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A KINETIC

K I N E T I C APPROACH TO
TO BALL MILL SCALE-UP
A

FOR DRY AND


AND WET
SYSTEMS
WET SYSTEMS

by
Mohammad Siddique
Siddique

A
A thesis
t h e s i s submitted
s u b m i t t e d to
t o tthe
h e faculty
f a c u l t y of
o f the
the
University
Utah in
partial
the requirements
U n i v e r s i t y of
o f Utah
in p
a r t i a l fulfillment
f u l f i l l m e n t of
o f the
requirements
for
f o r the
t h e degree
d e g r e e of
of

Master of
o f Science
Science
Master

in
in
Meta
M e t a 11
l l uurgy
rgy

Department
~~etallurgical
Department of
o f Mining,
Mining, M
e t a l l u r g i c a l and Fuels
F u e l s Engineering
Engineering
Uni
U
n i versity
v e r s i t y of
o f Utah
Utah
June
J u n e 1977
1977

THE UNIVERSITY OF UTAH GRADUATE SCHOOL

SUPERVISORY

COMMITTEE APPROVAL

of a thesis submitted by

Mohammad Siddique

I have read this thesis and have fou

de

/yJ!-z; LVz

Da

I have read this thesis and have faun

I have read this thesis and have found it to be of s. tis

ctory quality for a master's

Member, Supervisory Committee

THE UNIVERSITY OF UTAH GRADUATE SCHOOL

FINAL READING APPROVAL

To the Graduate Council of The University of Utah:

Mohammad Siddique

I have read the thesis of


final form and have found that

in its

(I) its format, citations, and bibliographic style are

consistent and acceptable; (2) its illustrative materials including figures, tables, and
charts are in place; and (3) the final manuscript is satisfactory to the Supervisory
Committee and is ready for submission to the Graduate School.

Approved for the Major Department

,(bdo,nl ;;J-L
David M. Bodily
Chairman! Dean

Approved for the Graduate Council

ABSTRACT
In this
t h i s investigation
i n v e s t i g a t i o n detailed
d e t a i l e d experimentation
e x p e r i m e n t a t i o n has been carried
carried
mill
out
i l l scale-up
s c a l e - u p uusing
s i n g a linear
linear
o u t to
t o establish
e s t a b l i s h a rrelationship
e l a t i o n s h i p for
for m
population
systems.
p o p u l a t i o n bbalance
a l a n c e model in
i n dry
d r y and wet
w e t grinding
g r i n d i n g systems.

Data were

d i f f e r e n t sizes
s i z e s of
o f mill
m i l l (la,
(10, 15
15 and 30
30 inches
i n c h e s in
in
o b t a i n e d in
i n three
t h r e e different
obtained
d i a m e t e r ) for
f o r limestone
l i m e s t o n e grinding.
grinding.
diameter)

t h e selection
s e l e c t i o n and
In each case the

breakage
breakage pparameters
a r a m e t e r s of
o f the
t h e population
p o p u l a t i o n balance
b a l a n c e model were determined.
determined.
Analysis
A n a l y s i s of
o f these
t h e s e data
d a t a showed that
t h a t the
t h e selection
s e l e c t i o n functions
f u n c t i o n s are
a r e propro
p o r t i o n a l tto
o the
t h e specific
s p e c i f i c power draft
d r a f t of
o f the
the m
i l l (Si
(S^ =
= S~(P/H))
S^(P/H))
mill
portional
f o r both w
e t and dry
d r y grinding.
grinding.
for
wet

a d d i t i o n the
the b
r e a k a g e functions
functions
In addition
breakage

i l l size,
s i z e , the
t h e same for
f o r wet
dry
were found
f o u n d to
t o be independent
i n d e p e n d e n t of
of m
mill
wet and dry
grinding.
grinding.

F o r dry
d r y grinding
g r i n d i n g the
the specific
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s (S~)
(S?)
For

grind.
f o u n d to be independent
i n d e p e n d e n t of
o f fineness
f i n e n e s s of
o f grind.
were found

W h i l e for
f o r wet
While

g r i n d i n g the
t h e specific
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s varied
v a r i e d with
w i t h fineness
f i n e n e s s of
of
grinding
grind.
grind.

T h e s e rrelationships
elationships w
e r e found
f o u n d tto
o constitute
c o n s t i t u t e a bbasis
a s i s for
for
These
were

m i l l scale-up.
scale-up.
mill

By
i n c o r p o r a t i n g tthe
h e specific
s p e c i f i c selection
s e l e c t i o n functions
functions
By incorporating

and breakage
f u n c t i o n s into
i n t o tthe
h e linear
l i n e a r population
population b
a l a n c e model
model
and
breakage functions
balance
i t was ppossible
o s s i b l e to
t o accurately
accurately p
r e d i c t dry
d r y pproduct
r o d u c t size
s i z e distributions
distributions
it
predict
d a t a obtained
o b t a i n e d in
i n the
the la-inch
1 0 - i n c h diameter
d i a m e t e r mill.
mill.
i n the
t h e larger
larger m
i l l s from
f r o m data
in
mills
E q u a l l y accurate
a c c u r a t e predictions
p r e d i c t i o n s were
a c h i e v e d for
f o r wet
w e t grinding
g r i n d i n g by
Equally
were achieved
e m p l o y i n g a linearization
l i n e a r i z a t i o n pprocedure
r o c e d u r e termed as the
the " similar
s i m i l a r fineness
fineness
employing
II

of g
g ri
r i nnd
d approach
approach".
of
II

ACKNOWLEDGEMENTS
The author
a u t h o r wishes
w i s h e s to
t o express
e x p r e s s his
h i s sincere
s i n c e r e gratitude
g r a t i t u d e to
t o Dr.
D r . John
Arthur
his
A r t h u r Herbst
H e r b s t for
for h
i s invaluable
i n v a l u a b l e guidance
g u i d a n c e and advice
a d v i c e which
w h i c h has lead
lead
to
t o the
t h e successful
s u c c e s s f u l completion
c o m p l e t i o n of
o f this
t h i s research.
research.

Thanks are
a r e also
also

extended
e x t e n d e d to
t o Dr.
D r . J.D.
J . D . Miller
M i l l e r and Dr.
D r . H.Y.
H . Y . Sohn for
f o r ttheir
h e i r interest
i n t e r e s t in
in
this
t h i s study.
study.
Thanks are
a r e due to
t o David
D a v i d J.
J . Kinneberg,
K i n n e b e r g , a fellow
f e l l o w graduate
g r a d u a t e student
student
for
f o r the
t h e time
t i m e he spent
s p e n t in
i n preliminary
p r e l i m i n a r y editing
e d i t i n g of
o f tthis
h i s tthesis.
hesis.

Also
Also

thanks
his
thanks tto
o Kuppuswamy
Kuppuswamy Rajamani
Rajamani for
for h
i s cooperation
c o o p e r a t i o n during
d u r i n g tthis
h i s study
s t u d y.
a p p r e c i a t i o n also
a l s o tto
o all
a l l the
t h e other
o t h e r fellow
f e l l o w graduate
graduate
. My compliments and appreciation

students
s t u d e n t s who provided
p r o v i d e d me with
w i t h companionship,
c o m p a n i o n s h i p , encouragement
encouragement and aa
pleasant
p l e a s a n t working
w o r k i n g atmosphere.
atmosphere.
The
National
T h e financial
f i n a n c i a l support
s u p p o r t by the
the N
a t i o n a l Science
S c i e n c e Foundation
F o u n d a t i o n is
is
v e r y gratefully
g r a t e f u l l y acknowledged.
acknowledged.
very

Finally,
F i n a l l y , the
t h e author
a u t h o r wishes
w i s h e s tto
o extend
e x t e n d special
s p e c i a l appreciation
a p p r e c i a t i o n to
to
his
parents
his p
a r e n t s for
f o r ttheir
h e i r constant
c o n s t a n t moral support
s u p p o r t and encouragement
encouragement
t h r o u g h o u t tthe
h e duration
d u r a t i o n of
of h
i s studies.
studies.
his
throughout

TABLE OF
OF CONTENTS
CONTENTS
TABLE
Page

ABSTRACT
ABSTRACT

..............................

iv

................................... ,. .... ,. .
..........................................

ACKNOWLEDGEMENT
ACKNOWLEDGEMENT
OF FIGURES
FIGURES
LLIST
I S T OF
CHAPTER II
CHAPTER

INTRODUCT ION
INTRODUCTION

CHAPTER IIII
CHAPTER

REVIEW OF
OF RELATED
RELATED STUDIES
STUDIES
REVIEW

.........................

vii
v i i

1
1

..............

Mode 1 Framework
Framewo rk ....................
Model

........

11

EQUIPMENT AND
AND EXPERIMENTAL
EXPERIMENTAL PROCEDURES
PROCEDURES ....
EQUIPMENT
....

16

Equi
pment ................................ .
Equipment

16^

Experimental
Procedure
E
xperimental P
rocedure

24

Applications
Related
A
pplications R
e l a t e d tto
o Scale-up
Scale-up

CHAPTER IIII
CHAPTER
II

i v

..................

1 1

1 6

2 4

CHAPTER
CHAPTER IV
IV

ANALYSIS OF BREAKAGE
BREAKAGE KINETICS
KINETICS
ANALYSIS

...........

28

CHAPTER V
V

SCALE-UP PREDICTIONS .................... .

44

Parameter
P a r a m e t e r Estimation
E s t i m a t i o n for
f o r Scale-up
S c a l e - u p ....... .

44

Predictive
P r e d i c t i v e Simulation
S i m u l a t i o n ................... .

CHAPTER VI
VI

2 8

4 4

4 4

CO
52

SUMMARY AND CONCLUSIONS .............

72
72

SYMBOL
SYMBOL TABLE
TABLE

76
76

REFERENCES
REFERENCES

............................................
..............................................

79
79

EXPERIMENTAL PRODUCT SIZE


S I Z E DISTRIBUTION
DISTRIBUTION
FOR CALCITIC
C A L C I T I C LIMESTONE GRINDING ......... .

83
83

COMPUTATIONS OF THE SPECIFIC ENERGY


INPUT
INPUT TO
TO THE
THE MILL
MILL ....................... .

97
97

VITA
V I T A ....................................................

107
107

APPENDIX II
APPENDIX II
II

LIST
L I S T OF
OF FIGURES
FFigure
igure

1.

Page

Photograph
P h o t o g r a p h showing the
t h e 10-in.
1 0 - i n . and
and 15-in.
1 5 - i n . diameter
diameter
mi
with
m i 11
l l ss w
i t h square
square 1
l iif fters
t e r s ..........
e e e

2.

(a) The
T h e configuration
c o n f i g u r a t i o n of
o f ramp lifters
l i f t e r s used in
in
tthe
h e 100 - iin.
n . rn;
m i1
l l1 .

(b) The
c o n f i ggurati
u r a t i oon
n of
o f square
square 1
l iiffters
t e r s used
T h e confi
in
h e 10-in.
1 0 - i n . and
and 15-in.
1 5 - i n . mills
m i l l s ...............
i n tthe
(c) The
c o n f i g u r a t i o n of
o f rounded lifters
l i f t e r s used
T h e configuration
mii 11
in
h e 3300 - in.
in. m
l l ...........................
i n tthe
3.

4.

Photograph
mill
P h o t o g r a p h showing tthe
h e 10-in.
10-in. m
i l l with
w i t h variable
variable
speed ttransmission,
t h e torque
t o r q u e sensor,
s e n s o r , coupling
coupling
r a n s m i s s i o n , the
and Sargent
S a r g e n t recorder
r e c o r d e r ............................

6.
7.

8.

19
19

20
20

Photograph
P h o t o g r a p h showing tthe
h e sideview
s i d e v i e w of
o f tthe
h e 30-in.
30-in.
111;'1..............................................
mill

21
21

Photograph
P h o t o g r a p h showing a view
v i e w of
o f the
t h e 30-in.
3 0 - i n . mill
mill
with
r o n y brake
brake in
i n position......................
position
w i t h pprony

21
21

Photograph
pinion
P h o t o g r a p h showing p
i n i o n shaft
s h a f t of
o f tthe
h e 30-in.
30-in.
mill
with
mill w
i t h tthe
h e belt
b e l t ppulley,
u l l e y , the
t h e ttorque
o r q u e sensor
sensor
and the
t h e chain
c h a i n coupling
c o u p l i n g ............................

23

Feed disappearance
and
d i s a p p e a r a n c e plot
p l o t for
f o r 10-in.,
1 0 - i n . , 15-in.
1 5 - i n . and
30;in.
3 0 j i n . diaweter
d i a m e t e r mills
m i l l s for
f o r tthe
h e dry
d r y grinding
grinding
(N =0.6,
=0.6, M
M =0.5) ... ... ...................... .....
B
Feed ddisappearance
and
i s a p p e a r a n c e pplot
l o t for
f o r 10-in.,
1 0 - i n . , 15-in.
1 5 - i n . and
3 0 - i n . diameter*mills
d i a m e t e r * m i l l s sbowing
showing the
t h e wet
w e t grinding
grinding
30-in.
n~nlinearity
=0.6, M
M =0.5,
= 0 . 5 , for
f o r 30-"in.
3 0 - i n . mill
mill
n g n l i n e a r i t y (N =0.6,
B
....
M
M =0.4,
= 0 . 4 , F=0.6)
F = 0 . 6 ) ..............................
?
B
A
A sample of
o f fines
f i n e s pproduction
r o d u c t i o n pplots
l o t s for
f o r arbitrary
arbitrary
chosen size
intervals
.............................
size intervals
B

9.

1199

Photograph
mill
P h o t o g r a p h showing tthe
h e 15-in.
15-in. m
i l l on
on tthe
he
1l ooadi
a d i nng
g port
p o r t ......................................

5.

17

29

10.
10.
11
11..

Feed size
breakage functi
s i z e breakage
f u n c t i oons
n s for
f o r dry
d r y gri
g r i nndi
d i nn9g
ii~
$ 110-in.~
0 - i n . . 15-in.
1 5 - i n . and
and 30-in.
3 0 - i n . diameter
d i a m e t e r mills
mills
N
= 0 . 6 , MS=0.5)
M =0.5) ................ e............. ....
N =0.6,
R

30
33

34

List
L i s t of
o f Figures
Figures

(Continued)
(Continued)

Figure
Fi9ure

12.
12.

Page
Feed size
wet
s i z e breakage
breakage functions
f u n c t i o n s for
for w
e t grinding
grinding
and 30:in.
30-in. d
i a m e t e r mills.
mills.
i n * 1 0 - i n . , *,*15-in.
15-in.
in*lO-in.
and
~iame~er
=0.6, M
M =0.5,
= 0 . 5 , for
f o r 30-1n.
3 0 - i n . mlll
mill M
M =0.4,
=0.4,
(N =0.6,
(~
B
S
F-O.6)
.... .......
F=0.6) ..................... ,... .........
?

35

Nonnalized
N
o r m a l i z e d feed
f e e d size
s i z e disappearance
d i s a p p e a r a n c e plot
p l o t for
f o r ddry
ry
g r i n d i n g * i n 10-iQ"
1 0 - i n . , l5-in.
1 5 - i n . and
and 30-in.
3 0 - i n . diameter
diameter
g:inding*in
=0.6, M
m i l l s (N =0.6,
M =0.5) ............. ...............
mll1s

36

13.
13.

B
14.
Normal
wet
14.
N
o r m a lized
i z e d feed
f e e d size
s i z e disappearance
d i s a p p e a r a n c e pplot
l o t for
for w
et
g r i n d i n g in
i n 10-in.,
1 0 - i n . , 15-in.
1 5 - i n . and*30-in.
a n d * 3 0 - i n . ~iameter
(jiameter
grinding
(N =0.6,
= 0 . 6 , MS=0.5
M =0.5
m i l l s , ~howi~g
showing n
o n l i n e a r i t y (N
mills,
no~linearity
for
=0.4,
F=0.6)
f o r 30-1n.
3 0 - i n . mlll
mill M
M*=0.4,
F = 0 . 6 ) ..................
?
B
15.
Feed size
15.
s i z e breakage
breakage functions
f u n c t i o n s for
f o r dry
d r y grinding
grinding
1 0 - i n . diameter
d i a m e t e r mill
m i l l with
w i t h square,*ramp
square,*ramp
i n 10-in.
in
=0.6,
and without
w i t h o u t lifters
l i f t e r s configuration
c o n f i g u r a t i o n (N =0.6,
a~d
M
M =0.5) ... ......................................
S
16.
Feed size
wet
16.
s i z e breakage
breakage functions
f u n c t i o n s for
for w
e t grinding
grinding
1 0 - i n . diameter
d i a m e t e r mill
mill ^
i t h square
s q u a r e and
and ramp
i n 10-in.
in
with
lifters
=0.6, M
Mg=0.5,
=0.6)
l i f t e r s configuration
c o n f i g u r a t i o n (N =0.6,
S=0.5, FF=0.6)
17.
Nonnalized
17.
N
o r m a l i z e d feed
f e e d size
s i z e disappearance
d i s a p p e a r a n c e plot
p l o t ffor
or
dry
wet
mill
d r y and
and w
e t grinding
g r i n d i n g in
i n 10-in.
1 0 - i n . diameter
diameter m
i l l with
with
sq~are,
s q u a r e , rawp
ramp and
and without
w i t h o u t lifters
l i f t e r s configuration
configuration
(N ==0.6,
MS=0.5, F=0.6)
0 . 6 , M*=0.5,
F = 0 . 6 ) ..........................
18.
Dependence of
on
18.
o f specific
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s on
the p
a r t i c l e size
s i z e distribution
d i s t r i b u t i o n iin
n tthe
h e bball
a l l mill,
mill,
the
particle
f e e d and
and -10 mesh feed
f e e d in
i n tthe
he
f o r 10x14 mesh feed
for
wet grinding,
g r i n d i n g , showing ppronounced
r o n o u n c e d nonlinearity.....
nonlinearity
B

19.
19.

20.
20.

37

38

39

41

43

Comparison of
product
o f experimental
experimental p
r o d u c t size
s i z e distridistri
f o r dry
d r y grinding
g r i n d i n g in
i n 10-in.
1 0 - i n . diameter
d i a m e t e r mill
mill
b u t i o n for
bution
f e e d ) and
and normalized
n o r m a l i z e d ffittings
i t t i n g s with
with
(10x14 mesh feed)
i n i t i a l S?
and 8
B..
. . estimates
e s t i m a t e s shown in
in
initial
S~ and
Table
T a b l e (11
( I I -233),
) , Ap~~ndix
A p j W n d i x II
I I ........................

54
54

Comparison of
o f experimental
e x p e r i m e n t a l pproduct
r o d u c t size
s i z e distridistri
bution
f o r dry
d r y grinding
g r i n d i n g in
i n 110-in~
0 - i n . diameter
d i a m e t e r mill
mill
b u t i o n for
(-10
(-10 meshEfeed)
m e s h r f e e d ) and
and normalized
n o r m a l i z e d ppredictions
r e d i c t i o n s with
with
initial
i n i t i a l S.
S . and
and S
B..
. . estimates
e s t i m a t e s shown in
in
Table
Ap~~ndix
T a b l e (11
( I I -233),
), A
p p e n d i x II
I I .........................

55

viii
vii i

List
L i s t of
o f Figures
Figures

(Continued)
(Continued)

Figure
Figure
21.
21.

Page
Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distridistri
bution
f o r dry
d r y grinding
g r i n d i n g in
i n 15-in.
1 5 - i n . diameter
d i a m e t e r mill
mill
b u t i o n for
f e e d ) and
and n
ormalized p
r e d i c t i o n s with
with
(10x14 mesh
me~h feed)
normalized
predictions
i n i t i a l S. and
and B
e s t i m a t e s obtained
o b t a i n e d from
from
initial
Bi. . estimates
1 0 - i n . di~meter
d i a m e t e r mill,
m i l l , shown in
i n Table
T a b l e (11-3),
(I1-3),
10-in.
A p p e n d i x II
I I ...................................... .
Appendix

22.
22.

o f experimental
experimental p
r o d u c t size
s i z e distridistri
Comparison of
product
f o r dry
d r y grinding
g r i n d i n g in
i n 15-in.
1 5 - i n . diameter
d i a m e t e r mill
mill
b u t i o n for
bution
(-10 meshEfeed)
m e s h r f e e d ) and
and nnormalized
ormalized p
r e d i c t i o n s with
with
predictions
(-10
i n i t i a l Si
S . and
and B.
B . estimates
e s t i m a t e s obtained
o b t a i n e d from
from
initial
1 0 - i n . diameter
diameter m
i l l , shown iin
n Table
T a b l e (11-3),
(I1-3),
10-in.
~ill,

56

A p p e n d i xx II II ...................................... .
Appendi

23.
23.

24.
24.

25.
25.

26.
26.

27.
27.

57

Comparison of
o f experimental
e x p e r i m e n t a l pproduct
r o d u c t size
s i z e distridistri
bution
f o r dry
d r y grinding
g r i n d i n g in
i n 30-in.
3 0 - i n . diameter
d i a m e t e r mill
mill
b u t i o n for
f e e d ) and
and normalized
n o r m a l i z e d predictions
predictions
(10x14 mesh feed)
i n i t i a l S~
S? and
and B
e s t i m a t e s obtained
o b t a i n e d from
w i t h initial
BO.. i. estimates
with
1 0 - i n . diamete~
d i a m e t e r mill
m i l l ,,'shown
shown in
i n Table
T a b l e (11-3),
(I1-3),
10-in.
A p p e n d i xx II II .......................................
Append;

58

Comparison of
product
o f experimental
experimental p
r o d u c t size
s i z e distridistri
bution
f o r dry
d r y grinding
g r i n d i n g in
i n 3D-in.
3 0 - i n . diameter
d i a m e t e r mill
mill
b u t i o n for
(-10 meshEfeed)
m e s h r f e e d ) and
and normalized
n o r m a l i z e d predictions
p r e d i c t i o n s with
with
(-10
i n i t i a l S.
S . and
and B
B..
. . estimates
e s t i m a t e s obtained
o b t a i n e d from
from
initial
1 0 - i n . di!meter
d i a m e t e r ~ill,
m i l l , shown in
i n Table
T a b l e (11-3),
(I1-3),
10-in.
A p p e n d i x II
I I .....................................
Appendix

59

The
wet
T h e comparison
c o m p a r i s o n ofEdry
o f r d r y and
and w
e t specific
s p e c i f i c selecselec
S . , (KWH/T) obtained
o b t a i n e d between
between
t i o n functions,
f u n c t i o n s , S.,
tion
10x14
a~d fi
f i rrst
s t four
f o u r gri
g r i nnds
d s .............
10x14 mesh feed
f e e d and

61

Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distridistri
bution
f o r wet
w e t grinding
g r i n d i n g iin
n 10-in.
1 0 - i n . diameter
d i a m e t e r mill
mill
b u t i o n for
f e e d ) and
and n
o r m a l i z e d fittings
f i t t i n g s with
with
(10x14 mesh feed)
normalized
initial
i n i t i a l S~ and
and B
B..
. . estimates,
e s t i m a t e s , shown in
in
Table
Ap~~ndix
T a b l e (11
( 1 11* 3),
3), A
p p e n d i x II
I I ........................

62

Comparison of
o f experimental
e x p e r i m e n t a l pproduct
r o d u c t size
s i z e distridistri. bution
b u t i o n for
f o r wet
w e t grinding
g r i n d i n g in
i n 10-in.
1 0 - i n . diameter
d i a m e t e r mill,
mill,
(E10
( 1 0 mesh feed)
f e e d ) and
and normalized
n o r m a l i z e d predictions
p r e d i c t i o n s with
with
( f i r m lines)
l i n e s ) and
St estimates
e s t i m a t e s with
w i t h method II (firm
S7
and
m~thod
method II
I I (dotted
( d o t t e d lines)
l i n e s ) ..........................

63

ix
ix

List
Figures
L i s t of
of F
igures

(Continued)
(Continued)
Page

Figure
Figure
28.
28.

Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distridistri
1 5 - i n . diameter
d i a m e t e r mill
mill
b u t i o n for
f o r wet
wet grinding
g r i n d i n g in
i n lS-in.
bution
(10x14 mesh feed)
f e e d ) and n
o r m a l i z e d ppredictions
r e d i c t i o n s with
with
(~Ox14
normalized
1 0 - i n . diameter
d i a m e t e r mill
mill
e s t i m a t e s obtained
o b t a i n e d from
f r o m la-in.
Si estimates
( f i rnn
m 1
l iinnes)
e s ) and method IIII
w i tth
h method II (fi
w,
(dotted
(dotted 1
l iinnes)
e s ) ...................................

65

Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distridistri
bution
3 0 - i n . diameter
d i a m e t e r mill
mill
b u t i o n for
f o r wet
w e t grinding
g r i n d i n g in
i n 30-in.
(10x14
mesh
f
e
e
d
)
and
n
o
r
m
a
l
i
z
e
d
p
r
e
d
i
c
t
i
o
n
s
with
(~Ox14
feed)
normalized predictions with
1 0 - i n . diameter
d i a m e t e r mills
mills
S|r estimates
e s t i m a t e s obtained
o b t a i n e d from
f r o m 10-in.
Si
( f i r m lines)
l i n e s ) and method II
II
w i t h method II (firm
w,th
((dotted
dotted 1
l iines)
n e s ) ....................................

66

Comparison
C o m p a r i s o n of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distridistri
bution
1 5 - i n . diameter
d i a m e t e r mill
mill
b u t i o n for
f o r wet
w e t grinding
g r i n d i n g in
i n 15-in.
f e e d ) and normalized
n o r m a l i z e d ppredictions
r e d i c t i o n s with
with
(-10 mesh feed)
(E10
S. estimates
1 0 - i n . diameter
d i a m e t e r mills
mills
e s t i m a t e s obtained
o b t a i n e d from
f r o m 10-in.
w~th
( f i r m lines)
l i n e s ) and method II
II
w i t h method II (firm
(dotted
1 i n e s ) ..... ~..............................
.
( d o t t e d lines)

67

31.'
Comparison of
product
31.
o f experimental
experimental p
r o d u c t size
s i z e distridistri
b u t i o n for
f o r wet
g r i n d i n g in
i n 30-in.
3 0 - i n . diameter
d i a m e t e r mill
mill
bution
wet grinding
f e e d ) and nonnalized
n o r m a l i z e d ppredictions
r e d i c t i o n s with
with
(-10 mesh feed)
(-E10
S.
1 0 - i n . diameter
d i a m e t e r mills
mills
S. estimates
e s t i m a t e s obtained
o b t a i n e d from
f r o m la-in.
w~th
( f i r m lines)
l i n e s ) and method II
II
w i t h method II (firm
( d o t t e d lines)
l i n e s ) ....................................
(dotted

68

29.
29.

30.
30.

32.
32.

33.
33.

Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distridistri
b u t i o n for
f o r an open circuit
c i r c u i t wet
g r i n d i n g in
in
bution
wet grinding
3 0 - i n . diameter
diameter m
i l l (-10
(-10 mes~
mesh feed)
f e e d ) and
30-in.
mill
n o r m a l i z e d ppredictions
r e d i c t i o n s with
w i t h S.
S4- estimates
estimates
normalized
1 0 - i n . diameter'mills
d i a m e t e r m i l l s with
with
o b t a i n e d from
f r o m la-in.
obta"ined
method II II .........................................

70

Detennination
D e t e r m i n a t i o n of
o f efficiency
e f f i c i e n c y factor
f a c t o r for
f o r the
the
30-in.
3 0 - i n . mill
m i l l using
u s i n g torque
t o r q u e sensor
s e n s o r attached
a t t a c h e d to
the
pinion
brake on the
p r o n y brake
the
the p
i n i o n shaft
s h a f t and prony
peri
p e r i pphery
h e r y of
o f the
t h e mi
m i 11
l l .............................

101

xx

CHAPTER I
INTRODUCTION
Grinding
G r i n d i n g operations
o p e r a t i o n s are
a r e of
o f great
g r e a t importance
i m p o r t a n c e to
t o tthe
h e mineral
m i n e r a l and
cement
U.S.
cement industries
i n d u s t r i e s in
i n particular
p a r t i c u l a r and tthe
he U
. S . economy as a whole.
whole.
g
At present, approximately 109 tons of material is ground annually
A t p r e s e n t , a p p r o x i m a t e l y 10

tons o f material

is ground a n n u a l l y

in the United States.

In the process about 1% of the U.S. steel

in the United S t a t e s .

In t h e p r o c e s s a b o u t 1% o f t h e U . S .

steel

production is consumed as grinding media and about 1% of the U.S.


p r o d u c t i o n i s consumed as g r i n d i n g media and a b o u t 1% o f t h e

U.S.

energy production is consumed in driving the mills.

In many regards

e n e r g y p r o d u c t i o n i s consumed i n d r i v i n g t h e m i l l s .

I n many r e g a r d s

grinding is the most important unit operation in a mineral processing


g r i n d i n g i s t h e most i m p o r t a n t u n i t o p e r a t i o n i n a m i n e r a l

processing

plant.

The objectives in the mineral industry are to liberate valu-

plant.

The o b j e c t i v e s i n t h e m i n e r a l

i n d u s t r y are to l i b e r a t e

valu

able minerals from the gangue materials and to reduce the size of
a b l e m i n e r a l s f r o m t h e gangue m a t e r i a l s

and t o r e d u c e t h e s i z e o f

the mineral particles so that they are suitable for subsequent mineral
the m i n e r a l

particles

so t h a t t h e y a r e s u i t a b l e f o r s u b s e q u e n t m i n e r a l

processing operations.
processing

operations.

Unfortunately grinding circuits involve high capital and operatUnfortunately grinding circuits

i n v o l v e h i g h c a p i t a l and

operat

ing costs and are notoriously inefficient.

Thus there is considerable

ing c o s t s and a r e n o t o r i o u s l y i n e f f i c i e n t .

Thus t h e r e i s

considerable

room for improvement in grinding circuits which would reduce the


room f o r improvement i n g r i n d i n g c i r c u i t s w h i c h w o u l d r e d u c e

the

processing costs.

The two areas in which the potential is greatest

processing costs.

T h e two a r e a s i n w h i c h t h e p o t e n t i a l

are:
are:

is

(i) mill scale-up design and (ii) automatic control.


(i)

mill

s c a l e - u p d e s i g n and ( i i )

automatic

control.

is concerned with improving procedures for scale-up design.


is concerned w i t h improving procedures f o r s c a l e - u p d e s i g n .

greatest

This study
This study

For the

For the

last three decades most of the mill scale-up work has been based,
l a s t t h r e e decades most o f the m i l l

s c a l e - u p w o r k has been b a s e d ,

directly or indirectly, on the empirical Bond energy-size-reduction


d i r e c t l y o r i n d i r e c t l y , on t h e e m p i r i c a l

equation(l).
equation^^.

Bond e n e r g y - s i z e - r e d u c t i o n

Although this approach has been used extensively in

A l t h o u g h t h i s approach has been used e x t e n s i v e l y i n

the mineral industry, occasionally serious design errors are made.


the mineral

i n d u s t r y , o c c a s i o n a l l y s e r i o u s d e s i g n e r r o r s a r e made.

2
,

In fact,
f a c t , two industrial
i n d u s t r i a l surveys
s u r v e y s suggest
s u g g e s t that
t h a t tthe
h e design
d e s i g n risk
r i s k aassocssoc
iated w
i t h tthis
h i s ttraditional
r a d i t i o n a l scale-up
s c a l e - u p method
method is
i s on
on the
t h e order
o r d e r of
of
20
20
iated
with
(2 3}
cent(2,3).
cent

'

pe
pe~

The principal limitations of the Bond equation appears


The p r i n c i p a l

l i m i t a t i o n s o f t h e Bond e q u a t i o n appears

to be its failure to account for important grinding circuit subproto be i t s f a i l u r e

to a c c o u n t f o r i m p o r t a n t g r i n d i n g c i r c u i t s u b p r o -

cesses, i.e., breakage kinetics, particle transport through the mill,


cesses, i . e . ,

breakage k i n e t i c s , p a r t i c l e

t r a n s p o r t t h r o u g h the m i l l ,

and size classification in an explicit fashion.

The Bond scale-up

and s i z e c l a s s i f i c a t i o n i n an e x p l i c i t f a s h i o n .

T h e Bond s c a l e - u p

approach lumps the influence of all of these subprocesses into a


approach lumps t h e i n f l u e n c e o f a l l
single
empirical correlation(l).
single empirical

of these subprocesses i n t o a

correlation^.

In recent years significant advances have been made in the


In r e c e n t y e a r s s i g n i f i c a n t advances have been made i n t h e

development of detailed phenomenological grinding models derived


from population balance con~iderations(l ,4,5,6).

d e v e l o p m e n t o f d e t a i l e d p h e n o m e n o l o g i c a l g r i n d i n g models d e r i v e d
In these models
( 1 4 5 6)

the explicit
from
p o p u l a t i oaccounting
n b a l a n c e of
c o ngrinding
s i d e r a t i o nsubprocesses
s ' *
.
5

(size
I n t h ereduction
s e models kin-

etics,
the e x pmaterial
l i c i t a c c transport
o u n t i n g o f ing r ithe
n d i nmill
g s uand
b p r osize
c e s s eclassification)
s ( s i z e r e d u c t i o ngives
kin
them
significant
simpler
e t i c s ,a m
a t e r i a l t r a nadvantage
s p o r t i n over
the mthe
i l l and
s i z e energy-size-reduction
classification) gives
equations.
e s complete
i m p l e r e n form,
e r g y - s is
i z e capable
- r e d u c t i oof
n
them a s i g n i This
f i c a n ttype
a d vof
a n t amodel,
g e o v e rin t hits
describing
e q u a t i o n s . the
T h i ssize
t y p edistribution
o f m o d e l , i nin i tas tumbling
c o m p l e t e mill
f o r mgrinding
, i s c a p a device
ble of
as
d e sac r function
i b i n g t h e of
s i ztime
e d i sand
t r i bmill
u t i o nposition.
i n a t u m bThe
l i n g breakage
m i l l g r i nprocess
d i n g d eis
vice
characterized
as a f u n c t i o n obyf two
t i m e physically
and m i l l p interpretable
o s i t i o n . T h e quantities,
b r e a k a g e p r o cae selection
ss is
function,
c h a r a c t e r i zwhich
e d by gives
two p the
h y s if~actional
c a l l y i n t e r prate
r e t a bof
l e breakage
q u a n t i t i eof
s , particles
a selection
and f raa cbreakage
fin
u n each
c t i o n size
, w h i cinterval,
h g i v e s the
t i o n a l r afunction,
t e o f b r e awhich
k a g e gives
o f p a rthe
ticles
resulting
average
i n each size
s i z e distribution
i n t e r v a l , and of
a daughter
breakage fragments
function, w
h i c h g i v e sfrom
the primary
a v e r a gbreakage
e s i z e d events.
i s t r i b u t i oThese
n o f dtwo
a u gquantities
h t e r f r a g m e allow
n t s r e sthe
u l t ibehavior
n g f r o m of
pri
each size
fraction
mary
breakage
e v e n t in
s.

the
T h emill
s e twoto q be
u a nrepresented
t i t i e s a l l o w mathematically
t h e b e h a v i o r ofor
f

grinding
importance(l).
each s i z e conditions
f r a c t i o n i nof t hindustrial
e m i l l t o be
represented

mFor
a t h ethese
m a t i c areasons,
lly f o r

the
g r i n dmore
i n g detailed
c o n d i t i o n smodels
o f i n dhold
u s t r considerable
i a l i m p o r t a n cpromise
e^ K
F for
o r t hreducing
e s e r e a s the
ons,
design
the morerisk
d e t associated
a i l e d modelswith
h o l dtraditional
c o n s i d e r a bmill
l e p r oscale-up
m i s e f o r methods.
reducing
d e s i g nTo r idate
s k a population
s s o c i a t e d wbalance
i t h t r a d models
itional

the

have
primarily in
m i l l been
s c a l eused
- u p methods.

