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Mineral Processing Lab

1. The document provides details on sizing rod mills and ball mills for mineral processing based on given ore properties and processing requirements. It includes questions on calculating mill dimensions, capacities, power requirements, liner requirements, and ball wear. 2. The questions cover topics such as determining the most feasible rod mill size based on constraints, calculating volumes occupied by rods and ore in a rod mill, estimating power draw and impact of ball size, and sizing a ball mill to reduce ore to a target size. 3. The problems require applying formulas to calculate values like reduction ratio, mill power, critical speed, liner requirements, and ball wear based on given mill dimensions and ore properties.

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Moosa Naseer
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40 views

Mineral Processing Lab

1. The document provides details on sizing rod mills and ball mills for mineral processing based on given ore properties and processing requirements. It includes questions on calculating mill dimensions, capacities, power requirements, liner requirements, and ball wear. 2. The questions cover topics such as determining the most feasible rod mill size based on constraints, calculating volumes occupied by rods and ore in a rod mill, estimating power draw and impact of ball size, and sizing a ball mill to reduce ore to a target size. 3. The problems require applying formulas to calculate values like reduction ratio, mill power, critical speed, liner requirements, and ball wear based on given mill dimensions and ore properties.

Uploaded by

Moosa Naseer
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Mineral Processing Lab

Homework Problems
Section B: Grinding
7. Rod Mill (A): The top particle size of the copper porphyry received from roll crusher (Problem
4) is 2.5 cm and is required to break down to a size of 2 mm to prepare a feed for ball mill. The
maximum space available to install a rod mill restricts the inner diameter of rod mill to 2.0 meter.
Determine the mill capacity, reduction ratio, mill power, mill length, critical speed (rpm), actual
speed (rpm), calculated peripheral speed (m/s) and actual peripheral speed (m/s).
If Rod mill with following dimensions (diameter x length) are available in the market, then
determine technically most feasible size for the given requirements.
a) 1.2 x 2.4, b) 1.8 x 2.7, c) 2.7 x 3.6, d) 3.0 x 4.8, e) 3.4 x 5.1, f) 3.8 x 5.4, g) 4.0 x 5.4, h)
4.2 x 5.7 (all dimensions in meters).
8. Rod Mill (C): A 3 m x 3 m rod mill was charged with 100 mm diameter steel rods having a
bulk density of 5.2 t/m3. In the stationary state the height of the charge occupied two-thirds of the
radius and the porosity of the bed was 35%. Determine:
1. The mill volume occupied by the charge (J)
2. The fraction of the mill volume occupied by the ore if U = 1.1
3. The fraction of mill volume occupied by the rods
4. The mass of rods in the mill.
9. Rod Mill (D): A wet rod mill was loaded to 45% of its volume with a charge consisting of a
gold ore and steel rods. The rods diameter was 70 mm. The mill had an inner diameter of 1980
mm and was rotated at 21 rpm with a rod load of 23.8 t. The rock volume was 0.4 times the rod
volume after taking into account the porosity of the bed. Estimate:
1. The fraction of the critical speed at which the mill operates
2. The maximum power drawn
3. The difference in power requirements if the mill was filled to the same extent with balls
having the same diameter as the rods.
10. Ball Mill (A): The top particle size of copper porphyry ore received from rod mill (Problem
7) is 2 mm. It is required to reduce the size down to 106 µm for feed preparation of froth flotation
separation process. Consider the copper porphyry ore is hard ore type, then determine the diameter
of grinding balls required at initial charge. Consider the mill capacity to be maintained in ball mill
is the same as determined in problem 7 and the density of copper porphyry ore to be 2.6 t/m 3,
estimate the mill size (diameter and length) and fractional volume of mill occupied by the bulk
rock and grinding media. Select an appropriate ball mill model from commercially available ball
mills according to your calculated mill size. If it is decided that double wave liner are to be used
as lifters in the ball mill, then determine the number of liners required. If the abrasion index of
copper porphyry ore is 0.147, then determine the average ball mass losses for wet operation.
11. Ball Mill (B): A crushing plant delivered ore to a wet grinding mill for further size reduction.
The size of crushed ore (Fso) was. 4.0 mm and the S.G. 2.8 t/m3. The work index of the ore was
determined as 12.2 kWh/t. A wet ball mill 1 m x 1 m was chosen to grind the ore down to 200
microns. A 30 % pulp was made and charged to the mill, which was then rotated at 60% of the
critical speed. Estimate:
1. The maximum diameter of the grinding balls required at the commencement of grinding,
2. The diameter of the replacement ball.

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