Escolar Documentos
Profissional Documentos
Cultura Documentos
1111
su .
Js
11.
\~11
. .
S..
's l!ook tlo\o\' S n>w liglt on the internal eclHics of mills. lt covers among
others thc following aspects: Ball, tube,
rod, ebl>le, IHtcl, grate-discharge, trunnion-overfiow, larc]inage and airswept
mills; open- and closed-circuit grinding;
dry and wet milling; contamination of
products. Single ball in mill; cascading;
cataracting; equilibrium surface of
charge, etc. The power to drive a mill.
Perfect crystals; heterogeneous boclies;
crushing a single particle; scale effects;
effects of impact velocity. Dirnensional
analysis; rate of g1inding. Effect of pulp
consistency preferential grinding; influence of shape of grinding media; size
distribution of grinding media: rate of
flow through continuous mills. Surging;
lifters; vib!'ation frequency spectrum: clestruction of geal'ing. Rose 's tleory of
metal \vear; factors affecting ball wear;
influence of coosion. The l'ole of aclditives in milling.
TR EA TI SE
IN TE RN AL ME CH AN IC S OF
BALL, TU BE AN D
R O D MILLS
by
. . RO SE
D.Sc .(Eng .) , Ph.D .
AND
R.
. .
SU LLI VA N
B.Sc.(Eng .)
~
'
1 9 5 8
CHE MIC AL PUB LIS HIN G CO., INC
.
212 Fijt h Ave nue
New York , . .
FOREWORD
by
PROFEssoR DR .-ING. RoBERT MELDAU
First published
1958
Chemical Publisl1in g Co., lnc.
e1- York
. .
I l g grinding media.
I ) , I ose is well-known to the F achgruppe "Staub I i l<" of the V erein D eutsch er Inge nieure, for his
l in Germ a ny on his researches into milling and
l 111 gen eral properties of p owdered m a terials and
1 y knowled ge of him and of the researches which are
111 ; d out under his direction, a m sure tha t Dr.
I ' : 1 d Mr. Sulliva n are well equipped to write on the
l j .
'
',
..
PREFACE
ROBERT MELDAU
PoL YTECHNISCHE HocscHULE,
HANNOVER.
LS
BAL L, TUB E J\ND ROD MIL
9
ied
appl
y
tivel
j wi tl1i11 the mill cann ot be mos t effec ess for whic h
proc
e
ofth
e
ledg
know
und
kgro
i : b
l 111 11 iR r quired.
revi ewin g the
l;: y,. t~e intr~d.ucti<;>n of a chap ter grou nds that
the
on
fied
justi
Is
tlves
addl
l1 1 / mill ing
ify the beha viou r of a
t I ~~ l Hl< nces can grea tly mod
so, even thou gh it is
and
"' 111 i,~ .turi ng com min utio n
actio n is phys ical,
this
her
~het
11 1 l ly kno~n
tted from a book
I 1 : l J' echanical, It cann ot be omi
atio ns ofth e
oper
rnal
/ rts to deal with the inte
mill.
'
(
.
l
give n to man y
1 , \' . !1 ugh final answers .can not y~t be
n and appl icati on
l l )I / 1 ms enco untere~ lll. t~e d es1g that usef ullin es
ed
hop
IS
l l l : /1 , ube and rod m1ll, It
r eade r.
l will be sugg este d to the
wor k is not a tet
this
that
ized
real
lly
\\! i I I i is fu
pted theo ries
lI i l s nse that wor ked out and acce
in whi ch is
ual
man
gn
'" ' 1l cl, nor is it a desi
ul data for
usef
and
ulae
form
of
; 111 I a ollec tion
ofin tere st
be
/ I : id oper ator , it is hop ed that it will ator , to the
oper
the
l \' l t .the rnill designer, to
read er with an
11111 / ng1neer and to the gene ral
ing.
neer
engi
and
"'',' i mcc ha?ics
ness to all the
I l1ors w1sh to express thei r inde bted
in part icul ar
and
,
i w l sc works have been cited
aney whose
Dev
and
hill
Cog
.
1 ~ / .Jol111 ross and M essrs
to the U.S.
l I . : .been quo ted at grea t leng th,
on of Min ituti
\ 111 11 1 111 Mn es and to the Ame rica n Inst nission to reperr
for
rs,
'''1' I al~urgical Eng inee
ous publ icati ons
1"" '''''' t ns1ve data from the vari
1111 I(IIIII '( / jn the text.
ture rs who have
I / l <r also due to all the man ufac
r nam es bein g
the!
,
d~ta
~ "''I l i.ll.ust.ratio ns and ot~er IllustratiOllS for thei r
ate
ropn
app
l/ l r,I.Jf1St the
e the mate rial
1
- t nnd perm issio n to repr oduc
repr oduc e Figs
to
"1111''''' ' he ... for perm issio n
reas en for per~
And
r
esso
Prof
I I, :. and 3.11, to
J. . Con nor
Dr.
to
and
4.11
Fig.
1111 '"" prod uce
PRE FAC E
CONTENTS
I
I,
1 1 '1R
PAGE
NTRODUCTION
17
of millig;
Ball mill;
) finitio of millig; Objects
I I Jnill ; Rod mill; Pebble mill; Batch mills; Grate
l1 1 l: ge mills; rui verflw mills; Hardige
1111 11 ; i r-swept mill ; Ope- ad clsed-circuit grindig;
I 11 y ill ig ; Wet milling; Cotaminati of prducts
'1
'
OF
MILL CHARGE
35
I"
ad "rllig"
POWER
charge.
DRIVE
MILL
69
COMMINUTION OF SOLID
109
)I) [ES
11
CONT ENTS
12
: D
l
theory ; The_ory of Carey and Stairm and; Geom etrica
t
impac
of
s
Effect
;
effects
Scale
ng;
crushi
in
rity
simi1a
velocity
5.
140
178
of
Prefer ential grindi ng in rod and ball mills; Effect
ball
of
Effect
ng;
grindi
ential
prefer
7.
MILL 203
8.
AL
WEA R
221
MILL S
s;
Rose's theory of metal wear; Obser vation of Engel
wear;
ball
ing
affect
s
Factor
es;
surfac
of
uring
Armo
Ana1ysis of the variou s factor s; Theor y of Hukk i; Influence of corros ion
9.
252
6.
13
MILL ING
236
i ; Index
r~ 1111 Index
253
257
LIST OF SYMBOLS
/
I
I
"'
11
fmill
rotation of shell
speed of rotation
l 'w drive the mill
I . t iy ofballs in ftight
1\ l ll l 1o u g hput (mass per unit time)
'" I of element of charge from centre of rotation
tli ofmill shell or R eduction ratio
fi surface (Surface per unit volume)
t : 11 i n l
,,
15
16
Total surface
Time of grindin g
Time of revolut ion of mill
Time for elemen t of charge to .traverse circula r path
Time for elemen t of charge to traverse parabo lic path
Diame ter of exit from mill
Pulp consistency (volume of solid to volume of liq1.1id)
Velocity of projection of an elemen t of charge or Fractional filling of solid
_ Volum e of powder + Volum e of space betwee n particles
Volum e ofspac e betwee n the balls
Wear of a single ball
Total wear of balls
Ratio of circula ting load to totallo ad
Angle of displacement of centre f gravity or Angle of
project ion
Parame tric angle
Angle of repose of charge
Angle betwee n rays of the equian gular spiral or Mean
density of the mill charge
Semi-angle subtend ed by the charge at the centre of the
mill
Parame tric angle
Angula r velocity of mill shell (radfsec)
Angle of displacement of centre of gravity of mill charge
from the vertica l
Coefficient of friction of charge
Absolute viscosity
Kinem atic viscosity
Weight ofball charge + Weight of powder charge
Ratio:
W eight of ball charge
Density of grindin g media or Radius of curvatu re of ball
path
Density of powder
Denotes "a function of"
parame ter
Angula r velocity of precession of the mill charge or element of charge
CHAPT ER
18
(3)
ral dressing,
Exam ples of the first two classes occu r in mine
desired ore
the
ate
in whic h size redu ction is used to liber
a form in
to
ore
the
ce
redu
to
from the gang ue and also
reage nts.
ing
leach
the
to
ce
surfa
large
a
whic h it prese nts
cinal
medi
y
man
U nder the third head ing may be classed
in,
izers
fertil
tuffs,
and phar mace utica l prod ucts, foods
size
the
falls
ing
head
h
fourt
the
r
secticides, etc., and unde
often being
redu ction of mine ral ores, etc.; these mate rials
hand ling,
in
redu ced to parti cles of mod erate size for ease
ofshi ps.
holds
the
into
stori ng and loadi ng into trucks and
prosuch
to
cted
subje
be
to
er
The quan tity of powd
the
to
rding
acco
ly
wide
s
varie
ction
redu
cesses of size
l
utica
mace
phar
indu stries invol ved, for exam ple in the
be
can
.
m
annu
per
lved
indu stries the quan titite s invo
of certa in
meas ured in term s of a few tons, or in the case
the ceme nt
drugs, possibly a few poun ds; wher eas in
of millions
tens
into
indu stry the quan tities invo lved run
prod uced ,
ng
havi
alone
stry
of tons; the British ceme nt indu
ent in
Cem
and
Portl
of
tons
on
milli
in roun d figures, 12t
1955.
man y
For the prep arati on ofsm all quan titite s ofpo wder freis
mill
ball
the
so,
even
but,
types of mill are avail able
of
tities
quan
st
large
the
of
ing
grind
the
quen tly used. For
st
almo
used
is
mate rial howe ver, the ball, tube or rod mill
h
whic
mill
of
types
exclusively, since these are the only
.
itude
magn
ired
requ
the
of
possess throu ghpu t capa city
ns, and
Thus , it is the extre mely wide rang e of appli catio conh
whic
mills
the grea t indu stria l impo rtanc e, of the
justi the
s
form
h
whic
ly
stitu te the "tum bling mill" fami
.
ficat ion for the prese nt work
l ball mills
The grea t rang e of sizes cove red by indu stria
the first
ln
1.2.
is well exemplified by Fig. 1.1 and Fig.
t 1-litre
abou
of
mill
h
batc
y
illus tratio n is show n a labo rator
in the
used
mill
tube
a
n
show
is
1.2
capa city, whilst in Fig.
F.
J.J
Labor atory Batch M iJJ
F.
1.2
I" a"ge lndus trial Tube Mill
21
INTRODUCTION
appears to be:
( I ) Ball mills.
(' 1 'fub e mi1ls.
('I Rod mills.
( I bble mills.
' crm
11
l l
ften to one.
"
FIG. 1.3
Industrial Ball Mill
mill".
MIL LS
BAL L, TUB E AND ROD
22
()
Batc h Mill .
Grt~ .
I J)( .
'~;;~~~~t$,~i~~F,..;;;j~-Trunnion.
Trun nion Orrflow Mill . (c)
~DustHood.
r- -- ------::.-,0-
Dischr9e Port s .
I
I
Disc harg e
Hopper.
P~riph~ ral Dischargfl' Mill
FG.
1.4
(d)
24
INTRODUC TION
25
fEED
HDPPER
1111 1)Owcler . Both the grate mill and the trunnion overI
ll may be operated in either of two distinct ways,
1 11 'l'Sp ectively as ''o en-circuit" operation and
1 I I r uit" oeration, and, furthermore , either of
I 1 t ' l l1 ds of operation m ay b e worked either "wet" or
",
ELECTRIC R
"'IRICONE .. ILL
1.5
d
"overflows" at the other end. In
an_d the grouhnd pro u~~e grating and d~scharge scoop
this case, t erere,
are eliminated.
d. h arge mill is sh own in Fig.
variant of the grate sc .
.
. .
d b th .
.
h' h the disch ar ge .scoop s elmnate
I 1
type, is necessary.
m ethod of operation of a mill eliminl I n nveyor system which was often used in earlier
1 l ) Innt to transport the product to the classifier and
1 111 Hi zc material from the classifier back to the mill.
I . , lowever, that such a system can only b e used
1 lll y when the m aterial undergoing treatment is
I l y light, and the particles produced are sufficiently
111 ll , I ' le desired final product to b e entrained in the
l . Furthermor e, the removal of the powder from
I " : -swept"
26
I.
<U
.
::
<U
....
"'
..
<U
<U
l1
-<
28
INTRODUCTION
29
lll '
tect the screens from injury and act as a linin~ for tl1'
tumbling charge; sometimes also the fine _screen ~s f~rth~r
rotect~d by coarse screens mounted drectly sde .t .
this type ofmill, which is often kno\-vn as the Kruppm~\i
is of interest since it rep~esents a very ear~y type of r:
which with modifications, has retaned ts p~pu~any .
The Krupp mill is particularly suited to the gnnd~g <~I
soft materials since the rate ofwear ofthe perforated lnc
(Harding< Co . lnc. )
Fra. 1.7
30
INTROD UCTION
31
l 11 . orten
' for example th e power to
.
. .very Iarge
II l I IH mll whch a given material is being wet
, ~y b. as much as 30% less than that of a similar
11 l y ~: nd~ng_. Furtheri? -ore the ~hroughput of a c
(I !ls greate~ wet gnnding ; probably due
,,, / : now propertes ofa pulp in compari son with
I. , a.. It appea~s, however , that the rate of ball
11 I I wnr s greater wet milling so the decision be1 ~ d dry operatio n is, in cases where the choice
"' , a matter of balancin g the economi c gain
f r~duced power demand and increase d
I L agast the increase d cost of replacem ent f
I I 11 : I trg and the mill liners and the Ioss of prod u~ l , the shut down period n ecessar for such re
1'' ~ be m ade.
is not erchoice
this
I I r ertain applicati ons,
a
1! , r example ' the grind'ng ofth e raw m
the
1111 111 :.r may be carried out either wet or dry but
~\ l t~1e cem entcan, from thenatur e ofthe material
'
l l .r r 'dout dry.
I,I _i mportant point of differenc e between wet and
t l .~ s_that we~ milling allows the easy introduc tion
I 11 f ll I' ; llVC med~a for the reductio n of the energy ref 11 : J)' duce ut n ew surface or for the inhibitio n of
1 f the fine particles . t is theoretic ally possible
l such substanc es in gaseous or vapo ur r:rm
I t 1 I b ut,
pr~cti~e, su~h methods have not been
r:act
adoption , and ,
tojustfy wde
l
successfu
iy
1
ll
.
.. . bl
I 1 "" I ,:
tca e method of ntroducing such material S
11 I
I II g.
32
INTRODUCTION
33
ll . y rotech.nic materia~s
/ : b le .
I 1111 t le foregoing OUtline of the problems inoled
l1 1l : ~ ~f ~ mill for a given purpose and in the pera
I , m lls, t s apparent that the subject is very coml
r thermore,
34
CHAPTER 2
' Jl,
OF CHAR GE
WITH IN MILL
36
l tto ti .
ns of th_e surfaces of the rods at the point of conand free motion inside the shell
l a t e?. In ths case the angle between the vertical
i :adus . vector joining the centre ofthe mill and the
of gr_avty of the pair of rods is much greater than
I I /
sngle rod. But, again, equality exists between
l ~.k . done to rotate. the she~l and that dissipated in
't < t the contact ponts and distortion ofthe metal
/_ '. . further increase in the number of rods would
i hs effect until relative rotation between the rods
1
~ opposte ~enses
~-----
S t l
11.I
---
St
Bolls Only.
Bolls W thA TrocOf Quo,.tz .
I
10
20 %>
Fc.
FG.
2.1
FG .
