International Journal of Mineral Processing, 22 (1988) 75-93 75

Elsevier Science Publishers B.V., Amsterdam -- Printed in The Netherlands

Design Considerations for Large Diameter Ball

Mills

Y.C. LO, J.A. HERBST, K. RAJAMANI and N. ARBITER

Utah Comminution Center, University of Utah, Salt Lake City, UT 84112 (U.S.A.)
(Received February 21, 1986; accepted after revision August 6, 1986)

ABSTRACT

Lo. Y.C., Herbst, J.A., Rajamani, K. and Arbiter, N., 1988. Design considerations for large di-
ameter ball mills. Int. J. Miner. Process., 22: 75-93.

Large mill (D > 5.0 m (16.5 ft)) performance has been successfullypredicted from small scale
batch experiment for grinding kinetics and an RTD correlation for transport using population
balance models. The effect of ball size must be properly taken into account in the scale-up. A
design method that combined the kinetic scale-up findings and the transport of material through
the mill has been developed.A computer program involving kinetic and transport considerations
has been tested and found to be satisfactory for mill design purposes.

INTRODUCTION

Large-diameter mills have potential advantages in capacity and relative cost.

It is important that an accurate scale-up method be developed for such mills.
Previous studies have shown that the detailed population balance models which
account for important grinding subprocesses (kinetics, transport and classi-
fication) provide an excellent basis for the analysis and predictions of large-
diameter mill performance from small scale batch tests ( H e r b s t et al., 1985).
In addition it has been found that the effect of ball size on the grinding kinetics
must be properly taken into account for accurate predictions in the mill scale-
up (Malghan, 1975; Austin et al., 1976; Lo and Herbst, 1986).
Procedures for scaling kinetic parameters (selection and breakage func-
tions) with mill power draft have been developed. However, transport has not
received proper attention in the large mill scale-up and design. Sometimes the
breakage kinetic and transport are considered to be independent subprocesses.
This appears to be valid for normal operating conditions, b u t is probably in-
appropriate for high specific throughout conditions. This is critical since the
combinations of breakage kinetics and transport completely determine the large
76

mill performance. Understanding of transport phenomena in mills is expected

to contribute significantly in determining the reasons for the design failures.
Recently the significance of recognizing and taking into account incipient
overload conditions in mill design procedures was acknowledged. Rowland and
Erickson (1983) indicated that mill volume, velocity of pulp flow through the
mill and residence time of the mill could be reasons for the limitations of mill
performance. Arbiter and Harris (1983) pointed out that pulp flow velocity
and mixing constraints may limit the mill capacity.
In our continuing effort to apply population balance models for scale-up and
design of large diameter mills, a design method that combined the kinetic scale-
up findings and the transport of material through the mill has been developed.
It is believed that this design method will reduce the risk of failure in large mill
design that has been recognized in traditional methods.

KINETIC CONSIDERATIONSFOR SCALE-UP

The size discretized population balance model for breakage kinetics has been
presented by several authors (Reid, 1965; Herbst et al., 1971; Austin,
1971-1972 ). In brief, a mass balance for the material in the ith size interval at
time t yields the kinetic model:
d(Hmi(t)) i-1
dt -SiHmi(t) + ~ bljSiHmj(t) (1)
j=l

where mi (t) is the mass fraction in the ith size interval and H is total mass of
material being ground. In eq. 1, Si, the size-discretized selection function for
the ith interval, denotes the fraction rate at which interval is broken out of the
ith size interval, and bii, the size-discretized breakage function, represents the
fraction of the primary breakage product of material in the j t h size interval
which appears in the ith size interval. Eq. i is referred to as the size-discretized
batch grinding model.
In order to apply the population balance model equations for scale-up the
dependence of the kinetic parameters (Si, bij) on mill dimensions and oper-
ating conditions must be known. According to findings presented by Herbst
and Fuerstenau (1973), the size-discretized selection functions are to a good
approximation proportional to the specific power delivered to the mill (P/H),
that is:
Si =S~(P/H) (2)
where S E termed the "specific selection function" is essentially independent
of mill dimensions. In addition the breakage functions bit have been found to
be to a good approximation invariant with respect to design and operating
variables over a wide range of conditions. Incorporating these findings into eq.
i yields the energy normalized form:
 77

