To use enter the required data or use the drop down list

This form is based on the work of Fred C. Bond and others.

Input Values
Wi =
Bond Work, kWh/short ton [Imperial units]
F=
Feed 80% passing size in microns
P=
Product 80% passing sizes in microns
Basic Energy Consumption
W=
Basic energy required
W = Wi*[10/P^0.5-10/F^0.5] kWh/ton

14 kWh/ton
12500 microns
150 microns
10.18 kWh/ton

in the highlighted cells

he highlighted cells

To use enter the required data or use the drop down list

in the highlighted cells

This form is for calculating the basic ball/rod/pebble mill factors.

This should be used as a guide only, with proper testing used for final selection.
This form is based on the work of Fred C. Bond and others.

Basic Input
Bond Work, kWh/short ton
Feed 80% passing size in microns
Product 80% passing sizes in microns

Wi =
F=
P=

14.5 kWhr/st
12500 F80
150 P80

W=

10.54 kWh/ton

Basic Energy Consumption

Basic energy required
Project:
Feed Tonnage:
By year
By Day
By Hour
Operating Schedule:

Gross Hours/year
Availability:
Actual Operating:
Net Hours/year
Mill Definition
Type
Wet or Dry:
Circuit (Open or Closed):
Mill Diameter
Mill Length
revolutions/minute
L to D check - for Rod Mills (if L is < 2*D rods can tumble and tangle)
Unit Volume
Assumed Drive Losses:
Number of Mills
Ball Type Factor - K1
Mill Type Factor (for makeup ball/rod/pebble size) - K2
Basic energy required - per mill
Capacity check - based on actual mills installed by Boliden & Koppers

210,000
600
28
24
7
50
8400
90
21.6
7560

hours
days
weeks

t/yr
t/d
t/hr
h/d
d/w
w/yr
h/yr
%
h/d
h/yr

Ball Mill
Wet
Closed
D=
L=
R=

14 ft
10 ft
12.0 rev/min

Nm =
K1 =
K2 =

1539
5
1
1.00
330
292.84
392.70
662

ft3
%

kWh
Hp
ft3

Adjustment factors
Ball charge efficiency factor
drop from inside top of mill to lowest discharge point
ball charge volume fraction
Fine grinding factor
Mill diameter factor for mill diameter D
Reduction ratio
Reduction ratio
Reduction ratio efficiency factor
Shell speed factor for shell speed
where Z=-[D/17.08]^3
Shell speed
Mill Type
Wet or Dry
Circuit Type
Diameter efficiency

Bcef =
Q=
V=
Fgf =
Fmd =
Rr =
Rro =
Ref =
Ssf =
Z=
S=

1.22
10.50
21.8%
0.93
0.89
83.3
11.6
1.00
1.33
0.55
8.80 ft/sec

MT
EF1
EF2
EF3

1.00
1.00
2.00
0.91

Et =

26.28
730.11
979.08
1,511

Comminution energy needed :

Energy transfer required within mill shell
Internal energy required - per mill

Capacity check - based on actual mills installed by Boliden & Koppers

kWh/ton
kWh
Hp
ft3

Mill Power Draw

Ball mass
Ball charge power factor
Base power draw Bpd = 6.52*L*D0.4*Bm [ 11.2*L*D2.4 maximum]
[8 ft wet o/f discharge mill, 75% critical speed]
Critical speed factor
% Critical speed
Theoretical critical speed rev/min
Reduction ratio power factor for F/P < 3
Ball diameter (or rod or pebble)

Bm =
Bcpf =
Bpd =

162.91
1.41

Csf =
Cs =
Nc =
Rpf =
B=

0.48
0.80
58.62%
20.47 rev/min
1.00
3.88

Low discharge factor

Base Power Draw
Mill power draw

Ldf =
Bpd =
Mpd =

1.01
11.88 kWhr
14.18 kWhr

Total Power
Comminution
Per Mill
Mill Power Draw
Total
Capacity check - based on actual mills installed by Boliden & Koppers

730.11
730.11
14.18
744.29
998.09
1,537

kWhr
kWhr
kWhr
kWhr
Hp
ft3

Currently US units only

W = Wi*[10/P^0.5-10/F^0.5] kWh/ton

L to D Okay

1.00 (cast iron) 1.08 (steel) 1.11 (forged)

Wet Pebble - 170,Dry Pebble - 175, Rod - 300, Dry Ball 330/335, Wet Ball 350
= W *t/hr / # mills

Mill sizing okay

Bcef = [0.4/V]^0.333
assume 75% of D or input if known
V = 1.13-1.26*Q/Wi
Fgf = (P+10.3)/1.145P for P < 75 microns
Fmd = [8/D]^0.2
Rr = F/P
Rro = 8 +5*L/D
Rref = (20*(Rr -1.35) +2.60)/(20*(Rr-1.35))
Ssf = [2 - 2.8/S]^Z

Based on Ball = 1, Rod = 2, SAG = 3 & AG = 4

Based on Wet = 1, Dry = 1.3
Based on Open =1, Closed = 2

Et = W*Bcef*Fgf*Fmd*Rref*Ssf*MT*EF1*EF2*EF3 kWh/ton

Mill sizing okay

Bm = 3.82*K1*V*D^2
Bcpf = 1.78 - 1.69V
Bpd = 6.52*L*D^0.4*Bm /(11.2*L*D^2.4)
Csf = 1.38*Cs*[1-0.1*(210*Cs-9)]
Cs = R*(D^0.5)/76.6
Nc = 76.6 /(D^0.5)
Rrpf = [F/P - 1.48]/[F/P - 1.35]
B=(F/K2)^0.5)*((Sg*Wi)/(100*CS*(d^0.5)))^0.5)
Ldf = 0.708 + 0.4Q/D
Bpd = 2.8*(D^0.4)*(3.2-3*V)*Cs*(1-0.1/(2^(9-10*CS)))
Mpd = Bcpf*Bpd*Csf*Ldf*Rrpf*Sf kW
t/hr * Et

Mill sizing okay

Open

Wet

Rod Mill

1.00 for cast iron balls

Closed

Dry

Ball Mill
AG (Autogenous)
SAG (Semi-autogenous)

1.08 for steel balls

1.11 for forged balls

170
175
300
335
350

Wet Pebble
Dry Pebble
Rod
Dry Ball
Wet Ball

Mill too small for required Hp

Mill sizing okay
Mill Length to short for Rod Mill L< 2*D
L to D Okay

K Factor
Grindlng Media
Wet-Overflow-Open Circuit
Wet-Overflow-Closed Circuit
Wet-Diaphragm-Open Circuit
Wet-Diaphragm-Closed Circuit
Dry-Diaphragm-Open Circult
Dry-Diaphragm-Closed Circuit

C.I. Balls Pebbles

350 350 330
170
330
170
335
175
335
175