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ISSN 0974-1267 (Online)

ISSN 0972-4257 (Print)

Journal of Metallurgy and Materials Science


(Formerly NML Tech. Journal)

Vol. 63, No. 1-2, January-June 2021

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

3. Effect of Operating Variables on Bond’s Work Indices Determination 21-32


Kumar P.S, Kavita.G and Ravi B.P

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

6. Tunable Heterojunction using Conducting Polymer for Photovoltaic Application 51-60


Sunil Luhar, Rajeev Gupta and Divesh N. Srivastava

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

J. MET. MATER SC., Vol. 63, No. 1-2, 2021 i


Journal of Metallurgy and Materials Science, Vol. 63, No. 1-2, January-June 22002211, pp.21-32
Printed in India, © NML, ISSN 0972-4257

Effect of Operating Variables on Bond’s Work Indices Determination


Kumar P. S., Kavita G and Ravi B.P.
Department of Mineral Processing, Vijayanagara Sri Krishandevaraya University, Karnataka, India.

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.

Keywords : Bond’s work index, grindability

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]

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Kumar P.S., Kavita G. and Ravi B.P.

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;

2. MATERIALS AND METHODS


2.1. Magnetite Sample
The iron ore sample was collected from Obalapuram, D.Hirehal Mandal, of Ananthapur District, Andhra Pradesh,
India. The sample was visibly greyish to black and attracted to a bar magnet containing hard and compact flaky
lumps of the max size of 50 mm with a considerable amount of fines. The portion of the head sample was initially
crushed in a laboratory roll crusher to prepare the feed for Bond’s work index study.

2.2 Characterization Studies


Physical examination reveals that the sample mainly consisting of compact hard lumps showing alternate bands
attracted to hand-magnet Figure1. The sample was free-flowing. Preliminary studies on the samples show the
angle of repose 38° and specific gravity of nearly 3.2 gm/cm3, and bulk density of 1.9 T/m3. Chemical analysis
indicated that the BMQ ore fines assayed 42.7% Fe(T), 6.07 % FeO, 36.3% SiO2, 0.4% Al2O3, 1.44% MgO,
0.119%P and 0.14%S. The X-ray Diffraction (XRD) study was carried out to identify the different mineral phases
present in the sample. Magnetite and hematite are the main iron-bearing minerals, whereas quartz is the major
gangue mineral, as shown in Figure 2.

Figure 1: BMQ field sample

22 J. MET. MATER SC., Vol. 63, No. 1-2, 2021


Effect of operating Variables on Bond’s Work Indices Determination

Figure 2: X-Ray Diffractogram of BMQ sample.

2.3. Grinding tests


The test work was carried out per the standard ball mill test enumerated by Bond et al. (1954). Standard Bond‘s
work index test conducted on iron ore sample using laboratory ball mill runs at 70 pm and the observed 9.25
kWh/t. Table 2 gives the test conditions for various grinding media viz., ball, cylpeb and rod charge. The quantum
of charge (700 cc), rpm was maintained constant for the entire test. The selected operating variables of bond’s
work index test viz., % circulating load, feed size(100 % passing size), test screen size ( 100% passing size )
of product, thereby reduction ratio (feed /product), media type ( ball/cylpeb/rod) are varied. The effect of the
selected operating variables on the GBP and the work index is studied using response surface methodology.
Equation 1 is used to calculate the Bond’s work index.

Table 2: Work index test conditions

Media Wt. in Total surface area Interstitial Volume of % Mill


Size of steelmedia Nos.
type gms Sq. inches media as % mill volume volume

Balls 0.625 to 1.5” dia 285 20128 722 4.2 22.0

Celeb 1”dia x1” long 237 20130 744 3.1 18.6

Rods 1.125” dia x11”long 18 20130 787 2.0 15.0

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

J. MET. MATER SC., Vol. 63, No. 1-2, 2021 23


Kumar P.S., Kavita G. and Ravi B.P.

2.4 Statistical Analysis:


The present study developed the relationship between the response functions (Gbps and work index) and test
variables, namely feed particle size (A), test sieve size (B) and percent circulating load (C) using Box–Behnken
factorial design. All the experiments were conducted as per the run order designed by the MINITAB Software.
The test variables and their levels are shown in Table 3. The results of each test were analyzed for Gbps and
work index. The Bond’s work index and Gbps for each designed run of the experiment are shown in Table-4. The
second-order quadratic models for these responses are of the following form:

Y = b0+ b1X1+b2X2+b3X3+b12X1X2+b13X1X3+b23X2X3 +b11X12+ b22X22+b33X32 . (2)


Where,

Y = the predicted response function (Fe grade /recovery/SE),


b0 = constant, b1, b2, b3 = linear coefficients,
b12, b13, b23 = cross product coefficients,
b11, b22, b33 = quadratic coefficients,
X1, X2, X3are the coded values of the variables varied (Kumar et al., 2008).

