Professional Documents
Culture Documents
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\ 11
FRED C. BOND
Processing Machinery Deportment
ALLIS-CHALMERS MANUFACTURING COMPANY
Milwaukee, Wisconsin
ABSTRACT
This paper presents a summary of equations useful in crushing and grind-
ing calculations, starting with the Third Theory. Each equation is explain
ed briefly, but in order to save spoce no numerical calculation examples
pr derivations are included. Nearly all are original with the author, and
many hove never been published before. Many are empirical, with numer
icol constants derived from experience. A list of references and a complete
I i st of the mathematical symbols used are included.
..
ALLIS-CHALMERS t\..t.1letr4
\'
07R9235B)
JC(tA,2,1~'1
622.731;621.926
'---'"
CRUSHING &
GRINDING
CALCULATIONS
PART I
The crushing and grinding of ores, rocks a nd mi nerals is an industrial process of great importance. Specialized
engineering knowledge is required for the solution of practical problems in particle size reduction, and
codification of thi s knowledge has hardly begun. The present paper is an attempt to assemble a highly
condensed summa ry of the principal calculation methods which the author has found useful. References are
given to articles w ith a mo re extensive expla nation and examples of calculations.
by FRED C. BOND
OMMINUT ION theory is concerned with the relationship between energy input and the product particle size
made from a given feed size. It continues to be a rich field
of controversy.
The oldest theory (1867) is that of RITIINGER,1 and it still
has adherents. He stated that the area of the new surface
produced by crushing or grinding is directly proportional to
the useful work input. The surface area of a ton of particles
of uniform diameter d is proportional to 1I d, and according to R rrriNGER the useful work input per ton is also
proportional to 1I d. H owever, the measured surface energy
of the new surface area produced is only a very small fraction of the order of 1I 1000 of the energy input actually
required to produce that surface in commercial crushing
and grinding. Nea.rly all of the required energy input appears as heat after the particles are broken.
The second theory (1885) is that of KICK. 2 He stated that
the work required is proportional to the reduction in volume
of the particles concerned. Where f is the diameter of the
feed particles and p is the diameter of the product particles,
the reduction ratio Rr is f I p. According to K rcK, the work
input required per ton is proportional to log Rr flog 2.
Since neither theory agrees with commercial crushing and
grinding results, the author developed the Third Theory in
1951.3 According to this theory, the work input is proportional to the new crack tip length produced in particle
breakage, and equals the work represented by the product
minus that represented by the feed. In particles of similar
shape, the crack tip length is equivalent to the square root
W=
10 Wi
10 Wi
y' p
y'F
.... (1)
where Wi is the work index. The work index is the comminution parameter which expresses the resistance of the
material to crushing and grinding. Numerically the work
index is the kWh per short ton required to reduce the
material from theoretically infinite feed size to 80 per cent
passing 100 microns, equivalent to about 67 per cent passing 200 mesh. When any three of the quantities in Equation
(I) are known, the fourth can be found by transposing the
equation. Useful forms are shown in (1a) and (1 b) below:
Wi
I(;p - ;F)
= w
p = (
10 Wiy'F )'
WVF + 10 Wi
.. .. (Ia)
.. .. (lb)
3.97 w.
If the material is homogeneous to size reduction, its Wi
- 1-
Reprinted From
x.2
.3
.4
Ei
.5
X2
Er
Cr
:::E
~
(.)
~
0
>tOL-----L-~~~L-~~~-ll--~U----i~~~
MESH
0
0
8
100"'
80
100
90
80
60
--
40
30
(!)
Ui
~o
0.. 8
~ 6
4
200
400
600
600 1000
...co
SCALPED FEED CORRECTION PLOT
- 2 -
diameter, as shown in the work index Equation (l). Crushing and grinding machines are essentially devices for the
conversion of mechanical energy into strain energy into
heat, under conditions which promote material breakage.
The energy register as used herein represents the specific
energy which has passed through the material as strain
energy, and includes heat losses and losses due to friction
and other causes. It does not correspond to the energy
content of the material.
The Third Principle deals with the relationship of particle
flaws to material breakage. A flaw is defined as any struc
lura! weakness in a particle which may develop into a crack
tip under strain. Flaws are always present in brittle
materials and may cause wide variations in the breaking
strengths of apparently similar particles.
