4.3.5 discusión del Método de Bond Limitations of the Bond Method Limitaciones del Método Bond Austin and Brame (1983) and Herbs and Fuerstenau (1980) have reviewed the Austin y Brame (1983) y Herbs y limitations of the Bond test. Perhaps the Fuerstenau (1980) han revisado las most serious in a fundamental sense is limitaciones del test de Bond. Quizás el más Bond’s claim that equation 4.2 is a serio en un sentido fundamental es la “universal law”, whereas it is known that llamada Bond que la ecuación 4.2 es una the specific grinding energy needed to take “ley universal”, considerando que se conoce a feed with a certain 80% passing size to a la energía específica de molienda necesaria product with a certain 80% passing size para tomar un alimento con un cierto 80% cannot be the same for a batch test, the tamaño pasante a un producto con un standard Bond locked-cycle test, or a cierto 80% tamaño pasante no puede ser el steady-state continuous mill with a real mismo para una prueba batch, la prueba residence time distribution. The method estandar de ciclo cerrado de Bond, o un ignores the fact that the shape of the molino en estado –estable continuo con product size distribution and the associated una distribución de tiempo de residencia specific grinding energy is different for real. El método ignora el hecho que la these three cases. forma de distribución de tamaño del producto y la energía específica de Criticism of Bond’s method as a “model” is molienda asociada es diferente para estos not really warranted since it is not intended tres casos. to be a model in any comprehensive sense. Its real value is as a method of Críticos del método de Bond como un distinguishing the grindability of different “modelo” realmente no garantiza desde ores in design (though better test may be que no se piensa que es un modelo en available), and as a yardstick to check the cualquier sentido comprensivo. Su valor energy utilization of current operations. real es como un método de distinguir la Experience in its use has demonstrated the moliendabilidad de minerales diferentes en following limitations: el diseño (aunque la mejor prueba puede estar disponible), y como una vara de It tends to be a poor predictor of what medir para verificar la utilización de energía happens in a real closed circuit when de operaciones actuales. throughput is increased, unless Experiencia en su uso ha demostrado las classifier performance is “adjusted” to siguientes limitaciones: cope with the new conditions. As implied earlier, it is not appropriate Tiende a ser una pobre predicción de lo in system where size distribution slopes que pasa en un circuito cerrado real change. cuando el rendimiento se incrementa, a menos que la operación del clasificador It is not a good predictor of the es “ajustado” para cubrir con las grinding of large rocks, and specifically nuevas condiciones. for AG/SAG mill behavior (though it has been adapted to such circumstances - Como implicado antes, no es apropiado see below). en un sistema dónde hay cambios en las pendientes de distribución de tamaños.
No es un buen predictor de la molienda
de rocas grandes, y específicamente para el comportamiento en la molienda AG/SAG (aunque se ha adaptado a tales circunstancias - ver debajo). It is unreliable for particles with unusual screening characteristics (i.e. of unusual shape), though this is a Es inestable para las partículas con las general problem for any technique características de tamizado inusual (es relying on sieving for the determination decir de forma inusual), aunque éste es of particle size. un problema general para cualquier técnica que confía en tamizar para la The square root relationship determinación del tamaño de assumed in equation 4,2 (arising from partículas. Bond’s assumption that work is proportional to new crack tip length) La relación de la raíz cuadrada asumida does not always hold. See also Figure en la ecuación 4,2 (proviene de la 2.1. asunción de Bond que el trabajo es proporcional a la nueva longitud de There is also a perception that Bond’s rotura punta de crujido) no siempre method failed to predict the performance of sostenga. También Vea Figura 2.1. the very large ball mills introduced in the early 1970s, though this was probably more Hay también una percepción que el método to do with the early learning curve de Bond no predijo la acciòn de los molinos associated with operating these mills and de bolas muy grandes introducida en los their associated classification process. tempranos 1970s, aunque éste era Certainly there was never a dedicated Bond probablemente más hacer con la curva de test for the Ag and SAG mills now in aprendizaje temprana asociado con operar common use. estos molinos y su proceso de la clasificación asociado. Había nunca una Other problems and inconveniences of the prueba de Bond ciertamente especializada Bond standard procedure include