Table 3 : Variable factors and their levels


Levels
No Variables
Low(-1) Centre(0) High(+1)
1 % Circulating Load 100 250 400
2 F80 in mm 0.75 1.75 2.8
3 P80 in mm 0.1020 0.2625 0.4200

Table 4 : Factorial designed WI experimental results with predicted values


Experimental Predicted
Circulating
Run no F80 in Microns P80 in Microns GBP Gm/mil. Work index GBP Gm/mil. Work index
Load (in %)
rev Kwh/st rev Kwh/st
1 100 0.7 0.2625 4.23 10.08 4.03 10.45
2 400 0.7 0.2625 8.01 7.02 7.42 7.10
3 100 2.8 0.2625 3.01 10.57 3.49 9.52
4 400 2.8 0.2625 7.31 5.56 6.89 6.16
5 100 1.75 0.1050 2.31 10.58 1.38 11.47
6 400 1.75 0.1050 4.74 6.18 4.77 6.40
7 100 1.75 0.4200 5.77 8.96 5.69 8.74
8 400 1.75 0.4200 8.83 8.00 9.09 7.11
9 250 0.7 0.1050 1.88 12.24 2.48 11.80
10 250 2.8 0.1050 1.63 11.54 1.94 10.87
11 250 0.7 0.4200 6.6 10.8 6.79 10.79
12 250 2.8 0.4200 6.63 8.74 6.26 9.86
13 250 1.75 0.2625 6.08 8.62 6.32 8.62
14 250 1.75 0.2625 6.08 8.62 6.32 8.62
15 250 1.75 0.2625 6.08 8.62 6.32 8.62

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Effect of operating Variables on Bond’s Work Indices Determination

3. RESULTS AND DISCUSSION


The feed particle size for the bonds work index is given as– 3.3mm to -0.5mm, and -0.5mm to – 0.044mm for
product size (Bond et al. 1954)—the empirical corrections factors assigned for the oversize feed factor, product
finesse factor. Very little attention has been given to the selected work index test variables. Hence, experiments
were carried out varying Feed sizes from 0.75, 1.7 and 2.8 mm (22, 10 and 8 mesh size), Product test size range
from 0.106, 0.250 and 0.42 mm (150, 60, 36 mesh size) and % Circulating load from 100, 250 and 400%. The
response surface methodology was adopted to ascertain the relationship between % circulating load, feed and
product size and reduction ratio to the responses like work index and grindability (Gbps).

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)

+ 47.0 P80*P80+0.0364 CL*P80

Gbp = -5.09 + 0.01131 CL + 2.488 F80 + 36.81 P80 - 0.784 F80*F80 - 44.0 P80*P80 (3)

3.1 Effect of test variables on Work index


The effects of F80 and P80 on the WI of the sample at the center level of the circulating load are shown in Figure
3. The work index value increases significantly with a reduction in product size P80 values. The work index is
inversely proportional to P0.73and applied a correction factor of P80 ≤ 74 microns as shown in the bonds equation
for work index (Eq 1). All the alternative methods reviewed by Vladislav and Leonid (2019) have indicated the
importance of product size in their energy–size relationship. Hukki (1975) suggested that the energy consumption
increases exponentially with a reduction in product size during size reduction. The correction factors for oversize
feed do not appreciably decrease the grinding efficiency for base work index ≤13Kw/short ton (Bond 1962) and
80%passing feed size ≤4000 microns.

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.

J. MET. MATER SC., Vol. 63, No. 1-2, 2021 25


Kumar P.S., Kavita G. and Ravi B.P.

12

11
Wi
10

9
0.4

0.3
1.0
0.2 P80
1.5
2.0
F80 2.5 0.1

Figure3:Effects of F80 and P80 on Work index

10.0

Wi
7.5

2.5
2.0
5.0
1.5 F80
100 1.0
200
300
CL 400

Figure4: Effects of %CL and F80on Work index.

