Chapter

ROD AND BALL MILLS

By:

Chester A. Rowland, J r .
and
Sr. Process - P r o j e c t Engineer
Process Development Engineering
Mining Systems D i v i s i o n
A1 1is-Chalmers Corporation

David M. ~ j o s , Mgr.
Grinding N i l 1
& Special Eqpt. Appl i c a t i o n
Mining Systems D i v i s i o n
A1 1 is-Chalmers Corporation

INTRODUCTION
M i n e r a l o r e comninution i s g e n e r a l l y a feed p r e p a r a t i o n s t e p f o r subsequent processing stages. Grinding, t h e f i n e product phase o f comminution, r e q u i r e s a l a r g e c a p i t a l investment and f r e q u e n t l y i s t h e
area o f maximum usage of power and w e a r . r e s i s , t a n t m a t e r i a l s .
G r i n d i n g i s most f r e q u e n t l y done i n r o t a t i n g drums u t i l i z i n g loose
g r i n d i n g media, 1 i f t e d by t h e r o t a t i o n o f t h e drum, t o break t h e ores
i n v a r i o u s combinations o f impact, a t t r i t i o n and abrasion t o produce
t h e s p e c i f i e d product. G r i n d i n g media can be t h e o r e i t s e l f (autogenous g r i n d i n g - primary and secondary), n a t u r a l o r manufactured nonmetal 1i c media (pebble m i l 1i n g ) o r manufactured metal 1 i c media - s t e e l
rods, s t e e l o r i r o n b a l l s . T h i s chapter covers rod and b a l l m i l l s
which u t i l i z e manufactured m e t a l l i c g r i n d i n g media. Fig. 1 shows t h e
cross s e c t i o n o f an o v e r f l o w r o d m i l l , F i g . 2 an o v e r f l o w b a l l m i l l ,
and F i g . 3 a diaphragm ( g r a t e ) discharge b a l l m i l l .
MILL DESIGN
.,.

The i n t e r i o r ' s u r f a c e o f rod and b a l l m i l l s exposed t o p u l p and/or

g r i n d i n g media a r e p r o t e c t e d f r o m wear and c o r r o s i o n by rubber, metall i c o r a combination o f rubber and m e t a l l i c wear r e s i s t a n t ma'terials.
Rod and b a l l m i l l s e s s e n t i a l l y draw constant power, t h u s a r e w e l l
s u i t e d f o r use o f synchronous motors w i t h power f a c t o r c o r r e c t i o n
c a p a b i l i t i e s 'as d r i v e motors. A n e t o f approximately 120 t o 130
percent o f running torque i s r e q u i r e d t o cascade the charge i n these
m i l l s . The p u l l - i n torque i s about 130 t o 140 percent w i t h t h e p u l l o u t torque t o keep t h e motor i n - s t e p (in-phase) g e n e r a l l y i n excess o f
150 percent. When r o d and b a l l m i l l a r e s t a r t e d across-the-line t h e
s t a r t i n g and p u l l - i n torques r e s u l t i n i n r u s h c u r r e n t s exceeding 600

240

MINERAL PROCESSING PLANT DESIGN

Fig. 2

Overflow B a l l M i l l

Fig. 3

Diaphragm B a l l M i l l

MINERAL PROCESSING PLANT DESIGN

percent which r e s u l t i n p o s s i b l y h i g h v o l t a g e drops. To d e l i v e r 130
percent s t a r t i n g torque t o t h e m i l l t h e motor design must t a k e i n t o
account t h e maximum a n t i c i p a t e d v o l t a g e drop. Motor torque decreases
as t h e decimal f r a c t i o n o f t h e v o l t a g e a v a i l a b l e squared. E.g., a
motor r a t e d 160% ~ t a r t i n g ~ t o r q uwei t h a 10% system v o l t a g e drop w i l l
d e l i v e r 160% x (100%-10%) o r 129.6% torque t o i t s o u t p u t s h a f t .
100
when, i t i s n o t p o s s i b l e o r p r a c t i c a l t o s t a r t a f u l l y loaded synchronous motor a c r o s s - t h e - l i n e i t i s p o s s i b l e t o u t i l i z e t h e motor,'^ p u l l o u t torque t o s t a r t t h e m i l l . By u s i n g a c l u t c h , normally an a i r
c l u t c h , between t h e motor and t h e m i l 1, t h e motor i s brought up t o
synchronous speed b e f o r e the c l u t c h i s energized. I f the motor has
an adequate amount (175 o r g r e a t e r ) o f p u l l - o u t torque t h e p u l l - o u t
torque s t a r t s t h e m i l l w i t h o u t major d i s r u p t i o n s on the e l e c t r i c a l
system.
Since t h e energy r e l e a s e a t i n i t i a l cascade o f t h e m i l l ' charge i s . an
i n v e r s e f u n c t i o n of a c c e l e r a t i o n time, a minimum a c c e l e r a t i o n t i m e o f
6 t o 10 seconds o r more i s recommended t o prevent damage t o t h e m i l l
o r t h e m i l l foundation.
Economics a t t h e t i m e o f p l a n t design and m i l l purchase determine t h e
d r i v e t o be used. The s i m p l i e s t d r i v e i s t h e low speed synchronous
motor w i t h speeds i n t h e range o f 150 t o 250 RPM connected t o t h e m i l l
p i n i o n s h a f t by e i t h e r an a i r c l u t c h o r f l e x i b l e coupling. Using a
speed reducer between t h e motor and p i n i o n s h a f t permits u s i n g motors
having speeds i n t h e range o f 600 t o 1000 RPM. I n t h i s speed range,
i f power f a c t o r c o r r e c t i o n i s n o t r e q u i r e d i n d u c t i o n motors can be
used; s q u i r r e l cage where t h e r e i s no r e s t r i c t i o n on i n r u s h c u r r e n t ;
s l i p r i n g where a slow s t a r t and low i n r u s h c u r r e n t i s r e q u i r e d . A i r
c l u t c h e s can a l s o be used t o ease s t a r t i n g problems w i t h s q u i r r e l cage
motors. I n some areas o f t h e w o r l d i n d u c t i o n motors and s t a r t e r s a r e
l e s s expensive than synchronous motors a t a s a c r i f i c e o f motor e f f i c i e n c y and power f a c t o r c o r r e c t i o n .
Dual d r i v e s , t h a t i s two p i n i o n s d r i v i n g one gear mounted on t h e m i l l ,
become economical f o r ba.11 m i l 1 s drawing more than 3500 t o 4000 horsepower (2600 t o 3000 k i 1owatts) .
F u r t h e r developments o f t h e 1ow frequency , low speed synchronous motors
w i t h t h e r o t o r mounted on t h e m i l 1 she1 1 o r an extension o f one o f t h e
m i l l t r u n n i o n s c o u l d improve t h e c o s t p i c t u r e f o r these "gearless
d r i v e s " , making them p r a c t i c a l f o r l a r g e b a l l m i l l s .
The percent o f c r i t i c a l speed, which i s t h e speed a t which t h e c e n t r i f u g a l f o r c e i s s u f f i c i e n t l y l a r g e t o cause a small p a r t i c l e t o adhere
t o t h e s h e l l l i n e r s f o r t h e f u l l r e v o l u t i o n of. the m i l l i s given i n
m i l 1 s p e c i f i c a t i o n s . C r i t i c a l speed i s determined ' f r o m t h e f o l l o w i n g :

ROD AND BALL MILLS

Where D i s mill diameter inside l i n e r s .specified in meters.

Cs i s c r i t i c a l speed in RPM.
When D i s specified in f e e t :
m -

Peripheral speed, which doesn't influence mill power but i s a factor

in 1iner wear and t o an extent media wear, has to be considered in
mill design. I t can be determined by the following e i t h e r as meters
per minute or as f e e t per minute.

where
Mp = Peripheral speed.
D = Diameter inside l i n e r s .
N = Mill speed in rpm.
To obtain some balance of c r i t i c a l speed and peripheral speed as mill
diameters increase, the average recomnended speed as percent of c r i t i cal speed reduces a s shown in Table I . These are guide lines f o r i n i t i a l plant design. Actual speeds may d i f f e r from these to s u i t e specif i c ore and economic conditions t h a t apply t o the, specific plant.
ROD 'MILLS

To prevent most kondi tions leading t o rod charge tang1 ing, the generall y recommended relationship of rod length t o mill diameter inside l i ners i s 1.4 t o 1.6. When t h i s r a t i o becomes less than 1.25 the r i s k
of tangling increases rapidly. For rod mills larger than 3 . 8 meters
(12.5 f e e t ) in diameter rod a v a i l a b i l i t y and quality have t o be considered. Table I1 gives rod length to mill diameter r a t i o s for the
larger diameter rod mills.
6.8 meters (20 f e e t ) i s a practical limit on the length of good quali t y rods ( t h a t i s rods that will stay straight in the mill and will .

break into pieces t h a t will discharge from the mill when worn). This
length i s a function of rod quality and production l i m i t s imposed by
the suppliers. The mill length inside end l i n e r s measured along the
surface of the she1 1 l i n e r s should be 0.1 t o 0.15 meters (4" to 6")
longer than the rods, so that the rods will f i t in the length of the
grinding chamber without tipping or laying across the charge. A slope
a s steep as possible should be used for rod mil 1 head (end) 1iners to
Prevent unsupported ends of rods from protruding from the charge and
being broken under impact from other rods.

