Powder

14 (1976)

Technology,

@ Elsevier Sequoia

The Effect

Sk.

71 - 79
Lausanne - Printed in the Netherlands

71

of Ball Size on Mill Performance

L G. AUSTIN
Deporlment
Pa. 16802

of

Materials

Science. dlineral Processing

Section,

7%~ Pennsylcnnia

State

Uniuersity.

University

Park.

(U.S.A.)

K. SHOJI
hisso Engineering

Compnrsy

Ltd..

Department

of Technical

Deuelopment.

l-4-3,

Einji-rho.

Chiyodn-1:~.

Toi:yo

(Japan)

P. T. LUCKIE
Kennedy

(Received

Van Saun

September

Corporation,

Danviile.

Pa. I7821

(bi_S_A.)

10. 1975)

SUMMARY

The specific rates of breakage of particles in

a tumbling ball mill are described by the
equation Si = ax: Q(z), where Q(Z) is the
probability function which ranges from 1 to 0
as particle size increases. This equation
produces a maximum in S, and the particle
size of the maximum is related to ball
diameter by x, = k 1d2_ The variation of a with
ball diameter was found to be of the form (z =
k2/d*-5_ Both kl and k2 vary with mill
diameter, and simple power laws have been
assumed, k, 0: Do-,
k2 = Da6_
If it is also
assumed that the mean overall values of Si for
a mixture of balk is the weighted mean of Sj
values for each ball size, equations are derived
for calculating this mean value. As an example,
the results are used in a mill simulation to
show the quantitative effect of different balI
mixes in a two-compartment
cement mill
versus a uniform mix over the whole mill.

INTRODUCTION

One of the most difficult questions to

answer in the optimal design of ball milling
circuits [l] is the choice of the mixture of
bail sizes to be used in the mills. An empirical
rule which has been used for many years [2] is
x=Kd2
where K = lo- 3 to (0.7) (10s3) for soft to
hard materials; d is ball diameter in mm, x

(1)

particle sieve size in mm_ This is only a rough

guide to the best size of balls to use to break
a given size of particle_ In particular, of
course, a spectrum of ball sizes is established
in the mill [ 31 due to wear of balls and
continual addition of larger ball sizes. To
perform any kind of rigorous optimization
of
ball charge, it is necessary to be able to
predict the behavior of different mixtures of
balls. This paper gives a method of converting
experimental
data for specific rates of
breakage of a material from one ball size to
another, and one mill diameter to another,
and also proposes a method of getting overall
specific rates of breakage for a mixture of
ball sizes.

ABNORMAL

BREAKAGE

It has been found for many materials that

the normal breakage of a given size fraction
(for example, JZ
or *size
interval) of
material in a batch ball mill can be described
by a first-order law [4] t
rate of breakage

of size i = SiWi

(2)

where Wi is the weight fraction of charge of

size i, W is the total weight of charge, and Si
is the specific rate of breakage. On the other
hand, when a particle is too large with respect
to the ball size, the result is as shown in Fig. 1,
where w1 (0) is the starting fraction of the
largest size present The reasons for this abnormal breakage have been discussed [ 53.

GRINDING

Fig. 1. Experimental
8 x 10 mesh cement

3
TIME.

MINUTES

results of abnormal breakage of

clinker in an S-in--dim.
baii miI1.

This type of result can be treated as if it were

the sum of a harder and softer componen:: 161,
with o the fraction of harder component A,
e.g..

dw (t)
-=
dt

dwl.a(t)
dt

+(1-o)

dwldt)
dt

where

dw,(t)
dt

dwdf)
dt

= -%=Lwl_A(t)
= -%w1l3

(f)

The variation of specific rate of breakage

with particle size for the two appsrent
components is then as shown in Pig. 2. As a
first approsimation, we can force-fit a single
mean value of S to the curve given in Fig. 1.
The method of back-calculating S values used
by KeIsalI and Reid 171 in effect performs
this force fitting since it assumes ah breakage
is first-order_ We use a mean rate of breakage
defined by the time needed to break 95% of
the material in the size interval to smaller
sizes. Snow [S] used the function Si/Sm =
(xi/x,)=
exp[-(xJx,)]
to fit mean results
such as those in Fig. 2. We did not find it
possible to fit our resuhs with this function as
its more generaI form
Si 5

QX~eXp[-(WXf)"]

(4)

where Q. Q, w, n are descriptive parameters.

