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LESSON 2

Grinding

The type of grinding mill is identified by the type of grinding media
utilized. Each type of mill has characteristics that adapt it to certain grinding
applications. The operational characteristics of each mill type must be evaluated
in relation to the objectives of the grinding requirements being studied in order
to select the optimum mill. The common mill types are discussed in the
following sections.

Rod mills can accept feed up to approximately 2 diameter and generally
are selected to grind product to the 4 mesh to 35 mesh range. Grinding
actions is by line contact between rods extending the length of the mill. Rods
tumble and spin in roughly parallel alignment and in so doing simulate the
crushing and grinding action from a series of roll crushers.

Large particles spread the ends of rods and is so doing impart an additional
action termed scissoring. These actions result in preferential grinding of coarse
material and a minimum production of slimes and excessively large material
termed tramp oversize. A relatively uniform sized product is produced. Due to
the nature of the grinding action, rod mills can sometimes advantageously
replace the fine crushing of damp or sticky material that tends to coat the faces
of crushing surfaces. Rod mills can produce a final product on sand, brick, lime,
or coke breeze where the feed contains low moisture and is often ground dry. In
the metal mining industry most rod mill applications involve wet grinding were
material is reduced in size from crusher product size to a size suitable for ball
mill feed. Rod milling in the size range utilized is more efficient than ball milling
in that the desired product is obtained at a lower cost per ton.




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Rod Mills over Ball Mills?

Rod milling in the size range utilized is more efficient than ball milling in
that the desired product is obtained at a lower cost per ton. This is due to
several reasons:

1. Grinding rods do not require cascading as do ball charges, thus enabling rod
mills to be operated at lower peripheral speeds than ball mills.

2. Less void spaces exist in a rod charge than in a ball charge. Therefore, there
is more grinding contact between metal and ore per surface area of media in a
rod mill.

3. Lower steel consumption per ton of product occurs in a rod mill than in a ball
mill due to better contact between steel and ore. The action within the rod mill
causes the energy of rods to be directed to the largest sized pieces of ore.
Often in a ball mill the balls grind on one another or against ore already ground
fine enough.

4. Rods are more suited than balls to breaking larger pieces of ore due to their
much higher weight. (Energy is equal to half the product of the mass times the
velocity squared). Larger media are capable of transmitting more energy per
collision.

5. Grinding rods can be maintained in good working condition because broken
and worn rods can be removed through the large open discharge end. Often
broken pieces of rods will float out with the pulp thus avoiding entanglements.



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In a rod mill it is important that the rods stay essentially parallel to one
another. If rods become misaligned, grinding action is lost and more
importantly, rod entanglements will occur. For this reason, rod mills are
designed with their length roughly 1.3 to 2.0 or more times their diameter. Rod
mill size depends on the feed and product size, capacity, type of grinding circuit
and the power required to achieve the grind. The limitation on rod mill length is
in the ability to make rods that will remain straight enough not to tangle. The
current practical limit on rod length is about 20 feet. The diameter of a rod must
increase as the length increases if the rods are not to sag appreciably under
their own weight. Rod mill speed, rod charge and percent solids affect the
horsepower the mill is capable of developing.