dmi(/~) i-1
SEmi(E) + ~, bijSEmj(E) (3)
dE j=l
where/~ is the specific energy input to the mill, given by JE=Pt/H. The nor-
malized form of the model can be extended to continuous grinding using resi-
dence time distribution (RTD) information (Herbst et al., 1971). The mill
product size distribution for a continuous mill is given by:

roMp = _1mbatch ( E ) 0 ( E ) dE (4)

o
where roMp is an average of batch responses, mbatch(E), weighted according to
the amount of material that resides for various energy inputs in the mill. 0 (E)
is an energy density function (or "input energy distribution") that is related
to the residence time distribution by:
O(E)dE=O(t) dt (5)

Constant ball size

A procedure has been developed in which laboratory tests are performed

with the same ball size distribution as that of the plant. The laboratory grind-
ing equipment and experimental procedure used here have been described in
earlier papers (Herbst and Fuerstenau, 1980; Herbst et al., 1985). The ball
size distributions approximated those of "equilibrium charge distribution" ex-
pected for the worn in charge existing in commercial mills. In these tests the
top size ball used in the batch tests corresponds to the make up ball size for
the commercial mill. A synthetic feed approximating that which feeds the large
mills was used for batch tests. Ore samples of synthetic feed were collected
from all streams of the large mill grinding circuit during the plant testing. The
procedure for operating the large mills during the sampling campaign was as
follows: A strip chart, or computer output of critical operating variables was
obtained in each case, to verify that the operation was steady during sampling.
Initially, the feed rate was set at desired value. T h e n 1-2 h were allowed to
pass to permit the mill to achieve steady state. After making sure that there
were not intermediate perturbations, the sampling was started.
The kinetic parameters were determined from batch data using an efficient
Gauss-Newton estimation scheme (Herbst et al., 1977). The computer pro-
gram, ESTIMILL, provides statistically best estimates of kinetic parameters
from batch grinding data. As an example, Fig. 1 shows the breakage function
and specific selection functions estimated from batch grinding data for Pinto
Valley copper ore. For wet grinding systems, the specific selection functions
depend on the size distribution in the mill (product fineness). The procedure
78

1.O 10

Breakage

nction

O.1
F

O,O1 9.1
100 1OOO
PARTICLE SiZE,microns

Fig. 1. Breakage function and specific selection function for Pinto Valley ore wet grinding.

suggested here is based on determining model parameters for a similar specific

energy to that used in the large mill (batch grinding over a narrow specific
energy range corresponding to the energy input for the large mill) for selection
function estimation. The success of the scale-up procedure is dependent upon
the quality of kinetic parameter estimates. Fig. 2 shows that the specific selec-
tion functions obtained in the 381 mm (15 inch) small batch mill and in the
5.5 m (18 ft) large mill are statistically indistinguishable from one another at
the 95% level.

10(

SELECTION FUNCTIONS

~1.0

I- b'°h'lsln l
-- - continuous 118ttl
95% confidence
interval

//7, .
1OO 1OOO
PARTIGLE SIZE, microns

Fig. 2. Comparison of batch and continuous specific selection functions.

 79

100
. . . . . . . . . . . . . . . . . . ..,..o..~.o....~..~. ,-
1o 0 ~
PREDICTIONS O~'O <z
FOR 5.SxS.4m MILL O/o C~
o/

o/O / c
o/ o
o/ O
ZlO
0.~ K~a/TY / 0
Q
O
FEED 0
o Experimental, 76.2 mm bails
-- Predicted from 76.2mm ~ l l s

10 100 1000
PARTICLE SIZE ,microns

Fig. 3. Comparison of experimental product size distribution and predictions for copper ore wet
grinding.

For this procedure to be successful for commercial application, it must result

in accurate predictions of continuous grinding mill performance. The scale-up
procedure based on the estimated kinetic parameters and measured RTD gives
very satisfactory prediction of the 5.5 X 6.4 m (18 X 21 ft) mill performance at
Pinto Valley as shown in Fig. 3. The product size distribution error (the root
mean squared deviation between fitted and experimental values) is 2% with a
mill volume scale-up factor of 4250 to 1.