To d a t e p o p u l a t i o n b a l a n c e models have been used p r i m a r i l y i n

the
t h e analysis
a n a l y s i s of
o f the
the pperformance
e r f o r m a n c e of
o f laboratory
l a b o r a t o r y scale
s c a l e grinding
g r i n d i n g mills.
mills.
In the vvery
past
e r y recent
recent p
a s t there
t h e r e have been a few attempts
a t t e m p t s to
t o evaluate
evaluate
the
the appropriateness
a p p r o p r i a t e n e s s of
o f population
p o p u l a t i o n bbalance
a l a n c e models for
f o r use in
i n the
the
scale-up
ball
s c a l e - u p design
d e s i g n of
o f dry
dry b
a l l milling
m i l l i n g systems(1,6,7).
s y s t e m s ^ ^7).

Efforts
E f f o r t s in
in

this
t h i s area
area have been devoted
d e v o t e d to
t o finding
f i n d i n g the
t h e rrequired
e q u i r e d relationship
relationship
between model parameters
mill
p a r a m e t e r s and m
i l l design
d e s i g n and operating
o p e r a t i n g variables.
variables.
Basically
been explored.
B a s i c a l l y two approaches have been
e x p l o r e d . The
T h e first
f i r s t involves
i n v o l v e s the
the
with
correlation
c o r r e l a t i o n of
o f selection
s e l e c t i o n and breakage
breakage functions
functions w
i t h mill
m i l l diamediame(6 7)
ter(6,7).

The second involves the correlation of model parameters

ter '
T h e second i n v o l v e s t h e c o r r e l a t i o n o f
with
the . specific
power draft of the mill(1,6,7).

model

parameters
As discussed
by

w i t h the s p e c i f i c power d r a f t o f t h e m i l l ^ ' ^ ' .

d i s c u s s e d by
Herbst' et. al. (1) the mill diameter correlation is As
really
a special
Herbst e t .

al. ^

the m i l l

diameter c o r r e l a t i o n is r e a l l y a special

case of the specific power draft correlation which is only valid if


case o f the s p e c i f i c power d r a f t c o r r e l a t i o n w h i c h i s o n l y v a l i d

complete dynamic similarity of charge motion in mills of differc o m p l e t e dynamic s i m i l a r i t y o f c h a r g e m o t i o n i n m i l l s o f

if

differ

ent diameters is maintained.

Both types of correlation have been

ent diameters is maintained.

Both t y p e s o f c o r r e l a t i o n have been

used successfully in predicting dry ball milling behavior in large


used s u c c e s s f u l l y i n p r e d i c t i n g d r y b a l l m i l l i n g b e h a v i o r i n

large

batch m i l l s based on e x p e r i m e n t a l measurements made i n small

mills.

batch mills based on experimental measurements made in small mills.


Virtually nothing has been done in the area of wet ball mill
V i r t u a l l y n o t h i n g has been done i n the a r e a o f wet b a l l

mill

scale-up using population balance models.

Although wet grinding

s c a l e - u p u s i n g -p o p u l a t i o n b a l a n c e m o d e l s .

A l t h o u g h wet g r i n d i n g

is more important industrially than dry grinding, wet processes

i s more i m p o r t a n t i n d u s t r i a l l y than d r y g r i n d i n g , wet p r o c e s s e s

are much more difficult to treat due to inherent non-linearities


a r e much more d i f f i c u l t

t o t r e a t due to i n h e r e n t

in the breakage process(4,8).


i n t h e breakage p r o c e s s

non-linearities

Recently Kim(8) has shown that the

R e c e n t l y K i n r ' has shown t h a t the

parameters of a linearized population balance model for wet grindparameters o f a l i n e a r i z e d p o p u l a t i o n b a l a n c e model f o r w e t g r i n d

ing can be correlated with mill operating variables in a similar


ing can be c o r r e l a t e d w i t h m i l l

operating variables in a similar

manner to the specific power draft correlation used in dry grinding.


manner t o t h e s p e c i f i c power d r a f t c o r r e l a t i o n used i n d r y g r i n d i n g .

It has been speculated that this approach may also be successful in


It

has been s p e c u l a t e d t h a t t h i s approach may a l s o be s u c c e s s f u l

accounting for the effect of mill design variables(8).


(8)

accounting f o r the e f f e c t o f m i l l design v a r i a b l e s ^


.
The
objective of this thesis research was to provide
T h e o b j e c t i v e o f t h i s t h e s i s r e s e a r c h was t o p r o v i d e

in

additional
additional

44

confirmation
balance
c o n f i r m a t i o n of
o f the
the appropriateness
a p p r o p r i a t e n e s s of
o f ppopulation
opulation b
a l a n c e models as
a basis
b a l l mill
m i l l scale-up
s c a l e - u p and to
t o extend
e x t e n d this
t h i s approach to
t o wet
wet
b a s i s for
f o r dry
d r y ball
systems.
systems.
and

The
T h e experimental
e x p e r i m e n t a l portion
p o r t i o n of
o f tthis
h i s study
s t u d y involves
i n v o l v e s the
t h e dry
dry

all
wet batch
m i l l i n g of
o f limestone
l i m e s t o n e in
i n two laboratory
l a b o r a t o r y scale
scale b
w~t
batch milling
ball

in a p
i l o t scale
s c a l e mill.
mill.
and in
pilot

mills
mills

e s t work
w o r k with
with
a d d i t i o n , ppreliminary
r e l i m i n a r y ttest
In addition,

w e t continuous
c o n t i n u o u s open circuit
c i r c u i t mill
m i l l has been conducted.
conducted.
a wet

T h e data
The

a n a l y z e d in
i n the
t h e context
c o n t e x t of
o f the
the p
o p u l a t i o n bbalance
a l a n c e framework
framework
have been analyzed
population
d r a f t as a bbasis
a s i s for
f o r model pparameter
a r a m e t e r scale-up.
scale-up.
u s i n g specific
s p e c i f i c power draft
using
P r e d i c t i o n s of
o f large
l a r g e mill
m i l l performance
p e r f o r m a n c e from
f r o m small
s m a l l scale
s c a l e batch
batch mill
mill
Predictions
s u g g e s t that
t h a t tthe
h e population
p o p u l a t i o n balance
b a l a n c e approach to scale-up
s c a l e - u p is
is
data suggest
c a p a b l e of
o f yielding
y i e l d i n g considerably
c o n s i d e r a b l y more accurate
a c c u r a t e designs
d e s i g n s for
for w
e t and
capable
wet
d r y ball
ball m
i l l s than iis
s p
ossible w
i t h the
t h e traditional
t r a d i t i o n a l approach.
approach.
dry
mills
possible
with

CHAPTER III I
REVIEW OF RELATED STUDIES
STUDIES
In this
basis
t h i s chapter
c h a p t e r the
the formal
formal b
a s i s of
o f population
p o p u l a t i o n balance
b a l a n c e models
for
ball
with
a l l milling
m i l l i n g is
i s reviewed
r e v i e w e d along
along w
i t h existing
e x i s t i n g experimental
e x p e r i m e n t a l evievi
for b
dence supporting
s u p p o r t i n g tthese
h e s e models.
models.

Then actual
a c t u a l applications
a p p l i c a t i o n s of
o f this
this

type
t y p e of
o f model tto
o tthe
h e scale-up
s c a l e - u p design
d e s i g n pproblem
r o b l e m are
a r e ddiscussed.
iscussed.
The
be determined
by the
T h e character
c h a r a c t e r of
o f a mathematical
m a t h e m a t i c a l model can be
d e t e r m i n e d by
the
physical
handle
p h y s i c a l details
d e t a i l s it
i t can h
a n d l e and tthe
h e computational
c o m p u t a t i o n a l complexity
complexity
associated
with
associated w
i t h its
i t s application.
application.

A
A completely
c o m p l e t e l y predictive
p r e d i c t i v e model will
will

have a complex mathematical


m a t h e m a t i c a l solution
s o l u t i o n while
w h i l e simple
s i m p l e models are
a r e usually
usually
by ignoring
has put
obtained
o b t a i n e d by
i g n o r i n g several
s e v e r a l subprocesses
s u b p r o c e s s e s in
i n the
t h e system.
s y s t e m . Bond has
put
forward
f o r w a r d a simple
s i m p l e empirical
e m p i r i c a l equation
e q u a t i o n for
f o r specific
s p e c i f i c energy
e n e r g y calculacalcula
tions(9,lQ,11).
^
).
tions (
9 s l

s 1 1

Bond1s
parameter:
B o n d ' s equation
e q u a t i o n contains
c o n t a i n s tthree
hree p
arameter:

i n d e x , a feed
f e e d size
s i z e pparameter
a r a m e t e r and a pproduct
r o d u c t size
s i z e parameter.
parameter.
index,

a work
These
These

p a r a m e t e r s are
a r e used to
t o compute the
the specific
s p e c i f i c energy
e n e r g y requirement
r e q u i r e m e n t for
for
parameters
g r i n d i n g processes.
processes.
commercial grinding

F o r the
the scale-up
s c a l e - u p ppurpose
u r p o s e Bond's
For

t h a t breakage
breakage kkinetics,
i n e t i c s , transport
t r a n s p o r t through
through
e q u a t i o n implicitly
i m p l i c i t l y assumes that
equation
i l l and classification
c l a s s i f i c a t i o n subprocesses
s u b p r o c e s s e s are
a r e characterized
c h a r a c t e r i z e d by aa
the m
the
mill
single p
arameter, a
a work index.
index.
single
parameter,

The b
a s i c assumption
a s s u m p t i o n in
i n Bond's
B o n d ' s equaequa
The
basic

t h a t the
t h e breakage
breakage behavior
b e h a v i o r of
o f all
all m
a t e r i a l s is
i s the
the same
t i o n is
i s that
materials
tion
t h a t of
o f an 'ideal
' i d e a l Bond material
m a t e r i a 1(1).
l'^.
as that

U
n f o r t u n a t e l y tthe
h e work inin
Unfortunately

o f many materials
m a t e r i a l s does n
o t remain
constant w
i t h the
t h e product
product
dex of
not
remain constant
with

size
s i z e (10)
' ) ..
1 0

The work index


by locked
i n d e x is
i s evaluated
e v a l u a t e d by
l o c k e d cycle
c y c l e grinding
g r i n d i n g ttests
e s t s in
i n a standstand
mill
us"ing
perfectdass;f;cat;on.
ard
a r d grindability
grindability m
ill u
sing p
erfect classification.

Butln
But
i n indusindus

trial
t r i a l scale
s c a l e classifiers
c l a s s i f i e r s it
i t is
i s extremely
e x t r e m e l y difficult
d i f f i c u l t to have a perfect
perfect
In
I n a Bond test
t e s t it
i t is
i s also
a l s o assumed tthat
h a t a full
f u l l scale
s c a l e mill
mill

separation.
separation.

has a pplug
and
l u g flow
f l o w characteristic
characteristic
and tthat
h a t equilibrium
e q u i l i b r i u m iis
s equivalent
equivalent
t o steady
s t e a d y state
s t a t e in
i n a continuous
c o n t i n u o u s pplug
l u g flow
flow m
i l l operated
o p e r a t e d in
i n closed
closed
to
mill

ci
c i rrcui
c u i tt.
.
In contrast
balance
are
c o n t r a s t to
t o Bond's equation,
e q u a t i o n , ppopulation
opulation b
a l a n c e models a
re
^
j i
Sucn
models

d e r i v e d in
i n a pphysically
hysically m
eaningful w
a y ^ '4,5,8,12)^
derived
meaningful
way(1,4,S,S,12).

u c n

m o c

have been shown to


product
t o provide
p r o v i d e very
v e r y accurate
a c c u r a t e ppredi
r e d i ccti
t i oons
n s of
of p
r o d u c t si
s i zzee
distribution
produced
batch,
distribution p
r o d u c e d in
in b
a t c h , locked-cycle
l o c k e d - c y c l e and
and continuous
c o n t i n u o u s open
and closed
c l o s e d circuit
c i r c u i t mills(l).
m i l l s S e vSeveral
e r a l investigators
i n v e s t i g a t o r s have presented
presented
convincing
use of
balance
models as an
an
c o n v i n c i n g cases for
f o r the
t h e use
o f ppopulation
opulation b
a l a n c e models
(1 ,4,13,14).
4 13 14)
alternate to the Bond equation for scale-up deSign(l
a l t e r n a t e t o t h e Bond e q u a t i o n f o r s c a l e - u p d e s i g n
r~ode
Model1

'

Framework

The formulation
population
f o r m u l a t i o n of
o f the
the p
o p u l a t i o n balance
b a l a n c e models and
and

~ubsequent
subsequent

discussions
by several
d i s c u s s i o n s of
o f their
t h e i r characteristics
c h a r a c t e r i s t i c s have been ppresented
r e s e n t e d by
several
authors(4,S,12,15,16).
authors^' '
> ).
8

1 2 , 1 5

1 6

Most
most uuseful
Most authors
a u t h o r s agree
a g r e e that
t h a t tthe
h e most
s e f u l form
form

o f these
t h e s e models is
i s the
t h e size-discretized,
s i z e - d i s c r e t i z e d , time
t i m e continuous
c o n t i n u o u s descripdescrip
of
tion.
tion.

I n this
t h i s model tthe
h e breakage
r o c e s s iis
s completely
c o m p l e t e l y charactercharacter
In
breakage pprocess

i z e d by
by two
two sets
s e t s of
of p
h y s i c a l l y interpretable
i n t e r p r e t a b l e quantities,
q u a n t i t i e s , the
t h e size
size
physically
ized
d i s c r e t i z e d selection
s e l e c t i o n functions
f u n c t i o n s and
and tthe
h e size
s i z e discretized
d i s c r e t i z e d breakage
breakage
discretized
functions.
functions.

T h e development
d e v e l o p m e n t of
o f this
t h i s model is
i s bbriefly
r i e f l y described
d e s c r i b e d below.
below.
The

Consider
batch m
mill
C o n s i d e r that
t h a t the
t h e size
s i z e range of
o f mass H
H in
i n a batch
ill

be

d i v i d e d into
i n t o n intervals
i n t e r v a l s with
w i t h maximum size
s i z e x-j
and minimum size
s i z e xx +- j '.
divided
xl and
nl
T h e ith
i t h interval,
i n t e r v a l , bounded by
x . above and
and x ^+- j below,
c o n t a i n s aa
The
by xi
i l b e l o w , contains
n +

77

In
I n many instances
i n s t a n c e s X
1

mass fraction
mi(t)
time tt..
f r a c t i o n of
o f material
material m
. ( t ) at
a t time

a r e related
r e l a t e d by
x . = r x +^ (i=1,2,
n - l ) where r is
is
and xi^+-lj are
by xi=r
i l ( i = l , 2 , ......... ,n-l)
the
A
the geometric
g e o m e t r i c sieve
s i e v e rratio.
atio.
A mass bbalance
a l a n c e for
f o r ith
i t h size
s i z e interval
interval

yields
y i e l d s the
t h e kkinetic
i n e t i c model:
model:

i i-1
-1
d[Hm.(t)]
L:
boo
m.(t)
iz
= - S.(t)H m.(t) +
I b
. . S.(t)
S.(t) H m
.(t)
j _j=l
i i JlJ J J
JJ
Ul

01-1
(II-l)

where mi(t)
material
m. ( t ) is
i s the
t h e mass fraction
f r a c t i o n of
o f the
the m
a t e r i a l in
i n tthe
h e interval
interval i
at
at any
any ttime
i m e tt,, Si(t)
S . ( t ) is
i s the
t h e size
s i z e discretized
d i s c r e t i z e d selection
s e l e c t i o n function
f u n c t i o n ffor
or
the
t h e ith
i t h size
s i z e interval,
i n t e r v a l , denoting
d e n o t i n g tthe
h e ffractional
r a c t i o n a l rrate
a t e at
a t which
w h i c h material
material
is
i s broken
b r o k e n out
o u t of
o f the
t h e ith
i t h size
s i z e interval
i n t e r v a l and
and b . . iis
h e size
s i z e discrediscreij s tthe
tized
breakage function
primary
t i z e d breakage
f u n c t i o n representing
r e p r e s e n t i n g tthe
h e fraction
f r a c t i o n of
of p
r i m a r y breakage
breakage
which
product
material
p r o d u c t of
of m
a t e r i a l from
f r o m the
t h e jjth
t h size
s i z e interval
interval w
h i c h appears in
i n tthe
he
(1 4)
ith size interval(l,4).
ith size i n t e r v a l

The size discretized selection functions can,

The s i z e d i s c r e t i z e d selection functions can,

in general, be dependent upon the size consist in the mill at any


i n g e n e r a l , be dependent upon t h e s i z e c o n s i s t i n t h e m i l l

time t, i. e. ,
time t ,

a t any

i.e.,

S^t)

= S

(H,

rn^t),

k *= 1,2,
1 , 2 , ...... ,n)
,n)

but
but are
a r e not
n o t explicitly
e x p l i c i t l y ttime
i m e dependent(1,4,8).
dependent^ ' \
1

4 , 8

The
T h e kkinetic
i n e t i c model iis
s

s a i d to
t o be
l i n e a r with
w i t h constant
c o n s t a n t coefficients
c o e f f i c i e n t s when both selection
s e l e c t i o n and
said
be linear
and
breakage functions
f u n c t i o n s are
a r e independent
i n d e p e n d e n t of
o f size
s i z e consist
c o n s i s t in
i n tthe
h e mill.
mill.
breakage

The
T h e following
f o l l o w i n g assumptions
a s s u m p t i o n s are
a r e associated
a s s o c i a t e d with
w i t h tthe
h e development
development
of
o f equation
e q u a t i o n (11_1)(4,8):
(II-l)^ ^:
4 , 8

1.

The
T h e size
s i z e interval
i n t e r v a l i is
i s sufficiently
s u f f i c i e n t l y narrow
n a r r o w to
t o ensure
e n s u r e that
that
the
be
the bbehavior
e h a v i o r of
o f all
a l l particles
p a r t i c l e s iin
n the
t h e interval
i n t e r v a l can
can be

8
,

described
by the
parameters
bij
d e s c r i b e d by
t h e interval
i n t e r v a l average
average p
a r a m e t e r s S;(t)
S . ( t ) and
and b
. . .
The
not
on
T h e size
s i z e discretized
d i s c r e t i z e d breakage
breakage functions
f u n c t i o n s do
do n
o t depend on

2.

the size
s i z e consist
c o n s i s t in
i n the
t h e mill,
m i l l , ii.e.,
.e.,

i =
= 1,2,
1 , 2 , ........ ,,n).
n).

b...j

~ b ..
m.(t),
f
. j (H,
(H, m
.(t),
1J
1

3.
3.

Agglomeration
A g g l o m e r a t i o n of
o f particles
p a r t i c l e s is
i s non-existent
n o n - e x i s t e n t and
and attrition
attrition

1J

is
i s negligible.
negligible.
The distinct
d i s t i n c t advantage
a d v a n t a g e of
o f equation
e q u a t i o n (11-1)
( I I - l ) is
i s that
t h a t tthe
h e parameters
parameters
Si(t)
bij
byy experiments(14,17,18).
In
S. ( t ) and
and b
. . can
can be
be obtained
o b t a i n e d directly
directly b
experiments^
' ^.
In
the
ball
t h e dry
dry b
a l l milling,
m i l l i n g , tthe
h e selection
s e l e c t i o n and
and breakage
b r e a k a g e functions
f u n c t i o n s have been
4 , 1 7

shown to
mill.
t o be
be independent
i n d e p e n d e n t of
o f the
t h e size
s i z e consist
c o n s i s t in
i n the
the m
ill.

1 8

Also
A
l s o tthe
he

breakage
b r e a k a g e functions
f u n c t i o n s are
a r e independent
i n d e p e n d e n t of
o f mass hold-up,
h o l d - u p , H,
H , hhowever,
o w e v e r , tthe
he
(8)
selection functions are strongly dependent on mass hold-up(8),
i.e.,
s e l e c t i o n f u n c t i o n s a r e s t r o n g l y dependent on mass h o l d - u p

S^t)

= S . ( H , m ( t ) k = 1,2
k

, i.e.,

n) = S . ( H )

When the selection functions are independent of mill size conWhen t h e s e l e c t i o n f u n c t i o n s a r e i n d e p e n d e n t o f m i l l s i z e c o n

sist the set of n differential equations represented by equation 01-1)


s i s t the s e t o f n d i f f e r e n t i a l equations represented by equation

(II-l)

can be expressed as a single matrix equation with constant coeffican be e x p r e s s e d as a s i n g l e m a t r i x e q u a t i o n w i t h c o n s t a n t

cients (1,4,8).
1

coeffi-

cients* ' ' ).


(t)
d m!!l (t)
- f dt
t

U-

=]J ~(H) m(t) ........


= - [ i - B] S(H) m ( t )

(I1-2)
(II-2)

where m(t)
nx1
m ( t ) is
is a n
x l vvector
e c t o r denoting
d e n o t i n g mass fractions
f r a c t i o n s in
i n n size
s i z e interinter
vals
B is
v a l s at
a t any
any time
t i m e t (mi(t),
(m^ ( t ) , i=1,2,
i = l , 2 , ........ ,n),
, n ) , J3
i s a nxn
nxn lower
lower

9
ffunctions~
u n c t i o n s , S(H)
S / H ) is
i s tthe
h e diagonal
d i a g o n a l matrix
matrix

triangular
t r i a n g u l a r matrix
m a t r i x of
o f breakage
breakage

o f selection
s e l e c t i o n ffunctions
u n c t i o n s and
and l^ the
t h e identity
i d e n t i t y matrix.
matrix.
of

ing wwith
i t h an
an arbitrary
a r b i t r a r y initial
initial

F o r batch
grind
For
batch grind-

feed~
has
feed, H
H m(O),
m ( 0 ) , the
t h e equation
e q u a t i o n (I1-2)
( I I - 2 ) has

an analytical
a n a l y t i c a l solution
s o l u t i o n of
o f tthe
h e type:
type:

U-

m( t) =
m{O)
m(t)
= exp
e x p [l-il - B)S
B ) S(H)t]
( H ) t ] m(0)

(I
( H1-3)
-3)

For
when no
F o r tthe
h e case when
no two
two selection
s e l e c t i o n functions
f u n c t i o n s are
a r e equal,
e q u a l , tthe
he
e x p o n e n t i a l in
i n equation
e q u a t i o n (I1-3)
(11-3) can
can be
be simplified
s i m p l i f i e d by
by similarity
similarity
exponential

transformation
o yield(l,4,S,14,20).
yield^ > > > ' ).
t r a n s f o r m a t i o n tto
1

-1l

T
m(t) == :::::;;;:T l(t)
J ( t ) =TT
-m(t)

1 4

2 0

m(0)
-m(O)

(II-4
( I I - 4 ))

where tthe
h e elements
elements of
o f matrices
matrices T
T and
and J . are
a r e given
g i v e n bby:
y:

T .. =
lJ

i < j

j
i =
= J

i1-1
-1

b.
b . . SS. , ((H)
H)

~ U~ - S( .H(H}
S.H
kj
V1 H
) kTj

ii >> Jj

exp

[-S^Hjt]

ii

=
= jJ

"f j

L:

k=l

and

J ..
J

ilJ
j " <

o0

Equation
batch mill
E q u a t i o n (11-4)
( I 1 - 4 ) is
i s useful
u s e f u l for
f o r batch
m i l l .simulations.
.simulations.

However,
However,

it
by incorporating
i t can
can be
be extended
e x t e n d e d for
f o r the
t h e continuous
c o n t i n u o u s grinding
g r i n d i n g by
incorporating

10
,

residence
time distribution
r e s i d e n c e time
d i s t r i b u t i o n information
i n f o r m a t i o n in
i n the
t h e J matrix
m a t r i x and
and attains
attains
19
the
t h e forn/
f o r m )..
( 1 9 )

(I
( I I1-4A)
-4A)

where
00

00

o0

i1 t-t Jj

oo

and

= 5j

f/ exp
e x p [-(SiT)e]E(e)de
[-(s^JelEteJde

~p is
rn^p
i s the
t h e steady
s t e a d y state
s t a t e size
s i z e distribution
d i s t r i b u t i o n of
o f mill
m i l l product,
product,

~F
i s the
t h e steady
s t e a d y state
s t a t e size
s i z e distribution
d i s t r i b u t i o n of
o f mill
m i l l feed,
f e e d , 0 is
i s dimendimen
m^p is

sionless
mean residence
E(e) is
s i o n ! ess ttime
i m e variable,
variable, T
t is
i s the
t h e mean
r e s i d e n c e time
time and
and E(e)
is
the
t h e dimensionless
d i m e n s i o n l e s s exit
e x i t age
age distribution
d i s t r i b u t i o n for
f o r material
m a t e r i a l transport
transport
through
t h r o u g h the
t h e mill.
mill.
For
F o r the
t h e successful
s u c c e s s f u l application
a p p l i c a t i o n of
o f the
t h e model to
t o the
t h e simulation
simulation
of
o f grinding
g r i n d i n g behavior
b e h a v i o r an efficient
e f f i c i e n t method for
f o r estimating
e s t i m a t i n g model parapara
meters
i s rrequired.
equired.
m e t e r s is

This
V..
T h i s method is
i s discussed
d i s c u s s e d in
i n Chapter
Chapter V

The above model has


ball
has successfully
s u c c e s s f u l l y been applied
a p p l i e d tto
o dry
dry b
a l l millmill
ing
not
b u t is
is n
o t strictly
s t r i c t l y applicable
a p p l i c a b l e tto
o wet
w e t systems due
due to
t o an
i n g systems
s y s t e m s but
i n h e r e n t non-linearity
n o n - l i n e a r i t y in
in w
et b
a l l milling
m i l l i n g which
w h i c h apparently
a p p a r e n t l y arises
arises
inherent
wet
ball

from
pulp
t h e classifying
c l a s s i f y i n g action
a c t i o n of
o f tthe
he p
u l p in
i n tthe
h e mill(4,8).
mill^' '.
f r o m the
8

A detailed
A
detailed

(4)
non-linear model has been developed to account for this behavior(4),
n o n - l i n e a r model has been d e v e l o p e d t o a c c o u n t f o r t h i s b e h a v i o r ^

however, it is mathematically and computationally quite complex.


however, i t is mathematically

and c o m p u t a t i o n a l l y q u i t e c o m p l e x .

Since it is highly desirable to take advantage of the matheS i n c e i t i s h i g h l y d e s i r a b l e t o t a k e a d v a n t a g e o f t h e mathe

matical simplicity of a linear model for engineering applications,


m a t i c a l s i m p l i c i t y o f a l i n e a r model f o r e n g i n e e r i n g

applications,

there is considerable impetus to explore the applicability of linear


t h e r e i s c o n s i d e r a b l e impetus t o e x p l o r e t h e a p p l i c a b i l i t y

of linear

11
(21)
Herbst
Mika(2l)
have ddiscussed
H e r b s t and
and M
ika
have
iscussed

models
models to
t o non-linear
n o n - l i n e a r systems.
systems.

this
t h i s possibility
p o s s i b i l i t y from
f r o m a theoretical
t h e o r e t i c a l standpoint
s t a n d p o i n t demonstrating
d e m o n s t r a t i n g that
that
for
will
f o r any non-linear
n o n - l i n e a r system
s y s t e m there
there w
i l l be rregions
e g i o n s of
o f operation
o p e r a t i o n (grind
(grind
times,
t i m e s , retention
r e t e n t i o n times,
t i m e s , feed
f e e d size
s i z e distributions,
d i s t r i b u t i o n s , etc.)
e t c . ) over
o v e r which
w h i c h aa
linear
will
l i n e a r or
o r linearized
l i n e a r i z e d model w
i l l be applicable.
applicable.

Kim(8)
K i m ^ found
f o u n d that
that

at
high
a t low speeds and h
i g h ball
b a l l loads,
l o a d s , the cascading
c a s c a d i n g action
a c t i o n of
o f the
the
r e s u l t s in
i n minimum turbulence
t u r b u l e n c e conditions
c o n d i t i o n s in
in w
h i c h the
the kinetics
kinetics
media results
which

of
o f breakage are
a r e l1nearly
" n e a r l y linear
l i n e a r " for
f o r short
s h o r t and intermediate
i n t e r m e d i a t e grind
g r i n d times.
times
ll

For
breakage conditions
F o r these
t h e s e linearly
" n e a r l y linear"
l i n e a r " breakage
c o n d i t i o n s a linear
l i n e a r or
o r linearized
linearized
model will
w i l l be applicable.
applicable.
Applications
A
p p l i c a t i o n s Related
R e l a t e d to
t o Scale-uR
Scale-up
the p
opulation b
a l a n c e models are
are p
h e n o m e n o l o g i c a l in
in
Because the
population
balance
phenomenological
n a t u r e , tthere
h e r e is
i s no apriori
a p r i o r i method for
for p
r e d i c t i n g the
t h e dependence
predicting
nature,

of
model parameters
o f model
p a r a m e t e r s on mill
m i l l design
d e s i g n and operating
o p e r a t i n g variables(4,8).
variables^'^.
I n s t e a d the required
r e q u i r e d relationships
r e l a t i o n s h i p s must be obtained
o b t a i n e d from
f r o m a fundamental
fundamental
Instead
a n a l y s i s of
o f the breakage
a n d / o r correlations.
correlations.
analysis
breakage phenomena and/or

Various
Various

a t t e m p t s have been made tto


o correlate
c o r r e l a t e kkinetic
i n e t i c pparameters
a r a m e t e r s with
w i t h mill
mill
attempts
d i m e n s i o n s , mill
m i l l speed,
s p e e d , media shape,
s h a p e , media load
l o a d and density,
d e n s i t y , ball
ball
dimensions,

diameter
hold-up
d i a m e t e r and h
o l d - u p mass(l,6,7,22).
mass^
' ^.

HHowever,
o w e v e r , cconsiderable
o n s i d e r a b l e eexperixperi

e f f o r t will
w i l l have to
t o be devoted
devoted
mental effort

to
io

accurately.
accurately.

d e f i n e tthese
h e s e relationships
relationships
define

R e c e n t l y a somewhat different
d i f f e r e n t approach tto
o such a correcorreRecently

l a t i o n was attempted(4,5,6).
attempted * '
lation
v

t h i s work
w o r k it
i t was shown tthat
h a t for
f o r aa
In this

d r y ball
ball m
i l l i n g operation,
o p e r a t i o n , the
t h e size-discretized
s i z e - d i s c r e t i z e d selection
s e l e c t i o n functions
functions
dry
milling
a r e proportional
p r o p o r t i o n a l tto
o the
t h e sspecific
p e c i f i c power input
i n p u t to
t o tthe
he m
i l l (P/H),
( P / H ) , i.e.,
i.e.,
are
mill

Sj = S * ( P / H )

(II
( H - -5)
5)

12

where S~
S . termed the
t h e 'tspecific
s p e c i f i c selection
s e l e c t i o n function',
f u n c t i o n ' , is
i s essentially
essentially
independent
i n d e p e n d e n t of
o f mill
m i l l operating
o p e r a t i n g conditions.
conditions.

In
was found
I n addition
a d d i t i o n it
i t was
found

that
bij
t h a t the
t h e breakage
b r e a k a g e function,
function, b
. . , is
i s to
t o a good approximation
a p p r o x i m a t i o n invariant.
invariant.
W i t h equation
e q u a t i o n (II-5)
( I 1 - 5 ) the
t h e solution
s o l u t i o n to
t o equation
e q u a t i o n (11-1)
( I I - l ) for
f o r tthe
h e ttop
op
With
s i z e (i=l)
( i = l ) can
can be
shown to
t o bbe:
e:
be shown
size

(II-6)
(II-6)

m ^ t ) = m ^ O ) exp [ - S * ( P / H ) t ]

Since
product
power and
to
S i n c e tthe
he p
r o d u c t of
o f the
t h e specific
s p e c i f i c power
and ttime
i m e is
i s equal to
the specific
be
s p e c i f i c energy
e n e r g y input
i n p u t to
t o tthe
h e millm i l l - E,
F , equation
e q u a t i o n (11-6) can
can be
expressed
e x p r e s s e d aas:
s:

01-7)
(H-7)

m ^ E ) = m ^ O ) exp [-S^ F ]

and equation
be rrewritten
normalized
e q u a t i o n (11-1)
( I I - l ) can
can be
e w r i t t e n in
i n tthe
he n
o r m a l i z e d form
f o r m aas:
s:
d m. (E)

i-l

dE

"

j =1

_...:.-'- = - S. m. (E) +

2:

b.. S~ m. (I)
'J

(II
( H --8)
8)

Similarly
be wwritten
S i m i l a r l y equations
e q u a t i o n s (11-2)
( I 1 - 2 ) and
and (11-3)
( I 1 - 3 ) can
can be
r i t t e n iin
n normalnormal

byy replacing
byy S
S~.
ized
i z e d forms b
r e p l a c i n g tt by
b y IE and
and S.
S b
^ . These
T h e s e normalized
n o r m a l i z e d grindgrind
i

ing equations
have also
e q u a t i o n s have
a l s o been successfully
s u c c e s s f u l l y applied
a p p l i e d to
t o tthe
h e prediction
prediction
(6 7)
of dry grinding behavior in different sizes of batch mill(6,7).

The

of d r y g r i n d i n g b e h a v i o r i n d i f f e r e n t s i z e s o f batch m i l l
'
. The
st~dies involved 1) obtaining
s c a l e - u p p r o c e d u r e used i n t h e s e s t u d i e s i n v o l v e d 1) o b t a i n i n g

scale-up procedure used in these

batch grinding and power data in a small laboratory scale mill


batch g r i n d i n g and power d a t a i n a small l a b o r a t o r y s c a l e

mill

2) estimating reduced selection functions and breakage functions


2) e s t i m a t i n g

r e d u c e d s e l e c t i o n f u n c t i o n s and b r e a k a g e

functions

from this data 3) using the parameter estimates obtained in (2)


from t h i s data

3) u s i n g t h e p a r a m e t e r e s t i m a t e s o b t a i n e d i n (2)

13
13

along
a l o n g with
w i t h specific
s p e c i f i c power draft
d r a f t information
i n f o r m a t i o n for
f o r larger
l a r g e r mills
m i l l s tto
o prepre
dict
mills.
t h e size
s i z e distributions
d i s t r i b u t i o n s expected
e x p e c t e d for
f o r these
these m
ills.
d i c t the

The
off
T h e range o

m i l l diameter
d i a m e t e r examined (at
( a t constant
constant L
/ D ) was
n c h e s to
t o 20 inches-inches
LID)
was 5 iinches
mill
f o l d range
r a n g e of
o f mill
m i l l volume.
volume.
a 64 fold

I n all
a l l instances
i n s t a n c e s the
t h e predictions
predictions
In

t o be
be in
i n good agreement
agreement w
i t h experimentally
e x p e r i m e n t a l l y measured size
size
f o u n d to
were found
with
distributions.
distributions.

