Comminution Handbook – Contents
Chapter 1
Comminution – An Overview.............................................................................................................................1
Introduction
Context
Background
Fundamentals of comminution
Breakage mechanisms
Classification mechanisms
Comminution machines
Chapter 2
Mineral Liberation...............................................................................................................................................11
Introduction
Why is liberation necessary?
How does liberation happen?
Measuring liberation
Modelling mineral liberation in comminution processes
Mineral liberation in separation processes
Chapter 3
Particle Measurement Techniques.................................................................................................................25
Introduction
Sampling
Wet/dry sieving
Laser diffraction particle size analysis
Sedimentation (sedigraph) and column settling
Hydrocyclone methods
Particle counting
Surface charge techniques
Photomicroscopy-optical
Electron microscopy
X-ray diffraction
Surface area analysis
Chapter 4
Ore Comminution Measurement Techniques...........................................................................................43
Introduction
Breakage definitions
Bond grindability test
Hardgrove grindability test
Zeisel test
Drop Weight Test
SMC Test®
SPI® test
SAGDesign™ test
Compression test
Bond Work Index values (Bond, 1953)
Split Hopkinson pressure bar test
Chapter 5
Tumbling Mills......................................................................................................................................................61
Introduction
Ball mills for cement
Ball/tube mills for coal
Ball mills for ores
Autogenous/semi-autogenous grinding mills
Rod mills
Rotary breakers for coal
Scrubbers
Grinding balls
Building large tumbling mills
Chapter 6
Compression Machines.....................................................................................................................................79
Introduction
Primary crushers
Conventional cone crushers
High-capacity crushing circuits
Bed breakage crushers
Rolls crushers
Mineral sizers
Roller mills
High-pressure grinding rolls
Vertical roller mills
Horomills
Energy used in different circuits
Chapter 7
High-speed Impact Mills...................................................................................................................................99
Introduction
Vertical shaft impact crushers
Hammer mills
Atrita mills (combined hammer and attrition mills)
Beater wheel mills
Chapter 8
Stirred Mills......................................................................................................................................................... 107
Introduction
Comminution in stirred mills
Vertical stirred mills
Horizontal stirred mills
Hosokawa Alpine fine-grinding mills
Chapter 9
Mill Liners............................................................................................................................................................. 125
The role of liners in tumbling mills
Variations in liners for ore mills
Materials of construction
Potential issues with liners
Types of liners
Designing mill liners
Liners for mill types
Liners in cement mills
Inspections, wear monitoring and ongoing optimisation
Condition monitoring of liners
Relining mills
Chapter 10
Classifiers............................................................................................................................................................. 145
Size separation in comminution processes
Classification
Trommels
Rake and spiral classifiers
Hydrocyclones
Fine screens
Air classifiers
Chapter 11
Comminution Circuits for Ores, Cement and Coal................................................................................ 167
Comminution circuits for ores
Comminution circuits for cement clinker
Comminution for coal preparation plants
Control of coal mills in power stations
Control of comminution circuits in coal preparation plants
Control of comminution circuits in cement plants
Chapter 12
Milling Circuit Calculations............................................................................................................................ 191
Introduction
Classifier calculations – mass balancing and circulating load
Power calculations using Bond grindabilities
Chapter 13
Modelling Comminution Circuits................................................................................................................ 215
Introduction
Perfect mixing ball mill model
Efficiency curve model for classifiers
Fitting example for ball mill – hydrocyclone circuit
Conclusions
Chapter 14
Process Control.................................................................................................................................................. 227
Introduction
Process measurement
Control elements
Transmission
Process control systems and devices
Measurement and control costs – ‘rule of thumb’
Grinding circuit control
Response of the semi-autogenous grinding mill to change in feed rate
Control of a crusher
Role of the metallurgist
Process control techniques and skills
Advanced process control systems
Chapter 15
Case Studies of Control Systems................................................................................................................. 245
Introduction
Grinding circuit control at the Phu Kham mine in Laos
Grinding circuit control at Newmont’s Ahafo gold mine in Ghana
Chapter 16
Circuit Design..................................................................................................................................................... 265
Project definition
Process development and circuit design
Sample selection and test work
Design criteria
Flow sheet options
Comminution energy calculations
Equipment sizing and selection
Plant layout
Glossary...................................................................................................................................................................... 303
Index............................................................................................................................................................................ 309