MINERAL PROCESSING PLANT.DESIGN

TABLE I
AVERAGE % OF CRITICAL SPEED

.% OF CRITICAL SPEED

MILL DIAMETER
INSIDE LINERS
METERS

FEET

0.91-1.83
1.83-2.74
2.74-3.66
3.66-4.57
4.57-5.49

3-6
6-9
9-12
12-15
15-18

---ROD MILLS
76-73
73-70
70-67
67-64

TABLE I 1
ROD MILL DIAMETER

MILL DIAMETER
INSIDE LINERS
METERS
3.81
3.96
4.11
4.27
4.42
4.57
4.72
4.88

5.03

FEET
12.5

13

'

13.5
14
14.5
15
15.5
16
16.5

BALL MILLS

80-78
78-75
75-72
72-69
69-66

ROD LENGTH

ROD LENGTH
L = 1.25 D
L=1.4D
,

I
I

METE'RS .FEET
-

METERS

FEET

ROD AND BALL MILLS

.I

245

The r o d s p e c i f i c a t i o n s given i n Table I 1 1 can be considered as a m i n i mum s p e c i f i c a t i o n . B e t t e r r o d q u a l i t y , which reduces breakage, a l l o w s

wearing t h e rods t o a smaller s i z e and which can reduce r o d o p e r a t i n g
c o s t s a r e a v a i l a b l e . The b e t t e r q u a l i t y rods a r e g e n e r a l l y recommended when u s i n g 100 mm ( 4 " ) diameter. rods and/or t h e l a r g e r .diameter
rod mills.
The feed end o f rods wear i n t o a l o n g tapered "spear-shaped" p r o f i l e ,
w h i l e t h e discharge ends wear i n t o more o f a c o n i c a l shape. Approximately t h e middle two t h i r d s o f t h e r o d l e n g t h e v e n t u a l l y wears i n t o
an e l i p t i c a l shaped section. Small pieces o f broken rods can accumul a t e i n t h e m i l l b e f o r e being discharged. The tapered wear and accumu l a t i o n o f broken rods reduces t h e b u l k d e n s i t y o f the m i l l charge,
and thus m i l l power. The r o d charge b u l k d e n s i t y given i n Table I V
can be used t o determine t h e power a r o d m i l l w i t h a worn-in charge
should draw. Bulk d e n s i t y i s a v a r i a b l e s u b j e c t t o c a r e given a r o d
charge, and experience i n d i c a t e s m i l l diameter a l s o has an e f f e c t on
b u l k d e n s i t y o f t h e worn-in charge. The l a r g e r t h e diameter o f t h e
r o d m i l l t h e l e s s p r a c t i c a l " c u l l i n g " o f t h e charge becomes.
Rod m i l 1s normally c a r r y from a 35 t o 40% by m i 11 volume r o d charge,
t h e y can c a r r y up t o a 45% charge. The l i m i t s on charge l e v e l are:
keeping t h e feed end t r u n n i o n open so feed w i l l go i n t o m i l l , and
keeping t h e r o d ' c h a r g e low enough so rods w i l l n o t work i n t o discharge
end t r u n n i o n opening, where t h e y can t i p and cause r o d t a n g l i n g .
Rod m i l l s a r e n o r m a l l y f e d by spout feeders as shown i n Fig. 4. A
minimum head o f 1.5 meters ( 5 f e e t ) above t h e m i l l c e n t e r l i n e t o t h e
bottom o f t h e feed hopper t o which t h e feeder i s attached i s r e q u i r e d
t o g e t t h e proper f l o w o f feed i n t o t h e m i l l .
Heavy d u t y s i n g l e wave she1 1 1i n e r s c a s t o f ' e i t h e r 'a1 l o y s t e e l (mang.
anese s t e e l i s n o t recommended). o r . wear r e s i s t a n t a1 l o y e d c a s t i r o n
are most f r e q u e n t l y u s e d ' i n r o d m i l 1s. The number o f l i f t e r s t o t h e
c i r c l e i s u s u a l l y equal t o approximately 6.6 D - i n meters ( f o r D i n
(2.5") t o 90 nnn
f e e t d i v i d e 6.6 D b y 3.3). These l i n e r s have 65
(3.5") h i g h waves above 65 mm t o 75 mm ('3") l i n e r s . Rubber backing
can be used between t h e l i n e r s and s h e l l ' . t o p r o t e c t t h e s h e l l from
washing and c o r r o s i o n . However, w i t h rubber backing care must be
taken w i t h t h e l i n e r b o l t s p e c i f i c a t i o n s , and s e a l e r assembly t o assure
t h e l i n e r s w i l l s t a y t i g h t and n o t move on. t h e s h e l l . T h i s creates
l e a k y l i n e r b o l t s and causes t h e b o l t h o l e s i n t h e s h e l l t o wear i n t o
an elongated shape. There a r e m o d i f i c a t i o n s such as t h e two piece
1 i n e r - l i f t e r design t h a t can be used i n s t e a d o f the s i n g l e wave
l i n e r . Rubber s h e l l l i n e r s have been successfully a p p l i e d i n the
s m a l l e r diameter r o d m i l l s running a t slow speeds. When u s i n g rubber
l i n e r s care must be given t o u s i n g good q u a l i t y rods and c u l l i n g broken and t h i n rods from t h e charge. Rubber l i n e r s can h e l p reduce t h e
n o i s e l e v e l emanating from a r o d m i l l .

MINERAL PROCESSING PLANT DESIGN

TABLE I1 I

M I N I M UROD
M SPECIFICATIONS

Grinding ~ n i l lrods should be hard enough t o remain s t r a i g h t throughout

t h e i r e n t i r e l i f e , y e t they cannot be so b r i t t l e a s - t o break up a t coaise
sizes.
When rods a r e too s o f t , they a r e subject t o bending in the m i l l . Bending
causes premature breakage and tanglement of rods. Tangled rods make mil 1
cleaning d i f f i c u l t and hazardous, and cause c o s t l y downtime.
Material of the following chemical analysis i s recommended :
CHEMICAL ANALYSIS
Carbon

0.85 t o 1.03%

Manganese

0.60 t o 0.90%

Silicon

0.15 t o 0.30%

Sulphur

0.05% Max.

Phosphorous

0.04% Max.

PHYSICAL REQUIREMENTS
Rods should a l s o have the following physical requirements:

. Rods a r e t o be special commercial straightened.

. Rods a r e t o be hot sawed t o length where mill
( s t e e l ) f a c i l i t i e s permit. If hot sawing i s
not possible, use amabrasive c u t t i n g wheel
o r machine c u t both ends t o proper length.

. All

grinding mill rods should be 152 mn (6

inches) s h o r t e r in length than the working
length of t h e rod mill.

247

ROD AND BALL MTLLS

TABLE I V
BULK DENSITY WORN-IN ROD CHARGES
BULK DENSITY
KG PER CUBIC METER
LBS PER CUBIC FOOT
NEW RODS

6247

WORN-IN CHARGE
M I L L DIAMETER
METER

FEET

Fig. 4

Spout Feeder

390

MINERAL PROCESSING PLANT DESIGN

248

End l i n e r s a r e g e n e r a l l y a t h i c k , smooth l i n e r c a s t o f a l l o y s t e e l .
Impacting from t h e r o d charge, which has a l a t e r a l movement i n t h e
m i l l , r e q u i r e s g r e a t c a u t i o n i n u s i n g wear r e s i s t a n t c a s t i r o n end liners. Rubber l i n e r s can be used w i t h c a u t i o n as they can be s u b j e c t
t o damage from t h e sharp ends on worn rods. Except when u s i n g rubber
l i n e r s t h e r e should be a rubber backing between t h e head l i n e r s and
t h e heads. End l i n e r s should be smooth w i t h no waves o r . l i f t e r s as
these can d i s r u p t r o d a c t i o n and cause r o d t a n g l i n g .
Rod m i l l s can be equipped w i t h trommels t o remove bioken pieces of
rods and tramp o v e r s i z e from the r o d m i l 1 discharge. The discharge
end o f a r o d m i l l can be enclosed i n a housing which w i l l h e l p cont a i n t h e n o i s e and splash coming from t h e m i l l . A door should be prov i d e d a t t h e end o f the housing which can be opened f o r charging rods.
S u f f i c i e n t c l e a r space a t t h e discharge end o f the m i l l should be a l lowed f o r charging rods. See F i g . 5.
The f o l l o w i n g equation i s used t o determine the power t h a t a .rod m i l l
should draw.

where
K W ~=

K i l o w a t t s per m e t r i c tonne o f rods (1000 kg).

= M i l l diameter i n s i d e l i n e r s i n meters.

= F r a c t i o n 'of m i l l volume loaded w i t h rods.

f b s = F r a c t i o n o f c r i t i c a l speed.

I n terms o f m i l l diameter i n f e e t and rod charge i n s h o r t tons (2000

pounds) t h e equation becomes:

Table V l i s t s many o f t h e common s i z e r o d m i l l s g i v i n g speed, l o a d i n g

and power data. The power i s i n horsepower a t t h e m i l l p i n i o n s h a f t .
For d i f f e r e n t l e n g t h r o d m i l l s power v a r i e s d i r e c t l y as r o d l e n g t h .
For d i f f e r e n c e between new and worn l i n e r s increase power draw by 6%,
and a d j u s t f o r b u l k d e n s i t y per Table I V .
Wet g r i n d i n g r o d m i l 1s a r e normally used. i'n minerals processing p l a n t s .
Experience w i t h d r y g r i n d i n g g e n e r a l l y i n d i c a t e s many d i f f i c u l t problems and should be avoided except where a b s o l u t e l y necessary; i n which
case t h e problem should be r e f e r r e d t o the m i l l manufacturers f o r r e comnendations.
The v a r i o u s r o d m i l l manufacturers have d i f f e r e n t equations f o r d e t e r m i n i n g t h e power r o d mi 11s draw, b u t a1 1 come c l o s e t o the same c a l c u l a t e d power draw.

ROD AND BALL MILLS

249

TABLE V
ROO M I L L POWER AT M I L L PINIONSHAFT (HORSEPOWER)
ROO
MILL
DIAMETER

'ROO
MILL
LENGTH

-.

'

ROD AND BALL MILLS

251

BALL MILLS

Being free o f t h e 1 i m i t s imposed on r o d m i l 1s by t h e rods, b a l l m i l 1s

have more v a r i a t i o n s i n l e n g t h t o diameter r a t i o s , ranging from LID
There a r e
r a t i o s o f s l i g h t l y l e s s than 1 :1 t o some g r e a t e r than 2:l.
no f i x e d r u l e s on t h e proper LID r a t i o s t o use as these vary w i t h the
c i r c u i t used, o r e type, feed s i z e and o v e r a l l g r i n d i n g requirements.
Table V I gives some rough guide 1 ines showing, based upon past e x p e r i ence, t h e general C/D r a t i o s used i n t h e a p p l i c a t i o n o f b a l l m i l l s .
G r i n d i n g b a l l s can be made o f f o r g e d o r c a s t s t e e l o r c a s t i r o n . The
q u a l i t y depends upon t h e source o f supply. While n o t always t r u e ,
f r e q u e n t l y t h e b e t t e r qua1 it y b a l l s a r e forged s t e e l . General 1y b a l l s
a r e s p h e r i c a l shaped, b u t t h e y can be i n various c y l i n d r i c a l , c o n i c a l
o r o t h e r i r r e g u l a r shapes. B a l l s vary considerably i n hardness w i t h
s o f t b a l l s having B r i n n e l l hardnesses i n the range o f 350 t o 450, and
t h e hard b a l l s having hardnesses i n excess o f 700. A r u l e o f thumb
s u b j e c t t o arguments i s : " t h e harder t h e b a l l the b e t t e r i t s l i f e "
(provided i t i s n o t too b r i t t l e and b r e a k s ' o r becomes t o o h i g h l y p o l ished and t o o smooth t o n i p t h e m a t e r i a l being ground). .Local economics and the s p e c i f i c g r i n d i n g a p p l i c a t i o n g e n e r a l l y a r e the d e c i d i n g
f a c t o r s i n s e l e c t i n g t h e b a l l s t o use. The b a l l s g i v i n g the lowest
o p e r a t i n g c o s t and b e s t performance a r e g e n e r a l l y selected. This
need n o t be t h e lowest p r i c e d b a l l s a v a i l a b l e nor t h e ones g i v i n g t h e
1owest wear r a t e , b u t can 'be a compromise between t h e two extremes.
B a l l s should -be s o l i d w i t h a reasonably u n i f o r m hardness t h r u t h e ent i r e b a l l . They should wear i n a r e l a t i v e l y u n i f o r m p a t t e r n . An i n d i c a t o r o f good b a l l wear i s when t h e worn b a l l s d i s c h a r g i n g from t h e
m i l l a r e around 16 m i l l i m e t e r ( 5 1 8 " ) o r smaller i n s i z e and a r e p o l y gon shaped having as many as 8 t o 12 surfaces, which can be s l i g h t l y
concave. Evidence o f broken b a l l s i s found when pieces o f b a l l s a r e
being discharged, some as c i r c u l a r discs, some as h a l f rounds, some
crescent shaped. Pieces o f worn o r broken b a l l s w i t h holes i n them
i n d i c a t e poor q u a l i t y b a l l s w i t h sand i n c l u s i o n s and/or blow holes
and/or h o l l o w centers.

