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Minerals Engineering
journal homepage: www.elsevier.com/locate/mineng
a r t i c l e i n f o a b s t r a c t
Article history: The effect of grinding media on milling kinetics has been generally studied using one media shape. How-
Received 27 October 2010 ever, very little work has been done on investigating mixtures of media shapes.
Accepted 10 March 2014 Combining different grinding mechanisms in term of contacts, the volume of grinding zones can be effi-
Available online 31 March 2014
ciently increased when there is an optimal mixture of two or more grinding media with different shapes
and, therefore the milling kinetics will be improved.
Keywords: A series of batch grinding tests was carried out using the same mass of spherical balls, Eclipsoids™ and
Grinding
cubes to break coarse, medium and fine sizes of quartz material. Then, mixtures of the same mass made
Grinding media shape
Mixture of grinding media
of spherical balls and cubes, spherical balls and Eclipsoids™ were successively considered. The breakage
Selection and breakage functions parameters were determined and used to evaluate the grinding performances of the mixtures of grinding
media under the same conditions.
It was found that mixtures of grinding media shapes can increase the breakage rate in a particular mill-
ing environment. But, spherical balls remain the most efficient grinding media. Finally, an optimal mix-
ture made of spherical balls and grinding media of different shapes, namely cubes and Eclipsoids that are
cheaper to manufacture can be used in the grinding process alternatively to 100% balls.
Ó 2014 Elsevier Ltd. All rights reserved.
1. Introduction products and used the least power for constant batch grinding time
(Norris, 1953). Alternative shapes to balls have been suggested to
For decades milling has been the subject of intensive research. reduce the grinding costs and increase the milling efficiency.
Describing and understanding the process has been challenging However, the spherical balls which are predominantly used in
because of the tumbling mill environment itself. The problem with ore grinding change shape through breakage and wear. They can
tumbling ball mills is that they are extremely wasteful in terms of even break during the grinding process. The movement of these
energy consumed (Wills, 1992). The behaviour of the mill load irregularly shaped components through the mass of the charge is
plays an important role in the overall grinding mechanism. It is believed to differ significantly from the behaviour of initial grind-
directly influenced by some major factors, among them the consti- ing media shapes. Additionally these worn balls experience surface
tution of the charge, the speed of rotation of the mill, and the type and linear contacts with each other, while spherical ones have
of motion of individual pieces of medium in the mill (Gupta and only point contact interactions. The breakage is then done with a
Yan, 2006). From an industrial point of view, the main operational mixture of grinding media of different shapes rather than with a
flexibility is the amount and composition of the charge. Ideally, defined single shape of media.
grinding media should have the largest possible surface area to In this research, we investigate the breakage rate for different
provide suitable contact with the material being ground and they grinding media shapes and for the mixtures made of these shapes.
should be as heavy as possible to have sufficient energy required This requires a complete breakage characterization of the material
for breaking the ore particles. Spherical balls or spheres (here re- being described. The breakage parameters are determined for mix-
ferred as ‘‘balls’’) were found to be more efficient than other grind- ture of grinding media of different shapes, and then compared to
ing media shapes (Kelsall et al., 1973). Balls produced the finest the parameters of individual grinding media shapes. The overall
impact of the mixture of grinding media shapes is then evaluated
in terms of their grinding performances.
⇑ Corresponding author. Tel.: +27 11 717 7558; fax: +27 11 717 7591. The grinding process is satisfactorily described using the popu-
E-mail address: k.pascal.simba@gmail.com (Kalumba P. Simba). lation balance model. In this model, milling is expressed in terms
http://dx.doi.org/10.1016/j.mineng.2014.03.006
0892-6875/Ó 2014 Elsevier Ltd. All rights reserved.
K.P. Simba, M.H. Moys / Minerals Engineering 61 (2014) 40–46 41
d
of the selection function and the breakage function (Austin et al., xi
1981). On a laboratory scale, the selection and breakage functions /j ¼ /1 ð7Þ
x1
are determined by batch grinding tests performed on single parti-
cle sizes for a ball charge consisting of a single size. where d characterizes the degree of non-normalization.
The selection function is the fractional rate at which a given size Some materials are subjected to abnormal breakage in labora-
of particle is broken into smaller particles. The breakage of a given tory mills where a departure from first-order kinetics occurs par-
fraction of material usually obeys a first-order pattern (Austin ticularly for the larger particle sizes in the mill feed (Austin et al.,
et al., 1984). 1973). Several models were proposed to explain it (Austin et al.,
1977; Bilgili et al., 2006).
