JMMS Vol 63 Issue 1 2
JMMS Vol 63 Issue 1 2
JMMS Vol 63 Issue 1 2
CONTENTS
Pages
1. Development of Carbon Composite Iron ore Slime Briquettes for using in Ironmaking 1-12
Jagannath Pal, Y. Rajshekar, Sanjay Kumar, T. Venugopalan
2. Study of Sulphur Speciation in New Zealand Coal by Density Gradient Separation 13-20
K. Kumari, S. Chakladar, V. K. Saxena, M. Sharma, S. Chakravarty
4. Prediction of Surface Roughness for CNC Turning of Aisi 1030 Steel : A Machine Learning Approach 33-40
Harinarayan Sharma, Ankit Sahay, Sonam Kumari, Aniket K. Dutt
5. Simultaneous Leaching of Zinc Sulphide Concentrate and Manganese ore in Sulphuric Acid 41-49
Sanjay Prasad and Manoj Kumar
7. Effect of Aging on Hardness and Tensile Properties of Advanced MG-SN Based Alloys 61-73
Sonika, A P Murugesan, Debdas Roy, Palash Poddar
8. Laser Directed Energy Deposition based additive Manufacturing of Metallic Multi-Material : A Review 75-87
C P Paul, S Yadav, A K Rai, Jinoop A N and K S Bindra
Abstract : Grinding is a vital step in mineral processing, upon which the significant quantum of efficiency and
economics of the mineral processing depends. Bond’s work index determination, since its inception in 1952, is
being used to estimate the power required for milling, sizing of mills and calculation of milling circuit efficiency.
The laboratory method of Bond’s work index determination though tedious still reigns supreme. Without the
critical examination of associated variables during experimentation like feed size, the effect of test sieve opening,
circulating load and to a certain extent the media shape, the Bond’s work indices values obtained may vary,
leading to some ambiguity. An attempt has been made to study the effect of feed size, product size, subsequently,
reduction ratio, circulating load on Bond’s work index and grindability of a Banded Magnetite Quartzite material.
The effect of media shapes like spheres, cylpeb and rods on Bond’s work index is also qualitatively assessed.
Correlations are drawn between the size of feed, size of the product (test sieve), reduction ratio, circulating load,
shape factor to Bond’s work index and grindability for a banded magnetite quartzite (BMQ) iron ore material.
1. INTRODUCTION
Bond’s work index is widely used in energy estimation during ball milling and scaling-up ball mill (Man, 2002)
for ore grinding. Generally, all the mineral processing operations like gravity, magnetic and flotation circuits
work efficiently with the closer size distributions. The grinding circuits carry a significant role in producing tight
control on product size distributions. Variation in the milled product can alter all phases of the consequent mineral
processing operation. Optimization of grind size is a critical factor for several reasons, with the most fundamental
reason is to liberate the valuable mineral grains out from gangue. In 1961, Fred Bond established a procedure for
determining the working index of ore grinding. The method for determining the work index of a given ore sample
requires nearly 10 kg of ore sample and the standardized ball mill. Depending on several conditions (size of the
test sieve, homogeneity of material, grain-size composition, etc.), the testing process takes up to 12 hours.
The grinding circuit design uses the Bonds method as one of the components to evaluate the power required and
mill size for a respective mineral. The Bond work index method is a time-consuming method and very sensitive
to procedural errors. Alternative methods to Bond’s method (Deniz et al., 2003; 2004) have been proposed by
many investigators to find the work index of a given ore sample in the shortest time. Table 1 depicts the review
of the best available methods and results compared with original Bond’s work by evaluating accuracy levels
(Vladislav and Leonid 2019). The Bonds work index is influenced by the grinding conditions (Magdalinovic
1989) and the test methods. Scanty works focus on the effect of operating variables on the work index values—
the finer grind size control results in higher energy consumption during grinding. This study focuses on the
critical examination of work index operating variables viz., feed size, test screen size, circulating Load, and a
certain extent of the media shape on the Bond’s work indices values. The problems associated with the feed and
product sizes have been addressed by Deniz (2003) and Bond et al. (1954). Similarly, the difficulties related to
percentage Circulating Load have been discussed by Austin et al. (1984), Amstrong (1986), Deniz (2003) and
Deniz et al. (2013). The effect of feed size, product size, subsequently reduction ratio, circulating Load and media
shapes like balls, cylpebs and rods on Bond’s work index and grindability of a BMQ material are studied using
statistical design of experiments.
Corresponding author :
E-mail : [email protected]
Table 1.The alternative methods for determining the work index of Bondball grinding
(after Vladislav & Leonid, 2019)
*М, **∆1, ***∆2, Relative
Year Method Error (%) Remarks
kg error (%)
1961 Bond F.C 10 - - The reproducibility of the results of the standard methodology
of F. Bond is in the range of 3-5%.
