Beruflich Dokumente
Kultur Dokumente
Abstract
The effect of liner/lifter profile on kinetics of batch grinding and the milling capacity in general was assessed using mono-size quartz
material of 30 · 40 mesh (600 + 425 lm) as feed. The liner profiles tested were, (i) bevel with 60 lifter face angle to represent the new
liners, (ii) bevel with 45 lifter face angle to represent the worn liners and (iii) worn bevel modified with cone-lifters. The tests were con-
ducted under identical conditions to allow a comparative analysis of the results. In all cases, the breakage followed the first order hypoth-
esis. The experimental size distribution data was well predicted by the S and B model, thus allowing for estimation of breakage and
selection parameters (i.e., c and aT) for the three liner situations tested. The optimised values of the specific rate of breakage, Si for
the three liner profiles tested were 0.381, 0.287 and 0.365 min1, respectively, which clearly indicates the benefit of cone-lifters. The break-
age distribution function (Bij) values did not vary significantly with liner profile, which echoes the findings by other researchers.
2006 Elsevier Ltd. All rights reserved.
0892-6875/$ - see front matter 2006 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mineng.2006.03.002
1440 A.B. Makokha, M.H. Moys / Minerals Engineering 19 (2006) 1439–1445
2. Fundamental theory of milling progeny fragments resulting from primary breakage can
be described by a cumulative breakage distribution func-
The theory of milling is well covered in literature, hence tion (Bij), determined from the product size distributions.
this paper will only outline on the fundamentals. Basically, Basically Bij is the sum of the mass fractions of material
for efficient particle breakage events (normal breakage), the broken out of size j that is smaller than the upper size of
size reduction process follows the first order law (Deniz, interval i (Tangsathitkulchai, 2003). The duration of grind-
2004). According to the law, the specific rate of breakage ing over which the Bij values can be determined is chosen
does not vary with grinding time over a range of particle such that only 20–30% breakage occurs in the top size
size (i.e., an average rate of breakage, Si is assumed over interval to minimize re-breakage of smaller particles. The
the total grinding time). The size of the particlespisffiffiffi defined
pffiffiffi following expression was used to determine the Bij values
by screen intervals separated in a sequence of 2 or 4 2. (Austin et al., 1984):
For breakage of mono-size material, the process can be log ½ð1 pi ð0ÞÞ=ð1 pi ðtÞÞ
described by the following kinetic equation: Bij ¼ ; i > j; ð3Þ
log ð1 pjþ1 ð0ÞÞ=ð1 pjþ1 ðtÞÞ
dw1
¼ S 1 w1 ðtÞ; ð1Þ where Pi(t) is the weight fraction of the material in the mill
dt
less than size xi at time t. The Bij values can be fitted to an
where, S1 is the specific rate of breakage of the feed size empirical function proposed by Austin et al. (1984) which
material (i.e., i = 1) and w1(t) is the mass fraction of the is presented as follows:
material remaining in the feed size interval after time t.
As breakage proceeds over a longer period, the material be- Bij ¼ /j ½xi1 =xj c þ ð1 /j Þ½xi1 =xj b ; n P i P j P 1.
comes finer and breakage slows down. At this stage, the ð4Þ
non-first order breakage ensues (abnormal breakage). This
is in line with Griffith’s fracture theory whereby it is diffi- The model parameters (/j, c, b) are characteristic material
cult to initiate breakage in smaller particles as compared properties for a given ore.
to larger particles because of the presence of pre-existing
flaws in the larger particles. To determine the variation of 3. Experimental
specific rate of breakage Si with particle size, Austin
et al. (1984) used the following model: 3.1. Batch equipment configuration
S i ¼ aT xai Qi , ð2Þ
A laboratory scale mill measuring 526 mm in diameter
where, xi is the maximum limit in the screen size interval i (inside liners) and 400 mm long was utilised in the experi-
(mm), and aT and a are characteristic constants which are mental work. The mill configurations and test conditions
dependent on material properties. The parameter aT is also are described in Table 1. Fig. 1 illustrates the details of
dependent on mill conditions. Qi is the correction factor the bevel liners used in the experimental work. The liners
(taken as unity for lower size intervals, i.e., xi dball). In were cast with integral lifters having a face angle of 60 tan-
this study, xi < 1 mm hence Qi is taken as unity. gent to the mill shell on one side and 45 on the other,
Increasing aT and Si increases the effective breakage rate which replicates the profile of the new and worn liners,
of the original particle in size class i to undersize. Hence, a respectively. This configuration further allows the experi-
high value of aT implies a faster grinding process. The mental work to be performed with both worn and unworn
parameter a in Eq. (2) is a material property which is inde- profiles by simply reversing the liners or direction of mill
pendent of mill conditions (Austin et al., 1984). rotation.
