Grinding Mills by New Concept Projects/Osborn

Suppliers of: Ball Mills Sag Mills Rod Mills Fag Mills Liners Anxillary Equipment Turnkey Project Management

NCP supplies new Grinding Mills and all ancillary equipment to clients across the globe.

New Concept Projects

Liners
New Concept Projects (NCP), are highly regarded as leading manufacturers and suppliers of New Osborn Grinding Mills into Africa and internationally. Additionally, as suppliers of refurbished plant & mining equipment, NCP are able to meet demand and assist on projects carrying constrained budgets or accelerated delivery timing requirements. Regarded as experts in their field, NCP are centered on the supply of Capital equipment and the management of related turnkey services, to deliver equipment to clients exacting specifications. The primary purpose of mill liners is to protect the internal surfaces of the mill which would otherwise come in contact with the grinding charge and be subject to wear. The lining due to its position becomes the final link in transmitting the energy of the rotating mill to the mill load, therefore careful consideration must be given to the shape of the liners. Various profiles and types are used, depending on the application. (diagram below) Shell and head liners can be made of manganese steel, chrome moly steel, other wear resistant alloys, silica blocks, rubber or ceramic. Liner bolts are generally made of forged steel with an oval head to prevent turning and loosening within the liner. Leak proof washers are furnished with liner bolts for wet or dry grinding applications. Liner wear results from a combination of corrosion, abrasion and impact. The relative importance of each factor varies with the grinding application. The most significant milling variables relative to wear are feed size, media size, mill speed, mill diameter, ore hardness, ore abrasiveness and corrosiveness of the pulp. Wear increases as each of these variables increase. As liners become worn, the volume within the mill increases. The increased mill volume allows for additional ore and media within the mill. Additional load within the mill results in an increased mill power draw. Power draw can increase by up to 8% as liners wear to their replacement condition, if the charge level relative to the mill axis remains constant.

Product Range
1. NEW EQUIPMENT Grinding Mills & Communition Circuits 2. REFURBISHED EQUIPMENT Grinding Mills & Comminution Circuit Equipment Crushers & Crushing Plants Thickeners Conveyor Equipment Pump Projects Ventilation Fans Shaft Compressors Mine Winders Power Generation Equipment Cranes The product range offered by NCP includes: ROD MILLS BALL MILLS ROM BALL MILLS SAG MILLS FAG MILLS LINERS GRINDING MEDIA ANCILLARY EQUIPMENT NCP is actively involved with supplying and developing a wide range of mill types with mills being identified by the type of grinding media used. Each type of mill has characteristics that enhance its grinding application and the operational characteristics of each must be evaluated in relation to the objectives of the grinding requirement.

SINGLE WAVE TYPE (Normal Rod Mill)

GRID TYPE (Ball or Run-of-Mine Mill)

DOUBLE WAVE TYPE (Normal Ball Mill)

TWO PIECE RUBBER TYPE (Rod or Ball Milll)

Grinding Media Liners & Grinding Media

PRroduct Range

Many factors are involved in the selection of grinding media. Including ore hardness, feed size, mill size, mill speed and feed rate. Media selection is important because the cost of media is a major expense in grinding with significant savings available by optimizing the use of grinding media. Media diameter can be selected so as to provide for the best mill performance as well as media shape selection (established shapes are either spherical or cylindrical).

Choice of materials used in grinding media is significant. Grinding balls should be made of forged steel, or cast steel having the same resistance to breakage. Rods should be hot rolled, hot sawed or sheared with standard tolerances and machine straightened. NCP typically undertakes DEM Analysis (Discreet Element Modelling) to determine optimal Liner Design & Mill charge characteristics.

Mill Types
Rod Mills
Rod Mils can accept feed up to approximately 25mm and are generally selected to grind products in the -4mm to -0.5mm range. Grinding action is by line contact between rods which extends the length of the mill. Large feed particles spread the rods at the feed end and in so doing ,allow preferential grinding of the coarse fraction. A minimum amount of fines are created and a relatively uniform sized grading is produced. Rod Mills are usually operated in open circuit. Most rod mill applications involve wet grinding where material is reduced in size from crusher product size to a size suitable for ball mill feed. Rod milling in the size range utilised is more efficient than primary ball milling, in that the desired product is obtained at a lower cost per ton. To avoid breakage or tangling of rods the L/D ratio of rod mills is kept within the limits 1.3/1 to 2/1. 1. Ball Mill - Overflow Discharge: As the name implies, material is discharged from an overflow mill by overflowing the discharge opening. In this type of mill the balls are kept in the mill by keeping the top of the ball charge below the level of the discharge opening. A reverse spiral in the discharge trunnion liner also assists this condition.
OVERFLOW BALL MILL

