Grinding Mills

NCP supplies new Grinding Mills

and all ancillary equipment to clients
across the globe
 New Concept Projects

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 exact specifications.

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 NCP is actively involved with supplying and developing a wide
BALL MILLS range of mill types with mills being identified by the type of
ROM BALL MILLS
grinding media used. Each type of mill has characteristics
SAG MILLS
FAG MILLS that enhance its grinding application and the operational
LINERS characteristics of each must be evaluated in relation to the
GRINDING MEDIA objectives of the grinding requirement.
ANCILLARY EQUIPMENT

1
Liners
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)
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.

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.
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.

SINGLE WAVE TYPE GRID TYPE DOUBLE WAVE TYPE TWO PIECE RUBBER TYPE
(Normal Rod Mill) (Ball or Run-of-Mine Mill) (Normal Ball Mill) (Rod or Ball Milll)

Grinding Media
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.

2
Rod Mills

Rod Mils can accept feed up to approximately 25 mm and are generally selected to grind products in the -4 mm to -0.5 mm
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.

NCP actively supply the three most common Rod Mill types

OVERFLOW ROD MILL END PERIPHERIAL DISCHARGE CENTRE PERIPHERIAL DISCHARGE

ROD MILLS ROD MILLS

1. Rod Mill 2. Rod Mill 3. Rod Mill

Overflow End peripheral discharge (EPD) Centre peripheral discharge (CPD)

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.
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.
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.

Ball Mills
Ball Mills accept feed that ranges in size from 80% passing 15 mm to fine feeds in regrind applications. Products may be as
coarse as 0.5 mm 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.

3
 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

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
GRATE BALL MILL 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.

ROM Ball Mills

3.Run-of-Mine Ball Mills (ROM Ball Mills):

Run-of Mine Ball Mills can accept ROM up to 150 mm. 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 circuit through a single Mill.

SAG Mills
4. Semi-Autogenous Mills (SAG Mills):

AUTOGENOUS OR
SEMI-AUTOGENOUS MILL (US STYLE)
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 120 mm. The ball charge is generally in the range of 2 to 12% of the mill volume.

5. Trunnion Supported vs Shell Supported Mills:

Trunnion supported mills have been proven by many years of operation. NCP/Osborn have over
Trunnion Supported Mill 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

4
Mill Sizing and Power Draw Calculations
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.

MILL CALCULATIONS

A common method used in determining power Wi is usually obtained from laboratory batch tests or records
requirements uses the Bond theory where the following kept from previous tests. The value W can now be metricated by
mathematical relationship applies: multiplying by 1.1 (Kwh/tonne) and then by the feed rate to give
kilowatts at pinion shaft.
W= 10 Wi ( 1/P80 - 1/F80 )
A series of correction factors are considered when using the Bond
where, method, in the table to the right.

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
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.

ID Shell m (ft) 1,07 (3- 6) 1,37 (4- 6) 1,68 (5- 6) 2,00 (6- 6) 2,30 (7- 6) 2,60 (8- 6) 2,90 (9- 6)
Mill Type Grate Over Rod Grate Over Rod Grate Over Rod Grate Over Rod Grate Over Rod Grate Over Rod Grate Over Rod
Flow Flow Flow Flow Flow Flow Flow
% Charge 45 40 40 45 40 40 45 40 40 45 40 40 45 40 40 45 40 40 45 40 40
% Critical 79,2 77,7 76,6 75,5 74,7
Speed (Ball)
RPM 27,1 25,8 24,3 22,7 22,2 20,4 20,5 18,5 19,1 17,1
Rod PFM 405 425 449 465 483
LENGTH Kilowatt draw at pinion shaft with new liners
m (ft)
0,914 (3) 8 7
1,22 (4) 10 9 9 12 11
1,83 (6) 15 14 13 18 16 25 48 42 45 76 67 -
2,44 (8) 21 33 64 56 60 102 90 91 151 135 214 189 -
3,05 (10) 70 75 127 112 114 189 168 163 268 27 220 363 321
3,66 (12) 84 134 137 201 196 321 284 264 435 386 348
4,27 (14) 157 235 228 331 308 508 450 406
4,88 (16) 269 379 352 - 514 464
5,49 (18) 426 - 578 522
6,10 (20) (1) Power values shown are for Rod & Ball charges - 643
6,70 (22)
(2) Sizes marked - Are suitable for AG, SAG or Run of Mine units.
7,31 (24)
Powers on application.
7,92 (26)
8,53 (28) (3) Powers for AG, SAG & Run of Mine sizes within the range
in (1)
above are also available on application.
9,14 (30)
9,75 (32)
10,36 (34)
10,97 (36)
11,58 (38)
12,20 (40)