The weakest flaw in a particle determines its breaking
strength in crushing and grinding. It also controls the number of particles produced by breakage. Particles with the
weakest flaws break most easily and produce the largest
product particles. However, they are not necessarily easier
to grind to a given product size requiring several stages of
breakage than are particles of the same size whose weakest
flaw is stronger.
~~~
The Third Principle states that the weakest llaw in a
particle determines its breaking strength but..not its work
index. The work index is controlled by the average flaw
structure throughout the entire size range tested. Work
index variations at different product sizes result from flaw
concentrations or shortages at those sizes, usually caused by
natural grain sizes.
Three Principles
Comminution phenomena have recently been redacted into
three principles, which are useful guides for the considera
tion of all crushing and grinding data.
The First Principle states thaL since energy input is neces
sary fiirs Jze reduction. all feea particles of finite size have
a certain energy register, or energy level, which must be
added to the energy input during crushing or grinding to
obtain the energy register of the product. All statements of
the energy"'utilized in comminution must satisfy this condi
tion:
energy input = energy register of product - energy
register of feed.
The Third Theory work index Equation (1) follows this
principle, with the energy register equal to the total specific
energy input in kWh per short ton. The work index Wi is
the energy register to 80 per cent passing I 00 microns.
Jf the energy which bas been expended in preparing the
feed particles is neglected in analysing comminution data,
the first principle has been violated. and application of the
calculated result to different feed and product sizes will be
distorted.
The Second Pria~pje states that the useful work input in
crusung ana gri n mg is proportional to the 1ength of the
new crack tips produced. Tn ordinary crushing and grinding,
rock particles absorb strain energy and are deformed under
compression or shear until the weakest flaw in the particle
fails with the formation of a crack tip. This minute change
of shape causes other crack tips to Corm at other weak flaws,
and the particle breaks, releasing the bulk of the strain
energy as heat. The strain energy required to break is proportional to the length of the crack tips formed. since the
additional energy required to extend the crack tips to
breakage is supplied by the flow of the surrounding resident
strain energy to the crack tips.
Since the crack tip length is proportional to the square
root of the new surface area produced, the specific work
input required is inversely proportional to the square root
of the product particle diameter minus that of the feed
(-=-)IX
k100
(2)
Sc = P
1]
.... (3)
- 3-
p miC:toll$
10
100
0. 10
0.20
0.30
0.40
o.so
0.60
0.70
0.80
0.90
1000
Cr
Er
207.0
212.0
208.5
202.0
19 1.9
183.0
176.0
165.8
160.0
79.8
93.0
102.1
110.0
115.2
119.4
123.0
125.8
128. 1
27.3
36.6
42.5
48.1
52.7
57.1
60.8
64.3
67. 5
10.65
14.00
16.89
19.56
21.95
24.25
26.35
28.40
30.35
3.76
5.25
6.60
7.87
9.00
10.04
11.00
11.94
12.85
1.37
1.93
2.47
2.96
3.44
3.91
4.37
4.81
5.22
0.495
0.735
0.936
1.136
1.337
1.523
1.699
1.860
2.029
( w)
.. . (Sa)
10 )
- yF
(1)
10
10 )
yF
.... (8)
- 5-
'
Crushing
Crushing is accomplished by contact with metal or other
surfaces maintained in a fixed position or in a rigidly constrained motion path, although many crushers have safety
features which allow release under excessive pressure. This
is contrasted with grinding, which is accomplished by the
free motion in response to gravity and other forces of
unconnected media such as rods, balls, rock pieces and
pebbles.
Free media grinding has several inherent advantages over
fixed media crushing, and as reduction machinery increases
in size and strength larger particles become amenable to
grinding which could formerly be reduced only by crushing.
Cases in point are the development of large peripheral discharge rod mills and autogenous grinding mills. However,
the commercial production of particles larger than about
t in. is still a crushing process.
Crushing is usually done dry in several stages with small
reduction ratios ranging from 3 to 6 in each stage. The
machines used include: gyratory crushers. jaw crushers
(both single and double toggle), crushing rolls, and impact
crushers, hammer mills or pulverators. It is done with both
screened and natural feeds, in stages with screens between
each stage to remove undersize, as well as in open circuit
and in closed circuit with screens.
Excessive moisture, fines, or both, in the feed can cause
packing in the crusher, resulting in a decrease in capacity,
increase in power drawn, and increase in the crushing pla)lt
work index. This is usually remedied by screening out more
fines ahead of the crusher.
