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The document summarizes the Bond Ball Mill Work Index test procedure used to determine the grindability of ores. The test involves grinding a sample in a standardized small ball mill and measuring the amount of material passing through a screen after set numbers of revolutions. This data is used to calculate the Bond Work Index, which indicates the energy required to grind a particular material in a ball mill. The test involves multiple grinding periods, screening, and calculations to determine the net undersize produced per revolution and other parameters needed for the Bond Work Index calculation.

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Dan Manaig
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0% found this document useful (0 votes)
2K views80 pages

Post Lab Discussion

The document summarizes the Bond Ball Mill Work Index test procedure used to determine the grindability of ores. The test involves grinding a sample in a standardized small ball mill and measuring the amount of material passing through a screen after set numbers of revolutions. This data is used to calculate the Bond Work Index, which indicates the energy required to grind a particular material in a ball mill. The test involves multiple grinding periods, screening, and calculations to determine the net undersize produced per revolution and other parameters needed for the Bond Work Index calculation.

Uploaded by

Dan Manaig
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Bond Ball Mill Work Index

Procedure
Work Indices
• Measures of the energy necessary to break a
particular type of ore
• Relates the power input and the reduction
ratio in comminuting ore
• Generally dependent on material; but some
equipment factors should be considered when
using different methods for determining WI
Bond’s Energy Equation
• Derived from FC Bond’s 3rd theory of
Comminution
 1 1 
E  10Wi     EF
 P F
E = energy input, in KWh/MT or HP F
= Feed size in microns P=
Product size in microns EF =
Efficiency Factor

• Generally used for all equipment!


Bond Ball Mill Grindability Index
• This parameter controls the calculation of the
basic energy requirements of the comminution
circuit
• It can be used to determine the grinding
power required for a given throughput of
material under ball mill grinding conditions
• It is the most important parameter
Bond Ball Mill Grindability Index
• 12-in diameter by 12-in long (internal
dimensions) horizontal axis mill with rounded
corners and a smooth lining. There are no
lifters. The mill rotates at 70 rpm
Bond Ball Mill Grindability Index
• BWI Equipment

• Data obtained: Grindability


Grindability
• A material property
• Defined as the ease at which a mineral particle
is reduced to a prescribed size, given the
amount of energy input
• For BMWI test, grindability is the net grams of
undersize product per revolution of mill
Bond Ball Mill Grindability Index
• Equation is given as:
4.45
Wi 
0.23 0.82  1 1 
pi Gbp   
 P F
pi = test sieve size in microns Gbp
= grindability P=
product size in microns F =
Feed size in microns
Procedure
1. Set the test sieve size (100 mesh = 150μm)
2. Prepare 10 kg of 100% passing -6 mesh of
sample (the FEED)
3. Obtain an initial particle size distribution
– Should be representative!
4. Determine % of undersize of the FEED
Procedure
5. Pack fill a 1000-mL plastic graduated cylinder
to 700mL level,
– This fraction shall be the constant charge weight
6. Set aside the remaining sample for
replenishment
7. Determine the weight and bulk density
Procedure
8. Determine the intended product passing
(IPP) by dividing the 700mL material weight
by 3.5
Intended Product Passing
• The target weight of material as 100%
PRODUCT UNDERSIZE with 250% circulating
load

• Illustrative example:
– Feed weight of 700mL sample = 1050 grams
Intended Product Passing
Feed Weight, 700mL 1050 grams
IPP  
3.5 3.5
IPP  300 grams

– 300 grams is the 100% (target undersize weight)


– 750 grams is the 250% (target circulating load)
– 300 + 750 = 1050
– 100% + 250% = 350% = 3.5!
Procedure
9. Run in the ball mill for 100 revolutions (initial,
arbitrary)
10. remove the charge from the ball mill,
ensuring that all material is recovered
11.Screen the material using test screen for
oversize and undersize
12.Fill-in the table
Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under %
revs size per Circu-
Fresh Feed Undersize, Over size Under Net Rev lating
fresh feed size Undersize Load

1
2
3
4
5
6
7
8
9
10
Example
• Sample: 10 kg of Calcite (Limestone) from
Camp 6, Benguet
Example
• PSA of feed Calcite (100% Passing 6 mesh)
Example
• PSA of feed Calcite (100% Passing 6 mesh)
Formulae
• Fresh feed = weight of fresh feed
= weight of 700mL material
(for period 1 only!)

