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- Rod mills are always monochamber and are working in overflow mode (without grate at the outlet).
- Speed of rotation is lower than ball mills in order to avoid tangling of the rods.
Speed of rotation varies from 62 to 70% of the critical speed.
- The ratio L/D must be well defined in order to avoid tangling of the rods (not to be lower than 1,3-1,4).
For bigger diameters (> 2m), L/D = 1,4-1,8
For smaller diameters (< 1,5m), L/D = 2-2,5
- The length of the rods is limited to 20ft (6,08m).
A 150 mm clearance being required to the ends of the mill.
- Rods density is varying from 5400 kg/m3 to 6400 kg/m3.
- Available diameters of the rods are generally: 105,95,80,50 and 25mm.
- Due to the restriction of rod length, the maximum shell diameter allowed will be 4,4-4,6m (to keep the right L/D ratio!).
- Unlike ball mills, the volume load can be drastically higher.
Values between 35 and 40% (even more) are normal.
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Values between 35 and 40% (even more) are normal.
- Linings of steel or rubber are accepted.
- Concerning the fresh feed, F80 (size in of the 80% passing in the fresh feed) must be comprised between 5 and 20mm.
It is generally accepted that the optimum fresh feed (80%) is 15-17mm.
Allis Chalmers developed a formula to define the right fresh feed:
Where:
F80 is the size in of the 80% passing in the fresh feed and
Wi is the Bond Index
- Concerning the final product, we consider the following:
* P80 (size in of the 80% passing in the product) is normally between 1 to 2mm
* Minimum P80 can reached 0,5mm (and even 0,3mm in closed circuit)
* NB: Rod mills are not producing very fine particles.
- Reduction Ratio:
According to Bond, it is around 16:1 (between 12:1 and 20:1 as maximum).
- Calculation of the absorbed power:
Bond developed the following formula:
Where:
P is the mill absorbed power at the shaft in kW,
Tr is the mass of grinding charge in tons
D is the internal diameter of the mill,
J is the volume load in % and
V crit is the percentage of the critical speed
- In the majority of cases, rod mills are operating in open circuit.
- Sizing a rod mill, see the link below:
http://www.themininggrindingoffice.com/rodballmillsizing.html
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2.2 AG and SAG mills:
- AG and SAG are the diminutives of (FULLY) AUTOGENOUS and SEMI AUTOGENOUS mills.
- AG and SAG mills circuits are commonly and advantageously applied in the high capacity circuits for processing ores
with lower metal grades.
2.2.1 AG mills:
- AG mills are used as first grinding step.
- Fresh feed can be:
* Run of mine ore: F80 is between 200 and 400mm (Mined ore of a size that can be processed without further crushing)
* Crushed ore: F80 is between 150 and 250mm
- AG mills operate with rocks of the ore itself as grinding media.
- For that reason, the feed has to contain a sufficient amount of coarse grinding stones.
2.2.2 SAG mills:
- Like AG, SAG mills are used as first grinding step.
- Fresh feed is usually:
* Run of mine ore: F80 is between 200 and 400mm (Mined ore of a size that can be processed without further crushing)
* Crushed ore: F80 is between 150 and 250mm
- SAG mills operate with big rocks of the ore itself plus steel balls to improve efficiency.
- The grinding media volume load is between 4 and 15%.
- Normally, balls of 125 and 100mm are used.
- The mill diameter is usually bigger than the length (L/D from 0,3 to 0,6). But SAG mills can also have a L/D > 1.
- Sketch of a SAG mill:
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- Pebbles mills are used as secondary grinding step.
- Fresh feed is the product of rod/SAG mills.
- Grinding media (pebbles) consists of screened out fractions of the ore itself, synthetic pebbles, or manufactured alumina
oxide.
- Dimension of pebbles from 50 to 90mm.
- Pebbles mills are operating with a grate discharge.
2.4 Slurry mills (ball mills):
- Slurry mills are used as secondary grinding step of a mining plant and in the raw section of cement plants.
- These mills are operating in open or closed circuit with hydrocyclones.
- Linings of steel or rubber are accepted.
- Mill discharge can be in overflow process or with a grate discharge.
Some raw mills are also equipped with an outlet flow control diaphragm.
- Sketch of a slurry mill:
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