37
30
40
50
2.3
2.2
38
D RO D MI LL S
BA LL , TU BE AN
of the
tio n in the dis pla cem ent fricalso shows tha t the va ria
of
t
ien
ffic
coe
less wh en the
cen tre of gra vit y is mu ch hig h, wh ich ind ica tes tha t, for
is
es
fac
sur
wh en
tio n be tw een the
g of the ch arg e is effective
this con dit ion , the loc kin olv ed.
bu t a few ele me nts are inv of the mi ll is so low tha t th
If the spe ed of rot ati on
ted , the n
ele rat ion ma y be neg lec
e will
effects of cen tri pe tal acc
ch
tre of gra vit y of the arg
the dis pla cem ent of the cen possible lim itin g con dit ion s is
o
inc rea se un til eit he r of tw ing :
be
s
ion
dit
rea ch ed ; these con
to ma inforce at the shell, necessary of th
() Th e tan ge nti al
tre
cen
ss
ma
the
tai n the dis pla cem ent of
the fri cti on al force. Wh cn
cha rge , becomes eq ua l to
wh ole ch arg e slips bac k.
this sta te is rea ch ed the
wh en ,
cem ent , , rea che s 30
(2) Th e ang le of dis pla
n fall
the
s in eac h lay er
since the centres of the rodof rod s collapses.
on ver tic al lines, the he ap
eta l
e, since the effects of cen trip nts
In fac t this is a triv ial cas
me
ele
affect the mo tio n of the
acc ele rat ion pro fou nd ly
tio n /'
speeds of rot ati on the mo
w
giv cn
t
of the cha rge , bu t for slo
tha
to
s
ate
xim
mill ap pro
will
the ch arg e in a pra cti cal
s)
s mo tio n the balls (or rod mill,
by case (2) abo ve. In thi
he
oft
ll
cen tric wi th the she
tra ve l on cir cu lar arcs, con is rea ch ed , aft er wh ich th y
y
ilit
tab
th
un til the po int of ins
is inc lin ed at ab ou t 30 to
ich
wh
e,
fac
n
tio
roll do wn the sur
mo
pa ral lel layers. Th is
nt
ho riz on tal , in a series of
en thr ou gh the tra nsp are
tak
sho wn on a ph oto gra ph . 2.4. It will be no tic ed tha t
en d of a mo de l mi ll in Fig s the mi dd le of the ch argr,
ard
sm all "v ort ex " exists tow the balls no lon ger roll down
on
ati
rot
of
eds
spe
r
pro
At hig he
bu t, at a cer tai n po int , are
the sur fac e of the cha rge rea fte r describe approximatelg
the
th s
jec ted int o spa ce an d
ain me eti ng the ba ll mass;
ag
ore
bef
ths
to b
pa rab oli c pa
ar
pe
ap
in Fig. 2.5 . Th ere
ba ll pa ths be ing as sho wn me s for these two types
na
no un ive rsa lly ad op ted the evi den ce ap pe ars to be
t
bu
,
rge
cha
ing '
mo tio n of the
the first typ e an d "ca tar act
for
g"
din
sca
fav ou r of "ca
AR GE
OF CH
WI TH IN MI LL
(Dr.
y [ London)
J. . Connor and the Uniit
Fc.
(Dr. J.
of London)
Connor and le University
F.
2.5
39
2.4
~ I ' '
OF
41
40
for the second type. These names will be adopted for thc
present work.
As the speed of rotation of the mill is increased thc
partic1es are projected with progressively greater ve1ocitics
until the theoretical trajectory for a particle, which is in
fact 1ying against the mill shell, wou1d fall wholly outsid
the shell. Clearly, since the partic1e cannot pass through
the shell, it wou1d 1ie against the shell throughout the cycl
and so be carried around continuously with the mill shell.
This condition is known as centrifuging and the speed ('
rotation at which it occurs, for the outermost 1ayer ('
particles, is known as the "critica1 speed" of the mi\1.
This speed, the critica1 speed, is of considerab1e importan
in mill techno1ogy since, for example, other factors beinf.(
equa1, the equal performance of two mills of different siz
demands that the ratio of the actua1 running speed to th
critica1 speed should be the same for the two mills. An
expression for the critica1 speed of a mill will now b
derived.
By reference to Fig. 2.6, it is easi1y seen that if th
trajectory is not to fall inside the shell, the radius of curv<
ture of the path, , must be greater than R, that is tha
that of the mill she11. Furthermore, this must be true f
from wherever the trajectory might start.
From the dynamics of a partic1e it follows that for tl11
trajectory,
Fc.
-R
V3
gV cos
vz
gcos
' =
cos
" = }
y' = V sin - gt
y" = g
A1so, from e1ementary mathematics, the
curvature, , of any curve is given by
{1 + (dy fdx)2}3/2
=
d 2yfdx2
which by substitution (for examp1e, see Todhunter's
jerential Calculus, p. 174) gives
(y'2 + '2) 3/2
=
x'y" -y'x"
2.6
cos
V2
~ -
gR
.... (2.3)
DU
V2jgR
1 i (~
V=
which
'
= 1
= gfR
= y(gfR)
.... (2.4)
---~~-
--
-~--
-----
42
.. . . (2.r.)
....
(2.)
-~
-------~----
43
e a~onab1e condtn
= y{2g/(D-d)}
f h
s necessary or
I ~ttentio_n will now be turned to a more detailed analysis
' e motn. of t~e. ball charge. the first p1ace, the
; _~~ ~
1 ,~ ~
w
'
. of
1 a pont ' Fig 2 7' at wh'ch th e proJ. ectn
: ::: partc e occurs a~d let this. point be at a distance r from
1 . e~tre of the mll. In ths connection the "
. t f
I'' c~ cton" may be considered to be the point at whf~~ t~e
I ' 1 ; Itory of the partic1e is influenced by gravity and is not
controlled by the packing of the
, re.
surroun d'ng
.onsder
11
I' .r _ proJecton
. .
to occur, it is necessary that the radius of
; vLtu[e
r ~
I ,
: ; :cL~
-
'i
2rf g
r,
- _,
(2. 7)
an
ence
r
Ic'
V2f (g cos
(gf 2 )
cos
.... (2.8)
he
' C
44
BALL, TUBE
FG.
FIG. 2.7
.
nd from the theorem of gc<~
angle is a nght a!l~~e a circle is a1so a right anglc, !
metry that the a~gle wt ~ h projection takes plac
follows that the lne fro~ w /~c 2. the "Davis circle".
arc of a circle of radus g '
.
an
. .
his leads to 1he expresson
By a simple substtutn t
(2.< )
rc = 0408/n2
45
11111 l i ninating
2.8
eteri~g ay ~,
MI LL S
TU BE AN D RO D
out
BA LL
t
me
u1are1e ce the ara the sam e anu1ar e1eme~t as
it ad so, si
ied ? pts:
~face bR c is defers
iO ~f thc
tra jec tor y mu st termta~:
b . d by the it ect r IS ~h
it origiates. ~hus, the
ere
wh
r;
ius
tanl~c1e ofr ad
suc h as R, wh tch are . a c ori iates. represe~atit:.
h
WI~
y
tor
arabo1ic tra jec
the traJeCtbory. dgby the
. . as.
. tiO
padius at wh ich
R
r oit, suc h as ' m ay be . the oit of proJec o1 a wlth
of the pa rab
.Y't
ues, of
h
va1gi
fhe ori
p
the
of
the
s
ge re::.erred to these co-or.di atc
ou1
th e circ1e of rad ius r th~
c
Cir
the
f
.
o
Th e equati
is
. -- ... . (2.12)
2ry Sl
2 +y 2 + 2rx si -
determiatiO
taie
ad tafkil:t~rsectfo
by (2 .11 ). On
1a is give
ara bo12
ressn
.
exp
the
),
(2.
Pi
h)
oft
iOm (2 1
uat
.eq
the
d
a
fro
1g
tut
sti
sub
g2x4
4V2 cos4
is
obtaied;
~ + (sec2
- {; sin
V2 cos
h
fro m w h IC
g2
( 4V2 cos2
No w fro m
2 -
- V2 ~~s )2
)x-grcos + V2--
) x2-(gta
equatio
(2. 7),
ing
. the immediate1y pre ced
wh ich sub sti. tut e d
1eads to
2
- tan =
--;3
4r cos
ad
an d a1so
V2 = gr cos
Th e
so1utios f
= 4r si
cos 2
equatio,
... . (2.13)
~ '
CH AR GE
in the pr ese
o wh ils t the fou rth ,
<rcat zer
'i'1 ),ri.~ Ll1
req uir ed .
sti tut ed
l ' /1s value for is sub
t,
rl r f ' t/) la, it is foud tha
1
MI LL
47
cle i fou r
ral , a pa rab ola Cuts a cir qu art ic
lr; r Lhat, in genet
the
of
ts
roo
case, thr ee
OF
t . 1C/,
equatio
give
by
equatio for
the
2
. . .. (2.14)
y = -4rsi cos
t the
essary to plo
pu rpo ses it is t ecint
b
be
y
r r , t" most the
ma
R
po
reps:resetative
cto ry,
// r// r<~
.r me tri cal ly thu
/ rr.r"
costruction
/{
/ /1
48
tc
face wh ich does t oscula
the mil l ad represets a sur S, ad, i cosequece, fron
wit h the segmet of circle OP
pla ce. Th e rad ius of this arc
wh ich projectio takes
l{
oti
the mill cha rge ad, de
fixed by the ma gni tud e of
es the expressios
the rad ius by r;, Davis giv
... . (2.15)
r;/R =
thi s
beig, i
expressio,
the
OF
0- 4)
= (36360
c
/ 11 ,
i / lim
' l y
... . (2.l(i
-0 02 4+ 03 9y (7- 10 J)
wh ere
49
MI LL
CH AR GE W
e [
l , ',, iH l /n ad thebytim ' c> or the ball to cover the
e
giv
is
11 I I I );) tl1
~ ~ '
RO D MIL LS
BA LL , TU BE AN D
1 '
2 si cos
fractioal
t the mill
tha
tha zer o, it follows
Sice caot be less
erece b~
erf
it
t
abo ut 7 wit hou
fillig caot exc eed
vis sta t
Da
lly
tua
Ac
takig pla ce.
twee the par ticl es
ur, r; should
erece sha ll t occ
tha t, i ord er tha t iterf
i revolu ed
28/n 2 , wh ere n is the spe
t be less tha 02
per second.
wh ich is i "fl igh t" ca br
Th e fractio of the cha rge
s.
cal cul ate d fairly sim ply thu
(2.14) ,
give, fro m equatios
is
2.8
.
Th e agle i Fig
by
2cos-rcos)
-= - -n
( 1/r)(4rsi
(4 cos3
Fro m var iou s
si
ad
so,
cos
-3
tites
trigoometrical ideti
r = JR 2;r ;2
= cos 3,
cos
bu t
= cos (18 0- 3)
-),
sice si =cos (90
cos
(90-)
= cos
90- =
or
(180-3)
180-3
-= 90-3
or
agle
4.
... . (2.17)
passed
Now, the
the par abo lic pat h is + 9
d to be 54 44'
/ I i agl~ wil l be fou
.
b
th
d
a
d
1e
ag
11 , ; f this
e a OVe expressios, l t lS fou
I I
wh
1, = 03/n
c = 03 9/n;
1
.
th
of
ti
spe
, / tim e
e Circu ar pat h ' as a fJract
is
1e
cyc
the
of
'
'
this leads to
(2.18)
.
ed tha t th
11 w t is ass um
oft he cha rge ma y
t
m
e
.
th
by
d
.. 11 cs nte
par tic le at the rad ius
mot~ofol of the
/ ;' of. the ch~ rge
essary to fi d t h e ag1e
, It IS ec
rad ius .
'[) dg to the
tios
si
V cos
= 1/n
'
039
0 56 =5 6 %
... . (2.19)
1- 03 = '
f
b
tio is give by
/ , ( /
um er cyc1es p er revo1u
,; = 1/07 = 145
(2.20)
.
.
'I
t
firs
a
as
t
of
" ~, lt foll ows tha e .
1 approximat , 56 %
iss p etith' Circu ar p ath ad a so t h at the
d
mill sh 11
11 1 , I twee the
the cur ves dP a bR C is
ah
b
iede
u
occ
a
are
l ",, the
~ e cha rge wh e the mill
. s t. It also fol lo! s tha {' 1a. average, every ball
I ' ao the r 145 tim es p er rev o utiO of the Inill.
W MIL L
OF CHA RGE
MIL LS
BAL L, TUB E AND ROD
50
, is ope n to criticisn1
The analysis of Davis, just outl ined
the fric tion al cha re,
mpl
exa
on a num ber of grou nds . For
the effects of intc racteristics of the cha rge are igno red, cha rge in a givcn
the
actions betw een the elem ents of
een adja cen t traj e betw
e
enc
rfer
inte
the
and
traj ecto ry
etal forces acti ng on
trip
cen
the
tories are neg lect ed, as are
the equ atio ns involv d
the part icle s. Fur ther mor e, some of
wid e app roxi mat ions .
app ear to incl ude a num ber ofra ther atte mpt to deri ve
ous
Eve n so this wor k was the first seri
, whi lst form ing a good
rati ona l theo ry of the ball mill and
also pav ed the way for
basis for mill calc ulat ions , it had
late r studies.
the abo ve trea tme nt
The first imp orta nt mod ific atio n to
ted out that th
poin
who
5);
ger(
Stei
was sug gest ed by von
alon g the ascending
hyp othe sis of free flight of the part icle
lid since the con
inva
is
bra nch of the para boli c traj ecto ry
traj ecto ry result
any
g
alon
tinu ous pro ject ion of mat eria l
Thu s for the ascending
in con tact betw een the part icle s.
g the arc is con stan t ;
bra nch ofth e par abo la the spee d alon ht of particles.
flig
not vari able as is the case with free
tha t the intrinsi c
On refe rrin g to Fig. 2.9, it is seen al acce lera tion
radi
equ atio n to the nor mal is, since the
of the grav itati ona l
ent
pon
com
mal
nor
the
pro vide d by
acce lera tion , give n by
V2 f
whe re
poi nt .
= g cos
FIG. 2.9
V2
g cos
V 2 sin d
dy =
n
whi ch
2
V2
- dsfd = g cos
..
(2.21)
y-y o = V
g
V2
or
from whi ch
V2
g
= - cos
ds = - dx
-ds
ecto ry at tl1
is the radi us of curv atur e of the traj
Thu s
5}
cos
[log cos ]
cos
1og cos
. . . . (2.23)
(2.24)
52
MI L L
O F CHAR GE WITH IN
V2
y, - yo = - g log sec 0
.... (2.25)
The surfac e from which the projec tion of the partic lcH
occurs is unalte red by this treatm ent and is, as befor,
2
given by a circle of radius gf 2 drawn in the way pn
themselves are con
ories
traject
The
ned.
explai
y
viousl
sidera bly altere d, howev er, since for the same initial conditions, the horizo ntal veloci ty of a partic le, at the summ it ,
is greate r under the assum ption of von Steige r, and so thc
partic le travels a greater distan ce horizo ntally . Also tl1 r.
height of the summ it above the point of projec tion is dif~
ferent in the two cases. Furth ermore, since from contin uity
consid eration s, a trajec tory on termin ation must cut thr.
surfac e of the ball charge at the same radius as that a
which it comm ences, it follows that the equili brium surface of the ball charge is modif ied. These differences ar
clearly broug ht out by the diagra m of Fig. 2.10 in whi
traject ories startin g at the same point are plotte d
accord ance with the two treatm ents and the corres pondin H
surfaces of the charge are shown .
As alread y stated , the motio n of a mill charge is considera bly more compl icated :than the previo us treatm entH
would imply , and so far the variou s propo sed treatment
are not compl etely satisfa ctory.
One of the most compr ehensi ve analyses, and that up
which most of the remai nder of this chapte r is based,
that develo ped by Barth (6) and, indep enden tly ofBar th, by
Hinsle y and Fobele ts. (7) *
, was d evelop!'cl
* This work, which h as not previously been publishedwho
were appar
over a number of years by M essrs. Hinsley and Fobelets,
ently unawar e of the prior work of Barth .
their mater ir l
Messrs. H insley and Fobelets h ave very kindly m ade all on the bal
written,
was
apter
ch
this
of
uch
m
and
authors
availabl e to the
of the presc: rI
of their m a terial, before the work of Barth came to the notice
writers.
indebtedness
The present authors are pleased to acknow ledge their
tter.
a
m
this
in
Fobelets
and
M essrs. Hinsley
53
t be establ1shed.
of
heap
l
conica
large
a
g
formin
by
ined
determ
y be
1
1
Bc- c
RAJcov .
FIG. 2. 10
54
55
<)
1
equating the forces acting on the particle the follow, xpression is obtained:
'/ 2
cos
( - )+ mg
sin
+ mr2
sin
(- )
= mg cos
.... (2.2(1)
. . . (2.27)
F .
2.11
F.
( / ~ sin
+r
cos
"
cos
+r
gf 2
cos
sin sin )
r sin cos
I h en substitute = r cos ,
l y i which then gives
(gf2+
2.12
I l \VCVCr, cot
cot
y = r sin
+y) = gf2
dyjdx,
cot
r cos
-+y
(gf2
sin
SO
dyfdx(gf 2 +y- )
+y)
56
57
-z-
dz
z+
dx = -z
This is the standard form of homogeneous equation '
first order and may be solved by putting z = kx, wherc
is a function of .
This, on integration, gives,
log
tan-1 k-t log (1 +k 2) +log C
z
Jx 2+z2
tan-1 -log
~
~:::-----25
-5
z
x2+z2
tan- 1 log - c
Now ifwe write: x2+z 2 =R 2, tan- 1 (zfx) =, the exprcli
or
son
R =
Ce
(2.28)
c
F G.