Snow [4] also apparently assumed this fullction to apply directly to a mixture of b&Is as

PARTICLE

SIEVE

SIZE.mm

Fig_ 2. Specific rate of breakage as a function of

particle size, S-in. ball mills (afiintervals).
Cement
clinker Type II: l mean. A slower; Taut5 gold ore:
m faster, l mean, A slower.

the mixture behaved as a single size of ball.

We did not find this approach to be valid for
our data.
Gupta and Kapur 191 have suggested a
met;., d for converting Si values at one bah
diameter to values for another ball diameter,
using the data of KeIsaII et al. [lo] . The
method we give below was developed before
their paper appeared and is, in our opinion,
somewhat more convenient for our purposes.
if

EFFECT

OF BALL

DIAMETER

Results of many tests suggest that the form

of the S function for normal breakage in bail
mi&is
Si=MF

(5)

It is consequently very convenient to have a

more general fitting function which reduces
to this for lower values of x, to the Ieft of the
maximum shown in Fig. 2. For simplicity, as
few additional parameters as possible should
be used in the more general function.
We have used the function
Si = &Q(Z)

(6)

where z = log(x,/p)/Iog u and Q(z) is the

Gaussian probability function
Q(z) = (l/G)

f
z

e*E*r

d(E/fl)

'73

Fig. -I. Plot

_..

0.5

0 01

of esp(-z*/!?)Q(z)

VS. z -

2.5.

09
r

= s,foIp

Fig. 3. Log-probability
plot
different
ball diameters_

of y us. particle

size for

which can be readily calculated from wellknown polynomial approximations.

From experimental values of Si and ax:,
the ratio
Si/axs
can be determined:
(Si/aXy)

= Q

log xi log

log p
(3

Thus a plot of Xi uersus Si/aXf

on logprobability paper should give a straight line
from which p and u can be determined_
Figure 3 shows data of Kelsall et al_ [lo] for
E, % and 1 in. diam. steel balls, wet grinding,
piotted in this way_ The results can be fitted
by a straight line over much of the range;
a was found to be about 2.0, and from a loglog plot Of Si versus Xi for small Xi, CYWaS
found to be 1.33. Figure 2 shows the
applicability of eqn. (6) to our own results.
Accepting this function as a first approximation to the shape of the mean S function,
bearing in mind that the use of mean S is in
itself an approximation, ~i/dx
= Q(z)ccYx~-~
log (T) exp(--z2/2),
hence for
- (ax Q-1/fi2.3
the maximum in S,
2_3a&

OF BALL

d. mm

vs. ball diameter

for

the

log u = exp(-z%/2)lQ(X,)

where z, = log(x,/p)/log
a; and x, is the
particle size for maximum S for the given baii
diameter. Figure 4 shows a plot of the function exp(-9/2)/Q(z)
WEUS z + 2.5, which
gives over the range of interest:
=na= 1.75(2.3ofi

log u)~~* -

2.5

or
log(X,/P)

DIAMETER

Fig. 5. Plots of a and x,

data of Ketsall ef aI_

= log u [4.352(a

log a)452 -

2.51

(7)

PARTICLE

Fig. 6. Comparison
with experimental
(a
intervals)_

SIEVE

SIZE.

of the predictions
of eqn. (10)
resmelts, for data of Kelsall et al.

Knowing a and a, then, x,/cc can be determined. For the data of KeisalI et al_, x,/p = l-15_
Figure 5 shows the variation of x, with ball

7-I
TABLE

Values of descriptive constants

for data of Fig. I?. Units of x. d. D in mm, S

Material

Goid

(h)(lO

in

min-
Mill
diameter (mm)

k;,(lo3)

0.65

20

206

kz

ore

harder
mean
softer

-50

0.86

2.75

0.95

3.56

1.23

1.79
1.99
2.36.

