4.3.
5 Discussion of the Bond Method
Limitations of the Bond Method
Austin and Brame (1983) and Herbs and
Fuerstenau (1980) have reviewed the
limitations of the Bond test. Perhaps the
most serious in a fundamental sense is
Bond’s claim that equation 4.2 is a
“universal law”, whereas it is known that
the specific grinding energy needed to take
a feed with a certain 80% passing size to a
product with a certain 80% passing size
cannot be the same for a batch test, the
standard Bond locked-cycle test, or a
steady-state continuous mill with a real
residence time distribution. The method
ignores the fact that the shape of the
product size distribution and the associated
specific grinding energy is different for
these three cases.
Criticism of Bond’s method as a “model” is
not really warranted since it is not intended
to be a model in any comprehensive sense.
Its real value is as a method of
distinguishing the grindability of different
ores in design (though better test may be
available), and as a yardstick to check the
energy utilization of current operations.
Experience in its use has demonstrated the
following limitations:
 It tends to be a poor predictor of what
happens in a real closed circuit when
throughput is increased, unless
classifier performance is “adjusted” to
cope with the new conditions.
 As implied earlier, it is not appropriate
in system where size distribution slopes
change.
 It is not a good predictor of the
grinding of large rocks, and specifically
for AG/SAG mill behavior (though it has
been adapted to such circumstances -
see below).
4.3.5 discusión del Método de Bond
Limitaciones del Método Bond
Austin y Brame (1983) y Herbs y
Fuerstenau (1980) han revisado las
limitaciones del test de Bond. Quizás el más
serio en un sentido fundamental es la
llamada Bond que la ecuación 4.2 es una
“ley universal”, considerando que se conoce
la energía específica de molienda necesaria
para tomar un alimento con un cierto 80%
tamaño pasante a un producto con un
cierto 80% tamaño pasante no puede ser el
mismo para una prueba batch, la prueba
estandar de ciclo cerrado de Bond, o un
molino en estado –estable continuo con
una distribución de tiempo de residencia
real. El método ignora el hecho que la
forma de distribución de tamaño del
producto y la energía específica de
molienda asociada es diferente para estos
tres casos.
Críticos del método de Bond como un
“modelo” realmente no garantiza desde
que no se piensa que es un modelo en
cualquier sentido comprensivo. Su valor
real es como un método de distinguir la
moliendabilidad de minerales diferentes en
el diseño (aunque la mejor prueba puede
estar disponible), y como una vara de
medir para verificar la utilización de energía
de operaciones actuales.
Experiencia en su uso ha demostrado las
siguientes limitaciones:
 Tiende a ser una pobre predicción de lo
que pasa en un circuito cerrado real
cuando el rendimiento se incrementa, a
menos que la operación del clasificador
es “ajustado” para cubrir con las
nuevas condiciones.
 Como implicado antes, no es apropiado
en un sistema dónde hay cambios en
las pendientes de distribución de
tamaños.
 No es un buen predictor de la molienda
de rocas grandes, y específicamente
para el comportamiento en la molienda
AG/SAG (aunque se ha adaptado a
tales circunstancias - ver debajo).
 It is unreliable for particles with
unusual screening characteristics (i.e.
of unusual shape), though this is a
general problem for any technique
relying on sieving for the determination
of particle size.
 The square root relationship
assumed in equation 4,2 (arising from
Bond’s assumption that work is
proportional to new crack tip length)
does not always hold. See also Figure
2.1.
There is also a perception that Bond’s
method failed to predict the performance of
the very large ball mills introduced in the
early 1970s, though this was probably more
to do with the early learning curve
associated with operating these mills and
their associated classification process.
Certainly there was never a dedicated Bond
test for the Ag and SAG mills now in
common use.
Other problems and inconveniences of the
Bond standard procedure include the need
to use a Bond mill (which may not be
readily available), the requirement of about
10 kilograms of feed sample, which needs
special preparation, and the fact that
conducting the test is time consuming. A
number of attempts have been made in the
past to determine the Bond Work index by
means of simplified procedures (Yap et al
1982).
Empirical methods which allow for a direct
calculation of the work index using a
straight forward procedure are often more
practical and better suited for plant
application. For example the Anaconda
simplified method (Yap et al 1982) which
uses an ordinary laboratory mill and only 2
kilograms of sample, is not time consuming
and has proven to be very practical and
flexible in a number of different
applications. However, the full Bond test
gives the maximum confidence in
prediction.