Crusher motor sizes are usually limited to protect the
crushers against breakage. For the same reason uncrushable
pieces of metal are usually removed from the feed magnetically, or the crusher is designed to open up and let them
pass through.
Crusher Product Sizes
The crusher product size which 80 per cent passes at full
- 6-
'
Size
~ee
Mrcron~
Inch
Mesh
- d(=Pol
3 in.
2 in.
I ln.
76,200
50.800
26,670
18,850
13,330
9,423
ln.
in.
Mesh
3
4
6
8
10
14
20
28
35
48
65
100
ISO
200
270
325
400
6,680
4,760
3,360
2,380
1,680
1,190
840
S90
420
297
210
149
lOS
74. 2
52.5
44
37.1
30
2S
20
IS
10
As
Cr
Fe
Slope o r
sle\e lines
cm.cc
Mlc:rons equivlllcnt
19.30
15.73
I 1.42
9.60
8.56
6.79
0.626
0.769
1.057
1.260
1.500
1.782
255.000
163,000
76,000
50,400
34,000
23,000
5.70
4.82
4.0S
3.14
2.86
1.41
2.024
1.699
1.432
1.205
1.012
.853
.716
.602
.506
464
.426
.383
.350
313
.l71
. 221
.156
2.12
2.51
2.98
3.55
4.22
5.02
5.97
7.13
8.45
10.01
I 1.94
14.18
16.90
20.02
23.9
26.1
28.4
31.6
34.6
38.7
44.7
54.8
77.5
(Er~O.OS)
Fineness Adjustment
Experience bas shown that extremely fine grinding
requires additional energy input beyond that indicated by
the work index Equation (1). There are several possible
reasons for this, including :
(a) The ball sizes customarily employed are too large
for extremely fine particles.
(b) In fine grinding the closed-circuit classification is
usually either inefficient or absent.
(c) In dry grinding of fine particles the amount of ball
coating ranges from incipient to complete. Ball
coating cushions the metal contacts and decreases
grinding efficiency.
(d) In wet grinding a thick viscous pulp can cause ball
cushioning and decrease grinding efficiency.
(e) The production of particles smaller than the grind
limit Li of 0.1 micron involves breakage across the
unflawed space lattice, and requires several times as
much energy input as the customary breakage along
planes of lattice displacement.' Considerable amounts
of trans-grind-limit particles may be produced in
ultra-fine grinding.
V{hen the product size P jsJ ess than 70 microns the work
input W as calculated from laboratory tests is multiplied
bY the following empirical adjustment factor A1, which
equals
A -=
1o.3
1.145P
The fine product factor A1 was derived for the fine dry
grinding of cement clinker, and applies to dry grinding down
to P values of 15 or less. For wet fine gr inding, A1 should
have a maximum value of 5.
Conversely, the plant operating work index from Equation (la) should be divided by A1 and by (8/D)02 for direct
comparison with the laboratory work index Wi.
15,400
10,400
8,000
s,soo
3.760
2,600
1.800
1,220
835
580
375
250
158
103
71
59
so
40
34
27.3
20.7
14.0
7.0
Grinding
Correction for Feed and Products
Closed-circuit grinding and complex grinding circuits
which include concentration and separation equipment arc
best analysed by considering each circuit as an integrated
unit. I n closed-circuit grinding the unit consists of the mill
and the classifier, with a single feed to the mill or classifier
and a single classifier undersize product. Calculations from
the mill discharge and circulating load are usually unsatisfactory because the harder fraction of the material accumulates. and the circulating load bas an unknown higher work
index than the new feed. If the closed circuit includes concentrating equipment such as magnetic separators which
reject a tailing, the product of the grinding circuit is a calculated composite of the classifier undersize and the separator tailing, which should always be screen analysed for this
purpose.
Calculations involving unnatural feed from which part
or all of the fines have been removed should be avoided
whenever calculations of integrated circuits can be substituted. However. the empirical methods described under
"Scalped Feed to Crushers" can be used when necessary
in grinding circuits.
When grinding tests arc made in a small, continuous,
pilot-plant mill of diameter D, the gross power input per
- 7-
. ... (12)
ln Equation No.