1.69
1.91

0.59
0.68

1.66
1.73

0.86

157

195

l-25

O-40

1x-l

1.33

570

303

2.14

O-75

ND.

0.98

104

196

Cement clinker II
harder
meifn
Qi.KWtr
(Kelsall EL nf. )
mf=an
Cement clinker

mean
*It1

= 0.2

diameter, again using the data from Kelsall

et al. The results are of the form
= fi,d

s,

(8)

where for this data, kL = 1.25 X 10-3, mm-l.

Kelsall et a[_ did not deduce this result,
presumably because of the considerable
scatter of the esperimental data (see Fig. 5)
However, Snow [S] reported the result based
on their data and also pointed out that this
agrees with the rule given in eqn. (I), since
the position of the maximum in the specific
race of breakage corresponds to the particle
size, which is broken best by that particular
ball diameter_ Fi,we 5 also shows the variation
of a with d:
a = k, jdl-=

(9)

For units of S of mm-, and x, d in mm, kz =

570 for the Kelsall data. Then eqn. (6)
becomes
S,(d) = (Wd=*)x?Q(xi,

P, a)

2-51)

WI 9
or
k, = k,,(D/I)

u [4_352(Q log u)Q5* -

W)

Figure 6 shows the fit of this expression to

Kelsalis data; it describes the values of S to
the left of the maximum quite accurately,

(12)

where klo is the value of k, at unit mill

diameter_ A trial and error fit of results from
a 13-ft.-diam. cement mill [ 121 suggests that
the exponent is 0-L Thus eqn_ (11) goes to
zr = k,,(D/l)RI

where
D = k, d2/antilog(log

and the position of maximum S, but the value

of the maximum fits well only for the
smallest and largest sizes. Considering the
inherent variability of wet ball mill tests, and
the correction procedures necessary in the
Kelsall-Reid technique 173 to get the values
of S, the fit is considered as satisfactory.
Other results are shown in Fig. 2, for cement
clinker and gold-bearing ore [S] ground with
1-in_-diam_ balls_
From very limited results from an S-in.diam. mill compared to one of 2 ft. diam.

d2/antilog{log

oC4.352

(a log u)Q=2.51)
(13)
where nl = 0.1 to 0.2; further experimental
work will be needed to decide on the correct
value for n1 _
Table 1 summarizes the data values for k,,
kIO and u, determined by leas~squares regression analysis.

75

0.1

00

0
a

0.2

0.3

f,.FRACTfON

MILL VOLUME

Fig_ 7. Variation
powder filling.

of absolute

MIXTURE

OF BALL

FILLED

rates of breakage wirh

SIZES

(14)

dj

of balls of

Thus, from eqns. (lo), (11) and (12) the

overall values of Si can be calculated for a
given mix of balls, knowing kl. k2, CKand u.
Let t)i.i_k be the fractional breakage into
size i from breakage of size j by size k balls_
The total specific rate of breakage into size i is

If biej k is not a function

EFFECT

OF MILL

rate of breakage

from

the mean &j,j is given by

bi.j.kSi.k

OTHER

F.z 0~ Do-6

(16)

The variation of absolute rate of breakage

in the normal breakage region with powder
filling for normal values of J is shown in Fig. 7
[13,14]
_ These data for steel balls can be
approximately
described by

k2 = (f&T)*

AND

ON k,

(l/0.159)

[2( 0_159/f,)Q

l] )

(17)
where f, is the fractional volume filling by
powder and (f,S)*
is the maximum value of
Sf,, in the almost horizontal region of the
plot. Assuming this relation can be used for
other values of J,

2 Si.kmk

k=l

DLXMETER

that is, one set

We will
rather limited
bi.1 values do
or mill
operating

O-05 < f, < 0.3

k=l

bi,j =

of k, this reduces

We will assume this to be true,

of biOi values only will be used.
further assume, on the basis of
experimental
information,
that
not change with mill conditions
diameter in the region of usual
conditions_

s = (f.S)X
bi.i.&i.kmk

Hence,

BY BALL BED

It is reasonably well established [ 111 that

k2 will change with miII diameter according to

Si(d)dm(d)