Herbst
have discussed
between specie t . ale
a l . (1)
^
d i s c u s s e d the
t h e relationship
r e l a t i o n s h i p between
speciH e r b s t et.
and direct
d i r e c t mill
m i l l diameter
d i a m e t e r scale-up.
scale-up.
f i x power scale-up
s c a l e - u p and
fix

T h e y point
point
They

t h a t the
the m
i l l power and
and material
material h
old-up H
can be expressed
e x p r e s s e d in
in
o u t that
out
mill
hold-up
H can
o f mill
m i l l dimensions
d i m e n s i o n s and
and dimensionless
d i m e n s i o n l e s s operating
o p e r a t i n g conditions
c o n d i t i o n s as
as
terms of
follows:
fol1ows:

P -

(N , M , M , q ) L
B

H = d> (M* , M* ) L D
2

D -

(II-g)
(H-9)

(2.0)

(II-10)
(11-10)

L is
i s the
t h e mill
m i l l length
l e n g t h and
and 0
D is
i s tthe
he m
i l l diameter
d i a m e t e r and
and l
^ and
and <f>
where L
mill
2
2

are
on the
N* , dimena r e functions
f u n c t i o n s which
w h i c h depend on
t h e dimensionless
d i m e n s i o n l e s s mill
m i l l speed N
dimen-

* , dimensionless
sionless
ball
sionless b
a l l load
load M
Mg,
a r t i c l e load
l o a d Mp
M* and
and dimensiondimensionB d i m e n s i o n l e s s pparticle
less
b a l l size
s i z e and
and lifter
l i f t e r geometry
g e o m e t r y vvariables
a r i a b l e s q.
q* . The
T h e pparameter
a r a m e t e r 50
l e s s ball
p

i s zero
z e r o by
by dimensional
d i m e n s i o n a l analysis,
a n a l y s i s , but
b u t takes
t a k e s a vvalue
a l u e between zero
z e r o and
is
and

0.1 iinn ppractice(l).


ractice^ K
1

Substitution
S u b s t i t u t i o n of
o f equations
e q u a t i o n s (11-9)
( I 1 - 9 ) and
and (11-10) into
i n t o tthe
h e scale-up
scale-up
expression
e x p r e s s i o n for
f o r selection
s e l e c t i o n functions,equation
f u n c t i o n s , e q u a t i o n (II-5),
( I I - 5 ) , yields:
yields:

- S^ (N*,
3

Mg, Mp, q* ) D < B

5 + 5

>

(II-ll
( H - 1 1 ))

14
14
f u n c t i o n 3
4> is
i s given
g i v e n by 1/2'
4>-j/4> where the function
3

Considering
C o n s i d e r i n g two mills
m i l l s of
o f diameters
d i a m e t e r s 01
D-j and 02'
D2 llengths
e n g t h s Ll and
k

-k

L2 with complete dynamic similarity i.e., N* , M*B, M*p ' ball diameter
[_2 w i t h c o m p l e t e dynamic s i m i l a r i t y i . e . , N , Mg, M , b a l l d i a m e t e r
and lifter configuration, the ratio of selection functions for the
p

and l i f t e r c o n f i g u r a t i o n , t h e r a t i o o f s e l e c t i o n f u n c t i o n s f o r

the

two mills should, according to equation (11-11), be given by


two m i l l s s h o u l d , a c c o r d i n g t o e q u a t i o n ( 1 1 - 1 1 ) , be g i v e n by

(II-12)
l

V 2

This
T h i s type
t y p e of
o f rrelationship
e l a t i o n s h i p has been observed
o b s e r v e d iin
n two studies
studies
involving
with
i n v o l v i n g mills
m i l l s operated
operated w
i t h complete
c o m p l e t e dynamic similarity.
similarity.

TThe
he

values
20 inch
v a l u e s of
of 0
<5 observed
o b s e r v e d were
w e r e 0=0.06
5=0.06 (5
(5 inch
i n c h tto
o 20
i n c h diameter
d i a m e t e r mills)(5)
mills)^
and 0=0.1
6=0.1 (8
(8 inch
i n c h to
t o 24 inch
i n c h diameter
d i a m e t e r mills)(l3).
mills)' \
1 3

At
was available
A t the outset
o u t s e t of
o f this
t h i s study
s t u d y no direct
d i r e c t iinformation
n f o r m a t i o n was
available
ball
using
population
balance
models.
for
f o r wet b
a l l mill
m i l l scale-up
scale-up u
sing p
opulation b
alance m
odels.

Wet

(8)
grinding results obtained by Kim(8)
do, however, appear to have img r i n d i n g r e s u l t s o b t a i n e d by K i n r ' d o , h o w e v e r , appear t o have i m

portant implications concerning scale-up.

In a series of batch

portant implications concerning s c a l e - u p .

In a s e r i e s o f batch

experiments in a lO-inch mill, using various ball loads, mill speeds


experiments in a 10-inch m i l l , using v a r i o u s ball l o a d s , m i l l

speeds

and pulp percent solids, he found that 1} the selection functions


and p u l p p e r c e n t s o l i d s , he f o u n d t h a t

1) the s e l e c t i o n f u n c t i o n s

are to a good approximation proportional to the specific power


a r e t o a good a p p r o x i m a t i o n p r o p o r t i o n a l t o t h e s p e c i f i c power

draft (P/H) and inversely proportional to the pulp percent solids


d r a f t (P/H) and i n v e r s e l y p r o p o r t i o n a l to t h e p u l p p e r c e n t s o l i d s

2) the breakage functions for a given percent solids are to a good


2) the breakage f u n c t i o n s f o r a g i v e n p e r c e n t s o l i d s a r e t o a good

approximation independent of mill speed, ball load and particle


a p p r o x i m a t i o n i n d e p e n d e n t o f m i l l s p e e d , b a l l l o a d and p a r t i c l e

load.

If Kim's wet grinding results can be extended to mills of

load.

I f K i m ' s w e t g r i n d i n g r e s u l t s can be e x t e n d e d t o m i l l s o f

different diameters in the same manner that Herbst and Fuerstenau's(l)


d i f f e r e n t d i a m e t e r s i n t h e same manner t h a t H e r b s t and F u e r s t e n a u ' s ^ '

original results were extended to dry grinding in different size


o r i g i n a l r e s u l t s were extended to d r y g r i n d i n g i n d i f f e r e n t

size

mills, it may be possible to define an accurate basis for wet ball


m i l l s , i t may be p o s s i b l e t o d e f i n e an a c c u r a t e b a s i s f o r wet b a l l

15
15

mill
m i l l scale-up.
scale-up.

Wet grinding
g r i n d i n g systems
s y s t e m s do,
d o , however,
h o w e v e r , have the
t h e addiaddi

tional
non-linear
t i o n a l complication
c o m p l i c a t i o n of
of n
o n - l i n e a r breakage
breakage behavior
b e h a v i o r which
w h i c h must be
taken
which
be ddeveloped.
t a k e n into
i n t o account
a c c o u n t in
i n any scale-up
s c a l e - u p strategy
strategy w
h i c h is
i s tto
o be
eveloped.

CHAPTER III
III
EQUIPMENT AND EXPERIMENTAL PROCEDURES
PROCEDURES
In this
t h i s chapter
c h a p t e r tthe
h e equipment
equipment and tthe
h e experimental
e x p e r i m e n t a l procedures
procedures
followed
f o l l o w e d are
a r e discussed.
d i s c u s s e d . The
T h e experiments
e x p e r i m e n t s were
w e r e designed
d e s i g n e d tto
o provide
provide
a quantitative
q u a n t i t a t i v e gUide
g u i d e for
f o r correlation
c o r r e l a t i o n of
o f three
t h r e e mills
m i l l s of
o f different
different
size.
size.

The
the tthree
mills
T h e data were
w e r e obtained
o b t a i n e d from
f r o m the
hree m
i l l s for
f o r testing
t e s t i n g the
the

predictive
p r e d i c t i v e capability
c a p a b i l i t y of
o f tthe
h e model described
d e s c r i b e d iin
n Chapter
C h a p t e r II.
II.

Dry
D r y and

wet
wet batch
batch grinding
g r i n d i n g experiments
e x p e r i m e n t s were
w e r e pperformed
e r f o r m e d in
i n each of
o f the
t h e mills
mills
to
t o provide
p r o v i d e the
t h e basis
b a s i s for
f o r comparison
c o m p a r i s o n of
o f the
t h e two systems
s y s t e m s and verifiverifi
c a t i o n of
o f tthe
h e model.
model.
cation

M o n o - s i z e (10
(10 xx 14
14 mesh) and 'natural
' n a t u r a l ''
Mono-size

(-10 mesh) size


s i z e distribution
d i s t r i b u t i o n feeds
f e e d s were
w e r e examined.
examined.
(-10

The
Utah CalT h e material
m a t e r i a l used was a limestone
l i m e s t o n e acquired
a c q u i r e d from Utah
Cal
cium, A
r a g o n i t e , Utah.
Utah.
cium,
Aragonite,

The X
- r a y diffraction
d i f f r a c t i o n ppattern
a t t e r n showed
The
X-ray

t h a t tthe
h e material
m a t e r i a l contained
c o n t a i n e d limestone
l i m e s t o n e and calcite
c a l c i t e crystals.
crystals.
that

The
by ppicnometer
was found
be 2.69.
T h e specific
s p e c i f i c gravity
g r a v i t y as measured by
i c n o m e t e r was
f o u n d tto
o be
2.69.
The transparent
t r a n s p a r e n t calcite
c a l c i t e crystals
c r y s t a l s and opaque llimestone
i m e s t o n e particles
particles
could
the breakage
breakage proc o u l d be visually
v i s u a l l y differentiated
d i f f e r e n t i a t e d iin
n tthe
h e feed,
f e e d , but
b u t the
pro
perties
p e r t i e s of
o f tthe
h e two types
t y p e s of
o f particles
p a r t i c l e s were
w e r e similar
s i m i l a r enough tto
o ensure
ensure
homogeneous breakage
breakage behavior.
behavior.
Equipment
Three
T h r e e mills
m i l l s of
o f 10-inch,
1 0 - i n c h , lS-inch
1 5 - i n c h and 30-inch
3 0 - i n c h diameter
d i a m e t e r were
w e r e used
for
batch tests.
f o r dry
d r y and wet batch
tests.

The
T h e 10-inch
1 0 - i n c h and lS-inch
1 5 - i n c h diameter
d i a m e t e r mills
mills

were of
o f stainless
s t a i n l e s s steel
s t e e l construction
c o n s t r u c t i o n (Figure
( F i g u r e 1),
1 ) , each 11.S
11.5 inch
i n c h long
long

17
17

1.
FFigure
i g u r e 1.

Photograph
the 1lO-in.
P
h o t o g r a p h showing the
0 - i n . and lS-in.
15-in.
mills
with
ddiameter
iameter m
ills w
i t h ssquare
q u a r e lifters.
lifters.

18
l
having
h a v i n g eight
e i g h t square
s q u a r e lifters
l i f t e r s (Figure
( F i g u r e 2b).
2b).

The
T
h e laboratory
l a b o r a t o r y scale
s c a l e mills
mills

were equipped
with
equipped w
i t h a Graham variable
v a r i a b l e speed ttransmission
r a n s m i s s i o n coupled
coupled
BLH ttorque
with
w i t h a BLH
o r q u e sensor
s e n s o r and a Sargent
S a r g e n t recorder
r e c o r d e r to
t o measure power
d r a f t (torque)
( t o r q u e ) directly
d i r e c t l y from
f r o m the
the drive
d r i v e shaft
s h a f t between
transmission
draft
between the
the transmission

and the
t h e mi1l
m i l l (Figures
(Figures 3
3 & 4).
4).

The
T h e system
s y s t e m was identical
i d e n t i c a l to
t o the
the one

(23)
(4 8 ~[Q)
described
and oother
d e s c r i b e d by
by Yang
Yang et.
e t . al.,
a l . , (23) and
t h e r iinvestigators(4,8,19).
nvestigators^ * *
'.
;

Stainless
were
mill
S t a i n l e s s steel
s t e e l balls
balls w
e r e used in
i n tthe
h e lO-inch
10-inch m
i l l experiments.
experiments.
Mild
balls
mixed
the l5-inch
M i l d steel
steel b
a l l s were m
i x e d with
w i t h stainless
s t a i n l e s s steel
s t e e l balls
b a l l s in
i n the
15-inch
m i l l as a grinding
g r i n d i n g media.
media.
mill

E
xperiments p
e r f o r m e d in
i n the
t h e lO-inch
1 0 - i n c h mill
mill
Experiments
performed

h a t grinding
g r i n d i n g behavior
b e h a v i o r was identical
i d e n t i c a l with
w i t h media charges concon
showed tthat
s i s t i n g of
o f entirely
e n t i r e l y stainless
s t a i n l e s s steel
s t e e l bballs
a l l s or
or m
i l d steel
steel b
a l l s or
or a
a
sisting
mild
balls
m i x t u r e of
o f tthetwo.
he'two.
mixture

T h e bball
a l l sizes
s i z e s used in
i n all
a l l experiments
e x p e r i m e n t s ranged
The

f r o m 1/2
1/2 inch
i n c h to
to 1
1 1/2
1/2 inch
i n c h in
i n diameter.
diameter.
from

A bball
a l l load
l o a d of
o f 30.5
30.5 kg was
A

used in
i n the
t h e 10-inch
1 0 - i n c h mill
m i l l and 68.6
58.6 kg in
i n the
the 15-inch
1 5 - i n c h mill,
m i l l , each correcorre*

4-

sponds to a ball filling of 50% (M;=O.S)+ of the struck volume


sponds to a b a l l

filling

o f 50% (Mg=0.5)' o f the s t r u c k volume

of the mill.

The ball size distribution approximated that of an

o f the m i l l .

The ball

s i z e d i s t r i b u t i o n a p p r o x i m a t e d t h a t o f an

"equil i bri um charge di s tri buti on" H frequently used in 1aboratory


" e q u i l i b r i u m c h a r g e d i s t r i b u t i o n " ^ f r e q u e n t l y used i n l a b o r a t o r y

tests for mill scale-up des;gn(4,8).


tests for mill

scale-up d e s i g n ^ ^ .

The precise distribution used


The p r e c i s e d i s t r i b u t i o n used

in each of the mills is given in table on page 22.

i n each o f t h e m i l l s i s g i v e n i n t a b l e on page 22.

The pilot scale mill used in this study is a standard Denver


The p i l o t s c a l e m i l l

used i n t h i s s t u d y i s a s t a n d a r d D e n v e r

mild steel ball mill having an internal diameter of 30-inch and a


mild steel
1

ball mill

h a v i n g an i n t e r n a l

diameter o f 30-inch

and a

M:=MB/M
+ M
Mn/M RC ' where
where MR
M is
i s the
t h e mass
mass of
o f balls,
balls, M
Mp
the mass
mass of
o f balls
balls
Br the
wnen
the
mill
is
completely
filled
with
balT~
under
static
when the m i l l i s c o m p l e t e l y f i l l e d w i t h b a i t s u n d e r s t a t i c
conditions.
conditions.
=

H
^ In

practice
p r a c t i c e only
o n l y one size
s i z e of
o f ball
b a l l is
i s charged
c h a r g e d to a commercial mill.
mill.
h e passage of
o f time
time the
the ba1l
b a l l size
s i z e reduces and new balls
balls
With tthe
a r e added. After
A f t e r a certain
c e r t a i n time
e r i o d tthe
h e ball
b a l l size
s i z e distridistri
are
time pperiod
This b
a l l size
s i z e distribution
d i s t r i b u t i o n is
is
b u t i o n attains
a t t a i n s an equilibrium.
e q u i l i b r i u m . This
bution
ball
c a l l e d the
t h e "Equilibrium
" E q u i l i b r i u m Charge Distribution.1I
Distribution."
called

19

/
/

"2.5"----------~~I
~---------~

//

\\

4
11.8"

Figure
F i g u r e 2.

(a)
(a) The
T h e cconfiguration
onfiguration
la-in.
1 0 - i n . mill
mill
(b)
(b) The
T h e configuration
configuration
101 0 - iin.
n . and 151 5 - in.
in.
(c)
(c) The
T h e configuration
configuration
the
3 0 - i nn.. mill.
mill.
t h e 30-i

>

of
o f ramp 1
l iifters
f t e r s used in
i n the
the
of
o f square
s q u a r e lifters
l i f t e r s used in
i n the
the
mi
m i11
lls
of
o f rounded lifters
l i f t e r s used in
in

20

Figure 3.

4.
FFigure
i g u r e 4.

Photograph showing the 10-in. mill with


variable speed transmission, the torque sensor,
coupling and Sargent recorder.

Photograph
showing the
the 15-in.
mill
P
h o t o g r a p h showing
15-in. m
i l l on the
the
lloading
o a d i n g port.
port.

21

Figure 5.

Photograph showing the sideview of the


30-in. mill.

Figure
F i g u r e 6.
6.

Photograph
Photograph showing a vview
i e w of
o f the
the 30-in.
3 0 - i n . mill
mill
with
w
i t h pprony
r o n y brake in
i n position.
position.

22

The Equilibrium
E q u i l i b r i u m Charge Distribution
D i s t r i b u t i o n of
o f Balls
Balls
Ball
Percent
Mass (Kilograms)
B a l l Diameter
Diameter P
ercent
(Kilograms)
(inches)
(by
wgt)
15-in
mill
30-i
mill
(inches)
w g t ) 10-in
10-in m
ill
15-in mill
3 0 - i nn mi
m i11
ll
50% filling
f i l l i n g 50% filling
f i l l i n g 40% filling
f i l l i n g 50%
50% filling
filling
1.50
1.50

52.79%

16.10
16.10

36.23

181.40
181.40

226.80

1.
00
1.00

30.16%

9.20
9.20

20.70

103.70

129.60

0.75
0.75

11.80
11.80

3.60
3.60

8.05
8.05

40.60

50.70

1.
60
1.60

3.,60
3.60

18.10

22.60

30.50

68.58

0.50
0.50

5.25%
100.00
100.00

length
l e n g t h of
o f 18-inch.
18-inch.

343.80
343.80

429.70

This
T h i s mill
m i l l comes fitted
f i t t e d with
w i t h eight
e i g h t rounded lifters
lifters

(Figure
2 c ) , similar
s i m i l a r in
i n configuration
c o n f i g u r a t i o n tto
o a wavy liner.
liner.
( F i g u r e 2c),
d e s i g n e d to
t o be a component of
o f a ccontinuous
o n t i n u o u s system.
system.
designed

The
mill
was
The m
i l l was

I t was
was mounted
It

h e a v y duty
d u t y ball
b a l l bearings
b e a r i n g s and
and driven
d r i v e n in
i n two
s t a g e s by
b y an
on two
two heavy
two stages
e l e c t r i c motor
m o t o r tthrough
h r o u g h bbelts
e l t s and
and gears
gears as
as shown in
i n Figures
F i g u r e s 6 and
and 7.
electric
S i n c e the
t h e mill
m i l l did
d i d not
n o t have a central
c e n t r a l shaft,
s h a f t , tthe
h e BLH
BLH ttorque
o r q u e sensor
sensor
Since
o tthe
h e pinion
p i n i o n shaft
s h a f t tto
o record
r e c o r d the
t h e power input
i n p u t transtrans
c o u p l e d tto
was coupled
t h e shaft
s h a f t to
t o tthe
h e mill
m i l l (Figure
( F i g u r e 7).
7).
m i t t e d tthrough
h r o u g h the
mitted
c o u p l e d to
t o a Sargent
S a r g e n t recorder.
recorder.
coupled

T h e sensor
s e n s o r was
The
was

T h e power input
i n p u t to
t o tthe
h e mill
m i l l was
was oobb
The

tained b
m u l t i p l y i n g the
t h e rrecorded
e c o r d e d torque
t o r q u e by
b y the
t h e gear
g e a r ratio
r a t i o and
tained
byy multiplying
and
a p p l y i n g appropriate
a p p r o p r i a t e corrections
c o r r e c t i o n s for
f o r losses.
losses.
applying

T h e speed of
o f the
t h e pinion
pinion
The

v a r i e d by
by an
an adjustable
a d j u s t a b l e ppulley
u l l e y mounted on
on the
t h e motor
motor
s h a f t could
c o u l d be
shaft
be varied
shaft.
shaft.

F o r dry
d r y grinding
g r i n d i n g experiments
e x p e r i m e n t s a ball
b a l l load
l o a d of
o f 429.70 kg,
k g , correcorre
For

t o 50% b
a l l filling,
f i l l i n g , was
was used and
and for
f o r wet
w e t grinding
g r i n d i n g experiexperi
s p o n d i n g to
ball
sponding
a ball
b a l l load
l o a d of
o f 343.80
343.80 kg
kg was
c o r r e s p o n d i n g to
t o 40%
ball
ments a
ments
was used
used corresponding
40% ball

23

FFigure
i g u r e 7.
7.

P h o t o g r a p h showing ppinion
i n i o n shaft
s h a f t ooff the
the
Photograph
belt
mill
with
330-in.
0-in. m
ill w
i t h the
the b
e l t ppulley,
u l l e y , the
the
torque
the cchain
t o r q u e ssensor
e n s o r and the
h a i n coupling.
coupling.

24

filling.
filling.

The
ball
The b
a l l size
s i z e distribution
d i s t r i b u t i o n corresponded
c o r r e s p o n d e d to
t o the
t h e IIEquilibrium
"Equilibri

Charge Distribution
mentioned
m e n t i o n e d earlier.
earlier.
Distribution
1 ll
1

Experimen~al
E
x p e r i m e n t a l Procedure
Procedure

To pprepare
r e p a r e a 10
10 x
x 14
14 mesh feed
f e e d for
f o r the
the 10-inch,
1 0 - i n c h , 15-inch
1 5 - i n c h and
30-inch
mills,
was first
30-inch m
i l l s , the
t h e lias
"as rreceived
e c e i v e d " limestone
l i m e s t o n e was
f i r s t sieved
s i e v e d through
through
ll

a set
s e t of
o f Sweco screens,
s c r e e n s , discarding
d i s c a r d i n g +10
+10 mesh and -14
-14 mesh material.
material.
The product
was further
p r o d u c t was
f u r t h e r sieved
s i e v e d for
f o r thirty
t h i r t y minutes
m i n u t e s through
t h r o u g h Tyler
Tyler
ff-"interval
narrow
/ 2 T - i n t e r v a l screens
s c r e e n s to obtain
obtain a n
a r r o w size
s i z e of
o f 10
10 x
x 14
14 mesh. The
The
material
with
m a t e r i a l was then
then washed w
i t h water
w a t e r tthrough
h r o u g h a 28
28 mesh screen
s c r e e n in
in
o r d e r to
t o remove any fine
f i n e pparticles
articles w
h i c h may have been attached
a t t a c h e d to
to
which
order
the 10
10 x
x 14
14 mesh material.
material.
the

The grinding
procedures
grinding p
r o c e d u r e s for
f o r tthe
h e 1Q-inch
1 0 - i n c h and l5-inch
1 5 - i n c h mills
mills
were identical
material
i d e n t i c a l except
e x c e p t that
t h a t the
the total
t o t a l mass of
of m
a t e r i a l ground
g r o u n d in
i n the
the
two m
mills
g , respectively.
respectively.
i l l s was 3.3
3.3 kg and 7.425 kkg,

These
T h e s e particle
particle
*

loadings corresponded to 100% filling of the interstices (M;=1.0)+


l o a d i n g s c o r r e s p o n d e d t o 100% f i l l i n g o f the i n t e r s t i c e s

(M =1.0)
p

of the ball charges in the two mills.

The speed of the mills for

o f the b a l l charges i n t h e two m i l l s .

T h e speed o f t h e m i l l s

for

all experiments was kept at 60% of the critical speed (N*=0.6)tt


all

e x p e r i m e n t s was kept a t 60% o f the c r i t i c a l

speed (N = 0 . 6 ) '

and in wet grinding the percent solids was also kept constant at
and i n wet g r i n d i n g the p e r c e n t s o l i d s was a l s o kept c o n s t a n t

at

60% by weight (F=O.6).


60% by w e i g h t

(F=0.6).

A detailed description of the procedure used for each batch


A detailed

d e s c r i p t i o n o f the p r o c e d u r e used f o r each

batch

experiment in the 10-inch and 15-inch mills is given below:


e x p e r i m e n t i n t h e 1 0 - i n c h and 1 5 - i n c h m i l l s
I

t'

is given below:

M;=Mp'/Mpf.'
mass hhold-up
and MMpf. the
the mass
mass ooff
p M p / p r where
e MMp iis
s tthe
h e mass
o l d - u p and
particles
that
completely
fills
the
interstices
between
the
p a r t i c l e s t h a t c o m p l e t e l y f i l l s the i n t e r s t i c e s between the
balls
under
n d e r static
s t a t i c conditions.
conditions.
b a l l s (Mac)
(Mg ) u

w n e r

p c

II

tt NN*=N/N
N is
N the
= N / N ,, where
where N
i s the
t h e mill
m i l l speed,
speed, N
the critical
c r i t i c a l speed
speed of
of
per
mill
m i l l i~
i n revolutions
revolutions p
e r minute
m i n u t e at
at whi~h
w h i c h the
t h e first
f i r s t layer
l a y e r of
o f the
the
balls
will
( NC
p=265/v'IJ-O
= 2 6 5 / / D - d rpm,
rpm, 0
D the
the mill
m i l l diameter
d i a m e t e r in
in
balls w
i l l centrifuge
c e n t r i f u g e (N
inches
b a l l diameter
d i a m e t e r in
i n inches).
inches).
i n c h e s and
and d
d the
the maximum
maximum ball
T T

25
,

1. The
was charged
with
material
T h e mill
m i l l was
charged w
i t h balls
b a l l s and
and feed
feed m
a t e r i a l in
i n aa
layer
l a y e r load"ing
l o a d i n g manner(4,8)
m a n n e r ^ ' ^ that
t h a t is,
i s , alternating
a l t e r n a t i n g layers
l a y e r s of
of
balls
mixing
b a l l s and
and feed,
f e e d , tto
o ensure
e n s u r e thorough
thorough m
i x i n g at
a t the
t h e start
s t a r t of
of
each test.
test.

The
was locked
T h e replaceable
r e p l a c e a b l e end
end plate
p l a t e was
l o c k e d into
into

place
proper
p l a c e for
for p
r o p e r sealing.
sealing.

In
I n the
t h e case of
o f wet
w e t grinding
grinding

2200 grams and


water
and 4950 grams of
of w
a t e r were
w e r e added to
t o tthe
he
mills,
10-inch
1 0 - i n c h and
and 15-inch
15-inch m
i l l s , respectively,
r e s p e c t i v e l y , through
t h r o u g h tthe
h e ports
ports
provided
p r o v i d e d in
i n the
t h e back
back plate
p l a t e of
o f each mill
m i l l (Figure
( F i g u r e 1).
1 ) . TThe
he
m i l l was
was then ttransferred
r a n s f e r r e d tto
o tthe
h e rollers
r o l l e r s and
and coupled
c o u p l e d to
to
mill
the drive
d r i v e shaft
s h a f t (Figure
( F i g u r e 3).
3).
the

2.

The
mill
was adjusted
The m
i l l speed was
a d j u s t e d with
w i t h variable
v a r i a b l e speed arrangement
arrangement
p r o v i d e d on
on the
t h e shaft.
shaft.
provided

o f critical
c r i t i c a l speed corresponded
corresponded
60% of

t o 54 rpm
and 42 rpm
f o r the
t h e 10-inch
1 0 - i n c h and
and l5-inch
1 5 - i n c h mills,
mills,
to
rpm and
rpm for
respectively.
respectively.
ime.
mined ttime.

The m
i l l was
was a.llowed
a l l o w e d to
t o run
r u n for
f o r a predeterpredeter
The
mill
T h e mill
m i l l rrevolutions
e v o l u t i o n s were
w e r e recorded
recorded b
counter
The
byy a counter

a t t a c h e d to
t o the
t h e shaft
s h a f t and
and tthe
h e ttorque
o r q u e was
r e c o r d e d on
on aa
was recorded
attached
S a r g e n t strip
s t r i p chart
c h a r t recorder.
recorder.
Sargent

3. After
was uunA f t e r completion
c o m p l e t i o n of
o f a pparticular
a r t i c u l a r grind,
g r i n d , tthe
h e mill
m i l l was
n
coupled
back to
c o u p l e d and
and ttransferred
r a n s f e r r e d back
t o the
t h e loading'port
l o a d i n g p o r t (Figure
( F i g u r e 4).
4).
The end
was gently
e n d plate
p l a t e was
was removed and
and tthe
h e mill
m i l l was
g e n t l y discharged
discharged
with
over
o v e r a grizzley.
g r i z z l e y . The
T h e material
m a t e r i a l was
was washed w
i t h water
w a t e r through
through
the
the grizzley
g r i z z l e y and
and was
was collected
c o l l e c t e d in
i n buckets.
buckets.
4. The
was wet screened
T h e ground
g r o u n d product
p r o d u c t was
s c r e e n e d tthrough
h r o u g h a 400 mesh
s c r e e n mounted on
on a vvibrator.
ibrator.
screen

T h e -400 mesh slurry


s l u r r y was
was ddeeThe

watered u
sing a p
r e s s u r e filter,
f i l t e r , tthe
h e cake
cake and
and +400 mesh propro
watered
using
pressure
d u c t thus obtained
o b t a i n e d were dried
dried u
n d e r the
t h e infrared
i n f r a r e d heat
under
heat lamps.
duct

5.

The
and
T
h e dry
d r y +400 mesh fraction
f r a c t i o n of
o f tthe
h e product
p r o d u c t was
was weighed
w e i g h e d and

26

.
0

split
using
split u
s i n g a rrifle
i f l e splitter
s p l i t t e r to
t o obtain
o b t a i n a representative
representative
sample of
o f about
a b o u t 500 grams.

This
T h i s sample was
was then sieved
sieved

T y l e r screens
s c r e e n s (from
( f r o m 14 mesh down to
t o 400
u s i n g a-series
JT~-series
using
Tyler
o r 30 m
i n u t e s on
on a rotap
r o t a p sifter.
sifter.
mesh) ffor
minutes

6. The
was determined
T h e weight
w e i g h t of
o f each size
s i z e fraction
f r a c t i o n was
d e t e r m i n e d using
using a
two place
p l a c e Mettler
M e t t l e r balance.
balance.

Then each screen


s c r e e n was
was well
well

o ensure
e n s u r e the
t h e recovery
r e c o v e r y of
o f all
a l l the
t h e material
m a t e r i a l sieved.
sieved,
c l e a n e d tto
cleaned

7.

The
was weighed
mixed
T h e -400 mesh cake
cake was
w e i g h e d and
and m
i x e d with
w i t h +400 mesh
product,
material
and additional
a d d i t i o n a l -400 mesh m
a t e r i a l was
was added tto
o
p r o d u c t , and
f o r any
any weight
w e i g h t loss
l o s s (typically
( t y p i c a l l y less
l e s s than 0.4%),
0.4%),
make up
up for
t h e losses
l o s s e s in
in h
a n d l i n g were of
o f vvery
e r y fine
f i n e particles.
particles.
presuming the
handling
m a t e r i a l was
was then
e p t for
f o r subsequent
s u b s e q u e n t grinds.
grinds.
The material
then kkept

The experimentation
e x p e r i m e n t a t i o n in
i n tthe
h e 30-inch
3 0 - i n c h mill
m i l l was
was somewhat cumbercumber
some as the
batch tests.
t h e design
d e s i g n was
was not
n o t suitable
s u i t a b l e for
f o r batch
tests.

The
T h e sequence

of p
r o c e d u r a l steps
s t e p s was
was essentially
e s s e n t i a l l y the
t h e same as outlined
o u t l i n e d for
f o r tthe
he
of
procedural
1 0 - i n c h and
and l5-inch
1 5 - i n c h mills.
mills.
10-inch

T h e mill
m i l l was
was loaded
l o a d e d and
and uunloaded
n l o a d e d through
through
The

0
1/4 inch
i n c h diameter
diameter p
o r t s , spaced at 120
120 along
a l o n g the
t h e periphery
periphery
three 2
ports,
three
2 1/4

o f tthe
h e mill
m i l l (Figure
( F i g u r e 5).
5).
of

E
x t r e m e care
c a r e was
i n loading
l o a d i n g and
and unloadunload
Extreme
was taken
taken in

o f tthe
he m
i l l tto
o avoid
a v o i d pparticle
a r t i c l e bbreakage.
reakage.
ing of
mill

T h e inlet
i n l e t and
and discharge
discharge
The

o f the
t h e mill
m i l l were
w e r e sealed
s e a l e d with
w i t h ttin
in p
l a t e s and
and putty.
putty.
ends of
plates

IIn
n the
t h e case

o f dry
d r y grinding
g r i n d i n g tests
t e s t s the
t h e feed
f e e d material
m a t e r i a l weighed
w e i g h e d 46.54 kg
f o r aa
of
kg for
a l l filling,
filling, w
h i l e in
in w
et g
r i n d i n g tests
t e s t s tthe
h e feed
f e e d weighed
weighed
50% bball
while
wet
grinding
f o r a 40%
40% ball
b a l l filling.
filling.
37.23 kg
kg for

Since, u
l t i m a t e l y this
t h i s scale-up
scale-up
Since,
ultimately

s t u d y will
w i l l be
a p p l i e d to
t o a continuous
c o n t i n u o u s system
s y s t e m in
i n which
w h i c h a maximum of
of
be applied
study
a l l filling
f i l l i n g is
i s practical,
p r a c t i c a l , wet
w e t ttests
ests w
e r e carried
c a r r i e d out
o u t at
a t a 40%
40% bball
were
40%
b a l l filling.
filling.
ball

F o r 60%
60% solids,
s o l i d s , 24.82
24.82 kg
kg of
of w
a t e r was
was added.
added.
For
water

was rotated
r o t a t e d for
for a
a ppre-determined
r e - d e t e r m i n e d ttime.
ime.
was

T h e mill
mill
The

The m
a t e r i a l was
unloaded
The
material
was unloaded

27
27

through
t h r o u g h the
the bottom pport
o r t into
i n t o several
s e v e r a l bbuckets.
uckets.
were then
then separated
s e p a r a t e d by hand.

The
T h e bballs
a l l s and material
material

The
product
washed,
The p
r o d u c t was w
a s h e d , dried
d r i e d and

sieved
the 10-inch
s i e v e d as in
i n the case of
o f the
1 0 - i n c h and 15-inch
1 5 - i n c h mills.
mills.
Batch ttests
were
the tthree
ests w
e r e performed
p e r f o r m e d in
i n the
h r e e different
d i f f e r e n t mills
m i l l s wet
wet
and dry
d r y with
w i t h both the
the 10
10 x
x 14
14 mesh feed
f e e d material
m a t e r i a l and ' nnatural
a t u r a l ' (as
(as
I

received
the +10
+10 mesh material
r e c e i v e d feed
f e e d with
w i t h the
m a t e r i a l rremoved).
emoved).

