610 649 616 7011 784 659 101
49.1 54.0 60.1 54.1 §9.5 67.0 614 718 741 782 861 128 715
$6.4 64,4 72.5 62.2 71.9 19.9 812 864 909 942 : 1044 877 9l3
61.4 111.2 19.9 61.1 11.4 87.1 896 954 99] 1040. IIU 968 10)0
12.3 82,7 92.0 19.1 ".1 102 106) 1130 1111 123l 1365 1148 mo
18.2 89,4 99.8 86.2 98;5 111 118_9
m' 1321 1319 15ll 1204 IJ61
90.7 194 IH 100 115 129 IJ75 W.4 1521 1595 1111 1485 1581
98.0 112 126 108 12) IJ9 1492 1588 1656 lllO 1921 1611 1115
129 144 124 141 IS9 1101 1811 189) 1900 2196 1844 1962
138 155 m 152 171 1838 19S6 2011 2132 2361 1905 2112
151 179 151 l1l 194 2004 2217 2309 2411 2618 2m 2394
161 188 161 184 Znl 2229 m o 24(16 2585 186] 2401 2560
189 212 182 208 234 2595 2m 2881 3010 3344. 21103 2985
3053 3190 lS4l 2910 3163
3414 3569 3961 ll2l 3538
\,O .r-.
ball charge exceeds 35% of mill The Comcartmented Ball Mill, Fig-
vol~e the mills do not: use the ure 6a consists of two or more
power for efficient grinding. A grate discharge ball mills in se-
ball chatge between 32 and 35% in ries built into one rotating as-
5.49 meters (18.0 feet) diameter sembly. Power dravn by these
wet grinding ball cills seems to mills can be as high as 12,000 HP.
be a maximum to obtain an effi- Mill diameters are as large as 5.5
use of power. The sama meters (18.0 feet). Mill lengths
cient
problem has not occurred in dry are as great as 15 meters (50.0
grinding ball mills of the same feet:). !he most frequent use :ts
d!ameter.
for dry grinding eement clinker to
produce Port:land Cement. !bey can
also be used for dry grinding ee-
V. COMPAR'D!EN'!ED MI1..LS ment: raw materials when it: is not:
economical or is not practical to
Cocpar~mented mills have two or use ring roller mills (see Figure
more compartments using balls, 7 )•
pebbles, or rods as grinding media
combining t~o or more grinding Multi-Comnartme nt: Drver - 1-till.
stages into one unit. !bese mills (Figure 15) th1S circuit utilizes
are particularly popular in the a three compartment mill with
cement industry, but can be used classification between the grind-
wherever scage milling is requ1red ing stages. The dryer (first com-
without an intermediate separation partment) is located internal to
or classification step. Recently, the large diameter trunnion bear-
peripheral discharges bave reap- ing and material is "flash dried"
peared in the Cement lndustry per- by high voluce air swept gases.
mitting discharging ground materi- Dryer lifters are specially de-
al from each compartment for stage signed to promete drying effic1en-
classification becween the stages cy. A Double Rcitator mill sepa-
ot the compart:>ented mUls to re- ratea the dryer and coarse gtind-
duce overgrinding. ing compartment from the fine
grinding compartment by a periph-
!he Rodoeb Mill, Figure 6, is a tral discharge. Tbis discharge 1s
~et grinding multi-compartme nt -large enough to handle high volume
mill wit:h rods in the first com- of vent gases with relatively high
partment and balls in the second grain loading and the material
compartment. Several minor com- prcxluct of both compartments.
promises are necessary when speci-
fying the mill. !he diameter is Double Rotator mills handle mois-
the same for both compartments. cures up ~o 1:
preheater kiln
Wi~n
!he operat!ng speed in terms of exhaust gases and up to 14 to 15%
?ercent of critical speed is a with high temperatura gases. Grit
comprom1se being on the high side separators are utilized to remove
for rod milling and the low side the coarse ma t.erial- befor·e eñter-
for ball milling. Rodpeb mills ing a cyclone collector which pre-
are most frequently operated in cedes che baghouse or electrostat-
open ci~cuit. The usual applica- ic collector. Air separator re-
tion is to grind materials with jec'ts are· ·returned to ·the fi:1e
low ab't'as!v.e characteristies . grinding comparoent_ or ~ if de-
Adding replac~eot rods and clean- si red, a portian can be recurned
1ng out broken rods and vorn rods to the coarse grind1ng end of the
is ~ore tiQe consuming than 1n rod mil l.
~lls. The t~o principal applica-
t!ons have been for wec grindi~g llet grinding c0111parcmented ball
raw materials for cement =aking mills are rarely used. Ihe prin-
kilns and gr~nding of bauxite in cipal use, is for wec opea gr!nd-
causcic solutions. 1ng of cement ra~ :aterials in we~
~~~ns ana g~~ua~ng OI caux•~e ~~ c;,;¡,pa.J. Y~~, •~ .. .., .... ._.. ""l"'-- o• ... .--
causcic solutions. 1n2 of cement ra~ :aterials in we~
....·. ,
' .
....· •' . '.
_____ , -------··-
-26-
Table IX
Pebble Mills Power
1 1-l/4" L i ni na 1 3" LinlnQ i ~· L i n1 no
Si.ze of Mill 1 Mi 11 J Mi 11 1
Mill 1 H.P. 1 R.P.M. 1 H.P. 1 R.P.M. 1 H.P. ! R.P.M. 1
1
7' X 10.' 82 22.0 77 22.6 7l. 23.0
. 7. X 12' ·. lOO 22.0 92 22.6 84 23.0
7' 14'
X 111' 22.0 106 22.6 97 23.0
1
1 7' 15' 134
X 22.0 120 22.6 111 23.0
7' •• 8' . 151 22.0 135 22.5 124 23 .. 0
1 "'} 1 X
X 20' 168 22.0 149 22.6 137 23.0
1' 7' X 22' 185 22.0 165 22.6 151 23.0
i
¡
8' X 12' 139 20.0 128 1 20.6 120 21.0
1' 01 140 21.0
i X 14' 163 20.0 149 20.6
'
' 8' X 16' 186 20.0 170 20.6 159 i 21.0
8' X 18' 210 20.0 191 20.6 178 1 21.0
20.6 197 '1 21.0
8' X. 20'. 234 20.0 213
8' X 22' 258 20.0 234 20.6 217 20.0
8' X 24' 282 20.0 255 20.6 235 21.0
'g• X 14' HS 19.• 0 198 19.3 188 19.6
. 9' X 16' 246 19.0 227 19.3 213 19.6
. 9' X 18' 277 19.0 255 19.3 239 19.6
9' X 20' 309 19.0 284 19.3 254 19.6
9' X 22' 341 19.0 312 19.3 291 19.5
9' X 24' 372 19.0 340 19.3 315 19.6
9' X 26' 403 19.0 367 19.3 342 19.5
. ,
media. the mill manufac~urers.
Pebble mills can be used for are designad for a 45 to 50% volu-
ei~her open or elosed cireuit metric charge load but normal
grinding. Ncrm&lly these applica- cperating level is around 40%.
ticns call fcr dry grinding. When
dry grinding to ~he very fine size Peb.ble mills are goce! applic:a~ions
ranges all passing 10 microns or !or rubber and wear resis~ant c:ast
f1ner scme caterials develop fluid iron liners. Rubber liners usual-
flcw eharacteristics . In ~bese ly have separate lifters wbile the
cases ~he mill should have an we.ar l'es1S-tant c.aS~ iron and cast
overflow discharge the same as in steel liners are of the in~egral
wet mills. there are cases vhere single wave design. With rubber
we~ grinding is used particularly there can be up to a 10: loss in
when making feed for flo~ation or the power dralolll by ~he mill ._1. th a
some ocher wet beneficia~ion c:orresponding l:oss in capacity.
methcd.
The feed for secondary au~ogenous
VI. SECO~~RY AUTOGENOUS MILLS mills is normally either roe! mill
(?EB BU: MILLS) produet or primary au~ogeaous mill
product. There are a few in-
Secondary au~ogenous grinding Stanees where it has been ball
mills, also referred to as pebble mill product and ene case where it
mills, use pebbles from the ere as vas the product of an intermediate
grinding media. !he sized ore can autcgenous mill (lump mill). An
either be sereened out of the ore intermediate autogencus mill is a
s~ream in a erushing plant or can secondary type mill fed a eoarse
be extracted from a primary autog- feed (red mill feed size or
enous mill. !bey are us.ed instead slightly larger) which is ground
of a ball mill vhen the pebhles in by pebbles in the 100 mm (4") ~o
~he ore make good grinding media l7S mm (7") size range.
and ~he wear ra~e will be lesa
than the ra~e at which pebbles can v¡¡. REGRI~'D M!Lts
be obtained. Pebbles are fed ~o
the mill in a eontrolled manner to Ball mills wbich are used to grind
maintain a constant · power draw. rougher ecncentra~es, middlings,
It is generally an interrupted final c:oncentrates or tailings are
feed with ~he en-off frequency ealled regrind mills; beeause they
great enough to require autcma~icn are fed material that has been
cf the pebble feeding system. !he ground, then trea~ed in one cr
average pebble size ranga is from more processing step. Relatively
40 mm (1.5•) te 75 mm (3·). ~l size ~alls are used. They
can be used in opea or closed cir-
Seeondary autogenous mills gener- euit. !he diseussions on ball
ally are used for wet elosed eir- mills fits regrind mills.
cuit grinding. To give a flow
gradient through the mill they VIII. ORE TESTING FOR MILL SELECTlON
have low level grate diseharges.
This prevents the tendeney fcr After the grind requiremen~s are
small pebbles and pebbl.e chips to established, testing for the se-
float on the slurry in the mill, 1ection of c:omminution circu1 ts
reduciag grinding efficiency. and mill size can be initiated and
can depending upcn the application
Mill power· is a funeticn of the include all o~ some cf che follow-
bulk density of the pebbles and of ing:
the si:e of ~he ore media (peb-
bles). - Primary Autogenous ~edia
'
1 Compe~eney
Mill speed is usually between 70 - Primary Autogencus and
and 7~% of eritical speed. Mills Semi-Autogenous ?ilot Plant
-
that the pilot plant m1l.1 power Sinc:e the
-30-
Bond grindab ility test requires a !he power deter:nin ed from equa tion
ratio of reductio n of about &:l to 7 is for the followin g speeifie
obtain aeeurate resulta it aay be conditio ns.
neeessar y to run the test at a
finer si:e than required by the A. Rod Milling - wet, open'ei r-
speeifie d grind or if this eannot euit grinding in a 2.44 meter
be done a speeial tegrind grind- (8') diamete r inside liners
ability test will have to be run. rod mill.
This will give a good cross sec- a. Ball Milling - wet, closed
tion of the grindab ility of the circuit grinding in a 2.44
ore and will allow for aeeurate meter (8') di ame ter inside
calculat ions of the grinding power liners ball mill.
required .
C. Power ealculat ed is the power
The balance of this 'diseuss ion required at tha pinionsh aft
will be an example demonst rating o'f the mill; which includes
the selectio n of a primary grind- mill baarings and gear pinion
irtg eircuit 'and a regrind cireuit losses but does not include
where all of the ore is ground to motor loases or 1osses in any
the required produce size in the other drive_ compone nt, such
primary circui t. - _For grindins as redueers and clutches .
eircuits where eoneen¡; r¡¡tion is
ineluded in the eircuit the basic The feed for Bond Grindab ility
approaeh is the sama as givan in Iests is:
tha exilmple, consider ing ,_ eaeh
stage as a separata entity and ad- Rod milling ore erushed to minus
justing for new feed ratas and 13,200 mierome ters {0.530") or
feed sUe (whieh eould be differ- finer.
ant than che rate and produet size
from the precedin g staga). Ball milling ore crushed to minus
3,350 microme ters (6 mesh) or
IX. EQUAIlONS US ED TO DETE:l!MlNE finar vhieh-ha ve been used toes-
GRlNDlNG POWtR tablish optimum rod artd ball mill
feed size:s.
Ihis fitst step in selectin g
grinding aills is to deter=in e the
power needed to produet the de- !here are eight e!ficien cy factors
sired grind. The basic equation to be applied to the ealculat ed
used for .this is the Bond Equa- grinding power to allow for·- varia-
t.ion. tions from the specifie d eondi-
tions and optimum feed sizes.
using th~. base mill .diameter llall millins: Fo =4000}. 13 ')0 "' (12)
cf 2•.44 meters .(8') inside . \ w, ..
liners, the ci~ter effi- Use the Work lndex !rom a grinc-
ciency factor can be calcu- alitll~:Y'·test at:·the desired grind
lated f:om the following: for ·Yi·" in equa:tion 9. For equa-
tion ll, use ei:her the Work lndex
w~en D is in meters: · frOOL a Bond 1mpact te&t or a rod
till grin~ability test, whichever
is higher. For equation !2, use
•(8) the Work. Index from a rod mill
grindab111ty test, since this more
· tepr8seiit_.a/iñe coa:rse . -;:fraction of
Yhen D is in feet: the feed¡ if not available then
use the ball mill grindability
te•St results,
(8a) EFs - F!nenuis of Gr:!.<>d · Fac:or -
this appl.j:es to fine grind-
. ·ing when thé 80% passing
Tabla XI gives a_tabulati~n size of the pródud; is finer
of the EF3 factors for some 'than 75 aicrometers (::!00
of the more common aill di- mesh),· The equation te de-
ameters in both the imperial termine ::his is:
.. 1
and metric measuring sys- .. EFo =p- .0,.3
-~.
teQS. 1.145 p (1:3)
,-.EFe= r - J. U...~
teQS. 1 'l L~ l) fl~'\
Table XI
Oiameter Efficiency Multipliers .
-34-
l) When ealeulacing rod lall Mill co Grind Pr~ary
mill power for a rod- ;em1-Autogenous Mill Produce
milling-only applica- ~egrind llall Mill
tion, use an 1neff1e1en-
cy factor of 1.4 when 'd rate to che pr~ary mill cir-
the feed is to be pre- ,t is 500 metric tonnes per hour
pared with open circuit luding factor for availability.
crushing, and use 1.2 ,d rate to regrind mill is 40
when the feed is co be ric tonnes per hour.
preparad With closed
circuit crushing. The .<>d mill feed and feed for ·single
mill diameter, low or stage ball m1ll Will be prepared
high ratio of reduction, w1th closed circuit crushing. The
and oversize feed fac- feed sizes for the various mills
tors also muse be ap- Will be:
plied to the ealculaced
grinding power .. - Rod ~ülling: minus 25 mm W1 th
80% passing 18 mm.
2) When calculating rod Single scage Ball Mill: minus
mill power for a rod 12 mm_SO% passing 9.4 mm.
mill-ball mill circuit, Ball Mill and Pebble Mill fol-
do noc allow for im- lowing Rod Mill· and llall Mill
provemenc in che ball following Pr~ary Aueogenous or
mill performance due to Semi-Autogenous Mill: minus 2
receiving rod mill feed. mm 80% passing 1.2 mm.
lf the rod mill feed is - Regrind llall Mill: 80% passing
produced With open cir- 210 micrometers.
cuit crushing, apply a
1.2 inefficiency faccor !be circuits are all wet grinding
to the power calculated type. All ball or pebble mills
for the rod milling are closed eircuit with the excep-
stage only. lf the rod tion of the regrind mill whieh
mill feed Will consis- will be open circuit for this ex-
, tently be the same, such ample.
as produced With closed
circuit crushing, do not Pebble. size for pebble milling
apply a rod mill 1neff1- plus 30 mm minus 70 mm With a peb-
ciency factor. !he mil~
diameter, low or high ble consumption of 30 metrlc
ratio of reduccion, and tonnes per hour which is 6% of the
oversize circuit production rate.
feed factors
should be applied co the
calculaced grinding The specified grinds are: pr~ary
power. grinding circuit 80% passing 175
micromecers, regrind circuit 80%
x. EXAMPLE GRINDING PO~~R CALCULA- passing 45 micrometers.
TIONS AND GRINDI~G XILL SELECTION
PROS~ NO. 1 llenen scale grindability test re-
sults are to be used for grinding
Select rod mills, ball mills and power calculations. The test re-
pebble mills as required for the sults to be u sed in the example
following eircuits. are:
Rod Mill - llall Mill Bond lmpact Crushing
-Single Scage Ball Hill. York Index •••••••••••••• 11.5
Rod Mill - Pebble (Secondary Rod Mill Grindabil!ty Test
Autogenous) Mill (W 1 ) a~ 10 mesh ••••••••• l3.2
(W 1 ) at 325 mesh
on regrind mill feed •••• 14.0
Abrasion lndex (Ai>•••••••• 0.215 Fo •
- 15.0
u;,ooo-v'l3/D. 2
!he follo~~ng demonstrates che use - 15,878
of the Soud Work lndex Method to
determine the power required to Fo 1s leas than F, so
produce the des1red grind, After apply EF4.
the griudiug power has beeu deter-
minad by chis or other methods, 15 :+' (13.2-7) es ,ooo-! s, 878)
the !llill(s) that will draw elle. re-
quired power can be selected. For
final mill si:e recommendations
E.F4
-
• 1.06
15
15,878
(12 foot) diGmeter i~side shell c3pi:al cos~ than the one rod
cill ~wo ball mills all of 5.79 meter (19.0 foot) long
the same diamecer circuit. diaphragm (grate) ¿ischarge
ba.ll mills ....~ th .a 40:· by vo.l.-
3692 + 2 • 1846 HP ume hall charge.
w --y 117
175
117
"V2,100
4.88 x 1.25 • 6.1 meters
(20.0 feet)
• 6.29 kWh/s. ton Theref ore, use two 5 •. 03 meter
(16.5 foot) diamet er inside
Total: 1.52 + 6.29 shell 4.85 meter (15.9 foot)
diamete r inside new liners by
• 7.81 kWh/s. ton 6.1 meter (20.0 foot) long
overflo w ball mills w1 t.h a
7.81 X 1.102 X 1.341 X 500 40% by volume ball charge.
• 5766 HP, uncorre c:ed. The alterna te grate dischar ge
mill can be as follows : Re-
t!ficie ncy Factors : ferri~g to Table VIII for
sizing a grate dischar ge mill
tF¡ does aot apply. a 4.72 meter (15.5 foot.) dia-
meter by 4.57 meter (15.0
EF? does not anply, foot) grate dischar ge ball
mill with a 40% by mill vol-
tF3 Mills will be larger than ume ball charge, new shell
3.81 meter in· diamete r so liners and 65 mm (2.5") dia-
use 0.914. meter balls draws 2269 HP.
175 .. 53.7 2952 - 1.30
2269
F0 • 4,0001 /13/13, 2 • 3970
4.57 x 1.3 • 5.93 meters
F0 is less than F, so (19.5 feet)
apply E:F4.
Theref ore, use t~o 4.72 meter
53.7 + (11.7-7 ) (9,400- 3,970) (15.5 foot) d!amete r inside
EF4 .. ------------~~--~3~9~7;0~~ shell 4.54 meter (14.9 foot)
5 •7 diamete r inside new liners by
6.1 meter (20.0 foot) long
• 1.12 d!aphra gm (grate) dischar ge
ball m!ll w1 th a 40: by vol-
tFs, E:Fó, EF¡ and tFs do not apply. ume ball charge.
5766 X 1.12 X 0,914 • 5903 HP o. Ball M!ll: Follo•~ng Autoge -
nous or Se~i-Autogenous ?ri-
Use 2 ;nllls mary Mill
;:,;e-
Table Vl!I a 5.03 meter-( 16:5 lection is the
.' same as
above. lf ~be ball =~ll feed be done on samples .of the
size 1s d1fferent. from tiU.s, coarse material from the pr1-
the sama pr~edure as covered mary class1fier. ln this
by either.. s·ac:l;ion B or C case--, the ball ..111 feed rate
(wh1chever' fpplies) should be is· based upon :he amount o!
used to detenoine grínding eQarse ut.erial.. ·c:Ol%i::lg !rom
power, aod b-ül mill si :te se- the primary classif~er and
lec.tion. not on the feed :-¡,:te t,o the
circ:u.it.
The produc t from a .pri:ary
aucogenous mill or a semi- Tbe more tomGo~ circuit has
autogenous mill can have a the pr~ary mill product be-
d1fferent particle si.:e dis- !ng fed to the classifier
tribut!on than a produc~ ~ith used to close the ball mill
the same 80! passiug size circuit. In this case, use
made in a'- rod -mill or f!:ae the prilllary mill c1rcu1:: pro-
crushing cene c:rusher or in ducts for grindability tests
e rushing rolls and thus pos- and pr~ry mill feed ~ate as
sibly 1t could have a differ- the feed rate t.o t.lle ball
ent vorlt index. ln selecting · mill cireui t.
ball mills to grind primary
autogenous or semi-autogenous If samples from pilot plane
milla produc:t if primary mill tesu are not available 1t
product is available use a will be necessary to use sam-
sample of this for the grind- ples of the ore for gri.nd-
ability tests necessary to ability tests whieh may or
de:er.nine tha power required may not be .the same as the
for grindin& tiU.s prodÚc:t in product from the primary au-
a ball 111111! togenous or $emi-autoge~ous
tf good pilot pl«nt data is mill. In this case, the feed
available,·so that- an oper- rate to the ball mill is the
ating work index basad upon same as the feed rate to the
net power is available (see pri:ary mUl.
Eq ua tion 6) , t his can be usad
to determine ball mill E. Pebble M!.ll: (Secondary Au-
power. togenous) Red l'd.ll Pebble
Mill Circui t
Primary autogenous or semi-
aucogenous mill product can The cal~ulation for deter-
contain a si:teable quantity mining grinding power for
of ground material !iner tr~n Pebble milling (secondary au-
che de si red ball Íllill produc t togenous) ·cán be the same as
si:e. By feeding this to a for ball milling from rod
classification stage, chis mill product size to ·c.he .de-
· produc t size material is re- sired specified s~ze, ne- <
rei¡ui red =o d<!tenoine_ power down to. rod ,mill produé t. size
~-~····-~ ~-- ~-11 -~,,4~- --- '
F • 70,000 micrometers the controlling point.