The total specific

sizej is

06

to

CONDITIONS

&xix,

05

0.4

Assuming independent
be_havior of the
balls, the mean value of S,, Si say, is

j&Z

04

Fig. S. Proportional variation of powder with mill

filling, based on Rose and Sullivan formula [ 15 ] _

BY POWDER

where mk is the weight fraction

size k, or alternatively,

03

J. FRACTION OF MILL VOLUME FILLED

wnSEEBACH
(13) 50% BALLS
AUSTIN et of (141 20% BALLS
UC/O 159~[2:2(0.159/1,1~ 35-q
0.1

0.2

Wz/S Sj.kmk
k=l

(15)

[2(0.1-59/f,)-55

l]

(17a)

In addition, it can be reasoned that the

maximum absolute rate of breakage (Sf,)*
varies with ball filling J in a manner proportional to the variation of power input to the
mill. The power input to a mill, based on the

i6
TABLE

Weighting factors for ball charge in a large tube mill;

rnk = weight fraction
Ball size
in_
mm

I
L
I

3
3

0
-

,.I,,,

EXPERIMENTAL_
StMULAlEO
t

t I.,,.
1000

100
SIEVE

SIZE,pm

Fig. 9. Rosin-Rammler
plot of circuit simulation
vcrsws experimental results; assuming simple power
function for S.

data of Rose and Sullivan [ 153 , varies with J

according to
* (J) = 3.0453

f 4.55 J -

20.4J3 + Y_2.9J4
(16)

is proportional to mill power, or

where

0 (J)

(f,S)*

0 F(J) = J-i- 1.5 J -

6.75s -I-4.253
(16a)

Figure 8 shows the proportionality between

this absolute rate of breakage and J. which
applies for filling conditions which give breakage in the horizontal region of Fig_ 7. The
optimum value of J for normal breakage lies at
about J = O-4_
Combining eqns. (17a) and (Ma) gives
kz 0 [ 2(0.159/f,)-5

(J + 1.5J-

l]

6.7 J3 + 4.25 J)

(19)

Then, for a fixed value off,, k2 is proportional to F(J), as shown in Fig. 8_ Thus for
low values of J the specific rate of breakage
increases almost linearly with the number of
balls, other factors held constant. This is in
reasonable agreement with experimental
results 1143 _ Equation (19) wiII probably be
modified for different mills as more information on the variation of S with f, and J
becomes available. Note that for filling conditions to just fill the ball interstices, that is,
f, = 0_4J, the value of k2 does not vary widely
with J due to compensating factors in eqn.
(191.
Rates of breakage do not vary much with
fraction of critical speed provided that the
mill is run close to the optimum value for
maximum power, which lies between 65 and

31.4
3
2%
2
1%
1%
1

718

69
76
63.5
51
38
31.6
25.4

22.3

First
compartment

Second
compartment

mk

mk

0.30
0.37
0.23
0.10
O-19
0.30
0.26
0.25

overall
WC
0.10
0.12
0.07
0.03
0.13
O-20
0.18
0.17

85% of critical speed depending on the size of

the mil!, ball and powder filling in the mill,
and the powder size.

APPLICATIONS

In a recent paper 1161 it has been shown

how a mathematical model can be constructed
for a large-scale cement clinker grinding circuit, using data for a lSft.-diam.
by 34ft.long, two-compartment tube mill. In the
construction of the model, laboratory data on
S values from an S-in. ball mill loaded with
1-in.-diam. balls was extrapolated to larger
particle sizes using the simple power furl&ion
of eqn. (5), Si = ax:. It was assumed tnat a
single conversion factor existed between
specific rates of breakage in the small mill and
the overall values (mean for all ball sizes) in
the big mill:
(large mill Si) = (k) (small mill Si)

(26)