NCP actively supply the three most common Rod Mill types:

GRATE BALL MILL

2. Ball Mill - Grate Discharge: This mill type embodies the principle of steep pulp gradient, quick discharge operation. A grate assembly at the discharge end of the mill permits retention of a higher ball charge (45%) than is possible in an overflow mill, which has a practical limit of around 40%. Behind the grates are pulp lifters, which pick up the ground material as it passes through the grates and transports it out of the mill. This quick removal of ground material produces overgrinding especially when operated in closed circuit with a classifier. The classifier removes the particles, which are within the product specification, and returns the oversize back to the mill feed chute.

OVERFLOW ROD MILL

END PERIPHERIAL DISCHARGE ROD MILLS

CENTRE PERIPHERIAL DISCHARGE ROD MILLS

ROM Ball Mills

3. Run-of-Mine Ball Mills (ROM Ball Mills) Run-of Mine Ball Mills can accept ROM up to 150mm. The large feed particle size reduces effective Ball charge carrying capacity of the Ball Mill, thus ROM Ball Mills typically operate between 20-32% Ball charge. ROM Ball Mills carry a low aspect ratio & can generate a final Grind size in closed cuit through a single Mill. cir

1. Rod Mill Overflow An overflow mill is constructed with a feed opening at one end and a discharge opening at the other, both on the axis of the mill. Material leaves the mill by overflowing at the discharge end. Used for producing the finer end of the product range.

2. Rod Mill End peripheral discharge (EPD) The end peripheral discharge mills steeper gradient produces shorter retention time and thus a coarser product than the overflow type. Product is discharged through port openings equally spaced around the periphery of the shell at the discharge end. Grinding may be accomplished wet or dry. End peripheral discharge is used to good advantage in damp grinding of coke or steelwork sinter plants.

3. Rod Mill Centre peripheral discharge (CPD) Feed is from both ends and is discharged at the centre through discharge ports, equally spaced around the mill periphery. The ports are in a separate ring between the shell halves. The fact that the particles only travel half the mill length makes the CPD rod mill an outstanding unit for coarse grinding and rapid removal of finished material.

SAG Mills

Ball Mills
Ball Mills accept feed that ranges in size from 80% passing 15mm to fine feeds in regrind applications. Products may be as coarse as 0.5mm or as fine as 40 microns or below. Grinding is accomplished with spherical-shaped media generally made of steel. In a ball mill the length may be less than, equal to, or greater than its diameter. A short length mill has a lower retention time and produces a coarser product. Longer mills have a longer retention time and therefore produce a finer grind. Ball mills can be operated in an open circuit but modern practice generally utilises closed circuit operation.

AUTOGENOUS OR SEMI-AUTOGENOUS MILL (US STYLE)

4. Semi-Autogenous Mills (SAG Mills): SAG Mills use semi-autogenous grinding in place of autogenous grinding when the ore does not produce the necessary competent media. Forged steel balls are used to supplement the coarse ore. With this additional load by adding steel balls, more motor power is required and the physical design of the mill requires to be more robust. Most clients envisaging autogenous operation however request their mill be designed to cater for semi-autogenous loads. Ball sizes commonly used are 100 to 120mm. The ball charge is generally in the range of 2 to 12% of the mill volume.

Mill Types

Trunnion Supported Mill

5. Trunnion Supported vs Shell Supported Mills Trunnion supported mills have been proven by many years of operation. NCP/ Osborn have over 180 mills in the field with powers from 2 kW for laboratory use to 3880 kW on production units. NCP also carry shell supported designs for mills >12 ft diameter. Shell supported designs reduce the bending moment on shells by reducing the effective distance between support points. Limitations on trunnion openings is removed, thus shell diameters can be increased.

Shell Supported Mill

Mill Sizing and Power Draw Calculations

Material Specs
When selecting a grinding mill it is necessary to first calculate the amount of power (kW) required to achieve the process requirement. Once the power value has been determined a suitable mill size and shape can be selected. The methods and tables below will enable an approximate sizing to be made for project purposes.
Material No. of Tests 60 4 16 12 308 18 8 18 10 15 5 8 209 6 8 83 22 27 119 15 2 11 3 27 8 4 16 17 7 17 7 6 12 6 3 9 16 20 10 Specific Gravity 3.09 2.67 4.06 1.63 1.51 3.02 2.82 2.59 6.75 5.91 4.91 2.65 2.98 2.86 1.75 3.96 3.88 3.44 3.37 2.69 2.68 3.74 2.89 3.32 2.65 2.66 2.37 3.48 2.71 2.64 2.71 2.65 2.73 2.72 2.93 2.39 2.10 3.94 4.23 2.70 3.68 Work Index 13.49 10.57 9.66 11.37 20.70 13.13 11.31 11.67 8.87 7.77 12.83 26.16 9.76 14.83 45.03 15.44 10.21 11.40 11.35 11.61 10.18 12.46 134.50 11.88 13.03