1966 Berry 1 8.0 6.3 The stated relative error lies within the range of 8% for
apatite-nepheline ore
1968 Smith and Lee 2 8.2 16.6 The average relative error of 16.6% for 45 types of various ores
1970 Kapur. P.C 3 8.0 9.5 The average relative error of 8.6% is shown for 35 types of
various ores
1976 Horst 5 7.0 8.4 The difficulty in reference ore is required
1982 Yap R 2 4.1 - The average relative error for more than 20 samples was 4.1%.
1990 Lewis 2 3.5 - The average relative error is less than 3.5%.
2000 Oksana B 4 3 - The stated relative error for this method is shown within 4%
2009 Ahmadi 5 7.0 6.8 The error of 3.5% versus 7% in the standard edition of the
method on apatite-nepheline ore
2016 Gharehgheshlagh 10 5.0 3.5 The stated relative error lies within the range of 4.5%, and
for apatite-nepheline ore showed 3.5%
2017 Todorovic 2 4.0 0.3 Grinding cycles are more
2019 Armstrong 3 6.0 - Useful for wet rod mill grinding applications
* M – the approximate required sample mass;
∆1 – the average relative error of the method stated by the author;
***∆1 – the received relative error;
44.5
WIB = (1)
Pi Gbp
0.23 0.82
( 10 - 10 )
√F80 √F80
Where,
WIB =
Bond’s ball mill work index in KWh /short ton
Pi = Test sieve size in microns
GBP = Net grams of test sieve/mill revolution at stipulated circulating load%
P80 = 80% cumulative passing size of the product
F80 = 80% cumulative passing size of feed
For better understanding, three-dimensional (3D) response surface plots of predicted models are used to describe
the effect of process variables of experiments on Bond’s work Index (Figures 3, 4 and 5) and Gbps in Figures
6,7,8 and 9. Each Figure shows the 3D response surface plots between two experiment variables at the center
level of the third variable.
The second-order response functions representing the work index and the GBP could be expressed as functions
of the circulating load, F80 and P80(Test sieve size). The model equations for the same are given in Eqs. (2) and
(3) respectively.
Wi = 17.80 + 0.0094 CL - 3.76 F80 - 37.0 P80 - 0.000060 CL*CL + 0.947 F80*F80 (2)
Gbp = -5.09 + 0.01131 CL + 2.488 F80 + 36.81 P80 - 0.784 F80*F80 - 44.0 P80*P80 (3)
Figure 4 shows the effect of the % circulating load and the F80 of the BMQ ore sample on the work index at the
centre level of P80. The work index increases with a decrease in circulating load (CL) (Deniz et al. 2013).
Figure 5 shows the effect of the circulating load (CL %) and the P80 on the work index. The work index increases
with a decrease in CL %. In practice, the circulating load significantly depends on mill product/classifier feed size
and classifier product size P80. The work index is inversely proportional to the product size in Bond’s equation. The
classifier feed/mill discharge product size should be close to classifier overflow to reduce the CL %, necessitating
a higher energy requirement for size reduction. Hence, in the Bond’s work index determination, the work index
decreases with a decrease in % CL as feed to classifier 80% size should be close to P80. In any closed circuit size
reduction, the efficiency and the separating size, cut point or parting size of classifier or screen is important (Bond
1962). Increasing the classifier/screen efficiency in closed circuit size reduction and gentle increase in separating
size reduces the %CL and energy consumption. Work index is inversely proportional to product aperture size Pi,
which controls P80. Hence product size has a significant effect on the work index.
12
11
Wi
10
9
0.4
0.3
1.0
0.2 P80
1.5
2.0
F80 2.5 0.1
10.0
Wi
7.5
2.5
2.0
5.0
1.5 F80
100 1.0
200
300
CL 400
12
10
Wi
8
0.4
6 0.3
P80
0.2
00
200
300 0.1
CL 400
The effect of the work index on the reduction ratio indicates that as the reduction rate increases higher than the
nominal value of 15, the work index increases exponentially. Exponential growth in specific energy consumption
in ultra-fine grinding action of the mill on par with Hukki (1962 ) equation where specific energy is a function of
exponent value (n -1) of particle size tends to follow Rittinger’s law as n approaches from 1.5 to 2. However, the
work index tends to increase with a reduction ratio of <3. Incidentally, Bond (1952) opined that though the ball
mills are less sensitive to changes in reduction ratio, but suggested an empirical correction factor if the reduction
ratio is <3. The effect of the reduction ratio is elaborately discussed in Figure 6.
6
GBP
4
0.4
2 0.3
P80
0.2
1.0
1.5
2.0 2.5 0.1
F80
GBP 6
4
2.5
2.0
100 1.5 F80
200
1.0
300
CL 400
6
GBP
4
0.4
2 0.3
P80
0.2
00
200
300 0.1
CL 400
The effect of the reduction ratio on grindability (Gbps) is shown in Figure 10. Generally, the grindability decreases
with an increase in reduction ratio, with a significant drop in grindability when the reduction ratio is lower than 5.
Experimental results and the predicted values obtained using model Eqs. (2) and (3) are tabulated in Table4,
which shows the predicted and the observed data points relationship indicating an excellent agreement (R2 of
0.89 and 0.96 for Wi and Gbps of ore sample, respectively) of the response equations and is shown in Figures 10
and 11 respectively.
4. CONCLUSIONS
An attempt has been made to study the effect of feed size, product size, subsequently, reduction ratio,
circulating load on Bond’s work index and grindability of a Banded Magnetite Quartzite material. The
effect of media shapes like spheres, cylpeb and rods on Bond’s work index is also qualitatively assessed.
An increase in reduction ratio reduces the grinding rate, grindability and increases the work index. An
increase in circulating load increases grindability and marginally reduces work index (increasing product
size and decreasing the ratio). The grindability decreases, and the work index increases as media changes
from rods, cylpebs and balls (with an increase in feed– product size and decrease in reduction ratio).