Ball size correlation

A procedure has been developed in which batch tests are performed with the
same ball size distribution as that of the plant, which yields excellent predic-
tions as described above. In some cases reasonably accurate predictions of large
mill performance can also be obtained based on batch tests involving different
size balls. In other cases the accuracy of such predictions is not satisfactory.
In early studies concerned with the application of population balance models
to scale-up (Herbst and Fuerstenau, 1980; Herbst et al., 1982) it was believed
that the ball size per se was of minor importance and that changes in grinding
rates were merely reflected in changes in power draw of the different ball
charges. This view is corroborated by data such as that shown in Fig. 4 where
relatively accurate predictions of limestone grinding with top ball sizes ranging
from 38.1 m m (1.5 inch) to 76.2 m m (3.0 inch) could be obtained based on
batch data collected with 38.1 m m (1.5 inch ) top size balls. Subsequent studies
with other materials in larger mills (see Fig. 5) show that significant errors
were made in predicting the mill performance using laboratory data obtained
with different top size balls. These later results indicated the criticality of
properly accounting for actual plant ball size distribution in the scale-up
procedure.
80

100
PREDICTIONS ~'~"~
FOR 0.91x1.;~lm MILL i~ "~'~

Z 10

A Experimental, 76.2mm balls

o Experimental, 50.Smm balls
-- Predicted from 38.1mmballs

1 , , , . . . . . . . . . . . . . . .
10 100 1000
PARTICLE SiZE,microns

Fig. 4. Comparison of experimental product size distribution and predictions for limestone wet
grinding in the 0.91 X 1.21 m (3 X 4 ft) mill.
100 . . . . . . ,,.
. . . . . . . . . ~ o ~ ?._~ .,,...,m.

j o
.1.1. o /"
1.7" o o

10 0.96 K~/T o '

FEED J "
o E x p e r i m e n t a l , 3"baJIs

-- - Predicted Iroml.5"balls

1 J , , . . . . . , , , , J , . . . . . i , i , , , ,

10 100 1000
PARTICLE SIZE, MICRONS

Fig. 5. Comparison of experimental product size distribution and predictions for copper ore wet
grinding in the 5.5×6.4 m (18)<21 ft) mill.

Several correlations have been proposed to describe the variation of the

grinding-rate parameters, Si, with ball size (Yang, 1969; Gupta and Kapur,
1974; Malghan, 1975; Austin et al.,1976). It is significantthat most of earlier
reported work is based on tests using single size balls in the mill, a condition
which isnever achieved in practice.Recently work has been done to investigate
the interactions between particle size and ball size distribution for the grinding
of the various materials and to obtain experimental information concerning
the influence of the entire ball size distribution on selection function and
breakage function as is pertinent for mill scale-up. A method of converting
experimental data for the specific selection function for one ball size distri-
 81

19.1 25.438.1 76.2 mm

0.75 1.0 1.5 3.0 in
100

Z
E

_~10

//
Ill
0.1 1.0 10
BALL SIZE d , inches

Fig. 6. Ball size distributions used experimentally.

bution to another has been proposed by Lo and Herbst (1986). Batch tests
were performed with different top size balls (Fig. 6) for different monosize
and full size distribution materials of various hardness, i.e., quartz, limestone,
magnetite, copper ore and phosphate ore. In all experiments power measure-
ments were made and several levels of energy input to grinding were evaluated.
As examples, the specific selection functions estimated from batch data for
quartz, and copper ore are shown in Fig. 7 and 8, respectively. In all cases the
specific selection functions variation with ball size appears to exhibit a pivotal
point (or pivotal region) indicating that, for particles coarser than that size,
the selection function increases with increasing ball size, and for particles finer

QUARTZ
SPECIFIC SELECTION FUNCTION

0.1 i i i , i i L i i ih i
50 100 10o0

PARTICLE SIZE, microns

Fig. 7. Specific selection functions for quartz wet grinding with different size balls.
82

COPPER ORE bllll size,ram

SPECIFIC SELECTION FUNCTION

1.O,

O.t
1OO 1OOO
PARTIGLE SiZE,microns

Fig. 8. Specific selection functions for copper ore wet grinding with different size balls.

than that size, the selection function decreases with increasing ball size. The
pivotal point and the rate of change of the slope depend on the properties of
the material. Considering the fact that breakage rates can decrease sharply in
coarse size range for hard materials, an empirical log-polynomial selection
function of second order is used for converting experimental data from one ball
size distribution to another. T h a t is:
Xi (X-11)ln(Xi/X1)
SE=kSpIv(Xp) XiE
(6)