A,
26
27
A,
A,
B
Bl
b
5
4
6
9. 37. 38, 39. 40, 41
33, 35, 36
Cs
12, 13, 19
II,
33
39,40
28,29
19, 21-25
27,38
I
11
4b
I, 2, 3, 4, 19, 32
Cl
Cp
Cr
Css
Cw
cpm
Dp
Ecc
Er
F
Fe
Fo
~~ 31, 32
Fp
{Jd
Gbp
40
:3, 34
Grp
Hd
9
28
Kwb
Kwr
kau
L
Li
"'Nc
No
Oss
p
P,
8d
p
Rf
Rp
Rr
Rro
Sc
Sg
Ss
Sw
Tb
Tr
29
22
21
2, 3
j6, 17
39,40
18
20
10
13, 14
13
23
3
35, 36
37, 38
4,5
2S
3
6
24
5
16
17
39,40
f{;d
23
IS
I, 2. 3. 4
I, 6-13
Wt
w
X
y
ex
I, 10
Wi
W!P
w.,
2. 3
42
42
Ff
= 160
Wi Sg
100 Cs
yD
.... (l3)
Wben the reduction ratio Rr = F I P is less than 8, the calculated value of B should be increased by t in.
Description
Exponential plot slope.
Fine product adjustment factor.
Rod mill Rr adJustment factor
Ball mJU Rr adJUStment factor.
D iam. in inches of balls and rods fed.
Blaine surface area in sq. em/gram.
Exponential size distribution coefficient.
Ft-lb per inchl impact crushing strength.
Per cent circu ating load/ I 00.
Microns 80 per cent of concentrate passes.
Total crack lengtb-emJce.
Fraction of mill critical speed.
Close side crusher setting in inches.
Per cent weight of concentrate in feed.
Per cent passing in classifier tine product.
Cycles per minute in free vertical oscillation .
Inside mill diameter in feet.
Per cent of diseharee pa.s sina size P.
Microns 80 per cent p:.sses.
Eccentric throw of crusher in inches.
Exponential plot exposure ratio.
Feed si~c--illicrons 80 per cent passes.
Equivalent size of scalped feed.
Maximum efficient feed size in mlcrons.
Per cent of new feed passing size P.
Diameter of feed particle in microns.
Per cent passing in mill new feed.
Grind differential
Ball mill arindability A- C, net grams{
revolution.
Rod mill arindability A-C, net granuf
revolution.
h
K
Kvo
Hardgrove grindability
Inches of free vertical oscillation.
Grindina media size constant.
Kilowatts per ton in free vertical oscillation.
Kilowatts per ton of balls.
Kilowatts per ton of rods.
Schuhmann microns I 00 per cent passes.
Length of mill interior in feet.
Grind limit in microns.
Per cent passing in mill discharge.
Critical mill speed in rpm.
Optimum mill speed in rpm.
Open side crusher setlin& in inches.
Product size-microns 80 per cent passes.
Sieve openin11 in microns-A-C ifindability.
Feet from top of mill to charge.
Feet from top of mill to lowest diseharee
point.
R=!l'on factor between concentrate and
feed.
Per cent of oversize passing size P.
Reduction ratio - F /P .
Optimum rod mill reduction ratio.
Surface area in sq. cm/aram.
Specific gravity of ore.
Ball slump subtraction quant ity.
Sq em per gram, Wagner surface.
Tons of balls in mill.
Tons of rods in mill.
Per cent passing in classifier coarse product.
Fraction mill volume occupied.
Fraction of mill volume below discharge
level.
Work input in kWh per short ton.
Work index: kWh/ton to 80 per cent100 mJerons.
Work total: kWh/ ton to product si~c.
kWh/ WI
Exponential plot abscissa.
Per cem cumulative retained on any size.
Slope of size distribution line.
Work Index from plot at product size P.
Work Index from plot at feed size F.
In this paper three classes of symbol are used: lower case single letters. upper
case single letters and compound symbols consisting of an upper case letter
followed by one or more lower case letters. They are distinguished by the sequence
rule; lower ease single letters are written first. followed by upper case single letters,
and in every term the compound symbols are writlen last.
8-
Number of balls or
feet rods
One ball
One ft rod
13,500/B' balls
750tB' fr rods
balls
1.9
146/ fr rods
Equilibrium charge fed
with B balls
OJD'
lb.
0.1488'
2.678 1
2.000
2,000
290
390
2,000
cu. ft.
Sq. in.
surface area
6.89
5. 13
I
I
3.14281
37.8B
42,500/B
28,400lB
6,160fB
5,510 B
6.89
57,500/ 8
622.731:621.926
Fig. 1. Fourteen
800-hp ball mills
installed at Southern
Peru Copper Corp.'s
concentrator, Toquepalo, Peru, grinding
30,000 tons of copper ore daily.