In addition
a d d i t i o n an

* =.4,
c i r c u i t ttest
e s t was conducted
c o n d u c t e d in
i n the
the 30-inch
3 0 - i n c h mill
m i l l (N * ==.6,
.6, M
Mg=.4,
open circuit
S
F = . 6 ) with
w i t h 'natural
' n a t u r a l ' size
s i z e distribution
d i s t r i b u t i o n feed
f e e d material.
material.
In tthis
h i s concon
In
F=.6)
I

t i n u o u s test
t e s t the
the m
i l l was run w
i t h a feedrate
f e e d r a t e of
o f 1040
1040 lbs/hr
I b s / h r for
for
tinuous
mill
with
m i n u t e s to allow
a l l o w all
a l l transients
t r a n s i e n t s in
i n the
i l l to
t o die
d i e out.
out.
60 minutes
the m
mill

Once

s t e a d y state
s t a t e was achieved,
a c h i e v e d , samples of
o f feed
f e e d and product
p r o d u c t were taken
taken
steady
simultaneously.
simultaneously.
analysis.
analysis.

addition m
i l l contents
c o n t e n t s were
w e r e discharged
d i s c h a r g e d for
for
In addition
mill

F o r tthe
h e analysis
a n a l y s i s of
o f tthese
h e s e samples the
t h e same procedure
procedure
For

f o l l o w e d as in
i n tthe
h e 10-inch
1 0 - i n c h and l5-inch
1 5 - i n c h mill.
mill.
was followed

The data
mills
data obtained
o b t a i n e d from
f r o m the
t h e above mentioned
m e n t i o n e d three
three m
i l l s for
f o r dry
dry
and wet
wet grinding
Appendix
g r i n d i n g experiments
e x p e r i m e n t s are
a r e ttabulated
a b u l a t e d in
in A
p p e n d i x I.
I.

The
T h e propro

cedure used to
power draft
mills
t o determine
d e t e r m i n e net
net power
d r a f t for
f o r each of
o f tthe
he m
i l l s and
specific
s p e c i f i c energy
e n e r g y inputs
i n p u t s for
f o r each experiments
e x p e r i m e n t s are
a r e given
g i v e n in Appendix
A p p e n d i x II.
II.

CHAPTER IV
ANALYSIS OF BREAKAGE KINETICS
In this
t h i s chapter
c h a p t e r a preliminary
p r e l i m i n a r y analysis
a n a l y s i s of
o f data is
i s presented.
presented.
Breakage
wet
Breakage kinetics
k i n e t i c s in
i n the
t h e dry
d r y and w
e t grinding
g r i n d i n g systems
s y s t e m s are
a r e described.
described.
The dependence of
o f breakage
breakage and selection
s e l e c t i o n functions
f u n c t i o n s on the
t h e mill
mill
o p e r a t i n g variables
v a r i a b l e s and vverification
e r i f i c a t i o n of
o f scale-up
s c a l e - u p rrelationships
e l a t i o n s h i p s is
is
operating

di
d i sscussed.
cussed.
Dry
D r y grinding
g r i n d i n g kinetics
k i n e t i c s were
w e r e found
f o u n d tto
o be essentially
e s s e n t i a l l y linear
l i n e a r for
for
a l l grind
g r i n d times
t i m e s in
i n each mil'.
mill.
all

I n contrast
c o n t r a s t the
the w
e t grinding
g r i n d i n g behavior
behavior
In
wet

e x h i b i t e d a significant
s i g n i f i c a n t deviation
d e v i a t i o n from
f r o m linearity.
linearity.
exhibited

Feed size
s i z e selection
selection

f u n c t i o n s can be determined
d e t e r m i n e d from the
t h e slope
s l o p e of
o f feed
f e e d disappearance
d i s a p p e a r a n c e plots
plots
functions
( l n ( m . ( t ) / m . ( 0 ) ) , vvs.
s . t)
t ) according
a c c o r d i n g to
t o the
the rearranged
r e a r r a n g e d form
f o r m of
o f equation
equation
(In(mi(t)/mi(O))
( I I - l ) i.e.
i.e.
(11-1)

s, (t) = - r [In(m i (t)/m i (0))]


S

(Iv
( I V --11 ))

" 3t [ ^ ( m ^ t J / m ^ O ) ) ]

Figures
plots
Figures 8
8 and 9
9 show p
l o t s of
o f the
the fraction
f r a c t i o n of
o f feed
f e e d remaining
remaining
( m . ( t ) / m . ( 0 ) ) vversus
e r s u s time
t i m e (t)
( t ) for
f o r dry
d r y and wet grinding
g r i n d i n g respectively
respectively
(mi(t)/mi(O))
f o r each mill.
mill.
for

I t is
i s found
f o u n d tthat
h a t for
f o r the
the dry
d r y system
s y s t e m tthe
h e breakage
breakage
It

k i n e t i c s are
are linear,
l i n e a r , that
t h a t is
i s the
t h e feed
f e e d size
s i z e selection
s e l e c t i o n function
f u n c t i o n (S,)
(S-j) is
is
kinetics
i n d e p e n d e n t of
o f the
t h e extent
e x t e n t of
o f grind
g r i n d ttime.
ime.
independent

I n the
t h e wet
wet system
s y s t e m the
the
In

d e v i a t i o n from linearity
l i n e a r i t y becomes significant
s i g n i f i c a n t when tthe
h e fraction
f r a c t i o n of
of
deviation
r e m a i n i n g in
i n the top
t o p size
s i z e interval
i n t e r v a l drops
d r o p s below 0.1
0.1 in
i n the
feed remaining
the case
o f all
a l l the
t h e tthree
hree m
i l l s (see
(see Figure
F i g u r e 9).
9).
of
mills

I t is
i s also
a l s o observed
o b s e r v e d that
that
It

29

1.0

\0

(!)

BATCH DRY

0.5

z
z

IOxl4 Mesh Feed

tJ.j

a::

.tJ.j

'N

0.2

en
cr
w
tJ.j

LL

O\:
\,
/:).

O. I

LL

o 10 in. mill
o 15 in. mill
A 30in.mlll

Z
0
~

0.05

,,",,"

a::

,,",,"
,,",,"
,,"
"

LL

en
en

:E

0.02

0.0 I ....._ ........._ _....L..._ _""--_---L_ _......L.._ _....L-_--I


0.01

o0

Figure
F i g u r e 8.
8.

4
4

5
5

GRIND TlME t minutes


GRIND T I M E , minutes
Feed
and
Feed disappearance
d i s a p p e a r a n c e pplot
l o t for
f o r lO-in.,
1 0 - i n . , l5-in.
1 5 - i n . and
30;in.
diaweter
mills
for
.dry
grinding
3 0 - i n . diameter m i l l s f o r .dry g r i n d i n g
(N
(N =0.6,
=0.6, M
MB=O.5).
=0.5).
B

30
30

<ro------------------...,

1.0
1.0 <2

<.!>

BATCH W
WET
ET
lOx
14 Mesh Feed
10x14
Feed

0.5

z;
Z

Z
<
<t

W
UJ

a:::
rr

UJ
N
N
CO
en

0.2
0.2

oo
w
LU
W

UJ
LL
LlLL
LiO

0.1
0.1

o 10 in. mill
015 in.mill
t::. 30 in. mill

O
o
r

oO
<
<t
a:::
or

0.05
0.05

LL

en
en
en
c/)

<
<t

\\

\\

\\

\\

.0.02
0.02

\\

\
\

0.01
0.01

\\
\
i_\

FFigure
i g u r e 9.
9.

2
5
4
3
GRIND TIME,
TIME , minutes

66

Feed disappearance
plot
disappearance p
l o t for
f o r la-in.,
1 0 - i n . , lS-in.
1 5 - i n . and
3D-in.
1~let grinding
3 0 - i n . diameter*mills
diameter^mi 11 s sQml/ing
sjjowing tthe
h e wet
grinding
n~nlinearity
(N
=0.6,
f'
1
for
30-in.
=O.S,
mill
n o . n l i n e a r i t y (M = 0 . 6 , M = 0 . 5 , f o r 3 0 - i n . mill
B
B

M =0.4,
~1B=O.4,
B

F=0.6).
F=O.6).

31

the
on the
t h e mill
m i l l diameter.
diameter.
t h e feed
f e e d size
s i z e selection
s e l e c t i o n functions
f u n c t i o n s depend on

This
This

o b s e r v a t i o n is
i s in
i n accordance
accordance with
w i t h the
t h e findings
f i n d i n g s of
o f an
an earlier
e a r l i e r study
study
observation

by Malghan
Malghan and
and Fuerstenau(6).
Fuerstenau^.

However,
8
H
o w e v e r , it
i t ;s
i s noticed
n o t i c e d from Figures
Figures 8

and 9 that
t h a t in
i n the
t h e case
case of
o f 3D-inch
3 0 - i n c h mill
m i l l the
t h e feed
f e e d size
s i z e selection
s e l e c t i o n funcfunc
i n relation
r e l a t i o n to
t o any
any of
o f the
t h e two
t i o n s cannot
cannot satisfy
s a t i s f y equation
e q u a t i o n (11-12) in
two
tions
l a b o r a t o r y scale
s c a l e mills.
mills.
laboratory

T h e reason
r e a s o n which
w h i c h could
c o u l d be
p u t forward
f o r w a r d was
The
be put
was

t h a t the
t h e lifters
l i f t e r s of
o f the
t h e 3D-inch
3 0 - i n c h mill
m i l l were
w e r e rrounded
o u n d e d (Figure
( F i g u r e 2c) and
that
and
did n
o t lift
l i f t the
the b
alls h
i g h enough to
t o draw more energy
e n e r g y resulting
r e s u l t i n g in
in
did
not
balls
high
s l o w e r grinding.
grinding.
slower

T h e effect
e f f e c t of
o f lifter
l i f t e r configuration
c o n f i g u r a t i o n of
o f the
t h e mills,
mills,
The

h e breakage
and selection
s e l e c t i o n functions
f u n c t i o n s is
i s discussed
d i s c u s s e d later.
later.
on tthe
breakage and

Writing
W r i t i n g the
t h e first-order
f i r s t - o r d e r disappearance
d i s a p p e a r a n c e kkinetic
i n e t i c equation
e q u a t i o n ffor
or
the
normalized
the n
o r m a l i z e d model (equation
( e q u a t i o n (11-8)),
( I I - 8 ) ) , the
t h e following
f o l l o w i n g expression
e x p r e s s i o n is
is
obtained:
obtained:

(IV-2)
(IV-2)

m ^ E ) = m ^ O ) e x p [ - S ^ E]

It
r e d i c t s that
t h a t the
t h e kinetics
k i n e t i c s of
o f breakage
breakage for
f o r tthe
h e top
t o p size
size
I t ppredicts
interval
be nnormalized
with
can be
ormalized w
i t h respect
r e s p e c t to
t o the
t h e specific
s p e c i f i c energy
e n e r g y input
input
i n t e r v a l can
he m
ill.
t o tthe
to
mill.

T h e appropriateness
a p p r o p r i a t e n e s s of
o f this
t h i s normalized
n o r m a l i z e d relationship
relationship
The

in F
i g u r e s 13 and
and 14 for
f o r the
t h e dry
d r y and
and wet
w e t systems,
systems,
i s illustrated
i l l u s t r a t e d in
is
Figures
respectively.
respectively.

I t is
i s shown that
t h a t all
a l l tthe
h e kinetic
k i n e t i c data
d a t a from tthe
h e three
three
It

o a single
s i n g l e line
l i n e when grinding
g r i n d i n g ttime
i m e is
i s replaced
r e p l a c e d by
he
m i l l s reduce tto
mills
by tthe
s p e c i f i c energy
e n e r g y input.
input.
specific

F o r the
t h e dry
d r y grinding
g r i n d i n g system
s y s t e m tthe
h e rresults
e s u l t s aare
re
For

consistent w
i t h Malghan
M a l g h a ns(6,7)
' s ^ ' ^ findings.
findings.
consistent
with
1

Malghan
has demonstrated
demonstrated
Malghan has

( m i l l speed,
s p e e d , ball
ball
the same rresults
esults w
i t h various
v a r i o u s operating
o p e r a t i n g variables
v a r i a b l e s (mill
the
with
l o a d , ball
b a l l size
s i z e and
and lifter
l i f t e r configuration,
c o n f i g u r a t i o n , mill
m i l l diameter).
diameter).
load,
(o\

F o r tthe
he
For

wet
has ddescribed
phenomena with
wet system
s y s t e m Kim(8)
Kinr
has
e s c r i b e d tthe
h e nnormalizability
o r m a l i z a b i 1 i t y phenomena
with
;

32
32
v a r i o u s operating
o p e r a t i n g variables
v a r i a b l e s (mill
( m i l l speed,
speed, b
a l l load,
load, p
a r t i c l e load,
load,
various
ball
particle
p e r c e n t solids)
s o l i d s ) but
b u t only
o n l y in
i n la-inch
1 0 - i n c h diameter
d i a m e t e r batch
mill.
batch mill.
percent

Comparison of
o f the
the specific
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s for
f o r dry
d r y and
wet grinding
g r i n d i n g under the
the same operating
o p e r a t i n g conditions
c o n d i t i o n s in
i n the
the lD-inch
10-inch
wet

mill
m i l l show a slightly
s l i g h t l y smaller
s m a l l e r value
v a l u e of
o f s~ for
f o r dry
d r y grinding
g r i n d i n g than
than for
for
wet grinding.
grinding.
wet

T h i s may be due tto


o the
the ppreferential
r e f e r e n t i a l grinding
g r i n d i n g in
i n the
the
This

wet system
s y s t e m in
in w
h i c h tthe
h e probability
p r o b a b i l i t y of
o f breakage
o f coarse
c o a r s e particles
particles
wet
which
breakage of
is h
i g h e r rresulting
e s u l t i n g in
i n higher
h i g h e r rrate
a t e of
o f breakage
breakage (Sl)
(S-|) of
o f material
m a t e r i a l in
in
is
higher

the
the top
t o p size
s i z e intervals.
intervals.

The energy
wet system
e n e r g y drawn by tthe
h e wet
s y s t e m is
i s slightslight

l y higher
h i g h e r than the
t h e dry
d r y system
s y s t e m (Appendix
( A p p e n d i x II),
II), b
u t is
i s insufficient
i n s u f f i c i e n t to
to
ly
but

drop
d r o p the
t h e numerical
n u m e r i c a l vvalue
a l u e of
o f the
the specific
s p e c i f i c selection
s e l e c t i o n function
f u n c t i o n values
values
l f o r dry
wet system.
of
o f wet
s y s t e m . The
T h e value
v a l u e of
o f S~ was 1.438
1.438 (KWH/Tf
(KWH/T)"^ for
d r y grinding
grinding
and 1.714
wet grinding
1.714 (KWH/T)-l
( K W H / T ) " for
f o r wet
g r i n d i n g (Table
( T a b l e 11-3,
1 1 - 3 , Appendix
A p p e n d i x II).
II).
1

f e e d size
s i z e cumulative
c u m u l a t i v e breakage
breakage functions
f u n c t i o n s Bil can be computed
The feed

from tthe
h e relationshiP(17):
relationship^ ^:
7

(IV-3)
(IV-3)

- ^

where Sl
S-j is
i s the
t h e feed
f e e d size
s i z e selection
s e l e c t i o n function
f u n c t i o n determined
d e t e r m i n e d from
f r o m a feed
feed
d i s a p p e a r a n c e pplot
l o t and Fi is
i s the
the initial
i n i t i a l slope
s l o p e of
o f tthe
h e fines
f i n e s producproduc
disappearance
t i o n plot
p l o t for
for m
a t e r i a l finer
f i n e r than
s i z e Xi (Figure
( F i g u r e 10).
10).
tion
material
than size

F i g u r e s 11
11
Figures

and 12
breakage functions
12 show plots
p l o t s of
o f feed
f e e d size
s i z e cumulative
c u m u l a t i v e breakage
f u n c t i o n s vversus
ersus
particle
wet systems
p a r t i c l e size
s i z e in
i n dry
d r y and wet
s y s t e m s rrespectively,
e s p e c t i v e l y , for
f o r the
t h e three
three
di
d i ffferent
f e r e n t mi
m i 11
l l ss..

It
I t is
i s found
f o u n d that
t h a t tto
o a good approximati
a p p r o x i m a t i oon
n the
the

breakage functions
f u n c t i o n s are
a r e tthe
h e same in
i n the
h r e e mills.
mills.
breakage
the tthree

The lifters
not
l i f t e r s in
i n the
the 3D-inch
3 0 - i n c h mill
m i l l were n
o t geometrically
g e o m e t r i c a l l y identical
identical
t o the
t h e ones in
i n the
the la-inch
1 0 - i n c h and 15-inch
1 5 - i n c h mills.
mills.
to

T h e r e f o r e , it
i t was
Therefore,

33

0.3 ~----------------------------------------~
0.3

a::
w

0.2

z
0

a::

>
~

0.1

...J

:::>
~

:::>

oo
------~------~------~------~------------~
2
33
0
1
2
GRIND

Figure
F i g u r e 10.
10.

TIME
T
I M E ,t MINUTES
MINUTES

A
production
A sample of
o f fines
fines p
r o d u c t i o n plots
p l o t s for
f o r arbitrary
arbitrary
chosen size
s i z e intervals.
intervals.

CL

(/)

01

J -h
J" O-s
to
Q-s
II *<
o to
-s
_l.
13
D_
~ T

14

1000

2000

MEAN VALUES
RANGE OF VALUES

28

500

_L.

MESH SIZE

-+>

200

rt

100

cr
Z3
n

SIZE, MICRONS
j
O

CO
N
m

o-j.
C/l

50

(O
CO

PARTICLE
13
O.
cr
OJ -s
o CO
1 Q>
7T

d size breakage functions for dr~ grindi~g in 10-in.,


in. and 30-in. diameter mills (N =0.6, MB=0.5).
II to
O

m
CO
X

AGE FUNCTION FOR


d 30 INCH MILLS
TCH DRY

_i.
N

-J.

3rc>

r+
rD
-s
3

VI

MESH SIZE
MESH
8
200
100
40
28
400
200
4
0
28
14
1.0 ....----~--T---T__-___,r__-.....,.--_r--""r'.,

(!)

<{

0.5

<{

w
ex:

BREAKAGE FUNCTION FOR


10,15 and 30 INCH MILLS
BATCH WET

en

0.05

MEAN VALUE
RANGE OF VALUES

en

LL

0.02~----2~0-------50~----10~0-----20~0------5~0~0----10~O~O----2~O~0-O~
20

50

100

200

500

1000

2000

PARTICLE
P A R T I C L E SIZE,
S I Z E , MICRONS
MICRONS

Figure
F i g u r e 12.

Feed size
s i z e breakage
breakage functions
f u n c t i o n s for
f o r wet
w e t ~rinding*in
g r i n d i n g ^ i n 10-in.,
10-in.,
and 30;in.
3 0 - i n . diameter
d i a m e t e r mills.
mills.
(N =0.6,
= 0 . 6 , MB=O.S,
M = 0 . 5 , ffor
or
1 5 - i n . and
lS-in.
(N
3 0 - i n . mill
m i l l ~1B=0.4,
M = 0 . 4 , F=0.6).
F=0.6).
30-in.
R

36
36

1.0 fIf

~O
~ R,

f-

'0

0.5

(!)
o

2
z
z
Z

<!
<

r-

"0

lLJ
LU
.0::
(T

0.2

LU
W
N
en
CO

~N

I:)
Q
W
LU
W
Ld
IJ...
Lu

O.
0.1I

0""6

i~

U.
l..L.

0O

I-

2
Z
0O
hIu
o
<t
0::
01
l..L.
Lu

I-

0.0510.05

<

en
CO
en
CO

f-

BATCH
DRY
BATCH DRY
o
o
oO
/).
A

lOin.
10 in. mill
15 in. mill
3Oin.mill
30in.mill

<t

<

~
2

0.02

f-

________________


0.01

o
0

~'

______I ______' ______


i ____

1.6
2.0
2:42A
1.6
ENERGY INPUT,
INPUT,E
E (KWH/T)
(KWH/T)
SPECIFIC ENERGY

FFigure
i g u r e 13.

0.4

0.8

1.2
1.2

2.8

Normalized
N
o r m a l i z e d feed
f e e d ssize
i z e disappearance
d i s a p p e a r a n c e pplot
l o t for
f o r ddry
ry
g r i n d i n g ^ i n 1lO-i~.,
0 - i n . . , lS-in.
1 5 - i n . and
and 30-in.
3 0 - i n . diameter
diameter
grinding*in
=0.6,
M =0.5).
mills
(N =
0.6, M
=0.5).
m i l l s (N
B
B

37
37

1.0
1.0

\~

.(.!)
CD

\\
; \

z'
Z

<
::

0.5
0.5

lJ.J
UJ

0:::
tr

ss

lJ.J
UJ
N
N

en

if)
0
Q
lJ.J
UJ
W
UJ
u..
Lu

0.2
0.2

\b.0
VO

u..
Li_

0O

0.1

0O

r()

o
0:::
<
u..
Ll.

0.05

<

BATCH W
WET
ET
o
in. mill
mill
o 10
10 in.

en
en
<{
~
2

D.02
).02
0
"0

oO 15
mill
15 in.
in.mill
t::.
n. mill
A 30
30 iin.mill

0.4
0.4

i
0.8
0.8

cA

1.6
2.0
2:4
1.6
2.0
2.4
SPECIFIC ENERGY INPUT
INPUT,t E
E (KWH
( K W HIT)
/T)
1.2
1.2

2.8
2.8

Figure
F i g u r e 14.
14. Normalized
N o r m a l i z e d feed
f e e d size
s i z e disappearance
d i s a p p e a r a n c e piot
p l o t for
f o r wet
grinding
g r i n d i n g in
i n 10-in.,
1 0 - i n . , l5-in.
1 5 - i n . and*30-;n.
a n d * 3 0 - i n . ~iameter
(Jiameter
mi11s,
ng nonl;
5
(N =0.6,
= 0 . 6 , MB=O.
M =0.5
m i l l s , showi
showing
n o n l i nea
n e arity
r i t y (N
for
f o r 30-in.
3 0 - i n . mill
m i l l M;=O.4,
M = 0 . 4 , F=0.6).
F=0.6).
R

at
CD...

ru
z
=>
u..
w

1.0.--------------------------...
BREAKAGE FUNCT~N FOR
DIFFERENT LIFTER CONFIGURATIONS
10-INCH MILL
BATCH DRY

0.5

(!)

<l:

<l:
W

a::

at

0.2

>

:5

0.1

:E

u=>

~ 0.05

MEAN VALUES
RANGE OF VALUES

en
Cl
Q

W
LU
LU
W

u..
^

0.02~----~------~----~----~----~~--~~--~~~
0.02
1
1
1
"
1
J
1

10
10

20
20

50
50

PARTICLE
PARTICLE

Figure
F i g u r e 15.
15.

100
100

200
200

500
500

1000
1000

2000
2000

SIZE,
S I Z E . MICRONS
MICRONS

Feed size
s i z e breakage
breakage functions
f u n c t i o n s for
f o r dry
d r y grinding
g r i n d i n g in
i n 10-in.
10-in.
diameter
with
d i a m e t e r mill
mill w
i j h squar~,ramp
s q u a r , r a m p and without
w i t h o u t lifters
lifters
c o n f i g u r a t i o n (N =0.6,
=0.6, M
Mg=0.5).
configuration
B=0.5).

oo

m
00.

Z
o

1.0

.--------------------"1'-----,

z
(2
w
(!)

0.5
0.5

a::

0.2
0.2

w
m

BREAKAGE
FUNCTION FOR
FOR
BREAKAGE FUNCTION
DIFFERENT
D
I F F E R E N T LL1FTE
I F T E RR CONFIGURATIONS
CONFIGURATIONS
10-INCH MILL
10-INCH
BATCH W
WET
ET

>

ti

-.I

0.1

:J

:2:

:J

u 0.05
0.05

MEAN
MEAN VALUES
RANGE
RANGE OF
OF VALUES
VALUES

en
oQ

W 0.02
0.02
~
10

20

1
50

100

200

500
500

1000

2000

PARTICLE
P A R T I C L E SIZE,
S I Z E , MICRONS
MICRONS

Figure
F i g u r e 16.

Feed size
s i z e breakage functions
f u n c t i o n s for
f o r wet
w e t grinding
g r i n d i n g in
i n 10-in.
10-in.
di~meter
d i a m e t e r mill
mj.ll with
w i t h square
square and
and ramp lifters
l i f t e r s configuration
configuration
(N =0.6,
=0.6, M
M =O.5,
= 0 . 5 , F=O.6).
F=0.6).

B
R

40
40

decided
perfonn
the effect
e f f e c t of
o f lifter
lifter
d e c i d e d tto
o p
e r f o r m experiments
e x p e r i m e n t s tto
o detennine
d e t e r m i n e the
configuration
c o n f i g u r a t i o n on the
t h e breakage
breakage and selection
s e l e c t i o n ffunctions.
unctions.

In the
the

lO-inch
were
with
1 0 - i n c h diameter
d i a m e t e r mill,
m i l l , experiments
experiments w
e r e performed
performed w
i t h square
s q u a r e lifters,
lifters,
l i f t e r s and without
w i t h o u t lifters
l i f t e r s (Figure
( F i g u r e 2).
2).
ramp lifters

I t was found
f o u n d that
t h a t the
the
It

a p p r o x i m a t i o n independent
i n d e p e n d e n t of
o f lifter
lifter
breakage functions
f u n c t i o n s were
w e r e to a good approximation
breakage
c o n f i g u r a t i o n in
i n dry
d r y and wet
w e t systems.
systems.
configuration

F
i g u r e s 15
15 and 16
16 illustrate
illustrate
Figures

the range ooff variance


v a r i a n c e of
o f feed
f e e d size
s i z e cumulative
c u m u l a t i v e breakage
functions
the
breakage functions
d i f f e r e n t lifter
l i f t e r configurations
c o n f i g u r a t i o n s for
f o r dry
d r y and w
e t grinding
grinding
w i t h different
with
wet
respectively.
respectively.

T h e s e rresults
e s u l t s supported
s u p p o r t e d the
t h e rresults
e s u l t s already
a l r e a d y demon
These
demon-

t h a t the
the
s t r a t e d in
i n Figures
F i g u r e s 11 and 12 for
f o r the
t h e simulation
s i m u l a t i o n purposes
p u r p o s e s that
strated
a p p r o x i m a t i o n independent
i n d e p e n d e n t of
o f mill
mill
breakage functions
f u n c t i o n s are
a r e to
t o a good approximation
breakage
d i aameter.
meter.
di

Figure
F i g u r e 17
17 illustrates
i l l u s t r a t e s the
t h e specific
s p e c i f i c power correlation
c o r r e l a t i o n for
f o r selecselec
tion
lifter
t i o n functions
f u n c t i o n s nonnalizibility
n o r m a l i z i b i 1 i t y is
i s valid
v a l i d and independent
i n d e p e n d e n t of
o f the
the lifter
c o n f i g u r a t i o n and that
t h a t tthe
h e kkinetics
i n e t i c s of
o f breakage
f o r the
t h e top size
size
configuration
breakage for
i n t e r v a l are
a r e normalized
normalized w
i t h rrespect
e s p e c t to the
the specific
s p e c i f i c energy
e n e r g y input
input
interval
with
t o the
the mill.
mill.
to

The results
presented
results p
r e s e n t e d so far
f a r have demonstrated
d e m o n s t r a t e d that
t h a t tthe
h e breakage
breakage
f u n c t i o n s and the
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s are
a r e independent
i n d e p e n d e n t of
of
functions
the specific
m i l l diameter,
diameter, b
a l l load,
l o a d , and lifter
l i f t e r configuration.
configuration.
mill
ball

T h e s e results
results
These

s u g g e s t that
t h a t a scale-up
s c a l e - u p scheme based on the
t h e specific
s p e c i f i c energy
e n e r g y input
input
suggest
i l l would
w o u l d be a useful
u s e f u l criterion
c r i t e r i o n for
f o r predictive
p r e d i c t i v e simulation
simulation
t o tthe
he m
to
mill
o b t a i n e d from the
the laboratory
l a b o r a t o r y scale
scale
i n the
t h e larger
larger m
i l l s from tthe
h e data obtained
in
mills
mill.
l11ill.

In
o r d e r to
t o further
f u r t h e r confinn
c o n f i r m this
t h i s hypothesis
h y p o t h e s i s tthe
h e predictive
predictive
In order

c a p a b i l i t y of
o f the
the linear
linear n
o r m a l i z e d model (equation
( e q u a t i o n II-8)
I 1 - 8 ) should
s h o u l d be
normalized
capabi1ity
d i f f e r e n t mill
m i l l sizes
s i z e s in
i n dry
d r y and wet
wet systems.
systems.
t e s t e d for
f o r different
tested

In the
the
In

wet
wet system
s y s t e m in
i n which
w h i c h inherent
i n h e r e n t nonlinearity
n o n l i n e a r i t y exists
e x i s t s the
the linear
l i n e a r model has

41

1.0 ...- - - - - - - - - - - - - - - - - - -....


c.!)

10-INCH MILL
BATCH DRY and WET
lOx 14 MESH FEED

.Z

<t

.:E

0.5

0::

W
N

en

.0

0.2

W
,l1..
lJ..

0.1

I-

'0::
lJ..

~
<t

0.05
square lifters r--. 0 ramp lifters
D. without lifters - - - - 0

-----==-----

0.4

0.8

SPECIFIC

Figure
F i g u r e 17.
17.

1.2

ENERGY
ENERGY

I. 6

2.0

2.4

2.8

INPUT, E
E (KWH/T)
(KWH/T)

Normalized
disappearance
N
o r m a l i z e d feed size
size d
i s a p p e a r a n c e pplot
l o t for
for
wet grinding
ddry
r y and wet
g r i n d i n g in
i n 10-in.
1 0 - i n . diameter
d i a m e t e r mill
mill
wit~out
with
w
i t h square,
s q u a r e , ramp *and
^and w
i t h o u t lifters
lifters
M =0.5,
= 0 . 5 , F=0.6).
F=0.6).
configuration.
= 0 . 6 , :v1
configuration.
(N =0.6,
B
n

42

its
i t s limitations
l i m i t a t i o n s and should
s h o u l d be applied
a p p l i e d over
o v e r nnarrow
a r r o w ranges of
o f specific
specific
energy
the kkinetics
e n e r g y input
i n p u t where the
i n e t i c s would
w o u l d be linearly
" n e a r l y linearll.
linear .
1 1

The
nonThe n
on-

l i n e a r i t y phenomena is
i s bbriefly
r i e f l y discussed
d i s c u s s e d below.
below.
linearity

Unlike
U n l i k e dry
d r y grinding,
g r i n d i n g , wet
w e t grinding
g r i n d i n g is
i s inherently
i n h e r e n t l y nonlinear.
nonlinear.

The

spatial
material
plays
s p a t i a l distribution
d i s t r i b u t i o n of
of m
a t e r i a l in
i n tthe
h e mill
mill p
l a y s an important
i m p o r t a n t role.
role.
A p p a r e n t l y iin
n w
e t grinding
g r i n d i n g system
s y s t e m the
t h e fine
fine p
a r t i c l e s ttend
e n d tto
o suspend
Apparently
wet
particles
ball
i n the
t h e water
w a t e r while
w h i l e the
coarse p
a r t i c l e s are
a r e settled
s e t t l e d in
i n the
in
the coarse
particles
the ball
e s u l t i n g in
i n an increased
increased p
r o b a b i l i t y of
o f breakage
breakage of
o f the
coarse
mass rresulting
probability
the coarse

particles(4,8).
particles^'^.

This
phenomenon is
T h i s phenomenon
i s termed as "IIpreferential
p r e f e r e n t i a l breakage".
breakage".

t h e grind
g r i n d is
i s extended
e x t e n d e d more and more fine
f i n e particles
p a r t i c l e s are
are produced
produced
As the
r a t e of
o f breakage
breakage of
o f coarse
coarse p
a r t i c l e s while
while
r e s u l t i n g in
i n the
the increased
i n c r e a s e d rate
resulting
particles
r a t e of
o f breakage
breakage of
o f fine
f i n e pparticles
a r t i c l e s decreases.
decreases.
the rate
the

I t demonstrates
demonstrates
It

t h a t the
the selection
s e l e c t i o n function/specific
f u n c t i o n / s p e c i f i c selection
s e l e c t i o n function
f u n c t i o n strongly
strongly
that
the size
s i z e distribution
d i s t r i b u t i o n in
i n the
the m
ill.
depend upon the
mill.

T h i s effect
e f f e c t of
of
This

n o n l i n e a r i t y is
i s illustrated
i l l u s t r a t e d in
i n Figure
F i g u r e 18.
18.
nonlinearity

The linear
not
l i n e a r model in
i n its
i t s general
g e n e r a l form is
is n
o t valid
v a l i d for
f o r simulasimula
system.
t i o n of
o f nonlinear
n o n l i n e a r wet
w e t system.
tion

But
s i m u l a t i o n s with
w i t h estimates
e s t i m a t e s from
from
But simulations

1 0 - i n c h mill
m i l l for
f o r similar
s i m i l a r fineness
f i n e n e s s of
o f grind
g r i n d are
are in
i n good agreement
agreement with
with
lO-inch
e x p e r i m e n t a l product
p r o d u c t size
s i z e distributions.
distributions.
experimental
i s discussed
d i s c u s s e d in
i n Chapter
C h a p t e r V.
V.
approach is

T h e rationale
r a t i o n a l e for
f o r this
this
The

10.0.-------------------..,....---------,
5.0

/
/

10-INCH
10-INCH MILL
BATCH W
WET
ET
IOxl4 MESH aand
n d --10
I O MMESH
E S H FEED
FEED
10x14

en

o
LL

2.0

./

//
./

./ / / '

if ;/

;:
/' /; ; ; ;

0.5

-I

en

en

//

/ .// / . /

1.0

u
iL
u
w
a..

./

z
o
t-

)/ /

;'

tu

z
=>

/'/

1LI._

/'
/ /

-
-

/'

0.2
/

//' /-,7

/. /

lOx
10 x 14 Mesh Feed, Estimates Between
-min. grinds
Feedd and 4.0
4.0mln.
grinds
- Fee
mln. and 6.0
6.0 min.
mln. grinds
- - - - 4.0 min.

F e e d ,I Estimates Between
0 Mesh Feed
- 110
Feed
and 0.5
0.5 min.
mln. grinds
-- 0.5mln. and 2.0
2.0 min.
mln. grinds
-
0.5min.
-- 4.0min.
4.0mln. and 6.0
6.0 min.
mia grinds

0.1 ~--~------~~~~--~------~--~----~------~--~
10
20
50
100
200
500
1000
2000
5000
20
50
100
200
500

GEOMETRIC
GEOMETRIC

Figure
F i g u r e 18.