Rate of breakage of size i ¼ Si wi W ð1Þ
The basic mill power drawn equation described by Hogg and
where wi is the weight fraction of material of size i, W is the total Fuerstenau (1972) is given by:
material charge in the mill and Si is the specific rate of breakage
of size i.
2pNs
P¼ ð8Þ
Since the total mass W is constant, this equation becomes: 60
dwi ðtÞW where N is the mill speed in rpm, s is the torque exerted by the mill
¼ S1 w1 ðtÞW ð2Þ minus friction in the bearings.
dt
S1 is the specific rate of breakage when the feed is ground for a set of
time t1, with units of time1. Then, if S1 does not vary with time, we 2. Experimental
obtain after integration:
The small Wits laboratory mill was used to carry out the batch
log w1 ðtÞ log w1 ð0Þ ¼ S1 t=2:3 ð3Þ
grinding tests on the quartz sample. This mill was fitted with eight
where t is the grinding time. equally spaced lifters. The mill has 0.302 m diameter and 0.282 m
The formula used for the variation of the specific rate of break- length, and driven by a 0.25 kW mono-phased variable speed mo-
age Si with particle size is: tor. It was run at 75% of the critical speed with a ball filling J of 20%
a and a powder filling U of 75%.
xi 1
Si ðdÞ ¼ aðdÞ QðxÞ with QðxÞ ¼ h iK ; K>0 ð4Þ
x0
1 þ lxðdÞ
i
2.1. Grinding media and test materials
where a(d) and a are parameters dependent on the material ground Balls, cubes and Eclipsoids™ made of cast iron were used for the
in a particular mill under defined operating conditions; xi is the par- batch tests. Eclipsoids™ are semi-prolate spheroid (stretched ellip-
ticle size in mm; x0 is a reference size, usually 1 mm; l(d) defines soid of revolution). Their shape is similar to that of a half rugby
the particle size at which Q(x) is 0.5 and K is an index of how rap- football (Fig. 1).
idly the rate of breakage falls away (Austin et al., 1982). The equa- The spherical balls, cubes and one of the mixture used in this
tion relating the value of the size xm (at which the rate of breakage study are presented in Fig. 2.
is a maximum for a given material) to the parameter l(d) is as 40 mm balls, 40 40 mm Eclipsoids and 32 mm cubes were
follows: used. The total load mass was kept constant for all grinding media
1=K shapes, as well as for the mixtures of grinding media for an average
K
l ¼ xm 1 ; on condition that K > a: ð5Þ porosity of 0.4 (Austin et al., 1984). The grinding media shapes
a were used to grind 11 different mono-sized feed fractions of quartz
The specific rate of breakage increases steadily with particle with a specific density of 2.64 g/cm3. The size fractions chosen for
size which reflects the decreasing strength of the particles as size the tests were ranging between 16,000 and 300 lm. These size
increases. This is attributed to the greater density of microflaws fractions were picked in order to get the value of the parameter
in the interior of larger particles and to the greater likelihood that a and the value of xm, the size at which the maximum value of
a particular large particle will contain a flaw that will initiate frac- the breakage rate S occurs.
ture under the prevailing stress conditions in a mill. The decrease The physical properties of the grinding media used are pre-
in particle strength does not lead to an indefinite increase in the sented in Table 1.
specific rate of breakage. As the particle size becomes significant
by comparison to the size of the smallest media particles, the pre- 2.2. Experimental methods
vailing stress levels in the mill are insufficient to cause fracture and
the specific rate of breakage passes through a maximum and de- The one-size-fraction method (Austin et al., 1984) was used to
creases with further increase in particle size (King, 2001). perform our batch grinding tests. Four grinding times were consid-
The breakage function describes the size distribution of the ered: 0.5, 1, 2 and 4 min. For every test, a blank sieving test was
products of breakage. The general fitting model of the breakage done on the prepared feed material. The prepared material was
function is given by: then loaded and ground in the laboratory mill for 30 s. After this
c b grinding period, the mill content was discharged. A full particle
xi1 xi1
Bi;j ¼ /j þ ð1 /j Þ ; 0 /j 1 ð6Þ size distribution was done on the collected product using nested
x1 x1
screens in decreasing order of sizepffiffiffifrom the top screen down to
where c, b and /j are all characteristic of the material being ground the 75 lm screen at interval of 2. After all this, the material
and xi is the top size of the size interval indexed by i. was then recombined for batch grinding for 30 s to reach a total
Bi,j represents the cumulative weight fraction of material broken grinding time of 1 min. The very same process was performed.
from size j which appears in size interval i. The subscript 1 refers to Then load was ground for 1 min to reach 2 min, and finally it
the original material of size 1 at time t = 0, the subscript i refers to a was ground for 2 min to reach 4 min. Each grinding process was
smaller size than the size j and the subscript j refers to the size followed by a size analysis and the material was recombined at
from which material that appears in size i are broken. the end of each process.