P • 1,200 m!crometers Refer to Table x. The
w1 • 13.2 EFz factor is 1.2.
w - 10 X 13.2 - 10 X 13.2
i/ 1,2.00 'V7o,ooo
tF3 Because
smaller
balls will be
than 40 !li!D
(1.5") and other minor
• 3.31 kw~/s. ton factors neglect EF3 ua-
less mill diameter is
!be 1nefficiency factor to less than 2.44 meter
allow for the 1neffic1ent use (8.0') diameter inside
of power in wearing down from liners.
pebble size to rod mill pro-
duct size is 2.0. Feed rate EF4 does not apply.
for pebblas 30 mtph.
EFs Grind is 80 percent
3.31 X 2.0 X 1.102 X 1.341 X 30 passing 45 mic:.rometers.
• 294 HP
4039
45 + 10.3
l.l43 X 45 - 1.07
-43-
Table XII
.f· _w ' '• ••
125 (5.0") 18
llS (4.5") zz '2o
,
100 (4. o· l 10 , 23 20 1
90 (3.5") 14 20 27 "
,
20 . ,
75 (J. o· l 11 15. 21 33 31
..
65 (2.5"). 7 10 15 ,
21 39 34
.
,
50 (2.0") 9 12 17 26 30 66
TOTAL ~ct ,
100 lOO 100 lOO 100 100
1
Table XIII
Start-Up Equilibria Grinding Ball Cnarges, Percent Weighf
Make•Up
Balls Fed
Sizes,
MM s S 115 100. 90 75 65 so 40
4.5" 4.o· 3.5" 3.0" 2.5" 2.0" 1.:>-·
No. Average
Material 1
! Tests ! 1
1
.
Range
Aluminum Oxide
Basait
1
l
2
5
1 .86
.45
' .58
.19
-- !.14
.83
eauxi:e i 11 1 .02 .003 - .12
Seryll i um Ore
Cement Cl i nker-
i1
1
2
15 .
.45
.08
.~5 -
.009 - .17
.,é,S
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f¡ ~ ---
1- dl1 /.11
-i¡_=- -f.:(I+C.)/C. i
• 1
Si se. =~.., los sj ¡.or sJ =- sj ~ ~.rol"~
1
k.. Cor'l S es 1den hu
1 J
¡;o.ra.. 't' = 'LQ.l'l\e ri o r /14.. 1 u de. u ..-
Q~ _ k..vJ
__:,__
U-t c..) TCln~~fioí
. AS: 1 M- e.v~ k, ~ ~ ~ ~ .uAa.Jt...
W no te~ t.Ot'IOu.d.o J
~i.
-,+-
1+
1i
c.
t .f;.
e 't'
Jp¿
e
o S-Go.
~-i + c.. f~ : e f¡ 1 f'i
1..
1 '
. .
t; J
k ,_,
f~ e ~ cli3 Aj [ ~~ -t
1 fi ] =- clú A¿~;.+ eJ.¿~ 4i 'ft + ;, ~iJ ~l [ ~i.¡
1- d"
l.l ,.,_
A •
ti = f: fe
'L~ ~ l '}i. + e .fA. ) 1( t+ e)
-f,: ,. l ')\ + e f i) A~ / c.
<
./
(1-C}
1 1AL 1.;.
~¡. ,.¡
~ ~.i.
·.t
e "t ... e .
1
. '
C.:.
1- e,
• 9t
~r.
. 1 e, ~·/..
s.
c.,+Cz
.¡:./..
. Ct+C2
Pi t 1
ti.. t
c2.
1.-
r~ .~ L. t:l¡j fj.
. , -=.¡ ' ' :
i,J,.o~, d. rAe.b..-po..wt.""eh-.,
. la:.s ew.-~ne~ ~e.c.e~~es
i-1
f:: .d!i A,¡ <Ú + j~ [
~u A,j~J -t A:1j .pj]
1- d¡¡ A.'l.Í
11\
1
L
.
A1 . et.
4. ~ ~
l:.t
Wl
.
)
c:l. ::: !- Ct7- A,¡_ ~t]
.1.:;1
ti-¡~ : 1 )
l. ;.l J 'l'l =9 c. \rcui+-o t.e. rra.do d.w.Jó
.~-~:
~ VIVIWO Y.) ~ ~ 5<.- S j MO ~ p.- C.fAO >
: .
1
! ~"<r>.
. • ~
"
.~. ~ e...f-....:~~ de- .....,litnd,v ~
~
• •
JMJ..,;,
~t.f..o.J.,
•
'
.M.~ tiJ. ~
. i
.k. .lk~ d..tJL m.o\í ... o 1 entonce~ \¡;¡_ Md.xi"'\o.. capaci.dai.l. o~ o..·
' .
'\o. ~ÍI'Y\0... ~ ci.M:·~olol'lte_ trv.,.o:.tocfcJ.tc.. o.- -1-tcwi, h l ""<>lino • No
,obskllte. _, \a.. sol.,re.co..rc¡c.,.., d.d '"'-<>¡¡.,o oi~fi"'Í>'~v~e. lo.. e{-¡c,ien«AA,; ¡>of ~'""ito se
'he.c:esi k v .... ~~.- le.¡ 9.-"e. rela.Aone. \') ..\.unel ~(.. dt.. u.li..trte>\t o.~;, ¡:: ~., e 1
"iuel ~ tG\M}""" il<\1-e.rno.. W k >W(te_,:~. 5e.<:J~" Ausl·il'\ :
Aie"d.o w, 1 ~. ,tJc..-e& tcr.cc.c:.d.os lu ,_,¡..¡ .... ~ ) v"a... <c><d...~
e.N\
. ~
-Lp. ~~ o..t ! ~ a- ~ .AAl~ w.tlNt~ ~ ~
.o- ~ ~~S a.. "X.~ j ¡¡;_ e,l. tf4'1> dL. WO.~ d..t.,.
~ "-<>. (') tcn~iSten\-e. t-oo'\ &.. ~9 k ~ d...t.. r-otL...ct:,)
o~ ro~ ó..t.. c..onver~~c.t ....
•
i
. i
1 1
·•
'
'
CAPITULO 3
FRACTURA S Y B
DETERMINACION DE LAS FUNCIONES DE
--.-.
31
e S 16x:Ztl•O.S06 min.·'
Á S 40xso-o. :!?o min;'
T S 140x:ZOD-O.OSS m,in:'
• S4x6-<l. 06í min: 1
o ----------
¡o-2~ 5
~~~-- :zo ~----~25
---------~
10 -----15
TIEMPO DE MOLIENDA, minutos
,.
B. 1 "
log[(1-P;(0 ))/(1-P;(t} )J
i> 1, Método BII ( 3. 3)
log[(l-Pz(0 ))/(1-Pz(t) )) ·
log((1-P;(0 ))/(1-Pi(t)) )
B; . = -~~-~~~~--:--:-,-::-- i> 1 (3.3a)
,J log[(l-Pj+1 (0))/(1-Pj+ l(t))]
donde 4> es 1a inter cepc ión que se mues tra en 1ión.a Figur a 3. 3 y r es
Como r y $ son
la pend iente de la parte fina de la distr ibuc del lado derec:lo1 de
estim ados desde el diagr ama, el últim o térmi no r de s.
la ecuac ión{3 .4) se calcu la y grafi ca para dar el valo
1.0 1
--¡
1 1 1 1
1 ' ' 1 '
-=.... -
...-.<..•
-...
A
:S
g
-...A
¡:¡ A
< ~
~
¡:
u o. 1 e - 1
~
... -e
o
...J
...!
=
""' 1
i...
ii!
-o
e
T § ~
J
~
~
Q
o e 1.20 0.59 =
w
J
E
o
A
o
1.22
1.27
0.60
0.58
4
4
- 1
0.01 1 r r 1 1 1 1 1 1 1
;;
o.::
-..... o.:
Q
>
<
::::!
~
u
1!
<
J
INTERVALO DE TAMÁÑO 1
J
MALtAS
AL i2 X 14 !
e:o x zs
.45 X 50
T~ O::J x i20
14 13 12 11 10 9 8 5 4 3 2 1
19 18 i7 16 15
INTERVALO OE TAMAÑO
er de
FiG. 3.3. Va-lores exper iment ales de la funci ón B para clink
cemento del tipo II, para vario s tamañ os de alime ntaci ón.
1.0 - - - - - - - - - - - . . . . - - - - - - - - - - - - -
•• c.: 1-
ca
...
z -
-...!....
u
¡¡
-
1:!
z c.:z 1-
--
C.l
100 :eo 1CCO :c:-o
TAMAÑO (LIMITE SUPERIOR DEL INTERVALO 12), ~m
que intro duce el parám etro adici onal ii. Para valor es de S que pasan
por un máximo con respe cto al tamaño:
a
S¡ • A(x; /x¡) Q;
por la distr ibuc ión
donde los facto res de corre cción Q; son desc ritos
logís tica de dos parám etros :
1
Oi = A
l+(x; /u)
i-1
t i=j
k•l
i >1
i -1
1 i >j
¡; Skbik akj
·• S;-Sj k=j
suficie nte tomar ~j"LO para los valores mayores de j (tamaño x;
•
más pequeñ os).
Hasta la fecha, cada vez oue heinos -ejecut ado una extens ión
cuidado sa de las distrib ucione s granul ométri cas, para la moliendoa
de primer orden, hasta tamaños menores a los de tamizad o, teniend
en cuenta las d~-:"erencias de factore s de forma, hemos conclu ido que
los resulta dos están de acuerdo· con las predic ciones obteni das· de
la extens ión de las funcion es de potenc ia .de los paráme tros S y 8
a tamaños menores.-
F.n genera l, si la forma de la distrib ución granulo métrica cambia
en el tamaño, o cerca del tamaño en el cual se cambia de método s
de anális is granul ométri co, el cambio de inclina ción debe ser
conside rado como sospech oso.
SSQ con ó"O media nte el test F para comprobar si la ística adició n oe
varia ble 6 proou jo un mejor amien to estao ment e
la
signi ficati vo. Si este no fuese el caso se hace ó=O.
se encue ntre
(3) Se elige una alime ntació n de tamaño mayor tal loquemenos a cuatr o
a la derec ha del máximo de S y se muele por
tiemp os, produ ciend o cuatr o distri bucio nes granu lomét ricas.
s, junto a
(4) Los valor es de CL, s. y y ó, previa mente determ inado utiliz an
t¡ y A, todos escal ados para el nuevo monotamaño, si búsqueda
como datos fijos en el programa de retro •cálc ulo y la
se hace solamente por u y A.
duran te
La posib l idad de ajust ar uno o más de los parámetros mante
te ner
1a búsqueda ha demostrado ser muy va 1iosa porqu e: (a) permi forma ·preci sa
en su valor corre cto aquel las varia bles que se conocen en bilida d de
de la exper iment ación ; (b) permi te inves tigar laos sensi
centr o 1aaos de
cua 1quier a de 1os parám etros en funció n de cambi
para los tamaños
otros parám etros. En parti cular , los valor es de B;j 1es, de modo que
mayores pueden ser difer entes de 1os va 1ores norma valor es de B;j
es conve niente sumi nistra r una matri z conoc ida de
para determ inar buenos valor es para u y A. Se debe hacer notar
cualq uier
que este programa impone una ley de prime r orden sobre to del primero
resul tado que provenga de una cinét ica de orden distin y A son va 1ores
obten ido con tamaños mayores, de modo ta 1 que u de r orden .
promedio efect ivos que se basan en una cinét ica los prime result ados no
No es novedad por lo tanto , que simul acion es de los valor es
pueden repro ducir muy exact amen te, en este caso,1a fractu ra de
exper iment a 1es para 1a molienda disco ntinu a, porque . Sin embargo,
los tamaños mayores no es neces ariam ente de prime r orden es de molinos
el uso subse cuent e de los parám etros para simul acion o tiene una
conti nuos, donde la alime ntació n que entra al molinfracc iones ae
distri bució n granu lomét rica comp leta, con pequeñas
tamaños mayores, ha demostrado ser basta nte exito sa.
de
También se· debe notar que el programa de retro -cálc uloente
íficam
S y B para la molienda disco ntinu a está diseñ adoun espec monotamafio de
para opera r con datos de ensay os que util í·zan
alime ntació n. Cuando se aplic a a datos con una ampli a distri bució n
oranu lomét rica exis'Ce normalmente demasiado error B, exper iment al para
esper ar obten er valor es corre ctos de los parám etros .porque enton ces
se hace
el cambio de la distri bució n granu lomét rica con el tiempo
insen sible a los valor es de y.
DE
3.4. RETRD-CALCULO DE LOS PARAMETROS DE FRACTURA DESDE DATOS
MOLIENDA CONTINUA
El modelo oenera l
U;.} 2 d ( 4 • 1)
j
• o (4. 2)
( 4. 3)
ga de bolas en el molino :
( 4. 4)
f
~~B
Reemp lazand o (4.1) a (4.4) en la ecuac i6n de
( 4. 6)
N(d,z} • v
8 !.t)~(d,.t)
(4.7)
lfl¡ld, .t)d(d) y $ 0 (d,.t)d (d) son los nümer os de bolas con ta-
maño entre d y d+d(d} que entran y salen de la carga de b~
las por unidad de tiemp o, respec tivam ente. ,g(d) es la velo
cidad de desga ste de una bola de di~metro d.
La ecuaci6n (4.9) representa una forma general del bala~
$z (d,.tl y. $o (d,.tl.
dependencia no es significativa.
, {4.1 0)
( 4 .12)
(4.1 3)
dw!d l .. 1 pnd 2g(d l
d.t 'f
obti ene :
Igua land o las ecua cion es (4.1 0) y {4.1 3) se
( 4 .14)
p
.ag,ao
"5
c.
"70
~60
o.o
"'so
"'O
-...
E
~-'0
:~30
o
o 30 -'0 so 60 70 80 90 100
Tiempo de opt>ración t. días
la di.sm inu-
En el caso de solic itaci ones de i!npá cto puro ,
dwid ) (4.15 )
d.t "
cto,
dond e 11. es la cons tante ciné tica de desg aste por impa
1
ro del moli -
la cual depe nde de.l a fluid ez de la pulp a dent
de velo ci-
no, tama ño y dens idad de las bola s, porc enta je
las bola s
dad criti ca de giro del moli no Y,.re siste ncia de
isotr 6oic o
C) Corr osió n-ero sión pura en bola s ccn desc aste
nuev amen te
En el caso de corr osió n-er osió n el desg aste es
de las bola s .
un proc eso que- sólo comp rome te a la supe r:!:ic ie
•
No obsta nte 1 se di~erencia de la abras ión pura en que la
consta nte cinét ica de desca ste 11. es ahora una funció n de
- c.
_, las condi ciones electroqu~micas del medio ; en efecto , la
raday :
M,,.!
dw 1d) = " e a ( d) = k a(d) (4.17)
e
Z+ + ·~ 2 e
Fe. = Fe.
-re 2 + + ZOH = Fe.{OH1~
se ob tie ne ;
Co mb ina ndo (4. 17} con (4. 13}
)
(4. 18 )
g (d ). d[d •a e'· a e
ar
era ció n, (4. 18 ) es for ma lm en-
Pa ra co nd ici on es da da s de op
ere nc ia rad ica en qu e no rm al-
te idé nti ca a (4. 14 }. La dif
s
nd en cia de ~e con las va ria ble
me nte lae! >> laAl· La de pe
o-
tes , ob ede ce a mo del os ele ctr
ind ep en die nte s señ ala da s an
lec ido s De bid o al ro l
qu im ico s cin éti co s bie n est ab
en
n en los con sum os de ace ro
pre po nd era nte . de la co rro sió
ien tem en te se ha ini cia do el
mo lie nd a hdmeda de me nas , rec
tra
for ma sep ara da al pre sen te
est ud io de es te fen 6m eno en
de ex plo rár alt ern ati va s de
ba jo y con el pro pó sit o fin al
ctr oq u!m ica .
pro tec ció n ·a la co rro sió n ele
(4.1 9)
:g(d ) • aA (d)
- Abr asió n pur a
(4.2 0)
- Imp acto pur o
(4.2 1)
- Cor ros i6n -ero si6 n pur a :g[ dl = ac( dl
las rel a-
Del tra baj o d~var ios aut ore s,se des pren Úd que
nta das por func J.on e;;
ció nes dt d) pue den se:r .cie n :rep rese
(4.2 2)
U' S.
9 ( d) • ¡; a.·d j (4.23)
]
jd
partic ulas.
~~r--.-----r---------r---------~--~_,
~
DESCARGA
...,
-"
"E' o
C!
.:! ALIMENTACION
"
o;
...
o
C!
.~50
Vl
•C!
E
1 2 3
Diámetro de bolas d , pulgadas
FIG. 4.2. Distribuc iones de tamaño de bolas de alimenta-
ción y descarga. Melino Marcy de 12.5' x 16';
0.75 pulgadas abertura nominal de la parrilla
de descarga;
s al rnol::".no
Segti.-"1 lo ex;lU esto, el fluj o de en'::. rada de bo2.a
lsos en los
pued e represen~arse por una s~~a de va~ios i~pu
1, 2,. ~.,K y ap~c:c:.ma_é.a!Thent.e ::.ndepenC.:i.er::~e
....
... aman es
~ ,J
~.~.k., k. s
de lle-
ge!"le!:'a t:...'"':L -:::a nsie nte en el pe::: !i.l de tama fio y r:ive l
renc: ::a en-
nado de bola s, cuya mag nitud depe nde de la c::::e
i~icial y el es~a~o es~acio~a=io
t=e el es~a~o esta cion ario
O?e=aci6~ eleg ido. Seg~~
fina l cor= espo nCie nte al modo Ce
lo an te:ri or, el fluj o ~.(d,z) de entr ada de bola s es:
J.
K 1 (4.2- 'l
~j(d,:t) ~r l:: m 0 ( d) o(d- d" )
k.= 1 ¡.;.
(4. 25)
o!d- d.l
1<
=o para d 1 d¡z
+oo
_..,
en la form a:
(4. 27)
sal ida ,
es el fluj o num éric o de bcl as a la
(t)
don de 0 ~
te de bol as
Form a exp líci ta del mod elo de des cas
Intr odu cien do (4.2 4) y (4.2 7) en (4.9 ) se obt ien e una for -
de bol as:
ma man ejab le del mod elo de des gas te
K 1
aN! d,tl a
~ {N( d,t) g{d )} = 4> ¿ m (dlé (d-d }-4> m~(d)éi(d-d)
o
aZ + r k.= 1 o k. o
(4.2 8)
(4. 30)
n ea l y de
nc ia l en de ri va da s pa rc ia le s li
ec ua ci 6n di fe re ta po r
a pu ed e se r fo rm al m en te res~el '
st
pr im er or de n. E ís ti co
an ge E l si st em a ca ra ct er
el m ét od o de La gr
de {4 . 33 ) es :
[ 4. 33 )
d;t d( d) dN (d ,.t l
- - #
S
T a.
nc ia le s
de 2 ec ua ci on es di fe re
siste~
qu e co ns ti tu ye un ec ua
y de pr im er or de n. La pr im er a
al es
or di na ri as , li ne
ci 6n es :
( 4. 34 )
d! d)
-- ;u : = a.
tá da da po r:
cu ya so lu ci 6n es
(4 .3 5)
:
6n de l si st em a es
La se gu nd a ec ua ci
K. ( 4. 36 )
dN [d ,t]
d( dj • -ll
!
k= 1
to m a la fo rm a. :
qu e al in te gr ar la
K. ( 4. 3 7)
-a.
___- '!"-
,
donde U es la funci ón escal ón defin ida por:
.-~
. {; d > dk.
;,.(_
U(d-d¡¿l ( 4. 3 8)
;,.(_ d < dk
(4.39 )
es decir :
4>r
a ( 4. 40)
4>¡ K r
i {d-a.t) " l: m 0 (d~)U{d-at-d~)-N (d-a.t )
0 ( 4. 42 )
(ll, k= 1 " "
siendo:
<1>1
N(d,:C} • No(d-a:C] +--
a
Soluci6 n aenera l
(4.45)
dN(d,:C)
(4.46)
1 ' dar d)
~
1 k=l: 1m0 (d)ó(d- dk)-N( d,.t) d(d)
/ ./ '!
d ( dl • g(d) ( 4. 4 7)
dT"
( 4 • 4 8)
dld) ( 4. 49)
.9 ( d)
(4.50)
( 4. 51)
-,."1'-·
Si se aplic a la cond ici6n inic ial (4.29 ) a la ecua
ci6n
(4.5~), ento nces :
-<
6{fd (d) }
grar ( 4 • 5 2)
Llam ando n al argum ento de 6, ento nces ~sta func i6n tiene
la form a:
( 4. 53)
de dond e:
K 1
t Crt-.tl .. ~r l: mo (dk)U (d{n -t)-d k1-N 0 ldln- .tl )_g (d(n -t) J (4.54 )
k= 1
dond e:
( 4. S 6)
•
La ecua ci6n (4.5 6) es la solu ción gene ral
de la ecua ción
de bala nce pob laci onal . La form a exp l!ci ta
de la solu ci6n '
depe nde sola men te de la form a func iona l de
g(d) . Si ésta
es del tipo (4.2 2), se dist ingu e 2 caso s de
inte rés: ciné
tica de orde n S =
1 y ciné tica de orde n S ~ l.
1.tn .d-: t
a
.. (4 .57)
lueg o:
n • .!..
a
.e.n d
( 4. 58)
Adem ás:
Intro duci endo (4.6 O), (4.6. 1) y (4.6 2) en (4.5 6) se obti ene:
(4. 6 3)
-- donde:
--
' U(d exp{-a.:t}-dl<.) =
{; ,6.(.