On this basis, the best match between

experimental and computed m_filsize distributions was obtained with a value of k = 2.75,
treating the mill as one continuous mill with a
residence time distribution corresponding to
ten equal fully-mixed reactors in series.
Applying these estimates of Si to the complete
mill circuit gave the size distributions shown
in Fig. 9.
Equations (lo), (13), (14), (15) and (16)
enable us to make better estimates of the
proportional specific rates of breakage in the
large mill by a more valid extrapolation to
larger particle sizes, by aIIowi.ug for the mix
of different ball sixes, and by scaling for mill

77

10.0

0.1
102

103
SIEVE

IO4
SiZE.prn

Fig_ lo_ Estimation of overall values of specific rates of breakage (*intervals)

from Fig. 3 by Da6 (plotted against upper size of interval).

SIEVE

SIZE.

Fig_ 11. Rosin-RammIer

plot of circuit simulation
results us_ experimental
results: function with
maximum in S values, two-compartment
mill.

diameter. The weighting factors ml are shown

in Table 2, where the final column gives the
values to be applied if all the balls were mixed
in a single compartment. The values of the
parameters determined for Bond filling conditions in the S-in. test mill for Type I cement
clinker, with I-in.-diam. balls, were Q = 0.98,
k,, = (0.75) (l(r3),
k2 = 104. The value of J
was assumed to be that shown for cement
clinker in Fig_ 2, Le. 1.73. Thus applying
-ns.
(lo), (13), (14) and (16) gives a set of
Si values as shown in Fig. 10. Using this set of
data in the simulation of the mill [lS, 171
gave best agreement between computed and

in the production

mill, scaled

experimental mill product size distributions

for a conversion factor of 0.76.
Note that the conversion factor is now
much closer to unity, although the ballpowder loading conditions in the small test
mill do not match those in the large mill, so
even if the scaling laws of eqns. (lo), (13) and
(14) were exact, k would not be exactly 1.
The model was immediately taken a step
closer to reality by considering the twocompartment tube mill to be equivalent to
two mills in series. Since it is likely [17] that
the residence time distributions of each
compartment is roughly proportional to
compartment length, the tube mill was
considered to be equivalent to a mill of three
equal reactors in series containing the first set
of balls, followed by a mill of seven equal
reactors in series with the second set of balls.
The two sets of mean Si values are shown in
Fig. 10. Again, the value of scale-up factor k
was adjusted to give the best agreement between computed and experimental results,
and a conversion factor of k = 0.71 was
obtained.
As before, the converted values of S were
used in a complete circuit simulation 1121 and
gave the size distributions shown in Fig. 11.
Comparing Fig_ 11 with Fig_ 9, it is seen that
the influence of the maximum in S values is
to allow larger sizes to pzsist longer than if

no maximum esisted, so that the match between the computed and the experimental
size distributions of the mill product and
recycle is considerably better for the upper
sizes. In addition, the values of k for the singlecompartment tersus the two-compartment
will show directly the quantitative advantage
of using a mix of larger ball diameters in the
first compartment and smaller in the second
instead of a complete mix through the whole
mill. The reasoning is as follows:
The real mill is more efficient than the first
simulation using a mix of balls because it
contacts the larger feed particles with a higher
proportion of larger balls_ Thus, to force the
false simulation to fit the real result, an
artificially higher conversion factor (of 0.76)
is required. On the other hand, the second,
real, simulation gives a truer estimate of O-71;
the comparative difference in efficiency is
approximately 0.05;0.71,
or 7%. Put another
way, if the S, values were corrected using the
true 0.71 factor and applied to a singlecompartment mill with a miu of all balls, the
flow rate through the mill (and hence circuit
output rate) would have to be decreased to
get the desired product size distribution (by
about 7%), or if the same flow rate were used
the product size distribution would be coarser.

same amounts of balls in a single mix

throughout the mill.
For future work, the equations we have
developed here will be used to establish the
optimum mixture of balls to go from a given
feed to a desired product, and we are
currently formulating and programming this
problem. This will provide a considerably
more sophisticated criterion for ball selection.
We will then be able to answer such questions
as whether the ball mixes used in the cement
mill were optimum, what would be the effect
of classifying liners which classify the balls by
size along the mill length, etc_
It should be noted that the equations need
further esperimental verification, since they
are based on quite limited data_