2.13
58
59
' ase, the prOJCCtn takes place from the Davis circle
l nstr_ucti?n fo~ the terminat ion of the trajectories:
1 :. e~rl1er, 1s val1d. ln the second case, in which the
projectio n
I I bnum surface _falls above the D avis circle,
reached.
is
surface
I ' not occur unt1l the equilibri um
I
F c .
2.14
Fc .
2. 15
'
l n~vious construc tion must be modified.
11 asoning very sim~lar ~ that used previously, it can
I l own _ that the te.rminatiOn of a paraboli c trajector y,
nCing at a pnt ' above the Davis circle is ob1 c w~en, Fig. 2.16, distance P'Q.: = Q:R 'and the
/' 1 / C ' zs on the D avis circle. Thus the construc tion is
I : to the pre~ious except that point Q: is on the Davis
' 11 whereas pnt Q is on the mill circle. So for either
-----
--
--
60
61
F.
F.
2.16
( )
( ')
(~)
2.17
62
cos
... . (2 .2!1)
= xfx'
= xfr
cos
. . . . (2.30)
63
r(xfr
xfcos
= PS
(2.32 )
PS dr
l1 to
(2.3 1)
xfcos
'hen,
cos
64
1l ~; it follows that
I ll filling for which
65
2.1
,.
Area of
circle
nill
( 2)
Area giving
"rolling"
charge
(in2)
Area giving
"flying"
charge
(in2 )
Jmax
(%)
Ratio Ratio
,
Mr
,
1111
.
75
11'1
111
075
() ()
11
IHi
075
O!J
(b )
F.
2.18
that when this gap is 1ess than 005 of the diameter of tiH
mill the charge will appear to be cascading; this gap bein
cho;en because, in view of the finite size of the ball in :
rea1 mill, it is improbab1e that a gap_ smaller than tl1 H
figure wou1d be discerned. By the p1ottlng of a number <!I
such figures the conditions for a g':'-p of 1ess than the sp~c
fied size to occur are soon estab1Ished. The constructOJ
for the determination of the "flying" and "rolling" b;ll
charges is then app1ied to each ofthese 1i~iting ca_ses wh 11
the resu1ts given in Tab1e 2.1 are obta1ned. S1nce any
increase in the mill filling above these va1ues will reduce tl
3 14
314
314
314
050
081
128
015
050
09
205
410
698
023
038
042
10
077
062
058
314
314
314
046
090
126
015
05
09
190
450
691
025
036
042
075
064
058
3 14
314
3 14
038
082
115
015
050
09
171
415
650
028
038
042
072
062
058
t photographs ofthe motion ofthe ball charge, pub11 l by Rose and Evans, <9 1 have been questioned
I A'ounds that they show cataracting. study of
l orgina1 artic1e shows, however, that the three cases
.! = 025, J=05 and J=075, with N fNc=056 in
l ase. From Tab1e. 2.1, however, it is seen that each
1 l l se va1ues of J is above the maximum for which
66
l 1\ : tl1eory an~ practice. Unfortunately, the introduci / h a vanable quantity very much complicates
l . I matical analysis.
\ 1 , 1 1 and very important, use to which
'111 ns can be placed is to ensure that
10
81-- <i> -
)(-
OS
10
20
--,
~ 0-6
z
Pol< .
1/
:::;
.J
t'
:
-'
.J
v
v
CASCADING
Rc .
0 2
0.2
--
CAT ARACTNG
REGION
0 4
(t-y'Nc)
FG.
2.19
67
FIG.
2.20
the foregoing
the condition
68
that the charge shall not slip the milllining is fulfill '(\ .
For this purpose,
(1) Use the previous constructi ons to de~ermine ~11 '
configura tion of the "rolling" charge the m\1 ;
shown shaded in Fig. 2.20a.
.
,
(2) Determin e the position of the centre of gravty, (,,
of this area.
.
2
3 Through G plot the radial acceler~ton r!:
( )
d' 11 and the gravitatio nal acceleraton g vc.rl!
ra lla ~Note. radial force = MrG2 and vert :\
~~rc~ = Mg, ~ these vectors are proportio nal to th
forces.)
(4 ) Obtain the resultant of thes~ vectors.
.
Draw a straight line connectng the centre of mll ~)
(S) to the point , where the resultant cuts the m\1
shell, and determine the angle. .
. .
, .
(6) Compare tan with the coefficent offncton . ~
safety must exceed tan by a reasonabl e marg.
The last condition is clear from Fig. 2.20b, ~ince th
resultant has radial and tangential compo.nents a~ showln .
The tangential componen t tends to gi":e nse to s~ a: t ~~:
surface and slip will, in fact, occur f the rato .t
tangential force ~. the radial force exceeds the coefficcn t
of friction: that s f tan > .
I
.
.
3.
4
5.
6.
7.
.
9.
REFERENC ES
VANS D. .
Proc. Instn mech. Engrs,Lond., 1956, 170,
RosE, . ., and E
'
773.
.
f 1
R
and S D. . Loc. ct., r e . .
.
GOSE, . w'' Lecture 'to the Fachausschuss fir Staubtechnk of tl
RUNDER,
D AVIS,
CHAPTER 3
DRIVE
111 tl1
111 1 , ,1ll
l
l1
elements of the machine; and to the latter beother factors being equal, the most economic al
is that which demands a minimum power for
70
i. n
111
I'
FG.
3.1
71
/>(L,
D, d, , J, , g,j, e, b, , V, , , U, h, n)
(3.1)
( n' :)
equatio.
72
Theoretically, the dimensionless groups can be combined in any way and it is the function of experiment t
determine these relationshipso ln the present work, however, it has been found that, in most cases, the functions
of the dimensionless groups may be multiplied togethcr
and the results of the experimental analysis have been
arranged in this wayo
On this basis equation (32) can be written:
(n5~3)
(33)
(3.4)
gfD =
, 2
(38)
(LjD) = K(LfD)
I\ l '
73
..
(36)
'
tionship between the P?Wer group ( PfD6N2)
I [ I : gr~up (,/ ), oaso determned by experiment, is
I ',',' 11 ! fg 3_.~, and t s seeon that for speeds less than
I tl 11
cntcal, the relatnship ' (,/ ) can be
,, 1 , ~~~ 1 by
'(,J') = K 2 (N,jN) 2
(39)
ll 11
11 1<
I I
75
74
s.ooo
Smo!,hJII.i
1,000
500
1./
I
I
/
/1~ Mill with lifters.
1/
10
oj_
5
10
I
F.
100
50
SMOOTH MILL Nc/ N
10
5
MILL WITH LIFERS Nc/N
10
FIG.
500
1,000
3.2
3.3
~ -~- .~-~-- --
76
10.000
5.000
~
~
~J(jl
"'
::
<(
::
1.)
1.000
::
u
I
::
500
I
/
4:ooth LD'=
"-
:;'
"'"'
"'
mill;
steel balls;
100
100
500
,_/
1.000
5.000
TABLE 3.1
Materia1
7"
..
"""-
10,000
77
Specific gravity
Glass
265
Stee1
78
L ead
1 J.4
are present,
inclusion of
l '' wl red material, then it follows that the torque to
! t l1 c mill will be proportional to the total weight of the
I ~, i 1 the mill. Thus it would be expected that, at least
~ approximation, the power to drive a mill con f', R powder can be calculated from the equation
'll l>l to a mill containing balls only, provided that
l l ity of the balls, in the latter case, is increased by an
t sufficient to include the effects of the additional
l to the powder charge. If this point of view is
l , it follows that the mill charged with powder
l s a special case of the mill containing only a ball
1 l11 - , and effects arising from the particle size and other
1 I 11 : t ristics of the powder charge may be expressed by
''' i ns to the equations applicable to the mill without
I '"~ . On this basis, for a mill containing a powder
1
11
- :
(a)
I ' input
FIG. 3.4
3 .1. t is a t once seen tha t an extremely good linear r lationship holds between these variables and so it must b<
concluded that the suggested relationship is valid.
If now the material undergoing grinding occupies th
spaces between the balls of the ball charge, it follows that
the centre of gravity of the powder mass will coincide witl
that of the ball mass. Thus, if the mill charge retains th
78
79
TABLE 3.2
= (15 30+085)
Material
Iron
Emery
Silica sand
Density (gfcm3)
79
. 95
27
r:
I 111' sentative
duction to
I I) :bove, are
Q.
V>
r:
::
EFFECiVE
DENSIH OF RODS .
(b)
FIG. 3.4
(1-0 4)+04(1-04)
(1-04)
= (1
+04/)
1~ ,-4 / 2,"1 /- , ~ { 7 14
1 + 4 ,2 (;./~,& ~ i ) 13
( .... (3.10)
80
This result would be expected since, although the coefficient of restitution of the metals would affect the conditions of rebound when clean solid particles make contact,
the effects of changes in the coefficient of restitution of th
metals are, in the case of a ball in a mill, masked by th
energy dissipating capacities of the loose bed of balls anr\
JSO r - - - - . - - - , . - - - - - , - -
--,----,-----~--,
"'>-
81
~Joor--~~~-+~~-+---+-~~~~J-4-~
z
Smooth mill.
~2\0,L--~---~--~--~--_L_ _J_J___j
1 :
.;?:
~J~'--,--4---~--~--~--~~~
8 -Smooth Mills.
@ - Lifter Mills.
Lifter mill; n
= 6.
Quanz.
Emery.
Iron.
(c)
FIG.
~.4
--i---__;~---\--1
06
08
10
FIG. 3.5
l1 1 \ cnce between the balls. There is also interference
I w ~ the balls and lifters, etc., and, when the relation1 iHdetermined by experiment, a vastly different curve
. :ls? shown in. Fig. 3.5, is obtained. The importanc~
l l ~ dfference wll bec?me apparent later, when various
l d f~mulae, whch. have been proposed for the
w requrements of a mll, are discussed.
11 l1 a~ already .been explained in Chapter 2, in which
I I t of a mll charge is discussed that the coefficient
l : between the ball surfaces ~nd the number of
l . ii H the charge are, from the point of view of motion of
, '' , not independent variables. For this reason the
82
83
of the mill.
to test the effects of variation of the coefficient
order
84
J Q-75 ,
.......
10
0 -8
-~;.::-::
J s-
v
/
I\ 11 J 0 25 ....-
Bo lls Onl y.
StZc l Bolls With Trocc Of Quortz
\ .
20 . D
(!)
Fc .
30.
~~=
I li
,I
D;d 20
t?f I
0 7
40.
S tZcl
---
............_
(')
02
85
5
IO(D/d) 15
for(IJ.j)<20 Muily j1) <n> &y
5
20
25
50 ,
4
N umb r
3.7
Fc.
.
greater
than
this figure. It 1S
.~s.eHecl
6
L if t c:r s - n .
10
3.8
Bond, <5>
rp
\11
l1 l a.
rp
86
0 8
- --
'4
""::.
e - D;d=20
@ - DlJ = 10
Q-4
Rot
0 1
Fa .
3.9
87
l
11
lll , .
I''
89
L-+--+--+--t--- R
with
l v:il able this point . The quest ion is boun d up
ofBOO
jb)
(D
of
ratio
a
and
le
partic
ofthe
size
1/ 1 . / s lute
.__-4----+--+-~---:-"~t-li....,---- ~
(/
.._.f!ll',
.. , "
L-+--+--+-----ir----- ~ ~
,,
,
)4
2
200
400
600
(%)
800
FIG. 3. 11
. --L~-~~~-~~-~~~-~6-~o
~L
Sll~W HlOOWS (qja)'
..:.
e>
CD
,.._
"'
jl
, ,
90
l : blc
91
11111 :>ses .
l case of the overflow mill, in order that the pro l N l a ll overflow through the hollow trunnion, it is
NH: ry that the genera1 leve1 ofthe powder surface must
' > nd to about a 45- 50 % filling of the mill Then
tl1e ball filling is about 45-50% the overflow Inill
''' : nds to a batch Inill, and so the power input shou1d
I l tly calculable from the present work. For small
14
~r----
~
........
Not~!
02
"
01
0.3
0 2
Boll
F c .
Charg~
0 4
0 5
-J .
3.1 2
.. . . (3.1
IH
'c'
93
3(J) is
4 ( dfD)
94
610
HJRENCI
600
Gra~
HOL[GR
L_
SUIY-INE
v
[{;'
t
ENGELS
....
~~
ENGH~
L
MAGNA
L.
!?
i'
2
V
O
LL
v/
F~NOH D 'ERDE
lL/
F'
NIHD
lEROE
1
"'-...
mill .
~--
I
~OLI
v/
HI.&.MI
i/
'/
//
UrAH__,)
ARTHUR
}'
~ s
~
iL:=
~/
L v-v
ROAD
~/
~/
10
000
'"
JOO
'"
)00
)10
GRAH BA.LL
'"
500
510
600
650
100
HlLS-HORSEPOWER
~~so--~oo~7..,.o-,,~oo-,>~so--~Joo~~Jo~~oon-~..~O-~
OBSER VfD POW[R
95
(/> '(c!)
Fro. 3.13
lt
'e
(,
~3 )
( 1+
96
or
= 820,000 ft pdlfsec
= 495 h.p.
I 111
so
=
=
tl1is CaSe,
=
KD Zo
(3 .14)
lo
(1.
mil1.
I . , it has been found by Gow, Guggenheim , Campj,, 11 111 Coghill,<B) Fahrenwald and Lee(9) and others
l , i
( '
IIJ
I"
I~
4 '/d)
(
,. '!
.e
'''"''~'"'"'/
(%) 75
11
Kfy'D
D5. (K/D) 3/ 2
KDH
j ll
11 1
.... (3.12)
l l
p =
97
. . . . (3. :)
10
F.
(%)
15
20
25
3.14
' n
l ( f) jrl)
98
99
is
so
general.
equation developed by Bond(ll) for mills dryling is
1 11
=4~------~-----4-------+------~~~~~
I'
126{D04
~c (6 16- 575J) -
01
210(N,/N-06)-l}
~N3J-------+------+-----~~~--~------I
.... (3.18)
Q
1-
~------~----~~~---+-------+------~
c(
(( ~~----~~----~------+-----~~-----1
2
L~
nqth-
FG.
F~~t .
3.15
(l-K5)
( 1-7) }
+ 0000880 ( 1 _ 2 ) 518
where the value of
mate equation:
=
....
(3.1)
-0024+039(7-lQJ)I /2 .... (3 .1 7)
(05L-l)K+1
11 .
101
11 ~S
' =
==
==
K 1D 5 N 3 D~
2 2 (J) t ( 1 +0-4~)
2 {D 3 3 (J)}L
00005 lNC3L
(3.2 1)
l , he general form of
n nt b~t the value
lc : s to be lll error.
'(C/D)3
ByExpHim~nt . ?. '\
C3 = D 3(C/D )3
but (CjD ) is the sinc ofthe semi-angle, , subtended by tl
surfacc of the chargc at the centre of the mill and so
C3 = D3sin3
02
04
3(J)
n oc 1/y D
Then, on making these substitutions, equation (3.1] )
F.
08
10
3.16
?e
102
103
c: pulp conditi ons would be relativ ely more iml in mills for which the charge is small. This con in fact follows from the observ ations of Gow
' '' n leim, Campb ell and Coghill<t6). Thus it would b~
I that, for large fillings, the effects ofthe variati on
l l u lp charac teristic s would be, largely , in accord ance
l what would be expect ed to result from the conse'1'" linl changes in the coefficient offrict ion involve d.
2 5r-------.-----------~
~ 1 5r---t---+"""--7L_+-----;;;~-----1
V>
:
1 0
r---i-7'-'------+---:"'---+--+--~
02
0 4
0 8
1 0
Pup CoNSSHNCY
FIG. 3.17
104
105
.nalysis of this method in the light of the previous disshows that the effects of the weight of the charge,
l so ( 1 +0 4f ) , are inc1uded. Also the effects of
-- -
Smooth
is .
- - Ltfttr Mills
0 20
-40
0 60
D-BO
tyN,
. . . . (3. 22)
FIG.
3. 18
106
%,
( ~)
_ ( 1-l ) +0 1(1-0 4)
(1-l)
l+0 067f
.... (3.23)
1 - 01 = 15
1 - 04
Thus, the pwer t drive a rd mill, withut a
charge, will be give apprximately by
PR = l5PB
pwd
.... (3.21)
107
I ,
REFERENCES
I ( , , . ., and EVANS, D. ., Proc. Instn mech. En:grs Lond
17 .
l. , W. ., and D, F. D.