,6.(.
d exp {-a.:t} >
d exp {-a.:t} <
dk
dk
( 4 • 6 4)
d1-B
a(l-S)- .:t = C¡ ( 4. 6 5)
luego:
d1- B
n "' ( 4. 6 6)
a!1-Sl
1
1-S
d!nl • [o:(I-B) n] (4.67)
1
d(n-.t) • [dl-S- a{1-S).t JH (4.68)
Además:
8
1-S
g(d(n-.:tll -a{l-S).:t J (4.69)
(4.70)
Reempla zando (4.6B), (4.69) y (4.70) en (4.56) se obtiene :
1 G -v
1
N,[d,.t}. , No![d - 5 -a!1-B). t f-=6) [7-a(J-B ld-{T-Bl .t]J-"8
(4. 71)
donde:
U { [ d 1- B-a ( 7- S J.,t
)'í-6- d¡¿} .,
(4.72)
se define como:
y,(d,.t) • ( 4 • 7 3)
1
3
d N(d,.t}d( d}
Jdo
y la func i6n dist ribu ci6n más ica Yl( d,t) :
(d z 3Ntz ,.t) dz
J d
o
( 4. 7 4)
Para eva luar y.(d ,t], Yl(d ,t) se debe exp lici tar la dis-
trib uci6 n inic ial N0 (d] de tama ño de bola
s en las exp resi o-
nes deri vad as ante s para N(d ,.t). Se dist ingu e 2 situ acio -
nes ffsi cas de inte rés: a) un mol ino que
ha oper ado por un
larg o peri odo bajo una cier ta con dici 6n
de reca rga de bo-
las y que se dese a cam biar por otra con
dici 6n y b) un mol i-
no que reci én inic ia su ope raci 6n. En
el prim er caso No (d)
deb iera corr espo nde r apro xim adam ente a
la dist ribu ci6n es-
taci ona ria bajo la con dici 6n ante rior
de reca rga de bola s y
en el segu ndo caso , la dist ribu ci6n inic
ial norm alme nte se
calc ula en base a una dist ribu ci6n de
tama ño de bola s en
esta do esta cion ario . En con secu enci a,
los 2 caso s de in-
teré s cond ucen a repr esen tar la dist ribU
ci6n inic ial No(d ]
por una dist ribu ci6n de esta do esta cion
ario .
dond e el. sub! ndic e 1 deno ta el cicl o prev io que orig in6
la carg a inic ial de bola s. La form a func iona l
de N0 de-
pend e del orde n ciné tico S 1 • Se dist ingu e dos
alte rna ti•
vas:
1) Orde n cin~tico 61 • 1
(4. 76)
,.·
Para el caso part icul ar B 1 = O la ecua ci6n (4. 7 7) se redu -
ce a:
! f
(4.7 8}
~I K 1 r · [
--- ¡; d- mofd .. ) U(d
a. k=l (4. 79)
"
Se debe eva luar :
(d
3
J z N(z ,t.)d z
do
3
(dk exp{ cxt.J J ]urd -dk
(4.8 1)
ao
i'•r•.•r•r•r •
(4.82)
Luego:
!13 (d,.t)
(4.83)
Además:
Ysld,.t) .. [ <~>¡ 1 ~~ m! 1
3
{d,_H[d 3-!d,_ exp{a 1 .t}! ]urd-d,_e.xp{a¡.t}i-
alf<.~l "' "' "'
[d 3-d03] } - a<1>¡ K 1
k.;lmo!dk.){
[3d -(dk. exp{a.t}l
3) U(d-dk.e.xp{a.t}
)- [á 3 ·dnU(d-d,_)}]![ ~ ~ 1
mt 1 (d~..}{d 3 -{dke.xp{al.t}J 3
K Cl¡k_:J K 0 J<.
I K 1 3 - ]]
} - --a¡¿,
<1>
t
l
m0 (d,_ldk
"-·
l1-exp{3a.t} (4. 84) _t-'
En el estado estacionario :
1(
-- t m~(dk)3d 2 [utd-dkl-1]
·- y~s ¡ dl "
k= 1
K (4. 85)
-e<
t m! (df¿ ) [ d 3 -dk 3]
0
k= 1
K
t
k= 1 (4.86)
N(d,.t)
Se debe evaluar:
1
~-"a"
ut[d 1'-a -a{l -SJ. t] -dk.f }
(4.8 9)
dl
j
d
e
d 3 Nld, .t)d( d)
K 1 1 1-S+
I: mo ( d~) ..,...-¡¡ - {(d k.
ak.= 1 "·"- "
(4. 90)
Lueg o:
!h (d,.t ]
.....
~r K
- r {4.91)
a k:l
y también:
4> K¡
y3 [d,.t ) a [ -
1 1 .... m1¡.
a 1 k= 1
r-s1
o 1dk ) 7
-
{ (d4- fl 1 - ( d «~ 1-S 1 +cq ( 1 -13¡ ) .t¡,
7
-r:a;-
-a¡{I-B¡)~ -
41 I K
-
a
1
r mo ( d,_)
k~J "-
4-B
+a ( 1 - B ) .t)
n ] U{
(4.92)
y en el estado estaciona rio:
...
-
~ m!
k•1 .
3
(d .. l (4-S)d - 8 [u(d-d .. J-7]
... 1<.
(4.93)
[/~s
0
-d -a.L
4 ; m!
(dkl 4 [d -~-dk ·sJ
4 u (d-dkj
ySS ( d) =_ .,......_ _ __.:::k.:.•:_1- - - - - - - - - - - (4.94)
3 I: m! (dk) [do 4-13 - dk 4-¡¡]
k• 1 .
~h Kl
I:
k•1 _ _ _ _ _ _ _ _ _ __
a¡_,.;;:...:_
IJs ( d, .t) • _
~ 1
.J..l. i:
a 1 k• 1
(4.95)
Además:
-,
(4. 96)
SS ( d) • (4. 97)
!j3
y~ S [ d) ( 4 :9 S l
(4.99)
K
np~!
Wss
1 4 a 4 6
"' [d J {d -"-d. - } (4.100)
B " 6o. [4-6) " m~ k 0 "
k•J
de donde:
6cr(4-6) W~S
(4 .101)
"
<d 4-6_ d 4-S}
• o k
Consumo de acero
·----
{A) Consu.'l\o de acero por ees9aste de bolas, Cv (.t)
1
l..
cv C.tr d+od
Es decir:
d¡ w ( d¡)
do W(d )
o
d¡
.. -f Hld,<)g[d)~d,d[d) (4.103)
do
En este caso N(d,.t) está dada por (4.79) y g(d) ?Or (4.22)
grando se obtien e:
(4.104)
(4.105)
ss :
CV ·wss a
-;, B
(4.106)
2) Ci né tic a de ord en 8J , S_i__!.
1
.¡.ex t 1 -e J t] J -e J 3} (4. 107 )
(4. 108 )
En el
(4. 109 )
qu e ll1 = B= O, se ti en e:
ul ar
En el ca so pa rt ic
(4 .1 10 )
y tambi~n:
(4 .Í ll )
(4 .1 12 )
Css
o "
(B) Consumo de acero por purga de bolas , C
0 (~)
n
Como él mode lo supon e que todas las bolas purga das tiene
un tamañ o d0 , enton ces:
í:i
o
Se distingu e nuevame nte 2 casos de interés segün la ciné-
tica de desgast e.
aN(d,.tl
a.t
(4.116)
(4.117)
En régime n
,,Í.l- 8 1
cN(d,. tJ u \ 1e a -
d.t
1
., r::e¡
et 1 [1- S 1 ) .tj
(4.120 )
( 4 .121)
1
,¡-:-¡¡
cdl-B).:tj -dkl}
(4.122)
. -!·
1-'
"' '-1 1
y en estado estacionario :
(4.123)
•
aN 1d, ..t) K
: +t. I m!ld.l6ld-a.. t-d.l
'11.=1 "' <C
(4.124)
J.. demás:
¡;p~T~· K¡
eP l..t l = -6,--:..:.. ¡;
k=7
ITp ~! K 7 ~
...'" méld.)d"l!(d -a .:t-dk)
r~ O
(4 .. 125)
6 h=l O
(<:.126)
y en estado estacionario:
K r 3 d3
¡ m0 (dk.ld o
SS
.. k.~ 1 o 4w~sa: (4.127)
Cp 4W~Set = K r
I m 0 (dk. ) {d o -d~}
4
· I m~(d }{d 4-d 4 } 11.-1 r.
11.= 1 11. o 11.
(4.128}
w (.d¡) .
CT - !-t) = N(d ,.t)c(d )w[d )- N(d,:t)g (d] dw(d) (4.J.30)
'01 o - o o
l
w[d
0
)
d¡ '
de donde:
'-J(dl'.t)9(d¡)
do
N(d ,.t)9(d )
0 0
entonces:
, dl 'dl
d(d) (4.133)
se obtiene:
*-:
(4.13 4)
(4.13 5)
(4.13 6}
; . . ... -- .
y en régimen estacionario:
(4.137)
CTOT (.t) e
m! {dkl {d!-{dk.+a.t)
3
+d~U(d 0 -a..:t-dk)}
( 4 .138)
!: m~ ( dk) { d~- dk4 }
k:1
SS (4.139)
cror ..
,. ~-·-·-·· :- ·. "-
1
l
" (4.14 0)
E:; posib le escri bir las ecuac iones funda ment ales del mode
lo
en expre sione s indep endie ntes del orden cinét ico del des-
gaste . Para ello basta defin ir la funci 6n:
d • u:p{:: a ..t} para s.= 1
.{. J j
z .(d.:, ±.t)" (4.14 1)
B.! 1
[d.{.1-a:
. ·, ...]1-r
j±r:t.· ¡ 1-13·-<- j para S· 1 1
J j J
y tambi én:
(4.14 3)
ll
Enton ces las ecuac iones funda menta les del mode lo queda n como
sigue :
(4.144)
(4.146)
,,.,. ... --
,,,,
,,
¡.
(4.147)
(4.149)
(4.150)
':':'·
'
--~
b) caso estacionario '
(4.151}
(4.152)
(4~153)
~'
ss
CV (4.1S4l
•
(4.155)
J.MENAC HO
(Chile)
Miningan d Metallur¡¡ical Research Center. CIMM, Cosilla 170. Correo 10, Santiago
arul F. CONCHA
Concepci ón (Chile)
Departme nt of Metallur¡¡ical Engi11uring, University of Concepción, CasiUo 53-C,
(Receiyed Nooembe r 6, 1985)
¡~e'<>' ["o•o,,~,,~r<c~ 1
C!oos [18]. Balls of white iron with a· Ll !II'I'J9lh. <j•c"f1r\;n, i
martensitic matrix oí low hardness and a
small amount of chromium carbides of high
hardness show higher resistance to wear than
balls of greater mean hardness: the hard phase
reduces the abrasive action and protect.~ the
matrix, while the matríx maintains the
carbides at the surface.
In wet grindi.ng, the redox potential of the
pu!p is also of primary importance . The Fíg. L Ba.l! wear represented as a particul&tf! rate-
formation of surface oxides of low adherence process [ 28 J.
increases the wear rate by a corrosion-·
erosion mechanism (19, 20).
Simulations of bala1·1ced ball charge, possibly the type and rate of ore processed.
starting from the hall make-up orocedure, The input to the reactor is the make-up of
have been reported by Bond [12. 21]. Bartol balls and the output is the purge through the
[22, 23]. Azzaroni [24, 25], Lorenzetti [8) discharge grate. Finally, there. is rnmetial
. _,
and more recently by Austin et al. [26, 27] transport through the reactor and the abra:
and Vermeulen and Howat [ 14]. sion of balls tPpresf:nts the reaction.
In their analysis, Bartol [22, 23], Azzaroni Ball wear is a very simple case of a popula-
[ 24. 25] and Lorenzeiti f 8] assumed im- tion balance. With respect to the balls. the
plicitly that, with regard to hall wear, the mil! will be considered a fuEy mixed contínu·
grinding process may be consídered as batch ous reactor wherf' steel is lost from the balls
between two tim~s of ball addltion. Their ball by wear and where no fracture of balls takes
size distríbution is valid for each batch, place. Therefore, a model hased on the spa~e
eventually reaching to a pseudo-stea dy state. avéraged population.balanc~ ,will b.~ sought.
On Lhe ot.her hand, Bond [12, 21], Austin
et al. [26, 27] and Vermeulen and Howat SpQce-auerogeti population b!llance .
r14] u sed a shell balance type of approach, , The population balancE' is based on the
restricting their analysis to the steady stat~ definition,o f a, phase §pace with three spatjal
from the beginnmg. co-ordinate s and a fíniW number of intcma.l
In spite of the extensive researeh work co-ordinate s {29, 30]. The former fU:, .lht>
that has been done on this sub¡ect, the fact ís particle position and the lat.t.er thejr charac-
that no complete picture of the field exists. teristic properties. Defjpjng a -~Ur-JÚk:r. den.sity
Jt is the purpose o.f this work to formulate a function ¡/J of the particulate- system, thf:
general theory of ball wear. establishing a space-avera ged population balance may he
phenomeno logical model, and to analyse th•• written in the form ¡ 31. 32}
solution of this model witb a constitutivE>
equation of zero-order ball wear. A later a , - ·.. ¡;;;,,¡,, - .
- -Qo¡j;.o
ilr {Vl/J).~
paper will discuss other constitutiv e equa-
tions.
J a ( .· ct~, ·
-" ~ -¡:- VJ -· ) + vñ (l)
jo.] a,¡ . dt .
GE:VERAL THEOR Y OF BALL WEAR
where Ji d!; is the number ot particles in the
The behavior of the balls m a tumbling mill systenl, pef unit volume, with inte;mal co-
conforms to thE> general description · of a ordinates between ~ and :~ -+ d~. v. is _th~
partículate rate process [ 28]. The bali mil! active volume of the-pa_rt.ieU.late-system. Q j~
may be regarded as a reactor charáct~rized hy the volumetric fhnv througi·; Lht.• in1et or
its Jength~ diarneter and oth('r geomctrical _out!et of \l, R d~ is the net rat~of g-enf'ration
factors su eh as lifter design and type of dis- of partides per tlnit volume and thP subscripb
charge. The operating condit:ions are repre- l and O indkate mlet or outkL
sented prineipaliy by the fraction of baU For the ball charge in a tum bl\ng miJL Wt>.
fílling, the fractwn <Jf eritical speed and will ,conslder on,]y one int:ema:Oqv~ordin<?r,~.
-----~-,.,., ----
89
so~
-~
E
assume no fracture of balls in the mill, that is, ,:
SA~~
f'f._CC __¡
R ~ O. Define the new variables. ~
u
z 1 ·'
V 1
f
"l
-1
"' 1
i ~
~
40
IJ>J(d, t) = Q,(t) ~,(d, t) "' '
"'"' 1
<f; 0 (d, t) = Q0 (t) ~o(d, tl "''>"' ~
~
20 .
g(d) =-
d(d)
g<O
¡;:
q
-'
w
t~~ ~ ~ ¡,1 ' !
dt <r
BALL OlAMETE R,
' C/254 rmmJ
(5)
..-,
+-
p
- -
number frequenc y !or the balls in the inflow hall fed to the mili.
90
1</>¡ "
) --'1'd 0 "-d)
" 3(d ,t=<
m + •
1 Ú¡
CX1 "= 1
19)
91
at stea dy state :
we obta in the mass dist ribu tion func tion
p
d.-'m~(d.)(d - d .. )U( d- d•)
4
4
(d 4 - d 0 ) - L (11)
k"" 1
Mf( d) =
4
(d, 4 -do l -
..
r ,d,- mi(d¡,)(d,
p
3 4
-á. ')
••
W8 (t} = J w(d )N(d , t) d(d)
do
d, that is
whe re w(d ) is the mass of a baJl of size
"o 6
whic h, afte r integ ratin g, beco mes
p 4
P,
L d.-' m1( d.)[ (d•- cd) - d,']
-(d.~o:,t) ]
4 4
2: d.-·'m~·(d,)[d 0
+ pfiq,, k=! (12)
w (t) = pfi<I>J, _._._,- - - - - · - - - - 24a p
B 24a 1 P, l Id )
-;;' d k···> m3-,
2: d_,- 3 m~•(d.) ~
k"' 1
k
k,.., 1
----
I anu uuc PVJ.~o;.:
from two cont ribu tíon s) the wea r l,wU
~H._. ..,.wv~~ ~·----
d~dw
Cw(tl =- f -N( d. t) d(d)
dt
do
d, dw d(d)
= -j - -N(d t) d(d)
dt '
do d(d)
TI
= -p zf dl ...
d"g(d)N (d, t) d(d)
(14)
do
Substit uting eqns. (7) and (10) in eqn. (14) and integra ting leads to
P,
3 3
~ d.- 3 m~•(d.)[(d• + <> 1 t) -d 0 ]
ew.(tl• = pnq,,,
6
:.•:.·:...'- - - - - - - - - - (15)
p,
~ a.,- 3 m1•<d•)
•• 1
iation:
The purge Cp{t) is given by al! the balls that enter the mil! minus the accumu
c.(t) = w(do) 1
r
f d,
</l(d) d(d)- fd,oN(d ' tl.d(d) l
l•o do ilt
yields
lntrodu cing eqns. (6). (7) and (lO) in the last equatio n and integra ting
(16)
CT(t) is obtaine d. At steady
By summin g eqns. (15) and (16), the total steel consum ption
state, cr is
pil<;f;,_ _
~=--.:.:;:.::.::.;
6 "'
.. ,p
1 (d Jt,)
~-; d ~e --3 m::.
W~',
or, in tenns of the ball hold-up
4cdl'ri
Ci!'= p
4
"'d Ir" 3 (d o4 -d k' lm 1 (d )
- 3. "
k"" 1
Q' \
~=4wr- i\ - 1
dl i
/ /. /,.
~'
d 0 = O, eqn. (11) yields 1
. d .•
-t •ool
(<.; 1
z 1
M!j'( d)=(- _l 2
;o:+
d, ' ICüllV€ 1 l
~ 1
For grate-discharge milis, the size distrib ution
~
!2 ' .,'
of balls does not confo rm to a Schuh mann
8
~
w
i _' C\JR\If. 1
'i
'
functi on, as can be seen in Fig. 7. ~
"'
"'
~
1
Steel consu mptio n
']
u
~- rJCt
•,¡¡,
" A,,rt
~v
J
(3 in) r~eharge. Curve 2 shows the change of bal!
~
6C~
quaiity from Cf = - Z. 226 X l 0-:: mm/b to o· :=:
"C
¡.
z¡_or¡ <.0 ~ -1.2:26 x 10-1 mm/h.
::>
~
!
z
o >C ~
¡::
u
z 1 !'
··o r ':¡ ~ sscir
¡;: '~ <v
z
9
6 r•· ~
J
i
~
::> "r i
~
1
.J!
"'ii .j
~
<!!
o 1
¡
."'""' i
(:';
' .ímml
BA!...L O!AMETER. d/254 -i
!
Fig. >t. Simula ted steady :;;tate ball size distrib ution
for differe nt chargin g proced ures. Curve 1, 100% :_¡ t~:-· os 1 ¡e ·&,:;
101.6 mm {4 in). Curve 2, 100% 76.2 mm (S in). ;ooys!
TIME,.'
Curve 3, 50%76 .2 mm (3 in), 00%50 .8 mm (2 .ín}.
Curve 4, 50% 76.2 mm (3 in). 50% 25.4 mm (1 ln). Fig. 6. Effect of an increas e of the baH fe-eC r-a.te on
theo steel consum ption in a hall mili (f/>/4> 1 "" L: 6 ).
Curve.! ), 50% í6.2 mm (.1 in), 50% 12.7 m_r,; (0.5 in).
Curve 4, 50% 76.2 mm (3 in). 50% 25.4 mm {1 in). t'Jg. b. 1::.nec1: o: an ;ru:n::tt...o:: v.~ ~""' ..,.,., •-..~.-.... ~ .......... .
Curve f>. 50% í6.2 mm (3 in}, 50% 12.7 mr,; (0.5 in). theo steel consum ption in a hall mili (f/>/4> 1 "" L: 6 ).
94
a= -2.22 6 X 10-' mm/h and a ball rechar ge three concen trators having thP operat íng data
of 50% 76.2 mm (3 in) and 50% 50.8 mm given in the Table.
(2 in). Chang es in make-u p hall size and hall
Figure 7 shows a compa rison betwee n
quality give similar transie nt respon se: steel simula ted size distrib ution using eqn. (11) and
consum ption decreases rapidly down to a the actual size distrib ution determ ined from
minim um value with a furthe r slower increase the three mills of the Table.
--- up to the new steady state condit ion. The
minim um (\(t) is related to a minim um
Taking into consid eration that eqn. (11)
has no adjusta ble param eter, the corres pon-
surface area of the whole charge of balls. dence of predic tions and measu remen t,
Figure 6 shows the effect of a 16% increase shown in Fig. 7, can be consid ered excell ent
in the hall flow rate to the mil!. A 55 t ball and it confirm s the validit y of the modeJ
hold-u p is expect ed under the new steady develo ped in this work.
state condit ion. The rate of change in CT(t) is Not only the zero-o rder rate for the wear
monot onical ly increasing in time and after is shown to be adequa te, but the assum ptions
143 days of operat ion the final steady state of a contin uous functio n for the hall chargi ng
is reache d. proces s and the impuls e in size type of this
functio n are also confirm ed. The shape of
the exit size distrib ution of balls from the mill
RESULTS AND DISCUSSION could be more accura tely model ed by intro-
ducing a classíf ication functio n for thE' balls
Model ualidation at the grate discha rge of the mil!. Todo thís,
The quality of the model develo ped in this more experi menta l data on the size distrib u-
work was tested by compa ring predic tions tion of the balls discha rged from mills are
with the model at steady state and actual necess ary.
industr ial ball size distrib utions obtain ed by
screen ing the entire ball charge of three
industr ial milis in three differe nt mining CONCLUSIONS
plants in Chile.
The three sets of industr ial data were ob- The presen t work al!owed the follow ing
tained from April 1982 to July 1984 from conclu sions to be drawn .
TABLE
Operati ng da~ of three eonef!n trators
--- --- --- --- --- --- --- --- --- --- --· -
mm/h
----------
---------·--
----~-------
95
~-
1
lOO lOO -~
1
100 - 90
90
~ 9(.
"'
90 "'
70 '~
"'
~
"(l
,·" í>C •
"' "'" r~
v-:..;""1
-
C>
50
tr¡
,,
SO-
"u:""\ "
"· ,:f ,:f
P.
:0
10
"'
a:
J>
10
''
·:E '~
~l
¡e, 7
"·v• '' . 5
":1 1
3 !_ 3
i
'r
: ; 7 "
~
'
91 o 1!'.> J
'
e • !' 9 \J., 11 ¡ 15 J 5
' 1 s ·.no 1,
" J
' 1 '
.SOLan
(7) Man y mark ed ball tests perf''orm ed to 1 T. K. Prentice. J. Che-m. Me! . .Mm . .Soc
:- --· ___ ,_ -~ #~:,.,.., .T .. ,... !lt).t~) 99.