12

10
Wi
8
0.4
6 0.3
P80
0.2
00
200
300 0.1
CL 400

Figure5: Effects of %CL andP80onWork index.

26 J. MET. MATER SC., Vol. 63, No. 1-2, 2021


Effect of operating Variables on Bond’s Work Indices Determination

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.

Figure 6: Effect of Reduction Ratio on Work index

3.2 Effect of test variables on Gbps


Similar to the Wi, the predicted models are described in terms of three-dimensional (3D) response
surface plots for Gbps, as shown in Figures 7.8.9 and 10, respectively. Figure 7 shows the effects of F80
and P80 on Gbps of the ore sample at the circulating load center level, i.e., 250%. Grindability (Gbps)
increases With an increase in the product size P80 and reduction in feed size F80, concurrent to Bond’s
equation indicating that a lower reduction ratio enhances Gbps. Grindability is inversely proportional
to Wi, as shown in the work index equation. Figure 8 shows the effect of the % circulating load and the
F80 of the test ore sample on the grindability Gbp, at the centre level of P80.The grindability decreases
with a decrease in CL. Similar observations were noticed by Deniz et al. (2013). Feed size seems to have an
insignificant effect on grindability Gbp. Figure 9 shows the impact of the %circulating load and the P80
on the grindability Gbp. As mentioned, grindability decreases with a decrease in circulating load as
the circulating load is inversely proportional to the finished product produced. As discussed above,
grindability (Gbps) increases with an increase in the product size.

6
GBP
4
0.4

2 0.3
P80
0.2
1.0
1.5
2.0 2.5 0.1
F80

Figure 7: Effects of F80 and P80 on Gbps.

J. MET. MATER SC., Vol. 63, No. 1-2, 2021 27


Kumar P.S., Kavita G. and Ravi B.P.

GBP 6

4
2.5
2.0
100 1.5 F80
200
1.0
300
CL 400

Figure 8: Effects of %CL and F80on GrindabilityGbp.

6
GBP
4
0.4
2 0.3
P80
0.2
00
200
300 0.1
CL 400

Figure 9: Effect of %CL andP80on GrindabilityGbp.

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.

28 J. MET. MATER SC., Vol. 63, No. 1-2, 2021


Effect of operating Variables on Bond’s Work Indices Determination

Figure 10:Effect of Reduction Ratio on Gbps.

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.

Figure 10: Matching between observed and predicted Wi

Figure 11:Matching between observed and predicted Gbps.

3.3 Effect of WI, Grinding Rate and Gbps on Reduction Ratio.


This study is aimed to know the effect of operating variables on work index, grinding rate and the GBP; reduction
ratios were calculated for all the set of experiments as shown in Table 3 using the relationship (F80/P80), where F80
and P80 is 80% passing size of feed and product respectively. The grinding rate is calculated using the following
relationship.

J. MET. MATER SC., Vol. 63, No. 1-2, 2021 29


Kumar P.S., Kavita G. and Ravi B.P.
Gbp+60
Grinding rate = gms/rev. (4)
70
Figure 12 shows the effect of the reduction rate on the grinding rate. It is seen from the plot that, as the reduction
ratio increases, the grinding rate decreases, which is logical. The results are similar to that of Deniz et al. (2003
and 2013).

Figure 12 : Effect of Reduction ratio on the Grinding rate.

3.4 Effect of mill charge type on work index and grindability


Tests were conducted on stage crushed feed (700 ml)of -6 mesh feed with 60 mesh product sieve at 250%
circulating load. The results are shown in Table5. The results indicate that for the same reduction ratio, weight,
circulating load, feed size and product test sieve size, the grindability decreases—the work index increases as
media changes from rods, cylpebs and balls. Hence for coarse feed and coarse product size, it is advantageous to
use crushing to grinding. The WI tend to increase with increase in interstitial volume of media and % mill
volume of media
Table5 : Effect of media type
Media F80 µ P80 µ *RR Wt. gms *TSA Sq.In. % Mill Interstitial Volume of
volume media[%mill volume] GBP WI
(-6#) (- 60#)
Balls 2200 225 ~10 20130 722 22.0 4.2 3.70 9.46
Celeb 2200 230 ~10 20130 744 18.6 3.1 4.65 8.48
Rods 2200 231 ~10 20130 787 15.0 2.0 4.80 7.78
*RR-Reduction Ratio *TSA – Total surface area

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).

30 J. MET. MATER SC., Vol. 63, No. 1-2, 2021


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