'
.,
1956 170
'
'
108
,
. .,
'
CHAPTER
'
14. ~~"~~: :{::. Trans. Amer. Inst., min. (metall. ) Engrs, 1934, 112, 77
15. TAGGART, . F. Loc. czt ., r ef. 6
d C GHILL W. 11 .
16. Gow, . ., GuooNHEIM, ., CAMPBELL, . . , an
,
Loc. cit., ref. 8.
f 7
17. CAREY, W . F. , and SAIRMAND, C. J. Loc. czt ., r e
COMMINUTION OF SOLID
BODIES
bl
:rus
, ( .
l :
l<:
109
110
~-
-~~
---
stage.
earlier
the
i
tha
lt
poit is more difficu
t l~
to
ratios
coside
these
applied
has
g
Hitti
cular,
gridig process.
Thus, a graph of fieess attaied agaist the expecli
ture of work ecessary to attai the fieess would be
pected to have a form somew hat as show in Fig. 4.1 : .
Clearly , i the case of metals, it would be highly improl
able that all the grai boudaries would fail before ay of
the crystals failed. Micro- photog raphs, by Felix a11l
Geiger, (2 ) of samples of steel which have failed undt~ r
brittle conditi ons show clearly that the fractur e is pro_p-
111
Enorgy lnput .
Htrrogrnrous t.
.
j~tl
En<rqy lnput .
Homogr nrous Matrial.
b.
Enorgy lnput.
R<al Crystal.
c.
FG.
4.1
112
oly.
The imperfectios i a real homogeeous article m:y
be roug Iy c assifie u er t ree leadigs . tfie fir t
class may be placed "micro" defects, which may be of tlc
form of a i missig from a lattce poit or a simil:
defect i the ultimate structure of the material. Defects
this ature are probably so small i relation to even tlc
smallest idustrial particle, ad so uiformly distributc l
througho ut the particle, that, although they reduce l
stregth of the material below that which the san
material would have if the lattice were perfect, they havc
no marked effect upo the fracture characte ristics of tl
material ; which remais, i this respect, homogeeous.
the secod class may be placed "macro" d efc ,
Defects of this nature may be flaws or crac s extenai
113
114
/.
Ii
111
I1
115
,_
"'
!~--------~~--------~
...
:!
c
~
c
---~
-~------~~-------Timc
Scac .
FJG . 4.2
t: ll ine
1111 1i
116
1 11 1 , (7)
117
energ~orreseondin
to
Hurface energy.
'L'Le energy per unit surface is independent of
article size.
l the energy expended in elastic deformation is de' I c L from the energy input to the particle.
, \ 11 , for spherical particles the specific surface, in area
p r unit mass, is given by
S = 6Jd
.... (4.1)
S 1 -S0 =
(6/)(l/d 1
-l/d0 )
= S0 (R-l)
.... (4.2)
.... (4.2a)
WR
RI-1
WR2
= R2-l
.... (4.3)
118
R /R z
.... (4 .3 )
=
=
(6/)
W(1fdo -1/d )
W(So-S)
witl
mn NM
.... (4)
.... (4.4:)
btained experimental
vefication
119
of this law
' tl
l{e case or
.. 3
.
-~
.----------.--:-;-:-;--;----;---=""
2 1----+----~.r
::>
~~ I ~--~~---+----~--~
.,c
.....
2
Rducion
Raio-
FIG. 4.3
120
I I f'orcgoing analysis brings out a number of interest 11 111 i ts in connection with the fields of applicability of
l1 wo laws. In the first place Kick's law states that the
111 ,y bring about a specified change in the size of a
1 11 1 1rss of mateal is constant and, furthermore, since
1l1 I 'r energy to induce a certain critical stress in a
1111 : ss of material is also constant, it would ap ear that
l 1 s involved in breaka e in accordance wt
c s
I 1 . c boa orces an furthermore, after fracture the
I fl.Y~loula appear as heat. us,
ick's law would be
1 l to ho1d or particles for which the surface energy
111 ~, li ible; that is for large particles during coarse
11 li g.
i rse1y, Rittinger's law, which states that the energy
I 111 1'(d for fracture is proportionaJ tO the lleW SUrface
' < I , would be expected to hold for very fine grinding
1 , 11 this case, the surface is large and the surface
\ requirements could swamp the elastic energy
11 111 cments. In fact there is evidence that, in practice,
, : rushing is roughly in agreement with Kick's law,
11 ''ftS fine grinding is more nearly in accord with
I g r's law. At this point the implication of these two
I '"' relation to the physical process of crushing will be
. red.
, ka}(9) has pointed out that although Rittinger's law
1 " ~:nts a logical interpretation of the process of frma
i new surface, the manner in which the process is
. t d is disregarded. ln technical size reduction, the
1 i ; l s are crushed by impact, pressure or abrasion. The
111 . energy of the resulting newly formed surface is
11 c l at the expense of the elastic deformation energy of
dy; the balance of the energy reappearing as sound
1111 l cat . Smekal has also pointed out that particles ca
I> considered as being ofhomogeneous structure, and
11 1 g( ) has shown clearly how the influence ofthe micro ture affects the validity of the laws of crushing. The
race of inhomogeneity in the particle is shown by
l nc t that it is generally accepted that the calculated
(/) dW =
= (R+dR-R)/R
= dR/R
or, on integration,
W = Klog R
Spqclic
F.
.... (4.())
Surlacc .
4.4
121
122
Jj!
123
f, l w il 80 % passing
(4.7)
W . is the "work index" or the kilowatt-hours per
q u'i red to reduce from a theoretically infinite
I ' 1 I i l size
: : t tion
11 l
J'
W= W;
(4.8)
y'F
y'R
y'F-y'P = \IR-1
W;
y'R
y'P
= vR- 1
.... (4.9)
cess.
l1 as been pointed out by Walker, Lewis, McAdams
l
illil and<3) and more recently by Coulson and
l : rdson (14) that the various laws of comminution result
rgy relationships which can be derived from the
dWJdd = -Cd"
.... (4.10)
124
W = C(l/d1 -l /d0 )
. . . . (4. I I)
law~ l
125
' s,
WR = bfd0
(Rittinger's law)
WR =
(Kick's law)
l nnore
WR = bfy'd0
(Bond's law)
126
c ~ cc I
127
128
129
'
40
30
20
10
Nft En;:rqy lnut.- Kqm .Cm./Gn.
F.
50.
4.5
----
130
~--
- - - -
131
I'' \ i o s !y.
~400~----~~~74------+-~L_-i
u
..
u
~
~200~--~~--~~------+------i
2ooor------r-----+~L-~
40
20
CIO
Kgm.Cm.j Cm.
~---~~-----+-----4
"'"
80
&
300
200
..
FIG.
~250~----~~---4------+------i
"'.."
~
8 -
Natural .
0 -
Synotic.
40
20
t Enerqy lnput-
CIO
Kgm .Cm./Gm.
80
b.
F G .
4. 6
4.7
l < l into much finer size ranges. This work also shows
l I ' r the size range studied, the ratio of area by ad i to the area by permeability is fairly constant at
i I 19-20. Work was a1so carried out on the slow
1i , in
132
""'
tats,
~00
"'
"''u
~2000~-----------1----7~----~
,;..
..
Snglr Crytl .
Multiplc Croin.
;;:
. I
t'"200
"'"
.
..
::>
~ 1000~------or~~~----------~
n. 100
~
11'1
"'~ .
.
)<
100
200
200
400
600
Enrrgy Drnity- Kgm.Cm./Gm.
FIG. 4.8
FIG. 4.9
133
134
I'' l
135
80
..
....... 60
...,
c
:;,
.,.
..
c 40
...u...
20
Pr ~ ssurq
lmact
Crushinq.
Crushinq.
40
Grain Slzq- Mm.
FIG. 4-.10
60
136
I
I
_------------ -
ldealized.
Real .
1 1l . i1 th at the c1oser a
137
138
139
REFERENCES
'
'
,
w.,
141
CHAPTER 5
~ars
as
142
g,
, ,
t, J , u, U, V,
143
ll
.... (r.. l )
(S .D) =
' }
(Dgt2) '(J), (U), (V), ()
Fc.
(S.D) =
sary
: .
5.1
144
ROCESS
2 + )
= (
d; b)
it .
= /(dbf2J
(5 .3)
provided b is small compared with d; d and b being t]H
diameter of the ball and of the particle respectively.
Now the maximum number ofparticle s, Nmax> which ca
be in the operating zone are those which just form a rin ~
around the contact point. *
MILL
145
per
per
' w
2'(db2) = dN max
Nmax
~ +~ +~
or
or
OF GRINDIN G WITHIN
= 45(djb) 112
.... (5.1-)
S = Kt
.... (5.8)
146
>ROCE SS
~-----~~---r--~.-------r-----------~
;:.
=
~
~40r------------+-----------+-~~~----~
..
u
11'1
n/+ ~...
u20l_____
-~==f==~~----~fi~====~~:1
"'
10
2 0
Ball Diomot<r F .
5.2
ln. )
30
OF GRINDING WITHIN
MILL
147
111 11 ;
148
149
FIG. 5.3
11
or a
150
(S.D) =
relationshi
l (D 2 gfE )
(S. D ) =
K (D 2 gfE )
(5.9)
(S. D ) =
K ( D4g. 1 fD 2E )
151
[ Jat
(5.10)
the agreement
good.
,r--==::::::=----,
~ t----/-------1J?jf------l
(~'}
FIG. 5.5
2
Sp~cilic Croity
Ot
TABLE 5.1
Crindinc, M~di.-p,
FIG. 5.4
1\
al
Density
(g/cm3)
Increase in
surface per hour
Balls
Pebbles
Balls
Pebbles
78
78
27
27
154
460
55
169
Ratio of
surface
n crease
hou
Ratio for
=
78
27
and
From Fig.
5.4
I il r
ll l c
28
27
258
258
11
'l
153
152
= (l +04f )
~ +0-4 =J<:..("+04-<:r
(5011 )
I.
curves do show, however, that the use of lum s of
1es 1s a practice which, at least on
;s grinding
1ds of ming effiCiency, cannot be recommende do
' next p air of groups which may well oe stu 1e are
1 I co
' I :
Sf t oc 50- 2
(5o I
1
)
/........//
1/
.."'
c
4
Drnsity Of Powdt:r o'- GmjCm3
05
<'!>
FGo
507
FIGo 56
__
Pt-
50 -
+4
(5o I 'I)
equating to zero
:cl
2+08-20 =
or
= - 4 y(0162+20)
(5o ll)
I iHvariation
154
MILL
155
J ' i ~ . 5.8; a base of dfD being used since, again, the ball
l , tcr and the mill diameter are known. Since the time
l inding is comparative1y short, it is assumed that the
ll ive particle diameter is the average of the mean
111 11 i I size of the fe ed and of the product; the mean
( ' ( i lc size of the feed and product being assumed to be
l11 Hi ve size which passes (or retains) 50 % of the sample.
l11 tllis basis the data of Table 5.2 may be calculated.
now the curves of Fig. 5.8 are studied, it will be
11 d that the curves are similar in form and that they
. bc brought into coincidence by :
( I ) Multiplying the abscissae of each curve by a suitable constant, such that the maxima are brought on
to the same verticalline ; this constant being related
to the mean particle size of the material to which
the curve relates.
(' ) Multiplying the ordinates by a suitable factor.
e-
-65Muh .
( ) - -35M<sh.
<!>- -20
M <sh.
8 - -14 M<sh.
- - M <sh.
005
b.
FIG. 5.8
156
e-
-5 <h .
( ) - -35 Mcsh .
@- -20M .. h.
- -14 Mcsh .
50~--~~~--,_~r-r-----+-
Sc:ris
- Chcrt
L
~
"'
~u 40~--~~~--~~--~~~~~---i----~~----
157
i l d value of (d2fDb), are plotted agai:st the cor o nding values of (bfD ), the curves of F1g. 5.10 are
l. d .
;~ it will be seen that the curves may be brought
almost perfect coincidence by multiplying the
l a c for chert by 28 and, as a confirmation of the
a y of the treatment, this is almost exa~tly the ratio
l l c rates of milling obtained from the Independent
IN, naking use of balls and p ebb1es, summarized in
11
"'
: 30~~~4-----~-----t-----t----_,~~~r----
d_'2
- = 1 4 2
Db
)2
} 42\
-~
-r:
3
FG .
""
.......
~ ~ .
/CHERT.
0001
/
F.
0002
0003
5.10
5.9
d2 = 35b
d2 = 55b
(5 . ll )
ill
. ~~ ~
I :
IH' l
!i
ri able .
158
TABLE 5.2
'.
Feed Ball
mesh size
Mean
feed
size
(in.)
pa~ticle
lJ
( . )
( . )
00098
00098
00098
00098
00098
00098
00089
00085
00079
00072
00071
00070
00094
00092
00089
00085
00085
00084
00034
00046
00065
00085
00113
00138
0145
0105
0072
0052
0039
0032
000050
000048
000047
000045
000045
000045
275
20
138
10
075
00210
00210
00210
002\0
00210
002 \0
00140
00138
00138
00134
00126
00146
00175
00174
00174
001 72
00168
00178
00063
00087
00127
00172
00225
00285
0145
0105
0072
0052
0039
0032
000093
000092
000092
000092
000089
000094
275
20
138
00400
00400
00400
00400
00400
00400
00156
00119
00126
00109
00145
00301
00278
00258
00263
00255
00272
00150
00101
00129
00191
00255
00362
00565
0145 000147
0105 000135
0072 000139
0052 000134
0039 000144
0032 000185
....:-6- f-(j7s
00480
00480
00480
00480
00480
00152
00151
00186
00166
00329
00316
00315
00333
00326
00405
00115
00158
00240
00326
00540
0 145
0105
0072
0052
1039
000167
000167
000175
000171
000210
275
20
00690
00690
10
00690
00226
00232
00230
00286
00406
00460
00460
OMs8
00167
00230
00330
00488
0145
0105
0072
0052
000240
000240
000240
000258
25
65
20
138
10
075
I 062
_,.
35
. s
__.
tm"
20
~- ~
075
062
14
-- ~
0 04-8
I?
(in.)
CHERT
Mean
- -- -
20 8
10
275
20
138
10
sze
nn
in ~
t'
5.
' 75
<JU
10
075
(). 12
42!1
51HI
57 1
pa~ticle
sze
Mean
product
size
( .)
( .)
( . )
00098
00098
00098
00098
00098
00098
00075
00075
00071
00070
00070
00074
00184
00184
00184
00184
00184
00184
Mean
Increase
surface
per
minute
JJ
J5
00086
00086
00084
00084
00084
00086
00031
00043
00061
00084
00 113
00139
0 145
0105
0072
0052
0039
0032
0000455
0000455
0000440
0000440
0000440
0000455
00 122
00116
00108
00109
00107
00132
00 153
00150
00146
00146
00145
00156
00056
00075
00106
00146
00193
00252
0145
0105
0072
0052
0039
0032
000081
000078
000077
000077
000076
000082
15 1
187
209
230
-r
183
00374
00374
00374
00374
00374
00374
00142
00138
00138
00 142
00174
00285
00258
00256
00256
00258
00274
00329
00094
00128
00185
00258
00365
00530
0145
0105
0072
0052
0039
0032
000134
000135
000135
000136
000145
000171
144
164
193
184
174
121
00700
00700
00700
00700
00700
00328
00390
00512
00530
00622
00514
00545
00606
00615
0066 1
00187
00272
00441
00615
00885
0145 000272
0105 000286
0072 000320
0052 000325
0029 000350
134
153
eed
s z e
111
150
195
21-4
233
106
6(
:. 75
'
3SO
4:\/
I <18
570
10
075
67 r
m
3!
12
'11
54 !
57 !1
-;,.,,
3(
47 11
4 7'
5().11
";ffi.
:. 75
:.!0
138
10
075
062
47 11
111
275
20
138
10
075
.12:.7~
157
11-4
3:111
37
4!
~ ~ ~Q.f1o\-e ~)
d...:::. l
'
..D~ ' ' I (
( i . )
I : - u
2r
3
b~
M ean
ml
1\
" ' '1.('
1111
pt""
~ ~r 0 0690
159
MILL
DOLOME
Mean
product
size
d.
J ' .
.
160
>ROCESS
('~
20
I
I
0001
<%)
1------
0002
Sj t
W l.cn
I~
1/
06
~
0 4
02
~ J'-..._
..........