'
'

For c a l c u l a t i n g t h e power t h a t a b a l l m i l l w i l l draw, forged s t e e l

and c a s t s t e e l b a l l s a r e assumed t o weigh 4646 kilograms per cubic
meter (290 pounds e r c u b i c f o o t ) w i t h c a s t i r o n b a l l s weighing 4165
kg per m3 (260 p c f r .
B a l l mi 11s normally c a r r y a b a l l charge 'occupying from 40 t o 45% o f
t h e m i l l volume, b u t can c a r r y up t o a 50% o r s l i g h t l y higher charge.
F i g . 6 shows t h e r e l a t i o n s h i p o f m i l l power and v o l u m e t r i c loading.
For p l a n t c a p a c i t y and design purposes, b a l l m i l l s a r e f r e q u e n t l y sel e c t e d based upon c a r r y i n g 40% b a l l charges w i t h t h e m i l l s and d r i v e s
designed t o c a r r y h i g h e r charges i f required.

252

MINERAL PROCESSING PLANT DESIGN

TABLE V I
BALL M I L L L/D RATIO

APPLICAT.ION'
,,

FEED 8 0 % PASSING S I Z E

..

MICROMETERS

GENERAL GUIDELINES

.
..

'

MILLIMETER

LID ,RATIO

TOP. BALL S I Z E

INCHES

'

.,.
,

.
,

% OF MlLL VOLUME OCCUPIED BY BALL OR PEBBLE CHARGE

GRINDING MlLL POWER VS LOADING

Fig. 6

. ROD. AND -BALL.*MILLS .

253

When a 45 t o 50% b a l l charge i s t o be c a r r i e d , g e n e r a l l y a double

scoop feeder as shown i n Fig. 7 i s used. T h i s i s a more expensive
feeder than a spout feeder. as shown i n F i g . 4 , which can a l s o be used
t o feed b a l l m i l l s . P l a n t design, c a p i t a l c o s t and o p e r a t i n g c o s t s
a l l i n f l u e n c e b a l l m i l l feeder s e l e c t i o n . When a b a l l m i l l i s closed
c i r c u i t e d w i t h a rake o r s p i r a l c l a s s i f i e r , a scoop feeder i s r e q u i r e d
t o feed t h e c i r c u l a t i n g l o a d i n t o t h e m i l l . With cyclone c l a s s i f i e r s
spout feeders can be used. Spout feeders a l l o w arrangement where the
c l a s s i f i e r underflow f l o w s by g r a v i t y i n t o t h e spout feeder hopper.
Therefore, t h e cyclone c l a s s i f i e r s must be i n s t a l l e d h i g h enough t o
o b t a i n t h e head r e q u i r e d f o r t h i s f l o w i n t o t h e hopper. This can r e s u l t i n h i g h pumping heads and pump power t o pump t h e m i l l discharge
t o t h e cyclone c l a s s i f i e r s . F i g . 8 shows a s i n g l e stage b a l l m i l l i n s t a l l a t i o n u s i n g double scoop feeders w i t h cyclone c l a s s i f i e r s i n s t a l l e d a t about t h e h o r i z o n t a l c e n t e r l i n e o f the m i l l . Depending upon
t h e r a d i u s and w i d t h o f t h e scoops and t h e c a p a ~ i ~ t( yi n c l u d i n g c i r c u l a t i n g l o a d ) double scoop feeders consume from 25 t o 30 k i l o w a t t s (20
t o 40 horsepower). T h i s arrangement reduces considerably pumping head
and power and must be balanced a g a i n s t h i g h e r maintenance c o s t f o r t h e
scoop feeder.
Make-up g r i n d i n g b a l l s a r e f e d t o t h e m i l l as r e q u i r e d t h r u the m i l l
feeder w i t h t h e m i l l i n operation. B a l l s may feed d i r e c t l y through
a spout, b u t should not be f e d i n t o a scoop box because o f p o s s i b l e
jamming and serious mi 11 damage. Scoops usual 1y have a. c e n t r a l b a l l
feed p i p e o r a small charging drum t o accomplish t h i s .
.
:
There a r e many d i f f e r e n t designs and s t y l e s o f b a l l m i l l l i n e r s . As
w i t h ' g r i n d i n g b a l l s l o c a l economics and u l t i m a t e l y o p e r a t i n g costs
determine. the. best' design and m a t e r i a l t o use. The i n i t i a l s e t o f
1 i n e r s 'is , r a r e l y t h e f i n a l design, selected. Based upon i n d i v i d u a l
experience-, mil.1 superintendents develop perferences f o r l i n e r designs. 'The:following i s given as a guide l i n e f o r t h e i n i t i a l s e t
o f 1i n e r i ' ;
.
7 . ' . .. ' .
A. - ~ d 60
r mm ' ( 2 . 5 " ) and smal.ler t i p - i i z e . b a l l s f o r c a s t metal
1.i'ners use double wave 1 iners.:wi t h t h e number o f l i f t e r s t o
;
"
t h e c i r c l e approximately 13.1 D i n meters ( f o r D i s i n f e e t
. d i v i d e 13; 1 D by 3:3).
Wave h e i g h t above the 1 i n e r s from
1.5 t o 2 'times the l i n e r thickness. Rubber l i n e r s o f t h e
i n t e g r a l .molded design f o l l o w t h e c a s t metal design. I f
u s i n g the' replaceable l i f t e r b a r design i n e i t h e r metal o r
r u b b e r t h e number o f l i f t e r s should be about 3 . 3 T D i n
meters ( f o r D i s i n f e e t d i v i d e 3.3-fD
by 3,3) w i t h the
,
. . l i f t e r h e i g h t above t h e l i n e r s about t w i c e t h e l i n e r t h i c k ness. ...'
.
.
4 . .

'

.. .
.

--

'

.. . .

The use o f double wave. 1i n e r s , p a r t i c u l a r l y 'when using 5 6

inm ( 2 " ) . o r l a r g e r bal.ls, may show a l o s s of 5% o r so i n t h e
m i l 1 power draw u n t i l t h e waves wear i n 'and' t h e b a l l s can

MINERAL PROCESSING PLANT DESIGN

Fig. 7

- S i n g l e o r Double Scoop Feeder

Fig. 8

Duval S i e r r i t a P l a n t

ROD AND BALL MILLS

n e s t between t h e l i f t e r s . When l i n e r s , and double wave liners i n particu1ar;wear
w i t h c i r c u m f e r e n t i a l grooves, s l i p p i n g o f t h e charge i s indicated, and t h i s warns o f acceler a t e d wear. When t h e t o p s i z e b a l l i s smaller than 60 mm
(2.5") and m i l l speed i s l e s s than 72% o f c r i t i c a l wear r e s i s t a n t c a s t i r o n s can be used. For o t h e r c o n d i t i o n s a l loyed c a s t s t e e l i s recommended.
Rubber 1i n e r s a r e w e l l s u i t e d t o t h i s same area and n o t o n l y
reduce operating costs b u t can reduce n o i s e l e v e l s .
B.

S i n g l e wave l i n e r s a r e recommended f o r l a r g e r s i z e b a l l s (60

mm/2.5" and l a r g e r ) . The number o f the 1i f t e r s t o the c i r c l e equals approximately 6.6 D i n meters ( f o r D i s i n f e e t
d i v i d e 6 . 6 D b y 3.3). T h e l i n e r s a r e f r o m 5 0 t o 6 5 m m t h i c k
(2" t o 2.5") w i t h t h e waves from 60 t o 75 mm (2.5" t o 3")
above t h e 1 i n e r s . The replaceable l i f t e r bar design made
o f e i t h e r metal o r rubber i n about t h e same design proport i o n s can be used. There could be a l o s s i n power w i t h
rubber p a r t i c u l a r l y i f t h e m i l l speed i s f a s t e r than about
72% o f c r i t i c a l speed and t h e b a l l s i z e i s l a r g e r than 75
mm

Because o f t h e impacting from t h e l a r g e b a l l s , s i n g l e wave

1i n e r s f o r b a l l m i l l s are u s u a l l y made from a1 loyed s t e e l s
o r special wear-resistant a l l o y e d c a s t i r o n s . Because o f
t h e d i f f i c u l t y o f , balancing growth and wear w i t h work hardening manganese s t e e l i s used i n f r e q u e n t l y and then w i t h extreme c a r e t o a l l o w f o r growth.
C.

D.

End l i n e r s f o r b a l l m i l l s c o n f o r m t o t h e s l o p e o f t h e m i l l
head and can be made o f rubber, a l l o y e d c a s t s t e e l o r wear
resistant., c a s t i r o n . To prevent r a c i n g and excessive wear
. end 1i n e r s . f o r ' b a l l m i l l s are f u r n i s h e d w i t h i n t e g r a l r a d i a l
r i b s o r w i t h replaceable l i f t e r s o r w i t h both.
When a g r a t e discharge i s used t h e grates and wear p l a t e s
a r e normally perpendicular t o t h e m i l l a x i s w h i l e t h e d i s charge pans conform t o t h e slope o f t h e m i l l head. The
g r a t e s and wear p l a t e s a r e normally made from a l l o y e d wear
r e s i s t a n t c a s t s t e e l o r rubber. They a r e r i b b e d t o prevent r a c i n g and excessive wear. The dischargers and pans
a r e g e n e r a l l y made from e i t h e r wear r e s i s t a n t c a s t i r o n
o r rubber, o r wear r e s i s t a n t f a b r i c a t e d s t e e l .
S l o t p l u g g i n g can be a problem i n g r a t e discharge m i l l s .
Whether t h e grates a r e made o f metal o r rubber t h e s l o t s
should have ample r e l i e f tapered toward t h e discharge
side. T o t a l angles 7 t o 10 degrees (3.5 t o 5 degrees
p e r s i d e ) a r e commonly used. Metal grates o f t e n have

256
'

'

MINERAL PROCESSING PLANT DESIGN

'.
-.