When a material of any given size undergoes primary Fig. 2 shows the details of the cone-lifter design and the
breakage, a set of primary fragments are produced which installation criterion. The cone-lifters have a face angle of
would in turn have a probability of being re-broken. The 60 and height of 16 mm with a 7 mm bore to facilitate
Table 1
Experimental specifications and test conditions for the batch milling tests
Specifications Test A1 Test A2 Test A3
Liners Number 24 24 24
Profile Worn Worn + cone-lifters New
Cone-lifters Configuration – Staggered –
Number (Per row) None 12 None
Number of rows circumferential None 5 None
Ball media Diameter (mm) 10–6 10–6 10–6
Mill diameter (inside liners), D = 526 mm; mill length, L = 400 mm; load volume, J = 20%; speed, N = 75% of critical (58.8 rpm); interstitial powder
filling, U = 0.6.
A.B. Makokha, M.H. Moys / Minerals Engineering 19 (2006) 1439–1445 1441
Mill Radius
New (60˚)
were estimated. Three duplicate experiments designated
(R273)
Worn (45˚) as A1, A2 and A3 were performed each for a given period
of grinding time. Three liner profiles whose configuration
details are given in Table 1 were tested. The mill speed
and filling were kept constant during the tests. The aim
was to compare the grinding rates obtained with the three
liner/lifter profiles and to assess any influence on the selec-
tion and breakage parameters. The summary of the exper-
69 400
imental mill characteristics and test conditions are given in
Table 1.
Fig. 2. Snapshot of the experimental mill showing the worn bevel liners fitted with cone-lifters in staggered mode (h = 45, h = 5 mm).
1442 A.B. Makokha, M.H. Moys / Minerals Engineering 19 (2006) 1439–1445
pffiffiffi
of 2. The reason for maintaining the same sieves in all the due to the cushioning effect by the fines. The phenomenon
test runs is to ensure consistency in the results. This is given of cushioning is discussed in details elsewhere by Austin
the fact that different sieves have different reliabilities et al. (1984). In the first order region, the specific rates of
despite having same nominal aperture size. breakage, S1 for the cases of worn liner profile, worn liner
modified with cone-lifters and new liner profile are
4. Results and discussion obtained as 0.27, 0.34 and 0.36 min1, respectively. This
signifies an improvement of about 26% in milling rate with
4.1. Comparison of grinding rates the worn liner upon modification with cone-lifters.
To assess the performance of the three liner profiles 4.2.2. Determination of Bi1 values
under investigation, a comparison of the grinding data Fig. 4 shows the experimental results where the values of
was made. This data is graphically presented in Fig. 3, the cumulative breakage distribution function (Bi1) are
where the mass percentage retained on the top screen is plotted against size on the log–log scale. The Bi1 values
plotted against grinding time t on a log–linear scale. The were evaluated using Eq. (3). The grinding data obtained
results indicate that grinding follows the first order hypoth- after 1 min of grinding, which was just sufficient for mini-
esis (normal breakage). The slope of each line represents mum secondary breakage of material in the top size was
the specific rate of breakage, i.e., the selection function utilised in the evaluation. From the results presented in
(S1). This parameter is generally used in milling practice Fig. 4, the difference between the Bi1 values for the three
to give the fractional rate of breakage out of initial size j. liner profiles is indiscernible. This observation adds to the
The results further indicate a significant improvement in general consensus in literature (e.g., Austin et al., 1984)
milling rate for the worn liner profile upon modification that Bij function (where j = 1 in the present case) is inde-
with cone-lifters (i.e., by retrofitting). This implies that pendent of the mill conditions. The parameters (/, c, b)
the performance of worn liners could be optimised using can be obtained from the Bi1 curve as illustrated in the fig-
cone-lifters; but it is noteworthy that on full scale mills ure where the slope of the lower part of the curve gives the
the cone lifters protrude aggressively into the load and value of c while / is the intercept at (xi1/x1) = 1. The
therefore will be subject to a high wear rate leading to a life value of b is obtained as a slope of Bi1 /[xi1/x1]c
substantially lower than the originally installed liners. {= (1 /)[xi1/x1]b from Eq. (4)}, whose intercept is
However, replacement of the cone-lifters will be very easy (1 /) at (xi1/x1) = 1 (King, 2000).