42 K.P. Simba, M.H. Moys / Minerals Engineering 61 (2014) 40–46
Fig. 2. Photographs of spherical balls, cubes and a mixture of grinding media shapes used in this study.
Table 1
Physical properties of the grinding media.
Grinding media Balls Eclipsoids Cubes Mix B–Ea Mix B–C 1a Mix B–C 2a
Mass (kg) 0.256 0.256 0.260 – – –
Specific gravity (g/cm3) 7.64 7.64 7.93 – – –
Surface area (cm2) 50.27 62.84 61.44 – – –
Volume (cm3) 33.51 33.51 32.77 – – –
Grinding media number 72 72 71 36–36 36–35 54–18
Mass charge (kg) 18.432 18.432 18.460 18.432 18.432 18.504
Total surface area (cm2) 3619.58 4524.48 4362.24 4072.03 3987.60 3820.61
Total volume (cm3) 2413.06 2413.06 2326.53 2413.06 2368.03 2399.62
a
Mix B–E is the mixture made of 50% balls and 50% Eclipsoids, Mix B–C 1 is the mixture made of 50% balls and 50% cubes and Mix B-C 2 is the mixture made of 75% balls
and 25% cubes.
3. Results and discussion between 0.883 and 0.999 for the mixtures of grinding media used.
It can be seen that the first-order law is a good approximation for
The first order plots for different feed sizes of quartz ground by smaller sizes used, but it does not apply very satisfactorily for the
balls, cubes, Eclipsoids and the mixtures made of these media largest size (16,000 + 13,200 lm and 13,200 + 9500 lm) espe-
shapes were plotted using the weight fraction remaining on the cially for the mixtures. In this abnormal region, there are large
top size. They are presented in Figs. 3–8. lumps too strong to be broken in the mill or particles too big for
These plots can be described by first-order grinding kinetics
with coefficients of determination R2 between 0.972 and 0.999
for all the single shapes, but the coefficients of determination are
Fig. 4. First order plots for dry grinding of quartz with 40 40 mm Eclipsoids
Fig. 3. First order plots for dry grinding of quartz with 40 mm balls charge. charge.
K.P. Simba, M.H. Moys / Minerals Engineering 61 (2014) 40–46 43
Fig. 8. First order plots for dry grinding of quartz with the mixture of 75% balls and
Fig. 5. First order plots for dry grinding of quartz with 32 mm cubes charge. 25% cubes charge.
observed and the slow movement of air through beds of fine parti-
cles. This blows away particles or absorbs impact like a hydraulic
shock absorber (Yekeler, 2007). The bed of cohesive fine particle
may develop almost liquid-like properties flowing away particles
from the grinding media – grinding media collision region leading
to insufficient stress to be transmitted to individual particles for
fracture to occur. The quartz material used exhibits abnormal
breakage, and is assumed to comprise at least two fractions: a
fast-breaking fraction and a slow-breaking one.
The variations in the specific rates of breakage at different feed
particle sizes for balls, cubes, Eclipsoids and the mixtures are
shown in Table 2.
The rate of breakage varies with size. The specific rate of break-
age increases up to a maximum feed size and decreases rapidly
above this size fraction for all grinding media charges (refer to
description). The particle sizes at which the rate of breakage is
Fig. 6. First order plots for dry grinding of quartz with the mixture of 50% balls and maximum for each media shape used are presented in Table 3.
50% Eclipsoids charge.
Therefore, above the maximum xm, particles are either too
strong or too big to be properly nipped and fractured by the grind-
ing media used and have a slow rate of breakage.
Figs. 9–11 show the variation of the specific rate of breakage
with size using these different grinding media shapes.
These curves show that balls are the most efficient. The break-
age rates of balls are higher than the ones of the other grinding
media in the normal grinding region. But Eclipsoids are breaking
the coarser particles faster than balls. The specific rate of breakage
of Eclipsoids for coarser particles is higher than the one of balls
(see Table 2). Fig. 9 also reveals that cubes are the least efficient
of the three single grinding media shapes considered.