I
I
!/
d ~(~ ) ~
FIG. 5.12
MILL
161
:.
d3 ( l jd3)
= constant
.... (5.17)
1 0
08
' s
FIG. 5. 11
OF GRINDING WITHIN
100
162
cc
MILL
163
<' nsidered, and in Fig. 5.13 are given curves ofthe rate
f race productia re1ated to (d/D ) ratio, based upon
f' lf 11 of the work of Coghill and Devaney. A1though
l l. ata on the point are 1imited, it apP.ears that the rate
f f.\ 'inding increases steadi1y with the diameter of the rod
, l r 1arge rods becomes sensib1y constant. This resu1t
t surprising, however, since the rods act as crushing
ii and all the partic1es have to
surfaces. Thus, the probabi1ity
such an important variab1e as
100
-~
;;;::.
50
,./
//
Rod - n Crcut
_/. 0 7
@ -i - Q-4
c
0 02
0 0 4
INc
Q-08
0 10
FIG. 5.13
" '
li s
.... (5.19)
Finally, there is the question ofhow the rate of grinding
with the group (gjDN2) ; that is, from Chapter 3
with (NfNc)
'
: ries
164
...
30
<:
~<:
u 20
...,.
-~
<:
oc
10
MILL
165
nod erately dry pulp would, however, exhibit conN l ;bl e cohesive stregth ad so the balls would ted to
4 0r------r-----.~----,----------~
~
c
::
~2 0---------?&L----~----~~~
..
"
..
10
t-----~~---+------+------+--___j\---1
Dot OCoghill and ~q_<y .
Rod Mill-w<t Crndng- ( 60~sol i4
Data Cross.
Ball Mill -Dry Crinding .
a.
I
08
02
10
02
11
11
8-'D
0 8
10
FIG. 5.14
166
Brokt:n
Lin~s
Fq . S
-15.
11
30
I/
20
1/
10
40
-.,-so b. Ch crt .
//
--- -/
........-
OOLb . Cht:r .
------'
0 2
F.
:- ,
~200Lb . C
'~J
0 8
5.16
10
Pulp Eithcr Dry
or Vcry Wc .
y /
08
/___
/
/
/
',
\
\\
0 4
0 6
NfNc
F.
5.17
08
MILL
167
composition to be
between the curves
ttl J' ig. 5.17 is probably sufficient for most purposes;
i.ally as but few mills run at much above about 75%
ttl l critica1 speed.
will be noticed that in Fig. 5.15 the increase ofspecific
111 1 e per unit contact time is plotted for the continuous
1 11it operation and that when p1otted on this basis the
1 s correspond with those for batch mills. Thus it
ltt ll ws that if the surface produced per unit contact time
1 scd, a direct comparison between batch milling and
o Hnuous milling is obtained. Doubt1ess this is the basis
1 h e statement, often made without proof, that the perl mance of continuous rnills may be predicted from tests
1111 ba-tch mills provided that, in the case ofthe continuous
ati, the actua1 contact time is used.
onsidering now the rnill filling parameter 7 ( J), results
d upon tests by Gross (Table 32) and Coghill and
l >vaney (able 19) are given in Fig. 5.18, the former for
ltitl h milling and the latter for open-circuit milling. It is
. nce seen that a simp1e change of ordinate will bring
IH:s independent curves into coincidence; and, since the
I11Ul surface, S 1, is given by S J, these results may be
ralized into the curve of Fig. 5.19, for 7 ( J). These
nves are of the form which would be expected since,
wi l no balls present (J =) there would be no appreci. l > l grinding. Similarly, when the mill is packed full with
l : lls (J = 100%) there can be no ball motion and so no
' iding . In between these values the rate of grinding
ust attain a maximum. Furthermore, for small ball
l i ll ngs the rate of grinding increases almost directly with
111 ball charge and this would be expected since the
' bability ofimpact increases with the number ofballs. *
T he next variable which may well be studied is the
ftct of the variation of the fraction of the void space
ll
ball can only collide with its immediate neighbours, and so, p er unit
, the probability of collision is not the probability of collision of a given
with every other ball in the mill.
168
roor----,----.------,-------------,
801-----~------~~----,_----~~----~
::
-=
...
l w
MILL
169
js
tle
:360~---~f--.~~~~-;-~~-i~~-_,
0:
,,,
,,,
11
I\
....
~
~
20
---nr--,~+---:---:----:---:-:-:---=---:--1-:--:--~
Continuous Milling-Boll Lood Vori~d Chorg~
Constont .
20
40
Boll Lood
2 0 ~-~-+---~r-~~+---~---~---~
Cf)
1 1
-~--4~~-~---+--~~--~~~~-~
CHARc{J) - PERCENT
FIG. 5.18
I 00
"'
I
(J)
0 2
04
0 6
0 8
10
12
R - V.
F.
Wlen
w ih the
3 0 5 ---1----11------1--""........::-t----1
-er:-
20
40
F .
( J)
5.19
80
5.20
170
"
VChcrt (Hard)
0 (1
<
0-8
Rat io
~ ~~lomi tc (s .)
0 2
I
I
I( I
171
10
12
1-4
0 2
04
06
0 8
Rat io V
10
1 2
[\-... "+n
"'~Z t ro Hordnc: .
/
f--
02
l
0 -4
0 6
08
Rotio- V
10
-4
b.
Ro tlo- V
b.
FIG. 5.22
\
\
,,
~Hord Orc: .
~' ..........._
1----
0-8
Ratio - V
10
12
FIG. 5.21
172
}73
l c ltn
~ O S------t--+--+--+-----1
-e.::
111
02
24" Long.
FIGo 5023
to be evaluatedo
The question of the influence of the ratio of new feed to
: ulating load does not appear to have r eceived system. treatment, but general conclusions based on the
I"' '1ous treatment may be drawno
l "ro~ the previ~us treatment it is clear that, provided
l1 c rat of b all s1ze to average particle size is not too
~1 all,o th~ ratoe of grinding is not greatly influenced by the
z dstnbutns of the granular material, and the foreo ng work may be used for the estimation of the increase
surface in the mill. Thus, the combined feed may b e
l'('ated as a normal feed and the product size calculated
174
175
MILL
' .!I
Authority
Materia1
Chert
"
Do1omite
"
19 36
2 4 24
6848
19 36
10
10
036
036
060
060
080
080
Mill size
Diam. (in.)
Length
060
060
077
077
Gow, Guggenheim,
Coghillt (ab1 e 16)
Dolomite
78. 144
036
0715 078
Quartz 6-28
6-48
6-100
6-200
12 12
108
10
10
10
089
089
089
089
100
100
100
100
Chert
19 36
19 36
10
10
040
070
060
060
3648
05
075
100
"
Cement
Clinker
Starke
(~))
(b)
065
065
()o(J5
()o(J5
005
005
000 10
00008
00003
00010
070
003
098
098
098
096
!HJ94
IHJ94
( )( ) 4
11094
040
070
087
4(~)
-- --
2(~) a(b)
10
10
075
097
(V)
g ( V )
(J)
? ( J)
(~)
- -- - - - - -- -- - - -
100
100
100
100
100
100
100
100
050
050
050
050
070
070
070
070
30
30
30
30
06
06
06
06
0036
0030
0006
0030
000013 083
050
100
10
047
072
30
06
00082
085
085
085
085
060
060
060
060
036
036
036
036
40
40
40
40
02 13
0213
0213
0213
096
096
096
096
30
30
30
30
06
06
06
06
00079
00104
00121
00144
IHJ 6 00007
!10 6 00007
090
090
10
10
10
10
10
10
045
045
075
075
30
30
06
06
078
074
IHJ28 0001
100
060
03
50
048
07
20
08
0012
0 6 J
0005
0005
0005
0005
. 581 .
w l1 re
s =
(5.20)
095
100
073
095
068
. d
2 (d/D)
has
the
176
with taken as unity for ch ert. All these figures are seen
to be of the same order, there being about a 3 to 1 ratio
between the extreme values. This scatter probably ariscs
from difference in the bases of calculation of the chang
in specific su-face; since the various workers have diffe-en
methods. The agreement is such, however, as to suggest
that the genera1 method of approach is correct and tha
an accurate series of experiments for the eva1uation of thc
constant is the primary requirement. On the basis of thesc
1imited data, however, it appears safe to draw the provisiona1 conc1usion that the value of the constant , in
equation (5.20), may be taken as
(5.21)
kW
(5.22)
177
MILL
I . RosE, . .
(1938).
1957,35, 111.
179
MIL L
CHARAC T E RI S iC S OF
CHA PTE R 6
OT HE R CO NS ID ER AT IO NS
RE LA TIN G
LL
CH AR AC TE RIS TIC S OF MI
;..
--~~~--~+------4
~ ~~--+-----~--~~
'
of the various
IN the previous cha pter the influ ence
char ge has
mill
and
rnill
the
ning
phy sica l qua ntiti es defi
+------4
..u 40 --~.-+-----~-+-~------~~~
c;
05
20
15
Port clll
(-35 ~h
Ch~r .)
;.
.!
i 200
..
~~r---~~--~~~
t-~~i---~~--f7~~
c:
--~--~~~~_~
~ r-----+------~---f----
-3~--~o~~----~o~~~--~~aJ
o~--~o~-~~--~0-~2----~o~
Part iciC'
Diamrt~r
FIG.
6.1
Millimtrrs .
CHARACTERISiCS OF MILL
ii
11 1 t 1
---
---- .........,_
,
~
'
'\ I
"
I""-
11
11
PARTCLE
D . R - L L es .
Fc.
Q-2
'
""
~
DN stvOF
Roos .= 289-
- 5 0 -@
- 7 3 -
-......
f",'
~+
Q-8
RC.
6.2
181
""'
LFEEo .
"'< '-.....
~ --::.:--
I 2
14
).
DAMETER.- ..RS .
FG.
6.3
""
~ : icable
182
In Fig. 6.4 are plotted curves, again according to Coghill and Devaney, which show the effect of pulp density
upon selective grinding and it is at once evident that ;
more rapid reduction of the larger fractions is obtainccl
with a pulp of moderate thickness than with a very thi k
one. The probable explanation of this phenomenon jg
that with a fluid pulp the fine material is washed from
between the crushing surfaces, and so is ..not subject t
further grinding. In addition, cleaning the grinding zon c
of such materialleads to a higher efficiency of grinding /'
183
CHARACTERISTIC S OF MILL
. . . . (6.1)
~80~~~--+---+-~q---,_---r---r---r---+--~
u
~
~60 ~--~~~--+---4---~-~-r---r---r---+--~
w
4 ~--+---~~d-~~--,_--~~~---r---+--~
6-3)
10
PAFH CL E DAMEfER
IN
RS
FIG. 6.4
.
J-!ere the pre-suffix or S attached to , de_notes ~hat
l . power or the surface product~on, r~spectvely, s a
tion ofthe dimensionless quantty whch follows ..
The total surface, S 1, produced is, however, proportonal
le product of the specific surface produce_d and the
vo lume of the mill. Thus the rate of producton of total
t r ace is given by
~~
(6 -4 )
f.\' vcn
'1
by
....
(6.5)
184
CHARACTERISTICS OF MILL
..
. !:
0 2
'
12
( t;YNc)
F.
6.5
185
mill.
lt is also probable that for speeds above 70 % of the
i t i:al the power demand would fall away when mode . t l y dry pulps are undergoing milling and so, in this
. <' ls, the mill efficiency would remain sensibly inde l nt of the mill speed. Experimental evidence this
i is lacking, however, so a final conclusion cannot be
. l ( ly drawn, for this case.
appears to be safe to state, however, that, for all
: ical milling conditions, the mill efficiency is sensibly
l pcndent ofthe speed ofthe machine.
.
.
'' relationship between mill efficiency and mll fillng
1 i ll now be studied.
Fig. 6.6a is shown the curve relating the rate of
l"'oduction of specific surface to the mill filling (see Fig.
' . <) and in Fig. 6.6b is the curve of total surface produc , per unit time, deduced fr?m it. '!h~ curve Fig. 6.6c
lat ofpower input to the mll and s, fact, the curve
l l' ig. 3.5.
.
. . .
'le mill efficiency s then deduced by the ds of
l: rdinate of curve Fig. 6.6b by that of Fig: 6.6c and
I urve so obtained is plotted in Fig. 6.6d. From this
'il h it is seen that the mill efficiency is sensibly cons!ant
I flllings ofup to about 50% and that for greater fillngs
I ' fficiency increases rapidly.Thus, it would appear that,
l1 le greatest efficiency, a large filling, say 75%~ should
used. This is only partially true, however, for wth such
. lilling the rate ofproduction of~pecific surface is re~u~ed
. l so to obtain a product of gven fineness the mllng
t must be increased. If the energy to cause comminu 1011 were all that is involved, this would be immaterial,
t hc en ergy lost in friction in gearing, bearings, etc., is
. ! . t independent of the charge in the mill and this loss
ninimized by the reduction of the milling time to a
1ti1imum. Furthermore, the reduction ofthe milling time
ll H'rates the plant for other duties and so is economically
li able.
186
CHARACTERISTIC S OF
v !'>
""'-..
Mi tt
"""\
0 4
F lli ng
~0 5
""' ""
10
1/
I
4
Mll
J,
b,
10
/ \
06
Flling
I
v
0-2
Mll
6
4
Fill ing - J .
-~
0 5
'
02
04
--v
6
Mi ll Filling -
c.
J.
d.
FG.
6.6
MILL
187
: ntity of solid material present in the pulp, the para r ( V), can be examined.
this case Fig. 6. 7a shows the curve for the rate of
oduction of speci.fic s.u rface, ~ terms of this parameter
(' l<'ig. 5.21) and Fg. 6. 7b s the curve of total surface
l luced from it.
'he curve of Fig.
~I\
"'
l:r
... .:- ~~
"'
>
-....
.ci
~."-..
(Q
.;
~~~
400
so
25
7S
Hardn<ss Of Ball.
I/
'
"' "'"
11 11
"
.....
>
~~
----------4----~L-~
0...
- 6
500
"'
'
....
()
"'
. J)MOd
FIG.
6.7
soo
ISOO
FIG. 6.8
...
1000
()
- ~
~-
--'---J_
r l n<l l
S'
'#
f.....----------------1----/ ~
'!'
"'
200
11
I
I
----- -
,!
1----------+--------1----
'
(JU ! J! ~ J3 I/!~
1-----------1-------...- ~
..
"'
r----------------,-, ~
10 ~-----..-------.
16
<:'
-~ /.
189
MILL
k~~
.:
CHARACTERISTICS OF
'
<:'
~~
I
I
'
'!
190
CHARAC TERISTI CS OF
...
"""
"'....~""'....
"""
. . .
"' "'
::g~
MILL
U")
""
- - - -- - ----- -..ou
ti
~- ~
"
p..,
*....
"'....
"
"8
~ :::5
..,
::g5
U")
"""
""
""
U")
~"
"'
-~
"'
:::5
.... u
~-g
c: ....
"""
U")
""
>
U")
U")
,_
;::::>..
~ c:
c:.:::.
.
.....
.;-
>
~6
,_ I'-
--
<> ..
~
CJJB
U")
.,
,_
--
--
U")
U")
"'""" "'"""
~~
u-
"' "dY~~
~
::g"'
'5
<:
.;-,
-c-
'<:>
""
<>:J -
..c:
u:->'7'
-"'!"
"'~
"'
co
+ +
MU")
U")
....
::
-- --
- ....
~ ..C::!
-+
--
~~
"!:::.
c:
~
c:
-~
:-:::::>
..C:OJ
~~
-..
"' ""'
~8
"'
~
....
..c:"..
CIJ
~u
::
....
"'
:.
:>-
"'
""
~
"
:::5
"'
....
~lj
"..
OCIJ
~ ::g
u:::..o
;='
::g
192
CHA R ACTERISTICS OF
MILL
193
194
CHARACTERI STICS OF
....
195
MILL
"
";;:- 0 11----1-----b~=----+---f----1
..."
(];), (J)}
Mill
0 5
03
0.2
(6.7)
(JJ
Filling . -
FIG. 6.9
Sr---.---..-----,------
-;;
Q.
.c
"
"e
,_
.c
10
Q-6
0 4
( N/Nc)
FIG. 6.10
04 . . . - - - - - - - - ; - - - - . . . . . . , . , - - - - - ,
+-+.!1Nc"0 .7
----06
..:
"
2
':;;-
. - - - 05
04
..."
Rod
Damrt
Rotio
r.
lnch~s
50
FrG. 6.11
100
196
CHARACT ERISTICS OF
rod mill, in terms of the diameter of the rods. subsidiary scale also gives the correspon ding values of (d/b)
and it is seen that the rate of flow is substantia lly ind pendent ofthe ratio of (dj b) when the ratio is greater tl1a1
about 50. This result is in accord with a finding by one "
the present authors, Rose and Barnacle, 04) working 0 11
the flow of suspensions of solid materials through pip s,
that the hydraulic resistance is independe nt of the particlc
size provided the ratio of (D jd), where D is 'the pipe di ameter and d, the particle diameter, is greater than abol
30 to 40.