MEAN

PARTICLE
P A R T I C L E SIZE,
S I Z E , MICRONS
MICRONS

Dependence of
o f srecific
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s on
on the particle
p a r t i c l e size
size
i n the
t h e ball
b a l l mill,
m i l l , for
f o r lOx14
10x14 mesh feed
f e e d and
and -10
-10 mesh
d i s t r i b u t i o n in
distribution
feed
i n the wet
w e t grinding,
g r i n d i n g , showing pronounced nonlinearity.
nonlinearity.
f e e d in

CHAPTER VV
SCALE-UP PREDICTIONS
PREDICTIONS
In this
parameter
t h i s chapter
c h a p t e r the
the p
a r a m e t e r estimation
e s t i m a t i o n procedure
p r o c e d u r e used for
for
predictive
p r e d i c t i v e simulation
s i m u l a t i o n is
i s outlined
o u t l i n e d and the
t h e application
a p p l i c a t i o n of
o f the
the normalized
normalized
l i n e a r model (equation
( e q u a t i o n 11-8)
I 1 - 8 ) to
t o tthe
h e scale-up
s c a l e - u p ppredictions
r e d i c t i o n s is
i s ddiscussed.
iscussed.
linear
c r i t e r i o n for
f o r the
t h e correlation
c o r r e l a t i o n of
o f kinetic
k i n e t i c parameters,
p a r a m e t e r s , selection
selection
The criterion
r e a k a g e functions,
f u n c t i o n s , for
f o r scale-up
s c a l e - u p design
d e s i g n is
i s established.
established. A
A scheme
and bbreakage
to p
r e d i c t the
t h e behavior
b e h a v i o r of
o f grinding
g r i n d i n g in
i n tthe
h e larger
l a r g e r mills
m i l l s from
f r o m the
to
predict
the data
o b t a i n e d in
i n tthe
h e la-inch
1 0 - i n c h batch
i l l is
is p
r e s e n t e d for
f o r the
t h e dry
d r y and wet
wet
presented
obtained
batch m
mill
systems.
systems.

A c c u r a t e ppredictions
r e d i c t i o n s of
o f dry
d r y grinding
grinding b
e h a v i o r are
are achieved
achieved
Accurate
behavior

w i t h tthe
h e linearized
linearized m
odel.
model.
with

D i f f i c u l t i e s associated
a s s o c i a t e d with
w i t h the
the extenexten
Difficulties

s i o n of
o f the
t h e linear
l i n e a r model to
t o the
the p
r e d i c t i o n of
of w
e t system
s y s t e m behavior
behavior
prediction
wet
sion
f o r estimationestimationare discussed.
discussed. A
A ''similar
s i m i l a r fineness
f i n e n e s s of
o f grind
g r i n d approach'
a p p r o a c h for
are
1

o give
g i v e rise
r i s e to
t o good scalescaleprediction w
i t h the
the linear
l i n e a r model is
i s shown tto
prediction
with
r e d i c t i o n s in
i n the
t h e wet
system.
up ppredictions
wet system.

Parameter
P
a r a m e t e r Estimation
E s t i m a t i o n for
f o r Scale-up
Scale-up
For
F o r a complete
complete simulation
s i m u l a t i o n of
o f batch
batch and/or
a n d / o r open circuit
c i r c u i t grinding,
grinding,
parameters but
but also
not
n o t only
o n l y the
t h e feed
f e e d size
s i z e breakage
breakage parameters
a l s o those
t h o s e of
o f the
the
s m a l l e r size
s i z e fractions
f r a c t i o n s must be known.
smaller

e s t s are
are by far
f a r the
the
Batch ttests

s i m p l e s t ttype
y p e of
o f tests
t e s t s to
t o use to obtain
o b t a i n kinetic
k i n e t i c parameters
p a r a m e t e r s experiexperi
simplest
mentally.
mentally.

t e s t are
a r e easier
e a s i e r to
to
e s u l t s obtained
o b t a i n e d from a batch
The rresults
batch test

i n t e r p r e t quantitatively
q u a n t i t a t i v e l y because
t h e y do n
o t contain
c o n t a i n the
complica
interpret
because they
not
the complica-

tions
t i o n s of
o f rresidence
e s i d e n c e ttime(14,18).
ime^'^'.

methods for
Several
S e v e r a l methods
f o r estimating
e s t i m a t i n g the
the

45
45
selection
liters e l e c t i o n and breakage
breakage functions
f u n c t i o n s have been presented
p r e s e n t e d in
i n tthe
h e literature(8,12,14,15,17,18,2Q,24-26).
ature^
'
' ^.
8 , 1 2 , 1 4 , 1 5 , 1 7

1 8 , 2 0 , 2 4

2 6

A direct
A
d i r e c t measurement
measurement approach
approach to
to

estimation,
e s t i m a t i o n , similar
s i m i l a r to
t o that
t h a t described
d e s c r i b e d in
i n the
t h e last
l a s t section,
s e c t i o n , could
could
be used in
with
i n conjunction
conjunction w
i t h the
t h e grinding
g r i n d i n g of
o f a suite
s u i t e of
o f single
s i n g l e size
size
f r a c t i o n feeds
f e e d s or
o r by u
s i n g tracers.
tracers.
fraction
using
l a r g e experimental
e x p e r i m e n t a l effort.
effort.
large

T h i s approach involves
i n v o l v e s a very
very
This

I n s t e a d for
f o r this
t h i s thesis
t h e s i s an indirect
indirect
Instead

e s t i m a t i o n scheme has been used involving


involving n
o n l i n e a r rregression
e g r e s s i o n using
using
est"imation
nonlinear
i n i t i a l estimates
e s t i m a t e s obtained
o b t a i n e d by a method described
d e s c r i b e d by Herbst
H e r b s t and
initial
Fuerstenau^ '.
Fuerstenau(17).

T h i s indirect
i n d i r e c t approach was developed
developed w
i t h i n the
the
This
within

o f the
l i n e a r model (equation
( e q u a t i o n II-l)
II-l) w
h i c h was fonnulated
formulated
framework of
the linear
which
i n terms
o f a continuous
c o n t i n u o u s time
t i m e variable
v a r i a b l e and a discretized
d i s c r e t i z e d size
s i z e varivari
in
tenns of
able.
able.

E
s t i m a t e s obtained
o b t a i n e d by this
t h i s method minimize
m i n i m i z e the
the deviations
deviations
Estimates

p r e d i c t i o n s and experimentally
e x p e r i m e n t a l l y observed
o b s e r v e d size
s i z e distridistri
between model predictions

butions(4,6,7,8).
butions^ ^' ' '.
5

1.
1.

This
T h i s estimation
e s t i m a t i o n pprocedure
r o c e d u r e is
i s as follows:
follows:

Selection
S e l e c t i o n function:
function:

Feed size
s i z e selection
s e l e c t i o n function
f u n c t i o n can be

e v a l u a t e d by equation
e q u a t i o n IV-l.
IV-1.
evaluated

T h e remaining
r e m a i n i n g initial
i n i t i a l selecselec
The

t i o n functions
f u n c t i o n s estimates
e s t i m a t e s (Si'
( S . , i == 2,
2 , ..... ,n-1)
, n - l ) can be
tion

obtained
by an
o b t a i n e d by
an eexpression(l?):
xpression^ ':
7

i [

/ X l X i + 1

(v -1) )
(v1

where S1
S-j is
i s evaluated
e v a l u a t e d from equation
e q u a t i o n IV-l
IV-1 and a is
i s the disdis
tribution
the breakage
t r i b u t i o n modulus of
o f the
breakage function.+
function.^

+
^ The
The

For
F o r the
t h e dry
dry

distribution
d i s t r i b u t i o n modulus a is
i s obtained
o b t a i n e d by plotting
p l o t t i n g the feed
f e e d size
size
cumulative
particle
c u m u l a t i v e functions
functions B
B . . versus
versus p
a r t i c l e size
s i z e on a log-log
l o g - l o g plot.
plot.
in the
The slope
off tthe
slope o
h e pplot
l o t i,~
t h e fine
f i n e particle
p a r t i c l e size
s i z e range is
i s aa
(Figures
( F i g u r e s 11,
11, 12,
12, 15,
15, 16).
16).

46

and wet
wet grinding
the la-inch
g r i n d i n g the value
v a l u e of
o f a in
i n the
1 0 - i n c h mill
m i l l was
0.56.
0.56.

Therefore
T h e r e f o r e the
t h e specific
s p e c i f i c grinding
g r i n d i n g rate
r a t e function
function

dependence on pparticle
a r t i c l e size
s i z e can be approximated
a p p r o x i m a t e d by a
simple
s i m p l e power law,
l a w , obtained
o b t a i n e d by combining equations
e q u a t i o n s (11-12)
( V-1
- l) :
and (V

0.56
0.56
)

2.

Breakage function:
function:

(V-2)
(V-2)

The
T h e breakage
breakage function
f u n c t i o n estimation
e s t i m a t i o n is
is

based on the
the size-discretized
the fundamental assumption
a s s u m p t i o n that
t h a t the
size-discretized
breakage function
f u n c t i o n is
i s normalizable,
n o r m a l i z a b l e , i.e.,
i . e . (17)
,^^

8 ..
lJ

(V-3)
(V-3)

Bi-j+l,l
i-j+1,1

B . can be evaluated
e v a l u a t e d by a restrictive
r e s t r i c t i v e relationship
relationship
where Bij

between the
t h e breakage
breakage and selection
s e l e c t i o n functions:
functions:

B.. S.

= F.
i1

i1jJ JJ

(V-4)
< - >

where S.
S . is
i s obtained
o b t a i n e d by equation
e q u a t i o n (V-l)
( V - l ) and F. is
i s the initial
initial
J

slope
the fines
production
plots
s l o p e of
o f the
fines p
roduction p
l o t s (Figure
( F i g u r e 10).
10).
3.

Parameter improvement:
improvement: P
a r a m e t e r estimation
e s t i m a t i o n for
f o r a grinding
grinding
Parameter
Parameter
model involves
i n v o l v e s a large
l a r g e number of
o f adjustable
a d j u s t a b l e constants
constants
( f o r a 12 size
s i z e fraction
f r a c t i o n feed,
f e e d , 11 selection
s e l e c t i o n functions
f u n c t i o n s and
(for
breakage functions)
f u n c t i o n s ) which
w h i c h makes the
the estimation
e s t i m a t i o n problem
problem
65 breakage
difficult.
difficult.

i n e a r systems,
s y s t e m s , the
o f adjustable
adjustable
In llinear
the number of

parameters can be reduced by adopting


a d o p t i n g functional
f u n c t i o n a l forms for
for
parameters

47
(27)
the
t h e selection
s e l e c t i o n and
and bbreakage
r e a k a g e functions(27).
functions^

2c
S

= S

exp [ { ^ ( l n

X l

X i + 1

'
/x^x

)+ ^(ln ^l-Ll )
/x^x
2

(v
( V-5)
-5)

+
+ ..
. . . . }J]]

x,
B

ii

1 J

(x^-)
X

j+1

x.
+

O-*)

2
((V-6)
V-6)

( 7 ^ )

j+1

where Si
S . is
i s the
t h e selection
s e l e c t i o n function
f u n c t i o n and
and Bij
B . . is
i s the
t h e cumulative
cumulative
f o r the
t h e ith
i t h size
s i z e interval
i n t e r v a l and
and
breakage functions
f u n c t i o n s for
breakage

,
cj>, al
a-j and
and a2
a are
a r e adjustable
a d j u s t a b l e pparameters.
arameters.

^ , ~2'
? ,
~l'
2

In this
t h i s case the

number of
or'r
o f adjustable
a d j u s t a b l e parameters
parameters can
can be rreduced
e d u c e d tto
o five
five o
six
be estimated
s i x tthese
h e s e values
v a l u e s can
can be
e s t i m a t e d quite
q u i t e simply
s i m p l y from batch
batch
data
modified
d a t a uusing
sing a m
o d i f i e d Gauss Newton nonlinear
n o n l i n e a r regression
regression
(07)

program(27).

This linear est"imation approach can also be

program^

T h i s l i n e a r e s t i m a t i o n approach can a l s o be

'.

applied to nonlinear systems as special case for narrow


a p p l i e d t o n o n l i n e a r s y s t e m s as s p e c i a l

case f o r n a r r o w

ranges of values of specific energy input(8).


ranges o f v a l u e s o f s p e c i f i c e n e r g y i n p u t

Dry Grindin9
As discussed
d i s c u s s e d in
i n Chapter
C h a p t e r IV,
I V , grinding
g r i n d i n g kinetics
k i n e t i c s are
a r e said
s a i d to
t o be
linear
breakage pparameters
breakage
l i n e a r when breakage
a r a m e t e r s (selection
( s e l e c t i o n and
and b
r e a k a g e functions)
functions)
are
are environment
e n v i r o n m e n t independent.
independent.

IIn
n dry
d r y grinding
g r i n d i n g the
t h e selection
s e l e c t i o n and
and breakbreak

age functions
a r e independent
i n d e p e n d e n t of
o f grind
g r i n d time
t i m e and
and feed
f e e d size
s i z e distribudistribu
f u n c t i o n s are
tion.
tion.

Figure
F i g u r e 8 illustrates
i l l u s t r a t e s tthat
h a t in
i n all
a l l the
t h e three
t h r e e mills
m i l l s the
t h e feed
f e e d size
size

(S-j) is
i s independent
i n d e p e n d e n t of
o f the
t h e extent
e x t e n t of
o f grinding.
grinding.
s e l e c t i o n function
f u n c t i o n (Sl)
selection
t o estimate
e s t i m a t e the
t h e remaining
r e m a i n i n g Si vvalues
a l u e s tthe
h e 10 x
feed
o r d e r to
In order
x 14 mesh feed

48
data
times (0.5,
d a t a obtained
o b t a i n e d for
f o r tthe
h e first
f i r s t four
f o u r grind
g r i n d times
( 0 . 5 , 1.0,
1 . 0 , 2.0,
2 . 0 , 4.0
4.0
minutes)
m i n u t e s ) in
i n tthe
h e 10-inch
1 0 - i n c h diameter
d i a m e t e r mill
m i l l were used to
t o obtain
o b t a i n initial
initial
estimates
e s t i m a t e s of
o f the
t h e breakage
breakage pparameters.
arameters.

These
T h e s e parameters
parameters vvalues
a l u e s were

then improved
by the
and (V-6)
i m p r o v e d by
t h e functional
f u n c t i o n a l forms (equations
( e q u a t i o n s (V-5)
( V - 5 ) and
( V - 6 ) desdes
c r i b e d earlier.
earlier.
cribed

As
i l l u s t r a t e d in
i n Figures
F i g u r e s 13 and
and 17, ffor
or
As has
has been illustrated

the dry
d r y system
s y s t e m the
t h e specific
s p e c i f i c selection
s e l e c t i o n function
f u n c t i o n is
i s independent
i n d e p e n d e n t of
o f mill
mill
the
d i a m e t e r , size
s i z e distribution
d i s t r i b u t i o n in
i n the
the m
i l l and
and lifter
l i f t e r configuration.
configuration.
mill
diameter,
s e t of
o f selection
s e l e c t i o n functions
f u n c t i o n s obtained
o b t a i n e d was
was then transformed
t r a n s f o r m e d tto
o tthe
he
The set
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s by
by dividing
d i v i d i n g by
t h e specific
s p e c i f i c power input
input
specific
by the
(P/H) according
a c c o r d i n g to
t o equation
e q u a t i o n (11-5).
(11-5).
(P/H)

T h e specific
s p e c i f i c power input
i n p u t (P/H),
(P/H),
The

v a l u e s for
f o r the
t h e tthree
h r e e different
different m
i l l s are
a r e tabulated
t a b u l a t e d in
i n Table
T a b l e (11-1),
(II-l),
values
mills
A p p e n d i x II.
II.
Appendix

T h e specific
s p e c i f i c sselection
e l e c t i o n functions
f u n c t i o n s and
and the
t h e corresponding
corresponding
The

breakage functions
f u n c t i o n s are
a r e tabulated
t a b u l a t e d in
i n Table
T a b l e (11-3),
(I1-3), A
p p e n d i x II.
II.
Appendix
breakage

These
Tnese

v a l u e s of
o f tthe
h e kinetic
k i n e t i c parameters
w e r e used in
i n conjunction
conjunction w
i t h equaequa
values
parameters were
with
t i o n (11-8)
( I 1 - 8 ) tosimulate
t o s i m u l a t e the
t h e grinding
g r i n d i n g bbehavior
e h a v i o r in
i n the
t h e l5-inch
1 5 - i n c h and
and 3D-inch
30-inch
tion
d i a m e t e r mills
m i l l s uusing
sing m
o n o - s i z e (10 x 14 mesh) and
and 'natural'
' n a t u r a l ' (-10
(-10 mesh)
diameter
mono-size
feeds.
feeds.
Wet G
Gri
r i nndi
d i nn9
g,

In contrast
c o n t r a s t to
t o dry
d r y grinding,
g r i n d i n g , wet
w e t grinding
g r i n d i n g is
i s inherently
i n h e r e n t l y nonnon
linear.
linear.

As
As discussed
d i s c u s s e d previously,
p r e v i o u s l y , the
t h e nonlinearity
n o n l i n e a r i t y appears to
t o occur
occur

as a rresult
breakage'
e s u l t of
o f the
t h e 'preferential
'preferential b
r e a k a g e ' of
o f coarse
c o a r s e pparticles
a r t i c l e s which
which
are
are classified
c l a s s i f i e d due
due to
t o the
t h e suspension
s u s p e n s i o n of
o f finer
f i n e r pparticles
a r t i c l e s in
i n the
t h e fluid
fluid
(water
( w a t e r in
i n this
t h i s case)
case) and
and settling
s e t t l i n g of
o f coarse
c o a r s e particles
p a r t i c l e s in
i n the
t h e ball
ball
mass.

Thi
phenomenon rresulting
T h i ss phenomenon
e s u l t i n g in
i n an
an increased
i n c r e a s e d probabil
p r o b a b i l ity
i t y of
o f breakbreak

age of
particles
probabi1ity
o f coarse
coarse p
a r t i c l e s and
and decreased
decreased p
r o b a b i l i t y of
o f breakage
breakage of
o f fine
fine
particles.
particles.

This
T h i s environment
e n v i r o n m e n t dependence is
i s reflected
r e f l e c t e d in
i n the
t h e selection
selection

49

functions.
functions.

The
which
T h e nonlinearity
n o n l i n e a r i t y is
i s iillustrated
l l u s t r a t e d in
i n Figure
F i g u r e 9 in
in w
h i c h it
it

is
with
i s observed
o b s e r v e d that
that w
i t h a 10 x 14 mesh ffeed
e e d the
t h e nonlinearity
n o n l i n e a r i t y occurs
occurs
when the
t h e fraction
f r a c t i o n of
o f feed
f e e d rremaining
e m a i n i n g is
i s below 0.1 after
a f t e r about
about 4.0
minutes
mill.
m i n u t e s of
o f grinding
g r i n d i n g in
i n tthe
h e 10-inch
10-inch m
ill.

This
T h i s effect
e f f e c t is
i s shown even

d r a m a t i c a l l y in
i n Figure
F i g u r e 18 which
w h i c h shows specific
s p e c i f i c selection
s e l e c t i o n funcfunc
more dramatically
f o r various
v a r i o u s fineness
f i n e n e s s of
o f grind
g r i n d in
i n the
the w
e t 10-inch
1 0 - i n c h mill.
mill.
t i o n s estimated
e s t i m a t e d for
tions
wet
h e fineness
f i n e n e s s of
o f the
the p
r o d u c t in
i n the
t h e mill
m i l l increases
i n c r e a s e s the
t h e ttop
o p size
size
As tthe
product
and the
t h e fine
f i n e size
s i z e specific
s p e c i f i c selsel
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s increase
i n c r e a s e and
specific
e c t i o n functions
f u n c t i o n s decrease.
decrease.
ection

The specific
product
s p e c i f i c selection
s e l e c t i o n function
f u n c t i o n dependence on
on p
r o d u c t fineness
fineness
depicted
Figure
in F
i g u r e 18 was
was obtained
o b t a i n e d iin
n tthe
h e following
f o l l o w i n g way
way using
u s i n g tthe
he
d e p i c t e d in
l i n e a r model.
model.
linear

T h e initial
i n i t i a l estimates
e s t i m a t e s of
o f breakage
a r a m e t e r s were
The
breakage pparameters

h e first
f i r s t four
f o u r grind
g r i n d times
( 0 . 5 , 1.0,
1 . 0 , 2.0,
2 . 0 , 4.0 minutes),
minutes),
o b t a i n e d from
f r o m tthe
obtained
times (0.5,
w h i c h constitute
c o n s t i t u t e the
t h e coarse
c o a r s e grind
g r i n d or
o r 'nearly
' n e a r l y linear'
l i n e a r ' rregion
e g i o n in
i n tthe
he
which
wet gri
g r i nnding
d i n g system.
system.
wet

T h e parameters
i m p r o v e d by
b y tthe
h e functi
f u n c t i oona
n a1
l
The
parameters were improved

d e s c r i b e d earlier.
earlier.
forms described

F o r the
t h e wet
w e t grinding
g r i n d i n g system
s y s t e m it
i t was
was assumed
For

t h a t all
a l l of
o f the
t h e specific
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s are
a r e independent
i n d e p e n d e n t of
o f mill
mill
that
a l l load
l o a d and
and lifter
l i f t e r configuration
c o n f i g u r a t i o n (Figures
( F i g u r e s 14 and
and 17).
17).
diameter, b
diameter,
ball

TThe
he

breakage functions
f u n c t i o n s and
and the
t h e specific
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s obtained
o b t a i n e d aare
re
breakage
t a b u l a t e d in
i n Table
T a b l e (11-3),
( I I - 3 ) , Appendix
A p p e n d i x II
I I and
and the
t h e corresponding
c o r r e s p o n d i n g specific
specific
tabulated
( P / H , KW/T)
KW/T) and
and energy
e n e r g y (Pt/H,
( P t / H , KWH/T)
a l u e s are
a r e tabulated
t a b u l a t e d in
in
power (P/H,
KWH/T) vvalues
T a b l e (11-2),
(II-2), A
p p e n d i x III.
I.
Table
Appendix

P r e d i c t i o n s for
f o r tthe
h e 15 and
and 30-inch
3 0 - i n c h mills
mills
Predictions

w h i c h are
a r e based
on the
t h e estimates
e s t i m a t e s obtained
o b t a i n e d for
f o r the
t h e rregion
e g i o n where tthe
he
which
based on
breakage kinetics
k i n e t i c s are
a r e 'nearly
' n e a r l y llinear',
i n e a r ' , are
a r e referred
r e f e r r e d to
t o as
as Method
Method I
breakage
p r e d i c t i o n s in
i n the
t h e discussion
d i s c u s s i o n which
w h i c h follows.
follows.
predictions
i t has
has been established
e s t a b l i s h e d that
t h a t the
t h e kkinetics
i n e t i c s of
o f breakage
breakage aare
re
S i n c e it
Since

wet
highly
h i g h l y nonlinear
n o n l i n e a r for
f o r extended
extended w
e t grinding
g r i n d i n g it
i t was
was anticipated
a n t i c i p a t e d that
that

50

method II ppredictions
may be
be inappropriate
r e d i c t i o n s may
i n a p p r o p r i a t e for
f o r fine
f i n e grinding.
grinding.
an al
termed
a l tternati
e r n a t i vve
e set
s e t of
o f parameter
p a r a m e t e r estimates
e s t i m a t e s termed

r~ethod
Method

Thus

II II estimates
estimates

were also
mill
wet
a l s o obtained
o b t a i n e d from the
t h e lQ-inch
10-inch m
ill w
e t data.
data.
The rational
r a t i o n a l for
f o r this
t h i s alternative
a l t e r n a t i v e estimation
e s t i m a t i o n scheme is
i s as
follows:
follows:
a) The
T h e linear
l i n e a r model is
i s not
n o t strictly
s t r i c t l y vvalid
a l i d for
f o r wet
w e t grinding,
grinding,
particularly
p a r t i c u l a r l y for
f o r extended
e x t e n d e d grinding(4,8).
grinding' ' '.
4

However,
H o w e v e r , the
t h e linear
l i n e a r model

f i t t e d to
t o wet
w e t grinding
g r i n d i n g data
d a t a in
i n the
t h e nonlinear
n o n l i n e a r range and
and tthe
he
can be fitted

be used to
predict
kinetic
k i n e t i c parameters
p a r a m e t e r s obtained
o b t a i n e d can
can be
to p
r e d i c t tthe
h e grinding
g r i n d i n g bbee
h a v i o r in
i n the
t h e "neighborhood
" n e i g h b o r h o o d " of
o f tthe
h e data
d a t a used for
f o r estimation.
estimation.
havior
ll

T h e size
size
The

o f tthe
h e IIneighborhood"
" n e i g h b o r h o o d " for
for w
h i c h accurate
accurate p
r e d i c t i o n s can
can be made with
with
of
which
predictions

this
byy tthe
t h i s linearization
l i n e a r i z a t i o n technique
t e c h n i q u e is
i s determined
determined b
h e extent
e x t e n t of
o f nonlinearnonlinear, 8 , 2 1 ) _.
i .ty( (44,8,21)
1

t y

b)

It
wet
I t appears that
t h a t in
in w
e t systems
s y s t e m s the
t h e specific
s p e c i f i c selection
selection

f u n c t i o n s (S~)
(S^) values
v a l u e s are
a r e independent
i n d e p e n d e n t of
o f mill
m i l l design
d e s i g n and
and operating
operating
functions

variables,
v a r i a b l e s , they
t h e y are
a r e only
o n l y functions
f u n c t i o n s of
o f the
t h e size
s i z e distribution
d i s t r i b u t i o n in
i n tthe
he
mills,
m i l l s , i.e.,
i . e . , s~(mi'
s|r(m.., i

=
n).
= 1,2,3
1 , 2 , 3 ..... n
) . In
I n tthis
h i s context
c o n t e x t the
t h e equation
equation

(11-8)
be written
( I 1 - 8 ) can
can be
w r i t t e n as

m.
dm

E
i
_ T = - S . >(m)
)
--1 dE
dE

m. +
m.
+
1

i1-1
-1

E
F

1.:E b..
(!!0 m.
b . . S.
S*(m)
m.
lJ J
J
jj=l
=l
1 J

((V-7)
V-7)

and in
neighborhood
i n the
the n
e i g h b o r h o o d of
of a ~
m* , reference
r e f e r e n c e set
s e t of
o f mass fractions,
fractions,
the
t h e equation
e q u a t i o n assumes the
t h e form:
form:
d mm..
r
E
*^
1
- - = - S. (m ) m. +
r = - S^(m
1 - ) m.
1 +

dE
dE

'

i-1
i-1

r
E
**

1.:Z b
b ..
S. (m )) m.
m.
. . S^(m
lJ
J J
j=l
j=l

(V-8)
(V-8)

51

where S~(m*)
can be taken as constant.
1 r

where

c)
c)

(m ) can be taken as c o n s t a n t .

Based on (a) and (b) above it seems likely that if parameter

Based on (a) and (b) above i t seems l i k e l y t h a t i f

parameter

estimates of specific selection functions and breakage functions are

e s t i m a t e s o f s p e c i f i c s e l e c t i o n f u n c t i o n s and breakage f u n c t i o n s a r e

obtained in the 10-"inch mill for a "similar fineness of grind to


ll

obtained in the 10-inch m i l l

f o r a " s i m i l a r fineness o f g r i n d " to

that for which predictions are required in the larger mills, these
that f o r which p r e d i c t i o n s are r e q u i r e d i n the l a r g e r m i l l s ,

these

values should allow accurate predictions of large mill behavior in


values should allow accurate p r e d i c t i o n s o f large m i l l

behavior in

the neighborhood of the size distribution used for estimation.


li

II

the " n e i g h b o r h o o d " o f t h e s i z e d i s t r i b u t i o n used f o r e s t i m a t i o n .

Based on this scheme the breakage parameters were estimated from


Based on t h i s scheme t h e breakage p a r a m e t e r s w e r e e s t i m a t e d

from

data obtained within narrow ranges of values of specific energy input


d a t a o b t a i n e d w i t h i n n a r r o w ranges o f v a l u e s o f s p e c i f i c e n e r g y i n p u t

to the 10-inch mill using mono-size (10 x 14 mesh) feed.

Three

to t h e 1 0 - i n c h m i l l

Three

u s i n g m o n o - s i z e (10 x 14 mesh) f e e d .

ranges were selected for estimation using (i) 2.0 and 4.0 minute
ranges were s e l e c t e d f o r e s t i m a t i o n u s i n g ( i ) 2.0 and 4 . 0 m i n u t e

products, (ii) 4.0 and 5.0 minute products, and (iii) 5.0 and 6.0 minp r o d u c t s , ( i i ) 4 . 0 and 5.0 m i n u t e p r o d u c t s , and ( i i i ) 5.0 and 6.0 m i n

ute products, the corresponding specific energy values input to the


ute p r o d u c t s , t h e c o r r e s p o n d i n g s p e c i f i c e n e r g y v a l u e s i n p u t t o t h e

10-inch mill were obtained from Table (II-2), Appendix II.

The values

10-inch m i l l were obtained from T a b l e ( I I - 2 ) , Appendix I I .

The values

of specific selection functions thus obtained are tabulated in Table


o f s p e c i f i c s e l e c t i o n f u n c t i o n s thus o b t a i n e d a r e t a b u l a t e d

in Table

(II-4), Appendix II.

For a 'natural' (-10 mesh) feed ground in the

( I 1 - 4 ) , Appendix I I .

For a 'natural

(-10 mesh) f e e d g r o u n d i n t h e

10-inch mill, four ranges were selected for estimation using (i) 0.5,
1 0 - i n c h m i l l , f o u r ranges were s e l e c t e d f o r e s t i m a t i o n u s i n g ( i )

0.5,

2.0, 4.0 and 6.0 minute products, (ii) 0.5 and 2.0 minute products,
2.0,

4 . 0 and 6.0 m i n u t e p r o d u c t s , ( i i ) 0.5 and 2.0 m i n u t e p r o d u c t s ,

(iii) 2.0 and 4.0 minute products, and (iv) 4.0 and 6.0 minute pro( i i i ) 2.0 and 4 . 0 m i n u t e p r o d u c t s , and ( i v ) 4.0 and 6.0 m i n u t e

pro

ducts, the corresponding specific energy input to the lO-inch mill

ducts, the corresponding s p e c i f i c energy input to the 10-inch m i l l

values were obtained from Table (11-2), Appendix II.


v a l u e s were o b t a i n e d from T a b l e ( I 1 - 2 ) , A p p e n d i x I I .

The specific
The s p e c i f i c

selection functions thus obtained are tabulated in Table (11-5),


s e l e c t i o n f u n c t i o n s thus o b t a i n e d a r e t a b u l a t e d

Appendix II.
Appendix I I .

in Table

(II-5),

The specific selection functions obtained using 10 x 14


T h e s p e c i f i c s e l e c t i o n f u n c t i o n s o b t a i n e d u s i n g 10 x 14

mesh feed and -10 mesh feed were used to simulate grinding behavior
mesh f e e d and -10 mesh f e e d were used t o s i m u l a t e g r i n d i n g b e h a v i o r

in the 15-inch and 30-inch mills for grinding the corresponding feed

i n t h e 1 5 - i n c h and 3 0 - i n c h m i l l s f o r g r i n d i n g t h e c o r r e s p o n d i n g f e e d

with the corresponding energy input within the range for which the

w i t h t h e c o r r e s p o n d i n g e n e r g y i n p u t w i t h i n t h e range f o r w h i c h t h e

estimates were obtained.


e s t i m a t e s were o b t a i n e d .

52

Predictive
P
r e d i c t i v e Simulation
Simulation
t h e data
d a t a obtained
o b t a i n e d in
i n the
t h e 10-inch
1 0 - i n c h diameter
d i a m e t e r mill
mill
t h i s section,
s e c t i o n , the
In this
t o test
t e s t the
t h e predictive
p r e d i c t i v e capability
c a p a b i l i t y of
o f the
the n
o r m a l i z e d linear
linear
were used to
normalized

model

e q u a t i o n (11-8)
( I 1 - 8 ) for
f o r dry
d r y and
and wet
w e t grinding.
grinding.
equation

h e earlier
earlier
In tthe

t h e data
d a t a obtained
o b t a i n e d in
i n the
t h e three
t h r e e different
d i f f e r e n t mills
m i l l s have been shown
s e c t i o n the
section
be highly
h i g h l y correlated
c o r r e l a t e d with
w i t h tthe
he n
e t power drawn b
t h e mill.
mill.
to be
net
byy the
h e parameters
parameters of
o f the
t h e phenomenoE m p i r i c a l rrelationships
e l a t i o n s h i p s between tthe
Empirical
phenomenoand tthe
h e specific
s p e c i f i c power input
i n p u t tto
o tthe
he m
i l l have been
l o g i c a l model and
logical
mill
developed.
developed.

I n addition,
a d d i t i o n , the
t h e energy
e n e r g y input
i n p u t per
p e r unit
u n i t mass of
o f material
material
In

has been found


f o u n d tto
o be tthe
h e independent
i n d e p e n d e n t vvariable
a r i a b l e which
which
g r o u n d has
being ground
n o r m a l i zzes
e s the
the 1
l iinnear
e a r model tto
o a form whi
w h i cch
h is
i s independent
i n d e p e n d e n t of
o f mill
mill
normal
d e s i g n and
and operating
o p e r a t i n g variables.
variables.
design

T h e cumulative
c u m u l a t i v e feed-size
f e e d - s i z e breakage
breakage
The

f u n c t i o n s have
a l s o been found
f o u n d tto
o be independent
i n d e p e n d e n t of
o f operating
o p e r a t i n g varivari
have also
functions
a b l e s and
and tthe
h e nonfeed
n o n f e e d size
s i z e breakage
functions w
e r e assumed
assumed tto
o be
ables
breakage functions
were
be
normalizable.
normalizable.

T h e two
two sets
s e t s of
o f breakage
parameters (specific
( s p e c i f i c selection
selection
The
breakage parameters

f u n c t i o n s and
and breakage
f u n c t i o n s ) formed
formed the
t h e basis
b a s i s for
f o r predicting
predicting
functions
breakage functions)
g r i n d i n g bbehavior
e h a v i o r in
i n the
t h e larger
l a r g e r mills
m i l l s for
f o r tthe
h e corresponding
c o r r e s p o n d i n g specific
specific
grinding
e n e r g y input
i n p u t to
t o tthe
h e mill
m i l l for
f o r dry
d r y and
and w
e t grinding
g r i n d i n g systems.
systems.
energy
wet

Q.r,x
D r y Gri
G r i nndi
d i nng
g
For
off batch grinding,
F o r a complete
c o m p l e t e simulation
simulation o
g r i n d i n g , tthe
h e data
d a t a for
f o r tthe
he
breakage pparameters
a r a m e t e r s was
was obtained
o b t a i n e d experimentally
e x p e r i m e n t a l l y in
i n the
t h e 10-inch
10-inch
diameter
d i a m e t e r mill
m i l l using
u s i n g mono-size
m o n o - s i z e (10 x 14 mesh) feed
f e e d at
at N
N*=0.6,
=0.6,

* =0.5 and
*
M
M*=0.5
and Mp=l.O.
M*=1.0.
B
Since
breakage functions
S i n c e the
t h e breakage
f u n c t i o n s and
and the
t h e specific
s p e c i f i c selection
s e l e c t i o n funcfunc
tions
breakage kinetics
a r e environment
e n v i r o n m e n t independent,
i n d e p e n d e n t , the
t h e breakage
k i n e t i c s are
a r e said
said
t i o n s are
to be
be linear.
linear.