• Weight of 700 mL sample = 1,285 grams


Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under %
revs size per Circu-
Fresh Feed Undersize, Over size Under Net Rev lating
fresh feed size Undersize Load

1 1,285
2
3
4
5
6
7
8
9
10
Formulae
• Undersize Fresh Feed

  Weight of Fresh Feed    % Undersize *


 1,285   0.1528
 196.35

* Based on PSA of feed, 15.28%


Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under %
revs size per Circu-
Fresh Feed Undersize, Over size Under Net Rev lating
fresh feed size Undersize Load

1 1,285 196.35
2
3
4
5
6
7
8
9
10
Formulae
• # of Revolutions = 100
– Arbitrary, for the 1st period only!
Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under %
revs size per Circu-
Fresh Feed Undersize, Over size Under Net Rev lating
fresh feed size Undersize Load

1 1,285 196.35 100


2
3
4
5
6
7
8
9
10
Formulae
• Weight Oversize
– Weight of material retained on test screen

• Weight Undersize
– Weight of material passing the test screen

• Screening is done AFTER the prescribed revolutions


are applied!
Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under %
revs size per Circu-
Fresh Feed Undersize, Over size Under Net Rev lating
fresh feed size Undersize Load

1 1,285 196.35 100 850 435


2
3
4
5
6
7
8
9
10
Formulae
• Net Undersize
  Weight Undersize   Weight Undersize, Fresh Feed
 435  196.35
 238.65
Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under %
revs size per Circu-
Fresh Feed Undersize, Over size Under Net Rev lating
fresh feed size Undersize Load

1 1,285 196.35 100 850 435 238.65


2
3
4
5
6
7
8
9
10
Formulae
• Net Undersize per Revolution


 Net Undersize
 # of Revolutions 
238.65

100
 2.39
Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under %
revs size per Circu-
Fresh Feed Undersize, Over size Under Net Rev lating
fresh feed size Undersize Load

1 1,285 196.35 100 850 435 238.65 2.39


2
3
4
5
6
7
8
9
10
Formulae
• % Circulating Load


 Weight Oversize
 Weight Und ersize
850

435
 195.40
Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under % Circu-
revs size per lating
Fresh Feed Undersize, Over Under Net Rev Load
fresh feed size size Undersize

1 1,285 196.35 100 850 435 238.65 2.39 195.40


2
3
4
5
6
7
8
9
10
Procedure
13. Discard ALL the screened undersize
14. Replenish the oversize from the set-aside
sample, with the SAME AMOUNT discarded*
to maintain the total weight of charge (1285
grams)

*ensure that proper representative


sampling is performed to obtain
replenishment mass!
Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under % Circu-
revs size per lating
Fresh Feed Undersize, Over Under Net Rev Load
fresh feed size size Undersize

1 1,285 196.35 100 850 435 238.65 2.39 195.40


2 435 66.47
3
4
5
6
7
8
9
10
Procedure
15. Determine the # of Rev for Period 2 using
the formula:

IPP * - Undersize, fresh feed


# of Rev 
 previous Net Undersize per Rev
*IPP is computed as 367.14 grams (1285/3.5)
Procedure

IPP * - Undersize, Fresh Feed


# of Rev 
 previous Net Undersize per Rev 
367.14 - 66.47
# of Rev 
2.39
# of Rev  126
Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under % Circu-
revs size per lating
Fresh Feed Undersize, Over Under Net Rev Load
fresh feed size size Undersize

1 1,285 196.35 100 850 435 238.65 2.39 195.40


2 435 66.47 126
3
4
5
6
7
8
9
10
Procedure
16. return the replenished charge (previous
oversize + replenishment = 1285 grams) to
the ball mill
17. run the mill based on the computed # of
revolutions
18. repeat steps 10-17, until convergence is
reached!
Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under % Circu-
revs size per lating
Fresh Feed Undersize, Over Under Net Rev Load
fresh feed size size Undersize

