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Wear, 160 (1993) 309-316 309
(Received May 27, 1992; revised and accepted July 23, 1992)
Abstract
In the mineral processing industry, ball mills are used to reduce ore from one size distribution to another. Ball
mill wear occurs as a result of the violent interactions within the ball charge. In the present article, a mathematical
description of wear has been added to a ball charge motion model. Wear is associated with the comminution
mechanisms found in the ball charge profile. It is assumed that ball mill wear occurs in each of three comminution
zones, with adhesive wear found in the crushing and tumbling zones and abrasive wear arising in the grinding
zone. Wear rates are proportional to the energy dissipated in these zones as predicted by the charge motion
model. Three laboratory case studies are investigated followed by one full-scale example in a wet milling context.
Simulation results are compared with experimental data from which real-system predictions are presented. The
use of these results provides the possibility of optimizing ball mill performance while including the wear rate
factor.
1. Introduction 2. Background
Particle breakage, in a ball mill, is achieved by the
Ball mills play an important role in the mineral collision of balls, or by balls sliding past one another.
processing industry of today. Yet as such, they are Both these actions continually nip and break certain
difficult to study given the closed nature of the operation. quantities of material. This type of breakage is the final
Once operating, the ball mill becomes a black box event in a chain of energy transfo~ations which com-
where only input and output materials can be observed, mences with rotational energy of the ballmill trans-
as well as the power draw of the grinding system. As formed into the ball charge movement (Fig. 1).
The charge profile shows three zones that characterize
a result of the highly stochastic nature of the ball mill
the type of action produced there, namely; the grinding
environment, most ball mill studies to date have been
zone, which is described by ball layers sliding over one
experimental. This had led to the development of
another grinding the material trapped between them;
empirical and phenomenological ball mill models.
the tumbling zone, which is described by balls rolling
Models of this type have limited utility due to inadequate
over one another and breaking the material in low-
representation of the dynamic interaction and the effect energy impact; the crushing zone, which is described
of ball mill elements on ball mill operation and per- by balls in flight re-entering the ball charge and crushing
formance. the material in hip-ener~ impact.
In the field of wear, as observed in ballmills, a number
of studies have been completed. Some studies present
extensive experimental data [l-3], while others illustrate
models useful to the understanding of wear phenomena
[4-8]. The goal of this work is the development of a
better understanding of ball mill wear as a function
of mill element interaction. The following report will
limit itself to the presentation of a wear model and
to the model validation using published ball wear test
data, and conclude with a real-system simulated case
example. Fig. 1. Typical ball charge action [9].
1
Fig. 4. Ball lifter effect.
;
4=@-/3+arcsin y cos(O-p) (1) Fig. 5. Charge foot stability criterion development.
[
This relationship can also describe the ball lifter
effect (Fig. 4), where other balls can act as lifters [ll,
121.
When applied to the ball charge, eqn. (1) describes
two different cases:
(i) the angular position of the center of mass of a
layer of balls in slippage (I_L< 1.0)
C$= arctan@.,) - p
1
%-Abw2R
+ arcsin cos(arctan(p.,) - p)
g
(ii) the angular point of flight for a ball (ILz 1.0) Fig. 6. Charge discretization.
C#J
= arctan&) - p
p = tan arctan&)
[
- p+ T
2 1
and Ao is the slippage speed relative to the mill center
(4)
[ll-131.
A ball in the ball mill may follow one of two general
trajectories depending on whether it is in the charge
or in flight. The trajectory of the ball in the charge is
Fig. 2. Typical ball mill liners [9]. circular, while for the ball in flight the trajectory is
parabolic.
Before this description of ball charge motion can be
solved, the charge foot stability must be determined
by a moment calculation (Fig. 5).
(5)
Having thus defined ball charge motion, it now be- of wear as a function of the energy rate consumed in
comes possible to define and calculate the following wear. The mass rate of wear for these models is
energies: developed by multiplying the metal density with the
volume rate of wear, resulting in the following equations
[ 171:
adhesive wear
abrasive wear
(I31
3. Wear model
perimental data [18, 191. The objective of these sim- TABLE 3. Abrasion parameter back-calculation (dry grinding.
quartize)
ulation experiments was to determine the applicability
.-
of the wear model to reproduce laboratory data as a
Metal Wear Hardness Density Abrasion
function of ball and material hardness as well as grinding
rate (kg m-) factor
(wet/dry) conditions. Liner wear in these experiments (g h-) z mm-) e 0
is considered to be negligible.
Table 1 gives the laboratory physical specifications. Mild steel 2.73 127* 7800*** 5.32
Figure 7 illustrates the simulated ball charge profile High carbon 1.85 505* 7soo*** 14.08
low alloy steel
for dry grinding conditions.
Austenite 2.24 370** 7800*** 12.24
Table 2 shows the energy calculated in grinding for
three simulated grinding conditions. After a back-cal- *[18]; **[20]; ***[,,I.
culation (Table 3) from dry grinding conditions with
quartize, wear model parameters for abrasive grinding
wear were determined. By keeping these parameters
constant for changing grinding conditions, it was possible
to compare laboratory and simulated wearrates as a
function of material and grinding conditions (Fig. 8).
At this point, it should be noted that adhesive wear
was considered to be negligible in the laboratory test
data used because the calculated energy level in tumbling
and crushing (zones associated with adhesive wear)
were quite low or non-existent.
Length 4.27 m
Inside diameter 3.06 m (with lifters)
Operating speed 16.9 i-pm
Lifters Shiplap (see Fig_ $1)
No. of fifuxs 25 Fig. 12. Ener@ rate distrz&ution.
Lifter profiie area 0.0325 mz
Ball size 0.05 m
Ball density 7800 kg me3 ball charge; the smaller circles describe the charge
Bali charge voIume 30% of mill voluwre elements in flight.
Ball hardness 220 kg mm-2 To obtain the solution to eqn. (9), 5.325 s of real
Materiaf density 2900 kg me3 time were simulated, giving the energy rate values shown
(pyrochlore ore)
in Fig. 12.
Input tonnage 17.5 t h-
Ball mill liner life span = 2 years (= 51iS worn) Examining the simulated energy rate results, the
Charge and liner wear rate =0.04 kg per tonne production following eq~~t~~ns are obtained:
Operating condition wet &=0.12; rk;=1).09f
&;,=I0 kW
&=6O kW
I.$,,== 130 kW
with I$ = I,8 kW being calculated separately
Equations (17), (14), (16) and (15), in the order of
Fig. 10. Original and iinal Iiftcr profiles [23].
their use, give the following values as a ~~~t~on of
the real-system wear rate of I)fSlitot=0.00194kg s-:
5, Real-system simulative
LX Wcrl
Fig. 13. Energy rates as a function of rotation speed.
800 ROTATION SPEED
I% LJcrl
References
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O00 20 25 30 35 I-4
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&ml
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mbi ball mass (kg)
eff1 discretized element mass (kg)
li normal force (N)
Appendix A: Nomenclature rci radial position of mass center (m)
R Mill radius (m)
db ball diameter (m) vi element velocity (m s-r)
E. consumed . energy rate consumed by the mill (kW) 0 Arctan ( pL,)
E. crushing> E. CT energy rate distributed in crushing (kW) ASPpk static and dynamic friction factors [l]
egrinding, Egrc energy rate distributed in grinding (kW) 43 angular position of the ball in mill (ra-
4, energy rate distributed on liner through dians)
grinding (kW) @i angular velocity of the ball relative to
Ematerial energy rate used to lift mill material the mill center (radians s-l)
(kW) WO angular velocity of the mill (radians s-l)