the need para los molinos AG y SAG ahora en uso to use a Bond mill (which may not be comun. readily available), the requirement of about 10 kilograms of feed sample, which needs Otros problemas y inconvenientes de la special preparation, and the fact that Atadura el procedimiento estándar de Bond conducting the test is time consuming. A incluye la necesidad de usar un molino de number of attempts have been made in the Bolas (qué no puede estar prontamente past to determine the Bond Work index by disponible), el requisito de means of simplified procedures (Yap et al aproximadamente 10 kilogramos de 1982). muestra del alimento que necesita la preparación especial y el hecho que dirigiendo la prueba es el tiempo Empirical methods which allow for a direct consumiendo. Varios esfuerzos han sido calculation of the work index using a hecho en el pasado determinar el índice de straight forward procedure are often more Trabajo de Atadura por medio de los practical and better suited for plant procedimientos simplificados (Ladre el et al application. For example the Anaconda 1982). simplified method (Yap et al 1982) which uses an ordinary laboratory mill and only 2 Métodos empíricos que permiten un cálculo kilograms of sample, is not time consuming directo del índice de trabajo que usa un and has proven to be very practical and procedimiento delantero recto son a flexible in a number of different menudo más prácticos y buenos satisfecho applications. However, the full Bond test para la aplicación de la planta. Por ejemplo gives the maximum confidence in el Anaconda simplificó el método (Ladre el prediction. et al 1982) qué usa un molino del laboratorio ordinario y sólo 2 kilogramos de muestra, no es tiempo que consume y ha demostrado ser muy práctico y flexible en varios aplicaciones diferentes. El embargo del pecado, prueba del la del la la Atadura llena da la confianza máxima en la predicción.
The Bond method attempts to partially
compensate for idealizations in the test The Bond method attempts to partially procedure and shortcomings of the model compensate for idealizations in the test by making use of correlations between procedure and shortcomings of the model grindability test result obtained in a by making use of correlations between “standard” 2,44 m diameter milling circuit. grindability test result obtained in a Complete compensation is not possible “standard” 2,44 m diameter milling circuit. because this procedure cannot, for Complete compensation is not possible instance, take into account inevitable because this procedure cannot, for deviations in transport and classification instance, take into account inevitable characteristics of the commercial circuit deviations in transport and classification from those of the “standard” circuit. characteristics of the commercial circuit from those of the “standard” circuit. Since the method does not incorporate the above – order effects, it cannot be used as Since the method does not incorporate the a guide to optimize a given system, from above – order effects, it cannot be used as either the operating point of view or the a guide to optimize a given system, from economic point of view. Its is valid only as either the operating point of view or the a gross method for mills operating under economic point of view. Its is valid only as normal closed circuit conditions. a gross method for mills operating under normal closed circuit conditions. In spite of these limitations, the Bond method has two main advantages: it is very In spite of these limitations, the Bond simple, and experience has shown that it method has two main advantages: it is very works for many circumstances to a simple, and experience has shown that it reasonable degree of accuracy, since the works for many circumstances to a corrections are based on a large industrial reasonable degree of accuracy, since the database. corrections are based on a large industrial database. The operating Bond Work Index Work indices obtained from operating data The operating Bond Work Index on any mill can be compared to grindability Work indices obtained from operating data test results. The operating work index, on any mill can be compared to grindability WIo, can be obtained using equation 4.2, test results. The operating work index, by defining W as the specific energy being WIo, can be obtained using equation 4.2, used (power draw + new federate), F80 by defining W as the specific energy being and P80 as the actual feed and product used (power draw + new federate), F80 80% passing sizes, and WI as the operating and P80 as the actual feed and product work index, WIo. Once corrected for the 80% passing sizes, and WI as the operating particular application and equipment – work index, WIo. Once corrected for the related factors, WIoC, can be compared on particular application and equipment – the same basis as grindability test