1 1,285 196.35 100 850 435 238.65 2.39 195.40


2 435 66.47 126 870 415 348.53 2.77 209.64
3 415 63.41 110 915 370 306.59 2.79 247.30
4 370 56.54 111 915 370 313.46 2.82 247.30
5 370 56.54 110 915 370 313.46 2.84 247.30
6 370 56.54 109
7
8
9
10
Procedure
• Convergence is reached when:
– The last three (3) entries for % Circulating Load is
at 250 ± 5%
– The Weight Undersize approaches the IPP value
(367.14 grams)
Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under % Circu-
revs size per lating
Fresh Feed Undersize, Over Under Net Rev Load
fresh feed size size Undersize

1 1,285 196.35 100 850 435 238.65 2.39 195.40


2 435 66.47 126 870 415 348.53 2.77 209.64
3 415 63.41 110 915 370 306.59 2.79 247.30
4 370 56.54 111 915 370 313.46 2.82 247.30
5 370 56.54 110 915 370 313.46 2.84 247.30
6 370 56.54 109
7
8
9
10
Procedure
19. When convergence is reached, DO NOT
DISCARD the last screened Undersize
20. Determine the particle size distribution of
the last screened Undersize
Example
• PSA of the last screened Undersize
Example
• PSA of the last screened Undersize
Procedure
21. Compute the average of the last three (3)
entries for the Net Undersize per Revolution
22. this value is taken as the GRINDABILITY of
the sample!
Bond Work Index Table
Period Weight, grams # of Weight, Grams Net Under % Circu-
revs size per lating
Fresh Feed Undersize, Over Under Net Rev Load
fresh feed size size Undersize

1 1,285 196.35 100 850 435 238.65 2.39 195.40


2 435 66.47 126 870 415 348.53 2.77 209.64
3 415 63.41 110 915 370 306.59 2.79 247.30
4 370 56.54 111 915 370 313.46 2.82 247.30
5 370 56.54 110 915 370 313.46 2.84 247.30
6 370 56.54 109
7
8
9
10
Example
• Test sieve = 100 mesh = 150 μm
• Grindability = 2.818 grams/rev
• 80% Passing size of feed = 1,654.40 μm
• 80% Passing size of product = 97.89 μm
Example
• Equation is given as:
4.45
Wi 
0.23 0.82  1 1 
pi Gbp   
 P F

pi = test sieve size in microns


Gbp = grindability
P = product size in microns
F = Feed size in microns
Example
• Substituting the values:
4.45
Wi 
0.82  1 1 
150   2.818  
0.23
 

 97 .89 1,654 . 40 
kWhr
Wi  7.86
Mt
Mesh of Grind
Procedure
1. Obtain 1-kg of 100% passing 6-mesh sample
2. Determine the ball loading of the ball mill
3. Grind the sample for 5 minutes
4. Perform particle size analysis of the sample
5. Determine the cumulative 80% passing
6. Repeat steps 3-5 for an additional 5, 5, 5, 10,
15, and 15 minutes
Data Processing
C u m u lative % P a ss in g

100.00

80.00

60.00

15 mins
30 mins
40.00
45 mins
60 mins

20.00

0.00
0 2000 4000 6000 8000 10000 12000 14000

Microns
Data Processing
L o g C u m u la tiv e % P a s s

2.5000

2.0000
f(x)
f(x) =
= 0.32
0.36 x
x +
+ 0.65
0.46
f(x) = 0.36 x + 0.42
f(x) = 0.44 x + 0.05

1.5000

1.0000

0.5000

0.0000
1.5000 2.0000 2.5000 3.0000 3.5000 4.0000 4.5000

Log Size, microns


Data Processing

Time, min Log 80% Pass, um


Initial  
15 17,510.09
30 12,854.59
45 10,332.51
60 8,039.61
Data Processing
L o g 1 0 (C u m 8 0 % P a s s , u m )