PART
II
CRUSHING AND
GRINDING CALCULATIONS
The concluding part of this article is concerned with a number of factors affecting the grinding
process and the life of equipment, such as the fraction of mill volume occupied by the grinding charge, the quantities of rods and balls to be contained in a mill, we:ar of mill and
gri nding medium, and mill speed in terms of the critical speed. The effects of mill diameter, of
downward slippage of ball charge, ratio oversize:feed, upon performance and power consumption are discussed. Open-circuit multiplication factors are given for converting closed-circuit
work values to the open-circuit values and, finally, correction factors are given for work
index variations which arise when laboratory grindability and impact crushing tests give
different work index values.
by
FRED
c.
BOND
Metal Wear
ETAL wear is usually the second largest single item
of expense is conventional grinding, and in wetgrinding installations it may approach or even exceed the
power cost.
Metal wear is commonly expressed in lb/ton crushed or
ground. However, variations in feed and product sizes and
in work index are eliminated by expressing metal consump.
tion as lb/kWh, including rejected worn parts; it can be
obtained from the pounds of metal consumed per ton
crushed or ground and the kWh/too.
The pounds of metal both worn away and scrapped as
worn parts varies with the abrasiveness of the ore and the
abrasion resistance of the metal. The average values from
a large number of mills with ordinary mill linings and
grinding media, grinding wet a large range of siliceous ores,
are as follows :
Mill Type
Rod
Ball
0.21 rods
Media : lb/kWh
0.14 balls
0.026
0.020
Lining: lb/kWh
The metal wear in dry grinding averages about oneseventh that of wet grinding the same material. However,
many of the materialS ground dry are softer and less
abrasive than those ground wet. Ball coating in dry grinding
can reduce the metal wear still further.
Well over half of the metal wear in wet grinding results
from corrosion, or dissolution from the active nascent metal
surfaces continually being produced in the mill. For this
Abrasion Tests
Abrasion tests to indicate metal wear are made as
follows: 10 400 grams of -t + !-in. particles of the material
to be tested are placed in a rotating drum for 15 min. The
drum showers the rock through a rapidly rotating impeller
contained within it. The impeller rotates at 632 rpm and
consists of a 3 X 1 X tin. steel paddle with 2 sq. in. exposed
to wear, machined of SAE 4325 steel hardened to 500
Brinell. The grams of weight lost by the paddle after impacting four successive 400-gram batches of rock for 15 min.
each is called the abrasion index and designated as Ai.
The combined product of the four 15-min. periods is screen
analysed; it averages 80 per cent passing 13,250 microns.
Paddles of special alloy steels and cast irons can be
tested with a standard abrasive material to determine relative wear resistance of the metals.
The average Ai values of some typical materials from
125 tests are listed in Table IIA in the appendix. A firm
correlation with actual wear rates in crushers and grinding
mills has not been made as yet; however, it is apparent that
the abrasion index variations shown in Table IIA are much
greater than the variations to be expected in the metal
wear rates in commercial machines. It is observed that any
correlation between the work index and the abrasion index
is very slight.
Preliminary indications are that in wet grinding the
pounds of balls per kWh equals (Ai + 1) divided by a
- 9-
ro
- 10-
- - - - - - -
MICRONS
Vl
(/)
~
60
0..: 40
I-
zw
30
Fig. 2.
TOP: Classifier performance plot.
Oversize per cent cum. on plotted against undersize
per cent passing. Intersection shows 83 per cent
classifier efficiency and 165 microns parting size.
5 20
~
Cii
ex:
w
~
:)
a..
oO!
00
" ..
fu.
3: 6
3 -
20(Rr -
.... (27)
1.35)
8y
3:
+ 0.40;; Vpd J.
G~~-
:.::
Slump Correction
Ss =
:5
....
(24)
- 11 -
Lv'P
v'F
+ (Gd
-1)
_ (Gd -1)
.... (
+
+
1
2
34)
Gd1
1
Gd2
1
If the recession factor Rf is the number of standard '2
screen scale spaces between size P and size Cp, then
Rl
Cp (2)2
.... (35)
.... (36)
The Schuhmann slope a of tbe heavier concentrate is commonly greater than that of the lighter tailings.