to do, and the cone-lifters themselves should be substan- The parameter c characterises the relative amount of
tially cheaper than the liners, so lower overall liner cost fines produced from the breakage of the top size material
would be expected over several cone-lifters lifetimes. and therefore directly relates to the efficiency of the grind-
ing process. A higher value of c implies that the progeny
4.2. Determination of breakage and selection parameters fragments are coarser, i.e., their size is closer to the size
of the parent material being broken and that grinding is
4.2.1. Determination of S1 values taking place at a slow rate. On the other hand, a lower
The first order plots of experimental data for the three value of c would imply more effective breakage action with
liner profiles tested are presented in Fig. 3. The data dis- high production of fines. In general, softer materials would
plays mild but noticeable nonlinear behaviour after 2 min display lower values of c as compared to harder materials.
with the breakage rate beginning to slow down, possibly
1 1
100 100 Φ = 0.55
Cumulative breakage function (Bij)
Mass % retained (-600 +425)μm
S = 0.27 min-1
0.3 0.3
S = 0.36 min-1
γ
0.1 0.1
β
30 30
0.01 0.01
101 3x101 102 3x102 103
10 10
0 1 2 3 4 5 Size (xi) μm
Grinding time (mins)
Fig. 4. Breakage distribution function for 97% single size quartz feed
Fig. 3. Results of the batch test of first order grinding for mono-size (600 + 425) for a grinding time of 1 min (U = 0.6, N = 75% of critical,
quartz material (600 + 425 lm), N = 75% of critical, J = 20%. J = 20%).
A.B. Makokha, M.H. Moys / Minerals Engineering 19 (2006) 1439–1445 1443
100 100 RMSR values for the three cases investigated are less than
the critical value of 0.01 (i.e., 0.0039 for new liner, 0.0042
Cumulative % finer than size (xi)
for worn liner and 0.008 for the worn liner with cone-lift-
30 30 ers). On the basis of these results, it can be admitted that
the model fits the experimental data well. The root mean
square of normalised residuals was obtained as
10 10 rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
4 Min
P P J n
2
P ijðtÞ exp P ijðtÞpred
j¼1 i¼1 P ijðtÞpred
RMSR ¼ ; ð6Þ
3 2 Min 3 ðn 1ÞJ 1
Experimental
1 Min Predicted where Pi,j,exp and Pi,j,pred are the experimental and pre-
1 1 dicted cumulative fractions finer than size xi for the jth
10 1 3x101 10 2 3x10 2 10 3 combination of operating variables and grinding time.
Particle size (xi) μm
4.3. Comparison of power draw and milling capacity
Fig. 5. Experimental and predicted product size distributions of
600 + 425 quartz feed, ground with 10–6 mm balls (worn liner profile).
It is generally assumed that the energy required for
grinding per tonne of defined product size is approximately
constant. The general practice in milling industry is that, in
order to achieve the highest production rate, the mill must
100 100
draw maximum power. Thus, it is expected that the rate of
breakage will reach a maximum at the point when the mill
Cumulative % finer than size (xi)
30 30 440
Mill Power (W)
10 4 Min 10 430
1 1
10 1 3x101 10 2 3x10 2 10 3 0
0.4 0.45 0.5 0.55 0.6
Particle size (xi) μm
-1
Parameter aT (min )
Fig. 7. Experimental and predicted product size distributions of
600 + 425 quartz feed, ground with 10–6 mm balls (new liner profile). Fig. 8. Relationship between power draw and breakage parameter aT.
A.B. Makokha, M.H. Moys / Minerals Engineering 19 (2006) 1439–1445 1445
However, the trend does not pass through the origin; instead References
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