19 M. J. Mey!end yke. l'. ,J. Moro1. and D. ·;;.'. Smiü1.
2 H. A. \l.ibíte, J. Chcm. Me t. Min. Soc. So¡¡th
Preprint 84·393 SMR/A.l. ME F'ol! Me,tir;;z, lJemwr
Africn. Jan.l19· 13) 116.
Colorado . U.S ..A. (1984) l.
;-~ W. I. Garms and J. L. StE'vens, Trans. AIME. 169
20 J. W. Ow("ns, Preprinr. 84-373 SME/Ai ME Foil
(1946'! 133.
Me-eting, Denver Cul<Jrado, U5.1L i) t,¡:. . -J.) J.
4 'f. E. Nomtan and C. M. Loeb, Mining 'Te-eh·
21 F. C. Bond,M in. En.g .. JO (1958j S!-1:1.
nology, AIME Tech. Pub. No. 2319 (1948) l.
22 J. R. Bartol, PrQC. ~?nd Symp. Ofi Grindm¡¡ ,
5 T. E. Norman and C. M. Loeb, Trans. AI.ME, Jf;:?
Armco Chile, S.A.MJ .. Conc~~pci(m (1977) 31.
(1949) 330.
6 D. E. Norquis t and J. E. Moeller, Trans. AIAfE. 23 J. R. Bartol, Proc. :tnd Symp_ on Gnndin¡ ;,
Armco Chile. S.A.MJ. , Conct~pciún (1977) )_g;,_;_
187(195 0)721.
7 H. E. Rose and R. M. E. Sullivan, A TN•atise on 24 E. Axzaron i, Proc. 2nd Symp. on GrindiNR,
Arm.;.-o Chile, S.A.M"!. , Concepe jón ', l ~¡·;·¡: 1 .113.
the Interna/ Mechoni cs of Ball, Tubf and Rod
Milis, ConsU\b le, Lond~m. J 957. 25 K Azzaron i, Proc. Srd Symp. on CJrit:rlmg,
Armco Chil€, S.A.M.L , Viñ<~ del M¡,~- ( 19'30)
8 J. J. Lorenze tti, Proc. 3rd S_vmp. m1 Grindin¡,•
Armco Chile, S.A.JIU. , Vina d•J Mar (1980) 237.
284. 26 L. G. Austin, R. R. Klimpe! and P. T Luc.kit;;,
9 E. W. Davis, Tran.s. AlME. 6 f (1919) !!50. Process Engin~?ering of Size Reductio r:: Bá!l
10 E. L. Longmo re, Trarts_ Jnst ..i\-!:n_ Mft., 46 M iliing, SME/ AIME, New Y t~ri-., 1984. PJ''- 4 J 1 ·
(1937) 562. 415.
11 B. S. Crocker, J. Chcm. Me t. M in. Soc. S<:>uth 27 L. G_ Austin and R. R. Klimpel, Powder Technoi. ,
A{rica, Feb. (1944) 133. 41 (1985) 279.
12 F. C. Bond. Tran.s. AIME', 153 (lfl43l 37~~-
28 K. V. Sast.ry and F. Concha, Proc. !nt Symp m
13 F. C. Bond, J. Chem. Me t. M in. S oc. South Afineral Processin g, 5. Populati on Balanc.P u•ith
Afríca, Jan (1944) 131. A.pplica tions in Mine>ral Proce-ssing, Cnlve:rf::it y <·f
14 L. A. Vermeul en and D. D. Howat, Mmtek Cont:epc ión, Chile, 1985, p. 5.
Report, M201 (1985) l. 29 H. Hulbert and S. Katz, Chem. Eng. Sci .. !9
15 O. C. Jacox and J. C. Farge, Proc. 18th Ann. ( 1964) 555.
Can{. Meta!lur gists, Sudbury , Ont.. Canadü, 30 .L Randolp h and M. Lar.son. 1'heory of J'articulcte.
1979. Processes, Ac.ademic Press, New York, 'Ui'71.
16 T. E. Norman, A. Solomon and D. V. Doant-!. 31 D. M. Himmelb 1au and F . .R. Bischo!'f, Frocesti
Anal_vsis and Simulaii on, D€termír .í:;ti..: Svs.tef'>¡;,
Trans. AFS. 67 (1959) 242.
17 T, E. Sorman , Jm.·ited Lectl.j.res, Technicr.¡_l llni· Wiley. New York, 1 ~68.
versity Santa Marí."l., Vífl.a del Mar, Novemb er :12 J. M. Mt-nacho , in F. J. Concha (ed.),Ba l! Wcar
1983. Modd ar.d Bal/ Si.ze Optmú::r :tüm in 'Tu.mbim g
18 U. Cloos, World Mining, October (1983'1 59. Mills, Advance s in Mi_r¡_ Proc .. 1 (19rl5) 478.
GRINDING
MATHEMATICAL MODEL OF BALL WEAR IN
MILLS. II. GENERAL SOLUTION
J. M. MENACHO
Cen ter, CIMM, P.O . Box 170 ,
Mining and Me tall urg ical Res earc h
San tiag o 10 (Ch ile) .
F. J. CONCHA
erin g, Uni ver sity of
Dep artm ent of Me tall urg ical Eng ine
ción (Ch ile) .
Con cep ción , P.O . Box >3-C, Con cep
''
INTROOUCTION
p
aN(~¡tl + a~[N(d,t)g(d)]= ~l k=r 1ml(d
o
)ó(d -dkH (d ,t}ó (d-do)
o o
( 1)
subj ect to the initi al cond ition N(d,O ) = No (d), wher e N(d, t)d(d ) is
SUMMARY
. GENERAL SOLUTION
scale have shown that the ball wear kinetics are well represented by
a zero order wear l>aw [2 '.. 6]. Nevertheless, it has al so been c:laimed
that in sorne cases the time of experimentation has not been long
a more general solution that includes zero order as a special case [13].
. .;_
-N(d,tldai~l (2)
which after i'ntegra ting by the method of (agrange gives c 1 "' n-t
and
(2a)
solution of eqn. 2 arises from the relation f(c 1 ),,.c 2 , which evaluate d
p
f(n)• $¡! ml(dk)U (d(n)-dk )-N {d(n)}g{ d{n)}
k=l o o '
that i s,
is obtained as
g{d(n-t) }
N(d,t) aN0 {d(n-t)} ,
g{d(r¡)}
(3)
The explicit form of eqn. 3 depends only on the form of n, that is,
8
g(d) • a(d/d )
S
1
where d
5
is a characteristic size which can be taken as 1 mm and a, e
are experimental parameters representing the specific rate of- wear
of the Bond wear law (11] where the rate of loss of mass from a ball
i-s proportional to its surface area; B•l ls the Oavis wear law [8],
where the rate of loss of mass is proportiDnal to the ball volume.
be comes
(4)
Two different forms exist for N(d,t) depending on whethe_r or not the
computed from
{5a)
and
d
d; ~ 3 N(~,t)dt
3 (d,t) • ..;~---
0
M (5b)
io 1~3N(f,;,t)dt
where m (d,t)d(d) ls the mass fraction of balls with diameter between
3
d and d+d(d) in the mill at time t and ~{d,t) is the cumulati.ve mass
Hold-up of Balls
(6}
Powder tost by abras ion of balls. and by purge of the worn cores
through the grate discharge openings are the two contdbutions to -the
1
- ¡· mass rate of ball consump tion. The rete Cw{t) of stee1 eonsunrp tion ·
by wear is
(7)
and the eontribu tion CP(t) of balls of slze d leáving through the
0
grate openings is Trod 3 t /6, that is,
o o
~ 3 draN(d, t)
cP (t) • __...o,._[t - 1 · d (d)] (8)
6 I d
o
ct
Severa!·' exp 11 e i t formu 1ae for the ba 11 eonsuni~t ion a re g l ven in the
Appendlx .
conditio n$\.,ith regard to ball eonsump tion ata given hold-up of.. balls.
Assume, for example , balls wearing in a· mil! aceordi·n g toa .zero -arder
law, that is, ll•O. Ata certain time, called zero time, imagine that
in the mil! are repláced . For the sake of lllustra tiÓn the sainé value
of.a. is assumed. The simulate d change of ball consump tion CT(t) with
The effect of' Son the steady state ball size distributl,Qil.
H; 5
(d) is illustrated in Fig. 2: the slope of .the Schuhmann curve
Suppos i ng that the grate open ing üze were sudden 1y i ncrea¡;ed,
occur around the .stea.dy profile, see Tabl_e_ l, reaching the final steady
diameter of balls discharging from tbe mili increases, even though the
the sanie time, total steel consumption increases even though the
contribution due to wear decreases, see Fig, S.
the measured ball size distribut ion of the charge may assist in decide
the correct value of e; by the reverse, if the marked ball test has
used to define the actua 1 ba 11 si ze prof i le [ 15] • The above idea can
J Ms 5 (d.) - Ms 5 (d.). 2 C - 2
¡; w .( 3 ¡ exp 3 J model) + W ( Texp ~model¡
Mss (d ) C CTexp
J'•l MJ 3 j exp
where Mjs (dj)model and CTmodel are given by eqns. AS and A12 in
the Appendix, respectiv ely; wMj and wC are weighting factors which
depend on the rel iabil ity of the experimen tal data; J is. the number
may exhibit different wear kinetics depending on the actual environm ent
such as ihternal geometry of the mil!, material to be ground and
grlnding condition s, then marke.d ba11 test should be conducted under
REFERENCES
l. J.M, Menacho and F.J. Concha, Powder Techn ol., 47 (1986) 87-96
.
2. W. 1. Garms and J.L. Steve ns, Trans . AIME, 169(1946) 133-1 39.
3. J.J, Loren zetti, Ball Size Oistr ibutio n from Computer
Simu lation
to Produ ct, 3rd Symposium on Grind ing, ARMCO Chile , S.A.M
.I .,
Viña del Mar, Chlle , 1980, 113.
4, T,E. Norman and C.M. Loeb, Mining Techn ol., AIME, Tech. Pub.
N° 2319, (1948) i-31.
5. D,E. Norqu ist and J.E. Moel ler, Trans . AIME, 187(1950) 712-7 14.
6. J, M. Menacho and F.J. Concha, XV lnt. Min. Proc. Cong
ress, Cannes,
June 2-9, 1985, l ~ 157-168.
7~ L.A~·vermeulen, A Contr ibutio n to Ba11
Wear and Ball Size
Oistr ibutio n in Tumbling Milis , Powder Techn ol., 46(19 86)28
1-285 .
8, E.W, Davie s, Trans . AIME 61 (1919) 250-297.
12. L.A. Vermeulen and D.D. Howat, Mintek Report M-201, Minte k,
Johar. nesbu rg. Scuth -Afr i ca, (1985) 1-24.
13. J.M. Menacho, Modelo de Desga ste de Bolas y Optim izació
Perfi l de Tamaño en Molinos Rotat orios Conti nuos, Avancnes de su
Proc. Hin,, Ed. Univ. de Concepción, Chile , 1, 1985, 478 pp. en
¡_
1_)1'-
Table 1.- Simula ted transi ent ball s·ize distri bution produc ed by a
sudden increa se in the size of balls leavin g the mil!.
o: -o. .. - 2 .2 x 10-2
1
SS
mm/h, ,ss
w81 ,_ 6
.. w • ~7. t, d comm ,
8 01
d •38.1 mm (1.5 inch), 6¡=6= 0, ore feed rate~120 t/h,
0
previo us and curren t rechar ge of 76.2 mm (3 inch) and
50.8 mm (2 inch) diame ter balls, 50% of each size.
12.7 0.001
_,_-
FIGURE CAPTIONS
o: -a--2.2x10
-2 mm/h, wSS Rw SS • 47.o< t, d =d zO,S·;=O,
1 61 8 01 0
8=0.5, ore feed rate=120 t/h, previous and current
recharge of 100 %of 76.2 mm (3 inch) diameter ba11s.
FIG, 6.- Simulated steady state ball size distributio ns for different
sizes of ball recharge and balls leaving the mil l.
-2
o:=-1.2x10 mm/h, wSS
8
•47.6 t, flzO, ore feed rate•120 t/h.
..
·, 1 1 1
1
•
1 1
1 1
1 1
1 1
-w 1 t
1 1
1
1
-
t
0::
o·
1
1
1
: . . 90
-- ----
u. 1 1
O· 1
1
•. 1
1
z
CJI, 3000 - t
1
1
,....,,. 1
1
11 111
....1
....1
2
1
1
. 1 <
....n.. 1 1 ... ,~ 1
. 60
al
___ ____
1
u.
::E
:::;)
111
1
1
.. '
'
""
...... _
- ______ 1
1
.....11 .
o
n..
--
:::;)
~· '
o
(.) . 1
1
o....1'
....1. 1
1 o
w ' ' :e
....w
1
111 '
1
1
1
. 30.
1
1000
TIME TO RENEW THE ...¡
INITIAL BALL CHARGE 1
1142.6
1
1
l)' .
;.
.
..
80 120 160
o 40
:TIME . t ( days )
on the
F 1G. 1.- Simu la.ted effe ct of a step of S param eter
speci {i..: ball.•'Lcons.umpt ion and hall hold -up.
· · SS SS- ·
10 mtn/h , \,/ =~' ~47.6 t, d··¡=d :0, ~,=0,
ll¡z0 :•-2.2 X 0
B=O.S, ore feed rate •1~0 t~h, prev
0
ious and cur.r ent
diam eter ball s .
rech arge of 100% of 76.2 mm (3 inch)
..;::.,-
'D
w
N
¡;¡
o
~
V>
V>
f.
-
•
~
•
<(
10
CURVE
NO
KINETJC
OROER.~
:E 3
1 +
w 5
2:: 2 + 2
1-
<( + 1
..J 3
~ 4 o
;:::)
(,.)
7 5 - 1
6 - 2
7 - 3
BAU. OIAMETER , d
1 25.4 ! m m )
n fo r
at ed st ea dy st at e ba ll si ze di st ri bu tio
) m ake-up
FIG. 2. - Si m ul or de r. 76.2 mm (3 in ch
di ff er en t ki ne tic
ba lls do•0 .
KINETIC
ORDER.~
1 + 3
2
3
+
+
, 2
o'
-,
4
S
S - 2
7 - 3
0.5 . . L S 10
tion for
Fll;, 3.- Sirnu la.ted stea dy stat e ball s.ize d.ist 'ribu
el i ffe.r ent k i net i é ord~r. Make -up of
50 t ba; J s of
of 76.:m m
102 JlVÍl. (4 inch ) diam eter and 50 %ba lls
(3 i:nch) dhim d cQ,
eter , ..o
.
.'J.
1S'l
:1
T T 1
1
1
1 .
1 1
1 1
1 1
1
TOTAL BALL CONSUMPTION 1
' :1 .
1
1
1
1
1
1- 1
iw 1
_,o: 1
o 600 1-
1
1 .
'U. 1
·--
.o 1
1
~, 1
.en 1
,% '
1
1
i .
º
....o..
:E
;:¡
~
1
1
1
1
1/)
1 1
% 1 :
,g .1 :
_, 1 : •
500 ¡..
L---!~~~~~~~~~~~-J____ _
;W
....w
1/) 1 ·-
' .
1 1
1 1
1 1
1
1
1
1
1
'
.
TIME TORENEW THE
f INITIAL BALL CHARGE o
:
1
: : 71.3
¡ . ... ~ . . V .
o 20 40 50 80
TIME, t ( days)
-F
-
Ul
a: 450
o ··roTAL 8All
u.. CONSUMPTION
--
o
Ot
-'~
5 400
....
n..
~
--------
:::>
(/)
z
8
...J
w
w
....
350
BALL
-- - --
CONSUMPTION BY WEAR
(/)
300
1,2
o 0.4 0.8
OIAMETER OF BALLS LEAVlNG THE MILL, dof25.4,{mm}
FIG. 5.- Simul ated stead y state steel consu mptio n as a funct ion
of the dia~ter of 55 balls leavin g the mill.
cx=~1.2xl0- mm/h, w =47.6 t, S=O, ore feed rate= 120
t/h,
ball recha rge of 108% of 50.8 mm (2 inchf diam eter.
~-
~ .
•
:~
'""
100
'
""'
so
"CI.
0::
.....
;LIJ
2.0 1.0 51 357
:P"'• 10'
Cl)
~
::E
UJ
:::...
S
_,
<t
:J.
::E
::;)
t.)
3 4
.S 1. 2. 3. 4.
BALL DIAMETER, d /25 .4 (mm )
Wear
APPENOIX Exp! "icit Form of Cha racte risti c Func tions for Ball
then d(n) •d 5 e.x.p (an/d5 ), g{d (n) }•C1d/d 5 , d(n- t)=d Up(- at/d 5 ) and
g{d( n-t)} -a(d /d 5 }e.x.p(-at/d 5 ). Subs titut ion of these rela tion s into
~ d
N(d, t) = Il 5 -
c.l
(A 1)
.
where the subs cript 1 refé rs to the initi al cond ition insid e the mill
d ~0. the limi ting stead y state expr essio n of
For t>(d 5 /a 1 }i.n(d 0 /d 1 ), 0
the dens ity func tion is
(AZ)
The stead y ball flow rate ~Il can be expr essed in term s of the stead y
• SS d 1 1T 3 SS )
and
· N (i,: dt;
hold-up w81 -of ball s by equa ttng WBl e r o 1 6t; 1
- ,S S
do
integ ratin g using eqn. AZ. Thus
-.. 55
18a..l w81 /d S (A3)
~Il"'--=---:~---- 3
3
1TD¡p t mil (dk}{ d - -dk }
~- li-1 o o
11
. The number rela tive freq uenc y mO (d,)
A simi lar expr essi on hold s for ~
1 K
T
•
k).
The same tran sfor mati on is al so val id for m~(d
This means ~1; then g(d) =a(d /d )B and ~=d-S/(a(l-Bl/d S 8}. 1/(H 3)
1/1 (-S) S
6 1 8
Also d(n) ={a( l-B) n/d 5 B-j , g{d( r¡)}= a(dld 5 ) , d(n- tl={ d - -a(H 3)tl d/'}
-
¡ 6/1( 1-6)
6 /d 6 Combining thes e rela tion s
and g{d( n-t)} =a{d -?-a (1-8 )t/d S } S
s 1/(1 -S J
~.,d 5 s, P¡ -s1 11 1-s .
1-a (1-6 lt/d 11 1 -d )-1> +
r: d mO (d k ){U( Íd
N(d, t} =-:.......;- k=l • 1 1' S "' k .
a.¡
eqn. A4
At stea dy stat e, that
be comes
¡;
(AS)
_r
'
Note tnat for B=l eqn. A5 reduces to eqn. A2. Tne flow rate in
_,.._
number of balls entering the mi 11 at the initial condition is
given by
~ll =- - - - - - - - - - -
P¡ Il 4-S 4 B
1Tp· l: m (d ¡{d 1-d - 1}
1k•1 o k o k
and
(A6)
¡; mo \l.lkJt Y -uk 1
k=l o
and -
(A6)
In this case eqn. 5a is integ rated using eqn. A4, lead ing to
P¡ a ¡¡ 1
B S, 1/(H l 1 )
-dk) -1}+
Z d3- 1m 0 (dk){ U([d - 1-a. (1-8 )t/d 5 ']
k=l
1/(1 -B) ..
~dBP 1 1 r~
d3- 8mO (dk) {U(d -dk) -u(id -e-a .(1-8 )t/d S e..,j -d.K )}l;
Ia 5
z ~ •
k=l
~ d a, P1
!1 s ¡; mi 1 (d )__!__ f(d
a., k•1 o k 4- e
1
· o
·":,--
to the
lntro ducin g eqn. Al into eqn. 5b and integ ratin g leads
(A7)
4-S
{ ( dk 1-B+a( l-S)tld/ J 1-S -dk4-S}]
and
(A8)
Hold-up of Balls
lntegrat ing ean. 6 using eqn. Al gives the total mass of balls ,
W (t) in the mill :
8
and
(A9)
),/ ,'t) =
1lP <!>
1 !1S
d S¡ P¡
J: mil (d ){d 4-e, -(d 1-S 1
+a,(1- .f31)t/ ds
e1) r::s, }+
S ro
1- "1 ) k= 1 ° k 0
k
&a,'
4-B
'!TP<l> d S P 1-B B ¡:-¡r- 4-B
~.;..I.::,.s ¡:mi (d ){(dk +a(H 3) t/d 5 ) -dk }
&a(l-S )k•l o k
and '!Tp<!> d B P
wss. I S J: mi(d ) {d 4-S-d 4-e
B &a ( 4- S) o k o k }
k•l
'I!P ~
e (tl- 1 11
w 6
and
(A 1 O)
'l!p ~ P¡
CP( t)• l
3 11
Il ¡; d m (dk){l~U(d O e.xp(~et 1 t/d S )~d," .)}+
O O
6 k•l
'l!p~ p
~ i: d 03 m!(dk)U(d 0 e.xp(~at/d; dk)
k•l
and
(A 11)
;._•
S ~
no1~ 1 1 P¡
11 1 o +a (1-s )t/ d 1¡ l-S ¡_d 3 1 ...
Cw (t) "~...:.:. J: mO (d ){( d -"1 O '
k•l k k . 1 1 S '
6
and
np~I P I 3
" - J: m (d ){d -d o 3}
6 k=l o k k
obt ain ed
. The rat e of purge of cor es is
which ls ide nti cal to eqn . AlO
eqn . 8 usi ng eqn . A4; the n
by int egr atin g
_,¡¡___ ¡
'
and
which is the same eqn . A11. Fin ally , the tota l stee l consumption
core con trib utio n to the loss es;
is obta ined by summing the powder and
a use fu 1 form at the stea dy stat e i s
55
tt(4- S)W /d fl
8 S
(A12)
Css
T ·~-P----------------------
I:
I
al so val id for fl-1 , and whe re m (dk) is the mass frac ;tio n
which is 3
of bal ls of síze dk.
