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Minerals Engineering 19 (2006) 1439–1445

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Towards optimising ball-milling capacity: Effect of lifter design


Augustine B. Makokha *, Michael H. Moys
School of Chemical and Metallurgical Engineering, University of the Witwatersrand, P.O. Private Bag X3, 2050, Johannesburg, South Africa

Received 2 December 2005; accepted 1 March 2006


Available online 27 April 2006

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.

Keywords: Grinding; Comminution; Particle size; Process optimisation

1. Introduction most important parameter. The three major mechanisms


of particle breakage are impact, abrasion and attrition.
Comminution is an indispensable operation in mineral The rate of breakage is as a result of the combined effect
processing circuits in that it helps to achieve a certain level but when the particles become finer, attrition becomes
of fineness in the ore material inline with the process prevalent.
requirements at downstream stages. The process is influ- Substantial progress has been achieved in the design of
enced by a set of factors, which include the mill speed mill liners especially for autogenous (AG) and semi-autog-
and liner profile. Since the liner/lifters are the mechanical enous (SAG) grinding mills for over 35 years now (James
link between the mill and the load, their mode of energy et al., 1990). Today, the concern is slowly shifting from
transfer to the grinding media determines the rate of break- design of new liners to exploring new techniques of opti-
age. Kano et al. (2001) demonstrated that the specific rate mising the performance of existing liners/lifters over a
of breakage is proportional to the impact energy of the prolonged life. This in effect helps to increase the mill
grinding media regardless of the media size. Fuerstenau availability while mitigating the operating costs. In light
and Abouzeid (1985) maintain that the grinding rate and of that, an attempt is made in this paper to investigate
energy consumption in the mill are significantly affected how cone-lifters would affect the milling capacity. To assess
by the liner design and that the predominance of one this effect, similar tests (under same operating conditions)
breakage mechanism over the other would depend on were performed for three liner profiles as follows (i) new
mill conditions, of which liner design constitutes the (60 face angle), (ii) worn (45 face angle) and (iii) worn
(45 face angle) modified with cone-lifters. The broader
*
Corresponding author. Tel.: +27 11 717 7558; fax: +27 11 403 1471.
aim is to investigate the possibilities for development of
E-mail addresses: augustine_makokha@yahoo.com, amakokha@ more efficient liners/lifters and optimisation of the existing
prme.wits.ac.za (A.B. Makokha). ones to realise higher mill throughputs at lower costs.

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.

3.2.2. Feed material


Fig. 1. Laboratory version of the bevel liners used in the experimental The feed samples used in the test work were part of the
work. quartz material that had been used in many of our previous
experiments, owing to the consistent milling and sieving
installation on the worn liner profile. The height of 16 mm properties. The material had been sieved to 97% retention
was just sufficient to project the balls onto the bed of the of the top size in the screen interval of 30 · 40 mesh
charge at the toe region rather than on the mill liner wall. (600 + 425 lm). For each experimental run, a portion
The latter would promote further wear of liners. The cone- of the material representing a fractional interstitial filling,
lifters were designed to slightly overlap the worn liner pro- U = 0.6 (for load porosity, eL = 0.4) was used. This level
file upon installation, which adds to their strength. It also was carefully chosen to avoid powder ‘pooling’ and ‘cush-
allows the cone-lifters to be firmly held in position. The siz- ioning’ effects that result from high level of U. Very low lev-
ing was established numerically by discrete element simula- els of U will however propagate the media wear due to
tion (Moys et al., 2000) at the point of mill optimal direct impacts between the balls. The weight of the material
performance, for typical mill operating conditions of (powder) used was calculated as 6.1 kg for a mill length of
J = 20% of mill volume and N = 75% of critical speed as 400 mm. The specific gravity of the powder is 2.5 while the
found in ball mills at Matimba power station in South bulk density was measured as 1.48 g/cm3.
Africa. The cone-lifters were installed at axial and diagonal
centre to centre distances of 150 and 70 mm, respectively, 3.2.3. Experimental procedures
as shown in Fig. 2 (i.e., the diagonal pattern results from The experiments were performed in a batch wise mode.
the staggered arrangement of cone-lifters). They were In all the tests, the quartz material was ground for a total
secured onto the liner surface using Allen screws of 6 mm period of 4 min. Samples were collected from the mill after
in diameter which also lock the liners onto the mill shell. grinding times of 1, 2 and 4 min. This allowed for sufficient
The resultant cone-lifter height to spacing ratio in the diag- grinding to occur between successive sampling intervals. A
onal direction was 4.375, which lies within the conventional portion of between 200 and 250 g from each sample col-
range of lifter spacing of 3.5–4.5 as reported in literature by lected from the mill was split to obtain a sample that is rep-
Bigg and Raabe (1996). resentative of the properties of both coarser and finer
materials in the mill. A representative sample of about
3.2. Batch milling tests 50–60 g was then wet washed on the screen size (38 lm)
to remove the fines. The wet samples were then dried in
3.2.1. Experimental design an oven, which was followed by dry screening of each sam-
The experiments were designed with two independent ple for 20 min in separate runs but using the same sieves on
variables, i.e., liner/lifter profile and grinding time. The the shaker machine. The screens were nested (stacked) in
selection function (S1) and the breakage distribution (Bi1) decreasing order of size from 600 to 38 lm at an interval