CORRECTION FACTOR 1, CF1 (dry grinding) = 1,3 (wet grinding) = 1,0

CORRECTION FACTOR 5, CF5 (fineness of grind) If P80 < 74 m then

Cement Clinker Chrome Ore Coal Coke Copper ore Dolomite Feldspar Ferrochrome Ferromanganese

Cement Raw Material 87

Mill Calculations
A common method used in determining power requirements uses the Bond theory where the following mathematical relationship applies: W= 10 Wi ( 1/P80 - 1/F80 ) where, W = Kilowatt hours per short ton required Wi = The Bond Work Index (Kwh/short ton) P80= Size in microns which 80% of the product passes F80= Size in microns which 80% of the feed passes Wi is usually obtained from laboratory batch tests or records kept from previous tests. The value W can now be metricated by multiplying by 1.1 (Kwh/tonne) and then by the feed rate to give kilowatts at pinion shaft. A series of correction factors are considered when using the Bond method, in the table to the right. As the formulae for correction factor 3 includes the mill diameter a provisional mill size can be selected from the chart below using the power value (1). For this a suitable L/D ratio must be assumed. The final power in kilowatts can be obtained by multiplying the previously calculated value (1) by each applicable correction factor.

CORRECTION FACTOR 2, CF2 (open circuit ball milling) Reference % Passing 50 60 70 80 90 92 95 98 Correction Factor 2 1.035 1.05 1.10 1.20 1.40 1.46 1.57 1.70

CF5 = P80 + 10.3 1,145 P80 If P80 > 74 m then CF5 = 1,0

If closed circuit grinding: CF2 = 1,0

CORRECTION FACTOR 6, CF6 (ratio of reduction, rod milling) Optimum Reduction Ratio: Rr0 = 8 + 5L D1 Reduction Ratio, Rr = F80 P80 CF6 = 1+ (Rr - Rro)2 150

Ferrosilicon Flint Fluorspar Gold Ore Graphite Iron ore Magnetite Lead Ore Lead Zinc Ore Limestone Manganese Ore Mica

CORRECTION FACTOR 3. (diameter) CF3 = 8/D 1

Limestone for Cement 62

)0,2 where D=Dia inside liners

CORRECTION FACTOR 7, CF7 (low ratio of reduction, ball milling) If Rr < 3 then CF7 = (Rr - 1,35) + 0,26 2 (Rr - 1,35) If Rr >/= 3 then CF7 = 1,0

(or 0,914 minimum value)

Nickel Ore Phosphate Fertilizer Phosphate Rock Potash Ore Pyrite Ore Quartzite Quartz Silica Silica Sand Silica Carbide Silver Ore Slag Slag, Iron blast furnace Sodium Silicate Tin Ore Titanium Ore Uranium Ore Zinc Ore

Mill Sizing and Power Draw Calculations

Mill Sizing and Power Draw Calculations

10.13 8.88 8.90 12.18 12.77 13.53 16.46 26.17 17.30 15.76 12.16 13.00 10.81 11.88 17.93 12.42

CORRECTION FACTOR 4. (oversized feed) CF4 = Rr + (Wi - 7) (F - F0) 80 Rr where Rr = F80 P80 F0 (Ball milling) = 4000 13/W i F0 (Rod milling) = 16,000 13/W i If F80 < F0 then CF4 = 1,00 if F80 < F0

ID Shell m (ft)
Mill Type % Charge
% Critical Speed (Ball)

1,07 (3- 6) Grate 45 Over Flow 40 Rod 40 Grate 45

1,37 (4- 6) Over Flow 40 Rod 40 Grate 45

1,68 (5- 6) Over Flow 40 79,2 27,1 25,8 405 Rod 40 Grate 45

2,00 (6- 6) Over Flow 40 77,7 24,3 22,7 425 Rod 40 Grate 45

2,30 (7- 6) Over Flow 40 76,6 22,2 20,4 449 Rod 40 Grate 45

2,60 (8- 6) Over Flow 40 75,5 20,5 18,5 465 Rod 40 Grate 45

2,90 (9- 6) Over Flow 40 74,7 19,1 17,1 483 Rod 40

3,20 (10- 6)