 Es inestable para las partículas con las
características de tamizado inusual (es
decir de forma inusual), aunque éste es
un problema general para cualquier
técnica que confía en tamizar para la
determinación del tamaño de
partículas.
 La relación de la raíz cuadrada asumida
en la ecuación 4,2 (proviene de la
asunción de Bond que el trabajo es
proporcional a la nueva longitud de
rotura punta de crujido) no siempre
sostenga. También Vea Figura 2.1.
Hay también una percepción que el método
de Bond no predijo la acciòn de los molinos
de bolas muy grandes introducida en los
tempranos 1970s, aunque éste era
probablemente más hacer con la curva de
aprendizaje temprana asociado con operar
estos molinos y su proceso de la
clasificación asociado. Había nunca una
prueba de Bond ciertamente especializada
para los molinos AG y SAG ahora en uso
comun.
Otros problemas y inconvenientes de la
Atadura el procedimiento estándar de Bond
incluye la necesidad de usar un molino de
Bolas (qué no puede estar prontamente
disponible), el requisito de
aproximadamente 10 kilogramos de
muestra del alimento que necesita la
preparación especial y el hecho que
dirigiendo la prueba es el tiempo
consumiendo. Varios esfuerzos han sido
hecho en el pasado determinar el índice de
Trabajo de Atadura por medio de los
procedimientos simplificados (Ladre el et al
1982).
Métodos empíricos que permiten un cálculo
directo del índice de trabajo que usa un
procedimiento delantero recto son a
menudo más prácticos y buenos satisfecho
para la aplicación de la planta. Por ejemplo
el Anaconda simplificó el método (Ladre el
et al 1982) qué usa un molino del
laboratorio ordinario y sólo 2 kilogramos de
muestra, no es tiempo que consume y ha
demostrado ser muy práctico y flexible en
varios aplicaciones diferentes. El embargo
del pecado, prueba del la del la la Atadura
llena da la confianza máxima en la
predicción.
The Bond method attempts to partially
compensate for idealizations in the test
procedure and shortcomings of the model
by making use of correlations between
grindability test result obtained in a
“standard” 2,44 m diameter milling circuit.
Complete compensation is not possible
because this procedure cannot, for
instance, take into account inevitable
deviations in transport and classification
characteristics of the commercial circuit
from those of the “standard” circuit.
Since the method does not incorporate the
above – order effects, it cannot be used as
a guide to optimize a given system, from
either the operating point of view or the
economic point of view. Its is valid only as
a gross method for mills operating under
normal closed circuit conditions.
In spite of these limitations, the Bond
method has two main advantages: it is very
simple, and experience has shown that it
works for many circumstances to a
reasonable degree of accuracy, since the
corrections are based on a large industrial
database.
The Bond method attempts to partially
compensate for idealizations in the test
procedure and shortcomings of the model
by making use of correlations between
grindability test result obtained in a
“standard” 2,44 m diameter milling circuit.
Complete compensation is not possible
because this procedure cannot, for
instance, take into account inevitable
deviations in transport and classification
characteristics of the commercial circuit
from those of the “standard” circuit.
Since the method does not incorporate the
above – order effects, it cannot be used as
a guide to optimize a given system, from
either the operating point of view or the
economic point of view. Its is valid only as
a gross method for mills operating under
normal closed circuit conditions.
In spite of these limitations, the Bond
method has two main advantages: it is very
simple, and experience has shown that it
works for many circumstances to a
reasonable degree of accuracy, since the
corrections are based on a large industrial
database.
The operating Bond Work Index
Work indices obtained from operating data
on any mill can be compared to grindability
test results. The operating work index,
WIo, can be obtained using equation 4.2,
by defining W as the specific energy being
used (power draw + new federate), F80
and P80 as the actual feed and product
80% passing sizes, and WI as the operating
work index, WIo. Once corrected for the
particular application and equipment –
related factors, WIoC, can be compared on
the same basis as grindability test result.
This allows a direct comparison of grinding
efficiency. Ideally WI should be equal to
WIoC and grinding efficiency should be
unity. Power draw is determined using
equation 4.7, assuming grinding efficiency
is unity.
Application of Bond Theory to Autogenous
Mills.