Therefore
breakage parameters
T
h e r e f o r e the
t h e breakage
parameters obtained
o b t a i n e d for
for a

53

mono-size
m o n o - s i z e (10
(10 x
x 14
14 mesh) feed
f e e d were used to
t o predict
p r e d i c t product'size
p r o d u c t ' s i z e disdis
tribution
the 'natural
t r i b u t i o n even for
f o r the
'natural

(-10
(-10 mesh) feeds.
feeds.

The
T h e predictions
predictions

of
breakage behavior
o f breakage
b e h a v i o r in
i n lS-inch
1 5 - i n c h and 30-inch
3 0 - i n c h mills
m i l l s are
a r e in
i n good agreeagree
ment w
with
product
i t h the
t h e experimental
experimental p
r o d u c t size
s i z e distribution.
distribution.
Figure
F i g u r e 19
19 shows
shows a
a comparison
c o m p a r i s o n of
o f the
t h e experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e disdis
tribution
normalized
model uusing
t r i b u t i o n with
w i t h tthe
he n
o r m a l i z e d fittings
f i t t i n g s of
o f the
the model
s i n g the
t h e initial
initial
estimates
S~1 and B
.. from
mill
e s t i m a t e s of
o f S?
B^.
f r o m tthe
h e 10-inch
10-inch m
i l l shown in
i n Table
T a b l e (11-3),
(II-3),
1J
Appendix
A p p e n d i x II.
II.

Figure
normalized
F
i g u r e 20 shows the
the n
o r m a l i z e d predictions
p r e d i c t i o n s for
f o r 10-inch
10-inch

m i l l using
u s i n g a 'natural'
' n a t u r a l ' feed.
feed.
mill

T h i s confirms
c o n f i r m s that
t h a t the
l i n e a r model is
is
This
the linear

a p p l i c a b l e and that
t h a t the
breakage functions
f u n c t i o n s and specific
s p e c i f i c selections
selections
applicable
the breakage

functions
f u n c t i o n s are
a r e independent
i n d e p e n d e n t of
o f size
s i z e consist
c o n s i s t in
i n the
the mill
m i l l for
f o r a dry
d r y grindgrind
ing system.
system.

Figures
normalized
F
i g u r e s 21 and 22 show the
the n
o r m a l i z e d ppredictions
r e d i c t i o n s for
f o r the
the

1 5 - i n c h mill
m i l l uusing
s i n g mono-size
m o n o - s i z e (10
(10 x
x 14
14 mesh) and 'natural'
' n a t u r a l ' (-10
(-10 mesh)
mesh)
lS-inch

feeds,
f e e d s , rrespectively.
espectively.

The
T h e experimental
e x p e r i m e n t a l and
and ppredicted
r e d i c t e d pproduct
r o d u c t size
s i z e disdis

tributions
t r i b u t i o n s are
are in
i n good agreement.
agreement.

Figures
23 and 24
F i g u r e s 23
24 show such prepre

dictions
the 30-inch
d i c t i o n s for
f o r the
3 0 - i n c h mill.
mill.
Figure
25 shows
wet specific
F i g u r e 25
shows a
a comparison
c o m p a r i s o n of
o f the
the dry
d r y and
and wet
s p e c i f i c selecselec
tion
mesh feeds,
under
t i o n functions
f u n c t i o n s uusing
s i n g 10
10 x
x 14
14 mesh
f e e d s , indicating
i n d i c a t i n g tthat
hat u
n d e r the
the
same
same operating
o p e r a t i n g conditions
c o n d i t i o n s and
and feed
f e e d the
the two
two specific
s p e c i f i c selection
s e l e c t i o n funcfunc
tions
not
t i o n s are
are n
o t the
t h e same.
same.
Wet Grinding
Grinding
U n l i k e dry
d r y grinding,
g r i n d i n g , wet
w e t grinding
g r i n d i n g was inherently
i n h e r e n t l y nonlinear.
nonlinear.
Unlike
T h e specific
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s strongly
s t r o n g l y depended on the
t h e size
s i z e consist
consist
The
i n tthe
he m
i l l (Figure
( F i g u r e 18).
18).
in
mi11

I t is
i s observed
o b s e r v e d in
i n Figure
F i g u r e 18
18 that
t h a t geometric
geometric
It

a r t i c l e size
s i z e of
o f about
about 200
m i c r o n s was more or
o r less
l e s s a pivotal
pivotal
mean pparticle
200 microns

point
p o i n t indicating
i n d i c a t i n g that
t h a t pparticles
a r t i c l e s finer
f i n e r than tthat
h a t size
s i z e had higher
h i g h e r propro
b a b i l i t y of
o f suspension
s u s p e n s i o n in
i n tthe
he w
a t e r resulting
r e s u l t i n g in
in n
o n l i n e a r i t y in
i n the
the
bability
water
nonlinearity

MESH SIZE
14
88
28
200
100
48
400
1.0
1.0 ......---......:.;~-~~.-.;..;.;--~--~-0
.~.P~'It--,....,
....
I
I

a:::

w
z

0.5
0.5

u...

5
.....
0::

0.1

t:i

/'

/0
6.0min.
6.0min.
/
0.93
( I . 9 3KWH/T)
K W H / T )0
4.0 min.
/
4.0
mln.
(1.29
KWH/T)o
(I.29KWH/T)

:E
:::>

0/

/0

/0

0/

/0

,/ /
/0

/0
/,,0

0/'

0.05
0.05

/0

/0 P

0/'
0

>

:5

/'

/0/

0.2
0.2

u...

0"'" /'

0 / /0

TTIME
IME
(specific energy input)

10-INCH MILL
10-INCH
MILL
DRY
BBATCH
A T C H DRY
10x14
FEED
IOxl4 MESH FEED

2.0min.
_ /
0
(0.64
KWH/T)
(0.64KWH/T)
0

0/

n/

LOmin.
1.0 mi n.
0.02
0.02

/1

all

/0

/"

0/

(.)

0/

o Experimental
Experimental
- Fitted (all data)

(0.32KWH/T)
(0.32KWH/T)

0.5mln.
0.5 min.

(O.l6KWH/T)
(0.I6KWH/T)

0.0 IILO--.J20~---5J.0---10L..0--2..L0-0---5-00'--~10~00~~20~OO~"
0.0
1000
2000
20
50
100
200
500
10

PARTICLE SIZE,
S I Z E , MICRONS
F i g u r e 19.
19.
Figure

Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distribution
distribution
for
f o r dry
d r y grinding
g r i n d i n g in
i n lO-in.
1 0 - i n . diameter
d i a m e t e r mill
m i l l (10~14
(1Oxl4 mesh
feed)
f e e d ) and normalized
n o r m a l i z e d fittings
f i t t i n g s with
w i t h initial
i n i t i a l S.
S? and
B;j estimates
i n Table
T a b l e (11-3),
( 1 1 - 3 ) , Appendil
A p p e n d i x II.
II.
e s t i m a t e s shown in

400
400

1.0
a:::
or I. 0 IW
UJ
Z
u.

MESH
MESH
200

f-

ff:Li-

f-

O
~
<

LU
W

>
>
!;;{

0.210.2 -

10-INCH MILL
MILL
10-INCH
B A T C H DRY
BATCH
DRY
-10 MESH
MESH FEED
FEED

7
./

FEED
FEED

...J

28
0 __0
O0""""'/,,-O0./
~ ./
~
0 -......
I

14

,.,./

.,./
,.,./
/ 0 . / ./

TIME
TIME
(Specific
(Specific energy
energy Input)
Input)

4.0mln.
4.0min. 0
O
(1.26 KWH/T
KWH/T)

--\..1 _.,;1.14 --

48

0/

~
0.5
g 0.5'-

rH

SIZE
SIZE
100

0
o-

/ ///

,., ,.,

oO

./ ./

Experimental
Experimental
Predicted

./

FEED
FEED

./

::::>
ZD

::::>
0.
uO 0.1
10

Figure
F i g u r e 20.

20

50
100
200
200
PARTICLE
P A R T I C L E SIZE,
S I Z E , MICRONS
MICRONS

500

1000

2000
2000

Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distribution
d i s t r i b u t i o n for
f o r ddry
ry
grinding
g r i n d i n g in
i n la-in.
1 0 - i n . diameter
d i a m e t e r mill
m i l l (-10
(-10 mesh feed)
f e e d ) and
and normalized
normalized
i n i t i a l S.
S . and
and 8
B,..
e s t i m a t e s shm'm
shown in
in
predictions w
i t h initial
predictions
with
.. estimates
Table
Appendix
lJ
T a b l e (11-3),
(II-3), A
p p e n d i x 11.1
II.

Ul
Ul

MESH SIZE
MESH
400

200

48
48

100

28
28

88

14
14

1.0 r-----~::::-..:.;;;.;...--T--T--_r_--/--;:;o~r...,.'
i.o
r
1

a:::

15-INCH MILL
MILL
15-INCH
BATCH DRY
DRY
BATCH
lOx 14 MESH FEED
10x14

0.5
0.5

/0

/0

/0

O/'b

I.L.
Z

o
O

TTIME
IME
(specific energy
energy Input)
Input)
(specific

0.2
0.2

b
<!

4.0min.
4.0mln.
/0
(I.70KWH/T)
o
(1.70KWH/T) 0

<

0::
I.L.

w
LU

0.1
0.1

t:in
...J
:::>

/0

.,/0

>>

./

/0

2.0min.
Z
2.0mln.
/0
- (0.85KWH/T)"/
(0.85KWH/T)

/0

/0

/0

LOmln.
0
I.Omln.
o /
(0.43
KWH/T)
(0.43KWH/T)

0.02
0.0 2

0.01
0.01

0.5mln.
o~
0.5 mln.
(0.21
KWH/T)
(0.21 K W H / T )

10

20
20

50
50

/'

/ 0

=>
t)

/0

/0

0.05
o.05

::1iE

/0

/0

/0/'

/0

/0

/ 0/

Experimental

- Predicted

/0
/0

100
100

200
200

500
500

1000

2000

PARTICLE SIZE,
S I Z E , MICRONS
MICRONS

Figure
F i g u r e 21.

Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distribution
distribution
for
dry
grinding
in
15-in.
diameter
f o r d r y g r i n d i n g i n 1 5 - i n . d i a m e t e r mill
m i l l (lOx14
esh
( 1 0 x l 4 mmesh
feed)
i n i t i a l S.
SE
:
f e e d ) and normalized
n o r m a l i z e d predictions
p r e d i c t i o n s with
w i t h initial
and B
B.... estimates
e s t i m a t e s obtained
o b t a i n e d from lO-in.
1 0 - i n . diameter'
diameter
mill,'~hown
m i l l , Shown in
i n Table
T a b l e (11-3),
( I I - 3 ) , Appendix
A p p e n d i x II.
II.

MESH SIZE
MESH
400

48

100

28

14
TT

a:::

Z
LL

200

I-

15-INCH M I L L
B A T C H DRY
-10 MESH F E E D

TIME
(Specific energy input)
2-0min.
(0.87 K W H / T )

> 0.2
~

FEED
FEED

..J

=>

Experimental
FEED
FEED
Predicted

a~ QLo------2~0---------5~0------10~0------2~0-0--------50~0------10~0~0-----2-00~0--~
10

20

50

100

PARTICLE
PARTICLE

200

500

1000

2000

SIZE
S I Z E ,t MICRONS
MICRONS

Figure,
F i g u r e , 22. Comparison of
o f experimental
e x p e r i m e n t a l pproduct
r o d u c t size
s i z e distribution
d i s t r i b u t i o n for
f o r ddry
ry
g r i n d i n g iin
n l?-in:
15-in. d
i a m e t e r mill
m i l l (-10
(-10 mesh feed)
f e e d ) and
and normalized
normalized
grin~in~
~i~metef
predlctlons
wlth
n i t i a l S.
SV and
and B
B..
. . estimates
e s t i m a t e s obtained
o b t a i n e d from
from
predictions w
i t h iIn,tlal
10-in.
1 0 - i n . diameter
d i a m e t e r mill,
m i l l , show~
shown in
i n Ta~~e
T a b l e (11-3),
( I I - 3 ) , Appendix
A p p e n d i x II.
II.

MESH SIZE
100
400
200
48
28
14
8
4 0 0 200
100
48
I. 0 ....-----....,,....---.,~--...--I----rl---.,I~-/-O~~~r.---r-"II
::

ffi
z
~
zo

~
P
o
~
<

E
Li.
w
LU

0.5 -

/0
/
/0
/0

~o

TIME
~o
TIME
/
(specific
energy
input)
s
0.2
energy
0/
0.2 -

0/
4.0min.
4.0 min.

0/

o.i ~ (1.64
(1.64 KWH/T)
KWH/T)
0.1

~<
>

:=

-J 0.05 -

-I
=>
~
=>

/0

30-INCH MILL
30-INCH
BATCH DRY
FEED
10x14 MESH FEED
IOxl4

0.05

o~

~o

0/
0/

0/

o~

o~

0/

2.0min.
(0.82 KWH/T)
KWH/T)
(0.82

o
o Experimental
- Predicted

o
o

0.02
0.02 -

O.OI~

0.01

0.5 min.
o
(0.20KWH/T)
____ _ _ _ _ _ _

10

~I

20
20

~I

50
50

____

100
100

PARTICLE
PARTICLE

Figure
F i g u r e 23.
23.

~I

____

~I

______

200
200

~I

000
500

____

~j

____J~~

1000
1000

2000

S I Z E , MICRONS
SIZE,

Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distribution
distribution
for
f o r dry
d r y grinding
g r i n d i n g in
i n 30-in.
3 0 - i n . diameter
d i a m e t e r mill
m i l l (10x14
(10xl4^mesh
Emesh
feed)
and
normalized
predictions
with
initial
S.
f e e d ) and n o r m a l i z e d p r e d i c t i o n s w i t h i n i t i a l
and
from 10-in.
and B
B ..
. . estimates
e s t i m a t e s obtained
o b t a i n e d from
1 0 - i n . diameter'mill,
diameter m i l l ,
shownl~n
Appendix
s h o w n ' I n Table
T a b l e (11-3),
(II-3), A
p p e n d i x II.
II.
1

tn
oo
00

MESH
MESH
1.0 r1.0
IyW
UI0:::

f-

t5O 0.5
0.5
.-..

I-

or

lL.
u_

>
>

.-..
E

200
200
Ir

48
48
I1

28
28

, _ n o--u

14
u

88

0"'--

0/
0/

TIME
TIME
energy I
Input)
(Specific energy
npu/

I-

4.0 min.
4.0
min.

0O

(1.64
(1.64 KWH/T)
KWH/T)

Q 2 f_
0.2

./

FEED

-1
_j
::::>
ZD
::E
::::>

O 0.1
o
0.1

100
100
nI

0""'-0""""""-

ff_

<
~

4400
00
I1
30-INCH
3 0 - I N C H MILL
MILL
BATCH DRY
DRY
-10
FEED
-10 MESH FEED

SIZE
SIZE

10

Figure
24.
F i g u r e 24.

20
20

oO

./

'

Experimental
Experimental
FEED
FEED
Predicted
Predicted

50
50

iOO
100

200
200

500
500

1000
1000

2000

PARTICLE
PARTICLE

SIZE,
S I Z E . MICRONS
MICRONS

Comparison
Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distribution
d i s t r i b u t i o n for
f o r dry
dry
mesh feed)
a~d nonnalized
ggrin~in~
r i n d i n g iin
n 33~-in:
0 - i n . d~i~metef
i a m e t e r mill
m i l l (-10
(-10 mesh
f e e d ) and
normalized
predlctlons
\tilth
p
redictions w
i t h lnltlal
i n i t i a l S. and
and B
B ..
. estimates
e s t i m a t e s obtalned
o b t a i n e d from
from
10-in.
mill,
Ta~~e
1 0 - i n . diameter
diameter m
i l l , show~
shown in
in T
a D l e (11-3),
( 1 1 - 3 ) , Appendix
A p p e n d i x II.
II.

60
system.
system.

In
I n tthe
h e absence of
o f rreplicate
e p l i c a t e experimental
e x p e r i m e n t a l data it
i t was
was nnot
ot

possible
p o s s i b l e tto
o test
t e s t whether
w h e t h e r the
t h e ppivotal
i v o t a l point
p o i n t could
c o u l d serve
s e r v e as
as a fixed
fixed
p o i n t to
t o determine
d e t e r m i n e set
s e t of
o f specific
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s by
point
by knowing
the ttop
o p size
s i z e selection
s e l e c t i o n function.
function.
the
t o further
f u r t h e r investigations.
investigations.
to

H o w e v e r , this
t h i s observation
o b s e r v a t i o n is
i s open
However,

T h e effect
e f f e c t of
o f nonlinearity
n o n l i n e a r i t y was
strong
The
was strong

when a I' nnatural


40% below 200 m
microns)
was ground.
a t u r a l , feed
f e e d (:
(~ 40%
i c r o n s ) was
ground.
1

To obtain
breakage pparameters
o b t a i n breakage
a r a m e t e r s experimentally
e x p e r i m e n t a l l y in
i n tthe
h e lO-inch
10-inch
natural
diameter
mill
using
diameter m
ill u
s i n g mono-size
m o n o - s i z e and
and n
a t u r a l feeds
f e e d s experiments
e x p e r i m e n t s were

*
performed at N*=0.6, M*B=O.5, Mp=l.O
and F=O.6 (percent solids). The
p e r f o r m e d a t N = 0 . 6 , Mg=0.5, M = 1 . 0 and F=0.6 ( p e r c e n t s o l i d s ) . T h e
breakage parameters obtained for 'nearly linear ' region (0.0+0.5,
it

-k

ie

breakage parameters o b t a i n e d f o r ' n e a r l y l i n e a r '

region (0.0*0.5,

1.0, 2.0, 4.0 minutes) are tabulated in Table (II-3), Appendix II.
1 . 0 , 2 . 0 , 4.0 m i n u t e s ) a r e t a b u l a t e d

i n Table ( I I - 3 ) , Appendix I I .

The specific energy input to the mill values are tabulated in


The s p e c i f i c e n e r g y i n p u t t o t h e m i l l

values are tabulated

in

Table (11-2), Appendix II.

Figure 26 shows the fitting of these

Table ( I I - 2 ) , Appendix I I .

F i g u r e 26 shows t h e f i t t i n g o f t h e s e

estimates to the nornlalized model for the la-inch mill.

The agreement

e s t i m a t e s t o t h e n o r m a l i z e d model f o r t h e 1 0 - i n c h m i l l .

T h e agreement

is good as the region was a 'nearly linear ' region.


i s good as t h e r e g i o n was a ' n e a r l y l i n e a r '

region.

Since the breakage functions were independent of the environS i n c e t h e breakage f u n c t i o n s w e r e i n d e p e n d e n t o f t h e e n v i r o n

ment, the specific selection functions were the parameters to be


m e n t , t h e s p e c i f i c s e l e c t i o n f u n c t i o n s were t h e p a r a m e t e r s t o be

estimated for various predictions.

Two different approaches were

estimated f o r various p r e d i c t i o n s .

Two d i f f e r e n t

approaches were

used to estimate the specific selection functions.


used t o e s t i m a t e t h e s p e c i f i c s e l e c t i o n

Method I:
Method

functions.

This
T h i s approach is
i s identical
i d e n t i c a l tto
o the
t h e one
one used in
i n dry
d r y grinding
grinding

and assumed w
wet
e t grinding
g r i n d i n g kinetics
k i n e t i c s to
t o be
be linear.
linear.

The
T h e linearized
linearized

e s t i m a t e s (Table
( T a b l e 11-3),
II-3), A
p p e n d i x II
I I obtained
o b t a i n e d for
f o r tthe
h e 'nearly
' n e a r l y linear
linear'
estimates
Appendix

region
r e g i o n were used for
f o r simulation
s i m u l a t i o n in
i n this
t h i s method.
method.

The
T h e predictions
predictions

by tthis
not
h i s method were n
o t expected
e x p e c t e d to
t o agree
agree with
w i t h tthe
h e experimental
e x p e r i m e n t a l propro
duct
duct size
s i z e distribution,
d i s t r i b u t i o n , pparticularly
a r t i c u l a r l y for
f o r ffinely
i n e l y ground
g r o u n d products.
products.
Figure
F i g u r e 27 shows the
t h e ppredictions
r e d i c t i o n s (firm
( f i r m lines)
l i n e s ) for
f o r tthe
h e la-inch
1 0 - i n c h mill
mill

- 5.0,,--------------------------,

pJ -

X
~ 5.0

3:

10- INCH MILL


10-INCH
BATCH DRY and WET
WET
lOx
14
MESH
FEED
10x14

w.:
en
CO

Ul

"ION,

.5

2.0

lr
U
O
ZZ

Li.

1.0
'7

ZZ

/'

oQ

,/

J- 0.5

,/

oU
IJJ
LU

,/
/

....J
_J
IJJ
LU

,/
,/

en
to
U
o

,/

,/
,/

0.2

,/

ll..
Ll

oO
IJJ
LU
a..
CL
(f)

CO

ESTIMATES BETWEEN
B E T W E E N FEED
AND 4.0 MINUTE GRINDS
--DRY
DRY
WET
- - - WET

,/
,/

,/

0.1 ILO---2.L0---J.51.0---10.L.0---2.L.00---~50~0~-~IOOO~-~2~0:':0":0---:3000~
0.1
3000
20
50
100
200
500
1000
2000
10

PARTICLE SIZE, MICRONS


GEOMETRIC MEAN PARTICLE
Fi
F i ggure
u re 25.
25.

T~e
T h e comparison
c o m p a r i s o n of
o f dry
d r y and
and wet
w e t specific
s p e c i f i c selection
s e l e c t i o n functions,
functions,
S.,
S ^ , (K~JH/T)
(KWH/T) obtained
o b t a i n e d between lOx14
10x14 mesh feed
f e e d and
and first
first
f3ur
f o u r grinds.
grinds.

ON
H
1

MESH SIZE
.0

ffi5
z
Li_
i'i:

I
_
0.5
o.5

400
400

200
200

100
100

48
48

28

14

10-INCH
10-INCH MILL
MILL
B
A
T
C
H
W
ET
BATCH WET
IOxl4
10x14 MESH FEED
FEED

TIME
(specific energy input)

:2
go

~ 0.2
<
0::
l..L..
u.

w
LlJ

>
>

6.0 min.
(2.06KWH/T)
4.0 min.
(
I
.
3
7KWH/T)
0.1
0.1

ti....J

_
2.0min. ^
_
(0.69KWH/T?
3 0.05
0.05
::J
~

ZD
::J

o
O

I.Omln
o(0.36KWH/T)

Experimental
Experimental

- Fitted(all data)

0.02
0.02
0.5min
(0.I7KWH/T) '
0

0.01
0.01 ....----I"-----""'----'---....L.---.......--....I..--"""--..
10
20
50
100
200
500
1000
2000
20
50
100
200
500
1000

PARTICLE
PARTICLE

Figure
26.
F i g u r e 26.

SIZE,
S I Z E , MICRONS

Comparison
product
Comparison of
o f experimental
experimental p
r o d u c t size
s i z e distribution
distribution
f o r wet grinding
g r i n d i n g in
i n lO-in.
1 0 - i n . diameter
d i a m e t e r mill
m i l l (lO~14
(10x14 mesh
for
f e e d ) and normalized
n o r m a l i z e d fittings
f i t t i n g s with
w i t h initial
i n i t i a l S. and
feed)
i n Table
T a b l e (11-3),
(II-3), A
p p e n d i x II.
II.
B. . estimates,
e s t i m a t e s , shown in
Bij
Append~x
0\
N

MESH
MESH
1.0
1.0

a:::
lu
w

200
200

100

48

28

r------~--.....,r__--...,.._--~~""P"I""~~__,.~~

8
__-~

10-INCH MILL
MILL
10-INCH
ET
BATCH W
WET
-10 MESH FEED
FEED
-10

IJ...

400
400

SIZE
SIZE

0.5
0.5

O
o

TIME
(Specific energy Input)

t-

~
or
a:::

6.0 min.
(2.0 K W H / T )

I.L

o
0

LU 0.2
~
0.2

>

r>

2.0 min.
2.0m!n.
(0.67 KWH/T)
KWH/T)
(0.67

ti...J

FEED
FEED

.,/

Experimental
Predicted (method I)I)

,;.,/

Fitted ((method
method II)
II)

~
(.)

0.1
O.I~----~------~~----~------~------~~----~------L-~
50
2000
20
100
200
500
1000
10
20
50
100
200
500
1000

PARTICLE
PARTICLE

FFigure
i g u r e 27.
27.

SIZE,
S I Z E , MICRONS
MICRONS

off eexperimental
Comparison o
x p e r i m e n t a l pproduct
r o d u c t size
s i z e distribution
d i s t r i b u t i o n for
f o r wet grinding
grinding
mill,
normalized
iin
n 110-~n.
0 - i n . diameter
diameter m
i l l , (-10
(-10 mesh feed)
f e e d ) and n
o r m a l i z e d predictions
predictions
with
with
method II (firm
w
i t h Si eestimates
stimates w
i t h method
( f i r m llines)
i n e s ) and
and method
method II
II (dotted
( d o t t e d lines),
lines).

64

product
p r o d u c t size
s i z e distributions
d i s t r i b u t i o n s using
u s i n g a Inatural
' n a t u r a l ' l (-10
(-10 mesh) feed.
feed.

TThe
he

p r e d i c t i o n s do
do not
n o t agree
a g r e e with
w i t h tthe
h e pproduct
r o d u c t size
s i z e distribution
d i s t r i b u t i o n concon
predictions
f i r m i n g the
t h e dependence of
o f specific
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s on
on the
t h e size
size
firming
c o n s i s t iin
n tthe
he m
ill.
consist
mill.

F
i g u r e s 28 and
and 29 show nnoramlized
o r a m l i z e d predictions
predictions
Figures

( f i r m lines)
l i n e s ) in
i n the
t h e 15-inch
1 5 - i n c h and
and 3D-inch
3 0 - i n c h mills
mills u
s i n g 10 x 14 mesh
(firm
using
feeds.
feeds.

T h e predictions
p r e d i c t i o n s agree
a g r e e in
i n tthe
h e Inearly
' n e a r l y linear
l i n e a r ' l region
r e g i o n but
b u t do
The
do

n o t agree
a g r e e when n
o n l i n e a r i t y becomes evident.
evident.
not
nonlinearity

F
i g u r e s 30 and
and 31 show
Figures

normalized p
r e d i c t i o n s (firm
( f i r m lines)
l i n e s ) in
i n the
t h e 15-inch
1 5 - i n c h and
and 3D-inch
3 0 - i n c h mills
mills
normalized
predictions
a t u r a l ' I (-10
(-10 mesh) feeds.
feeds.
u s i n g a I' nnatural
using
orse.
are even w
are
worse.

Here
t h e Method
Method II predictions
predictions
Here the

T h e s e rresults
e s u l t s suggested
s u g g e s t e d that
t h a t Method
Method I predictions
predictions
These

f o r extended
e x t e n d e d wet
w e t grinding.
grinding.
are inappropriate
i n a p p r o p r i a t e for
are

Method
Method II:
II:

Simulations
S i m u l a t i o n s with
w i t h tthis
h i s method were
w e r e based on
on the
t h e specific
specific

i n tthe
h e lO-inch
10-inch m
i l l over
o v e r a narrow
s e l e c t i o n functions
f u n c t i o n s estimated
e s t i m a t e d in
selection
mill
t o the
t h e same specific
s p e c i f i c energy
energy
s p e c i f i c energy
e n e r g y range corresponding
c o r r e s p o n d i n g to
specific
t o tthe
h e larger
larger m
ills.
i n p u t to
mills.
input

T h e method of
o f estimation
e s t i m a t i o n of
o f breakage
breakage
The

and natural
n a t u r a l feeds
f e e d s have been explained
explained
parameters uusing
sing m
o n o - s i z e and
parameters
mono-size
i n tthe
h e chapter
c h a p t e r and
and tthe
h e values
v a l u e s obtained
o b t a i n e d are
a r e tabulated
t a b u l a t e d in
in
e a r l i e r in
earlier
T a b l e s (II-4)
( I 1 - 4 ) and
and (11-5),
(II-5), A
p p e n d i x II.
II.
Tables
Appendix

F i g u r e 27 shows tthe
h e normalized
normalized
Figure

i n the
t h e 10-inch
10-inch m
i l l for
f o r specific
s p e c i f i c energy
energy
p r e d i c t i o n s (dotted
( d o t t e d lines)
l i n e s ) in
mill
predictions
o f 0.67 and
and 2.0 KWH/T using
u s i n g separate
s e p a r a t e estimates
e s t i m a t e s of
o f tthe
he
i n p u t values
v a l u e s of
input
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s obtained
o b t a i n e d for
f o r the
t h e corresponding
c o r r e s p o n d i n g specific
specific
specific
e n e r g y rrange.
ange.
energy

These p
r e d i c t i o n s closely
c l o s e l y agree
agree w
i t h the
t h e experimental
experimental
These
predictions
with

p r o d u c t size
s i z e distributions.
distributions.
product

and 29 show the


t h e normalized
normalized
F i g u r e s 28 and
Figures

f o r the
t h e 15-inch
1 5 - i n c h and
and the
t h e 30-inch
3 0 - i n c h mills
mills
p r e d i c t i o n s (dotted
( d o t t e d lines)
l i n e s ) for
predictions
respectively u
s i n g 10
1 0 x 114
4 mesh feed
f e e d with
w i t h narrow
n a r r o w rrange
a n g e estimates.
estimates.
respectively
using
F i g u r e s 30 and
and 31
31 show the
t h e similar
similar p
r e d i c t i o n s (dotted
( d o t t e d lines)
l i n e s ) ffor
or
Figures
predictions

MESH SIZE
SIZE
1.0

w
z

0.5
0.5

L1..

o
r
u

0.2
0.2

L1..

0.1
0.1

.....J

=>

=>
u

100
100

48
48

28

14

...._..;8....

_
_

15-INCH
MILL
15-INCH MILL
B A T C H WET
WET
BATCH
10x14 MESH FEED
FEED
IOxl4

TIME
TIME
(Specific energy input)

^.j?

/0
0

Z
2.0 min.
2.0mln.
- (0.82KWH/T)
(0.82KWH/T)

>
r

200
200

4.0 min.
min.
4.0
(115
KWH/T)
(I.75KWH/T)

400
400

r-----.,.....-....;,.;;.--~~-....;.r.-....;;~-~~

/0

0.05
0.05

1.0 min
min..
1.0
0/
(0.66
KWH/T)
(0.66KWH/T)

0
0

0.5min.
0.02 _
0.02
(0.22KWH/T)
(0.22KWH/T) 0o

Experimental
Predicted
Predicted
(method I)
I)
Predicted
(method II)
II)

J.
0.01~--~----~----~---~------L---~----~--~
0.01
10
20
50
100
200
500
20
1000
2000
50
100
200
500
1000
2000

P A R T I C L E SIZE,
SIZE , MICRONS
PARTICLE
FFigure
i g u r e 28.
28.

Comparison o
e x p e r i m e n t a l pproduct
r o d u c t ssize
i z e distribution
distribution
off experimental
ffor
o r wet
r i n d i n g iin
n 1lS-in.
5-in. d
iameter m
i l l (10x14
wet ggrinding
diameter
mil~
(lOx14 mesh
f e e d ) and nnormalized
o r m a l i z e d ppredictions
redictions w
i t h S. estimates
estimates
feed)
with
o b t a i n e d from 1lO-in.
0 - i n . ddiameter
iameter m
ill w
i t h method II
mill
with'method
obtained
((firm
f i r m llines)
i n e s ) and method III
I ((dotted
d o t t e d lines).
lines).

MESH SIZE
200
28
28
14
8
400
100
48
14
400
200
100
48
1.0 .....----.....,..--...,....--...,..--"'T"'"--"T""-~~~-.,.......
1.0
30- INCH MILL
30-INCH
BATCH W
WET
ET
IOxl4
MESH
FEED
10x14 MESH FEED

0.5 0.5
0::
or
W
LU
Z
lJ...
Z

.-

TIME
T
IME
(Specific energy
energy Input)
,0'

0.2
0.2

<t
<

a::

w
LU

>
>

'

0,..."

4.0min.
4.0mln.
(1.80KWH/T)
(I.80KWH/T)

()
O

lJ...

....

0 .... "

0.1 Z
2.0 mln.
-(0.90KWH/T)
0.05
0.05

0 Experimental
-
- Predicted
(method I)
I)
"" Predicted
(method II)
II)

-.J

_J
:::>

_ 0.5mln.
(0.22KWH/T)
(0.22KWH/T)

3~

:::>
ID

0
O

^
0o

0.02
0.02

1
--'----....1--.
. 100
.100. ----"'---.....&..---'---...........
20
pO
200
1000
2000
2000
1000
20
pO
200
500

0.01 I .....
0.0
10

F i g u r e 29.
29.
Figure

50)

PARTICLE
P A R T I C L E SIZE,
S I Z E , MICRONS
MICRONS

Comparison
Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distribution
distribution
for
wet
grinding
in
30-in.
diameter
(10x14 mesh
for
g r i n d i n g i n 3 0 - i n . d i a m e t e r milt
m i l l (lOx14
feed)
and
normalized
predictions
with
S.
estimates
feed)
n o r m a l i z e d p r e d i c t i o n s w i t h S? e s t i m a t e s
obtained
o b t a i n e d from lO-in.
1 0 - i n . diameter
d i a m e t e r mills
m i l l s wit~
w i t n method II
(firm
lines)
and
method
II
(dotted
lines).
(firm lines)
II (dotted l i n e s ) .

MESH

W
0::
LU

20

to
U
<

~
~
Ll_

400
200
100
48
28
14
8
400
200
100
.0
T9"
I.O~--------~~--------~------~----~~------O----~~~~~~~~
0/- ~
_/
/15- INCH MILL
15-INCH
.0"
ET
BATCH W
WET
_0//
-10
.,
FEED
-10 MESH
M E S H FEED
.,
0.5
0.5
/0"
TIME
TIME
if"
(Specific energy
,,"
energy input)
/0"

--

()/

LU
w

>
>t<t
<
...J

SIZE
SIZE

0.2 0.2

2.0min.
2.0 min.
(0.89
(0.89 KWH
K W HIT)
/T)
FEED
FEED

::>

0/
O
.-

"
.-

.-

"

--

Experimental
Predicted ( method I)
I)
Predicted (method II)
II)

::>
_L
0.1
U O.I~----~~--------*-------~----~----------~----~------~---J
10
20
50
1000
2000
iOO
200
500
20
50
100
200
500
1000

PARTICLE
PARTICLE

Figure
F i g u r e 30.
30.