In most cases it was found that the exponent ~2 was approximately the same
for different size balls, k = 1/(Xp/X1 ~21n is constant. The exponent ) (Xp/XI),
~ depends on ball size dB, i.e. ~ = adB + b, where a, b are constant for a given
material, and can be determined by an arbitrary set of "ball size tests". As an
example, in the case of quartz and copper ore grinding the following expres-
sions result:
[ - ~, 0 . 8 9 4 d B - 1"423

Quartz SE=l.732~,-~pp) \~-~j

/ X i ~ -°'~53 ln(XJX~) (7)

-- -- 0.207riB -- 1.694 _ -- -- 0.326

Copper ore SE--15.195(X~) (-~1) ln(Xi/X1) (8)

By knowing the pivotal point (Xp) and value of S~iv, the specific selection
function can be converted from one ball size to another for a given material.
In all cases examined it was observed that only a slight change in the break-
age function occurs when different ball size distributions are used for the grind-
ing media. Fig. 9 shows a combined plot of the normalized breakage function
for quartz wet grinding with 19.1, 25.4 and 38.1 m m (0.75, 1.0 and 1.5 inch)
 83
1.0

/~
QUARTZ /I
BRE A KAGE FU N C T IO N S //. 501'1
.4s
.45

0.1

J/~ Max.ball size,

0~:1.05 mm
- o 38.1
//2" ~ 25,
i [ ~ ~ [::] 19.1
//.o ~ Co-li=,,=a
f//J B.j-a I I x . / x j i] °2 ÷ ( 1-Ol}[Xi/X j 11°3 Intervals

0.01 , , , ...... l i , , , hI,l , . . . . . . .

0.01 O.1 1.0
NORMALIZED SIZE, XI/Xj+I

Fig. 9. Comparisonof breakagefunctionsfor quartz wet grindingwith differentsizeballs.

top size balls. As shown in Fig. 9, for the values of the three parameters in
functional form ~3 is almost exactly the same for different ball sizes, and ~2 is
approximately the same for different ball sizes. Only ~1 changeswith changing
ball size even if these changes are very small. Therefore, the change of selection
functions should be the primary consideration in converting kinetic parame-
ters from one ball size to another.
This method is illustrated here with an example for copper ore grinding. The
specific selection functions for copper ore were converted from 38.1 mm (1.5
inch) balls to 76.2 mm (3.0 inch) balls with eq. (8). The converted specific
selection functions are shown in Fig. 10, It has been found that accurate scale-
up predictions are possible using this ball size-correction method. As is shown
in Fig. 11, the scale-up procedure (Herbst et al., 1985 ) with the specific selec-
tion function converted from 38.1 (1.5 inch) to 76.2 mm (3.0 inch) balls gives
accurate predictions of 5.5 × 6.4 m (18 × 21 ft) mill performance. The product
size distribution error is about 2% with a volume scale-up factor of 9500 to 1.
The scale-up procedure associated ball size-correction suggests that the most
accurate predictions will be obtained using the same ball size distribution in
the laboratory test as that of the plant. When it is inconvenient to run labo-
ratory experiments with the expected plant ball size distribution, scale-up can
be done from an arbitrary set of "ball size tests" in a small batch mill. The
population balance scale-up procedure with converted specific selection func-
tions also provides accurate predictions of large mill performance. This pro-
cedure is also very useful in analysis of grinding circuit performance with a
view toward determining alternatives for increasing mill capacity. The capac-
ities of large mills can be predicted by simulation using parameters obtained
from a limited number of batch ball size tests.
84

COPPER ORE
1.0 SPECIFICSELECTIONFUNCTIONS

i
/ /

~- /~////////// ~_---~_
-- E x p e r i m e n t a l , 3 8 . 1 m m balls

/ --- Converted from

.1 to 76.2mm bails

/
0.1 . . . . . . . . . . . . |, , i
10 100 1000
P A R T I C L E SIZE , microns

Fig. 10. Conversion of specific selection function from 38.1 mm (1.5 inch) to 76.2 mm (3.0 inch)
balls.
100 . . . . . . . . . . . . . . . . . . o~O~o~. ~o

PREDICTIONS j , , ./o ~ ~ "" " ' ~ " .