. ..

a small lead-i.n 'po,cket o r reces's whi'ih 'can f i1.1 i n w i t h

peened meta1"rather than have t h e * s l o t peen: shut.' With
t h e proper combinati.on o f metal, i - n t h a l s and rljbber surfaces,' rubber g r a t e s ' . h a v e " f l e x ' i b i l i t y t h a t tend'to make
them s e l f cleaning and y e t n o t f a i l due t o f l e x i n g .
Except when using rubber l i n e r s , t h e m i l l surfaces are
covered w i t h a p r o t e c t i v e rubber o r p l a s t i c m a t e r i a l t o
p r o t e c t t h e surfaces from p u l p r a c i n g and corrosion.
T h i s i s done i n wet g r i n d i n g m i l l s : Since d r y g r i n d i n g
m i l l s g e t h o t due t o heat from g r i n d i n g g e n e r a l l y rubber
l i n e r s and rubber m a t e r i a l s cannot be used.

E.

>

The follow in^ equation.'i's used t o determine t h e power t h a t wet g r i n d i n g overflow ba1.l m i l 1s- should draw.
..

= 1.879

.+ :
.

where

K W ~=

D
V
fFs
Ss

(3.2-3 vp)
. . . -. .

K i l o w a t t s per m e t r i c tonne o f b a l l s (1000 k g ) .

= M i l l diameter i n s i d e l i n e r s i n meters.

= F r a c t i o n o f m i l l volume loaded w i t h b a l l s .
= F r a c t i o n o f c r i t i c a l speed.

= B a l l s i z e factor..

I n terms o f m i l l diameter i n f e e t ' a n d power'per s h o r t t o n a t (2000

pounds) o f b a l l charge Equation 4 becomes:

For m i l l s l a r g e r than'. 3.3 meters. (10 f e e t ) diameter"inside' l i n e r s t h e

by. t h e niill.T h i s
t o p s i z e o f t h e b a l l s used a f f e c t s t h e. . power,drawn
.
.
..
i s c a l l e d t h e b a l l s i z e f a c t o r S.,
.-.L i .

'

where

,-

*
B = B a l l size inmillimeters.
D '= M i l l diameter i n s i d e l i n e r s i n meters:
Ss = K i l o w a t t s per m e t r i c tonne o f b a l l s .

'

I n terms o f b a l l s i z e i n inches and m i l l diameter i n f e e t and power

p e r s h o r t t o n of b a l l charge equation 5 becomes: ;

ROD AND' BALL MILLS

257

To determine t h e power t h a t a wet grinding, low l e v e l g r a t e discharge

m i l l should draw m u l t i p l y Kwb by 1'.16 +and f o r a d r y g r i n d i n g , f u l l
g r a t e discharge m i l l m u l t i p l y by 1.08.
.
For s p e c i a l a p p l i c a t i o n s :such as cement raw.materials, b a u x i t e i n caus t i c s o l u t i o n s and 'other.,clay-l ike m a t e r i a l s c o n s u l t the m i l l manufact u r e r s , s i n c e . these, mat,erial s a f f e c t t h e power drawn by b a l l mi 11s.
' , : ,

- .

:;

Table V I I 1ists,'
e i s e n t i a l l y "square" b a l l m i l l s g i v i n g h i 1 1 speed as
percent o f cri-t.ica.1, 'weight o f a '40% b a l l charge, t o p b a l l s i z e and
c a l c u l a t e d power .draw. B a l l m i l l power chan'ges i n d i r e c t p r o p o r t i o n
t o m i l l length:.' The power is horsepower a t ' the m i l 1 pi,nionshaft i n s i d e new s h e l l .li'ners. Increase power f o r worn.-shell. l i n e r s by 6%.
There are i n d i c a t i o n s ' t h a t ,rubber 1i n e r s ' may cause:
from a 5 t o 10%
-- . . . . . .
l o s s i n m i l 1 power.
:
,
,
.
.
.
.
.
:_
:.
,
.
.
. ... .. .. ..
.
The various. bd-l:l'-.mi'll man"facturers have : d i f f e r e n t equtitions f o r d e t e r mining t h e power ,ba.ll m i l l s draw, ,but a l l come close t o t h e same calcu. . .
l a t e d power'draw. . .
, .
. .
. , .
. 1.;. O R E TESTING FOR MILL-SELECTION
~.
A f t e r t h e g r i n d requirements a r e establ ished, t e s t i n g f o r the select i o n o f comminution c i r c u i t s and m i l l s i z e can-be i n i t i a t e d and can
include the following:
2

Primary ~ u t o ~ e n o uMedia
s
Competency
Primary Autogenous and Semi-Autogenous P i l o t P l a n t
Secondary Autogenous (Pebble) Testing
Impact Crushing
Bond Work Index
Rod M i l 1 Grindabi lit y - Bond Work Index
B a l l M i l l G r i n d a b i l i t y - Bond Work Index
Abrasion Index .
Crushing, Grinding and Concentration P i l o t P l a n t

T h i s discussion w i l l be 1i m i t e d t o t e s t i n g f o r s e l e c t i o n o f rod and

b a l l m i l l s . Rod and b a l l mill.ing, using g r i n d i n g media o f known quali t y , a r e w e l l e s t a b l i s h e d and r e q u i r e much s i m p l i e r g r i n d i n g t e s t
programs than r e q u i r e d f o r t h e s e l e c t i o n o f autogenous g r i n d i n g mi 11s
and c i r c u i t s .
- . .
Samples f o r g r i n d a b i l i t y t e s t s - s h o u l d be crushed. t o ab&t minus 1".
The samples can',be taken from a d i t s , p i t s , etc., ' i n the ore body o r
they can be crushed d r i q l cores.. . While i t i s h e l p f u l i n a n t i c i p a t i n g
v a r i a t i o n s i n -feed. r a t e s . t o know t h e g r i n d a b i l it y o f t h e various ore
types i n a deposit, f o r m i l l s e l e c t i o n g r i n d a b i l i t y t e s t s should be
r u n on composite samples r e p r e s e n t a t i v e - o f t h e blended m i l 1 feed. It
i s i n f r e q u e n t t h a t the. g r i n d a b i l i t y o f the. composite or, blend i s the
same as t h a t obta'iried by mathenia+jcal l y maki ng'.a p r o p o r t i o n a l blend
. . . . . it y t e s t s performed bn each: component.
based on grindab'il
Differential

TABLE

VII

BALL M I L L POWER AT M I L L PINIONSHAFT (HORSEPOWCR)

MILL

ROD AND BALL MILLS

259

g r i n d i n g occurs so t h a t each component can be ground t o a d i f f e r e n t

s i z e c o n s i s t than t h e composite which has been ground t o t h e r e q u i r e d
size.
Depending upon t h e s i z e o f t h e deposit, c a p a c i t y o f t h e concentrator,
l i f e o f t h e operation, complexity o f the o r e deposit, complexity o f
t h e e x t r a c t i o n o r subsequent processes, etc., t e s t i n g can range from
one s e r i e s o f g r i n d a b i l i t y t e s t s t o a l a r g e number o f g r i n d a b i l i t y
t e s t s and even p o s s i b l y p i l o t p l a n t t e s t i n g . Often p i l o t p l a n t t e s t i n g i s done p r i m a r i l y f o r m e t a l l u r i g i c a l t e s t i n g w i t h g r i n d i n g used
f o r feed preparation.
Frequently p i l o t p l a n t s a r e b u i l t using a v a i l a b l e o r used equipment
w i t h t h e g r i n d i n g c i r c u i t o v e r s i z e f o r t h e c o n c e n t r a t i o n s e c t i o n and
as such t h e two a r e n o t balanced operations. Caution, t h e r e f o r e ,
should be used i n s e l e c t i n g the t e s t data t o be used t o s e l e c t m i l l s
and c i r c u i t s f o r t h e p l a n t . The data should be selected from t e s t s
r u n s p e c i f i c a l l y t o o b t a i n g r i n d i n g data. This data should i n c l u d e :
M i l l Size
% v o l u m e t r i c l o a d i n g i n m i l l occupied by media.
Type o f c i r c u i t (open o r closed) and flowsheet diagram.
Any c o n c e n t r a t i o n steps i n t h e g r i n d i n g c i r c u i t .
S i z e and t y p e o f c l a s s i f i e r s .
I f cyclone c l a s s i f i e r s : size, r a t e d capacity, power
draw and speed o f cyclone feed pump.
,
S i z e a n a l y s i s c i r c u i t feed.
% m o i s t u r e i n m i l l feed.
Feed r a t e t o t h e c i r c u i t , d r y basis.
S i z e a n a l y s i s and p u l p d e n s i t y of:
1.) C i r c u i t product.
2.)
Discharge from each m i l l .
3 . ) Feed t o each c l a s s i f i c a t i o n stage.
4.) Oversize from each c l a s s i f i c a t i o n stage.
5.) Fines from each c l a s s i f i c a t i o n stage.
Power drawn by each m i l l (motor i n p u t ) .
Motor and d r i v e e f f i c i e n c y o f each m i l l .
S i z e o f and t y p e o f g r i n d i n g media used i n
each mi 11.
Speed i n rpm f o r each m i 11
L i n e r design and c o n d i t i o n i n each m i l l .
.Media wear r a t e .
L i n e r wear r a t e i f t e s t e d l o n g enough t o
obtain.
% c i r c u l a t i n g l o a d f o r each stage t h a t
i s close circuited.

During g r i q d i n g t e s t s obtain"samp1es o f m i l l feed f o r g r i n d a b i l i t y

t e s t s so t h a t work i n d i c e s ' c a l c u l a t e d from t h e p i l o t p l a n t data can
be compared t o g r i n d a b i 1it y t e s t r e s u l t s . Operating work i n d i c e s

MINERAL PROCESSING PLANT DESIGN

260

can be o b t a i n e d u s i n g p i l o t p l a n t d a t a i n t h e f o l l o w i n g e q u a t i o n :

where.

wio

= O p e r a t i n g Work Index.

W
P
F

= Kwh p e r t o n (can be m e t r i c , s t a n d a r d o r l o n g ) .
= P r o d u c t s i z e which 80% passes i n micrometers.

= Feed s i z e which 80% passes i n micrometers.