SIZE,
S I Z E , MICRONS
MICRONS

Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distribution
d i s t r i b u t i o n for
f o r wet
wet
grinding
f e e d ) and normalized
normalized
g r i n d i n g in
i n l5-in.
1 5 - i n . ^ ddiameter
i a m e t e r mill
m i l l (-10
(-10 mesh feed)
E e s t i m a t e s obtained
predictions
1 0 - i n . diameter
d i a m e t e r mills
mills
p r e d i c t i o n s with
w i t h S.
S . estimates
o b t a i n e d from 10-in.
( f i r m lines)
l i n e s ) and method II
I I (dotted
( d o t t e d lines).
lines).
w i t h method II (fir~
with

MESH
M
ESH
200
200

4400
00

SIZE
100
100

48
48

28
28

14
14

88

1.oP---------~~~--~~----~~----~--O----~-7r-~~~~-e---r-,
Kffi 1.0
1
Z

~
Z

0---

330-INCH
0 - I N C H MILL
MILL
BATCH W
WET
BATCH
ET
-10 M
MESH
FEED
-10
E S H FEED

0 .... -

2O.5
~0.5
0:::
DC

0o

>

|~ 0.2
0.2

2.0min.
2.0
min.
((0.90
0 . 9 0 KKWH/T)
WH/T)

---

,,---

oO

^ ^

FEED
FEED

:!:
::>
3
O

o.... . . . --- ---

0 ..... ---

"

0.1
QI

Experimental
Predicted (method I1))

<t
_J
-'
::>
=>
C,)

....

0 .......... ---

i-

oC,)
<<t

w
LU

0----

II)
Predicted (method II)

1 - - 1
1
1
1
'
LI0------2LO--------5~0------1~0-0-----2~0~0------~50~0~--~10~OO~--~2~0~O~O~
2000
1000
50
100
200
500
10
20
PARTICLE
PARTICLE

Figure
F i g u r e 31.

SIZE,
S I Z E , MICRONS
MICRONS

Comparison of
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distribution
d i s t r i b u t i o n for
f o r wet
wet
grinding
d diameter
i a m e t e r mill
m i l l (-10
(-10 mesh feed)
f e e d ) and normalized
normalized
g r i n d i n g in
i n 30-in.
30-in. E
predictions
1 0 - i n . diameter
diameter
p r e d i c t i o n s with
w i t h S. estimates
e s t i m a t e s obtained
o b t a i n e d from 10-in.
mills
( f i r m lines)
l i n e s ) and method II
I I (dotted
( d o t t e d lines).
lines).
m i l l s with
w i t h method fI (firm

69
69

the
the l5-inch
1 5 - i n c h and 3D-inch
3 0 - i n c h mills
m i l l s respectively
r e s p e c t i v e l y using
u s i n g -10
-10 mesh feed
feed
with
w i t h narrow
n a r r o w range estimates.
estimates.

In
I n all
a l l cases the
t h e agreement
agreement with
w i t h exex

p e r i m e n t a l product
p r o d u c t size
s i z e distributions
d i s t r i b u t i o n s is
i s good.
good.
perimental

A
the ppredictions
batch tests
A slight
s l i g h t deviation
d e v i a t i o n in
i n the
r e d i c t i o n s for
f o r batch
t e s t s in
i n the
the
3D-inch
mill
may be
be due ttoo the
the m
magnitude
30-inch m
i l l may
a g n i t u d e of
o f experimental
e x p e r i m e n t a l error
e r r o r assocassoc
iated
with
iated w
i t h charging
c h a r g i n g and discharging
d i s c h a r g i n g of
o f tthe
h e large
l a r g e mill
m i l l and variation
variation
o f efficiency
e f f i c i e n c y factor
f a c t o r (0.84
(0.84 +
+ 0.07)
0.07) for
f o r the
the computation
c o m p u t a t i o n of
o f the
t h e specific
specific
of

energy
e n e r g y input.
input.
From a practical
p r a c t i c a l standpoint
s t a n d p o i n t tthe
h e true
t r u e test
t e s t of
o f a scale-up
s c a l e - u p design
design
procedure
predict
p r o c e d u r e in
i n an evaluation
e v a l u a t i o n of
o f its
i t s ability
a b i l i t y tto
o p
r e d i c t the
t h e continuous
continuous
d a t a obtained
o b t a i n e d in
i n a laboratory
laboratory
grinding b
e h a v i o r of
o f large
large m
i l l s based on data
grinding
behavior
mills
s c a l e batch
11.
scale
batch mi
mill.

Figure
wet
F i g u r e 32 shows such a prediction
p r e d i c t i o n for
f o r an open circuit
circuit w
e t grindgrind
ing in
using
natural
(-10 mesh) feed
i n the
t h e 30-inch
3 0 - i n c h diameter
d i a m e t e r mill
mill u
sing a n
a t u r a l (-10
feed
1 0 - i n c h diameter
d i a m e t e r mill.
mill.
w i t h estimates
e s t i m a t e s obtained
o b t a i n e d in
i n tthe
h e lO-inch
with

T h e experiexperi
The

mental ttest
e s t was run at
at a constant
c o n s t a n t feed
f e e d rate
r a t e of
o f 1040
1040 pounds p
e r hour.
hour.
mental
per

All
A l l the
t h e transients
t r a n s i e n t s were let
l e t to die
d i e and steady
s t e a d y state
s t a t e was attained.
attained.
F o r tthe
h e purpose of
o f predicting
p r e d i c t i n g the
t h e steady
s t e a d y state
s t a t e behavior
b e h a v i o r it
i t was
For
h a t 1)
1) the
t h e mill
m i l l behaved as a single
single p
e r f e c t mixer
m i x e r 2)
2) all
all
assumed tthat
perfect
p a r t i c l e sizes
s i z e s share
s h a r e a common
common rresidence
e s i d e n c e time
t i m e distribution
d i s t r i b u t i o n during
d u r i n g the
the
particle
t r a n s p o r t through
t h r o u g h the
i l l , i.e.,
i . e . , E(e)=e-e
E ( e ) = e ~ in
i n equation
e q u a t i o n (II-4A).
(II-4A).
transport
the m
mill,
e

Since
the mean residence
material
mill
S i n c e the
r e s i d e n c e time
time of
of m
a t e r i a l in
i n the
the m
i l l is
i s given
given
by the
the holdup,
holdup, H
H divided
d i v i d e d by the
t h e steady-state
s t e a d y - s t a t e mass flowrate
f l o w r a t e MF
Mp and
E P
the selection functions are given by Si=S~(~),
the elements of the
the s e l e c t i o n f u n c t i o n s are g i v e n by S . = S . (jr), the elements o f

the

model matrix for continuous grinding (equation II-4A) are given by


model m a t r i x f o r c o n t i n u o u s g r i n d i n g ( e q u a t i o n

I I - 4 A ) are g i v e n by

PARTICLE
PARTICLE

SIZE
S I Z E ,t MESH
MESH

200
100
48
28
14
200
100
48
1.0
_-"'if\::=::cr--W~------,
_
.0 r--------------=-T=------T...:.-------,r--0 __
~~
O~
//
O~
//

~
F
(/)

~
:c

0/"""'/

0.5
0.5

/'"

J/

0/

OC

/'

/ - -

1040
1040 Ibs/hr.
Ibs/hr 0o
product

lL.

__ -- -- / '

./

MODEL
MODEL PREDICTION OF
PILOT SCALE
S C A L E OPEN
CIRCUIT BEHAVIOR FROM
10"
10" BATCH MILL DATA

./

ZW

o~ 0.2
~
<.)

feed

LL

W
>

0.1

experimental
predicted

--I
~

<.)

J
I I I I I I
J I I I
0.05 L....-..l...--2LO---'---L---150---.JL-..I--L....LJIOL.O----:-2~0-:-0--L---'-:5~0-=0---'-~~:-:IO~0-=0--~2=000
0.05
20

50

100

PARTICLE
PARTICLE
F i g u r e 32.
32.
Figure

200

500

1000

2000

S I Z E ,t MICRONS
MICRONS
SIZE

Comparison of
wet ~rind
o f experimental
e x p e r i m e n t a l product
p r o d u c t size
s i z e distribution
d i s t r i b u t i o n for
f o r an open circuit
c i r c u i t wet
grind
3 0 - i n . diameter
d i a m e t e r mill
m i l l (-10
(-10 mesh feed)
f e e d ) and normalized
n o r m a l i z e d predictions
predictions w
i t h S.
S?
i n 30-in.
ing in
with
estimates
1
1 0 - i n . diameter
d i a m e t e r mills
m i l l s with
w i t h method II.
II.
e s t i m a t e s obtained
o b t a i n e d from lO-in.
1

71
00

00
/
exp [ - ( s . x ) e ] E ( e ) d e
o

00

CO

JJ .

= ~/

exp
exp [-(S~(P/H)H/MFe)J
[ - ( s ! ( P / H ) H / M - e ) ] exp
e x p [-eJ
[ - 6 ] de
de
F

00

00

Ji

= ~/0

J.
J.

= --"'"=....--

e x p -- [S~(P/MF)e]
[ s ! ( P / M ) . 0 ] exp [-eJ
[-8] de
exp
F

(V-9
(V-9))

(l
+s~ E)
(1+S?
F)
1

rE

is
i s the
t h e continuous
c o n t i n u o u s specific
s p e c i f i c energy
e n e r g y input
i n p u t tto
o tthe
h e product,
p r o d u c t , P/M
P/Mp..
F
For
KW and
=1040 lbs./hr.
F o r this
t h i s case
case P=36.5
P=36.5 KW
and M
M =1040
l b s . / h r . so
so tthat
h a t E=2.ll
E=2.11 KWH/T.
KWH/T.
F
The speciffc
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s estimates
e s t i m a t e s chosen for
f o r prediction
p r e d i c t i o n were
where

those
t h o s e obtained
o b t a i n e d in
i n tthe
h e lO-inch
1 0 - i n c h batch
batch mill
m i l l for
f o r the
t h e corresponding
c o r r e s p o n d i n g rrange
a n g e of
of
energy
e n e r g y input.
input.

These
with
wet breakage
breakage functions
T h e s e values
v a l u e s along
along w
i t h wet
f u n c t i o n s (Table
(Table

( I I - 4 A ) to
to
I I - 3 , Appendix
A p p e n d i x II)
I I ) were used in
i n conjunction
conjunction w
i t h equation
e q u a t i o n (II-4A)
11-3,
with
p r o v i d e the
t h e predictions
p r e d i c t i o n s shown
shown in
i n Figure
F i g u r e 32.
32.
provide

T h e excellent
e x c e l l e n t agreement
agreement
The

t h e predicted
p r e d i c t e d and experimental
experimental p
r o d u c t size
s i z e distribution
d i s t r i b u t i o n shown
between the
product
v e r y convincing
c o n v i n c i n g demonstration
d e m o n s t r a t i o n of
o f tthe
h e validity
validity
i n tthe
h e figure
f i g u r e provides
p r o v i d e s a very
in
o f this
t h i s scale-up
s c a l e - u p design
d e s i g n procedure
p r o c e d u r e for
f o r the
the range
r a n g e of
o f mill
m i l l sizes
s i z e s examined.
examined.
of

CHAPTER VI
VI
SUMMARY AND CONCLUSIONS
CONCLUSIONS
In this
t h i s investigation
i n v e s t i g a t i o n detailed
d e t a i l e d experimentation
e x p e r i m e n t a t i o n has been carried
carried
wet ball
out
o u t 'in
i n dry
d r y and wet
b a l l mill
m i l l systems
s y s t e m s to detennine
d e t e r m i n e the
t h e appropriateness
appropriateness
o f using
u s i n g linear
linear p
o p u l a t i o n bbalance
a l a n c e models for
f o r mill
m i l l scale-up
s c a l e - u p design.
design.
population
of
T h r e e mills
m i l l s were
w e r e involved
i n v o l v e d in
i n this
t h i s study:
study:
Three

two at
at the
the laboratory
l a b o r a t o r y scale
scale

( 1 0 - i n c h and 15-inch
1 5 - i n c h diameters)
d i a m e t e r s ) and one at
a t the
the pilot
p i l o t plant
p l a n t scale
scale
(lO-inch
T h e data
data was obtained
o b t a i n e d in
i n tthe
h e three
t h r e e mills
m i l l s under
under
The

( 3 0 - i n c h diameter).
diameter).
(30-inch

k
it
*it
the same operating conditions (N * =0.6, M*B=0.5, Mp=l.O,
F=0.6) except
the same o p e r a t i n g c o n d i t i o n s (N = 0 . 6 , Mg=0.5, M = 1 . 0 , F = 0 . 6 ) e x c e p t
in the 3D-inch mill for wet grinding where MB* was 0.4. The maximurn
p

in the 30-inch m i l l

f o r wet g r i n d i n g where Mg was 0.4.

T h e maximum

ball size was 1 1/2 inch and the ball distribution corresponded to
ball

s i z e was 1 1/2

i n c h and t h e b a l l d i s t r i b u t i o n c o r r e s p o n d e d to

the "equilibriurn charge distribution".

The batch tests were performed

the " e q u i l i b r i u m charge d i s t r i b u t i o n " .

T h e batch t e s t s w e r e p e r f o r m e d

in the three rnills and an open circuit test in the 3D-inch mill was

i n t h e t h r e e m i l l s and an open c i r c u i t t e s t i n t h e 3 0 - i n c h m i l l was

performed.
performed.

The kinetic data obtained in the batch mill were analyzed in the
The k i n e t i c d a t a o b t a i n e d i n t h e batch m i l l w e r e a n a l y z e d i n

context of the batch grinding model.


c o n t e x t o f the batch g r i n d i n g model.

the

The results confirmed the

T h e r e s u l t s c o n f i r m e d the

validity of the linear population balance model for dry grinding

v a l i d i t y o f the l i n e a r p o p u l a t i o n b a l a n c e model f o r d r y g r i n d i n g

and the specific power correlation previously observed by Herbst


and t h e s p e c i f i c power c o r r e l a t i o n p r e v i o u s l y o b s e r v e d by H e r b s t

and Fuerstenau(5) and Malghan and Fuerstenau(6).


6

and F u e r s t e n a u ^ and Malghan and F u e r s t e n a u ' ^ .

The breakage funcThe breakage

func

tion was found to be invariant over the range of operating variables


t i o n was f o u n d t o be i n v a r i a n t o v e r the range o f o p e r a t i n g

for the three rnills.


f o r the t h r e e m i l l s .

variables

The specific selection functions (S~=Si(P/H))


The s p e c i f i c s e l e c t i o n f u n c t i o n s

(S?=S.(P/H))

were found to be independent of the operating conditions and mill

were f o u n d t o be i n d e p e n d e n t o f the o p e r a t i n g c o n d i t i o n s and m i l l

design variables.
design v a r i a b l e s .

Once the breakage parameters (S~, Bij ) were


Once the breakage p a r a m e t e r s ( S ^ , B . . ) were

73
73
obtained
using
1 0 - i n c h mill
m i l l data
data u
s i n g 10
10 x
x 14
14
o b t a i n e d for
f o r dry
d r y grinding
g r i n d i n g from
f r o m the
the la-inch
mesh feed,
f e e d , the
t h e grinding
g r i n d i n g behavior
b e h a v i o r could
c o u l d be predicted
p r e d i c t e d in
i n the
t h e l5-inch
15-inch
3 0 - i n c h mills
m i l l s for
f o r all
a l l operating
o p e r a t i n g conditions
c o n d i t i o n s for
f o r 10
10 xx 14
14 mesh or
or
and 30-inch
-10 mesh feed.
feed.
-10

In the
case of
wet
nonlinearity
t h e case
of w
e t grinding
g r i n d i n g the
t h e inherent
inherent n
o n l i n e a r i t y reported
reported
by other
o t h e r investigators
i n v e s t i g a t o r s was also
a l s o observed
o b s e r v e d here.
here.

The
T h e specific
s p e c i f i c selecselec

tion
con
t i o n functions
f u n c t i o n s were found
f o u n d to
t o be strongly
s t r o n g l y dependent
dependent on tthe
h e size
s i z e cons i s t in
i n the
t h e mill.
mill.
sist

T h i s was due to
t o the
r e f e r e n t i a l breakage
breakage of
of
This
the ppreferential

c o a r s e particles
p a r t i c l e s and suspension
s u s p e n s i o n of
o f fines
f i n e s in
i n tthe
h e water.
water.
coarse
e x p l a i n e d in
i n Chapter
Chapter V
has been explained
V..

T h e phenomena
The

T h i s dependence of
o f specific
s p e c i f i c selecselec
This

i l l generated
g e n e r a t e d some probprob
t i o n functions
f u n c t i o n s on the
t h e size
s i z e consist
c o n s i s t in
i n tthe
he m
tion
mill
i n the
t h e aapplication
p p l i c a t i o n of
o f the
t h e linear
linear p
o p u l a t i o n balance
b a l a n c e model.
model.
lems in
population
a p p r o x i m a t i o n , by estimating
estimating
h e problem
p r o b l e m was overcome,
o v e r c o m e , tto
o a good approximation,
But tthe
r e g i o n s over
o v e r narrow
n a r r o w ranges of
o f values
values
parameters for
f o r 'nearly
' n e a r l y linear'
linear
parameters
regions
1

o f specific
s p e c i f i c energy
e n e r g y input
i n p u t to
t o the
the mills.
mills.
of

S i n c e the
the specific
s p e c i f i c selection
selection
Since

f u n c t i o n s were sensitive
s e n s i t i v e tto
o the
the size
s i z e consist
c o n s i s t in
i n the
m i l l , the
t h e prepre
the mill,
functions
d i c t i o n s for
f o r the
t h e larger
larger m
i l l s were made from
f r o m tthe
h e pparameters
a r a m e t e r s obtained
obtained
dictions
mills
10-inch m
i l l for
f o r an identical
i d e n t i c a l feed
f e e d and similar
s i m i l a r fineness
f i n e n e s s of
of
in tthe
h e la-inch
mill
p r o d u c t (approximately
( a p p r o x i m a t e l y the
the same
same specifi
s p e c i f i cc energy).
energy).
product

The conclusions
c o n c l u s i o n s are
a r e surrlllarized
summarized below:
below:
1.
breakage functions
1. In
I n dry
d r y and wet
wet gri
g r i nndi
d i nng
g systems
s y s t e m s the
t h e breakage
f u n c t i o n s were
to a good approximation
a p p r o x i m a t i o n independent
i n d e p e n d e n t of
o f mill
m i l l diameter,
d i a m e t e r , particle
particle
load,
ball
load, b
a l l load,
l o a d , lifter
l i f t e r configuration
c o n f i g u r a t i o n and the
t h e size
s i z e consist
consist
in
the mi
i n the
m i1l.
ll.
2.

In
wet grinding
I n dry
d r y and wet
g r i n d i n g system
s y s t e m tthe
h e se1ection
s e l e c t i o n functions
f u n c t i o n s were
found to
t o be p
r o p o r t i o n a l to
t o tthe
h e specific
s p e c i f i c power draft
d r a f t of
of
proportional
the mi 11
11..
the

74
74

3.

In
milling
the specific
ball m
i l l i n g the
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s were
were
I n dry
d r y ball
independent
i n d e p e n d e n t of
o f mill
m i l l diameter,
d i a m e t e r , lifter
l i f t e r configuration,
c o n f i g u r a t i o n , particle
particle
load
l o a d and the
t h e size
s i z e consist
c o n s i s t in
i n the
t h e mill.
mill.

4.
4.

In dry
milling,
were
d r y ball
ball m
i l l i n g , where the
the kinetics
kinetics w
e r e linear,
l i n e a r , the
the
linear n
o r m a l i z e d model was found
f o u n d to
t o be adequate
adequate for
for
linear
normalized
s c a l e - u p predictions
p r e d i c t i o n s for
f o r the
t h e l5-inch
1 5 - i n c h and 3D-inch
3 0 - i n c h mills
mills
scale-up
u s i n g the
t h e data obtained
o b t a i n e d from
f r o m the
t h e lO-inch
1 0 - i n c h mill.
mill.
using

5.

In wet
ball
wet b
a l l milling
m i l l i n g the
t h e specific
s p e c i f i c selection
s e l e c t i o n functions
f u n c t i o n s were
strongly
s t r o n g l y dependent
dependent on the
t h e particle
p a r t i c l e size
s i z e distribution
d i s t r i b u t i o n in
in
mill
the
the mill
m i l l but
but were independent
i n d e p e n d e n t of
of m
i l l diameter,
d i a m e t e r , particle
particle
load,
l o a d , ball
b a l l load
l o a d and lifter
l i f t e r configuration.
configuration.

6.
6.

The
T h e linear
l i n e a r model was found
f o u n d to
t o be valid
v a l i d in
i n wet
wet ball
b a l l milling
milling
only
o n l y if
i f the
the ppredictions
r e d i c t i o n s were
w e r e made for
f o r a narrow
n a r r o w range of
of
mills
the
the specific
s p e c i f i c energy
e n e r g y input
i n p u t to
t o the
t h e larger
larger m
i l l s using
u s i n g parapara
meters
mill
m e t e r s obtained
o b t a i n e d in
i n the
t h e laboratory
l a b o r a t o r y scale
scale m
i l l for
f o r the
t h e correscorres
ponding energy
e n e r g y range and similar
s i m i l a r fineness
f i n e n e s s of
o f feeds.
feeds.

7.

In an open circuit
prediction,
circuit p
r e d i c t i o n , the
t h e linear
l i n e a r model was valid
valid
with
wet
w i t h the
t h e same rrestrictions
e s t r i c t i o n s as applied
a p p l i e d to
t o tthe
he w
e t batch
batch
grinding
using
parameters obtained
g r i n d i n g case u
s i n g parameters
o b t a i n e d in
i n a laboratory
l a b o r a t o r y scale
scale
batch test.
test.
batch

The
T h e rresults
e s u l t s obtained
o b t a i n e d in
i n tthis
h i s investigation
i n v e s t i g a t i o n have important
i m p o r t a n t practipracti
cal implications
i m p l i c a t i o n s for
f o r commercial mill
m i l l scale-up
s c a l e - u p design.
d e s i g n . The
The w
o r k should
should
cal
work
be followed
f o l l o w e d with
w i t h similar
s i m i l a r studies
s t u d i e s in
i n still
s t i l l larger
larger m
i l l s and subsequentsubsequent
mills
l y commercial
commercial size
size m
ills.
mills.
ly
are:
are:

S p e c i f i c areas
areas which
w h i c h rrequire
e q u i r e further
f u r t h e r study
study
Specific

1) closed
c l o s e d circuit
c i r c u i t grinding--evaluate
g r i n d i n g e v a l u a t e the
the accuracy
a c c u r a c y of
o f scale-up
scale-up
1)

p r e d i c t i o n s for
f o r pilot
p i l o t scale
s c a l e and
and full
f u l l scale
s c a l e operation
o p e r a t i o n 2)
2) b
a l l size
size
predictions
ball
e f f e c t s s t u d y the
t h e effect
e f f e c t of
o f ball
b a l l size
s i z e on the
k i n e t i c s , as
effects--study
the breakage
breakage kinetics,

75

the
the bball
a l l size
s i z e used in
i n the
t h e commercial sca1e
s c a l e mills
m i l l s is
i s much 1arger
l a r g e r than
than
used in
i n the laboratory
l a b o r a t o r y scale
s c a l e mills
m i l l s and 3)
3) material
m a t e r i a l ttransport
r a n s p o r t effects-effectsstudy
mill
s t u d y tthe
h e effect
e f f e c t of
of m
i l l operating
o p e r a t i n g vvariables
a r i a b l e s and length
l e n g t h tto
o diameter
diameter
ratio
material
r a t i o on m
a t e r i a l residence
r e s i d e n c e ttime
i m e distribution.
distribution.

The
T
h e suggested
s u g g e s t e d work

t h e investigation
i n v e s t i g a t i o n rresults
e s u l t s ppresented
r e s e n t e d in
i n tthis
h i s thesis
t h e s i s promises
promises
based on the

to
provide
ball
mill
to p
r o v i d e a truly
t r u l y accurate
a c c u r a t e basis
b a s i s for
f o r commercial b
all m
i l l scale-up
scale-up
design.
design.

SYMBOL TABLE

77

Size-discretized
S i z e - d i s c r e t i z e d breakage
breakage functions,
f u n c t i o n s , cumulative
cumulative

b ..
. - ,,B
B .... ,,B
B
lJ

lJ

breakage
breakage function.
function,
dg

Ball
B a l l diameter.
diameter.

Mi
M i11
l l di
d iameter.
ameter,

exp

Exponential
Exponential

E(e)

An arbitrary
a r b i t r a r y residence
r e s i d e n c e time
t i m e distribution.
distribution.

E
E

Specific
S p e c i f i c energy
e n e r g y input
i n p u t to
t o the
t h e mill
m i l l (P/H).
(P/H).

Fraction
F r a c t i o n by weight
w e i g h t of
o f solids
s o l i d s in
i n the pulp
p u l p in
i n mill.
mill.

G
G

Reaction
R e a c t i o n force
f o r c e to
t o the
t h e force
f o r c e exerted
e x e r t e d by the mill
mill
on the
t h e lever
l e v e r arm of
o f the
the pprony
r o n y brake.
brake.

H
H

Mass holdup
h o l d u p of
o f material
m a t e r i a l in
i n the
t h e mill.
mill.

JI[

Identity
I d e n t i t y matrix
matrix

J,J

The
modal matrices.
T h e modal
matrices.

JJ ^..J ,J
J J ^ ..
J

Elements of
modal matrices.
o f modal
matrices.

Length
p r o n y brake.
brake.
L e n g t h of
o f the
t h e lever
l e v e r arm of
o f prony

Mi
M i11
l l length.
length.

1J

C1J

m.
m.j (t)
( t ) ,m.
, m . (E")
( F ) , ,m
m
1

Mass fraction
material
the ith
f r a c t i o n of
of m
a t e r i a l in
i n the
i t h size
s i z e interval
interval
at
a t ttime
i m e t,
t , at
a t specific
s p e c i f i c energy
e n e r g y input
input E
E and column
vector
v e c t o r of
o f mass fractions
f r a c t i o n s respectively.
respectively.

Mg,Mg,Mg

Mass of
balls,
mass of
balls
of b
a l l s , mass
of b
a l l s rrequired
e q u i r e d to
t o completely
completely
fill
f i l l struck
s t r u c k volume of
o f mill
m i l l and dimensionless
d i m e n s i o n ! e s s ball
ball
( M / M )'
l o a d (MB/M
load
BC ) .
The
T h e steady-state
s t e a d y - s t a t e size
s i z e distribution
d i s t r i b u t i o n of
o f the
the mill
mill
B

m^pjm^p

B C

feed
f e e d and mill
m i l l product.
product.

78
Mass hold-up,
h o l d - u p , mass of
o f pparticles
a r t i c l e s that
t h a t completely
completely
fills
f i l l s the
the interstices
i n t e r s t i c e s between tthe
h e balls,
b a l l s , the
the
(M /M ^).
d i m e n s i o n l e s s particle
p a r t i c l e mass (Mp/MpC).
dimensionless
p

Mill
M i l l speed,
s p e e d , critical
c r i t i c a l mill
m i l l speed and dimensionless
dimensionless
mill
m i l l speed (N/Nc).
(N/Nc).
p

Net
Net power drawn by the
t h e mill.
mill.

q*

Dimensionless
ball
Dimensionless b
a l l size
s i z e and lifter
l i f t e r geometry
g e o m e t r y variable.
variable.
Size
S i z e discretized
d i s c r e t i z e d selection
s e l e c t i o n function,
f u n c t i o n , specific
specific
selection
matrix
s e l e c t i o n function
f u n c t i o n and diagonal
diagonal m
a t r i x of
o f selection
selection
functions
f u n c t i o n s respectively.
respectively.

Torque
Torque

T .. ~T
lJ =

Elements of
o f eigenvectors
e i g e n v e c t o r s of
o f [L-]JS
[1-BlS and matrix
m a t r i x of
of
eigenvectors.
eigenvectors.
The mean rresidence
e s i d e n c e time.
time.

Time

Weight
Weight of
o f lever
l e v e r arm of
o f the
the prony
p r o n y brake.
brake.
Adjustable
A d j u s t a b l e pparameters
a r a m e t e r s in
i n the
t h e functional
f u n c t i o n a l form
f o r m for
for
breakage
breakage functions.
functions.
Power index
i n d e x showing power input
i n p u t dependence on
the
the mill
m i l l diameter.
diameter.
Adjustable
A d j u s t a b l e pparameters
a r a m e t e r s in
i n the
t h e functional
f u n c t i o n a l form
f o r m for
for
selection
s e l e c t i o n functions.
functions.

Dimensionless
D i m e n s i o n l e s s time
t i m e variable
v a r i a b l e tiT.
t/x.

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80
80

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S i z e s in
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APPENDIX II
EXPERIMENTAL PRODUCT SIZE
SIZE DISTRIBUTIONS
DISTRIBUTIONS
FOR CALCITIC
C A L C I T I C LIMESTONE GRINDING
GRINDING

84

TABLE 1-1
1-1
EXPERIMENTAL PRODUCT
PRODUCT SIZE DISTRIBUTIONS
Mill
M i l l Size:
Size :

10"

Medium: DDry
ry

10 x 14
14 mesh batch
batch
Feed Size:
S i z e : 10

Average
A v e r a g e Net
N e t TTorque:
orque:
H
H =
= 3300 grams
M**
MB
B

= 0.5
=

110.31 iin.
n . lbs.
lbs.

* =
= 1.0
1.0
N
N** =
= 0.6

t,~p
Wp

Passing
Cumulative
Fraction P
a s s i n g Stated
S t a t e d Size
Size
C u m u l a t i v e Mass Fraction
Size
Size
(Mesh)

0.0

0.5
0.5

- 10

1.0000

1.0000

1.0000

- 14

0.0450

0.2273

- 20

0.0000

- 28

Grind
G r i n d Time
T i m e (Min.
(Min.)
1.0
2.0
1.0

4.0
4.0

6.0

1.0000

1.0000

1.0000

0.3999

0.6170

0.8560

0.9522

0.1254

0.2352

0.4140

0.6815

0.8539

0.0000

0.0853

0.1624

0.2997

0.5372

0.7324
0.7324

- 35

0.0000

0.0609

0.1142

0.2186

0.4086

0.5909

- 48

0.0000

0.0456

0.0854

0.1644

0.3101

0.4645

- 65

0.0000

0.0348

0.0656

0.1278

0.2429

0.3705

-100

0.0000

0.0272

0.0513

0.0998

0.1897

0.2910

-150

0.0000

0.0224

0.0427

0.0821

0.1546

0.2353

-200

0.0000

0.0182

0.0350

0.0665

0.1253

0.1891

-270

0.0000

0.0162

0.0307

0.0587

0.1105

0.1649

-400

0.0000

0.0142

0.0261

0.0480

0.0882

0.1283

85

1-2
TABLE I-2
SIZE DISTRIBUTIONS
DISTRIBUTIONS
EXPERIMENTAL PRODUCT SIZE

Mill
M i l l Size:
Size:

1011
10"

Size:
Feed Size:

'natural'
mesh) batch
' n a t u r a l ' (-10 mesh)

~1edium:
Medium: DDry
ry

A v e r a g e Net
Net Torque:
Torque:
Average
H =
= 3300 grams
H
M** =
MS
= 0.5

i n . l1bs.
bs.
108.00 in.

* =
* =
N
N*
= 0.6

M = 11.. 00 .
~1p
p

Cumulative
C u m u l a t i v e Mass Fraction
F r a c t i o n Passing
P a s s i n g Stated
S t a t e d Size
Size
Size
Size
(Mesh)

0.0

- 10

1.0000

1.0000

11.0000
.0000

- 14

0.9698

0.9844

0.9989

- 20

0.8158

0.8916

0.9817

- 28

0.6955

0.7892

0.9380

- 35

0.5828

0.6735

0.8493

- 48

0.4904

0.5640

0.7360

- 65

0.4090

0.4726

0.6264

-100

0.3379

0.3904

0.5235

-150

0.2842

0.3265

0.4391

-200

0.2347

0.2671

0.3604

-270

0.2071

0.2341

0.3184

-400

0.1663

0.1803

0.2403

Grind
G r i n d Time
T i m e (Min.)
(Min.)
1.0
1.0

4.0
4.0

86

TABLE 1-3
1-3
EXPERIMENTAL PRODUCT SIZE
SIZE DISTRIBUTIONS
DISTRIBUTIONS
Mill
M i l l Size:
Size:

15"

Size:
Feed Size:

10
x 114
10x
4 mesh batch

Medium:
Medium: DDry
ry

A v e r a g e Net Torque:
Torque:
Average
H =
= 7425.0 grams
H
M** =
= 0.5
MB

i n . l1bs.
bs.
420.98 in.

* = a
* =
N*
= 0.6
0.6
N

M* = 1.
1.0
~1p

Cumulative
C u m u l a t i v e Mass FFraction
r a c t i o n Passing
P a s s i n g Stated
S t a t e d Size
Size
Size
Size
(Mesh)

0.0
0.0

0.5
0.5

Grind
G r i n d Time
T i m e (Min.)
(Min.)
1.0
1.0

2.0

4.0
4.0

- 10

1.0000

1.0000

1.
0000
1.0000

1.0000

11.0000
.0000

- 14

0.0450

0.2754

0.4707

0.7193

0.9082

- 20

0.0000

0.1435

0.2806

0.5102

0.7632

- 28

0.0000

0.0981

0.1966

0.3842

0.6259

- 35

0.0000

0.0695

0.1415

0.2859

0.4913

- 48

0.0000

0.0533

0.1067

0.2173

0.3801

- 65

0.0000

0.0408

0.0829

9.1691

0.3016

-100

0.0000

0.0318

0.0647

O.
131 a
0.1310

0.2370

-150

0.0000

0.0263

0.0534

0.1063

0.1929

-200

0.0000

0.0213

0.0431

0.0846

O.
1562
0.1562

-270

0.0000

0.0189

0.0376

0.0734

0.1370

-400

0.0000

0.0157
0.01 57

0.0306

0.0677

0.1082

87

TABLE 1-4
EXPERIMENTAL PRODUCT SIZE
SIZE DISTRIBUTIONS
DISTRIBUTIONS
Mil1
M i l l Size:
Size:

11
15
15"

r~edi
urn: DDry
ry
Medium:

Feed Size:
Size:

'natural'
(-10.mesh)
'natural
(-10 mesh) batch
1

Average
Net Torque:
i n . l1bbss .
A v e r a g e Net
T o r q u e : 430.00 in.
H
H =
= 7425.0
7425.0 grams
M**
MB
B

- 0.5
=

* = a
N
N** =
= 0.6

1.0
Mp = 1.
~~p

Cumulative
C u m u l a t i v e Mass Fraction
F r a c t i o n Passing
P a s s i n g Stated
S t a t e d Size
Size
Size
Size
(Mesh)

0.0

- 10

Grind
G r i n d Time
T i m e (Min.)
(Min.)
0.5
0.5

2.0

1.0000

1.0000

1.0000

- 14

0.9651

0.9830

0.9975

- 20

0.8065

0.8619

0.9544

- 28

0.6856

0.7453

0.8809

- 35

0.5758

0.6283

0.7733

- 48

0.4745

0.5274

0.6588

- 65

0.3957

0.4419

0.5575

-100

0.3269

0.3653

0.4645

-150

0.2736

0.3077

0.3929

-200

0.2241

0.2519

0.3268

-270

0.1986

0.2217

0.2897

-400

0.1570

0.1738

0.2302

88

TABLE 1-5
EXPERIMENTAL PRODUCT SIZE
SIZE DISTRIBUTIONS
DISTRIBUTIONS

Mill
M i l l Size:
Size:

3~''
30"

Feed Size:
Size:

10 x 14 mesh batch

Medium:
Dry
Medium: : D
ry

Average
Net
Average N
e t Torque:
Torque:

3551.2 in.
i n . l1bbs.
s.
1.00
Mp** = 1.
N* = 0.6

H
H = 46.5 kilograms
kilograms
M** = 0.5
MS

Cumulative
C u m u l a t i v e Mass Fraction
Fraction
Size
Size
(Mesh)

0.0

N =
Passing
P
a s s i n g Stated
S t a t e d Size
Size

Grind
G r i n d Time (Mi
( M in.
n . ))
0.5
2.0
0.5

4.0
4.0

- 10

1.0000

1.0000

1.0000

11.0000
.0000

- 14

0.0450

0.3024

0.7009

0.9020

- 20

0.0330

0.1803

0.5175

0.7668

- 28

0.0250

0.1279

0.4043

0.6415

- 35

0.0200

0.0918

0.3099

0.5186

- 48

0.0150

0.0695

0.2469

0.4130

- 65

0.0140

0.0525

0.1905

0.3313

-100

0.0075

0.0399

0.1468

0.2616

-150

0.0050

0.0318

0.1172

0.2113

-200

0.0040

0.0248

0.0906

0.1701

-270

0.0025

0.0212

0.0771

0.1452

-400

0.0020

0.0162

0.0583

0.1097

89

TABLE 1-6
EXPERIMENTAL PRODUCT
S I Z E DISTRIBUTIONS
PRODUCT SIZE

Mill
Size:
Mill S
ize:
Feed Size:
Size:

11
30
30"

Medium:
ry
r~ed i UIll: D
Dry

'natural'
mesh) batch
' n a t u r a l ' (-10 mesh)
batch

Average N
e t Torque:
Torque:
Average
Net

s.
3551.2 Ji nn.. l1bbs.