FOR 5"5xS'4m M I L L //ZI°~/"-

J"
/o.1°/./ o

.=,
zlo 39S K~/T I"
o.I.o.I° / / "

/
/"
FEED "
o Experimental, 7 6 . 2 rnm balls
-- Predlcted,withconversion,38.1 rnmbal

1 i i i . . . . . . . . . , , .... , , , L , ,,,
10 100 1000
PARTICLE SIZE, MICRONS
Fig. 11. Comparison of experimental product size distribution and predictions for copper ore wet
grinding in the 5.5 × 6.4 m (18 × 21 ft) mill, with converted specific selection functions.

TRANSPORT CONSIDERATIONSFOR SCALE-UP

A description of a continuous tumbling mill requires not only a description

of the breakage kinetics but also a mathematical description of material trans-
port through the mill. Methods of scaling rate parameters (selection and
breakage functions) with mill power draft have been fairly well developed.
However, to apply the scale-up methods one needs a priori the residence time
distribution (RTD) or transport behavior of material through the mill.

Residence time distribution ( RTD )

As mentioned in the discussion of eq. 4, ~ (t), the residence time distribution

is an experimentally determinable function (Rogers and Gardner, 1979). In
 85

I r I ] I

Pinto Valley
15 closed circuit RTD

1G

• Experimental
-- Fitted

5 10 15 20 25
Time,rain

Fig. 12. Closed circuit RTD model fit of the experimentally determined residence time distribu-
tion, 31=2.0 min, N~=2.2.

many instances the residence time distribution in a mill can be represented

with a highly flexible mixers-in-series model (Himmelblau and Bischoff, 1968)
i.e.:
N N ( t / T ) N-1 (Nt)
¢)(t)- F(N) exp -}- (9)

where N is the mixing parameter which gives the equivalent number of mixers-
in-series and T is the mean residence time for material in the mill. Based on
this model a "RTDUNEQW" program (Rajamani et al., 1983) has been de-
veloped for analyzing the residence time distribution.
Recently, a mathematical method for analyzing the closed circuit material
residence time in the continuous mill has been developed (Rogovin et al., 1986).
The residence time model parameters can be calculated using the relationships
between mean value and variance of tracer response to the mean residence
time and the degree of mixing in each of the circuit components ( Mann et al.,
1979; Mann and Rubinovitch, 1981). In both plants examined, the lithium
chloride tracers were injected into the mill inlet and detected at the mill outlet
before the sump. Component 1 is the mill while component 2 is the sump.
Considering ~2 (the mean residence time of the sump) and N2 (the number of
mixers-in-series in the sump) as equal 1 (full mixed) and all the plug-flow
times as negligible, the mean ~r and the variance a~ of the RTD are as follows:
86

oo

f t c ( t ) dt oo

]d,T="C1+ R( z~ +z2) = o~ fro(t)dt (10)

~
-

c(t) dt o
0

T1
a2=R(I+R)['c, +z2]2+-~I+R T1 +z 2
(;: )
oo

--
f t2c(t)dt
0
oo
¢yo

tt~= f t~¢( t)dt-lt~ (11)

fc(t)dt 0

and the exit age density function is given by:

t

O(t)-ooc(t) - Hi(t)+ E p n-1 X H*ln(x)

n=2

f c(t)dt
0
o

..2 (t-x)dx (12)

where c(t) is the concentration of the tracer at the detection point at time t
after the injection, zl and z2 are the mean residence time of the mill and sump,
N 1 is the number of mixers-in-series in the mill, R, ratio of recycle flow of the
tracer, p = R/1 + R, Hi (t) is the RTD density function in component i of the
circuit.
Figs. 12 and 13 show the experimental measurements and model fits for
intermediate feed rates (425 T / H with 380% circulating load and 405 T / H
with 550% circulating load) for the Chino and Pinto Valley mills. The values
of mean residence time ~1 are 2.2 and 2.0 min, the values of N1 are 3.5 and 2.2
for Chino 5.0 m (16.5 ft) mill and Pinto Valley 5.5 m (18 ft) mill, respectively.
This data indicates that the mean residence time is not too different for the
two mills but that the mixing parameter decreases as the mill diameter increases.