~-·
97
Powder T•chnolo n, 41 (1986) 97 • 99
J. M. MENACH O•
Mining ond M•tallurrical Rt,.arch Cenler o( Chile
(Chilt)
(Received Febmary 24,1986)
for t • O, yields: d • d 1 - Kot for the firat Flg. l. Di.menaionleu diameter end mua deeay u a
equation and d • d 1 exp(- K 1O for the second function of dime111lonleu uro-ordn wear time.
one. Expanding in series the exponen tial and
neglecting second- and higher-order terma
givea an apparen t zero-order wear behavior. sumptio n C4 at the steady-s tate conditio n,
To avoid this, the test time should be chosen with regard to the ball size distribu tion in
such that t > l{K 1 ; Verme u len suggests a 7.3 the ball hold-up W8 , is
mass reductio n factor as a lower limit to dis·
tinguish between zero- and first-order and (4-A)W8 K4
e" z ----'--... ..:.-=.... .::;..__
conclud es that usual marked ba1l teats are K
not long enough to distinguish these two ~ d,. -lm.(d,. •- 4 -a..•-")
laws. •••
Our experience in Chilean mills indicates
that resulta for short time of wear often where A ls the kinetic order, K" is the respec-
o bey a nearly linear relation and the limited tive rat.e constant , d• is the diamete r of balls of
number of marked balls and measure ments class k in tbe recharge (K classes in total), m. is
weaken any statistieal analysis to decide the correspo nding mass fraction and d • is the
safely whether the linear response is appar· size of bells leaving the mili through the gate
ent or true. But ata certain time, a crossing opening s. Assume one.size class in the recharge
should occur with a further divergence of of balls and d. • O, then C0 • 4W8 .:ofd 1 for
the curves, as is shown In Fig. l. The crossing zero-ord er wear and C1 • 3W9 K 1 for first·
point supplies a natural criterion to establish order wear. For a mili operatin g at steady
the lower time for which zero- and first-order state, the steel consump tion C and the size
can be distinguished. This crossing point may d 1 of the make-up balls is known and the
be unambiguously identifie d as follows: ac- hold-up W8 can be estimate d from the pow·
cordlng to Menach.o [ 2 J, the total steel con- er draw. Tbus, " values may be comput ed
as Ko • Cd 1{4W8 and K 1 • C{3W8 ; that is,
'· •Viaiting Reseatcher at The- !'ennsyl•a nia State Uni·
d•d 1 - (Cd 1/4W 8 )t for A• O and d•d 1 X
versity, University Park, PA 16802 (U .S.A.). exp[-(C {3W8 )tJ for /!,. • l. If K• is defined
0032·591 01861$3. 50
© Ebe:Yier Sequoia/P rinted in- The Ne.therland5'
A Cont.ributio u to 'Ball Weu and &11 Size Di.;t..dbul.ions ut Twnblwg Dall Mllls'
L. A. VERMEULEN
C:ouncil {ur A/intral1'<eltnoluiY, /'rival• But X3U/5, 114~td/HH'f !J}IS (St>t<lh llfri<•}
(lteceivcd Nontnber 20, 1986)
,
A Conl.rii.IUt.iou to 'Ball Wear and D;..ll Si2:e Dil;trjl.JuUous iu 'l'umbli ug Dall_l\1ills'
L. A. VERMEULEN
c."ot..,eil ''" AJIMN111\:cluwluty,l'rivate 8ug X3Ul$, &"dbu,. , 2l¡lS ~OH<Ih Afti<•)
{R.ecel..d Nonmbe r 20, 198C.)
8tJI\IMARY
will exltibit equal numbeu of ele¡neut s ¡,, all
the size intervals , provided that· équilibr ium
' Rec~mt work by Aunln Qnd Klimpel con- conditio ns obtain and only ~p.a~ balls
cerning the nature of ba/1 weer in rotary mills are fed to the mili. The theory has it& orlgin
is di#cu&Nd. TIM TCWI4rkab/e ambigui ty tllut in the idea that, in hall milling, lhe size r<.'<luc-
the: resulta o( a marked bull test con be · tion of tbe particles occurs predomi nanUy
accUrate ly descrlbed by either tlae uolume or by Uuee-bo dy abaoaive interaeti ons and, lince
the sur(ace theorin o{ ball wear la explalne d, it ia the surfaeea of Uwtbul)s tloat.are.ex.poil!d
and it i$ conclud ed that such tests cannot be t.o abraaion , the-·l'l!te of- ball. weáf
sbouíd he
u..d for determir&ation o{ the wlues o{ the proporti onal ·to r
and A, sÍ1ould 1>11, zero.
Austit~-KümJhiii"'IYtnl_eter A. uule..s Cllrlclin VigorOUtl corrosio u 1ñ 1<.-vu_l~ ul:;o_ c~tritn\ ¡"
condlllo naltte met. ·Tliu intportr~tat:parurlleler L:ó decJeUe uf tbe bóllllll., ..'S ata fate
l'ru¡Aor·
tionaUu r 2 • ·- · ·
can be detertninM {rom studiao ( the equilib·
do
rium bo/N;IH ·distrlbeztions m the glnd~ H.Aia unity, tl1en eqn. (l),corr e'POnd
charges o/ 0011 rnilh, and addition al moür.rtl- the '-lume ' tbeory !~l of Qalt)l(ear. This
tions for its rMasurement are pi'BIII!nted. theory ·predici. a h yperb9li<;. frequenc y si¡,e
distribu tion and ia basad Ol!;. the assumpt ion
that; in- baU millin11, partk:~ s~e reductio n
lNTRODUCTION oeeun predonlinan:tly by three-body_ impac·
tive interactiGnS; Durin11 these interacU ons,
Austin and Klimpel ( 1]- recently derived the pariicle& are stresaed ami lrw;ture .·i! the
funct.ioll$ to deecritie the size -distribu tions of a~Rsses aré sulficien tly large. As the imJ?Ulses
balls in tun>blin e milis in terms oí: a paramet er that balls delí'lfH" durinll collisioA5...,e.prop or·
.:l, whicli tl1ey ha\>~ introduc ed _into the Bond tlonal to their m,._s or U.eir. vplumes ,. the
formulaUon [ 2, 3) of tbe rate of ball wear in rute of ball wcnr shoui.J be proportion11l lo
the fonn. , r 1 U11<l .:). ,;lllmkll v ''J<ily iu <'<¡n, {J ) ..
Thcrc t.~u be lic, h: __ ,¡~.~ui•L Jhai l_,<.,Jh 1.-Yl ·~ . · •f
... ·tlm . H.o\
(1) 1:'itlturtu.:Li(,n ur~ P•· \t_aJcn-l--io _li~f.btJ-_ jn(,i\!s_i_-~ i: '
- - •kr
d1' '"tniUs. iudm.!d, snu'~'u.. und wciJ...~oTu~g_riudi"¡;
where m(T) ls u,._, IJ;dl mass aft<!r 7' tons M Cl\.-.JtenW, lu~utb.-r wMh lu:uk~n ur~s, tltt'
mÚl•·ríal huv" Wo.ui litin;,u, r is th.: blilli'IIMolius, of4tn fowKI üo UJC J!l'i~•dlug clwr¡¡eJ Q( mw.t
and k Í8 a 'conlll.ant' wboae ilimeliallma induatri al -ball Qlilla, thw pr<ividillll, stro!•ll
8upport tor Boad's idea Utnt ooth wear
do>pend on the ·vldue ot A; SiRCe T ,. tJ!, where
t ia t.itn& and P Uíe ·avera¡e- leed ·rate, 1t mecbanl áma are opcr-•tive in intlu:;t.rin 1 01111
· fullows that eqn. (1) i5 -tiall y a Ume- ! .loülün¡¡. Dmld J2, :-51-~uggcodoo !hutA woul<l
d<ipende nt eqilllli<m .litdeéd, in. most milling · .I\UV«!' a v_.luc hct \~'t"Cil ~u-ro, und \_-l.llit.'~~
op<~-rutiOn$, une Uliltally endftYo w:a to kwv JI ·. -·dcpend ing on thc H'tiltin;;--Com..ljt io1_1§; vUf~t~ ,:;
al a cotllilan t vlfloto\ c:k.ts«~ tu z~~,.•ro- Wütlhl itulkah~ .tu·ct_lc_JI;\¡W·U~I :·:
Ir 6'· ís zero,-H.cn ~'<)ti. (1) corruspo llds !o vlll1lSjV~~~Jlc-r:.tclit.nt~ atHl vulum;. ¡._:),.~~ Ío ,¡,, ;J y.
.ti•" 'surface ' 14 j 1hcory of uall wear. 'l'hhi (troJuani uw1Uy itutr:t.d ivc iutc-t·;,clioals•
.-,-!\u•linumil¡:liu.¡,.,] fl] ami u(hcr ro.'c"' ;.
u..:ury 1•-licü '""llh.. fh.'qllency »ize di.:;iri·
l>ution or.:rin.Jio·c .::lvuicut.. in ..... mduu~.:~ wurk P 1 h~vt>,,¡,,,
_. -
..'n' lhóil A o.:útl h<.. <Id<'•·
'.
and
fncJ .. r ¡, Umt r;.ueh dctf!mlinnl.ion R cnn n\!;o
pro\•iol~ n hn::tiJ=t fnr tlu~ Sf'h·~·Lion óf an
m,(1) • m.,(l- b1) 3 (21
~pprnprial.e haJI t.ypP. for ll (!ÍV•>Il milling Kit.Ull•
tinn-" racl.nr or con~kll'r:>hle economic E•Jlmtion (2h) h~~ also hN-n givm by
si¡:nifknnce. ll<>ner., if Íl wcro close t.o Z"ro Ausl.in and IWmp<'l[l]ln the form
for hnlls in a givcn milling siLnatlon, then a
swikh to balls of Feater hardness could be
advnnt.ageous; if .6. were close to unity, the r,(T) • r 0 (1- ~~) (2c
use of baUs made of toughn material eould
be oclvAnblgcous. lt m11y aiJo be notRd tha~ In e'lna; (2a) t.o (2c), the subKcrirt.~ v anrl s
~(' ,,_lnl.ive illl-"n~it.y Of flil' Ílnplll'tiV<' Ínter• refcr t.o U1e vnlumc ~.nd surfp~P. theori~• oC
:tc_!tínn~ in hnll millin(% cAJl 1~ inereA~l! e.g. h:lll wcnr WIJl<."'t.ivt'ly, 1', h. nnd k •re
Ío\' ;,..,,,n~ of Uw millsp.,~l.· Lhl' U!IP or )nrJ!I'f conr.tnut.R, m 0 nntl rn ""' fr.:'lf~clively the
h~llc. ór r'lu;; ¡·ill¡t of Utc lniiLwil.h lifl~r hRI'll. ori~io111l hnll ma._~ ~nd·b~ll rnoliu•; anrl r(.T) on<'
On t.líP. ot.hrr hond, lhe íntensity of A.bn:u;ive m( 7') Lhe bnll radius ami tmll 1nMS nrt.er T·lm
ínteractions can he enhanced, e.¡. by tite use ol material have heen mUied. In the derivatio·
of smaller balls, decrease·of the miU ~peed, or of lhese equations, a constant shape factor
operation with a smooth lining, and so on. w~ ass1uneq. This assumption is apparently
C!early, the measured values of A wíll provide unavoidahle in di~~eusslons Of hall weai: and
indications, nótonly of the inherent eharacter· ball·$ize dlstributio~ In milling. · Attempts
istics of the balls but also of t.lte miUing condi- have been mftde (1, !1] to take account of th's
tions. lndeed, it mi~ht be adv~mblgeous for factor, and to estiJ;~~ate t!te un~eÍtainties intro.
certain materials to be comminuted predom· duced hy its U8e, .
inanUy by abfasive interaatiom and othen. Tbe theoretical. de¡;i'endence' óf the hall
predominantly ~ lmpaetive interaetionk mass (or ~us) on the amount of matefial
· Austln and Klimpel ( lj llaVe noted that milled (or the time o! milling) as expreised br
data given by Dnvis [6] lead to A • 1, and eqns. (Za) and 2(b) can be compared directl:Y
that their own data and those of Lorenatti with measurements of the hall ¡nasses in
[!!JaHú .:ermeulen and Hownt [9] yicld A • marked-ball tests. Othcr workcrs, including
O. Thev have commented that tbe. 'situation Austin and Klimpel [ 1], have adopted the
is clea;ly confuM>d · and have questioned the, view that, if the data are best fitted by eqn.
asserlión of Vermetllen et al. 19] that UBE! can (2a), then the volume (A • 1) theory of ball
be máde of either the volume theory or the wear is applicable and, if the best fit is
surfnce t h""ry o t hall wear to give •n aeeurtte provided by eqn. (2h), then the surface (A~
description of the :rate or hall. wear in a O) lll'~ory is applicable.
marked-bal! test. The aim of the present com- In the marked-ball test to which reference
munication is t.o given a quantitative explana- is mnde [ 9), ~he masses of six ~trades of high-
·tion of the rcinarkable ambiguity thateach of chromium white-iron marluid balls wcre
these two theories oí ball weanpPeats to give monitored at montbly intervat~ over a period
á'v~ry accurate description o!the rate of ball of ahout ~ months in an 8 ft X !!ft rubber-
wffl!r, de~pite the fad that·n given thl'ory linerl,. industrial mili fitted wit h lifter bars.
· ascrihes all of tire wear to only one ot two Mert~n~ky R~f ore was ground to the
possible, although very different, wear mecha- requirro d"!!fCt' oí fineneRS nt a milling rateo:
ni<rns, an<l to show that tJ1e aceurate dt'tl'rmi- G50 t/d. Th<' l.(l!ltwas di5continued wh~n tlw
nnt.ion of A from the rerolts óf marked-hnll .~~earch for sufficient numher~ of the mark~~·
tt's!.s is not rossible un~<$• certain conclitinns hnll• t.o give rca•onably ac~urnte TI'Jlft'Scnk··
nre meL tion• of .the rnte of hall W<'nr lll'rame too
time-consuming.
AMBIG UJTY IN TI! F. HiTERrRET ATION OF TIIE The functions ¡¡iven in eqns. (2a) and (2hl,
RF.SULTS OF A MAin<ED·nALL TEST whirh descrihe r~pect.ively exponential ancl
cubic decays of the hall mass with the amou"
Equation (1) can be inteFated t.o yield of material milled (or the time of milling),
.f'H'U-~av'-'•• .1. _.._~--..a, .......... ,...,.,.., ................ ,....., •• ..,... ~ ·-- --------~ ~- . . .
RF.SULTS OF A MAin<ED·nALL TEST whirh descrihe r~pect.ively exponential ancl
- 1' ._. __ t__n ~--- --H.L .a.l¿- - · - - · · -
.. ·~-. ·-
283
r
expt -T/T ), wbic b be
r
. :, 3r
l
~ bigbe~-order terms
o ,.
.......................,
,,. ,,.
. '
'l' ,\'
{\:tll ·· · :•t riiiTntn..,t.t:r~' 11<:: rif"L~rn,iw·•l hy l.h.,. '~'•IU nf a markr.cl-btdl l ... t~tl { Aft~ Vermcnl,.n t!t ni. 1 "1)
eff,•o:fiv~OC$ of S~V~rnl bnlJ 1''Pe!< for ¡¡ivcn nre ~hnwn in TahlP., vnried hy :. fnct.or of more
lnillil·'"'.: 1:itunl.innr.. Th1•ir t·nh ... i~ m•wh lhttn =~. Thc nhov(~ cliscuAAion r.u~~~ts-lhAt the
rmh:•t·•'<'l'1 whrn lmllr. rf"'prt·~:··~d~liv<' of t.he r~vpl•l''~ $houltl, hccnn~ f.he milling condi-
uacl: ¡:round hall charge in n lllíll also ar~ tions wcre the same for all the hall types, be
mnrked and monitored durinp, the wst, and if related to the material properlies of the balls
the moni.Loring of the m""'"'" uf marked ball! under considemtion. Thís hypothesis is con-
is carried out as frequently as possil>le. firmed, for example in Fig. 2, which shows
The results obtained for the other ball
grades that were tested by Vermeulen et al. 1 10 6•C1f.,X,. t>f l)lllh '"*' IW:
«XX iti ..•'Cn .nu
[9} also have an important bearing u pon the
- - - - Tmwt of toa!l Mll'bl~y .,
present discussion. The Table !lives the values r-t~
11
ot cltrOfJIIIPI'I ~tt'llt
of r, b, and x' that were obtained for all the
ball grades under test, and shows that t11e
volume theory gives statístically the best
description of the ball consumption for three
2
of the ball grades, whereas the •urface theory
is best for the others. But the balls wcre ·
together i11 the same mili over the en tire·
perio<l or the test! That is to sny, they simulta-
neously internded with the snme Bg¡¡ressive
•-1----- .------,. ----..--
"
enviromnent in which the milling rate was
about. 650 t of new feed per dny. For sorne of Fig. 2. Depemi~nee of the tonn•.:~ parameter 'f·on
them, !:. was closer to unity t.hnn to zero chrotnium content.
whereas, for the others, it was closer to zero.
This result emphnsizes thnt th" vnlue of t:. is that t.he r-valu~s are undouht-<'dly related lo
not n propert.y of hall milling per se. lts the chromium content of tlw material from
preci-e value is determined partly by the which the balls were manufactured . Of
milling conditions and part.ly hy the propcr- course, one cannot deduce from this figure
ties of the materials from which the balls are that the hi~her the chromium content the
mnnufactured . Whf'n vRrious types of hall are more durable will be the ball, because other
present in the same mil!, they respond to the factors like microstructur e, the chromium-to-
given millinfl environment, i.e. the given in ten- carbon ratio, hardness, etc., play sígnificant
sities of abrasive ami impactive inter:~ctions roles.
that ure providrtl hy the milling condilions
(mili sp...,d, mill dinmeter, li•>er configuration,
pulp density, dmrg~ volum<'. ('le.), hy w~n.ring CONCI,USlONS
Ü; tJjffcrcnt \\':1f~
hy Virt.Uf' o( thPir diff(•ring
chemical and ml'tnlluf!!ical properties. 1'hus, Thc ahove analysis hn.' shown that the
in the given test, the rclntive durabilities of Aust.in-Kiimp el paramcter t:. cannot. hP dctPr·
the ball~. as measured by the values of T that mine<! unarnhiguol'"IY (rom .the r<'.<Ult.< of
ln J..IW giVen !;.CSt.t t.Oe n::Jfli,JVe' UUfH.OIIILU;~S Ql Jl.US{;In-.1\.Um~! )JH.fHJnCLt!T ¡,.>. ~:o:¡n!J(Ho IW UCl.P[·
the ball~. as measured by the values of T that mine<! unarnhiguou"l y (rom .the r<'sults of
2B5
marked ball tests, unless their duration s steady-s tate conditio ns will be approxim ately
correspo nd to at least 2r tons milled. The 3M/F(A ll1/AT), where 111 is the total mass of
conclusi ons of Prentice [ 4), Norman and ihe grinding charge, F ís the feed rate, and
Loeb (10), and Norquis t and Moeller [11], Alll/ AT is the ball consum ption (kilogra ms
who claimed that their results support the per ton millcd). Austin and Klimpel ! 1] and
surface th~ory of hall wear, but whose expcri· ihe present work have provided motivati ons
ments did not meet Ulis critcrion , have for JUt!asurement of the importa nt paramtt cr
therdor e \.o be treated with some reservat ion. A, the value of whidl should be intimaie ly
Althoug h the determin ation of A from thc relaied io the material properti es of the bulls
results of marked-Lall t~sts is difficull , such anJ the grinJing couJilio ns in tumhling ball
tests are very valuahle in that they are com- milis [7 ].
parativel y inexpensive, much less time-
consumi ng than plant tests, and can be used
for the simultan eous determin ation of the ACKNOW LEDGEM ENTS
relative durabi!i ty and cost-effe ciivenes s of
severa\ ball types. The results of such tests This paper is puhlishe d by permissi on of
are greatly enhance d when the masses of halls the Council for Mineral Technol ogy (Mintek ).
that are represen tative of the huckgro und hall Professo r D. D. llowat and Dr P. T. Wcdepo hl
charge are also monitor ed [9]. are thanked for discussio ns and criticism .
The valne of the paramet er A can be deter-
mined from studies of the ball-size distribu-
REFERE NCES
tions in conjunc tion with the distribu tion
function s that have been derive<.! by Austín 1 L. G. Au.slin and R. R. Klimpel, Powder 1'echnoL,
and Klimpel [ 1]. This is because the range of 41 (1985)27 9.
ball sízes in tl1e equilíbri um grínding charge 2 F. C. llonu, 1\-ons. AIME, 153 (1943) 373.
of a mili will be sufficien tly large. The greater 3 F. C. llonu, J. Chem. Metall. Min. Soc. S. A fr.
(Jan. 1943) 131.
the number of size intervals, the greater will 4 '!'. K. l'renlice, J. Ch<m. Metal/. Min. Soc. S. A fr.
be the accuracy and, if sample~ of the (Jan.194 3)99.
grinding charge are drawn from the mili, they 5 P. BernuU.t, Zement Knlk Gips, 9 (1964) 397.
must, of course, be represe ntative- a diffi. 6 E. W. Duvis,1'ra ns. AIAIE, 61 (1919) 250.
cult matter for one lo ensure. lt is ímporta nt 7 L. A. Vt:!rmcult!'n and D. D. Howat, J. S. A{r.
lnst. Min. Metu/1., 86 (Apr. 1986) 113.
for one lo notice that the distribu tion func- 8 J. J. Lorenz.ei.ti, ~roe. 3rd Symposiu m on
tions given by Austin and Klimpel in eqns. Grindi11g, A.rmco, Cllile, SAMI. Viva d~l Mar,
(14) and (15) o!theirp aper [1] apply only t.o 19~0.
as u.Jd h then at the croasing point exp[ -( 4/ where U(d-d•) ls the Step function, defined
3)K*t] e 1 - ~e• t. This non-linear equation as U(d > d.) • 1, otherwlse it is O. For
holds for ~e•t • 0.45( 44). The time necessary d 0 = O and one size of balls in the recharge,
for total disappearance of a ball of initial M 10(d) • (d/d 1¡4 -A; Fig. 2 illustrates the Bize
size d 1 , assuming the zero-order law, is T • profiles obtained in this case for dlfferent
1/K*, that is K*t • t/T • 0.45. Accordingly, values of A. The exponent in the resulting
the dimensionless size is d* .. d/d 1 • d 1(1- Schuhmann distribution is 4 for the zero-
0.45)/d1 = 0.55 and the dimensionleas mass order law as compared with 3 when the firgt.
is m• • (d*) 3 • 0.16, which represent a 6.2 order law applies. This difference is large .
m8S3 reduction factor, see Fig. l. enough to experimentally distinguish the
According to Lorenzetti [ 3], "o values two cases under discussion. The same behav-
range between 3.8 X 10-3 and 15.4 X 10- 3 ior applies for multiple size recharge of balls,
mm/h; d 1 is normally between 25 and 100 see Fig. 3. Experimental and predicted size
mm. Thus, ~e• is expected to vary between profiles for a Chilean mili are shown in Fig.