Classifier Performance
In closed-circuit reduction the efficiency and the separating size, cut point or parting size of the classifier or screen
are important. The efficiency is comJllonly expressed as
100 minus the per cent of finished material or "unders" in
the oversize returned to the mill or crusher, at a certain
selected sieve size,
The parting size is defined as the size at which the per
cent "unders" in the separator oversize equals the per cent
"overs" in the separator undersize. The separator undersize per cent passing, and the separator oversize per cent
cumulative retained on, are plotted as smooth curves on
100 _
[% ~od mill.disc~arge]
of
passmg parting s1ze
% Eft'.
[ 100
+ 100-% Eff.]
100 C/
.... (41}
- 12-
Open-circuit
multiplication factor
50
1.035
1.05
1.10
1.20
1.40
1.46
1.57
1.70
60
70
80
90
92
95
98
on the same sa~l~at different product sizes. This comtfficates tbe calculation of the work input required (W) in
kWh/ton from Equation (1), which is used with the desired
capacity to find the required motor and mill size.
When this happens the various work index values are
plotted vertically as ordinates on log-log paper against the
80 per cent passing sizes as abscissae, and the points are
connected by straight lines which are extended horizontally
to the edges of the paper. The 80 per cent passing sizes of
grindability test products are found by dividing the screen
openings P1 in micr ons by log 20 (1.301), or by the values
given following Equation (8) for fine ball mill tests. The
80 per cent passing size is 1.5 in. for the impact crushing
tests.
The work index values at the designated 80 per cent passing product size P and feed size F are fovnd from the
plot and designated as Wi11 and Wit. Then the work in ut
W is found from Equation (42) as given t;ioW:
10 Wip _ 10 Wip + IO(Wir - Wip'
w=
'\1 p
VF
l.SVF
.... (42)
Appe ndix
TABLE lA
Symbol In Equation No. t
A
A,
A,
A,
Bl
b
Cl
Cp
Cr
C$
Css
Cw
'lJm
Dp
d
&c
Er
F
Fe
Fo
Fp
4
26
27
5
4
6
9, 37. 38, 39, 40. 41
33, 35, 36
12, 13, 19
II
33
39.40
28 29
19: 21-25
27, 38
I
II
4b
I, 2, 3, 4, 19, 32
30, 31, 32
38
Gd
Gbp
40
33,34
8
Grp
Hd
9
28
fa
K
Kvo
Kwb
Xwr
29
22
21
Description
Jn this paper three eiii$$CS of symbol are used: lower case single leuers, upper
case single !etten and compound symbols consisting of an upper case letter
followed by one or more lower ease leuers. They are distinguished by the sequence
k,
L
Ll
m
Nc
No
Oss
sd
13, 14
IS
23
3
35,36
Rp
Rr
Rro
37, 38
4, s
25
3
6
24
P,
Sc
Sg
S4
Sw
Tb
Tr
I
Jlp
Ypd
Wi
16
17
39,40
IS
23
I, 2, 3~
I, 6-1
Wt
I, 10
4
4
2. 3
42
42
WJ,.
"''
Desctiption
Schuhmann microns 100 per cent passes.
Length of mlll interior in feet.
Gri.n d limit in microns.
Per cent passing in mill dis:harac.
Critical milt r:d in rpm.
Optimum mU speed in rpm.
Open side crusher setting in inclles.
Product siz-microiiS 80 per cent passes.
S1eve opcnlna in microns-A-C anndabllity.
Feet f roa- top of mUI to charge.
Feet _from top of mill- to lowest dlscharac
po1nt.
DensltrRecession factor between concentrate and
feed.
Per cent of oversizoAassina size P.
Reduction ratio - ~P.
Optimum rod mill reduction ratio.
Surface area in ~ cmfaram.
Specific &ravity o ore.
Ball alump subtraction quantity.
Sq em ~ Waan surface.
Tons of
In mill.
Tons of rods in milL
Per cent pas$ing in classifier coarse product.
Fraction mill volume occupied.
Fraction of mill volume below dlscbarac
level.
Worlc input In kW~r short ton.
Work index: kW ton to 80 per cent100 microns.
Work total: kWh/ton to product size.
kWh/ WI
E>rponentiaJ plot abscissa.
Per cent cumulative retained on any 1ize.
Stope of alze distribution line..
Work Index from plot at product size /'.
Worlc Index from plot at feed size F.
X
y
2, 3
16, 17
3
39,40
18
20
10
rule; tower case single letten are written lint. followed by upper case sin&Je lett en,
and in every tcnn the compound symbols arc wrluen last.
t Equations (2), (18), (39) and (40) were not derived by the author.