The a p p l i c a t i o n o f g r i n d i n g c i r c u i t and e q u i p m e n t - r e l a t e d f a c t o r s d i s cussed l a t e r i n t h i s c h a p t e r a r e a p p l i e d t o Wio t o p u t i t on t h e same

b a s i s a s g r i n d a b i l i t y t e s t r e s u l t s . T h i s a l l o w s a d i r e c t comparison
o f p i l o t p l a n t t e s t r e s u l t s and g r i n d a b i l i t y t e s t r e s u l t s . I n a d d i t i o n t o these, a1 so, be s u r e t o a p p l y motor and ' d r i v e e f f i c i e n c y f a c t o r s so t h a t t h e p i l o t p l a n t m i l l power d a t a i s r e f e r e d t o t h e m i l l
p i n i o n s h a f t o r t o t h e m i l l s h e l l (measured power d a t a . i s g e n e r a l l y
e l e c t r i c a l energy i n t o t h e m o t o r ) . F o r comparison w i t h g r i n d a b i l it y
t e s t r e s u l t s Wio has t o be p l a c e d on t h e b a s i s o f s t a n d a r d t o n s (907.4
kg)

With t h e d i f f i c u l t y i n o b t a i n i n g accurate p i l o t p l a n t data, p a r t i c u 1a r l y power data, Bond c l o s e d c i r c u i t g r i n d a b i lit y t e s t r e s u l t s o f t e n

g i v e t h e more a c c u r a t e d a t a f o r s e l e c t i n g r o d and b a l l m i l l s . G r i n d a b i l i t y t e s t work s h o u l d span t h e f e e d and p r o d u c t s i z e s of t h e p r o posed g r i n d i n g c i r c u i t . The g r i n d a b i l i t y t e s t work g e n e r a l l y recommended f o r p r i m a r y m i l 1 i n g c i r c u i t s . i n c l u d e s :

A.

Bond r o d m i l l g r i n d a b i l i t y t e s t s a t 10 o r 1 4 mesh f o r Work

Index .

B;

F o r each b a l l m i l l g r i n d i n g step, a Bond b a l l m i l l g r i n d a b i l i t y t e s t f o r Work I n d e x a t one mesh s i z e c o a r s e r t h a n

t h e d e s i r e d 80% p a s s i n g s i z e and a t t h e mesh s i z e o f o r
j u s t f i n e r t h a n the. 80% p a s s i n g s i z e .

C.

I f 50 mm x 75 mm ( 2 " x 3 " ) o r e .lumps a r e a v a i l a b l e an imp a c t c r u s h i n g Work Index, t e s t . , ' .

'

D.

I f 30 mm x 20 mm (1-114" x.314") o r e i s a v a i l a b l e an abras i o n i n d e x test.'

F o r r e g r i n d b a l l ' m i l 1 i n g o r b a l l m i l l i n g o f rougher c o n c e n t r a t e s p r o duced i n t h e g r i n d i n g c i r c u i t r u n b a l l m i l l g r i n d a b i l i t y t e s t s as o u t 1 i n e d i n B above. S i n c e t h e Bond g r i n d a b i l i t y t e s t r e q u i r e s a r a t i o

o f r e d u c t i o n of a b o u t 6 : l t o o b t a i n a c c u r a t e r e s u l t s i t may be necess a r y t o r u n t h e t e s t a t a f i n e r s i z e t h a n r e q u i r e d by t h e s p e c i f i e d

ROD AND BALL MILLS

g r i n d o r even a s p e c i a l ' t e s t w i l l have t o be run.

261
.

..

T h i s w i l l g i v e a good cross s e c t i o n o f t h e g r i n d a b i l i t y o f t h e o r e and

w i l l a l l o w f o r accurate c a l c u l a t i o n s o f t h e g r i n d i n g power required.
The balance' o f t h e d i s c u s s i o n i n t h e chapter w i l l be an example demons t r a t i n g t h e s e l e c t i o n o f a primary g r i n d i n g c i r c u i t and a r e g r i n d
c i r c u i t where a l l o f t h e o r e i s ground t o t h e r e q u i r e d product s i z e i n
t h e primary c i r c u i t . For g r i n d i n g c i r c u i t s where c o n c e n t r a t i o n i s i n cluded i n t h e c i r c u i t t h e b a s i c approach i s the same as given i n t h e
example, c o n s i d e r i n g each s t a e as a separate e n t i t y and a d j u s t i n g f o r
new feed r a t e s and feed s i r e ?which. could be d i f f e r e n t than the r a t e
and product s i z e from t h e preceding stage).
PROBLEM

S e l e c t r o d m i l l s , b a l l m i l l s and pebble mi 11s as r e q u i r e d f o r the f o l lowing c i r c u i t s .

Rod M i l l - B a l l M i l l
S i n g l e Stage B a l l M i l l
Rod M i l l - Pebble (Secondary Autogenous) M i l l
Primary Autogenous o r Semi-Autogenous M i l 1 - ' B a l l M i l 1.
Regrind B a l l M i 11

Feed r a t e t o t h e primary m i l l , c i r c u i t i s 500 m e t r i c tonnes per hour

i n c l u d i n g f a c t o r f o r a v a i l a b i l i t y . Feed r a t e t o r e g r i n d m i l l i s 40
m e t r i c ' tonnes per hour.
Rod m i l l feed and feed f o r s i n g l e stage b a l l m i 11 w i l l be prepared
w i t h closed c i r c u i t crushing. The feed sizes f o r the various m i l l s
w i l l be: . ,

Rod M i l l i n g : minus 25 mm 80% passing 18 mm.

S i n g l e stage B a l l M i l l : minus 12 mm 80% passing 9.4 mm.
B a l l M i l l and Pebble M i l l f o l l o w i n g Rod M i l l and B a l l
Mi 11 f o l l o w i n g Primary Autogenous o r Semi-Autogenous
M i l l : minus 2 mm 80% passing 1.2 m.
Regrind B a l l M i l l : 80% passing 210 micrometers.

The c i r c u i t s are a l l wet g r i n d i n g type. A l l b a l l o r pebble m i l l s are

closed c i r c u i t w i t h t h e exception o f the r e g r i n d m i l l which w i l l be
open c i r c u i t f o r t h i s example.
Pebble s i z e f o r pebble m i i l i n g p l u s 30 mm minus 70 mm w i t h a pebble
consumption o f 30 m e t r i c tonnes per hour which i s 6% o f t h e c i r c u i t
production rate.
,
. ,
The s p e c i f i e d g r i n d s are: primary g r i n d i n g c i r c u i t 80% passing 175
micrometers, r e g r i n d c i r c u i t 80% passing .45 micrometers.
. .

-,

262

MINERAL PROCESSING PLANT DESIGN

Bench s c a l e g r i n d a b i l i t y t e s t r e s u l t s t o be used f o r g r i n d j n g power

c a l c u l a t i o n s . The t e s t r e s u l t s t o be used i n t h e example are:
Impact Crushing Work Index
Rod M i l l G r i n d a b i l i t y Test a t 10 mesh
B a l l M i l l G r i n d a b i l i t y Test a t 65 mesh
B a l l M i l l G r i n d a b i l i t y T e s t a t 100 mesh
B a l l M i l l G r i n d a b i l i t y Test a t 325 mesh
on r e g r i n d m i l l feed
. Abrasion Index

EQUATIONS USED TO DETERMINE

GRINDING

11.5
13.2
11.7
12.1

,(Mi)
.'(wi)
(Wi),

14.0.
(Mi)
0.215 ( A * )
? :.
POWER.

T h i s f i r s t step i n s e l e c t i n g g r i n d i n g m i l l s i s t o determine t h e power

needed t o produce t h e d e s i r e d g r i n d . The b a s i c equation used f o r t h i s
i s t h e Bond Equation.

where
W
Wi
P
F

= kwh per s h o r t ton.

= Work Index.
= Product s i z e i n microns which 80% passes.
= Feed s i z e i n microns'which 80% passes.

,.

.I . -. .
The power determined from equation 7 i s f o r t h e f o l l o w i n g s p e c i . f i c
conditions.

wet, open c i r c u i t g r i n d i n g i n a 2.44 meter

( 8 ' ) diameter i n s i d e l i n e r s r o d m i l l .

A.

Rod M i l l i n g

B.

B a l l M i l l i n g - w e t , c l o s e d c i r c u i t g r i n d i n g i n a 2.44meter
( 8 ' ) diameter i n s i d e l i n e r s b a l l m i l l .

C.

Power c a l c u l a t e d i s t h e power r e q u i r e d a t t h e p i n i o n s h a f t
o f t h e m i l l , which includes m i l l bearings and gear p i n i o n
losses b u t does n o t i n c l u d e motor losses o r losses i n any
o t h e r d r i v e component, such as reducers and c l u t c h e s .

The feed f o r Bond G r i n d a b i l i t y Tests i s :

ing

o r e crushed t o minus 13,200 micrometers

Rod m i l l
(0.530") o r f i n e r .
B a l l m i l 1i n g o r e crushed t o minus 3,350 micrometers
( 6 mesh) o r f i n e r .
which have been used t o e s t a b l i s h optimum rod and b a l l m i l l feed sizes.

,'

'

ROD AND BALL MILLS

263

There a r e e i g h t e f f i c i e n c y f a c t o r s t o be a p p l i e d t o the c a l c u l a t e d
g r i n d i n g power t o a l l o w f o r v a r i a t i o n s from the s p e c i f i e d c o n d i t i o n s
and optimum feed sizes.
EF1

Dry, Gr.indi,ng':
. .

EF2 Open C i r c u i t B a l l M i l l i n g .
EF3 Diameter . E f f i c i e n c y Factor.
EF4 Oversized Feed.
EF5 F i n e G r i n d i n g i n b a l l m i l l s t o product sizes f i n e r than 80%
passing 200 mesh (75 micrometers).
EF6

High o r low r a t i o o f r e d u c t i o n r o d m i l l i n g .

EF7

Low R a t i o of r e d u c t i o n b a l l m i l l i n g .

EF8

Rod M i l l i n g .

The m u l t i p l i e r s f o r t h e e f f i c i e n c y f a c t o r s a r e determined by the f o l 1owing:

- f o r the same range o f 'work, d r y g r i n d i n g r e q u i r e s 1.3 times as much power as wet g r i n d i n g .