H =
= 46.5
4 6 . 5 kilograms
kilograms
H

M*
Mp

M**
MB

N*
= 0.6
N* =

= 0.5

= 1.0
1.0
=

Cumulative
C u m u l a t i v e Mass FFraction
r a c t i o n Passing
P a s s i n g Stated
S t a t e d Size
Size
G r i n d Time (Min.)
(Min.)
Grind
2.0

Size
Size
(Mesh)

0.0

- 10

1.0000

1.0000

1.0000

- 14

0.9225

0.9845

0.9970

- 20

0.7764

0.9278

0.9832

- 28

0.6693

0.8540

0.9540

- 35

0.5672

0.7552

0.8901

- 48

0.4838

0.6551

0.7939

- 65

0.4061

0.5623

0.6924

-100

0.3371
0.3371

0.4721

0.5899

-150

0.2813

0.3964

0.4976

-200

0.2291

0.3264

0.4145

-270

0.1995

0.2860

0.3705

-400

0.1534
0.1534

0.2191

0.2939

4.0

90

TABLE 1-7
1-7
EXPERIMENTAL PRODUCT
PRODUCT SIZE DISTRIBUTIONS
Mill
M i l l Size:
Size:

10"

Size:
Feed Size:

10x
batch
10
x 1144 mesh batch

Medium:
Medium: Wet-60% Solids
Solids

Net Torque:
Average
A v e r a g e Net
T o r q u e : 117.29 in.
i n . llbs.
bs.

H
H = 3300 grams

M* =
= 11.0
.0
~'1p

MB* = 0.5

N*

= 0.6

Cumulative
C u m u l a t i v e Mass FFraction
r a c t i o n Passing
P a s s i n g Stated
S t a t e d Size
Size
Size
Size
(Mesh)

0.0

0.5

1.0

(Mesh)

0.0

0.5

1.0

- 10

G r i n d Time
T i m e (Min.)
(Min.)
Grind
2.0
4.0
5.0
2.0

4.0

5.0

5.5

6.0

5.5

6.0

1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000 1.0000

- 10

1.0000

- 14

0.0450 0.3116 0.4702

1.0000
0.3116

1.0000

1.0000

1.0000

0.7180 0.9133 0.9605 0.9690

1.0000

1.0000

1.0000

0.9759

- 14

0.0450

0.4702

0.7180

0.9133

0.9605

0.9690

0.9759

- 20

0.0000 0.1562 0.2726

0.4983

0.7657

0.8596 0.8841

0.9068

- 20

0.0000

0.4983

0.7657

0.8596

0.8841

0.9068

- 28

0.0000 0.1040 0.1895 0.3681

0.6253

0.7410 0.7750

0.8125

- 28

0.0000

0.3681

0.6253

0.7410

0.7750

0.8125

- 35

0.0000 0.0708 0.1373 0.2722

0.4847

0.6009

0.6374

0.6801

0.6374

0.6801

0.1562
0.1040

- 35

0.0000

- 48

0.0000 0.0521

0.0708
0.0521

0.2726
0.1895

0.2722

0.4847

0.6009

0.1039 0.2048

0.1373

0.3722

0.4746 0.5082 0.5524

0.1039

0.3722

0.4746

- 48

0.0000

- 65

0.0000 0.0392

0.0816 0.1612 0.2920 0.3767


0.0816

0.5524

- 65

0.0000

0.2920

0.3767

0.4045

0.4396

0.0000 0.0304 0.0640 0.1260 0.2299

0.2984

0.3212

0.3502

-100

0.0000

0.0640

0.1260

0.2299

0.2984

0.3212

0.3502

-150

0.0000 0.0249 0.0527

0.1027

0.1894 0.2452 0.2638 0.2882

0.0304

0.1612

0.5082

0.4045 0.4396

-100
-150

0.0392

0.2048

-200

0.0000

0.0000

0.0249

0.0527

0.0427

0.0827

0.1546 0.1972 0.2134 0.2333

0.1894

0.2452

0.2638

-200

0.0000

0.0203

0.0427

0.0827

0.1546

0.1362 0.1718 0.1873

0.1972

0.2134

0.2038

-270
-270

0.0203

0.0000 0.0182

0.0375

0.1027

0.0725

0.2882

0.2333

-400

0.0000 0.0155 0.0302

0.0000

0.0182

0.0375

0.0570 0.1137

0.0725

0.1362

0.1339 0.1455 0.1587

0.1718

0.1873

0.2038

-400

0.0000

0.0155

0.0302

0.0570

0.1137

0.1339

0.1455

0.1587

91
91

1-8
TABLE I-8

EXPERIMENTAL PRODUCT
PRODUCT SIZE DISTRIBUTIONS
Mill
M i l l Size:
Size:

lO"
10"

Feed Size:
Size :

Medium: Wet-60% Solids


Solids

'natural
n a t u r a l I' (-10 mesh)

Average
A v e r a g e Net
N e t TTorqu.e:
orque:

batch
batch

113.34 in.
i n . l1bbss .
r'1p* = 1.0
M N
N* =
= 0.6

H
grams
H =
= 3300 qrams

M** =
= 0.5
MB

F r a c t i o n Passing
P a s s i n g Stated
S t a t e d Size
Size
Cumulative
C u m u l a t i v e Mass
Mass Fraction
G r i n d Time
T i m e (Mi
Grind
( M in.
n . ))
2.0
0.5

Size
Size
(Mesh)

0.0

- 10

1.0000

1.0000

1.0000

1.0000

- 14

0.9651

0.9817

0.9980

0.9995

- 20

0.8065

0.8684

0.9657

0.9928

- 28

0.6856

0.7566

0.9047

9.9710

- 35

0.5758

0.6394

0.8008

0.9131

- 48

0.4745

0.5339

0.6751

0.8111

- 65

0.3957

0.4465

0.5647

0.6868

-100

0.3269

0.3690

0.4635

0.5666

-150

0.2736

0.3092

0.3862

0.4728

-200

0.2241

0.2545

0.3163

0.3892

-270

0.1986

0.2236

0.2773

0.3433

-400

0.1570

0.1735

0.2101

0.2673

4.0

92

TABLE 1-9
TABLE
1-9
PRODUCT SIZE
SIZE DISTRIBUTIONS
EXPERIMENTAL PRODUCT
Mill
Size:
M
ill S
ize:

15"
15"

Feed SSize:
Feed
ize:

batch
''natural
n a t u r a l * I (-10
(-10 mesh)
mesh) batch

Medium: Wet-60% Solids


Medium:
Solids

Average
Net
A
verage N
e t TTorque:
orque:
-

=
M*
MB* =

H = 7425.0 grams
H
0.5
0.5

434.25 iin.
n . l1bbs
s.

* =
* == 0.6
N
N*
0.6

M* = 1.
1.0
r~p
0

Mass FFraction
Passing
Cumulative
C
u m u l a t i v e Mass
raction P
a s s i n g Stated
S t a t e d Size
Size
Size
Size
(Mesh)

0.0
0.0

0.5
0.5

- 10

1.0000

1.0000

- 14

0.0450

- 20

Grind
(Min.)
G
r i n d TTime
i m e (Min.)
1.0
1.0

2.0
2.0

4.0
4.0

1.0000

1.
0000
1.0000

1.0000

0.3295

0.5843

. 0.7926
0.7926

0.9620

0.0000

0.1709

0.3703

0.5801

0.8710

- 28

0.0000

0.1148

0.2685

0.4447

0.7559

- 35

0.0000

0.0799

0.1977

0.3359

0.6146

- 48

0.0000

0.0590

0.1480

0.2599

0.4810

- 65

0.0000

0.0456

0.1153

0.2044

0.3832

-100

0.0000

0.0355

0.0890

O.
1611
0.1611

0.3019

-150

0.0000

0.0290

0.0718

0.1321
0.1321

0.2480

-200

0.0000

0.0236

0.0560

0.1060

0.2049

-270

0.0000

0.0207

0.0478

0.0923

0.1830

-400

0.0000

0.0168

0.0381
0.0381

0.0758

0.1538

93

TABLE 1-10
I-10
EXPERIMENTAL PRODUCT SIZE DISTRIBUTIONS
Mill
M i l l Size:
Size:

151\
15"

Feed Size:
Size:

Inaturill
' n a t u r a l 'l (,...10
(-10 mesh)
mesh} batch
batch

Medium: Wet-60% Solids


Solids
Medium:

Average
A v e r a g e Net
Net Torque:
T o r q u e : 441
. 50 in.
441.50
i n . l1bbss .
H
H = 7425.0
7425.0 grams

M** =1.
=1.0
Mp

M** = 0.5
MB

N
N** =
= 0.6

Cumulative
F r a c t i o n Passing
P a s s i n g Stated
S t a t e d Size
Size
C u m u l a t i v e Mass Fraction
Size
Size
(Mesh)

0.0

Grind
G r i n d Time
T i m e (Min.)
(Min.)
0.5

2.0
2.0

- 10

1.0000

1.0000

1.0000

- 14

0.9651

0.9887

0.9992

- 20

0.8065

0.8874

0.9774

- 28

0.6856

0.7830

0.9278

- 35

0.5758

0.6644

0.8321

- 48

0.4745

0.5580

0.7127

- 65

0.3957

0.4659

0.5960

-100

0.3269

0.3857

0.4910

-150

0.2736

0.3259

0.4104

-200

0.2241

0.2709

0.3371

-270

0.1986

0.2409

0.2967

-400

0.1570

0.1941
0.1941

0.2319

94

TABLE I-11
1-11
EXPERIMENTAL PRODUCT
PRODUCT SIZE DISTRIBUTIONS
Mi
M i11
l l Size:
Size:

30"11
30

Medium: Wet-60% Solids


Medium:
Solids

Feed Size:
Size:

10
1 0 xx1 14
4 mesh batch
batch

Average
Net_Torque:
Average N
et T o r q u e :
H
H =
= 37.5 kilograms
kilograms
*

MS*

3141.7
3141. 7 in.
i n . l1bs.
bs.

*
Mp
M
*

= 1.
1.0
=
0
* = 0.6
N
N =
p

0.4
= 0.4

Cumulative
C u m u l a t i v e Mass Fraction
F r a c t i o n Passing
P a s s i n g Stated
S t a t e d Size
Size
Size
Size
(Mesh)

0.0

- 10

1.0000

1.0000

1.0000

1.0000

- 14

0.0450

0.3361

0.7584

0.9377

- 20

0.0420

0.1806

0.5617

0.8294

- 28

0.0250

0.1291

0.4445

0.7201

- 35

0.0125

O.
0951
0.0951

0.3488

0.5980

- 48

0.0115

0.0774

0.2769

0.4907

- 65

0.0110

0.0604

0.2221

0.4000

-100

0.0100

0.0484

0.1788

0.3248

-150

0.0100

0.0405

0.1490

0.2727

-200

0.0100

0.0340

0.1225

0.2257

-270

0.0100

0.0306

0.1083

0.1995

-400

0.0100

0.0261

0.0877

0.1597

G r i n d Time (Mi
Grind
( M inn.. )
0.5
0.5
2.0

4.0
4.0

95

TABLE 1-12
EXPERIMENTAL PRODUCT
PRODUCT SIZE DISTRIBUTIONS
Mill
M
i l l Size:
Size:

11
30
30"

Feed Size:
Size:

Medium: Wet-60% Solids


Solids

(-1 O~ mesh)
rnesh) batch
nna
a ttfJ
u rY'aal 1* { . (-10.
batch

A
verage N
e t Torque:
Torque:
Average
Net

i n . llbs.
bs.
3141.7 in.

H
H =
= 37.5 kilograms
kilograms

* =
M*
= 1.0
1.0
Hp

M*
= 0.4
MB* =

N*
= 0.6
N* =

Passing
C u m u l a t i v e Mass FFraction
raction P
a s s i n g Stated
S t a t e d Size
Size
Cumulative
Size
Size
(Mesh)

0.0

Grind
G r i n d TTime
i m e (Min.)
(Min.)
2.0

4.0

- 10

1.0000

0000
1.
1.0000

1.0000

- 14

0.9225

0.9968

0.9996

- 20

0.7764

0.9791

0.9982

- 28

0.6693

0.9415

0.9950

- 35

0.5672

0.8646

0.9700

- 48

0.4838

0.7609

0.9112

- 65

0.4061

0.6487

0.8090

-100

0.3371

0.5411

0.6874
0.6874

-150

0.2813

0.4464

0.5724
0.5724

-200

0.2291

0.3679

0.4692

-270

0.1995

0.3220

0.4127

-400

0.1534

0.2612

0.3257

96

TABLE 1-13
EXPERIMENTAL PRODUCT
PRODUCT SIZE DISTRIBUTIONS
Mill
M i l l Size:
Size:

11
30
30"

Feed Size:
Size:

'I nnaa tura1


tural

Feed Rate:
Rate:

1040 1bs./hr
lbs./hr

H
H =
= 80 lbs.
lbs.

*
M*
MB

= 0.4

Medium:
Medium: Wet
Wet
1

(-10 mesh)
mesh) open circuit
circuit

Average
A v e r a g e Net
Net Torque
Torque =
= 3096.0 in.
i n . l1bs.
bs.
N
N** = 0.6

Mass Fraction
Cumulative
C u m u l a t i v e Mass
F r a c t i o n Passing
P a s s i n g Stated
S t a t e d Size
Size
Size
Size
(Mesh)

Feed

Mill
M
ill
Contents
Contents

Mi
M i 11
ll
Di
D i sscharge
charge

- 10

1.
0000
1.0000

1.0000

11.0000
. 0000

- 14

0.9225

0.9930

0.9950

- 20

0.7764

0.9700

0.9850

- 28

0.6693

0.9417

0.9490

- 35

0.5672

0.8957

0.9099

- 48

0.4838

0.8299

0.8350

- 65

0.4061

0.7436+

0.7984
0.7984

-100

0.3371

0.6377

0.6888

-150

0.2813

0.5299

0.5766

-200

0.2291

0.4354

0.4765

-270

0.1995

0.3850

0.4247

-400

0.1534

0.2997

0.3337

+ differences
differences

in
mill
may
in m
i l l contents
c o n t e n t s and
and mill
m i l l discharge
d i s c h a r g e distributions
d i s t r i b u t i o n s may
be due
due tto
o selective
s e l e c t i v e losses
l o s s e s of
o f fines
f i n e s in
i n discharging
d i s c h a r g i n g the
t h e mill.
mill.

APPENDIX
APPENDIX II
II
COMPUTATIONS OF THE SPECIFIC
SPECIFIC ENERGY
INPUT TO THE
THE MILL

98
98

Energy
E n e r g y Calculations
Calculations
D u r i n g the
the experimentation
e x p e r i m e n t a t i o n tthe
h e ttorque
o r q u e exerted
e x e r t e d by tthe
he m
i l l has
mill
During
d i r e c t l y been measured in
i n the
t h e case of
o f the
1 0 - i n c h and 15-inch
1 5 - i n c h mills
mills
directly
the 10-inch
he p
i n i o n shaft
s h a f t in
i n the
t h e 30-inch
3 0 - i n c h mill.
mill.
and on tthe
pinion
the case ooff the
f i c energy
e n e r g y input
input
fic

measured.

T h e specispeci
The

(KWH/T)
t o the
the mill
m i l l can be computed from
f r o m the
the torque
torque
(K\~HjT) to

T h e computational
c o m p u t a t i o n a l method and pprinciple
r i n c i p l e involved
i n v o l v e d was ideniden
The

tical
Kim(10).
t i c a l to
t o the
t h e one used by K
im^^.
f r o m the
t h e fundamental
fundamental pprinciples.
rinciples.
from

He has derived
d e r i v e d the
t h e equation
e q u a t i o n used
T h e final
f i n a l equation
e q u a t i o n thus
t h u s obtained
obtained
The

is
i s given
g i v e n below:
below:
P
P

=
= 1.18
1.18

5 N'Tx 101 0 " NoT'


5

(KW)

(AII-l
( A I M)

where P
mill,
N the
the revoluP iis
s tthe
h e power in
i n kilowatts
k i l o w a t t s drawn by tthe
he m
ill, N
revolu
tions
per
minutes
tions p
er m
i n u t e s of
o f the
t h e mill
m i l l and T
T is
i s tthe
h e torque
t o r q u e recorded
r e c o r d e d directly
directly
by tthe
h e sensor
s e n s o r in
i n inch-pounds.
i n c h - p o u n d s . Then the
the specific
s p e c i f i c energy
e n e r g y input,
i n p u t , E,
E", to
t h e mill
m i l l is
i s computed from
f r o m the
t h e relationship:
relationship:
the

E = ^ i

(KWH/T)
(K\OIHjT)

(AII-2)
(AII-2)

where t is
H is
the particle
i s tthe
h e grind
g r i n d time
t i m e in
i n hours and H
i s the
p a r t i c l e mass hold-up
hold-up
i n tthe
he m
i l l in
i n short
s h o r t tons.
tons.
in
mill

In the
t h e case of
o f 30-inch
3 0 - i n c h mill
m i l l tthe
h e specific
s p e c i f i c energy
e n e r g y input
i n p u t tto
o the
the
the ppinion
mill
m i l l was measured from the
i n i o n shaft
s h a f t by a ttorque
o r q u e sensor
s e n s o r as shown
in
23.
i n figure
f i g u r e 7,
7, page 23.

The
T h e actual
a c t u a l energy
e n e r g y drawn by tthe
h e mill
m i l l is
i s comcom

u l t i p l y i n g the
the recorded
r e c o r d e d energy
e n e r g y by an efficiency
e f f i c i e n c y factor
factor
puted by m
multiplying

99
99

accounting
a c c o u n t i n g for
f o r the
t h e losses
l o s s e s in
i n the
t h e transmission
t r a n s m i s s i o n of
o f energy
e n e r g y from
f r o m the
the
pinion
p i n i o n shaft
s h a f t tto
o the
t h e mill.
mill.
Actual
Energy
Efficiency
Actual E
nergy =
= E
f f i c i e n c y xx Energy
E n e r g y measured

(AII-3)
(AII-3)

The
T h e efficiency
e f f i c i e n c y factor
f a c t o r was unknown and for
f o r the
t h e determination
determination a
prony
was designed.
p r o n y brake
brake was
designed.

The
T h e description
d e s c r i p t i o n of
o f the
t h e brake
brake is
i s given
given

Appendix.
in
i n the
t h e next
n e x t section
s e c t i o n of
o f this
this A
ppendix.
Prony Brake
Brake Measurements
Measurements
The necessity
n e c e s s i t y of
o f these
t h e s e ttests
e s t s arose
a r o s e out
o u t of
o f the
t h e fact
f a c t that
t h a t the
the
than that
actual
a c t u a l power drawn by the
t h e 30-inch
3 0 - i n c h mill
m i l l was lower
l o w e r than
t h a t recorded
recorded
by the
t h e ttorque
o r q u e meter
m e t e r at
at the
t h e ppinion
i n i o n shaft.
shaft.

Therefore
T h e r e f o r e the
the goal was to

determine
mechanical set
d e t e r m i n e tthe
h e efficiency
e f f i c i e n c y of
o f tthe
h e mechanical
s e t up (efficiency
( e f f i c i e n c y factor).
factor).
(22)
A prony brake was designed to measure the efficiency(22}.
A p r o n y brake was d e s i g n e d t o measure t h e e f f i c i e n c y

The
The

prony brake is a crude type of absorption dynamometer (sketched


p r o n y brake i s a c r u d e t y p e o f a b s o r p t i o n dynamometer

(sketched

below) and is shown on the mill surface in figure 6, page 21.


b e l o w ) and i s shown on the m i l l

s u r f a c e i n f i g u r e 6, page

21.

0)

Is
k

100
TOO

This
T h i s is
i s a simple
s i m p l e device
d e v i c e which
w h i c h measures the
the power transmitted
transmitted
by tthe
h e mill
mill M
M to
t o the
t h e steel
s t e e l band abcd.
abed.
wood blocks
b l o c k s K.

The
T h e band is
i s provided
p r o v i d e d with
with

The
T h e grip
g r i p of
o f the
the band on tthe
h e machined mill
m i l l surface
surface

can be adjusted
a d j u s t e d by a screw p.

As the
t h e grip
g r i p of
o f the
t h e band ttightens
i g h t e n s on

t h e rotating
rotating m
i l l the
t h e lever
l e v e r arm L,
L, w
h i c h is
i s welded
w e l d e d to
t o tthe
h e band and
the
mill
which

supported
to rrotate
s u p p o r t e d by the
the tie
t i e rrod
o d T,
T , ttends
e n d s to
o t a t e in
i n the
the direction
d i r e c t i o n of
of
the mill
m i l l rotation.
rotation.
the

S i n c e the
the lever
l e v e r arm end is
i s fastened
f a s t e n e d to
t o the
the
Since

t h r o u g h a spring
spring b
alance S
S rrecords
e c o r d s tthe
h e tangential
t a n g e n t i a l force
force
ground through
balance
exerted G
G (in
( i n pounds) on the
the lever
l e v e r arm.
exerted

a k i n g moment around
Then ttaking

t o t a l force
f o r c e exerted
e x e r t e d by the
the m
i l l ttangentially
a n g e n t i a l l y on the
the
p o i n t 0 the
t h e total
point
mill
s t e e l strap
s t r a p is
i s given
g i v e n by:
by:
steel

Gl

+
wl/2
+ w
l/2

(BII-l)
(BII-1)

where 11 is
the weight
i s tthe
h e length
l e n g t h of
o f the
t h e lever
l e v e r arm L
L in
i n inches
i n c h e s and w
w is
i s the
weight
(in
the lever
( i n pounds) of
o f the
l e v e r arm and tie
t i e rrod,
o d , assuming to be acting
acting
downwards at
at a distance
d i s t a n c e 1/2
1/2 ffrom
r o m the
t h e ppoint
o i n t O.
0.

With
W
i t h increasing
i n c r e a s i n g tension
tension

in
i n tthe
h e band abcd
abed the
t h e vvalue
a l u e of
of G
G increases.
increases.
The tests
t e s t s were mostly
m o s t l y carried
c a r r i e d out
o u t in
i n tthe
h e range of
o f power where
the
pO\<Jer drawn by
by the
a c t u a l power
t h e ppinion
i n i o n shaft,
s h a f t , at
a t tthe
h e time
time of
o f gr"inding,
grinding,
t h e actual
falls.
falls.

The mill
with
t h a t it
i t can be treated
treated
m i l l was packed w
i t h material
m a t e r i a l so that

as a solid
brake measurements.
s o l i d mass for
f o r pprony
r o n y brake

Various
V
a r i o u s rreadings
e a d i n g s were

taken simultaneously
brake and torquemeter
s i m u l t a n e o u s l y by tthe
h e prony
p r o n y brake
t o r q u e m e t e r at
at tthe
h e pinion
pinion
shaft
s h a f t for
f o r different
d i f f e r e n t tensions
t e n s i o n s applied
a p p l i e d to tthe
h e bband.
and.
per
p e r minute
m i n u t e were also
a l s o recorded.
recorded.

The
T h e revolutions
revolutions

Then the
by torquethe power rrecorded
e c o r d e d by
torque-

meter
brake readings
p r o n y brake
r e a d i n g s (Figure
( F i g u r e 33).
33).
meter was pplotted
l o t t e d against
a g a i n s t the
t h e prony

The
The

efficiency
mill
was then
then given
by the
the lline
e f f i c i e n c y of
o f the
the m
i l l was
g i v e n by
t h e slope
s l o p e of
o f the
i n e which
which
was 0.84
0.84
0.07
0.07 within
w i t h i n 95%
95% confidence
c o n f i d e n c e interval.
interval.

101
101

2.8
2.8

2.6
2.6

000

yO

;:
~

a::
or

2.4
2.4

x0

.-w
UJ

UJ
~

:J
S

2.2
2-2

a::
o

.0o

2.0
2.0

y/

~0.84

O~O
0o

0.84

....

1
I
i ----.i18----..,.2.0
i
1.8 L...---...J....----~--1.8
2.0
1.0
1.2
1.4
1.6
.
1.8
1.6

PRONY
F i g u r e 33.
33,
Figure

BRAKE (KW)
(KW)

Determination
30-inch
D e t e r m i n a t i o n of
o f efficiency
e f f i c i e n c y factor
f a c t o r for
f o r the 30-inch
m
i
l
l
u
s
i
n
g
t
o
r
q
u
e
s
e
n
s
o
r
a
t
t
a
c
h
e
d
to
the
p
i
n
ion
mill using torque sensor attached
pinion
s
h
a
f
t
and
p
r
o
n
y
brake
on
the
p
e
r
i
p
h
e
r
y
o
f
the
shaft
prony
on
periphery of the
mill.
mil 1.

102
102

TABLE II-1
II-l
SPECIFIC ENERGY INPUT
BATCH DRY
DRY
E(KWH/T)
10-IN MILL
10-IN

Feed
(Mesh)

P/H
P/H
(KW/T)

0.5

1.0
1.0

2.0

4.0
4.0

6.0
6.0

10x14
10x14

19.34
19.34

0.161

0.322

0.645

1.289
1.289

1.934
1.934

- 10

18.94
18.94

0.3156

1.262
1.262

Grind
G r i n d Times
T i m e s(Minutes)
(Minutes)

15-IN
- I N MILL
Feed
Feed
(Mesh)

P/H
(KW/T)

0.5
0.5

1.0
1.0

2.0
2.0

4.0
4.0

6.0

10x14
10x14

25.51

0.213

0.425

0.851

11.701
.701

- 10

26.06

0.217

Grind
G r i n d Times(Minutes)
Times(Minutes)

0.869

30 -IN
- I N MILL

Feed
(Mesh)

PjH
P/H
(KW/T)

0.5

24.53

0.204

Grind
G r i n d Times{Minutes}
Times(Minutes)
1.0
1.0

2.0

4.0
4.0

6.0

0.818

1.635
1.635

--

10x14
10x14
-10

103

TABLE 11-2
I12
SPECIFIC
SPECIFIC ENERGY INPUT
BATCH WET
WET
BATCH
E(KWH/T)
E*( KWH/T)
la-IN
10-IN MILL

P/H
P/H

Feed
(Mesh)

(KW/T)

0.5

10x14
10x14

20.56

0.171
0.171

10
- 10

19.97

0.166
0.166

Q > 5

Grind
G r i n d Times
T i m e s{Minutes}
(Minutes)
1.0
2.0
4.0
1.0
4.0
5.0
5.0
0.343 0.685 1.371
1.371

--

0.666 1.334
1.334

5.5
5.5

6.0
6.0

1.714
1.714 11.885
.885 2.056
2.056
-

1.997
1.997

15-IN
IN MILL
Feed
(Mesh)

(KW/T)

0.5
0.5

10x14
10x14

26.32

0.219

- 10

26.76

0.223

P/H
P/H

Grind
G r i n d Times{Minutes)
Times(Minutes)
1.0
2.0
1.0
2.0
0.439

4.0

0.877

1.755
1.755

0.892

30-IN
IN MILL
Feed
(Mesh)

P/H

(KW/T)

0.5
0.5

26.96

0.225

Grind
G r i n d Times{Minutes)
Times(Minutes)
1.0
2.0
1.0
2.0

4.0
4.0

10x14
10x14
-10

0.899

1.797
1.797

104
104

TABLE I 1I-3
-3
ESTH1ATED
ESTIMATED FEED SIZE
SIZE BREAKAGE FUNCTIONS
FUNCTIONS
AND SPECIFIC
SPECIFIC SELECTION FUNCTIONS
FUNCTIONS
la-IN
10-IN MILL

DRY
DRY

INDEX
INDEX i

B
..
B^.
lJ

WET
WET

S~^ (KWH/T)-l
S
KWH/T)"
1

B
.
B^.
lJ

S~S ^(KWH/T)-l
KWH/T)

1.
0000
1.0000

1.438
1.438

1.0000

11.714
.714

0000
1.
1.0000

1.162
1.162

1.0000

1.288
1.288

0.5551

0.939

0.5285

0.968

44

0.3390

0.759

0.3287

0.727

0.2276

0.613

0.2320

0.545

66

0.1665

0.495

0.1778

0.410

77

0.1295

0.400

0.1421

0.309

0.1050

0.324

0.1162

0.232

99

0.0868

0.261

0.0955

0.174

10

0.0728

0.211

0.0788

0.131

11
11

0.0620

O.
171
0.171

0.0658

0.099

12

0.0523

0.000

0.0541

0.000

105
105

TABLE 11-4
II-4
ESTIMATED SPECIFIC
FOR
SPECIFIC SELECTION FUNCTIONS
FUNCTIONS FOR
INPUT RANGES
STATED NARROW ENERGY INPUT

S~(KWH/T)-l
S^KWH/T)"
1

10-IN
10-IN MILL

BATCH WET
WET

10x14 MESH FEED

Index
Index i

1
0.0+2.0,4.0
0.02.0,4.0
min
min grinds
grinds

2
0.0+4.0,5.0
0.0*4.0,5.0
min grinds
min
grinds

3
0.0+5.0,6.0
0.0*5.0,6.0
mi n gri
min
g r i nnds
ds

1.763
1.763

1.777
1.777

1.860
1.860

1.322
1.322

1.358
1.358

1.407

0.991

1.038
1.038

1.065
1.065

44

0.743

0.793

0.805

0.557

0.605

0.608

66

0.418

0.463

0.461

77

0.314

0.354

0.349

0.235

0.270

0.264

99

0.176

0.206

0.199

10

0.132

0.158

0.151
O.
151 '

11
11

0.099

0.120

0.114

12

0.000

0.000

0.000

106

TABLE II-5
I1-5
ESTIMATED SPECIFIC SELECTION
FOR
SELECTION FUNCTIONS FOR
STATED NARROW
ENERGY INPUT RANGES
RANGES
NARROW ENERGY
1
S ? (KWH/Tf
(KWH/T)"
S~
1

10-IN
10-IN MILL

Index i1

BATCH
BATCH WET
WET
1
0.0+0.5,2.0,4.0,6.0
0.0+0.5,2.0,4.0,6.0
min grinds
grinds

0.0+0.5,2.0
0.00.5,2.0
min
min grinds
grinds

-10 MESH FEED


3
0.0+2.0,4.0
0.0+2.0,4.0
min grinds
min
grinds

4
0.0+4.0,6.0
0.0*4.0,6.0
min
min grinds
grinds

4.095

3.905

4.132

4.722

2.791

2.646

2.791

3.119

1.902
1.902

1.793

1.884
1.884

2.060

44

1.297
1.297

1.215
1.215

1.
273
1.273

1.361
1.361

0.882

0.822

0.858

0.897

66

0.602

0.558

0.580

0.593

77

0.411

0.379

0.392

0.393

0.280

0.256

0.265

0.259

0.190

0.173

0.178

0.170

10

0.130

0.118

O.
121
0.121

0.113

11
11

0.088

0.079

0.081

0.074

12

0.000

0.000

0.000

0.000

VITA
VITA
NAME:

Mohammad Siddique
Siddique

BIRTHPLACE:

Chaman, Pakistan
Pakistan

BIRTHDATE:

December 9,
9 , 1946

HIGH SCHOOL:

Islamia
I s ! a m i a High School
Quetta,
Q u e t t a , Pakistan
Pakistan

COLLEGE:

Government College
College
Quetta,
Q u e t t a , Pakistan
Pakistan

UNIVERSITY:
UNIVERSITY:

Engineering
E
n g i n e e r i n g University
University
Lahore,
L a h o r e , Pakistan
Pakistan
B. Sci.
1963-67, B.
S c i . (Mining Engineering)
Engineering)
Uni
U n i versi
v e r s i tty
y of
o f Utah
Utah
Salt
S a l t Lake City,
C i t y , Utah
Utah
S . (Metall
( M e t a l l urgy)
urgy)
1974-77, M. S.

PROFESSIONAL
PROFESSIONAL
QUALIFICATIONS:
QUALIFICATIONS;

PROFESSIONAL
PROFESSIONAL
ORGAN
IZAT IONS:
ORGANIZATIONS:

Second Class
C l a s s Mine
Mine Managers'
Managers
Competency Certificate,
Certificate,
o f Baluchistan,
Baluchistan,
Government of
Q u e t t a , Pakistan,
P a k i s t a n , 1972
Quetta,
Associate
off
A s s o c i a t e Member,
Member, Institute
Institute o
Mining
Mining Engineers
E n g i n e e r s of
o f Pakistan
Pakistan
Society
S o c i e t y of
o f Mining
Mining Engineers
E n g i n e e r s of
o f AIME

PROFESSIONAL
PROFESSIONAL
POSITIONS:
POSITIONS'-

Mining
Mining Engineer,
E n g i n e e r , Pakistan
P a k i s t a n Industrial
Industrial
Development
D e v e l o p m e n t Corporation,
C o r p o r a t i o n , 1968-73
1968-73
Quarry
Manager, State
Q u a r r y Manager,
S t a t e Cement Corp.
Corp.
I s k a n d e r a b a d , Pakistan
Pakistan
Iskanderabad,
Research AAssistant,
Research
s s i s t a n t , University
U n i v e r s i t y of
of
Utah,
U t a h , Salt
S a l t Lake City,
C i t y , Utah
Utah
1974-77

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