It is improbab le, however, that, in practice, the ratio
(dj b) would exceed about 40- 50, since this would giv
rods of excessively 1arge size in relation to tl1e particl .
Thus, it is probable that the lower values of (djb) on th~
curves of Fig. 6.11 would be relevant and, for this casc,
Qocdj b.
Thus, insofar as there are the data available for tl1
analysis, it appears that equation (6. 7) can be reduced
.. .. (6.8)
Q = KD 2.5J. ( / ,) . (djb).
From equation (6. 7) it is seen that, all other things b eing
equal, the throughpu t should vary as D 25. Unfortuna tely
data for the verificatio n of this equation are practically
non-existe nt, but those given in Table 6.2 suggest that tl1~
observed throughpu t is roughly in accord with this expression.
TABLE 6.2
Authority
Mill si ze
Di a m .
length (in. )
Coghill and
Devaneyl3 )
Norris\9)
19 36
68 48
050
050
90 68
0 30
Q/Ql 9 . 36 .
observed
(tonsfhr)
08
08
079
28
07
1520*
Calculated
10
25
26
Obse vrcl
10
35
19- 25
MILL
197
: l lasses:
( I ) mooth liners,
(' ) " Lifter" liners,
11 l " smooth" liners are those which have projection s
111 1 / ient to give appreciab le keying between the liner
1 I h ball charge, whilst lifter liners are those which are
l nvil y ribbed as to give rise to appreciab le interlocki ng
l .<" the balls and the liners.
: i o us common types of liners are illustrated in Fig.
I' . lthough these liners have various patterns of pr
ions, or depression s, to give an amount of interactio n
I 1- the liner and the grinding medium, it would be
>< c d that wear would round the edges. It is doubtful
i I r, after some time in service, the performan ce ofa
111 ill with these lincrs differs appreciab ly from that of a
ill with a smooth surface. Liners furnished with heavy
ll bars are also sometimes used and in such a case the
I 1 king f the ball charge to the sl1ell must be very effective.
N v heless, although a few vague general statement s to
l cct that a lifter mill gives a product with different
. 1 racteristics to that of a smooth mill have appeared,
I int does not appear to h ave been widely investigat ed .
I! tH bable, howeer, that, the grounds of differences
111 111 size characteristics of the products, ther,e exists
1 cl reason for the use of lifters in preference to the
'al smooth liners.
(d )
(Hardinge G'o. Inc. )
Wave liners
( Usines Ernile
Henrico
S .A. )
(c)
( 1-lardin.~e
Cornpat tnt
Co. Inc.)
grate
(f)
lines
( Usines
/e
1-/enricot S.A.)
(a)
liners
~l ll 2 4 m . d iam. 12 m. lon g. Fitted with H enricot classifying
11 0 1"
(b)
of M ill fitted wi th H enricot studded liners (underfill ed to show
ordered a rray imp osed th e ba lls.
Fro. 6.1 3
202
REFE RENC ES
EY, F. D. Ball Mill Grinding, U.S. u.
DEVAN
and
I . CocHILL, W .
581 .
.
Paper,
of Mines, Tech.
and CoGHILL, W.] .
2. Gow, . ., GuGGENHEIM, ., CAMPBELL, . .,
5 1.
Trans. Amer. Inst. min. (metall.) Engrs, 1934, 112,
ref. I.
3. CoGHILL, W. ., and DEVANEY, F . D. L oc. cit.,
) Engrs, 1934, 112, 91.
4. FAHRENWALD, W . Trans. Amer. l nst. min. (metall.
5, 87.
1957,3
Lond.,
Engrs,
.
hem
c
.
nstn
l
.
Trans
5. RosE, . .
6. ENGELS, . Metall, 1954, 3-4, 102.
ref. I.
7. CocHILL, W. ., and DEVANEY, F . D . L oc. cit.,
855.
118/1,
1924,
.,
J
Min.
Engng
.
D.
ILD,
8. FAIRCH
) Engrs, IY54, 63, 197.
9. NoRRs, G . C . Trans . Amer. l nst. min. (metall.
Engrs, 19 19, 61, 250.
.)
(metall
min.
.
Inst
10. Ds, . W. T rans. Amer.
11. ANsELM, W . ,Zement-Kalk-Gips, 1950, 3, 16.
12. PEARSO N, . . Rock Prod., 1951, 54, 106.
cit., ref. I .
13. CocHILL, W . . , and DEVANEY, F . D. L oc.
r, Ld., 1957, 203, 898.
14. R osE, . ., and BARNACLE, . . Enginee
15. RosE, . . Engineer, Lond., 1957, 203, 522.
16. BELWI NKEL, . ,Zement-Kalk-Gip.< , 1953, 6, 439.
. ,
CHAP TER 7
a subje ct upon
is
r, ienomenon of "surg ing" in a mill
mabl y becau se it
presu
en;
writt
een
b
has
1 l I very little
ted in mill opera tion
, ordition whic h cann ot be tolera
tion of some or
varia
by
l wl1ich must be elimi nated
cteris tics of the
chara
or
s
nsion
dime
, y of the physi cal
impo rtanc e,
such
of
is
ct
subje
The
e.
charg
11 or mill
a
from book deallt~ wv r, that it cann ot well be omitt ed
An attem pt will
mill.
ling
, wh the subje ct of the tumb
a revie w of the
ter,
chap
this
in
l - re be made to give,
ct.
subje
the
of
' : nt knowledge
a
phen omen on know n as "surg ing" consists of
'
mill,
ofthe
e
charg
e
whol
llum-like oscill ation ofthe
al
the mill shell. Thus for one part of the cyclic
mill
ofthe
e
centr
the
d
aroun
ng
movi
is
e
charg
l the
and durin g the
l same direc tion as the mill shell,
direc tion. As a
site
oppo
the
1 d part of the motio n, in
charg e, the
the
of
n
motio
atory
oscill
H guence of this
in stead y
shell
mill
the
tain
main
to
sary
neces
mstan ces,
circu
in
certa
t1 fluctu ates wide ly and, in
r that the
moto
ng
drivi
the
' nake such dema nds upon
of the
out
ing
throw
This
out.
n
throw
are
11 t brea kers
er
dang
the
evil since
1 break ers is, however, a lesser
more
died.
reme
be
such a case, appa rent and must
torqu e whic h are
It dang er is hidden in fluctu ations of
devices into
ctive
prote
t
crcui
the
bring
ffi ient to
existence of such fluctu ation s
1 <ti . In this case the
ce of fluctu ation s may
appa rent, and the main tenan
ng geari ng throu gh
drivi
the
of
n
. l to the destr uctio
1 l 11
203
204
Rs.
Fa .
+ g sin )
.. .. (7.1)
since is small.
Also, from the equations of motion
mk 2
mg
k2
FR
gr
= k2 cos - mk2
gy'(r2+2R2 cos2 )
.
k2
(sin cos - cos sn )
k2
gives
. . ~ . (7 .3)
1 l ' '
or
.. .. (7.2)
cos - FR
~ mR cos ( r 2
7.1
Then,
205
rR
cos
= __k_2_ _
and
206
r ' tme,
207
MILL
''' d
J,,,,
2
) , y [{2A 2/y( l +4 1 2 )} sin ( +) +C 1 e ]
(7 .6)
.2
. (
22
y(l + 4 12 ) sn +) +ce2 1
(7.5)
FIG.
7.2
FIG. 7.3
y(2-2)
208
= 1035 sec
209
II l
cm-
< l ;nd this curve is showr_ in Fig. 7.4. From this curv:e
ma
' 11
OL----------------------J
Timt
F.
7.4
I to mean torque is in fair accord with an observa1 11 1 l>y Hinsley, working the mill mentioned previously,
l .l during surging the current to the motor varied be about 300 and 700 amperes.
ll ;v ing regard to the theoretical nature of the treat f Rose, which involved a number of assumptions as
11 values of important parameters, the agreement
l11 w the observed and calculated magnitude of the
1 11 t surge is as close as can be expected. t appears
. Ho nable to conclude that peak values of the torque of
11 l ;s t two or three times the mean va1ue may be en1 t red during surging.
'/1 topological method is, however, not of a nature
210
agai deotes
211
are applied
.... (7.9)
a mill reduced
.... (7.10)
of the ch arge iH
of friction, , are, as far as the fluid ity
ld be expe ct cl
con cern ed inter chan geab le, and it wou
f~rm of tl~
the
in
that these' quan titie s wou ld o~cur
mental r:
expe
the
of
yss
prod uct J . Then , from anal
across tl1
n
draw
be
d
coul
line
a
that
sults it was foun d
nate a<l
ordi
th.e
field f a grap h, Fig. 7.5, whi~h (!) iswhc
of ~IH
part
~
(D fd) the abscissa, and accordng nto
nf.
surg
r
et~e
fell,
ts
poin
g
ati~
field of the grap h the oper
lsh wheth<:estab
to
r
orde
,
Thus
r.
occu
does or does not
O IS
0 10
::,
>(
....,
1\\
005
""
Surg1ng R:gion .
20
213
MILL
S URG I NG AND VIBR ATIO N
S
BAL L, TUB E AND ROD MILL
212
ion of
frict
of
ts
icien
coeff
'"' the stati c and dyna mic
henc e
and
,
essed
proc
g
bein
rial
mate
l11 l: ll char ge and
lly.
idua
indiv
ts
1l static and dyna mic coefficien
e
ofth
es
valu
al
reve
not
r a ti ofth e liter atur e does
to
le
icab
appl
on
fricti
mic
dyna
and
1 111 111. nts of stati c
ofpo wde r. How of balls load ed with vario us types
ofth ese
auth ors have mad e roug h dete rmin ation s
1 1 , 111
icab le
appl
be
to
y
likel
are
l ~ unde r cond itions whic h
in an
ed
plac
were
der
pow
and
balls
I I. 11 mills; that is,
the
and
ce
surfa
- 1 > ttom ed box on a smo oth steel
ns
mea
by
d
sure
mea
i v ' force necessary to mov e.the box
give
to
ved
belie
is
od
meth
l , sprin g bala nce. This
for the pres ent purp ose and a
11 l - of suffi cient accu racy
purp oses ofill ustra111 - ofsu ch results are show n, for
ll, Tab le 7.1.
ll he
TABL E 7.1
I' --
4.0
---
150
l1re
80
Rat io Dl,
FIG. 7.5
necessary . t
surg ing is likely to occu r or not it is only of the mll,
ng
fill
osed
prop
the
J,
establish the prod uct of
the bal~ charl-\< '
and , the effective coefficient offri ction of
plot ths a l
to
and material unde rgoin g milli ng, and
If the opcr; I
d.
/
D
ratio
agai nst the prop osed valu e of the
ing". z
-surg
'_'non
.the
e
insid
well
ing poin t so obta ined is
[ tl
but
e
surg
then it is impr obab le that the mll wll
t.
near
sly
erou
dang
poin t is inside the "sur ging " zone, or
:.
s
the
and
r.
occu
to
y
likel
is
boun dary line, then surg ing
g, or bot ,
filln
mill
the
of
e
nitud
mag
of the balls or the
of
11 ~ ; system
10
11
I
Coeff icient of
dynam ic frictio n
Mean value
of coeffic ient
of frictio n
018
018
018
025
018
02 1
037
30
033
042
04 1
04 1
0-44
042
043
/ .rteel:
l l 1 t d with
111 y denum
l l ~ l l1id e
l1 i cd
"'
with
a nd
l ln l
Coeff icient of
static frictio n
r<"c
silica
I" w l rr
\ /lce
" wl
emery
215
MILL
I
.;
-g
Observation
Conditions in mill
Mill-Cieaned and dried
Mill-Oiled
Mill- Treated with molybdenum disulphide
Miii-With about 1% of voidage filled with
silica powder
Balls and Mill- With about 1% of voidage filled with
emery
Balls
Balls
Balls
Balls
Surging
Surging
Surging
and
and
and
and
.z=
:;
.!!!
Q.
...
...-"' -...."' -g~
-- .z= "'
occur
occu
occu"
surging
I surging
1
...
.,::;,
TABLE 7.2
Q.
>-
"' ()...
~
()
~
e
.,
48
v
/
()
-- .., .
...v .
.:
11)
...,.
1/)
216
217
111 ,!10(} hours' service; whereas the other mills have given
l tcly satisfactory performance over a number of
< . T he reduction gearing of these mills, which were
l rc d and constructed by makers experienced in the
tion of gear trains such as those used in rolling
..,
FrG. 7.7
ur.
11 , i the absence of an exact knowledge of the com1"' i ion of the gear material and the heat treatment em~
i y d, it is assumed that the fatigue characteristics of the
, naterial are approximately the same as those for
1 l i : l1 the diagram Fig. 7.8, quoted by Morley,<6> was
l iv d, then this dia?;ram may be used for the further
c
218
Fig. 7.I\
analysis of the prese nt probl em. The diagr am of
befo
sals
rever
of
er
numb
inite
is such that, for an indef
shac!l
the
n
withi
fall
must
es
stress
ing
failure, the work
area.
in~
Now suppose that the mini mum stress, correspond ,
thrl
s
follow
It
.
in2
tonsf
20
is
e,
torqu
to the mean drivi ng
er
if failure is not to occur withi n a limit ed numb not
must
stress
appli catio ns of the stress, the maxi mum
atio
exceed abou t 25 tonsfin 2; that is, the allow able fiuctu
al ,
mean
the
of
25%
t
abou
d
excee
of torqu e must not
7.7, tiHt
Howe ver, it has alrea dy been suggested by Fig.
20r---------~~~~~-----~
~ ...
~ -~
~
c
~
,_
Of-------;~~M~>L--::.__
____ ___
--
0 1--------t~~_.:....-----------
Vl
0..
U O'L---~--------------------F. 7.8
qt
fiuctu ation s of this magn itude may well ase from
J 11 11
say,
by,
bly
possi
,
mode rate chang es in mill conditions
on of tl
varia tion in the value of the coefficient of fricti
brou~lt
be
well
could
es
chang
such
that
charg e, and
surfi
size,
le
abou t by differences in pulp density, partic
as
small
so
are
h
whic
finish ofthe balls and mill, etc.,
ap
d
woul
it
,
Thus
nt.
porta
unim
norm ally regar ded as
practi
in
ed
unter
enco
es
failur
gear
ed
plain
that the unex
tio;
migh t arise from differences in the plysical condi
iN,
terist
charac
er
powd
and
e
the mill liner, ball charg
bu l,
nt
porta
unim
as
ded
regar
be
to
as
Thes e are so small
atio N
in fact, have a profo und effect on the torqu e fiuctu
furtl
still
is
em
trans mitte d to the geari ng. The probl
MILL
219
e fiuctu ation s are
torqu
the
to
as
s
1 1 t s xact calcu lation
nable doub t
reaso
no
ins
rema
there
but
e,
11 1 cabl
n the "
withi
/ mill shoul d be opera ted as far
ble.
possi
is
f ~j" zone ofFig . 7.5 as
to the
11 l as alrea dy been point ed out that, owin g
n
withi
e
charg
the
of
n
motio
ng
surgi
any
of
l ity
the
e,
charg
the
of
toe
/ ll and to the collapse of the
d by the drivi ng
l ; s of the torqu e trans mitte
er ofhar moni cs.
numb
large
very
a
in
conta
1 /1 :1nism will
r at
, herefore, possible that reson ance migh t occu
ratus
appa
y
nearb
and
111t ' requency, betw een a mill
sensitive to vibra / , if the adjac ent equip ment were
origi n of whic h
the
,
ulties
diffic
to
rise
give
l , ould
natur e have
this
of
l , l not be easily trace d. Probl ems
whic h it is
in
,<7>
Anon.
e,
l liscussed in a recen t articl
mitte d
trans
be
may
tion
vibra
e
l 1w that appre ciabl
tras
being
tion
vibra
the
;
ation
found
piled
l ~h a
bedthe
gh
throu
mill,
< l down the piles bene ath the
the
ath
bene
piles
other
gh
1 /1 :nd then emer ging throu
exbe
not
d
woul
t
effec
This
.
ment
111 11\ l bouring equip
there
since
1 I < l to be so mark ed with friction piles,
trans mit the vibra l / then be no unde rlyin g rock to
duce consi derab le
intro
d
woul
<. nd the clay itself
that the corre ct
ar
appe
d
woul
it
s,
heles
I 1ing . evert
point of the trans / 1 /-\ 11 of found ation s from the view
ir of vibra tion, is essential.
that some vibra tion
1 he same articl e, it is ment ioned
was suggested that
it
and
ng
geari
mill
the
from
. ; ted
use of fibre or
the
nditio n could be allev iated by
/
view of
train.
gear
the
in
. / tooth ed drivi ng pinio ns
howe ver,
ter,
chap
this
of
part
r
earlie
11 liscussion in the
l
l I" l
220
n th l\
it appe ars that atten tion to the cond itions withi
cati o H
i
modif
such
than
ive
shell migh t be moe effect
wll l
tion
viba
of
type
er
furth
J.