EF1

- Dry G r i n d i n g

EF2

- Open C i r c u i t G r i n d i n g - when g r i n d i n g i n open c i r c u i t b a l l

.

m i l l s , t h e amount of e x t r a power required, compared t o

closed c i r c u i t b a l l m i l l i n g , i s a f u n c t i o n o f t h e degree
o f c o n t r o l r e q u i r e d on the product produced. The i n e f f i c i e n c y f a c t o r s f o r open c i r c u i t g r i n d i n g a r e given i n Table

VIII.
EF3 -.Diameter E f f i c i e n c y F a c t o r - using the base m i l l diameter
o f 2.44 meters ( 8 ' ) i n s i d e l i n e r s , the diameter e f f i c i e n c y
f a c t o r can be c a l c u l a t e d from t h e following:.
I

'

When D i s i n meters:

When D i s
EF3 =
Table I X gives a t a b u l a t i o n ' o f t h e EF
t h e more common m i l l diameters i n bot;
m e t r i c measuring systems.

f a c t o r s f o r some o f
t h e i m p e r i a l and

MINERAL PROCESSING PLANT DESIGN

TABLE V I I I
. ..

OPEN CIRCUIT INEFFICIENCY MULTIPLIER

INEFFICIENCY
MULTIPLIER '

PRODUCT SIZE CONTROL

REFERENCE % PASSING

DIAMETER EFFICIENCY MULTIPLIERS

MILL DIAMETER
INSIDE SHELL.
FEET

METERS

3.0
3.281
4.0
5.0
6.0
6.562
7.0
8.0
8.5
9.0

0.914
1.0
1.22
1.52
1.83
2.0
2.13
2.44
2.59
2.74

DI'AMETER
'EFFICIENCY

MILL DIPJ~ETER
INSIDE LINERS

.
,

FEET

METERS

2*.6
2.88
3.6
4.6
5.6
5.96
6.5
7.5
8.0
8

0.79
0.88
1.10
1.40
1.71
1.82
1.98
2.29
2.44

MULTIPLIER

.
".
'

.
.

1.25
1.23
1.17
1.12
1.075
1.06
1.042
1.014
1.000 Base
0

It' should be noted t h a t f o r m i l l s where the diameter i n s i d e l i n e r s i s

l a r g e r than 3.81 meters (12.5') t h a t the.diameter e f f i c i e n c y f a c t o r
does n o t change and remains 0.914.

ROD AND BALL MILLS

265

NOTE: I n s e l e c t i n g m i l l s f o r new operations, where t h i s f a c t o r i s

l e s s than 1.0 i t i s sometimes neglected and i s used as a
,
s a f e t y f a c t o r . I n t h e example i t w i l l be applied.
EF4

..

-.

Oversized Feed - when being f e d a coarser than optimum feed,

t h i s f a c t o r a p p l i e s t o r o d . m i l l i n g and b a l l m i l l i n g . However, t h e most frequent use i s found i n c o n j u n c t i o n w i t h
s i n g l e stage b a l l m i l l i n g . This i s t h e one e f f i c i e n c y f a c t o r t h a t i s r e l a t e d t o Work Index as i s seen . i n t h e f o l l o w i n g equation:

. where Rr = R a t i o o f r e d u c t i o n =
Fo = Optimum feed s i z e
Rodmilling:
16,000

(10)

(11

When a v a i l a b l e , use t h e Work ~ n d e x ' f r o m a g r i n d a b i l i t y t e s t a t t h e des i r e d g r i n d f o r Wi i n equation 9. For equation 11, use e i t h e r t h e
Work Index from an impact t e s t o r a r o d m i l l g r i n d a b i l i t y t e s t , whichever i s higher. For equation 12, use t h e Work Index from a r o d m i l l
g r i n d a b i l i t y t e s t , since t h i s . m o r e represents the coarse f r a c t i o n o f
t h e feed; i f n o t a v a i l a b l e then use the bal.1 m i l l g r i n d a b i l i t y t e s t
results.

- t h i s applies t o f i n e grinding
when t h e 80% passing s i z e of t h e product i s f i n e r than 75
micrometers (200 mesh) .- The equation t o determine t h i s i s :

EF5

- Fineness o f G r i n d F a c t o r

EF6

- High o r Low R a t i o of Reduction Rod M i l 1i n g - t h e equation

t o be used, unless Rr i s between Rro = -2 and, Rro = +2 i s :

5L
where Rro = 8 + D

(15)

MINERAL PROCESSING PLANT DESIGN

L = Rod Length
T h i s f a c t o r always
i t s application t o
needed, b u t should
Wi from t h e r o d m i
ceed 7.0.

a p p l i e s t o low r a t i o s o f r e d u c t i o n b u t
h i g h r a t i o s o f r e d u c t i o n i s n o t always
be used f o r m i l l s i z e s e l e c t i o n whenever
l l and b a l l m i l l g r i n d a b i l i t y t e s t s ex-

- t h e need t o use t h i s
f a c t o r does n o t occur very o f t e n as i t o n l y a p p l i e s t o b a l l
m i l l i n g when t h e R a t i o o f Reduction i s l e s s than 6. T h i s
shows up p a r t i c u l a r l y i n r e g r i n d i n g concentrates and t a i l ings. The equation f o r t h i s i s :

EF, - Low R a t i o o f Reduction B a l l M i l l

EF8

Rod M i l l i n g - a study o f r o d m i l l operations shows t h a t r o d

m i l l performance i s a f f e c t e d by the a t t e n t i o n given t o prep a r a t i o n and feeding a u n i f o r m t o p s i z e feed s i z e t o the
m i l 1 and t h e care given t o m a i n t a i n i n g t h e r o d charge.
T h i s e f f i c i e n c y f a c t o r has n o t been d e f i n i t e l y determined.
I n s e l e c t i n g r o d m i l l s based upon power c a l c u l a t e d from
g r i n d a b i 1it y t e s t s , t h e f o l l owing procedure has been recommended :
1)

When c a l c u l a t i n g rod m i l l power f o r a r o d - m i l l i n g - o n l y

a p p l i c a t i o n , use an i n e f f i c i e n c y f a c t o r o f 1.4 when t h e
feed i s t o be prepared w i t h open c i r c u i t crushing, and
use 1.2 when the feed i s t o be prepared w i t h closed c i r c u i t crushing. The m i l l diameter, low o r h i g h r a t i o o f
r e d u c t i o n , and o v e r s i z e feed f a c t o r s a l s o must be app l i e d t o the c a l c u l a t e d g r i n d i n g power.

2)

When c a l c u l a t i n g r o d m i l l power f o r a r o d m i l l - b a l l
m i l l c i r c u i t , do n o t a l l o w f o r improvement i n t h e b a l l
m i l l performance due t o r e c e i v i n g rod mi 11 feed. I f
t h e r o d m i l 1 feed i s produced w i t h open c i r c u i t crushi n g , apply a 1.2 i n e f f i c i e n c y f a c t o r t o the power c a l c u l a t e d f o r t h e r o d m i l l i n g stage o n l y . I f t h e r o d
m i l l feed w i l l c o n s i s t e n t l y be the same size, such as
produced w i t h closed c i r c u i t crushing, do n o t apply a
r o d m i l l i n e f f i c i e n c y f a c t o r . The m i l l diameter, low
o r h i g h r a t i o o f r e d u c t i o n , and oversize feed f a c t o r s
should be a p p l i e d t o t h e c a l c u l a t e d g r i n d i n g power.

GRINDING POWER CALCULATIONS AND GRINDING MILL SELECTIONS

.

The f o l l o w i n g demonstrates t h e use o f t h e Bond Work Index Method t o

determine t h e power r e q u i r e d t o produce t h e d e s i r e d g r i n d . A f t e r t h e

ROD AND BALL MILLS

267

g r i n d i n g . power has been determined by t h i s o r o t h e r methods, t h e

m i l l ( s ) t h a t w i l l draw t h e r e q u i r e d power can be selected. For f i n a l
m i l 1 s i z e recommendations a1 1 t h e process design data and c o n t r o l 1i n g
economic and geologic f a c t o r s should be given t o g r i n d i n g m i l l manuf a c t u r e r s and t h e i r recommendations obtained.
With t h e growth o f m i l l sizes and changing economic s i t u a t i o n s new fact o r s i n f l u e n c i n g g r i n d i n g power c a l c u l a t i o n s and mi 11 s i z e s e l e c t i o n
a r e becoming known and more w i l l become known. The g r i n d i n g m i l l manu f a c t u r e r ' s are a good source f o r t h e a p p l i c a t i o n of t h i s c o n t i n u a l l y
growing technology i n c l u d i n g t h e p r a c t i c a l appl i c a t i o n o f the newer
approaches and math model i n g being developed t h r u academic research.
A. . Rod M i l l s
F = 18,000 micrometers.
P = 1,200 micrometers.
Wi = 13.2

E f f i c j e n c y Factors:
E F ~ does n o t apply.
EF2 does n o t apply.
EF3 determine a f t e r power c a l c u l a t i o n s i s completed.
EF4

Feed s i z e ' i s coarser than 16,000 micrometers.

EF5 does n o t apply.

EF6

w i l l n o t apply as r a t i o o f r e d u c t i o n w i l l be
w i t h i n Rro +2.
Rro determined a f t e r m i l 1 s i z e s e l e c t i o n .

EF7 does n o t apply.

268

MINERAL PROCESSING PLANT.DESIGN

The r o d mi 11 feed w i l l be prepared by closed
EF8',
. . c i r c u i t crushing a i d t h e r o d m i l l w i l l , b e i t i
*. . a r o d m i l l - b a l l m i l l ( o r pebble m i l l ) c i r c u i t ' :
w i t h -no i n t e r m e d i a t e c o n c e n t r a t i o n stage'-so -no
, . EF
f a c t o r need be-'applied.' I f ' i t were j u s t a' ..
r o g m i l 1i n g c i r c u i t ' o r i f t h e r e were -an i n t e r mediate c o n c e n t r a t i o n stage between t h e r o d
a n d . t h e m.i l l , a 1.2 f a c t o r . would
. apply.
.

,.

c*.

conversion s h o r t t0.n t o m e t r i c t o n n e 1.102 . .

..
K i l o w a t t s . t o horsepower 1.341 .
2.83 x 1.06 x 1 . I 0 2 x 1.341 = 4.43 ~ph/metri'c'tonn.e
-*.- .
4.13. x 500 = 221 5 HP
R e f e r r i n g t o Table V two m i l 1s w i 11 be required. The 'prel i m i n a r y r o d m i l l s e l e c t i o n would be a 3.66 meter (12 f o o t )
i n s i d e s h e l l 3.46 meter (1.1.35 f o o t ) diameter i n s i d e new
s h e l l 1 i n e r s . R e f e r r i n g t o Table I X t h e EF3 (Diameter E f f i c i e n c y ) f a c t o r i s 0.931.

R e f e r r i n g t o Table V t h e 3.66 m x 4.88.111 r o d m i l l w i t h 4.72

m (15.5 f t . ) l o n g rods c a l c u l a t e s t o draw 972"HP. when c a r r y i n g a 40 percent r o d charge. w i t h a worn-in b u l k d e n s i t y o f
5606 kg per c u b i c meter (350 pounds per c u b i c f o o t ) . 1031
HP i s required. Therefore, increase m i l l l e n g t h by 0.3
meters ( 1 f o o t ) .