3.. 8 X 10-5 and 6.16 X lO_. h- 1 • The Table 4; in this particular case, the choice of A = O
shows the time necessary to reach the croasing is clearly better than A • l.
poínt for different ~e• values. Times are very An additional complication is the simul-
long for extremely hard balls, but in a variety taneous occurrence o! both types o f wear
of cases wear times are lesa than 3 months, law to give an apparent fractional t. value;
which is a common practice for marked ball in those cases, accurate ball size distribution
tests. In other words, in many cases it should measurements are required, especially of the
be possible to determine accurate values for smaller sizes if d 0 is small, see Figs. 2 and
A in feasibly short times of experimenta- 3, or of the intermediate ball sizes if d 0 is
tion. significant in comparison with the maximum
size inside the mili, see Fig. 4.
TABLE
Simulated times to roach the croasing point bet...,on 100,---.--..-..-.-,..,.-rrr---.--.r-r...,...,,..,..,,-,
zerop and firat-order weU lawa, for different .e•...,.lu.a
K* X 105 Time
(h-') (d)
3.8 498
ó.O 379
7.5
10.0
252
189 .
..~
20.0 95
30.0 63
......
40.0
60.0
60.0
61.6
47
38
32
31
>
~
,.
:l
5
...!!!L
'
2
.+.
liCII't(TIC:
9"0!:111,6
'
•'
+ '
"
u
•
•• -
- 2
1
100
r1 .
.!:1 50
¡ - •
.. 1
l.
1 l
f
.,.
. 1 1
.,
e
10
1 1 .
.."
>
>=
e_.
::>
"
S
..••
+1
1
11
11
1 1>•0
•.
:
.
:>
" o 11
11
-·_,
•1
1'
1
&ALL DIAM!TER, 41/25.4 (Wiftl) 1
Fi¡. 3. Slmulated tleady .. tata ball alzo dit:tribution ·-~~~~·~Á--~-7~
O.! o.s 1.0 3
~~·~
a 10
for differant klnetic orden (SO'JI. bolla 101.2 mm,
50'JI. baila 76.2 mm, d 0 • 0). BALL DIAMETER, d/25.4 (mm)
Fit. 4. Experimental and simulated ballaize distribu·
tion for a 2.9 m diamotor Maroy ball mil! (50.8 mm
Conclusions make-up baila:, d 0 • 22.1 mm).
A natural criterion to distinguish between
zero- and first-order wear laws is the crossing The ball size distribution in the ball hold-
point of the curves of size or mass of the up is an additional ctiterion to determine the
balls uerrus time. This point is characterized kinetic order of the wear law.
by a dimensionless time t• • 0.45, a dimen-
sionless diameter d• e 0.55 and a dimension- Re(erences
less mass m• • 0.16; the last means a mass 1 L. A. Vermeulen, Powder Tochnol.• 46 (1986)
reduction factor of 6.2, in good agreement 2 J. M. Menocho, in F. J. Concha (ed.), Adt10nce1
with the 7.3 value suggested by Vermeul"en in Mineral Procuting, "101. 1, Univeuity of Con~
[1]. cepcl6n, ChDe,l985, p. 69.
The usual marked ball test allows accurate 3 J. J. Lorenzetti, Proc. 3rd Symp. on Grinding,
Armco Chile, S.A.M.l., Vina del Mar, Chile,
determinatiotis of the .A-parameter in feasibly 1980, pp. 284.303.
short times of experimentation in a variety 4 J. M. Menaeho and F. J. Concha, Powder Toeh·
of cases. no/,, 41 (1986 ).
'
CAPITULO 5
D!S1'RIBUClON DE,TIElfPOS DE·RES!DENCIA
INTRODUCCION
t=O
(IMPULSO)
o = C Q dt + VdC
(entrada) = (salida) + (acumulación)
~rti l ~vJ
íi íi
... -t = t, -t ~,..
e, ,..
'"
t=ü t, tz
C=Co
-
t , E(GJ
-,
J3al-ance másico en el pr-imer- estanque (en inter-valo dt para t > O): ·"'
dC 1 ,._ ~ ot
===> e, ~o ':1. • l.t
z
" Q
===> ,. - ~ dt ::- + k
t
IU\ Í.::.O
V
lYlo
-')..y =
lueso ln 2C" = K
-Hjt.
c.• :. ':l.C" e.
\ldCr
..... --~
.. -!2-l/t
2 e e. Q dt = e;¿ Q c1..t + v d c2.
t:2. e !! -
e.
-- c.!l.)
2t 1t
~ .L.t e Vd. c.,_
f - ~~/ t
(.?.C. e. - C;t) dt :. y_Q d. c.1. )
V
ct,;( :. J¿_
-
t ; enbnce.
¡. :l.
e =tlt J~
. - - 0.9
4C*"t.e. cl.9 + t d.C.:z. /:de
4 e*" E e.- 'J.J:)
O sea :
- 2.€1
C:¡_/ e~ "' 49 e
===>
n
E:(9): e:,.. t\ e n-1 e- ne
c.• = r (n)
n - r¡ 't. ¡.:f
n tt./t)n -le.
E ('e)=
i rtl"l)
00
E! pro~]~n.__ <...~ -.. a;e:..:~·.:· ::-.a.r 'o~ !"" 4=-SlJ .. ~ddCJc tXj ••.:rJ.r~H!-r.:;e:a. .t;::·
!!?
! c¡,;1JC' ~ -=n':.r.):: '•!~ , t.\. • t--t~:""r.' f1il' .': oL ]~tl' dfliE-"t:.:·n~ · J y ctf;(J,::¡,-l d(\_. a.l t
tt d!I !: !JO!"':. t: dt1 flléii.'t't't:J. ..:t.J a l ! el \'~$ OtJ:' barH:C• de· f.'f:,.cld.S clL•
f} L: •..t"'JU I ~ d
pa:-t.ir dt: J<.1t:. !10t'iEU1'0.S ·:!•.. pt .1.me~ y t:~ ur1d c or dt•! d"= :c.. -:
.!- :.~ !b•.. -
C!.u r• !t: , t<~ d.t'Z~ r J: - & mtc! ..;.~ ~ ... e Ve!.: !cl:U::á !i!.e¿!..!i S t: ~:-:~ .. iCes ó.
e~ =~:.: ti t... a e :.o:.
DETERniNACION EXPERIMENTAL DE LA DTR USANDO
EL l'10DELO DE MEZCLADORES PERFECTOS EN SERIE.
:: Joo t {t/~
OC>
M, "'f = Jt E (t) dt
n" )n-1 e-ntft d.t
o o . t l'(n)
i
f = n Nn)
•
•
00
J( nt /i )l'l-1
o
o . 1
f't;l>dk - .2r J
OC) 00
o
o
\)2 ..
M.2. -+ r2.- lrr-t, :::. M:¿ + rl, -Ir M,
cr'l ... •
M.2 - f-·M'
.,
cr'- .. ( -n+ 1 ) -2
t -t- 2. =(~t-.r<')"i 2
n
la.ur: )
00
t = So 1: ett)a.t
~ 2. 00 CID l1.
n : [ J tE{t)d.tJ /(j "t'lEt-t)at-{j té(i.)dt)]
0 0 0
'P{t)
= 1.
~---------------------------11 •
t
'
t.mQJ{
3. Calcul ar IJ.: fo l>•(t¡) ó(i¡)
~....-
5. Calcular los momentos de primer y segundo orden
tmilC
M1 =j i:¡_ E (ti )óti.
o
'
tmQ.tC
M~"" J tf
o
E (t\ )cft¡
6. Calcular los parámetros t y n
7. Detenerse.
n
- Llámese d> = Z. ll JI.""R
to. ... o
'9 J.t
11..
t>
(>e:) d?c : f
~
b
4-(K) óp' +
( 1)
1'1 n 1'1
::: z:. Q.lt. Z:. Q.IL Z:. Ai.. .¡ lt. ( 1( ¡)
A. .. o lt•O ~:.o
:. •z:" A·1
ft·
¡.:o
!-
l•.o
A¡ ~ (x¡ )
••
.,
.z.
..... o
Ai ~ (x¡)
r'l
.:z:. A; .f (x¡)
l.•o
.- Se.¡6n esta 6ltima ecuac ión, el proble ma•ee reduce al cAlcu
lo de
1 os A, . A partir de ( 1) :
,.
J.. =.o r'., ~o (.lf o) + A1 .f., {.< 1 ) + ... + An -fo (lt,.) = J .fo (lt') ~
o.
~ ... , Ao.ft {~t.)+ At.ft (J(t)+ ... -+ An.f1 (JC,) "'jb..fr{><.)~
.
•
"'
- Como es uno quien propon e las funcio nes base, se pueden evalua r·
las inteel: 'al es del RHS ; tambié n se conoce n los o. (x,; , lue.¡o
las únicas incóe nitas son los A,.
DETERMINACION DE LA DISTRIBUCION DE TIEz.lPOS DE RESIDENCIA
EN CIRCUITO CERRADO.
''T~J
DECONVGI "
:-.
.- _,,-¡ 'J""R EN CIRCUITO CERRADO
C0 &Ct)
~0~000000000
LL 1CF
¡
j
1 ~--~000000000
¡ {:t~ ('~ o ., o o o o o o o
v~;-_.,o•••••••.
F
e R<t) "'
--------------------------~··--~
Ci+C>F
hatemat~camtnte :
C :¡: Cf(-l) dt = JL
1:
o
CF C~ (9) J[ 4> ('t..- 9)] de dt
t
o M.o. c.r(-t) =- Jc~te)4'(t-e)d9
o
.. ..Po {Xo) ~1 0 (lC 1 ) .-.., ~o (Xr\) Ao
luego : ~~(~o) -f,l.J(t)•••--f, (xl'\)
-· .•
•
••• .•
A,
•
.
-
An
- -,
-.,'.-
1 ... ·;-- -T-· . fA~--
. ~: ,.
x~ • • • )(; Az
•
•
•
.•
..)
., '
..
- En el caso especifico que ~.(x) = x~ con k = 0,2 , se lleea a
la f6rmula de Simpaon :
lea
Considere .>( 0 , x, 1 l(L ~ J +ex}~= Ao:l'("-)+ A1ot{"t)+A 1 ..fcx;¡,)'
"o
1
Aol r
.:t~ ~ A0 z l/3
Xo
)1:
"·"'L
1
lCz.
x.2.
l.
A ;:- tx¡.x; )l:t
' '
.... ,
..j
¡lx"
l ,_)t.") /3
' . -
~ Á¡ ..
.A2. ..
"'S./3
... ,,
j.~
xa
jXo~CJC.) d-;l a. ~ [ tc>.:o ) -+ -4 ~(X.} + .f<>t:~o) ]
l(n
•
J ..C(IC)~ "~[.f(Xn. 2 )+-4-H"- 1 )+ ot(.l:n))
"n-'L
x.,
.: J -+'(.:)~" ~[ ..f(xo) +.f.("'")+ 4 (.f(x, )+ f(x3)-t ••• +~C'<'n-1))+
"•
~ ( { (lCa. )+ +<><4) + •.. +.f. (Xo-2. )) J
'
Baei-endo-. ea.mbiO de ·ver-iabl e
t
c¡>(t) ~ J 4>t9)C~ lt-e)de
o
donde
}
t ~
Em:on<::es -: J cp (-t ) c1.t - Jo e'- ('f:) dk
o
'1 también
A .. J 00
o
cF- tt) tOS wt d.t
'!> = J cp..l~)
o
00
Se>, wt d.t;
00
J) :: j c.p ( i::) SI!#\ wt d.t
o
j Cp (wj) = c-l>j
es decir
At c.,+ Bj = e( At C..)+ BD + -I> ( 4.¡- c., )'t Be
A+C0 +Sj (Ate, ):z. + Bf¿ (A-t:Co)'Z. + B2.
.f
,o
o'-
80 ·- Eficiencia j¡•
e - Heal ~~
·o
·u
(]
u 60 ,_ .'/ Eficiencia -
··- / / Corregida
({)
u
o --- •
--- ;(--
/1 1
<IJ • 1 1
u L. O / 1 1 -
o
'ü
m
'ü
-·--·-· 1 1
• 1 1
¡¡::
w 20 1\ _ By- Pass Finos / l 1 Tamaño de Corte
,..... / . 1
f rr~
rj
""'* .~· 1 1 11 1
1 1 1 1 t 1 1 1 1 1
1 ......,..-• 1 1 ,; 10 000
o10 100 1,000 . [}
1~ ....
~
,.' ,',
' '
-~
-
"'TI
-~
--3
-oCD
CD
-
"l
"'--
.....
·~
e: "'TI
;:::::
-~
:>
N
-
"'TI
--·3 -·-3
-
e ~
1
-2-
-eco
-
"'TI
-
(m;lu l(m;) F-
E.c
1
= i=1,2 , .•. ,n ( 2 )
(1 - spfl
E.c
1
= ; i=l.2 , ... ,n ( 3 )
= ( 4 )
Además, si se defin e
E.l e ..
·o . para ( 5 )
enton ces
para ( 6 )
donde
donde
e (D0)0.385 P0.0935
( 9 )
dso = a3 (DU)O.Z86 (WOF)0.0192
donde
f'
'
- Ecuación de la Eficiencia de Clasificación
• e
-; ; i=l,.2., ... ,n ( 10 )
donde
ex 'o ( ax 1. ) - 1
E.c = i==1,2, ... ,n ( 11 )
1
exp (ax ) + exp (a)-2
1
d./d- e
1 :;: 0
y el cortocircuito de agua
WOF
l - . WF ( 12 )
S egun
- '~yncr.' y Rao ~
caCa un~ de las co~stantes
empíricas a1 , a , a y a son obtenidas a partir de un
2 3
úniao ensayo de clas1ficación con el mineral pertinente,
por inversión de 1as ecuaciones respectivas. Conoc:das
estas constantes, las cuatro correlacion~s básicas pr~
puestas por Lynch y Rao permiten predecir la respuesta
de u~ hidrocic1ón frente a una alimentaciór. de caract~rí~
ticas definidas. A continuación se describe el proced 4 -
miento de c&lculo recomenda¿o para ta: efecto :
A partir de la Ecuación 7 , evaluar la pres1on
de alimenta ción P requerid a por el hidrocic lón
para el caudal Q especifi cado.
= i= 1,2; ... ,n
(ver Figura. 2 ).
. '
n
Mo = ;.f¡ ~mi) Ó
( 14 )
l ( 15 )
1
y los porcent ajes de sólidos y demás caracte rís-
ticas de los flujos resulta ntes.
= ( .16)
" (rn 1 lu 1 Mu
Modelo de Plitt
.
~.
- Ecua ción de la Pres ión de Alim entac ión
a
1 o1 · 78 exp (0.00 55 PSV)
( 17 )
p =
donde :
donde
•.
- Ecuación de la Eficien cia de Clasific ación
( 20 )
donde
( 21 }
m = } ( P:..::.C_~...:.:.h) o. 15 ( 22 )
( 23 )
( zs )
R
se
= ,.~
1 f; E; e= fracción de los sólidos a re-
cuperar en la descarga en e1
caso teórico de que no exis-
tiese cortoci rcuito.
Modelo CIMM
donde
donde
0 19
h •
2 64
(DU/00) • exp (-4.33 41 + 8.77 il ( 28 )
S =
H0.54 (OC)0.38
donde :
( 29 )
donde
(Quin ta Ecuaci ón ! ) ( 32 )
Bpf = )..
Bpw
( 33 )
( 34 )
Rv = S1 (S+ 1 )
n
! ( 35 )
f; E; e
i=l
Las constantes empiricas a 1 •. a 2 , a 3 , a 4 y/. son
nuevamente calculables a partir de un ensayo único de
clasifica.ción. La rutina de cálculo recomendada para
1~ utilización de este· tercer modelo es· completamente
análoga a la recomendada para la utilización del modelo
de Plitt anterior; teniendo presente la existencia de
la Ecuación 32 que permite el cálculo de Bpf a partir
del valor estimado .para 8 pw' según la Ecuación 33.
1.- La Energí a Especí fica como Variab le Contro lante del Proces o
1
¡: B .. S.f. i=l,2 , ... ,n
j = i-t 1 J J J
E = Pt/H
donde
S .E = S .H/P
J J
resulta
1
= .L ; icl,2, ... ,n
J = 1•1
Por simple analog ía, es fácil demost rar que para un sistem a
continu o, la solució n lineal es nuevam ente válida siempr e y cuando
'
...,.. por -E y ~ por ~E , segun corresp onda. De hecho, sí M
se reemplace~
represe nta el flujo másico de alimen tación al molino (t), entonc es
s.H -
" (....L) E = si E E
P/E p
En síntes is, las ecuacio nes del modelo tanto batch como con-
tinuo son expres ables en función del paráme tro reconoc idamer .te con-
trolan te del proces o; la energí a especí fica consum ida. De esta
manera , cabe espera r que la función selecci ón especí fica SE sea Y
fundam entalme nte depend iente de las caract erístic as propia s del mi-
neral y no tanto de las condic iones operac ionales mismas bajo las
neral y no tanto de las condic iones operac ionales m~smas oaJo 1as
cuales se lleva a cabo el proceso de molienda; ya que el efecto
_(
de estas Últimas se reflejaría en el valor de E solamente. La
distribución de tamaño de bolas afecta los s{ y en algunos casos
ciertas condiciones de operación ext~ como excesivo contenido
de finos y cargas circulantes muy altas, también lo afectan.
1
1-Fi
sr 1
.tn ( 1- F 1 )
ícula s es
Si se supon e adem ás que el tamaf to inic ial de las part
o
cons idera blem ente mayo r que d 1 (F 1 -o> , enton ces :
-E. = 1
.tn <i--r¡l
l ST
1
d , a part ir
Simi larm ente, para una cier ta dime nsi6n d 2 meno t que 1
de la misma alim entac i6n grue sa
1
=
sr2
erida para re-
Lueg o, si F1 = F2 = 0.8, l.a ener gía espe cífic a requ
=d a un.p ro-
duci r una alim entac i6n de tamaf lo cara cter sitic o F80 1
ducto de tamaf to cara cter ístic o P80 =d 2 , resu lta
tn 5
relac i6n
Como se discu te más adel ante , se ha obse rvado que la
dien te ta-
exis tente entre la func i6n selec ci6n Si y su corre spon
maflo di pued e ser de la forma
Bajo tales
con d. 0 y J_ 1 parám etros cara cterí stico s del mine ral.
cond icion es, la ecua ci6n ·pa.ra bE se reduc e a
-·~
1 1
LIE = ( o. a )
P80 1 Fso 1
1n5 1 1 )
LIE = "-
de donde, definiendo 10 w :/-n5/.J_ Y tomando el caso muy particu-
1 0
t lard-.
1
=
0.5, se obtiene finalmente
LiE = 1o wI ( 1
lp
80
S·ld)
l\ = a.-tx·Jx
~~ 1 o )"
donde,
C¡ ., (O/Dr)N2(d/dr)N3
N l+(d*/d•);,"'
Cz • (d /d) O(
T
1
l+(d"'/d)AW
"
j
(0/Dr)Nl 0:>3.8m
CJ "
o ¡"'1-~
(3.8f'l( 0~3.8m
rr n
l+6.5J2.3
c4 " ( T )exp(-c(U-Ur)J
1+6.5J2.3
¡•c-0.1 }{l+exp[l5.7(•ci:D.94)] )
es " 9cr-O.l l+expll5.7(9c-0.94)
CAPITULO 8
CRITERIOS DE OPTIMIZACION DE CIRCUITOS
1 -
"La.épt~ma d~!uc~én
de óél~do¿ en !4 aLlmentac~án
e 6o n La¿
t~ma c~ga c~~cu!ant
a c~c!one6 46 l como la ép
Ltan de ope~a~ con :
qu e nece6~arnente ~e6u
de 66 Lid o6 en el p~oducto
E! mt~o conten~do
o6 en La de¿ca~ga
El m!x~o conte~do de ó6 Lid
ente: riac.t~ól.e de
de lo6 c~cl.onu, ope~aci.ont7-lm
implementa~".
1 + (C C) oo t. ee. 1 )
(f sS lop t. =
donde
os en el flu jo k
f 5k • fra cc i6n , en pe so, de só lid
ida como 1a
ce = raz ón de ca rga cir cu lan te, de fin de sca rga
os de
raz ón en tre los ton ela jes sec
y reb als e de l cla sif ica
do r.
~
_!;
--- --
11
o
"l'
¡g_ ""
lt)
/¡
.....
"'
-
(.)
l¡ 1 t
.......
(.!
1i 1 1 J
1 IJ ~
'O
....,
-¡1 CJ (.)
J ......."'CJ
"::;
~1 1 "'
(.)
.....
·~
.."
~
-'-'
""E
C.' CJ
......_
o
~
" ~
-"'
e:::
.:;¡
::
·o
c.·
"' ....
'O
"
o ·u.::¡ ·..;
e::
l -- "' o
l 1
,.J
(.)
-"'
"'
e•
~
~-::
o
-e
~
ª
1 ~
..... 1 CJ u
""""":..____...¡
~
21 i S
¡..
c.. ,_ ~
t ü¡
!,,
;::¡
1 1
1
-'
-, -
t\ij
<O ¡ ::: Ql
11
00
1!
...."'O>
'' :;2
u
e::: 21 1'
ti
ro
,_,
-
-- "'
e::: 1 S¡ 1 .....e-
Q
u
"'
Q _¡ ·--- "'...