Residence time distribution correlation

There have been some attempts presented in the literature to describe the
RTD of the mill for different L/D ratios and feed rates. Karra and Fuerstenau
 87

5.0

CHINO
4.0 closed circuit RTD

3.o
E
J i

2.0

1.O
• Experimental

5 10 15
T i m e , min

Fig. 13. Closedcircuit RTD modelfit of the experimentallydeterminedresidencetime distribu-

tion. T1=2.2 min, N~=3.5.

(1977) described the RTD of dry grinding with an axial dispersion model.
Rogers and Gardner (1979) applied a finite-stage transport model to phos-
phate ore wet grinding in 2.7X1.8 m, 5.2X3.8 m and 9.1X4.6 m mills; they
argued that the parameters of the finite-stage model were the same for the
three mills. Marchand et al. (1980) used a plug flow plus mixers-in-series model
to analyze RTD in 2.1X3.0 m and 2.4X3.0 m mills. They argued, based on
their data and others, that the dimensionless volumetric hold-up varies line-
arly with the dimensionless volumetric feed rate. None of these previous in-
vestigators made an attempt to correlate RTD data with wet mill characteristics
and operating conditions to account for the effect of percent solids, ball size
and L/D ratio. Such a correlation is needed for the scale-up design of large ball
mills. In order to accomplish such a correlation we analyzed not only our own
RTD data, but also the data of others. The data includes mill diameters ranging
from 0.4 to 5.5 m (1.3 to 15 ft) and lengths ranging from 0.4 to 9.8 m (1.3 to
32 ft) with ball sizes ranging from 38.1 to 76.2 mm (1.5 to 3.0 inches).
The development of this correlation was based on consideration of the tur-
bulence level in a mill and its influence on the extent of dispersion (back-
mixing) of material as it is transported through the mill. In this regard it was
assumed that the mixing parameter N could be correlated directly with the
Peclet number for the mill:
QL
Pe oc - - (13)
A De
with the dispersion coefficient, De, which is proportional to power input per
unit volume to the mill. In addition, studies of transport through packed beds
have shown that the Peclet number is also related to Reynolds number for
88

transport through the bed. The flow behavior through the dynamic ball mass
is somewhat akin to that of the flow through a packed bed. The comparison is
exact if the entire slurry stream passes through the ball mass and if the voidage
remains constant. Considering these factors and recognizing for N-mixers-in-
series description N is related to the Peclet number by:

1
N~- (14)
2 2
Pe pe 2 ( 1 - e -Pe)

a correlation involving a plot of N versus L/D times 1 / x ~ (where N* is

fraction of critical speed) and the Reynolds number:
Q
dBPslurry~--~
NRe - - (15)
slurry
was proposed. Fig. 14 shows this correlation for all of the data. A linear regres-
sion of the data gives:

N=O.3399 NRe ~ +1.1983 (16)

The regression line fits most of the data very well. There seems to be some
deviation for few data. However, this deviation is not significant when used in
the context of population balance model. Fig. 15 shows a comparison of exper-
imental product size distributions and predictions obtained with mixing pa-
rameter N= 2.2 (as determined from closed circuit RTD model) and N= 1.8
(as calculated from RTD correlation for 5.5 X 6.4 m (18 X 21 ft) mill at Pinto
Valley. The size distributions are virtually identical (error less than 0.2%)
indicating that the RTD correlation (eq. 16) is valid for accurate predictive
purposes.

EXAMPLE APPLICATION

In order to apply the above findings for large mills, a design method based
on SCALEMILL (Herbst and Rajamani, 1982 ) has been developed. The basis
of this computer program is:
(1) Population balance model with Si--SE(p/H), bij--constant and ball
size correlation.
(2) Transport using the N-mixers in series model with parameters corre-
lated with mill dimensions, slurry rheology and mill speed.
( 3 ) Power equation as given by Rowland and Kjos (1978) :
 89

° jo/O ~

• o
~ v
v

[~
+
D(ft)
1.33
1.33
L (ft)
1.33
2.66
o 1.30 4.00
• 2.50 1.50
• 3.00 4.00
~. 12.50 17.00
• 14.00 32.00
V 15.50 18.00
O 16.50 19.00
• 18.00 21.00
0 2 4 6 8 10
N L 1
R. I~-I ~ifl

F i g . 14. N m i x e r s - - slurry Reynolds number, mill dimensions, mill speed correlation.