result. related factors, WIoC, can be compared on This allows a direct comparison of grinding the same basis as grindability test result. efficiency. Ideally WI should be equal to This allows a direct comparison of grinding WIoC and grinding efficiency should be efficiency. Ideally WI should be equal to unity. Power draw is determined using WIoC and grinding efficiency should be equation 4.7, assuming grinding efficiency unity. Power draw is determined using is unity. equation 4.7, assuming grinding efficiency is unity. Application of Bond Theory to Autogenous Mills. Application of Bond Theory to Autogenous For the case of autogenous and semi Mills. autogenous milling it has been determined For the case of autogenous and semi that the work indices obtained from autogenous milling it has been determined standard Bond grindability tests cannot be that the work indices obtained from used (Section 9,6). It is necessary, standard Bond grindability tests cannot be therefore, to calculate a Work index from used (Section 9,6). It is necessary, operating data(e.g. from a pilot plant) so therefore, to calculate a Work index from that power draw and mill sizing can be operating data(e.g. from a pilot plant) so calculated . In some cases the feed is not that power draw and mill sizing can be used in the calculation as the factor calculated . In some cases the feed is not 10/√F80 becomes insignificant because of used in the calculation as the factor the large size of the ROM feed. For open 10/√F80 becomes insignificant because of circuit AG/SAG mills, the discharge can be the large size of the ROM feed. For open hypothetically classified at the desired circuit AG/SAG mills, the discharge can be closing screen size to provide a more hypothetically classified at the desired realistic P80 value for the work index closing screen size to provide a more calculation. realistic P80 value for the work index calculation. Macpherson has developed a test procedure for the design of AG/SAG mill Macpherson has developed a test circuits. It includes the conduct of standard procedure for the design of AG/SAG mill Bond rod mill and ball mill grindability test, circuits. It includes the conduct of standard together with a dry autogenous test in a 45 Bond rod mill and ball mill grindability test, cm air – swept Aerofall mill. A 250 kg together with a dry autogenous test in a 45 sample of -3.175 mm ores is required. The cm air – swept Aerofall mill. A 250 kg autogenous test is used to compute an sample of -3.175 mm ores is required. The autogenous work index, which is then autogenous test is used to compute an corrected for a full scale installation using autogenous work index, which is then empirical scaling procedures (based on corrected for a full scale installation using historical data) and by comparison with the empirical scaling procedures (based on rod and ball mill WIs. The autogenous WI historical data) and by comparison with the and the other data are then used to rod and ball mill WIs. The autogenous WI determine AG/SAG milling suitability, power and the other data are then used to requirement and circuit configuration. determine AG/SAG milling suitability, power Further details can be found in Knight et al requirement and circuit configuration. (1989). Further details can be found in Knight et al (1989). Using the Bond Work Index in a Process Model Using the Bond Work Index in a Process Although Bond chose to use the results of Model his laboratory ball mill test to determine an Although Bond chose to use the results of operating work index, much more his laboratory ball mill test to determine an information about grinding of an ore can in operating work index, much more principle be extracted. His test is a physical information about grinding of an ore can in model which approximates a closed circuit principle be extracted. His test is a physical ball mill, and so product sizing and model which approximates a closed circuit flowrates of each stream can be obtained ball mill, and so product sizing and from it. Research currently underway at the flowrates of each stream can be obtained JKMRC is testing the use of these data to from it. Research currently underway at the determine the relevant parameters for a JKMRC is testing the use of these data to ball mill model. The model is then used to determine the relevant parameters for a predict the performance of a full scale ball ball mill model. The model is then used to mill. This approach has the advantage of predict the performance of a full scale ball simultaneously generating a Bond ball mill mill. This approach has the advantage of work index and set of model parameters, simultaneously generating a Bond ball mill which can be used in a complementary work index and set of model parameters, fashion in design and optimization. which can be used in a complementary fashion in design and optimization.