' Q
1 "tl.t..
u
o
Ü'
s;f
u¡
1
1
'
""
J¡
11
1
El cump limie nto de la prim era cond ición , refer ente
-
a la diluc ión del reba lse, debi era esta r limit ado sola
mente por la disp onib ilida d de agua de la insta lació n,
la capa cidad de bombeo de pulpa a los ciclo nes y los re-
a
quer imie ntos de los proc esos subs iguie ntes en la caden
ión
oper ativa . La segun da cond ición , refe rent e a la diluc
ade-
del flujo de desc arga , es alcan zabl e por medio de una
cuada geom etría y número de ciclo nes en la bate ría.
..(
Bal anc e de Sól ido s
e de cad a una
A con tinu aci ón se pre sen ta el d•t all
señ ala r que la apl i-
de est as rel aci one s, per o ant es cab e
pla nte ado aba rca
cab ilid ad del cri ter io de opt imi zac ión
del cir cui to, aQn
un amp lio esp ect ro de con fig ura cio nes
e ref ere nci a esp ecí -
cuando en el pre sen te aná lis is s• hac
8.1 . En gen era l,
fic a al cir cui to dir ect o de la .Fig ura
cui tos inv ers os y
el mismo cri ter io es apl ica ble a cir
otr os de con fig ura ció n más com ple ja.
MS 2 = MS 3
( 8. 2)
MS 3 : MS 5
MS 5 : MS 6 + MS 7
M$2 = MS 3 = MS 5 = (1 + ce) MS 1
MS 6 = ce MS 1 ( A. 4)
MS 7 = MS 1
Balance de Pulpas
.¡.
M?,
~
= ( P. 5)
MP 1 = MS l/fsl
.....
MP 6 ( 8.6)
" MS6/fs6
MP 7 = MS 7 /fs 7
a (sól idos
En este caso , MPk den ota el tone laje de pulp
la frac ción ,
+ag ua) en el fluj o k mie ntra s que fsk deno ta
ra R.l) .
en peso . de sóli dos en el mismo ~lujo (ver Figu
nte un
Las EcJa cion es P.S y P.6 con stitu yen nuev ame
siste ma line al cuya solu ción está dada por
= MSl /fsl
" (~ + ~) MS 1
'sl Ts6
= (~- 1 ) MS
r;¡ 1
(8. 7)
's7
( 1 + ce) MS 1
=
fs7 t;6 -
=
ce MS 1
T-
's6
" MS1/fs7
agua al
donde MP 4 simp lem ente repr esen ta el caud al de
dilu ción
cajó n de la bomba requ erid o para alca nza r la
dese ada en el prod ucto fina l de reba lse. y:
~.1 '.
(1 + CC}
(8.8)
1
(--) + (.)-)
fsl 's6
(1 + ce l ( 8. 9)
(.,.ccl + ( 1 l
rs6 t;i
la cual, al igual que en la Ecuación 8.1, demuestra que
el contenido de sólidos en la pulpa de alimentación a
ciclones está completamente determinado oor la carga cir-
culante y los porcentajes de sólidos en los flujos de rebal
se y descarga de los ciclones.
MP - MS 6 ce(~ - 1)
6 's6
Bpw :
MP 5 - MS 5 : ( 8. 1 o)
' 1
\r;? -l) + ce (.)._
's6
- 1)
En la prác.
tica , un alto valo r de Bpw es indi cati vo
agua que
de una clas ific ació n def icie nte pues to que el
tícu las fina s
acompaña al sobr etam año arra stra cons igo par
que supu esta men te deb iera n repo rtar al reba lse.
la de
-Def inie ndo como "fin o" al_m ater ial bajo la mal
nar io de
menor abe rtur a util izad a para el con trol ruti
T~ler), es
gran ulom etría s (nor mal men te, 325 6 400 mal las
de bala nce
posi ble esta blec er las sigu ient es rela cion es
para el circ uito de la Fig ura s .1-
= mz
m· ( 8. 11)
= 5
ms = m6 + m?
s en el fluj o k.
donde mk repr esen ta el ton elaj e seco de fino
fres ca
Pue sto que las gran ulom etrí as de alim enta ción
y prod ucto fina l mol ido está n dete rmin
adas por los reou e-
ucti va, se
rimi ento s de las dem~s etap as de la cade na prod
·con oce :
=
1 a 12)
=
donde F1 y F7 representan el porcentaje de finos en
__!_
los flujos de alimentaci6n fresca y producto molido
respectivamente.
= (B. 13)
8of F7)
m2 = ( F1 + 1 -8 - MS,_¡,
pr
F7
IÍ13 = MS 1
(1 - Bpf)
m4 = o (8.14)
F7
m5 = MS
(1 - Bpf)
1
Bof F7 -
m6 = MS 1
(1-Bpf)
....
m7 = F7 (dado)
--
--;-;_-
Fl = F1 (da do)
B0 f F7 1
Fz = ( F1 + )
(1 + ce)
l~B -=
P•
F7
F3 =
{l- Bp f) (l+CC)
F4 = o
F7 (8. 15)
Fs = (l+CC)
(l~Bpf)
BEf F7
Fs =
(1- Bpf ) ce
\CC(~L-1)
'S 6 ( 8· .-
1 i )
'
(1L - 1) + ce (~ -1)
s7 's6
= F1 (dado)
,
CC(r- 1) F7
S6 1
1
F., +
~ r 1
\ -z-- -
~'
1) + {!-:\) e !,.\~- - 1) 1
(1 • e~
's7 ' .o
<'
(3.13)
(.,J._ - 1) + ce (;-L - l )
Ts7 ·ss
"'' ~
= Fs = 1 .. 1
~
1. (~ - 1 ) ( l- \) ce ·r..,-:- - 1)
's7 Sb
(~ - 1) F7
F6
's7
" (-.l.-
fs7
- 1 1'
-
+ ( 1- \) ce (~
's6
- -• '1
;
'"':i-'
"' = F~ (dado)
·- '7 1
Estas expre sione s perm iten evalu ar la fracc ión de
"fino s" conte nidos en cada flujo del circu ito, en funci ón
de las otras tres varia bles opera ciona les de relev ancia
para el prese nte anili sis que son : la fracc ión de sólid os
en el bajota mano o produ cto molid o (fs 7 ), la fracc ión de
sólid os en el sobre tamañ o o retor no (fs 6 ) y la razón de
carga circu lante (CC). Resu lta inter esant e enton ces
obser var las Figur as 8.2 y 8.3, donde se ilust ra gráfi ca-
mente el comp ortam iento de ias Ecuac iones 6.18, parti cular -
mente ias corre spond iente s a los flujo s de alime ntaci ón al
molin o (F 2 ) y desca rga molin o (F 3 ), para un caso .part icula r
hipot ético en que se desea aume ntar el conte nido de fir.os
del mate rial desde un 15 % en la alime ntaci ón fresc a hasta
un 40% en el produ cto final . De ellas se despr ende aue
para dism inuir el conte nido porce ntual de finos en los flu-
jos de alime ntaci ón y desca rga del molin o, es neces ario
que es preci same nte lo indic ado por el crite rio Ce c~ti~l
zació n propu esto. Las Figur as 8.2 y 8.3 tambi ér. sugiere~
que la alta carga circu lante norma lment e resul tante de la
aplic ación de este crite rio ooera ciona l, aunqu e perju dicia l
en térmi nos de corto circu ito de agua y finos , es bene ficio -
sa en el sentid o que contr ibuye a mante ner la carga dol
molin o libre de conta minac ión con partf culas suficiente~ente
•¡, Sólidos Cont. Finos
Rebalse
13
Rebalse : 4 o •¡.
12
40
S? 11
o
:E:
e;
:Q.
u
o 36
- o 1
--
•
• 'l ,..,~,...U'"'"O
L.<.K...,.11 DIRECTO
J
'
7 CC:3
>..:: 0.95
70 72 76 78 80
20
l 8 •¡, Só lid os
Re ba lse
o ~
-
t::
o
16
-..........:::......_......_ l. l.
O
,
l.
---
:!:
---............ ...............
_ _ ....
o
-.......-... 36
E
.,t::
"'o
1.1..
.._•
•
12
1o
wn t. Fin os A. Frese::. : 15 •¡,
---- t. o
36
8 ce = 3 ;>.. =o. 95
e e =s
.., '
1 ~ 75 76 so
70
rce~taje Ce só lid
os e~ la
Fi~u=a p.3.-E!ec~o Ce l po al
n~e~i¿o pcrcent~
de sc ar ga so b= e el co
ga de l mo lin o; co n
de fin os en la de sc ar
:e y el po rc en ta
je Ce
la ca rq a ci~c~lan
e co mo pa=á~et=os.
só lid os en el re ba ls
1
; ...
~ finas y a ~oder de es:a manera utilizar una mayor frac-
ción de la energía disponible en la trituración de
partículas más gruesas.
··-~-
"1'
l -, >,
~ .
:
"-~"!'
~-
58 No. Diam . Pre.siéri Carg a -"!. Sól ido s "1.- ;!00 #
,...
~·
..... '
-Sim.
-
tph
-
Ci::l. Apex
31/¡,
psi
9.6
-
\.-Ir C .
359
Alim .
6 5. 8
-Reb.
45.0
Dese .
74.8
Rel::c!~
57 .01.
l 150 1..
56 35.0 17.5 50. 12
.j .j ,¡ 1 2. 3 1.32 53.7
2
.j 13.9 433 54.5 .j 79.1 57.4 1
3 !55 J
,¡ ll . o 452 51.. 1 J 77.1 57.2 3
54 4 .j S
75.1 57.3 2
5 .j J 3 112 12.2 · 525 61.. 6. J
:::
·o
u"' 62
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e::. •
e 50
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o 1
o 1
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58
1 1 •
.5
•
4
•
.3 .
56
76 77 78 79 80
71. 75
. •f. Séliéi:Js en Desc ::rgc Ciclón
~=a¿icional- de wol~enCa/clasi!icac~6~.
'¡
J
por-
'J Las Con dici ones 4 y S ilus tran además e;ue, a
¡ un mayor
cen taje de sóli dos en el r.eb alse con stan te,
ya que
aumento en carg a circ ulan te no serf a ben efic ioso
o de desc ar-
este ir•a acompa~ado de una dilu ción del fluj
pare ce reco -
ga. Debido a este efec to com pens ator io, no
ión. t.) ni
men dabl e aum enta r el número ·de ciclo n-es (Co ndic
S) pue sto
tamp oco la abe rtur a de los ápic es (Con dici ón
za del
que ello no imp lica rla un aumento ni en la fine
Imp lica ría
prod ucto ni en la capa cida d de la secc ión.
te, en
sólo un aumento inne cesa rio de la carg a circ ulan
desc arga .
desmedro de la con cent raci ón de sóli dos en la
side raci ón
En el aná lisi s anterior~ está imp líci ta la con
vari able y
de que la bomba del circ uito es de velo cida d
ltan tes de
capa z de abso rver Jas nuev as exig enci as resu
les mod ifica cion es prop uest as.
sto el
Las sim ulac ione s pres enta das ponen de man ifie
oort amie nto
imo orta nte rol que le cabe al agua en el com
efec to no
de un circ uito dado de mol iend a/cl asif icac ión;
de Bond. En
con side rado en 1as form ulac ione s orig inal es
ació n de
la prác tica , a trav és de una adec uada dos ific
ce de trab ajo
agua al circ uito , es pos ible dism inui r el fndi
rmin ada y por
ope raci ona l para un min eral de una dure za dete
la secc ión.
1 ende , max imiz ar la capa cida d de trat ami en:o de
6n de cada
Dep endi endo de la condi~ión actu al de ope raci
aum ento s de
circ uito en par ticu lar, es razo nab le espe rar
, por este sólo
hast a un 15: en la capa cida d de -::ra tami ento
lisi s aauí
con cept o. Desde otro punt o de vist a, e1 aná
•
......
....
C"
•
i ALIMEflTACION
!<
,...
...J
<
i
!
=
o
z
....z:: 10
1i o
..,.,
.... 'l
:sor
-
c. ,¡::
'l ~O.
o:c
::
l.i.l /
.... SOBRELLEr~ADO
J
1
-
~
<
z
+
'i
1 ~
!
'""
e::
Q
c.
j oo 1 1
6
! 4 5
1 T r 1 1 !
1 1 1 1 1
~. f ' 1000
10 100
TAf-4AÑO, pm
"'~'
?.O-·
ESTUDIO lE CASOS
K"l (k) =
dende
(l, . dd~d'
~
1
u (dd-d') :J
~ lo,
~. l
ESTUDIO DE CASO : "Opti mizaé iqñ del Tamaf io 'de Botas .
Recar gadas en los Molin os Securu :l;a.rio s
,]
de una Plant a Chile na"
la
Es· conoc ido que ·tanto las veloc idade s de fract ura como
ibuci ón
distr ibuci ón de fragm entos prima rios varía n con la distr
de. bolas dentr o de un molin o.
op-
Al optim izar la recar ga de bolas , en realid ad se esta
ior del
timiz ando la distr ibuci 6nlie cuerp os moled ores en el inter
ón que la.
molin o. Es razon able supone'):' en una prime ra aprox imaci
spond e a
veloc idad neta de fract ura d'e la clas'e i 'de tamañ o, corre
s de ta-
algún tipo <le prome dio de la acció n de las div-e rsas clase
s en'té rmi
maño de bolas , ponde rada por las respe ctiva s abund al'lcia
nos de la fracc ión másic a mld l.1
y
Luego , si es posib le deter mina r como varía n Si:: s 1 (d 1 l
r de mé
Bij = Bij (d 1 ) , enton ces es posib le optim izar un ciert o facto
de bolas , que
rito basad o en el conoc imien to del model o de desga ste
distr ibuci ón
nos predi Ce para cada condi ción de reca"r ga, cual es la
de bolas dentr o del molin o.
En ~s:tas
' -expr,esiones
m.1 es.la
. . frecue ncia relati va en masa
.
de bolas en la recarg a., dR es el diám.e_ tro de bolas rechaz adas
del molino por la. pan;i lla. en pulga das, di es el diáme tro de
la
clase de recarg a y dl es el diáme tro de la clase de carga de-ntro
del molin o. Note que la distri bució n parcia l de bolas en el equá_
librio es simple mente m(k)" 'MM(k -l)'-MM (k)'
C SS , ton/h
T
t·ib = J * ( 1-' J * ob _ * v· !{ , t en
Las funcio nes selecc ión reduc ida y fractu ra acumu lada pon-
de: radas quedan expres adas como
-1
(kWh/t onJ -
ex-
La infor maci ón de plan ta disp onib le para evalu ar las
+ presi o:1es prec eden tes es
-·
Poro sidac de." lecho . = 0.40
Nive l de llena do J = 0.41
3
Volum en del Moli no 'J~1 = 50.l8 m
: 5.039 10- 4 pulg /h
Tasa de desg aste de bola s k X
cida
En la Figu ra 12 se pres enta la func; i9n se1_e cción ,redu
prác tica
E
si, para cada tamañ o de bola y la pond erada para cada
de recar ga.
de
En la Figu ra i3 se pres enta la func ión distr ibuc ióñ
fract ura Bij para cada tamañ o de bola y la pond erada para cada
r.
prác tica de recar ga evalu ada en el .mono tamañ o 4 x 6 41 Tyle
1: ~ Apet.oda
--~-·---~
1t Bolo
E
S!, Madt4
RaoQ1'1ia T1pa A
.,.e 4 f ----~::.-----
:;.!
,,
....._
SJ. Media
"'-
Rao¡rgo TtpO 8
2
'O
__, _____ ..........,- .. ·-
u
~<Y.
e
'O 0.8
·--< -;:?. ~~~-· ~ 3.0"
'{!!f?''. . . . .___ ...-;"'---,.
/,A_-~~/ ~ ~'·
u
u o. 6
(jJ
.....
<~
2s·
U)
e
o. 4 h';:</ 0' " ' ao·
~#;Y/ \\ \\
'ü
·--<
2
()
e:
0.2
~ .,,.
o. 1 -~--· -~-t-.
125
-
250
__ j_ t
-.
500
'
1000
1 .L
2000
< !
4000
J,,"O"
1 . ~ L -.l ... t.
-\_',
.!'1 .J. '•
..
ill
.... 1
...J.
j" j,
re------------------------------~~- .....
til
cl
.,.., '-
'-".... ...,
:J
o
o
"
-r;¡
..,u"
,,... -o
'-
1.1.
Ql
....
r;¡
o. ....o
-o
Ql
:::¡;
e
.....o
u
:J
·-
.t:J
...,' -
....
e
(/)
e
....oo
e
:J
u.
8 Q
..: c:
~ 1 a PT~PWT~d P~n~OP~a ap U9TOnqr~~STQ U9TOUnJ
3.- SIMULACIONES CON DIFE~ PRACTICAS DE RECARGA DE BOLAS
El cri ter io emp lead o con sist ió en rec orre r una ban da en
s ent re 80 y 70 \ -65> #
la gra nul ome tría de reb alse de cicl one
5 resp ecto al pun to eva -
Tyl er, con un mar gen de erro r de:! : .0.0
que el pro duc to tuv iera
luad o. En todo s los caso s se con side ró
al men os un 42 % -200 ~ Tyl er.
1
¡~
1'
'
"" Los resultad os de los dos conjunto s de simulac iones es-
.
: oecifica dos antes, ·se resumen.. ,en las Figuras 20 y '21 • En las fi-
guras sefíal,.ad as:se aprecia ·que los mayo.res tonelaje s se =nsiguen para
,] recargas de t.arn:aflo. pro111edi o d 8 en e 1 entorno a las· 2". Note
!que la recarga actual de 6-0 %. de 2" y 40 % de 3", correspo nde
.i a un diámetro promedio d 8 "'' 2. 4".
RECAR GAS
'3.
~
o MONOCARGA
a eo•t. 3"- 20 •¡. 2..
g A 60'/, 3''- 40'/, 2 ..
'"
o \f '0'1. 3''- 60'1. 2'"
:¡;
o 6(1'/.2.5"· 40"/. 2"
"8. O 40"/o2.5"· 60"/o %"
0 tSO
~ 20'/,2S"- 80'{, 2"
·•,
u
-
'"'
•.,"
~
"u 70
2. 100
··- 71 7l 73
u' "/.-65 #
" 75
......__ 76
.•
·- . .
80
1.0"
·-
500 1000 1500 2000 2500 3000 3500
Consum o de 1\.Ccro. C.r q/ton
!HOURA 21
•
··¡
200 RECIIRG.AS
MOIIORECARGA
v ,o•J.2" . . 60'f,3"
/1/
/ d 60'/., 2" .. LO'/~rl"'
'
150
1M
.,. ·65 1#
1.0"
FIGURA 20
j • i ~¡ • ~·~,
\)} ('¡ '
CASE STUDY "Cor npara tive Anal ysis Betw een Serni -
' autog enou s and Conv entio nal Grin ding
perfo rrned on a Chile an Ore"
INTROI>UCTION
progr arn
A chile an rnini ng cornp any has rece ntly star~ed up a
a cornp arati ve
for deve lopin g a silve r-go ld depo sit, requ iring that
ing of the
anal ysis betw een serni autog enou s and conv entio nal grind
defin e the most
ore be perfo rrned at pilo t plan t scal e, in orde r to
parar neter s for
appr opria te grind ing cond ition s and relat ed desig n
s.
a preli rnina ry sizin g of the full- scal e plan t faci litie
Proc essin g
For this pur·p ose, durin g May of 1988 , the Mine ral
s grind ing tests ,
Divi sion of CIMM cond ucted two pilo t semi autog enou
rator y scale .
besid es sorne cornp lerne ntary testw ork perfo rmed at labo
adop ted
A brie f desc ripti on of the expe rime ntal proc edur es
meto dolog ie·s to
for the exec ution of the test progr arn ·and anal ysis
eval uate the expe rime ntal resu lts is prese nted .
SCOPE OF WORK •
·¡
SAMPLE·
IOENTIFICATIOO
(*) It refers to the trannel undersize product fran the cascade mill
(see Appendix Al
Casca de Milli ng Proce dures
lines
" Our norma l opera ting routi ne follow s the gene ral guide
Co., the
inter natio nally accep ted and recom mende d by Kopp ers
casca de mill manu factu rer.
6' Ty-
Prior to each test, the sampl e is class ified in a 2'x
fract ions,
RcY"..k double -deck screen , which allow s to split it into four
fract ions
norm ally •-+6" , -6"/+ 3", -3"/+ 1" and -1". These size
(of about
are then prop ortio nally recom bined in small quan tities
mill, at a
100 kgs) just befor e handf eedin g them to the casca de
by the unit,
frequ ency comp atible with the fresh feedr ate accep ted
dure a11ow s
so as to main tain a stead y mill hold- up. Such proce
city and also
for an accurc .te contr ol of the mill 's opera ting capa
minim izes the risk of samp le segre gatio n: that is, fluct uatio ns
in the parti cle size distr ibuti oh of the feed. Parti cles coars er
above menti oned
than 10 inche s are broke n and recla ssifi ed into the
fract ions prior to the test.
the
The sainp le is trans porte d throu gh a belt feede r to
disch arge grate
Kopp ers 6' x 2' casca de mill equip ed with a 1;-inc h
can be
and a tromm el of adjus table scree n openi ng. The rnill
with a 12-in ch
opera ted el.the r in open circu it o-r in close d circu it
ing circu i t
s-pira l class ifier , s1mu lating vario us al terna ti ves grind
out in a fully
confi gurat ions. The grind ing proce ss can be carri ed
autog enous or semia utoge nous fashi on; the latte r being characteri~
media .
ed by the use of steel balls as an addit ional grind ing
casca de
The basic crite rion for the regul ar opera tion of the
also const ant
rnill cons ists on reach ing a stead y power deman d at an
nal mill
and satis facto ry mill fillin g (22-2 4 % of the inter
ient use of
volum e). Below this limit one does not achie ve an effic
.,_
the consumed energy and above the upper ·.:limi t, the operation •
becomes quite unstable and difficult to control. At equilibrium,
mill capaci ty is strongly dependent on the type of mineral and
circuit configuration being tested. For dif.ferent ores and
circuits, mill capacity may vary in a wide range.from 200 to
2500 kg/h.