The mixture of 50% balls and 50% Eclipsoids presents a higher
breakage rate in the abnormal region compared to balls and Eclip-
soids alone. This is illustrated in Fig. 10.
Fig. 11 shows that the three mixtures used have similar break-
age rate behaviour in the medium and the fine particle size region,
but they behave differently in the coarser region for the mill con-
Fig. 7. First order plots for dry grinding of quartz with the mixture of 50% balls and
50% cubes charge.
ditions used. And for the different mixtures made of balls (the most
efficient) and cubes (the least efficient), the 75%–25% mixture has a
higher breakage rate for coarser particles, compared to the 50%–
the energy of the tumbling mill to be used efficiently in causing 50% mixture. This is an indication of how important the proportion
fracture (Austin et al., 1984). In this region, the breakage rate de- of a grinding media shape is in the mixture.
creases with time in a non-linear manner (Bilgili and Scarlett, The specific rate of breakage parameters were estimated by using
2005). The energy applied is just sufficient to load comparatively the non-linear regression technique fitting the Si to Eq. (4) and are
few regions of the quartz particle to the fracture point, and only presented in Table 4. Basically, this technique finds the best combi-
a few particles result (fracture by cleavage). And relatively small nation of fitting parameters of a model by minimizing the square of
pieces are cleaved off the particle, leaving a particle of essentially the differences between the experimental values Pexpt(t) and the
the original size (Spottiswood and Kelly, 1990). The progeny size predicted ones Pmodel(t) (Katubilwa and Moys, 2009).
is comparatively close to the original particle size. The fine The parameter K was fixed and kept constant because we do
particles produced may then cause the slowing down phenomena not have enough information to determine it accurately. We used
44 K.P. Simba, M.H. Moys / Minerals Engineering 61 (2014) 40–46
Table 2
Specific rate of breakage for different particle sizes.
Table 3
Particle sizes at which the selection function are maxima.
Fig. 11. Variation of the specific rate of breakage with size for mixtures of grinding
media used.
Table 4
Breakage rate parameters obtained from the laboratory tests.
Grinding a l a K SSE R2
media
Fig. 9. Variation of the specific rate of breakage with size for balls, cubes and their Balls 0.272 8.81 1.14 3.70 0.012445000 0.996343153
mixtures. Cubes 0.151 9.49 1.14 3.70 0.009938289 0.991499046
Eclipsoids 0.258 9.08 1.14 3.70 0.011180000 0.986700132
Mix B–E 0.234 10.43 1.14 3.70 0.023279655 0.964345277
Mix B–C 1 0.257 7.61 1.14 3.70 0.035727100 0.954280896
Mix B–C 2 0.249 9.43 1.14 3.70 0.000370930 0.999511907
with rotational speed, ball load, ball size or mill hold-up over the
normal recommended test ranges (Austin and Brame, 1983) for
dry milling, but the value of a will vary with mill conditions. The
value of a that was found to satisfactorily characterize the break-
age rate is 1.14.
Then, a and l which vary with the mill conditions were deter-
mined using the same technique. The parameter a is directly pro-
portional to the specific rate of breakage. It is expressed in
time1. The parameter l is the particle size at which the correction
factor that allows for the slower mean breakage rate of the larger
sizes is 0.5. This parameter l is related to xm since both are depen-
dent on where the curve specific rate of breakage vs. particle size
starts to bend. The values of l were found to be directly propor-
Fig. 10. Variation of the specific rate of breakage with size for balls, Eclipsoids and
their mixture.
tional to the corresponding values of xm for each grinding media.
The values of the parameters a and l are presented in Fig. 12.
Balls present the highest a-value parameter while cubes have
the Austin’s value for K (Austin et al., 1982). a, which is character- the lowest one. Consequently, they have the highest rate of break-
istic of the material, was satisfactorily determined and kept con- age while cubes have the lowest rate of breakage among all the
stant. The parameter a is a positive number normally in the grinding media used. Balls also present the lowest value of param-
range 0.5–1.5. It is characteristic of the material and does not vary eter l among the single media shapes considered. This shows that
K.P. Simba, M.H. Moys / Minerals Engineering 61 (2014) 40–46 45
Table 6
Power drawn by different grinding media shapes.
4. Conclusions References
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Acknowledgement