4.
5.
6.
7.
ME TAL WE AR
MIL LS
from the work -
Rose,
rs,
autho
nt
prese
11 1 the
y
111 l treat ment will b e outli ned briefl here.
is that parti cles
I'11 basic idea unde rlying this treat ment
conta ct be
upon
will,
g
millin
g
rgoin
f I I : mate rial unde
nds
I v into the_ surfa ce of the b alls at a rate whic h dep~
the
cle,
parti
and
ball
c ~he relatve hard nesses of the
REFE RENC ES
F . Privat e Comm unicat
. HNSLEY,
2. RosE, . . Unpub lished R esearch.
3. R osE, . ., and BLUNT, G. D. Proc.
CHAP TER 8
'} '
'
'
1957.
~)
(New
Wiley
n
ng,Joh
Dressi
l
TAGGART, . F. Handbook of Minera
1948.
s.
Privat e Comm unicat ion to th e Author
.
reen & Co. (L l ),
MORLEY, . Strength of Materials, Longm ans, G
17.
68,4
1953,
Lond.,
Age,
. Chem .
Fig.
d partic les will,_ upon maki ng conta ct, as in
that
usion
concl
the
to
leads
then
11 , b e torn out. Ths
l surfaces at a rate
l c >artic les will be torn from the meta
ball and
I i is a funct ion of the relati ve hardn ess of the
relati ve
the
,
dded
embe
les
i le, of the numb er of partic
rs.
facto
ar
simil
I Ii g velocity, and
val of partic les
\V Ien the rates of embe dding and remo
er of partic les
numb
ibriu m
11 cq ual ther e will b e an equil
word s a cerother
in
or,
ces
I ><' lded in the m etal surfa
'
.
"arm oured "
be
will
ball
each
of
ce
surfa
the
1 11 ortn of
now, an embe dded partic le
1 I mbe dded partic les. If
part ofthe surfa ce
J ball trave rses the "una rmou red"
l c l l
22 1
222
()
223
MILLS
(b)
F c .
METAL WEAR
8.1
>
-.._ 5 1 + - - - - - " t - - + - - - - - - i
10~---+--~+-----i
":"
Relatir
F c.
(VJ
FIG. 8.3
Hardnrss -
8.2
't' l <~sc conclusions are confirmed by the practical ob' ;1 ns of Engels(2) that for the grinding of soft materials
1 /l mill body andoalls should be used, but for grinding
111 ma terials a soft bu t tough metal should be used for
l 1 inding surfaces. Similarly, the c~r~e of Fig. 8.3, is
l med by Smith, (3) who states that t s well known to
op rators that a impr0~ed fineness, in_a given t~m~,
t t r.ined when the quantty of powder the mll s
l . d, but that this improvement is obtained at the
I " ' lS of increased iron wear.
I rder to analyse the various published data, advan nay well be taken of the simplification offered by thc
META L WEAR
224
y
denst
upon the speed of the mill, , and upon the
ball mater ial, . It would also be expec ted to depen d
the energy necessary to increase the surface or I
225
MILLS
,, a mill and
, cs depen d
Sccific
dimen s o l
4 t----+---r
Ball
War
( // ),
r.
. . . . (11. 'I)
(Nf ,),
First exami ne the functi onal relatio nship
5 > relatin g to
<
Gross,
and
Data by Coghi ll and Devaney<3J
metal wear, are plotte d in F~g. 8.4, and on the same gr:l
the curve relatin g the rate of produ ction of specific s
face to the group (N fNc), taken from Fig. 5.17, is sl1ow
for compa rison. It is at once seen that there is clo
agreem ent betwe en the rate of produ ction of specific s
Cross
>
(11. ~)
Data Of
)'
2
This can be simplified, however: since (D jg) is,
2
equati on (3.7), equiva lent to (Nf Nc) .
Surfacc .
.
8
@
..
~ 0 21-----i"-----t---t----------1
.
(~~)
lncrcas
Ratc Of
0 2
04
0 6
(N/Nc)
FIG. 8.4
(/c)
= K(NfN c)OB ,
speeds
227
e has a shar ply defi ned
ll .' :.nd it is seen that the curv
exp lana tion of the form of this
111 Jrnu m. The prob able
becomes less effective but
<: is that the "arm ouri ng"
easi ng part icle size unti l
incr
l :bra~ion in~reases with
r this, even thou gh the
~ !'' ' max~m~~ s . re~ched . .Aftethe
part icle s sepa rate the
nounng IS still neffectve,
bear ings , and so,
ball
like
. l. surfac~s, ac.ting rath er
wea r of the
sive
abra
the
ce
redu
l ncreasing sze,
righ t-ha nd
the
that , for
, 1. It shou ld be noti ced
e, wea r
rang
l
tica
prac
I . h of th~ curve, :hich is the
dire ctly
,
thus
or,
/D)
(b
as
y
:s approxmately nversel
ely, for
vers
Con
.
eter
diam
mill
the
(D/b), and so :ith
alm ost
es
vari
r
wea
the
l I ft-h and portn of the curv e
MET AL WEA R MIL LS
226
LS
BAL L, TUB E AND ROD MIL
.
pen den t ofth e spee d ofth e mill
for speeds of 11
and
size
n
give
of
shows that , for a mill
er inpu t to a mill '"
abo ut 70% of the critical, the pow
. Aga in insofar a~
prop orti ona l to the spee d of rota tion
a stra ight linc
by
aced
curv e of Fig. 8.4 may be repl
y gen eral ly accll
this rang e, it also leads to the fairl
prop orti ona l to tl
conclusion that the rate of wea r is
ears that th . ll
app
pow er abso rbed in a mill. Thu s it
rate ofpro<l
both
to
l
ona
orti
wea r is, very roug hly, prop
mill. This ; l
the
to
t
inpu
er
pow
to
tion of surf ace and
of surface is rou i ll y
implies that the rate of prod ucti on
also been dedH'I'l
has
ch
prop orti ona l to pow er inpu t; whi
that to atteml t
,
ever
how
ed,
in Cha pter 6. It is cons ider
to pow er inpu t
calc ulat e the met al wea r by refe renc e
the calcultl 111
that
surface incr ease is artificial and
lving its w
invo
lem
prob
shou ld be trea ted as a sepa rate
ers.
met
para
mill
the
rela tion ship s betw een
obvious is 6 (/,fl)
The nex t rela tion ship whi ch is fairly
dire ctly as
vary
t
since the tota l rate of ball wea r mus
aini ng
rem
es
ntiti
qua
r
leng th of the mill; all othe
alte red.
2
it wou ld ap
Tur ning now to the grou p (Em fD g)
mus t tak l
ship
tion
that , on logical grou nds, the rela
form
. . . . (11.1 )
the tota l wea r, W, ,
since, all othe r thin gs bein g equ al,
valu e of Em. U
the
to
mus t be inve rsel y prop orti ona l
whi ch this r l
nst
agai
ence
evid
fort una tely ther e is no
tion ship can be teste d directly.
ther e are limit
Tur ning nex t to the func tion 5 ( b/D) est the gcn r
sugg
ch
whi
rele van t data by Mor tsell (6)
are plot ted in I'i ,
form of this rela tion ship . The se data
~{] ?1
0
< >
FIG. 8.5
nt.
hard ness on the
( : nsid erin g nex t the effect of rela tive has been preship
tion
rela
al
retic
theo
. c of _ball .wea r; a
king of this rela tion '. ' d Fg. 8.2. Dat a for the chec
but a few values of
ing,
l are alm ost com plet ely lack
es of ball , pub ness
hard
ell
Brin
I. 11 wea r, for diff eren t
Fig. 8.6. This curv e
l l d by McLeod<7J are plot ted in
definite corr elat ion
l ows the gen eral form of Fig. 8.2, but
eral s wer e mill ed
min
ed
1 n t be mad e sinc e very mix
is unk now n.
ness
hard
eral
min
: l t~e corr espo ndin g
plet e data it mus t be
l s, n the abse nce of mor e com
repr esen ts this rela tion . , me d that the curv e of Fig. 8.2
R
l .
228
METAL WEAR
. - - - - , - --
010 r - --
229
MILLS
----,----,
...J
0 05
~-~-/-t----'"""'=---t-----i
;:
6 00
4 00
200
800
Br inr ll Hardn r ss Or al ls .
F.
;)
v
li
?.....-
60
"
"'40
"
20
8.6
---
Cross
Cog hill
andD<on<y.
~ @-
@
Mc l <od .
....
10
40
30
20
<% >
Fa .
8.7
-v-=
50
"'""'-. 0556t%>0S
10
2%)
Fa.
8.8
40
50
- -
230
METAL WEAR
V=
\ l
oz
t.
oa
. y
J.
F.
231
MILLS
()
re
Volume of particles
+ Volume of space between the particles
Volume of space between the balls (or rods)
~::vrr JS
range of these
8.9
1(J). 10 ( V)
.. .. (8.7)
In. practical milling the ball diameter is usually ap1)I' XImately a constant multiple of the particle diameter
'
this equation becomes
W1
(8.8)
10
20
F.
8.10
W1
(8.()
.... (8.9)
....
( 8 .1)
232
METAL WEAR
Wb = K 6D265dl B5(NfNc)OBt
. .. . (8. 10 )
W1 = KD 25 (N fNc)d- lOLt
thos~ l
wt
11c l
~ quation
( 8. . )
Wb
= KDH5(NfNc) d-lOLt
... .
(8.13)
(8.14)
.. .. (13. 11 )
....
233
; r ,
IS
W/ =
KD 2 5(NJNc)Lt
MILLS
c l
(8 .1 2. )
(8K:b)
... . (8.15)
1 :vusly .
. lhorities.
234
W
1
REFERENC ES
....
(8.1/)
Authority
McLeodl71 test: ( 1) Chill-cast balls
(2) Sand-cast balls
(3) Annea1ed balls
16 10 8
1 6 10- 8
23 10 - 8
06 10 - 8
Mortse!lll
26 10 - 8
6-ft mill)
235
iman
I shou1d a1so be pointed out that corrosion has
o ant effect on the rate of liner wear. Thus, if corrosive
l)stances are present, the products of corrosion will be
noved from the wrking surfaces by abrasion and new
111 a1 will be constant1y exposed to chemica1 action. The
r arising from this cause will be proportion a1 to the
. of meta1 exposed, but there is insufficient data for an
ysis ofthis prob1em.
12 10- 8
CHAPTER 9
ROLE OF ADDITIVES
MILLING
'
236
237
238
239
240
241
:dditive.
242
ars to bc
havin g appre ciabl e effect. This concl usion appe
true for most addit ives.
low as
As previously noted , quan titite s of addit ive as
effect
ed
mark
a
had
008 % by weig ht of the solid prese nt
cing
produ
ut
witho
es,
surfac
mill
on the cleanliness of the
of
rate
The
ct.
produ
the
of
on
iorati
deter
r
notic eable colou
100
..
.:
.r
..,
.:
C7'
"
.:;
...
~~
--.....;:._
_., /
__...
"'<D
c
4:40
...
.!
..
320
i=
10
01
P~rcrntoq
F .
100
Colloid ol Corbon .
9.1
this sm:ll
grind ing is not, howe ver, mark edly impr oved by
quan tity of addit ive.
a sm:ll
The work of Bond(5) shows that the addit ion of
t
abou
ght
brou
t,
weigh
by
%
088
r,
wate
of
amou nt
.,
D.
ofT.
ion
solut
MILL ING
243
partic les.
nns1ng from adsor ption on the surface of the
amou nts
small
the
that
fact
the
by
orted
'his view is supp
mark ed
a
t
[ addit ive whic h are sufficient to bring abou
allow
to
ient
suffic
are
i provement in the rate of grind ing,
20%
than
less
on
layer
cular
l1e foration of a mono mole
that
fact
the
by
orted
supp
also
is
t
ce.
surfa
f the prod uct
ce
produ
d
woul
ven large chang es in the surface energ y
nded
dema
y
energ
the
in
but small propo rtion al chang es
energ y
by the whol e grind ing process (since the surface
nd
dema
y
energ
total
ofthe
on
fracti
Sall
repre sents a very
tives,
addi
solid
[ the process). t is also significan t tha t the
coati ng; proba bly
tlentioned earlie r, all tend toinh ibit ball
ing edia since
grind
the
to
ce
surfa
y
by iparting a greas
ting prope rties.
brica
lu
ed
mark
it
exhib
to
n
know
all
hey are
wate r in preof
s
The effect of very small quan titite
catio ns. For
appli
other
in
n
venti ng ball coati ng is know
n in the
know
well
is
it
that
states
xamp le, Manson<s>
enam els,
s
paint indus try that, in the grind ing of dry-proces
effective
be
can
r
wate
he addit ion of as little as 00625 % of
ermo re,
Furth
ng.
coati
liner
and
! the preve ntion of ball
d balls,
coate
badly
from
ved
remo
be
also
Lhe coati ng can
wet
few
a
of
unde r runn ing condi tions , by the addit ion
tive
selec
that
sts
sugge
(5)
balls to the mill charg e. Bond
the
be
t
migh
ce
surfa
ball
the
at
les
l1ydra tion of the partic
of
tities
quan
small
by
ng
coati
of
ition
inhib
the
-eason for
tive.
tenta
water. Such a suggestion is, at the most,
surThe reaso n for such prefe rentia l hydra tion at the
ed
mber
reine
be
must
it
but
,
clear
not
ace of the balls is
le
derab
consi
a
is
there
ct,
impa
of
ent
mom
the
that, at
this
of
some
tless,
moun t of energ y dissip ated and, doub
physicoould be used to bring abou t vario us chem ical, or
energ y.
of
input
an
nd
dema
h
whic
ions
hemi cal, react
n by
vatio
T his possibility is supp orted by an obser
to a
ged
chan
was
ore
Pryor, (9) who found that copp er
the
e
wher
s
point
at
level
y
energ
ompo und of a highe r
*
it.
ing
break
ut
witho
ore
the
ed
rubb
balls of the mill
244
()
ROLE OF ADDITIVES
MILLING
245
---
246
..,
l"i
.!::!
.n-
~0 4
~
- ....
..
-. "
6u"
....
; ;
;::
~02
"
u"
~ 0 04 ......----=:::::::..---'+-:::::::-------+----1
..
>
u"
Cur~ -Ouortzit~
"v
V1
.~ 02
. 08 r\
Cr i ndnq Umnton~.
\\
O CI
\"-~
"!'--...
\/')
.::
~ 0 4
..
:2
-~----------~
~--~~
0~----------P~rc~ntoq~
a:
Ot Additi~ .
0 25
P<rcontoq<
Limstont
.____.._._
Qurtzt .
70r-------.-------~~~-----~~~----~
60r-------r-----~~-+--~~--~------~
40r-------r-----~--~~-+~~--------~
..;
1 4
.2
~
.::
12
ue
"c
2 ~-----...,.__,.c.__+-_~:_-----------1
....
Friction .
r--
0 5
Sodium
F.
FIG. 9.2
"
MILLING
....
....~~~~
0 6
ROLE OF ADDITIVES
Surtoc~ .
075
Ol~at~ .
9.4
Crindinq
1\
Quortzit<
~~
Surfac
............:::
~ 0 6
I
~r: ic t i on
:;
"'0.4
r-----~~------~~------+-------~------~
>
"'
C7l
"'
..
u
..
F.
20--?L---r-~-----------+---------------1
0003
9.3
0.075
OOS
010
- - - - - With Additi .
Without Additivt .
9.5
concentration of additive exceeds a certain value is tentatively explained the basis of the lubricating effect of
these substances at high concentrations. This explanation
is supported by the data of Fig. 9.4 and Fig. 95, in which
curves of surface produced and coefficient of friction are
plotted against concentration of additive. These curves
.J'
..