5
MATERIAL SPECS

Material No. of Tests Specific Work Index

CORRECTION FACTOR 1, CF1 (dry grinding) = 1,3 CORRECTION FACTOR 5, CF5 (fineness of grind) Gravity
(wet grinding) = 1,0 Cement Clinker 60 3.09 13.49
If P80 < 74 m then Cement Raw Material 87 2.67 10.57
CF5 = P80 + 10.3 Chrome Ore 4 4.06 9.66
1,145 P80 Coal 16 1.63 11.37
CORRECTION FACTOR 2, CF2 (open circuit ball milling)
Coke 12 1.51 20.70
Reference Correction If P80 > 74 m then CF5 = 1,0 Copper ore 308 3.02 13.13
% Passing Factor 2 Dolomite 18 2.82 11.31
Feldspar 8 2.59 11.67
50 1.035 Ferrochrome 18 6.75 8.87
60 1.05 CORRECTION FACTOR 6, CF6 Ferromanganese 10 5.91 7.77
70 1.10
80 1.20
(ratio of reduction, rod milling) Ferrosilicon 15 4.91 12.83
90 1.40 Optimum Reduction Ratio: Flint 5 2.65 26.16
92 1.46 Rr0 = 8 + 5L Fluorspar 8 2.98 9.76
95 1.57 D1 Gold Ore 209 2.86 14.83
98 1.70 Reduction Ratio, Rr = F80 Graphite 6 1.75 45.03
P80 Iron ore 8 3.96 15.44
If closed circuit grinding: CF2 = 1,0 Magnetite 83 3.88 10.21
CF6 = (Rr - Rro)2 Lead Ore 22 3.44 11.40
150
1+ Lead Zinc Ore 27 3.37 11.35
CORRECTION FACTOR 3. (diameter) Limestone 119 2.69 11.61
0,2 Limestone for Cement 62 2.68 10.18
CF3 = (8/D1) where D=Dia inside liners
Manganese Ore 15 3.74 12.46
(or 0,914 minimum value) CORRECTION FACTOR 7, CF7 Mica 2 2.89 134.50
(low ratio of reduction, ball milling) Nickel Ore 11 3.32 11.88
Phosphate Fertilizer 3 2.65 13.03
If Rr < 3 then Phosphate Rock 27 2.66 10.13
CORRECTION FACTOR 4. (oversized feed) Potash Ore 8 2.37 8.88
CF7 = (Rr - 1,35) + 0,26
Pyrite Ore 4 3.48 8.90
CF4 = Rr + (Wi - 7) (F80 - F0) if F80 < F0
2 (Rr - 1,35)
Quartzite 16 2.71 12.18
Rr
Quartz 17 2.64 12.77
where
Silica 7 2.71 13.53
Rr = F80 If Rr >/= 3 then CF7 = 1,0
Silica Sand 17 2.65 16.46
P80 Silica Carbide 7 2.73 26.17
F0 (Ball milling) = 4000 13/Wi Silver Ore 6 2.72 17.30
Slag 12 2.93 15.76
F0 (Rod milling) = 16,000 13/Wi Slag, Iron blast furnace 6 2.39 12.16
Sodium Silicate 3 2.10 13.00
If F80 < F0 then CF4 = 1,00 Tin Ore 9 3.94 10.81
Titanium Ore 16 4.23 11.88
Uranium Ore 20 2.70 17.93
Zinc Ore 10 3.68 12.42