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

Worn liner (45° ) 0.03 0.03


Worn + Cone-lifter
New liner ( 60° )

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

4.2.3. Parameter estimation using a numerical method Table 3


A software tool (BALL-PARAM) from ‘Moly Cop’ Summary of the fitted parameters (selection and breakage)
was used to estimate the values of the parameters aT and Characteristic Worn liner Worn liner + New liner
c that would characterise the grinding process. The exper- constant profile (45) cone-lifters profile (60)
imental size distributions of the products at times t1, t2 aT 0.432 0.550 0.573
and t4 corresponding to grinding times of 1, 2 and 4 min, c0 1.104 1.104 1.104
c 1.106 1.103 1.102
respectively, and the feed were used as the input (raw data) /0 0.505 0.505 0.505
to the model. The parameters aT and c were then estimated / 0.55 0.7 0.8
by minimising the square of the differences between the a 0.80 0.80 0.80
experimental and predicted Pi(t) values assuming normal b 3.9 3.9 3.9
breakage. The objective function is given as the weighted S1 0.287 0.365 0.381
sum of the normalised errors (%) over the total grinding
time as variation was only minor. This value compares closely to
X4 X n  2 those established in literature by other researchers includ-
wi P iðexpÞ  P iðmodÞ ing Yekeler et al. (2001) who reported an optimised value
SSE ¼  100%; ð5Þ
t¼1 i¼1
W P iðmodÞ of c = 1.20 for wet milling of quartz and Austin et al.
where Pi is the size distribution of the mill product retained (1984) who obtained an average value of c = 1.1 for dry
on screen i, n is the number of screen intervals used, wi is grinding of quartz.
the weight factor that quantifies the reliability of the data The fitted values of parameter aT (min1) for the three
for each screen interval with respect to data from other liner profiles tested are presented in Table 3. The grinding
screens and W is the total sum of the weight factors. The data obtained with the liner profile which had been modi-
values of wi are known to vary within a narrow margin fied with cone-lifters gave a higher value of aT (i.e., 1.27
but generally the reliabilities of top and bottom screens times) as compared to the case without cone-lifters. This
are lower than the intermediate screens. The range of wi implies that grinding process would proceed in a faster rate
values used in the fitting algorithm is given in Table 2. with cone-lifters than without. The new liner profile on the
The fitting algorithm searches for the best combination other hand gave the highest value of aT (i.e., 1.33 times the
of parameters that minimise the residual error between worn liner). Note that the S1 values were calculated from
the experimental and predicted size distributions. The liter- Eq. (2) using the fitted values of aT. In view of these find-
ature values of / (denoted as / 0 ) and b by Austin et al. ings, it seems probable that the rate of disappearance of
(1984) were taken as initial estimates to the model in the fit- material from the top size interval is dependent on the level
ting process. As a rule of thumb, the number of parameters of cataracting in the mill, which is a function of mill speed
was reduced so as to obtain the value of aT that would give and liner/lifter profile among other factors. In essence,
the best fit. This was accomplished by fixing the parame- cataracting media produce high-energy impacts, which
ters, a, / (as / 0 ) and b since they are generally regarded are utilised in breaking larger particles during normal
as characteristic constants of the material, which for nor- breakage thereby enhancing the breakage rate. This result
mal breakage do not vary with mill conditions. In this case, is consistent with other observed trends in literature. It
the sensitivity of only two parameters to the milling condi- can therefore be deduced that the specific rate of breakage
tions, i.e., (aT and c) was investigated. Table 3 gives a sum- of a given material is significantly influenced by the mill
mary of the values of the breakage and selection liner/lifter profile.
parameters whose combination yielded the best fit to the Figs. 5–7 show the comparisons of the experimental and
experimental data. From the fitted parameters (shown in predicted results of the particle size distributions of quartz
Table 3), there was no significant variation in the values material obtained at different grinding times. The results of
of c for the three liner situations. grinding up to 4 min were compared. The predicted size
To estimate the parameter aT, it was considered appro- distributions relate to the values of the characteristic
priate to use an average value of c (i.e., c 0 = 1.104), since its parameters shown in Table 3 obtained using the parameter
fitting algorithm. From the results, good agreements can be
observed between experimental and predicted data within
Table 2
the limits of experimental error. No significant deviation
The weight factors, wi in the parameter fitting algorithm (BALL_
PARAM) is observed in the nonlinear region despite assuming first
order breakage in the fitting algorithm over the entire
Screen i Mesh wi
grinding duration. Presumably the nonlinear effect had
1 600 + 425 3
not strongly set in to have a clear impact on the grinding
2 425 + 300 4
3 300 + 212 5 process.
4 212 + 150 5 For reliable data, the root mean square of residuals
5 150 + 106 5 (RMSR) based on experimental errors associated with siev-
6 106 + 75 4 ing should not exceed the value of 0.01, at 99% confidence
7 75 + 53 3
level (Herbst and Fuerstenau, 1973). In our estimations the
1444 A.B. Makokha, M.H. Moys / Minerals Engineering 19 (2006) 1439–1445