Therefore, use two 3.66 meter .(.I2 f o o t ) diameter i n s i d e

s h e l l 3.46 meter (11.35 f o o t ) diameter i n s i d e n e w , s h e l l limers by 5.18 meter (17.0 f o o t ) l o n g o v e r f l o w r o d m i l l s w i t h
a 40 percent by m i l l . volume r o d charge,wi t h 5.02 meter (16.5
f o o t ) l o n g rods.

The'refore, E F assumption
~
i s confirmed.
.

These m i l 1s a r e r e q u i r e d t o prepare b a l l mi 11 feed.

With pebble m i l l i n g t h e pebble p o r t i o n o f t h e product does
n o t go t h r u the r o d m i l l thus t h e r o d m i l l feed r a t e i s r e duced by 3 0 ' m e t r i c tonnes per hour (6% o f 500 m e t r i c tonnes
p e r hour).

ROD AND BALL MILLS:

'

Therefore, use two 3.66 meter (12 f o o t ) diameter i n s i d e

s h e l l 3.46 meter (11.35 f o o t ) i n s i d e new s h e l l l i n e r by
4.88 meter (16 f o o t ) l o n g o v e r f l o w r o d m i l l s w i t h a 40
percent by m i l l volume rod charge w i t h 4.72 meter (15.5
foot) lonqrods.

..

. .

Rr.,= 15.0

~ t i k r e f ~' rE~F ,a~ s i i m p t i ' a n i s a1 so . c 6 f <.i r . h e d . here.

-. ., 5
,

B a l l M i l l s : .Rod

~iil- all

M i l l Circuit
s
.
. .
...
F = 1,200.'mi c r ~ i ~ t i r s . *. . . .
. ,.
'. P =
175 mi'crometers.
Wi. = 11.7 ( t h e g r i n d a b i l i t y work i n d e x ' a t 100 mesh
d i d n o t show any unusual c h a r a c t e r i s t i c s
t h a t would r e q u i r e s p e c i a l c o n s i d e r a t i o n ) .

, B.

'

.
,.

..

,.

..

,The
e f f i con1
i e ny c. ey f f iacci teonrc yEF3.
f&t& t h a t & p l i e s . ig,'the .,aiameter
.

5 . 4 7 ' x 1.102 x i . 3 4 i x.500 = 4039 HP:

By r e f e r r i n g t o Table V I I i t i s obv'ious' t h e m i l l ' i s l a r g e r

than. 3?81 meters (12.5 f e e t ) diameter i n s i d e l i n e r s so the
. : E F j ~ e r Table I X i s 0.914.
,
.
- ..
..
.. .
.
. . ,. . 4039 x.0.914 = 3692 . HP'
..
.. .
.
'Since 2 ' r o d m i l l s a r e required.use 2 b a l l m i l ' l s ( 1 b a l l m i l l
T h i s i s t h e s i m p l i e s t c i r c u i t t o operate and
' per rod m i l l ) ;
' c o n t r o l o r automate and 'represents' a lower c a p i t a l c o s t than
. t h e one
.
r o. d m i l l 'two b a l l m i l l s of the-same diameter c i r c u i t .
...
.

3692. p 2 = 1846. HP.

'

R e f e r r i n g t o Table V I t h e general g u i d e l i n e s i n d i c a t e the

b a l l m i l l s should have an L I D i n the a r e a . o f 1.5. R e f e r r i n g
t o T a b l e ' V I I 'a 4.12 meter (13.5 f o o t ) by 3.'96 meter (13.0

..

MINERAL PROCESSING PLANT DESIGN

f o o t ) o v e r f l o w b a l l m i l l w i t h a 40 percent by m i l l volume
b a l l charge, new she1 1 l i n e r s and 64. mm (2.5") diameter
b a l l s draws 1266 HP.

3.96 x.1.46 =.5:78 meters (18.96 f e e t )

Therefore,
s h e l l 3.93
5.79 meter
percent by

use two 4.12 meter (.13.5 f o o t ) diameter i n s i d e

meter (12.9 f o o t ) diameter i n s i d e new l i n e r s by
(19.0 f o o t ) l o n g o v e r f l o w b a l l m i l l s w i t h a 40
volume b a l l charge.

For lower o p e r a t i n g costs, s l i g h t l y b e t t e r e f f i c i e n c y , and

b e t t e r m i l 1 a v a i l a b i 1it y t h e c u r r e n t p r a c t i c e f a v o r s overf l o w b a l l m i l l s however, t h e r e a r e some operators t h a t pref e r g r a t e discharge m i l l s . R e f e r r i n g t o Table V I I a 3.96
meter (13.0 f o o t ) diameter by 3.96 meter (13.0 f o o t ) d i a phragm b a l l m i l l w i t h a 40 percent by m i l l volume b a l l
charge, new s h e l l 1 i n e r s and 50 mm ( 2 " ) diameter b a l l s draws
1311 HP.

3.96 x 1.41 = 5.58 meters (18.3. f e e t )

,

.,

C.

Therefore,
s h e l l 3.78
5.79 meter
mills with
Ball Mills:

use two 3.96 meter (13.0 f o o t ) diameter i n s i d e

meter (12.4 f o o t ) diameter i n s i d e new l i n e r s by
(19.0 f o o t ) l o n g diaphragm ( g r a t e ) discharge b a l l
a 40 percent by volume b a l l charge.
S i n g l e Stage-

The feed t o t h e standard Bond b a l l m i l l g r i n d a b i l i t y t e s t i s

minus 6 mesh. Thus, the coarser f r a c t i o n o f a minus 112"
s i n g l e - s t a g e b a l l m i l l feed i s n o t i n c l u d e d i n t h e feed t o
t h e g r i n d a b i l i t y b a l l m i l l . The minus 112" feed t o a standa r d Bond r o d m i 11 g r i ndabi 1 it y t e s t , however, does i n c l u d e
t h e coarse f r a c t i o n o f a single-stage b a l l m i l l feed. To
o b t a i n t h e complete g r i n d a b i l i t y p r o f i l e (Wi vs s i z e ) o f an
o r e when s e l e c t i n g a s i n g l e - s t a g e b a l l m i l l , i t i s a d v i s a b l e t o r u n both r o d and b a l l mi 11 g r i n d a b i 1it y t e s t s .
If t h e r e i s a d i f f e r e n c e i n the work i n d i c e s obtained from
t h e r o d m i l l and t h e b a l l m i l l g r i n d a b i l i t y t e s t s , which
f r e q u e n t l y occurs, then, p a r t i c u l a r l y i f t h e r o d m i l l t e s t
work index i s higher, a two-step c a l c u l a t i o n should be made
t o determine t h e r e q u i r e d g r i n d i n g power. . The r o d m i l 1 work

ROD AND BALL MILLS

271

index should be used t o c a l c u l a t e from t h e p l a n t b a l l m i l l

feed s i z e t o 80% passing 2100 microns. The c a l c u l a t i o n from
2100 microns t o t h e d e s i r e d product s i z e i s made u s i n g t h e
work index from t h e bal'l m i l l g r i n d a b i l i t y t e s t . The sum
o f these two gives t h e t o t a l uncorrected power per t o n r e quired f o r grinding.
,
F
P
Wi
Wi

.= 9,400 micrometers.
=
175 micrometers.
= Rod m i l l t e s t

13.2.

= B a l l m i l l t e s t 11.7.

Step one:
w = - 132

Q;roO

132 = 1.52'kwhIs. ton

Jm

. ,

Step two:

w = 177 - 1
17
m$ 2
. T o t a l .. ,.
..
7:81

= 6.'29 kwhls. t o n

7.81 kwhls. t o n

x 1.102 x 1.341 x 500 = 5766 HP, uncorrected.

E f f i c i e n c y Factors:
EF1

does n o t apply.

EF2 does n o t apply.

'

EF3 M i l l s w i l l b e . l a r g e r than 3.81 meter i n

. diameter so use 0.914.
EF4

Feed i s coarser than 4000 micrometers.

Rr = 9,400

Fo = 4,000 2-

175 = 53.7
= 3970

. ,
EF5, E F i , EF7 and E F do
~ n o t apply.
5766 x 1.12 x 0.914 = 5903 HP

272

MINERAL PROCESSING PLANT DESIGN

Use 2 m i l l s

Referring t o
Per Table V I t h e LID should be around 1.25.
Table V I I a 5.03 meter (16.5 f o o t ) diameter by 4.88 meter
(16.0 f o o t ) o v e r f l o w b a l l m i l l w i t h a 40 percent by m i l l
volume b a l l charge, new s h e l l l i n e r s and 64 mm (2.5") d i a meter b a l l s draws 2370 HP.

'

. ' .

4.88 x"1.25 = 8.1 meters'(20.0 f e e t )

Therefore, use two 5.03 meter (16.5 f o o t ) diameter i n s i d e
s h e l l 4.85 meter (15.9 f o o t ) diameter i n s i d e new l i n e r s by
6.1 meter (20.0 f o o t ) l o n g o v e r f l o w b a l l m i l l s w i t h a 40
. .
percent by volume b a l l charge..
R e f e r r i n g t o Table V I I . f o r s i z i n g a g r a t e discharge m i l l a
4.72 meter (15.5 f o o t ) di'ameter by 4.57 meter (15.0 f o o t )
g r a t e discharge b a l l m i l l w i t h a 40 percent by m i l l volume
b a l l charge, new she1 1 1 i n e r s and 64 'inn '(2.5") diameter
..
.
b a l l s draws 2269 HP.
.-

: . .

4.57 x 1.3 = 5.94 meters (19.5 f e e t )

Therefore, use two 4.'72'.meter (15.5 foot,) diameter i n s i d e
s h e l l 4.54 meter (14.9 f o o t ) , diameter' i n s i d e new 1 i n e r s by
6.1. meter (20.0 f o o t ) l o n g diaphragm ( g r a t e ) discharge b a l l
m i l l w i t h a 40 p e r c e n i by volume b a l l charge.
D.

B a l l M i 11 :
Mill

~ ol olw i n g ~ u t b ~ e n o "br
s s e m i - ~ u t o ~ e n o u ps r i m a r y
..

. ,

..

Ift h e product s i z e from t h e primary autogenous o r semi-autogenous m i l l i s t h e same' as from a rod m i l 1, t h e b a l l m i l 1

c a l c u l a t i o n and s i z e s e l e c t i o n i s t h e same as covered under
s e c t i o n B above. I f t h e b a l l m i l l feed s i z e i s d i f f e r e n t
from t h i s , t h e same procedure as covered by e i t h e r s e c t i o n
B o r C (whichever a p p l i e s ) should be used t o determine g r i n d i n g power, and b a l l m i l l s i z e .selection.