100
O~-,'O
PREDICTIONS ~ f <:
FOR 5 . 5 x 6 . 4 m MILL ~0"~ t/
/-
jo o
I/oj ° <>
0 ~0~ ©

ZlO
E 0.96KWH,~>~/~ <>
o

FEED 0

0 Experimental
-- Predicted, N=1.8
--- Predicted, N~2.2

m , , , , , , , , , , , m k m bl"O00
10 100
PARTICLE SIZE , m i c r o n s

Fig. 15. Simulated mill discharge for N = 1.8 and N = 2.2

L
P=2.7pba..(-~)D " M~(3.2-3M~)N*(1-O.i/29-1°N*) + S.
33 *

Design calculations can either be done for open circuit or closed circuit. The
program gives as output the calculated mill length, mill diameter, mill speed,
ball load, hydrocyclone number and the size distribution in all of the circuit
streams.
As an example: Select a mill to grind 425 tph of copper ore from a feed size
of 80% passing 2360/~m to a product of 80% passing 210 ttm. The mill is to be
loaded to 37 % of its volume with 76.2 m m ( 3 inch) to size balls and rotated at
a speed of 72% of its critical speed.
According to the scale-up procedure, batch experiments were conducted in
90

TABLE I

Results for design of copper ore grinding

P (kW) D (m) L (m)

Scale mill 1784 4.72 5.64
Plant data 1845 4.88 5.79
lO0 • o . . . . .

Circuit J OjO //t"

product / "
/
/
/
/
/
/
/
/
10 /
s
~ / Mill Design for Copper Ore
Fee(:l ~ o plant Experimental
- - predicted
o

1
10 100 1000
Particle Size, microns

Fig. 16. Comparison of plant experimental size distribution and predictions for copper ore grinding
circuit.

a 380 X 290 mm (15 X 11.5 inch ) mill with a B L H torque sensor for power de-
termination. The ball size distribution approximated that of an "equilibrium
charge" with top size of 76.2 mm (3 inch). The mill speed was kept at 72% of
its critical speed. Size distributions of feed and product, and power data were
input to the E S T I M I L L to estimate breakage parameters. In turn, the esti-
mated breakage parameters, R T D correlation data plus the design require-
ments were input to the computer program. The results from the program of
the power ( P ) , the diameter (D) and the length (L) required for this task are
shown in Table I. Also shown are the actual values obtained from the Chino
plant. Fig. 16 shows a comparison of the predictions and the experimental size
distributions obtained for the plant. The agreement between predictions and
actual performance is very close. In this case prediction errors are only 3.3%
on power and 2% on product size distributions.

CONCLUSIONS

In this paper the correlation of breakage kinetics and transport with mill
design and operating variables has been described for large mills.
Large mill ( D > 5 . 0 m (16.5 ft)) performance has been successfully pre-
dicted from small scale batch test for kinetics and an R T D correlation for
 91

t r a n s p o r t u s i n g p o p u l a t i o n b a l a n c e m o d e l s . T h e effect of ball size is s i g n i f i c a n t

a n d m u s t be t a k e n i n t o a c c o u n t in t h e scale-up. A m e t h o d h a s b e e n d e v e l o p e d
for specific s e l e c t i o n f u n c t i o n c o n v e r s i o n f r o m o n e ball size to a n o t h e r .
A p r e l i m i n a r y R T D c o r r e l a t i o n b e t w e e n t r a n s p o r t c h a r a c t e r i s t i c s a n d mill
design a n d o p e r a t i n g v a r i a b l e s h a s b e e n d e v e l o p e d for t h e s c a l e - u p design of
large mills.
A c o m p u t e r p r o g r a m involving kinetic a n d t r a n s p o r t c o n s i d e r a t i o n s h a s b e e n
t e s t e d a n d f o u n d to be s a t i s f a c t o r y for mill design p u r p o s e s .

ACKNOWLEDGEMENTS

T h e a u t h o r s g r a t e f u l l y a c k n o w l e d g e t h e f i n a n c i a l s u p p o r t of t h e U S B M ,
G r a n t No. 1125149, G e n e r i c M i n e r a l T e c h n o l o g y C e n t e r for C o m m i n u t i o n .

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