No.
Tested
I
6
I
2
Microns
15,500
13,330
12,100
I
I
12
10,200
12,900
I
I
I
2
II
2
3
4
3
15,200
Wi
Average
AI
0.3850
0.64-47
0.0073
10.9
IO.S
9.6
20.7
11.2
19.4
II 3
20. 1
14 8
14.4
19.0
8.6
5.4
8.3
Material
Limestone
Magnesite
Magnerite
Manganese ore
Nickel ore
Perlite
Pumice
Quartz
Quartzite
Rare cartlu
Rhyolite
Schist-biotite
Shale
Slag
Slate
Sulphur
Taconite
Trap Rock
O.O.o9
0.0372
0.1200
0.3095
0.0950
0.0061
0.2303
0.0160
0.5360
0.2000
0.3937
0.3051
0.0952
0.0770
0.1520
I'
Mleroas
19
3
2
I
2
2
I
7
3
I
2
I
2
I
I
I
7
13 000
14:400
II
(Total)
- 13 -
No.
Tested
Average
Wi
AI
12.1
16.8
10.2
17.2
11.9
0.0256
0.0750
0.2517
0.1133
0.0215
0.0452
0.1187
0.1831
0.6905
0.0288
0.4993
0.1116
0.0060
0.0179
0.1423
0.0001
0.6837
0.3860
11.9
12.8
12.2
13,200
11,200
14,900
--
t25(Av.) 13,250
23.5
11.2
15.8
13.8
li.S
16.2
19.9
-13.8
-0.228
'
'
TABLE rnA-Average Work Indexes by Types of Materials
Caution should be used in applying the average work indeiC values Usted here to spe<:itlc installations, since the individual variations between materials in any
classification maybe quite large.
Average
Average
Material
All materials tested
Andesite
Barite
Basalt
Bauxite
Cement clinker
Cement raw material
Chrome ore
Clay
.gi satcjpill
Coke
Coke, fiuio ~troi~um
Coke, petro eum
Copper ore
Coral
Diorite
Dolomite
~
Ferro-chrome
Ferro-manganese
Ferro-silicon
Flint
Fluorspar
Gabbro
Galena
Garnet
Glass
Gneiss
Gold ore
Granite
Graphite
Gravel
Gypsum rock
Ilmenite
Iron ore
Hematite
Hematit.,_specular
Oolitic
Limanite
Magnetite
Taconite
No. of
Tests
2088
6
II
10
It
60
87
4
9
7
10
12
2
308
5
6
18
4
8
18
10
15
8
4
7
3
5
3
209
74
6
42
5
1
8
79
74
6
l
83
66
Specific
Gravity
Sg
2.84
4.28
2.89
2.38
3.09
2.67
4.06
2.23
2.32
1.63
1.51
i.63
1.78
3.02
2.70
2.78
2.82
3.48
2.59
6.75
5.91
4.91
2.65
2.98
2.83
5.39
3.30
2.58
2.71
2.86
2.68
1.7.5
2.70
2.69
4.27
3.96
3.76
3.29
3.32
2.53
3.88
3.52
Work
Jndex
Wi
Material
Kyanite
Lead ore
Lead-zinc ore
~/
6.24
20.41
9.45
13.49 .
10.57
9.60
7.10
Limestone
..
~
20.70
3ii.6V
rnospnate rocK
73.80
13.13
10.16
19.40
11.31
Potash ore
Potash salt
Pumice
Pyrite ore
Pyrrhotite ore
Quartzite
Quartz
Rutile ore
Sandstone
Shale
Silica
Silica sand
Silicon carbide
Silver ore
Sinter
Slag
Slaa, iron blast furnace
Slate
Sodium silicate
Spodumene ore
Syenite
Tlle
Tin ore
~
8.87
1.17
12.83
26.16
9.76
18.45
10.19
12.37
3.08
20.13
14.83
14.39
45.03
25.17
8.16
13.11
15.44
12.68
15.40
11.33
8.45
10.21
14.87
Titanium ore
Trap rock
Uranium ore
Zinc ore
REFERENCES
' vON RtTTtNGI!Jt, P. RITTER. !.eltrbuch der Au/bereilungskunde, Berlin.
1867.
Ktc K, F'lttDIIJCH. Das Gesetz der proport/onalem Widerstand und Seine
Anwendrmg, Leipzig, 1885.