4.5000

f(x) = − 0.33 x + 4.64

4.0000

3.5000

3.0000
1.00 1.20 1.40 1.60 1.80 2.00 2.20 2.40

Log10 (Time, minutes),


Dense Medium Separation
Dense Media Separation
• Prepare SG 1.3 and 1.7 solutions of ZnCl2
• Obtain 10-g of powdered coal sample
• Place solution in 500-mL graduated cylinders
• Place sample in solution
• Scoop out the “float” samples
• Filter out the “sink” samples
• Burn the samples in the muffle furnace for 1
hour @ 9000C
Findings
• Separation by density
– Separate coal by grade
– Higher grade, higher density
– Separate other minerals

• Determination of ash content


– Verify coal grade by ash residue after burning
Hand Panning
Hand Panning
• Prepare 100 grams chromite @ 100% passing
30 mesh, 100% retained 50 mesh
• Prepare 100 grams silica @ 100% passing 10
mesh, 100% retained 20 mesh
• Mix the two minerals
• Separate by hand panning
• Collect the concentrate and tails and screen to
separate the two minerals
Findings
• Determine separation of minerals by gravity
and particle size
Findings
• Behavior of minerals:
Bubble Pick-up
Bubble Pick-up
1. Obtain 1-gram of ore sample
2. Place in 100-mL beaker
3. Fill with water
4. Ultra-sonicate for 3 minutes
5. Discard water
6. Repeat steps 3-5 until water is clear
7. Condition pH
8. Add collector
Bubble Pick-up
9. Condition pH
10.Add frother
11.Lower the glass tube into the pulp
12.Press the rubber plunger
13.Without releasing the plunger, raise the glass tube
and apply the bubble into a glass slide
14.Repeat steps 11-13 until 10 droplets were recovered
15.Dry and perform particle counting using the
microscope
Findings
• Simulate flotation response using a single
bubble
• Determine best dosage parameters before
froth flotation test
Froth Flotation
Froth Flotation
1. Obtain 1-kg sample
2. Grind, at the grinding time determined in the
MOG experiment
3. Place sample in flotation cell
4. Add enough water to cover
5. Pulp for 5 minutes
6. Add pH modifier
7. Condition for 5 minutes
8. Repeat steps 6-7 until proper pH is achieved
Froth Flotation
9. Add collector
10.Condition for 10 minutes
11.Check the pH, make adjustments if necessary
12.Add frother
13.Condition for 10-30 seconds
14.Scrape froth
15.After flotation, scoop out tailings solids
16.Perform assay of concentrate and tailings
Findings
• Determine the proper steps in performing
flotation
– Art vs. science

• Determine the effects of dosage parameters


to recovery
Flocculation
Flocculation
1. Prepare a 1000 mL 20:1 water-ore pulp using
100% passing 200-mesh ore from BWI undersize
2. Prepare 10 dosages of flocculant
3. Agitate pulp for 5 minutes
4. Determine the settling rate without flocculant
5. Mark the lowest settling level of solids
6. Add 1 dose of flocculant and agitate for 5 minutes
Flocculation
7. Determine settling rate
8. Mark the lowest settling level of solids
9. Repeat steps 6-8 until no change in settling
rate is observed
10.Graph the settling rates vs. time
Findings
• Determine the minimum dosage of
flocculation
• Observe stearic stabilization
• Observe “swelling” of flocculated solids
Sedimentation
Sedimentation
1. Prepare 1000 mL of 5, 10, 15, and 20% solids
pulp using 100% passing 200-mesh from BWI
undersize
2. Agitate for 5 minutes
3. Mark the level of the solids-water interface at
specified intervals
4. Mark the lowest settling level of solids
Findings

H1
H2

H3
Findings
• Determine thickener area using Kynch’s
formula:

tu
A
H 0 C0
A = thickener area
tu = settling time
H0 = initial pulp height
C0 = pulp consistency
Findings
• Determine thickener retention time using
Robert’s formula

t  tu  t c
t = retention time
tu = settling time
tc = time to
compression zone
Findings
• Determine the depth of compression zone:

t  x  1
d
24 A
d = depth of compression zone
tu = retention time
x = average dilution of pulp at compression zone
x = average dilution of pulp between the compression zone and
final underflow is reached
A = thickener area

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