'

E.

- Pebble

Mill:

ROD AND BALL MILLS

Rod ~ i l l ' p e b b l eM i l l C i r c u i t

The c a l c u l a t i o n for..determining g r i n d i n g power f o r Pebble

m i l 1i n g (secondary autogenous) can be the same as f o r b a l l
m i l l i n g from r o d m i l l product s i z e t o t h e d e s i r e d s p e c i f i e d
size, n e g l e c t i n g t h e diameter e f f i c i e n c y f a c t o r i f l e s s than
. 1.0.

5.47 x 1.102 x 1.341 x 500 = 4039 HP

To t h i s add t h e power r e q u i r e d t o wear t h e pebbles down t o
.rod .mil 1 product s i z e (pebble m i l l feed ' s i z e ) .

F = 70,000 micrometers.
P = 1,200 micrometers.
Wi = 13.2

The i n e f f i c i e n c y f a c t o r t o a l l o w f o r t h e i n e f f i c i e n t use o f
power i n wearing down from pebble s i z e t o r o d m i l l product
s i z e i s 2.0.

S e l e c t two 2200 HP pebble m i l l s . For s p e c i f i c s i z i n g r e f e r

t o m i l l 'manufacturers f o r recommendations as t h e y have prop r i e t a r y equations f o r c a l c u l a t i n g mi 11 power draw t a k i n g
i n t o account t h e various o r e media and p u l p f a c t o r s involved.
F.

Regrind B a l l M i l l
F = 210 micrometers.
P = 45 micrometers.
Wi = 14.0

E f f i c i e n c y Factors:
EF1

does n o t apply.

'

'

MINERAL PROCESSING PLANT DESIGN

EF

Many r e g r i n d operations a r e closed c i r c u i t , b u t

assume t h i s one i s open c i r c u i t and 80. percent
passing g r i n d w i l l be t h e c o n t r o l l i n g p o i n t . Ref e r t o Table V I I I . The EF2 f a c t o r i s 1.2.

EF3 Because b a l l s w i l l be smaller than 40 mm (1.5")

.
and o t h e r minor f a c t o r s n e g l e c t EF unless m i l l
diameter i s l e s s than 2.44 meter (3.0') diameter
inside liners.
EF4
E F ~

does n o t apply.
Grind i s 80 percent passing 45 micrometers.

EF6 does n o t apply.

EF7

Rr = 210

4 5 . = 4.67 which i s l e s s than 6;

EF8

does n o t apply.

R e f e r r i n g t o Table V I t h e L I D can be between 1.75 and

o r even g r e a t e r . R e f e r r i n g t o Table V I I a 3.05 meter
f o o t ) by 3.05 meter (10 f o o t ) o v e r f l o w b a l l m i l l w i t h
40 percent by mi 11 volume b a l l charge, new 1i n e r s and
mm ( 2 " ) b a l l s draws 491 HP.

2.0
(10
a
50

Using equation 5 t h e r e w i l l be a l o s s o f 0.55 Kw (0.74 Hp)

per m e t r i c tonnes o f b a l l s .

3.05 x 1.91 = 5.83 meters (19.1 f e e t )

Therefore, use one 3.05 meter (10.0 f o o t ) diameter i n s i d e
s h e l l 2.89 meter (9.5 f o o t ) diameter i n s i d e new l i n e r s by
5.79 meter (19.0 f o o t ) l o n g overflow b a l l m i l l w i t h a 40
p e r c e n t by volume b a l l charge. For rubber l i n e r s add 10%
o r 0.58 meters (approximately 2 ' f e e t ) t o t h e l e n g t h .

G.

Motor S e l e c t i o n
I n a l l cases t h e m i l l s should be d r i v e n by a l a r g e enough
motor t o a l l o w t h e m i l l t o operate w i t h a 45 percent by mi 11
volume charge w i t h new l i n e r s and a t l e a s t a 36 percent
charge w i t h worn l i n e r s . I t may be d e s i r e d t o u t i l i z e more
o f t h e a v a i l a b l e m i l l volume as the l i n e r s wear so a h i g h e r
charge can be s p e c i f i e d f o r worn l i n e r s . S p e c i f i c a t i o n s can
a l s o c a l l f o r t h e d r i v e and motor t o be r a t e d t o a l l o w using
p i n i o n s w i t h one l e s s and two more teeth, thus a l l o w i n g f o r
changing mi 11 speed if i t i s found necessary t o balance c i r c u i t , increase capacity, s u i t changing ore c h a r a c t e r i s t i c s ,
etc.

SELECTION OF GRINDING MEDIA SIZES AND ESTIMATING STEEL CONSUMPTION

The equation f o r s e l e c t i o n o f t h e l a r g e s t diameter r o d f o r t h e i n i t i a l
charge and f o r t h e make-up charge i s :

R
F
W.
S'

:C
D

=
=
=
=
=
=

Diameter o f r o d i n m i l l i m e t e r s .
Feed s i z e 80% passes i n microns.
Work Index.
Specific Gravity.
C r i t i c a l Speed.
Diameter i n s i d e s h e l l l i n e r s i n meters.

With R i n inches and diameter (D) i n f e e t equation 17 becomes:

Table X gives t h e e q u i l i b r i u m s t a r t - u p r o d charge f o r t o p r o d sizes

from 125 mm ( 5 " ) t o 65 mn (2.5").
The equation f o r s e l e c t i o n of t h e l a r g e s t diameter b a l l f o r the i n i t i a l charge and f o r t h e make-up charge i s :
(18)

B =
- J

B = Diameter o f b a l l i n m i l l i m e t e r s .

NOTE: Except f o r K which i s given below a l l o t h e r

terms t h e same as f o r equation 17.

276

MINERAL. PROCESS.ING PLANT DESIGN

TABLE X .
START-UP EQUILIBRJA

GRINDING ROO CHARGES, PERCENT WEIGHT

Make-Up
Rods ~ e d
Sizes ,
MM=R

125

. 115

T,OTAL Pct

100

100

100

100 ..

90

75

100

100

100

100.

65

'

100

TABLE X I

Make-Up
B a l l s Fed
Sizes,
MM=B
115
100
90
75
65
50
40
25

(4.5")
(4.0")
(3.5")
(3.0")
(2.5")
(2.0")
(1.5")
(1.0")

TOTAL PC.

100.0,

100.0

100.0

100

100

"

ROD AND BALL MILLS

. B a l l . Mi11 K F a c t o r
M i l l Type and
Grinding C i r c u i t

'

Steel o r
C.1: B a l l s

K
'

. .

Wet-Overf 1ow-Open C i r c u i t
Wet-Overfl ow-Closed C i r c u i t
Wet-Diaphragm-Open C i r c u i t .
Wet-Diaphragm-Closed.Circui t
Dry-Diaphragm-Open C i r c u i t
Dry-Diaphragm-Cl osed C i r c u i t

W i t h B i n inches and diameter .(D) . i n f e e t equation 18 becomes:

Table X I g i v e s . t h e e q u i l i b r i u m s t a r t - u p b a l l charge f o r t o p + b a l l s i z e s
from 115 mm (4.5"). t o 40 mm (1.5").
These two equations g i v e t h e l a r g e s t diameter o f the g r i n d i n g media
requi'red. Since t h e c a l c u l a t e d s i z e i s n o t always an a v a i l a b l e standa r d s i z e s e l e c t t h e nearest l a r g e r s i z e a v a i l a b l e . Actual o p e r a t i n g
experience may d i c t a t e a change from t h e c a l c u l a t e d s i z e . Theoretica l l y i t i s always a d v i s a b l e t o use a graded charge as a replacement
charge. Using a graded charge o f t e n i s n o t p r a c t i c a l . The l o s s i n
e f f i c i e n c y by n o t u s i n g a graded charge g e n e r a l l y can n o t be measured.
I n some cases, i t i s o n l y necessary t o add the l a r g e s t s i z e media c a l c u l a t e d as make-up. Operating r e s u l t s w i l l i n d i c a t e the n e c e s s i t y o f
u s i n g more than one s i z e of media i n the make-up charge.
The b e s t f i g u r e s f o r media and l i n e r consumption come from a c t u a l opera t i n g experience and as o p e r a t i n g data i s generated t h i s should be used
t o e s t a b l i s h wear r a t e s .
Actual t e s t i n g i n l a b o r a t o r y scale equipment t o determine the abrasion
c h a r a c t e r i s t i c s o f an o r e i s d i f f i c u l t , and a v a i l a b l e t e s t s a r e guides
f o r e s t i m a t i n g purposes b u t a r e n o t completely accurate. One abrasion
t e s t measures t h e weight l o s s o f a s t e e l paddle c o n t i n u o u s l y impacting
f a l l i n g o r e p a r t i c l e s f o r a prescribed time p e r i o d under standard cond . i t i o n s . From t h i s i s developed a measurement c a l l e d an abrasion I n dex, A i . From p l a n t data, emperical equations c o r r e l a t i n g w i t h A i :
were developed t o be used t o estimate rod, b a l l , m i l l 1 i n e r and crusher
1 i n e r wear r a t e s . . These equations are:
Wet Rod M i l l s :
Rods, kg/Kwh = 0.175 ( A i

0.020)'2

MINERAL PROCESSING PLANT DESIGN

L i n e r s , kglKwh = 0.175 ( A i
Wet B a l l M i l l s :
B a l l s , kg/Kwh = 0.175 ( A i
L i n e r s , kg/Kwh = 0.013 ( A i

0.015)'~

(20

- 0.015) 113

(21 )

- 0.015)'~

(22

M u l t i p l y equations 19, 20, 21 and 22 by 2.2 t o g e t pounds p e r k i l o w a t t .

These formulas g i v e estimates o f wear r a t e s which can be used as a
guide. They a r e s u b j e c t t o such t h i n g s as m i l l speeds, percent v o l u m e t r i c loading, a l l o y o f g r i n d i n g media and l i n e r s , o p e r a t i n g practices, etc.
The r e f e r e n c e i n f o r m a t i o n used t o prepare t h i s was:
Bond F. C.

Rowland C. A.

"Grinding C a l c u l a t i o n s Re,lated t o t h e Appl ic a t i o n o f Large Rod and B a l l M i l l s " , A l l i s Chalmers P u b l i c a t i o n 22P4704.

Bond F. C.

"Grinding B a l l Size.Selection",
n e e r i ng . May, 1958.

Rowland C. A.
& Nealey R. C.

Mining Engi.

" A p p l i c a t i o n o f Dry Grinding Rod M i l l s " ,

Transactions o f Society o f Mining Engineers
o f A.I.M.E.