3,66 (12- 0)

4,27 (14- 0)

4,57 (15- 0)

4,88 (16- 0)

5,49 (18- 0)

6,10 (20)

7,00 (23)

ID SHELL
Mill Type % Charge % Critical RPM Rod FPM Length m (ft)

Grate 45 73,9 17,9

Over Flow 40

Rod 40

Grate 45 72,9

Over Flow 40

Rod 40

Grate 45 71,7

Over Flow 40

Rod 40

Grate 45 71,2

Over Flow 40

Rod 40

Grate 45 70,7

Over Flow 40

Rod 40

Grate 45 69,5

Over Flow 40

Grate 45 68,3 11,8

Grate 45 68,0 11,0

RPM Rod PFM LENGTH m (ft) 0,914 (3) 1,22 (4) 1,83 (6) 2,44 (8) 3,05 (10) 3,66 (12) 4,27 (14) 4,88 (16) 5,49 (18) 6,10 (20) 6,70 (22) 7,31 (24) 7,92 (26) 8,53 (28) 9,14 (30) 9,75 (32) 10,36 (34) 10,97 (36) 11,58 (38) 12,20 (40) 8 10 15 7 9 14 9 13 12 18 11 16 21 25 33 48 64

15,9 499

16,5

14,8 535

14,9

13,2 560

14,3

13,0 592

13,8

12,8 623

12,7

Kilowatt draw at pinion shaft with new liners

Kilowatt draw at pinion shaft with new liners

0,914 (3) 1,22 (4) 42 56 70 84 45 60 75 76 102 127 67 90 112 134 157 91 114 137 151 189 135 168 201 235 269 163 196 228 214 268 321 189 27 284 331 379 426
(1) Power values shown are for Rod & Ball charges (2) Sizes marked - Are suitable for AG, SAG or Run of Mine units. Powers on application. (3) Powers for AG, SAG & Run of Mine sizes within the range in (1) above are also available on application.

220 264 308 352 363 435 508 321 386 450 514 578 643 348 406 464 522

472 567 662 756 418 502 585 669 753 836 920 518 592 666 740

800 934 1067 1200 707 825 943 1061 1179 1297 1415 1532 733 837 942 1047 1370 1566 1762 1957 1212 1386 1559 1732 1903 2078 2252 2425 2598 1359 1510 1862 2094 2327 2560 1648 1854 2060 2266 2472 2678 2884 3090 3296 1659 1843 2194 2468 2742 3017 3291 1942 2185 2428 2670 2913 3156 3398 3640 2217 3321 3690 2939 3266 3593 -

1,863 (6) 2,44 (8) 3,05 (10) 3,66 (12) 4,27 (14) 4,88 (16) 5,49 (18) 6,10 (20) 6,70 (22) 7,31 (24) 7,92 (26) 8,53 (28) 9,14 (30) 9,75 (32) 10,36 (34) 10,97 (36) 11,58 (38) 12,20 (40)

Application Data Sheet

Detailed below are the criteria used to size a mill for a specific application. Please complete and send to projects@newconcept.co.za for evaluation.

MILL - DESIGN CRITERIA

Item 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 Ore Specific Gravity F100 F80 P80 Level of Corrosivity in Feed Extraction Process Feedsize Analysis Mill Availablilty Circuit Circulating Load Feed Material Temperature Ball Charge Discharge Arrangement ELECTRICAL INFORMATION Power Supply to Plant Supply Voltage Overhead/Generated Power Large Drives Small Drives 3.3 3.4 Control Voltage Cycles V V V Hz Max Operating Ball Charge Grate/overflow Open/Closed % deg C % CIL, CIP, CIC, floatation Please supply details if available % & hrs/day Max feed size 80% Feed size passing 80% Product size passing Altitude Plant Design Life Mill Locations PROCESS CHARACTERISTICS Ore Type Precious metal recovered Moisture Content Ore feed Rate to Mill Bond Ball Mill Index Fresh feed Nominal Design % Dry t/h kWh/t kWh/t Tons/m m m m ph Inside Building/Outside Info Supplier Description SITE INFORMATION Client Project Name Country Located Air Temperature Maximum Minimum deg C deg C m above SL Years Details Units Measurement

Application Data Sheet

2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 3 3.1 3.2

PO Box 9411 Edenglen 1613 South Africa Tel: +27 87 353 6791 Cell: +27 82 889 8881 +27 82 462 9249 Fax: +27 86 743 7580 projects@newconcept.co.za www.newconcept.co.za
All information supplied herein is subject to change without notice. E&OE
N1109/12397/B1