Afterwards, once the test has been completed and the charge
removed, these .measurements are complemented by a direct determinatio r
of the apparent load density, excluding the steel balls if any.
For this purpose, the technician weighs a specially designed
container of 50 cm x 50. cm square section and 100-cm height, filled
with the solids recovered from the SAG mill. Whenever pertinent,
the final weight .of the steel balls is determined in order to
assess.the specific grindin~ media consumption.
in Table
The most relev ant pilot test resul ts are summ arized
y consu mptio n
1. Table 2 also repor ts the overa ll net spec ific energ
149 ~m) in the
value s (EN; kWh/ ton) to reach the same ci80 point ( ·•
ABC- 1. The
final pr:du ct size distr ibuti ons of Circu its SAG and"S
Work Index
calcu lat"i ons were done with the avera ge. Oper ation al
circu it confi g-
figur es iWT ; kWh/ ton) repor ted in Table 1 for both
'"o appli cable
ura'".: :>:os, by assum ing that Bond 's Theor y would be also
in .chis case.
mptio n
On the basis of the overa ll net spec ific energ y consu
attai n the same
figur es repre sente d in Table 2 (corr ected value s. to
it with
P size" 149 uml, the doub le-sta ge semia utog"E !nous circu
80 it),
remov al, crush ing and recyc ling of pebbl es (SABC -1 circu
inten ded
appea rs to be the most prom ising 'conf igura tion for the
appli catio n at in.du strial scal,e . In fact, the circu it SABC -1 would
c ton treat ed,
deman d appro xima tely 13.4 kWh .of net energ y per metri
confi gurat ion.
as compa red to 16.0 kWh/t on requi red on SAG cirtc uit
the invol ved
Howe ver, for a fair comp arison , one must also consi der
I and liner
steel consu mptio n costs (aris ing from grind ing mediC
es crush er,
consu mptio ns in the casca de and secon dary mills , pebbl
ll opera ting
etc.) which also take an impo rtant part in the overa
consi der
cost. Furth ermo re, the final decis ion shoul d also
capit al costs
other relev ant aspec ts such as inves tmen t risks and
which go beyon d the scope of the curre nt test progr am.
as
It is worth while emph asize that, in the same mann er
at CIMM up
it has been occur ring with all the ore samp les teste d
2, carne out
to date, the EN value s (net kWh/t on) shown in Table
the conve n-
great er than the 12.0 kWh/ ton (net value ) assig ned to
on an
tiona l crush ing /grin ding proce ss of the" chileá n ore, based
for this ore,
unco rrecte d Work Index figur e of 13.73 kWh/ Short ton
- .
l'ABLE 1.- Summary of Expt.>rim.ent al Conditíons and Test; Results
[~ ~-1
4.0
4.0
7.0
7.0
24.1
24.1
1
\
o.BJ.t
0.844
·-
8.64 10.36
8.19. 9.70
~---
27.2
2<\.CJ
----
4L9S 0.2Z7 0.23 0.272
39.18 0.210 0.21 o·.249
--- .
O.!Xl 0.1!34 2.91 3.49
o.oo
----
0.844 2.88 3.41
---
66 •.6
48.5
61.25
=
141562
60.66 141562
138
144
14.12
13.36 15.02
lJ~ - -· 13.74 15.28
24.1 0.100 S.42 10.03 :16.1 40.57 0.219 0.22 0.261 0.00 0.8J'J 2.\XJ 3.45 57.5 60.96 141562 141
AAX (S 1\t~ !S'R:-1} 4.0 7.0 1
TABLE 2 ..-Calculation of Ov'erall Specific Ene~ Cons~tion Values to Attain the Same
PrOOuct Siz~ Distributicm s on Circuit s.~ and SADC-1
Circui.t f',:<?d Sizc; P::t:Y!t•Ct Sizc; ~m•:J.onal Net Specific Energy
C-Onfiguratio n P (umt '*>rk lncl<!x ConstJI'!)tion (Corree~)
•so 80 kWh/r,
(3) um (s, Rl • ..,,,.tan.
~ ~
(3) See details in 1\ppe:ndix A, for circuit con.figuration. '> tested at pilot scale.
(4) and (5) 1\ typical encrgy consunption v<Jl~ of 1 kWh per ton of crushcd pebbles was O?nsidered. 1'he above-
fi9'ures aJ:e rcl.Jt('{.) to fresh ft:...-clratc of cac;c.::sde mili
displ<~yc-.d
(6} and m These vall.lf's are td(J:rn:d to ftcsh fa.">drate of cascade mil l.,
(8) Sareplill9 1-r·n, was consi&>rcd to providiO! a r value nearer to the desired one (" 80 'passing
80
100 mc~hl
(\ i
' , '
'
1 It is also interesting to note the high contents of fines
• existing in the trommel undersize stream discharged from the
cascade mill during the pilot evaluation of the circuit SABC-1
(see Table 1), which partially explains the low circulating loads
(average value of 58%), attained in the reverse. ball mill. grind-
ing-classification circuit treating this primary grind product
(the relatively high efficiency of the 8-inch spiral classifier,
also contributed to decrease the circulating load at pilot scale).
It worth rnentioning, that the excessive amount fo fines ('., 41 %
J.S
• . • (1 )
1
TABLE 3.- Summ ary of Bon d's Work Inde x Test Res ults 1
!
(*) 1
Samp le Mesh of Grind Mesh Grin dabi lity F8o P8o WI
(Tyle r Serie s) Open ing; Index ; '( kWh} j
Des crip tion Gbp (g/re vl (um} (um}
·' s.ton
p1 (uml i
'
1
i
i
Fresh Feed Ore !'
208 1.793 2330 158 13.73
to SJ>,G mi ll 65
!
' 1
Fresh Feed Ore
65 ' 208 1.895 1080 155 1 15.44 '
to Pilo t Ball- Mill
(trcm nel U'siz e) ! 1
'
1
1
.,
1
'
ucte d on
TABLE 4.- Summ ary of Lab. Torq ue Ball -Mil l Test s cond
Trom mel Und ersiz e Samp le from Casc ade Mill .
1
i (~\
80 % Passi ng Size (um) Net Spec. Energ y Cons. (tonl
j Grind ing ! '
1
1
!
Tirne
1 (rninl
Expe rimen tal ¡ Pred icted
(Ec. 1) 1
Expe rimen tal 1
'
Pred icted
(Ec. 1)
1
/
!
!
! 1
1
0.00 1 0.00
o 693 1 693 1 1.50 ''1'
1 339 336 1.53
3 3.13 1
6
12
226
145
1 229
145
3.07
6.13 6.12
¡
1
(Tlme, minl
d80 ( ,#111) 12
1000 .....-----~- - - - T--- --- --- r-- .,
3 6
Expe rJme ntaJ
Oata
900 TROMMEL UNDERSIZE PRODUCT o
FROM THE PILOT CASCADE MILL
<CIRCUIT SABC-1) Pred icted by
800 Ec. 1 (04=1 .2}
Fso= 693 um
700
600
500
400 t
300
200
100
1'
o~~~~-~~ ~-~~~~~~~~~
o 3 4 5 6 7
1 2
-
EN (klflh /TJ
FIGURE l.- 80%_ Pas sing Size (d80 : ~m) vers us
Net Spe ciFic Ener gy Can sum ptian (E"' ; klflh/ TJ
mea sure d in a Lab arat ary Tarc¡ue Bal l-M ill.
-
'-
..
l-
-
E11 (kH'h/TJ
10~----------------------------------~ Experimente
Oata
9 O(= l. 2 <leost sc¡uores technic¡ue) o
CHARLES-WALKER'S POSTULATE
8 EIV = Wi*[ <100/PSOf' - <1 00/FBOf' J ••• <D Predi e tea
by Ec. 1
{Bond ·as sumes o:= O. 5)
7
/
LJ W¡= 11.28 (kWh/t) 1
o. 2 o. 3 o. 4 o. 5 o. 6 o. 7
[ (J 00/PBOJor.- (; 00/FBDfXJ
FIGURE 2.- Craphical VeriFication oF Charles-
Jt'alker' s Pastulate when appl ied to Experimental
Data shown on Figure J•
..
-
Where , EN = Net spec ific energ y consu mptio n, measu red direc tly
in the lab. torqu e ball- mill at diffe rent grind ing
times (kWh /tonl
Bond 's Work Index value assoc iated to ore grind ing,
assum ing that param eter "a" is k,nown (Bond assum es
a =
0.5 for all test ores} .
80 % passi ng size in the ball- mill feed (u ro)
80 % passi ng size in the ball- mill produ ct, at
the requi red grind ing time (uml
a = Ernpi rical param eter, depen ding on type of ore being
teste d (if a =0.5, the stand ard Bond 's formu la is
obtai ned by repla cing this value in Eq. 1)
cular
The best value s of param eters WI and a for this parti
and Cl = 1. 2; and hence ,
ore, carne out to be : WI = 11.28 kWh/ ton.
the Bond 's
cauti on shoul d be exerc ised when apply ing direc tly
proce dure (a =
0.5) for sizin g the secon dary grind ing-c lassi ficat ion
stage of the indu stria l circu it. A prelim inary esti:n ate of the
scale for
net speci fic energ y consu mptio n requi red at full- size
can be obtai ned
ball- mill grind ing of the tromm el under zide produ ct,
ge data colle ct-
from Equat ion 1, by consi derin g the follow ing avera
ed at pilot scale : F 80 =1775 um (ball -mill feed sizel ;
P 80 = 203 um (ball -mill produ ct size) ; WI = 11.28
kWh pe.;:- "te trie
ton; and param eter a= 1. 2. By repla cing all these data into
Equat ion l¡ a preli mina ry estim ate of EN = 4.47 kWh/t on is obtai ned.
.
figur e,
This value match es well with the 4.80 ln~t kWh/t on)
dary
attain ed by comp uter simu lation of the indu stria l Secon
Grind ing-C lassif icatio n stage of Circu it SABC -1.
•
PLANT EQUIPMEN'l' SIZING ANO FINAL COMMENTS
~-.' .'~ . ~
See Table l.
. •. -5 . . . . : .. . .
K = 1 • .38273 x 10 · (an empirical·com3tant adjusted to
pilot plant data).
D = inside mi.ll diameter (ft.) = 6' ;Eor the Koppers
Cascade mill.
LÍD = mill length to diameter ratio · = l/3 for our
pilót mill
% C~ = mill speed, as a percent of critica! speed 172 % on
both pilot tests performed).
Pap = apparent C.ensity of the mill charge {balls + pulp),,
expressed as ton/m 3 •
%CL = percent of circulating load attained en the specific
pilot.grinding test (depending on ore hardness, rate
production of fines, classifier efficiency and the
circui.t configuration tested) . See Table 1.
% f = % filling (percentage of interna! miíl volume being
filleé! by_the mill charge). See Ta!Jle 1.
Let subind exes 1 and 2, denote the pilot plant and fÜll-sc ale
values for all variab les involve d in Equatio n 3. Let us assume
also, as a first es·ti!lla te,. 'that' (\~Ll = (\CL)? ' '(Oap) = (Oap) ,
1 1 2
and K1 = K •
2
.. . ...
-
Net PO'#er Consum ed by 'the Kopper s 6 'x 2' cascad e
.:,
TABLE 5.-
-· ,<
"'ap
(ton/.
\
·<=¡, ' '¡
%
f
Net PcMer (kW)
M:e3.mD !l'.redi.c! 1
1 %
1 i m3) : '
1
'
·cr::.l)3
¡ •
1
j E:::ror
¡ ' !
i
1 1-Ml
1-M2
1
1 SAG 6 1 1/3 72 1i2.311
'2Z7 28.6'
,¡
9.65 ¡ 9.94 ¡+3.0
i 1 ; 2.311 169 28.6·· 9.92 9.60 1-3.2
A'i!ER1GE (51\G) !n 6 1/3 1 7212.31 1 198
'
~ '28.6
11
9.79 i 9.78
1
i-O.l
; ¡
2 2-Ml ' SABC-1 72 1 2.580 27.2 1 24.1 8.64 1
8.44 ¡-2.3
6 1/3
2-M2 i 2.580 24.9; 24.11 8.19
'' !
8.42 1+2.8
AVDU\GE (SAOC-1)
6 1/3 72 2.580 26.1,24.1 1 8.42 ¡ 8.43 :+0.1
'' i
PN2.
-= •
(L/D)
2 ·[% t 2 - 1.076 xl0-2
(4)
(L/0) l
%f
1 - 1.076 xlO -2
We will apply now Eq. 4, for sizing an industrial cascade
' mill forming.part of a full-size concentrator treating 15,000
tons/day (about 625 tons/hourl of the chilean ore, under the
following operating conditions selected for the SABC-1 grinding
circuit :
We also have·
o
1 = 6 ft. (pilot mill diameter)
Then :
Rene e 0
2
= 5.89 X 6 = 35.3 ft 'C 36 Based on semi- autog enous
ft.}
and L = 35.3x 0.417 = 14.7 ft"' 15 ft. rnill world wide insta 11ati ons.
2
(*) REMARKS An over all Safe ty Fact or value (SF= 1.2) has
been
appl ied upon the above-calculat~d net powe r consu
figu res, so as to acco unt for samp le repre senta mptio n
tiven ess,
even tual diffe renc es arisi ng from pilo t testi ng
runn ing agai nst the expe cted indu stria l circ uit
perfo rman ce, over all syste rn losse s ocur ring in
grind ing circ uit (whic h inclu des mech anica l and the
powe r loss es), and so on. The corr ecte d net powe r
elect ric -
'·
consu mptio n figu re, there fore
powe r consu rned by the moto r at resem bles the gros s
indu stria l scal e .
(*) These oirerall figures, match well with tlie respective pilot plant
rreasurements (see Table 1 l
••• 1
--"!:-
•
•:!,..-
=
Then
and
D
L"
17.92 ft ~ 18'
(L/D)• D" 26.-89 f t " 27' ) 0 X L = 18' X 27'
(Selected ball-mill CUrnensions)
APPEND!X A
-.
-
....
--
1 CUQM
1 '
~
;
1 v..........
-·- l
($
l
..__ ...
---,~ llolliiU
·'
Cl!-c:utt SABC-1.- Doubt•-ri"9" s•I'IIClutog•nous,' wtth ,.,."avC>~
l
1
1
1
!
-<
APPENDIX ~
SECTION CONTENTS
·'
DIVISION MINERALURGIA
CIMM, 1988
PROYECTO
OBSER'J4CION"..S :
MINERAL
.•
PROYECTO : • '-:"
BALANCE DF MATERIALES
VALORES SIMULADOS
--- --- --- --- --- --- --- --- --- --- --
TOI€'.AJt SECO, TON/~ : 142.4 1578.6
ó25.C 953.7 625.0
17(1.0 17?1.0
Z75.4 E2.8 252.6 152.o 100.Cl
X 100.0 275.4
69é.~5 ó9b.5 7.7 131~.6 35~.0 957.6
~AIJM. AG'JA, M3 /HR : 1.1
2417.6 <417 .ó 150.1 2593.3 1310.; 1582.6
!ONELAJE ?V"..PA, TON!UR : 626.1
1334.0 ~334.0 6C.9 1899.3 1189.1
CAUDAL P'.LPA, ~3 Ml : 232.6
1812.3 -1812.3 2454.5 1523.4 1845.5 :33C.9
D:NS. PU'-=A, Co/l /LT : 2692.5
71.2 54.6 72.: 39.5
?OOC. SC<L:DCS, ftl PESO 99.8
~oc.~
~5240C. 83.02 ~Do.e ·.:::.:
76200. sg.6·: 54.97 ,90.G ."':"'..... t,;n
'.,.. 10D.G ""'r"·
/,,-'\.. .... _
""r">
·:JG.D
:aeoc. ~6 .• W BA.Z4 ~OC.J -:::.e ~oc.o :no.o
:::.u HJQ.D ~oc.c
42.7a
5 t?iOC. 30.za ;z.:;s ~nn ,.,
-... w' v 100.0
' ~7j!J.
,.., 'F''
:. '.wv 7.48 ~-.58
FT 32.00
TONE\AIE ..SECO,
.- ... . _-¡
,,.. __ f>ll
?~.-~.:
o 3 ¡;¡, ......... o,;:; • =-~ 9Z.?:
. .,.;: -.
' ~ -¡..,._,
~
61.Z3 ~G .:J::
a ' . .:;35C. =e• -,e,
.J ' ..... 39.::·
:¡ S 226C. 57.25 87.tt
¡, 1., ...,....
l·..l ~s
i too .. ·' :,5.29 86.!?
¡~ 1! -~
........
' 4 ::r 53.01 :'}! .. -?
......,., ......
:z ""
""" 85-0. 4~ .e:. 31.!5
-~ '7 23 .;i..;:_. 45.2~ 77 .:!!
·'4 3"!
""48~· 42:.. 70.2~
;
••- ,,
;::. 2a*~c: C;:..;,
,,'"
-~6 6; ........
.,~~
2·1. 75. ...., .
•"
1JG -·=-
......... -~S.4G .1' -:. ....
''""'"'
:8 -~so -::)L. 1·1. a~ J!.~2
·19 200 74. 9.~7 27 .~-;
•o
20
:::·¡
""'
:_¡u
4G·é 3"!
6.22
1:,.67
''·
"!-
2·i.9ó
.. -
:,
Z!!354. 90 . 733.04
SECTION B.2
SABC -1 CIRCU IT
DIVISION llliGil.IJ!GIA
CII1!1, 1938
=e • PROGRAIIA 9lil.l.BAL • = •
PROYECTO : 547
OBSERVACIONES :
BALA' ~ DE IIATERIAL ES
VALú;1:" Slii\Jt.ADOS
TON/HR . --·-·-·-
6..'5.0 757.7 787.7
··-------------
162.7 6..'5.0 162.7
TONELAJE SECO,
'l. 100.0 126.0 126.0 26.0 100.0 26.0
CA'JDAL AGI..'A, M3 /HR : 1.0 2b8.9 2b8.9 4.5 721.2 4.5
TONEI.AJE PULPA, TON/HR : 626.0 1056.6 1056.6 1>17.< 1346.2 1ó7 .2
CAUDAL PlJIJA, 113 /HR : 232.5 560.6 560.6 64.8 952.7 64.8
DENS. Pl.tPA, GR ILT : 2692.5 1884.7 1884.7 2581.3 1413.1 2581.3
PO!lC. S:lt.IDOS, EN PfSv 99.8 '4.6 74.6 97.3 46.4 97.3
--------------------------·--- ---------------------
GRAIM.OI'F.TRIAS IPO!lC. BAJO LA MA!.LAl
1 MAI.LA M!CROt~S
CAWL AGIMI, 113 /11! : Z68.'10 Déls. lf', CARGA BOUIS, TON/ 113 r 4.65
TON/111 : 105ó.60 NIVEL LlENA!lO BOLAS, '% 7.oo
T!lfl.AJE P\lPA,
113 llfl 1 560.60 l \e... CRITICA, X 76.00
CAW!t. l'UI..PA,
GR /LT 1 1884.70 POT. !fe-C A lf:TA, KW : 66'15.00
DEIIS. PI! PA, 8. 50
PORC. SOLIDOS, t : 74.60 CONS. ENEliGIA tEro, K"'!ITON 1
-- -- -- -- -- --
GRrtM.OI'IETRIAS ( l BAJO LA M.l.A l
1 IW.1A l'llCRONfS ALIIENTACION DESCARGA
--
DIVISION HINERALURGIA
CII'I'I, 198&
¡.
PRCYECTO
O!IXRVACIONES :
?arám~tros ae Diseño y Op@ractón ~e la ~olienda Secundaria
en Circai\o SABC-1 115000 TM'D:.
CIRCVITO Inverso.
~ROVECTO :
1 MLLA MICRONES
97.4i 'lb.'23 99.15 9!.25 %.23 100.00
1 4 4750. 100.00
98.7'1 9ó.61 'IZ,b~
2 6 3350. 94.72 92.69
98.~ 94. '18 89.17 100.00
3 a 2360. 92.06 89.17
93.41 85.80 ~00.00
4 10 1700. 89.52 as.ao 97.91
&b.30 8'.52 97.35 91.43 81.52 100.00
5 14 1180. mo.co
~.'1'1 95.45 8a.lló ~.'1'1
b 20 es!'J. 82.30
9ii',.94 ·
7i.61 b8.74 94.55 85.47 68.74
'! 28 1.00.
59.08 90.64 SC.64 59.08 99.2°
8 35 425. 71.98
&4.i1 74.44 ~.68 %.72
9 48 :co. 65.54 41l.ba
37.7ó 90.20
10 65 212. 58.69 37.16 74.28 1>5.92
29.78 b3.12 5i.57 ?9.78 31.60
~1 100 150. 52.76 69.7e
1fli>. 4ó.D4 2E.i? 50.22 47.98 '?.2..77
12 150 15.30 5C?.b2
74. 40.57 18.30 40.31 40.45
13 20C 15.16 51.0Z
•14 270 53. 35.61 15.16 32.'17 34.3'1
27. 7'1 29.62 12. (jQ 44.10
37. 31.21 12.90
15 400
--
1030.78 257.~ 410.61 108n.78 143.5:
D80, I'I!CRCNES
-- -- -
718.22
-- - -- -
AGUA AL POZO, M:l/HR 41. '10
CO/iS. ESDE:CIFICO OE OOGIA kllh/TM :· 4.!0
CON!': ''.'<!:S DE OPERACION Y DISE;íO
I'!Ol!NO
--·· -·----- ---
TllNE!AIE SECO, TON/HR : 540. 7'1 DIMTRO, FT 18.00
% f 81,,53 lARGO, FT 27.00
ClltiDAL AGUA, 1'0/HR: 197.11 DENS. AP. CARGA BOLAS, TON/ l'l:l : 4.65
TONElAJE PULPA, TON/HR : 737.'10 . NI\.9. Ll.ENAOO BOlAS, % 40.00
CAIJllAL PULPA, l'f.? /HR : 397.40 Xva. CRITICA, z 70.00
WlS. P~'LPA, GR /LT : 1856.81 POT. MECANICA NETA,
PORC. SOLIDOS, ., 73.29 COHS. ENERG1A NETO,
KW
KIWTON ·:
: 3000.00
5.55
•
---·--- ------ ----- ~------
-------~-.----------------------
PROYECTO r
<