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K I N E T I C APPROACH TO
TO BALL MILL SCALE-UP
A
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
SUPERVISORY
COMMITTEE APPROVAL
of a thesis submitted by
Mohammad Siddique
de
/yJ!-z; LVz
Da
Mohammad Siddique
in its
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.
,(bdo,nl ;;J-L
David M. Bodily
Chairman! Dean
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
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
72
72
SYMBOL
SYMBOL TABLE
TABLE
76
76
REFERENCES
REFERENCES
............................................
..............................................
79
79
83
83
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 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
U.S.
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
processing
plant.
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 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
the
processing costs.
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
mill
s c a l e - u p d e s i g n and ( i i )
automatic
control.
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 ,
equation(l).
equation^^.
Bond e n e r g y - s i z e - r e d u c t i o n
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~
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 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 -
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 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
of these subprocesses i n t o a
correlation^.
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.
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).
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
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
if
differ
large
mills.
mill
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
t o t r e a t due to i n h e r e n t
non-linearities
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
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
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
'
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
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 )
(II-l)
cients (1,4,8).
1
coeffi-
U-
(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
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 ^
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 .
applications,
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
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
mill
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
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
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
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
(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
In a series of batch
In a s e r i e s o f batch
speeds
1) the s e l e c t i o n f u n c t i o n s
load.
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
size
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
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-
filling
of the mill.
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
scale-up d e s i g n ^ ^ .
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
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
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.
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
*
(M =1.0)
p
T h e speed o f t h e m i l l s
for
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
(F=0.6).
batch
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
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
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.
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)
(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
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
o0
Figure
F i g u r e 8.
8.
4
4
5
5
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
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
m
CO
X
_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:
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
~'
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
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
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
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
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).
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
'.
case f o r n a r r o w
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 .
parameter
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
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
behavior in
II
from
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
The values
The values
in Table
( 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,
(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
The specific
The s p e c i f i c
Appendix II.
Appendix I I .
in Table
(II-5),
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
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
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
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
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 .
in
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
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
region.
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
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:
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
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
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
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
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
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
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
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
the
T h e r e s u l t s c o n f i r m e d the
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
func
variables
(S?=S.(P/H))
design variables.
design v a r i a b l e s .
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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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
- 10
1.0000
- 14
1.0000
0.3116
1.0000
1.0000
1.0000
1.0000
1.0000
1.0000
0.9759
- 14
0.0450
0.4702
0.7180
0.9133
0.9605
0.9690
0.9759
- 20
0.4983
0.7657
0.8596 0.8841
0.9068
- 20
0.0000
0.4983
0.7657
0.8596
0.8841
0.9068
- 28
0.6253
0.7410 0.7750
0.8125
- 28
0.0000
0.3681
0.6253
0.7410
0.7750
0.8125
- 35
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
0.1039
0.3722
0.4746
- 48
0.0000
- 65
0.0000 0.0392
0.5524
- 65
0.0000
0.2920
0.3767
0.4045
0.4396
0.2984
0.3212
0.3502
-100
0.0000
0.0640
0.1260
0.2299
0.2984
0.3212
0.3502
-150
0.1027
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
0.1894
0.2452
0.2638
-200
0.0000
0.0203
0.0427
0.0827
0.1546
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
0.0182
0.0375
0.0570 0.1137
0.0725
0.1362
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 :
'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
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
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
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:
(-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:
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
(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
(sketched
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
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
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