BoND, F. C. "Third Theory of Comminution", A.l.M.E. Trans., 1952,
193, 484; Mining Engineering, May 1952.
' BoNO. F. C. "Three Principles of Comminution", Mining Congress
Joumal, August, 1'160
SCKUliMANN, JR., R. "Principles of Comminution I", A.l.M .E . Tech.
Publ. 1189. 1940.
BoNO, F. C. "Confirmation of the Third Theory" , A .I.M .E. Mining
Transactions, 1960.
- 'BoND, F. C. "Standard Grindability Tests Tabulated", A.l.M.E. Trans. ,
1949, 183, 313, 1949.
BoNO. F . C. "Grinding Ball Size Selection; Mining Engineerina, May
1958". A.l.M.E. Trans., 1958, 211, 592.
No. of
Tests
4
22
27
119
62
15
I
2
6
II
9
3
2i
8
3
4
4
3
16
17
5
8
13
7
17
7
6
9
12
6
5
3
7
3
3
9
16
49
20
10
Specific
Gravity
Sg
3.23
3.44
3.37
2.69
2.68
3.74
5.22
2.89
2.70
3.32
1.76
2.65
2.66
2.37
2.18
1.96
3.48
4.04
2.71
2.64
2.84
2.68
2.58
2.71
2.65
2.73
2.72
3.00
2.93
2.39
2.48
2.10
2.75
2.73
2.59
3.94
4.23
2.86
2.70
3.68
Work
Index
Wi
18.87
I 1.40
11.35
11.61
10.18
12.46
16.80
134.50
12.97
I 1.88
18.10
13.03
iV.ij
8.88
8.23
11.93
8.90
9.57
12.18
12.17
12.12
11.53
16.40
13.53
16.46
26.17
17.30
8.77
15.76
12.16
13.83
13.00
13.70
14.90
15.53
10.81
11.88
21.10
17.93
12.42
- 14-
.. .,/
(X . ~TA ~ ~ o Ll2...!S
Co LU t-l.& I A \l~l \/tQS \TY
\-J EW "t'Ot?...K:. 2rJ N { .
fEnPriOl ~. !TAMnOATZU!
.\l'fi 1 , 1962
*'
By Fred C . Bond
Page
Colu mn
Paragraph
3-1
1
3-1
3-2
3-2
Remove:
"
usually caused by natural grain sizes."
Add:
''The natural grain size distribution of a
crushed or ground product delineates its flaw
s t r u c t u r e . ''
4-1
In line 4 insert:
"negative" between
"-- A is the" and "slope."
4-1
Page
Column
Paragraph
4-1
9
I
= O.j
Er
4-2
'l.s
(4c)
0(
+ 2. '2.0
[P] o.3~Ye. ...o.9~
190 E.r
. . .
( 4d)
. . .
( 4e)
. .
( 4 f)
los (E.- -r
o. 2.8) + D.77
o. 012 S'
"where Ce is the crock energy in joules
(watt-seconds per centimeter:
Ce
3. ~ 1 W i
S.9r{\;: t-
100
In line 3 change:
4-2
Change E q .
( 5 ) to :
Change Eq.
(Sa) to:
= 6. , 0 0 0 , 0 0 0 I B1
"
l.~~s
VSg
.. ( 5 )
Add:
o.9'l.
''
(Sa)
.p
1/
J::... SJ
... (5b)
2 0".
Insert paragraph following "--(8 /D)'
1000
. (7a)
Page
Co lumn
Paragraph
S-1
3
(Co nt.d )
\~
5-2
10 Wle
/0 W/p
Vr
1/P
I O{Wle- VJ/p)
(7b)
;.s~
(Sa)
Wi
100
The calculated
product size P
The calculated
Wip and WiF in
In line 3 change
11
Change Eq.
Kwr :::.
11-1
"--!!.
of 0.05 11 to
11
(8 b)
--Er of zero"
(21) to:
/.07
0 ( '-'3- S.4Vp) ~s
... (21)
11-1
o . OJ/1fo Wiloo Ss
I o g ( E ~ fD + o . .3) + o . 7 3
(22) change:
"2.80
0.4"
0 3"
to "3.10 '
(24) to :
... (24)
Page
Column
Paragraph
11-2 3
~hange
Eq. (27) to :
2 (.,q .... - /.3S)
A3=
12-1
+ o. 2.~
2.(~,.. -/.35")
...
(27)
t,.
..