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)

is drawing maximum power. On the basis of Bond’s grinda-


30 30
bility tests (Austin et al., 1984), the plot of energy per unit
mass of material (specific energy) versus milling rate should
10 10 give a straight line passing through the origin, which signi-
4 Min fies that at zero power, there is zero breakage. In this study,
2 Min
an attempt is made to assess the relationship between mill
3 Experiment 3
power draw and the parameter aT, which is an indication of
1 Min Predicted the milling rate; given that the other parameters in Si
(a, . . .) in Eq. (2) are fixed. Data obtained during 4 min
1 1 of grinding was used in the analysis bearing in mind that
1 1 2 2 3
10 3x10 10 3x10 10
no significant change in power is expected over this short
Particle size (Xi) μm
period of grinding, as observed from our earlier tests.
Fig. 6. Experimental and predicted product size distributions of
Fig. 8 shows the observed trend in milling rate (indicated
600 + 425 quartz feed, ground with 10–6 mm balls (worn profile by the parameter aT) as a function of the mill power draw.
modified with cone-lifters). Each data point corresponds to a different liner profile.
From the results, it is established that the value of the
parameter aT increases as mill power increases along a linear
path, which conforms to established trends in literature.
100 100
450
Trend of mill power proportional to S
Cumulative % finer than size (xi)

30 30 440
Mill Power (W)

10 4 Min 10 430

2 Min Bevel liner (45°)


420
3 3 Bevel (45°) + cone-lifters
1 Min
Experimental Bevel liner (60°)
Predicted 410

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
it intercepts the vertical axis at a finite value. This in practi-
cal sense shows how the milling efficiency and capacity are Austin, L.G., Klimpel, R., Luckie, T.P., 1984. Process Engineering of Size
drastically affected by liner profile as the liners wear down. Reduction: Ball Milling. AIME, SME, New York, USA.
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clear that possibilities still exist of sustaining the capacity
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and selection parameters that would result from the change Moys, H.M., Van Nierop, M.A., Van Tonder, J.C., Glover, G., 2000.
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IMPC, Rome, 23–28 July. pp. C3-39–C3-44.
Acknowledgement Tangsathitkulchai, C., 2003. The effect of slurry rheology on fine grinding
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Yekeler, M., Ozkan, A., Austin, L.G., 2001. Kinetics of fine wet
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