248
ve fr which i
shw that fr ccetratins f additi
gridig is hi A I ,
f
rate
the
high
is
cefficiet f fricti
a t l
but whe the cefficiet f fricti decre ases the r
fr<~.,
f
ciet
ceffi
f
s
gridig dimiishes als; the curve
,
J
r.
simila
y
clsel
eig
b
ig
ti ad rate f grid
i ~
fricti
f
ciet
ceffi
the
that
udes
ccl
Szath
ad that, at hi A i
majr imprtace i the gridig rate,
f fricti t
ciet
ceffi
ccetratis, the decre ase i
ti i sur< c
reduc
the
frm
d
gaie
weighs the advatages
the additiv .
f
pti
adsr
e
surfac
the
frm
g
eergy arisi
ctets
the
f
This result is als f iterest i the light
i a nll
g
surgi
that
sted
Chap ter 7, i which it is sugge
i tf,
ti
reduc
small
a
by
abut
ht
migh t be brug
s l
curve
the
cefficiet f fricti f the charg e. Thus,
mgll
tives
faddi
use
Fig. 9.4 ad Fig. 9.5 suggest that the
tl
reduc e the cefficiet f fricti by 40-50 % ad
mll ,
a
cause
t
iet
suffic
tha
mre
culd well prve
which therwise perfrms satisfactrily, t surge .
~
It is als iterestig t equire why the rate f millin
rl
Clea
.
fricti
f
ciet
ceffi
asig
shuld fall with decre
t
this must arise frm a reducti i the effective heigh
H
tl1i
ad
e
charg
fall f the cetre f gravi ty f the mill
tl
e
charg
the
f
g
wuld prbably arise frm slippi
l
t<
expe
be
wuld
it
the
s,
fact,
i
mill shell. If this is,
; l
that the use f adequ ate lifters wuld, t sme extet
aiHo
is
there
ly
least, restre the rate of gridig. Pssib
g ad the icreas l
sme relatiship betw ee the slippi
ig as cmpan l
grid
wet
with
wear,
ball
rate flier ad
with dry gridg, which is smetimes reprted.
crrelati betwee tl
ad their resistace
was also show that th<:
hi .:
is a prgressive decre ase i the resistace t scratc
bed tl
adsr
ve
additi
of
es
ti
quati
sig
with icrea
c
S]Jrface fthe bdy, there beig a clse correlatio betw
n,
r
isthe
ption
adsor
the
the resistace to scratchig ad
MILL ING
249
ed
with a minim um of resistace t abras ion beig reach
%
70
as
much
As
.
pti
adsor
ete
cmpl
of
under coditios
the
way,
this
in
red
measu
was
ess
hard
e
surfac
i
ase
decre
maxim um d ecreas e correspodig to the greate st differ
It
e.
surfac
the
ad
m
mediu
the
cce i polar ity betwee
would
is sugge sted by R ehbid er that -plar additi ves
ad plar
ials,
mater
philic
hydro
fr
ive
effect
most
be the
a dditiv es shuld be used for hydro phobi c crystals.
mff, (15) who
Egelhardt reprts the work of Obrei
the lamia
tig
separa
in
doe
work
elastic
the
measu red
to the
equal
y
of mica and foud that this was nume ricall
d.
forme
e
surfac
ew
the
th eoreti cal surfac e energ y f
prethe
i
out
d
carrie
was
a
lami
When splittig of the
e exsence of surfac e active m edia, hwever, the surfac
i
ased
icre
,
posed, for a give amou nt of strain eergy
by
d
cause
y
eerg
e
surfac
the
proporti t the d ecreas e i
the
t he adsorpti. Egelhardt furthe r coducted tests
i
disc,
e
carbid
silic
a
with
z
quart
of
ig
grid
abrasive
polar
that
foud
th e presece of varius additi ves. It was
i reducig the
ad diplar additi ves were very effective
quatities of
small
ular
partic
In
.
abrasi
resistace t
e i
octan ol or butyr ic acid in bezol or sdium silicat
ace.
resist
wear
water were effective i reducig
outstadig
Skaupy has recetly repor ted some
r i varius
pwde
fir
g
millin
the
frm
ed
results btai
i a
fluid m edia. Altho ugh the tests were carrie d ut
f
ds
gru
the
here
vibratig mill, they are icluded
ig
grid
f
rate
the
that
fud
was
their imprtace. It
tha
of irn was five times as great i glycl, ad less
air.
dry
i
as
l
twety times as great i is-amyl alch
ially
espec
were
ves
additi
The tests revea led that diplar
sureffective as gridig aids, as wuld be expec ted frm
ale.
s
erati
csid
y
eerg
face
effect the
Althugh, i view f the mre mark ed
energ y as
e
surfac
the
f
evide nce pits t a lwerig
ves i
additi
f
ti
pera
the
i
factr
being a imprtant
mre
is
g
millin
dry
f
case
the
in
ce
evide
the
g,
wet millin
pr with
ials
mater
cfused . The effectiveess f varius
16*
248
t/1c
show that for conce ntrati ons of additi ve for which
A" I ,
hi
is
ing
grind
of
rate
the
high
is
n
coefficient of frictio
/
but when the coefficient of frictio n decreases the rat
fri<
of
cient
coeffi
of
grind ing diminishes also; the curves
,
tion and rate of grind ing being closely similar. JL l
i$
n
frictio
of
cient
coeffi
the
that
udes
concl
von Szant ho
h~
major impo rtanc e in the grind ing rate, and that, at
t
n
frictio
of
cient
conce ntrati ons, the decre ase in coeffi
sur<<
in
tion
reduc
the
from
d
gaine
weighs the advan tages
additiv .
the
of
ption
adsor
e
surfac
the
from
g
energ y arisin
nts
This result is also of intere st in the light of the conte
n/1
a
in
g
surgin
that
sted
Chap ter 7, in which it is sugge
t/
in
tion
reduc
small
a
by
about
ht
migh t be broug
/
s
curv
the
Thus,
e.
charg
the
of
n
frictio
of
coefficient
ll
g
m
itives
ofadd
use
Fig. 9.4 and Fig. 9.5 suggest that the
tli
reduc e the coefficient of frictio n by 40-50 % and
m/1 ,
a
cause
to
ient
suffic
than
more
could well prove
which otherw ise perfo rms satisfactorily, to surge.
~
It is also intere sting to enqui re why the rate of millin
l
Clear
n.
frictio
of
cient
coeffi
asing
shoul d fall with decre
/
this must arise from a reduc tion in the effective heigh
H
tli
and
e
charg
fall of the centre of gravi ty of the mill
t/
on
e
charg
the
of
ng
would proba bly arise from slippi
l<l
expe
be
would
it
then
so,
fact,
in
mill shell. If this is,
t ;l
that the use of adequ ate lifters would , to some exten
aiHo
is
there
ly
least, restor e the rate of grind ing. Possib
/
some relati onshi p betwe en the slippi ng and the increa
an l
comp
as
ing
grind
wet
with
wear,
ball
rate ofline r and
with dry grindng, which is somet imes repor ted.
of
rt
suppo
in
l4)
hardt(
Engel
Rehbinder<z> and of von
t/
en
betwe
lation
corre
a
d
showe
inder
conclusions. Rehb
betwc
lation
s~rface ofthe body, there being a close corre
,
isother
ption
adsor
the
the resist ance to scratc hing and
MILL ING
249
ed
with a minim um of resist ance to abras ion being reach
70%
as
much
As
ption.
adsor
lete
comp
of
under condi tions
the
decre ase in surface hardn ess was measu red in this way,
differ
st
greate
the
maxi mum decre ase corre spond ing to
It
e.
surfac
the
and
m
mediu
ence in polar ity betwe en the
is sugge sted by Rehb inder that non-p olar additi ves would
polar
be the most effective for hydro philic mater ials, and
ls.
crysta
c
phobi
additi ves shoul d be used for hydro
Enge lhard t repor ts the work of Obrei moff, (15) who
a
measu red the elastic work done in separ ating the lamin
the
to
equal
y
of mica and found that this was nume ricall
d.
theor etical surface energ y of the new surface forme
prethe
in
out
d
carrie
was
a
lamin
When splitti ng of the
e exsence of surfac e active media , howe ver, the surfac
in
sed
increa
y,
posed, for a given amou nt of strain energ
by
d
cause
y
energ
e
surfac
the
propo rtion to the decre ase in
the
the adsor ption . Enge lhard t furthe r condu cted tests on
in
disc,
de
carbi
n
silico
a
with
z
quart
of
ing
grind
abras ive
polar
that
found
the prese nce of variou s additi ves. It was
the
and dipol ar additi ves were very effective in reduc ing
of
ities
quant
small
ular
partic
In
ion.
resist ance to abras
e in
silicat
m
sodiu
or
l
benzo
in
acid
ic
butyr
or
ol
octan
water were effective in reduc ing wear resistance.
outsta nding
Skaupy has recen tly repor ted some
in variou s
er
powd
n
ofiro
g
millin
the
from
results obtai ned
in a
d
fiuid media . Altho ugh the tests were carrie out
of
ds
groun
the
here
vibra ting mill, they are inclu ded
ing
grind
of
rate
the
that
found
was
their impo rtance . It
than
of iron was five times as great in glycol, and no less
air.
dry
in
as
twent y times as great in iso-am yl alcoh ol
ially
espec
were
ves
additi
The tests revea led that dipol ar
sureffective as grind ing aids, as would be expec ted from
.
alone
ons
derati
consi
y
face energ
the
Altho ugh, in view of the more mark ed effect
as
y
energ
e
surfac
the
of
evide nce points to a lower ing
in
ves
additi
of
tion
opera
the
in
factor
being an impo rtant
more
wet millin g, the evide nce in the case of dry millin g is
prowith
ials
mater
confused. The effectiveness of variou s
16*
250
6.
7.
8.
9.
.
2.
3.
4.
5.
251
APPENDIX
SUBJECT INDEX
_1__
15
30
45
60
75
90
105
120
135
150
165
180
J
0000
0003
0028
0090
0194
0335
0500
0665
0804
0910
0972
0997
1000
afR
C/R
1000
0966
0866
0707
0500
0259
0000
- 0259
-0500
-0707
-0866
-0966
- 1000
0000
0 259
0500
0707
0866
0966
1000
0966
0866
0707
0 500
0259
0000
252
bfR
0000
0034
01 34
0297
0500
0741
1000
1259
1 500
1707
1866
1966
1000
xfR
-
0960
09"0
0810
070()
0572
0430
0 2811
017 3
0091
002
0004
0000
F1ying, 48, 60
Profile, 5 1, 64,65
Rolling, 49
Total, 48
Circle, Davis, 44, 58
Classification, 24, 25
Contamination ofproduct, 31, 179,
187, 223
Coefficient of friction, 54, 213
Comminution:
Energy,distribution in, 115
Laws ofBond, 122
Carey and Stairmand, 125
Dobie, 124
Kick, 11 8
Rittinger, 117, 149
Modes ofAbrasion, 133, 140
Crushing, 137
Deep bed, 132, 133
lmpact, 130, 140
Sing1e particle, 133
of ca1cite, 130
Ball diameter, influence :
of cement clinker, 30, 240
Efficiency, 183, 186
of coa1, 110
M eta1 wear, 228
of coke, 11 3
Power, 81 ,97
ofdo1omite, 146, 154
Product characteristics, 178
of drugs, 32
Rate of milling, 153
of Durham anhydrite, 134
Surging, 210
of feldspar, 136
Ba\1 mi\1 , 2 1
of galena, ,130
Ball rationing, formula for, 192
of glass, 130
Ball wear. See under Wear, meta1
of graphite, 109
Balls:
of gran ite, 11
Cleaning, 242, 243
of moybdenum disulphid e, 109,
Particles embedded in, 144, 189
2 14
B1ow, cushioning of, 11 5
of pigmen ts, I 09
Bond's law, 122
of quartz, 109, 130, 146, 154
Breakage. See under Comminution
of rock salt, 130
of steel, 110
Charge:
Con tact:
Cascading, 38, 65, 75
Frequency of, 49, 161
Cataracting, 38, 65, 75
Time of, 163, 167
Coefficien t of friction of, 54, 2 13
Corrosion, 235
253
SUBJECT INDEX
SUBJECT INDEX
254
Pwer,
81
Millig, rate f (q.v.)
Surgig, 210,213
Critical speed, 42
.
.
Crushig. See under Cmmut
Crystallite, 112
Crystallizati, 134
Crystals :
Imperfect, 110
Perfect, 109
Davis circle, 44, 58
Desity
f gridig
bdes;
Griding:
i-
Pwer, 76
Desity f particle; ifluece :
f, 150
Pwer , 76
Diameter (ball, mill, particle, rd);
- , rate
ifluece :
174
71
Surgig, 210
W ear, metal, 224
Assciated, 125
Ba1ace, 128
Elastic strai, 128
Necessary, 116
Plastic strai, 128
Sufficiet, 116
Surface, 116, 245
Flight, time f, 49, 62
F1yig charge, 48, 60
Fracture, gemetry f, 112, 125, 136
Cefficie t f, 54, 213
Effects f additives 247
Ifluece -
flu ece :
Fricti:
He tergeeus, 109,
Hmgeeus, 109
P wer, 81, 97
Rate f millig ,
Surgig, 210
Materials:
bdies :
relative) ; influece
Pwer (q. v.)
Millig, rate f (q. v.)
Wear, meta1 (q.v.)
Lifters, 22
Lifters; ifluece :
Pwer , 81, 85, 86
Rate f milling, 197
Surging, 200,214
Liers :
Armurig f, 144,
Fucti f, 197
189
200
121
Mixed, 110
Metal, wear f. See under Wear
Mill, types f:
Air-swept, 22, 24
Batch, 22, 29, 90
Ball, 21
Grate discharge, 22, 90
Hadse1, 129
Hardinge, 26
Krupp, 28
Pebble, 21
Rd, 21, 30
ru verflw, 22, 90
Tube, 21
Mill prducts:
Ctamiati f, 31, 187, 223
Diffracti patte r f, 134
Mill surfaces, cleaig by additives,
242, 243
255
Millig:
Chage f
chemica1 state
243
Clsed circuit, 24
Dry, 25, 30
durig,
183
- - - fillg, 183, 186
- - pulp charge, 183, 188
- - - csistecy, 184
Mixed materials, 176
Ope crcuit, 25, 165
Rate fEquati fr, 142, 174
Dimesial aalysis fr, 142
Depedece up ball dam eter, 153
- - dry millig, 164
- - gridg bdy desity,
150
- - 1ifters, 197
-..,.- diameter, 174
- - - fillig 167
- - ___.: speed: 164
- - - thrughput, 163, 167,
173
- - millig ads, 236, 245
256
SUBJEC T INDEX
INDE X
Andreasen , . . ., 134
Anon., 216
Anon ., 219
Anon., 245
Anselm, W., 193
Axelson, ]. W., 122, 132
Baker, . C., 238
Barnacle, . ., 196
Barth, W., 52
Belwinkel, ., 200
Berry, C. ., 241 , 245
Blunt, G. D., 210
Bond, F. C., 84, 99, 122, 74, 233,
240, 242, 243, 250
Bowden, F. . , 134
Cadena, F. , 174
Carnpbell, . . , 73, 97, 99,
103, 4, 86
Carey, W. F., 95, 4, 125
Coghill, W. ., 73, 77, 97, 99,
103, 104, 46 , 5, !56, 156,
178, 186, 187, 9 , 194, 96,
228,234
Couson, ]. ., 23
Craig, . ., 240, 241
102,
102,
74,
224,
Fahrenwal d, . W. , 97, 89
Fairchild, D. ., 9
Fai-s , G. ., 33
Felix, W ., 110
Fobelets, , 52, 60
Garrns, W. . , 233
Geiger, ., 10
Gilliand, . ., 123
Gotte, . , 244, 245
Gow, . ., 73, 97, 99, 102, 103,
104, 174, 86
Gross, ]. , 127, 129, 133, 149, 224,
228
Gr.inder, W., 42
Guggenhei m, . , 97, 99, 102, 103,
104, 174, 186
Hall, R . G., 129
Hancock, R. . , 100
Hinsley, J. F., 52, 204
Holrnes, J. ., 76
Honig, F. , 121 , 122
Hukki, R. ., 232
Hurnphrey s-Owen, S. F. . , I 3
H.ittig , G . F., 110, 3 0
Kennedy, . L ., 24
Kick, F., 8
Kwong, J. . S., 129, 3
Lee, . . , 97
Lewis, W . . , 23
Loeb, C. ., 233
Mackenzie , R. C., 34
Manson,. . ., 243
Martin, G., 127, 137
Maxson, W. L. , 74
M cAdarns, W. ., 23
McLeod, . . , 227, 228, 234
Mi1ne, . ., 34
Moeller, J. ., 233
Mor1ey, ., 2 17
Mortsell, S., 226, 233, 234
Moser, F., 147
M.iller, R., 137
Nordquist, D . . , 233
Norrnan, . . , 233
Norris, G. C., 9, 96
257
258
INDEX