ACKNOWLEDGEiUEPil-S

We gratefully acknowledge the financial

assistance of the National Science Foundation,
Grant No. GK41901_

LIST

a
A

hi
Equations are given which enable the
conversion of specific rates of breakage
measured for one set of ball milling conditions
to values for other conditions, in particular
the conversion from one ball diameter to
another or a misture of balls. The position of
the maximum in the specific-rate-of-breakage
versus particle size plot is related to ball
diameter d by x, = h, d. This can be compared to the well-known criterion for ball size
selection, that is, x = Kd where d is the
best ball size to break particles of size x_
Clearly, this old criterion is crude, since the
particles do not stay at size x as they move
through the mill. We have demonstrated that
using the developed relations combined with
a mill model for a large cement mill enables
us to predict that a mix of larger balls in the
first compartment and smaller in the second
compartment is 7% more efficient than the

bi.i.k

J
k

OF SYMBOLS

constant defined by eqns. (4), (5) or

(6), min- 1 mm-subscript to denote harder material
weighted mean value of bi.i.k for the
mixture of balls in the mill
the primary breakage function; the
fraction of sizej material which after
primary breakage by size k balls
appears in size i
subscript to denote softer material
ball diameter, mm
inntemal mill diameter, e.g. mm
fraction of mill volume filled by
powder
mavimum value of f,S; at f, = 0.16,
min- r
a number denoting the particle size
interval being considered, e.g. 1 for
the top size interval, 2 for the next
smaller, etc.
fraction of mill volume filled with
static ball bed, based on a formal ball
bed porosity of 0.4
subscript denoting ball size range, or,
in eqn. (20). a scale conversion factor
defined by eqn. (20)

79

k-1

k2
k
K1
mk
n

Q(z)
Si

constant defined by eqn. (S), mm-

constant defined by eqn. (9), k2 =
SdL5/x = mmL5/(mm)Q
mm
value of kl for D = 1
the constant in eqn. (l), mm-
weight fraction of balls of size k
a constant
Gaussian probability
function
specific rate of breakage of material
in size interval i, minthe weighted mean value of Si for
the mixture of ball sizes in the mill,

i3f

minSi.k

t
wiA

tf)

wi(rl

W
_x

*In

G,(J)
log u

specific rate of breakage of size i

material being broken with size k
balls, min-
grind time, min
weight fraction of material of type
A which is of size i, at time t
weight fraction of total mill charge
which is of size i, at time t
total mill charge, g
particle (sieve) size; for a size
interval the upper size is used to
represent the particle size, mm
particle size for which S is a
maximum for a given ball and mill
diameter, mm
dimensionless p ammeter log(x,/p)/
log u
value of 2 for _x = x,
a constant
value of particle size at which Q(z)
is 0.5, mm
a constant, length- 1
apparent weight fraction of ith size
material at t = 0 which is component A
a function of J defined by eqn. (18),
proportional
to mill power
standard deviation of the probability function

REFERENCES
1 P_ T_ Luckie and L. G. Austin, Review introduction
to the solution of the grinding equations by digital

computation,
Miner. Sci. Eng., i (1972) 2-2_
2 W. H. Coghill and F. D. Devaney, Ball mill grinding,
U. S. Bureau of Mines, T_ P. 581 (1937),
p_ 47.
3 F_ C. Bond, Grinding ball size selection. Min. Eng.,
10 (1958) 592.
4 L. G. Austin, Review introduction to the description of grinding as a rate process, Powder Technol.,
5 (1971172)
1.
5 L_ G. Austin, K. Shoji and M. D. Ever-all,
Explanation cf abnormal breakage of large
particle sizes in laboratory mills, Powder Technol.,
7 (lSi3)
3.
6 W. J. Taut&, P. Meyer and L. G. Austin. Comparison of breakage parameters in two tumbling ball
mills of different diameters, Proc. Symp.
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