For the case of autogenous and semi
autogenous milling it has been determined
that the work indices obtained from
standard Bond grindability tests cannot be
used (Section 9,6). It is necessary,
therefore, to calculate a Work index from
operating data(e.g. from a pilot plant) so
that power draw and mill sizing can be
calculated . In some cases the feed is not
used in the calculation as the factor
10/√F80 becomes insignificant because of
the large size of the ROM feed. For open
circuit AG/SAG mills, the discharge can be
hypothetically classified at the desired
closing screen size to provide a more
realistic P80 value for the work index
calculation.
The operating Bond Work Index
Work indices obtained from operating data
on any mill can be compared to grindability
test results. The operating work index,
WIo, can be obtained using equation 4.2,
by defining W as the specific energy being
used (power draw + new federate), F80
and P80 as the actual feed and product
80% passing sizes, and WI as the operating
work index, WIo. Once corrected for the
particular application and equipment –
related factors, WIoC, can be compared on
the same basis as grindability test result.
This allows a direct comparison of grinding
efficiency. Ideally WI should be equal to
WIoC and grinding efficiency should be
unity. Power draw is determined using
equation 4.7, assuming grinding efficiency
is unity.
Application of Bond Theory to Autogenous
Mills.
For the case of autogenous and semi
autogenous milling it has been determined
that the work indices obtained from
standard Bond grindability tests cannot be
used (Section 9,6). It is necessary,
therefore, to calculate a Work index from
operating data(e.g. from a pilot plant) so
that power draw and mill sizing can be
calculated . In some cases the feed is not
used in the calculation as the factor
10/√F80 becomes insignificant because of
the large size of the ROM feed. For open
circuit AG/SAG mills, the discharge can be
hypothetically classified at the desired
closing screen size to provide a more
realistic P80 value for the work index
calculation.
Macpherson has developed a test
procedure for the design of AG/SAG mill
circuits. It includes the conduct of standard
Bond rod mill and ball mill grindability test,
together with a dry autogenous test in a 45
cm air – swept Aerofall mill. A 250 kg
sample of -3.175 mm ores is required. The
autogenous test is used to compute an
autogenous work index, which is then
corrected for a full scale installation using
empirical scaling procedures (based on
historical data) and by comparison with the
rod and ball mill WIs. The autogenous WI
and the other data are then used to
determine AG/SAG milling suitability, power
requirement and circuit configuration.
Further details can be found in Knight et al
(1989).
Using the Bond Work Index in a Process
Model
Although Bond chose to use the results of
his laboratory ball mill test to determine an
operating work index, much more
information about grinding of an ore can in
principle be extracted. His test is a physical
model which approximates a closed circuit
ball mill, and so product sizing and
flowrates of each stream can be obtained
from it. Research currently underway at the
JKMRC is testing the use of these data to
determine the relevant parameters for a
ball mill model. The model is then used to
predict the performance of a full scale ball
mill. This approach has the advantage of
simultaneously generating a Bond ball mill
work index and set of model parameters,
which can be used in a complementary
fashion in design and optimization.
Macpherson has developed a test
procedure for the design of AG/SAG mill
circuits. It includes the conduct of standard
Bond rod mill and ball mill grindability test,
together with a dry autogenous test in a 45
cm air – swept Aerofall mill. A 250 kg
sample of -3.175 mm ores is required. The
autogenous test is used to compute an
autogenous work index, which is then
corrected for a full scale installation using
empirical scaling procedures (based on
historical data) and by comparison with the
rod and ball mill WIs. The autogenous WI
and the other data are then used to
determine AG/SAG milling suitability, power
requirement and circuit configuration.
Further details can be found in Knight et al
(1989).
Using the Bond Work Index in a Process
Model
Although Bond chose to use the results of
his laboratory ball mill test to determine an
operating work index, much more
information about grinding of an ore can in
principle be extracted. His test is a physical
model which approximates a closed circuit
ball mill, and so product sizing and
flowrates of each stream can be obtained
from it. Research currently underway at the
JKMRC is testing the use of these data to
determine the relevant parameters for a
ball mill model. The model is then used to
predict the performance of a full scale ball
mill. This approach has the advantage of
simultaneously generating a Bond ball mill
work index and set of model parameters,
which can be used in a complementary
fashion in design and optimization.