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

Grate Over Rod Grate Over Rod Grate Over Rod Grate Over Rod Grate Over Rod Grate Over Grate Grate Mill Type
Flow Flow Flow Flow Flow Flow
45 40 40 45 40 40 45 40 40 45 40 40 45 40 40 45 40 45 45 % Charge
73,9 72,9 71,7 71,2 70,7 69,5 68,3 68,0 % Critical
17,9 15,9 16,5 14,8 14,9 13,2 14,3 13,0 13,8 12,8 12,7 11,8 11,0 RPM
499 535 560 592 623 Rod FPM
Kilowatt draw at pinion shaft with new liners Length
m (ft)
0,914 (3)
1,22 (4)
- - 1,863 (6)
- - - - - - 2,44 (8)
472 418 - - - - - - 3,05 (10)
567 502 800 707 - - 3,66 (12)
662 585 518 934 825 733 1370 1212 - - - - - 4,27 (14)
756 669 592 1067 943 837 1566 1386 1862 1648 2194 1942 - - - 4,88 (16)
- 753 666 1200 1061 942 1762 1559 1359 2094 1854 1659 2468 2185 3321 2939 - - 5,49 (18)
- 836 740 - 1179 1047 1957 1732 1510 2327 2060 1843 2742 2428 2217 3690 3266 - - 6,10 (20)
- 920 - 1297 - 1903 2560 2266 3017 2670 - 3593 - - 6,70 (22)
- 1415 - 2078 - 2472 3291 2913 - - - 7,31 (24)
- 1532 - 2252 - 2678 - 3156 - - - 7,92 (26)
- 2425 - 2884 - 3398 - - - 8,53 (28)
- 2598 - 3090 - 3640 - - - 9,14 (30)
- 3296 - - - - 9,75 (32)
- - - - 10,36 (34)
- - - 10,97 (36)
- - - 11,58 (38)
- - 12,20 (40)

6
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 Info Supplier Description Details Units Measurement
1 SITE INFORMATION
1.1 Client
1.2 Project Name
1.3 Country Located
1.4 Air Temperature Maximum deg C
1.5 Minimum deg C
1.6 Altitude m above SL
1.7 Plant Design Life Years
1.8 Mill Locations Inside Building/Outside
2 PROCESS CHARACTERISTICS
2.1 Ore Type
2.2 Precious metal recovered
2.3 Moisture Content %
2.4 Ore feed Rate to Mill Fresh feed Dry t/h
2.5 Bond Ball Mill Index Nominal kWh/t
2.6 Design kWh/t
2.7 Ore Specific Gravity Tons/m
2.8 F100 Max feed size m
2.9 F80 80% Feed size passing m

All information supplied herein is subject to change without notice. E&OE

2.10 P80 80% Product size passing m
2.11 Level of Corrosivity in Feed ph
2.12 Extraction Process CIL, CIP, CIC, floatation
2.13 Feedsize Analysis Please supply details if
available
2.14 Mill Availablilty % & hrs/day
2.15 Circuit Open/Closed
2.16 Circulating Load %
2.17 Feed Material Temperature deg C
2.18 Ball Charge Max Operating Ball Charge %
2.19 Discharge Arrangement Grate/overflow
3 ELECTRICAL INFORMATION
3.1 Power Supply to Plant Overhead/Generated Power
3.2 Supply Voltage Large Drives V
GrindMill/0512/Rev1

Small Drives V
3.3 Control Voltage V
3.4 Cycles Hz

Head Office:
57 Jansen Road, Elandsfontein

PO Box 8182
Elandsfontein, 1406
www.newconcept.co.za Johannesburg
South Africa
PO Box 9411 Tel: +27 87 353 6791
Edenglen Cell: +27 82 889 8881 Tel: +27 11 820 7600
1613 Fax: +27 86 743 7580 Fax: +27 11 388 1136
www.osborn.co.za
South Africa E-mail: projects@newconcept.co.za E-mail: osborn@osborn.co.za