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Bond, F.C. - Testing and Calculation PDF

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225 views12 pages

Bond, F.C. - Testing and Calculation PDF

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vpgLion
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ate Fo 15, Mion tid encry el (Corte Sorterent ll Ca) (GENERAL ASPECTS OF COMMINUTION 5. TESTING AND CALCULATIONS F.C. Boxe ‘Nature of Empirical Caleutatona ‘The sie reduction of large tonnages of ore and rock it an operation of great magnitude It is a necesary and important pan of industry. Its development has ben motivated by practical need and has fllowel the path f an industrial art without much help from theoreticd ‘Knowledge hasbeen accumulated from experienc. Trial and errr ‘tablished te methods: then collected data wee tabulated and served 1s the basis for empirical equations tht have been continually mode fed and amplifed as new data became avaiable. These equation, ow constitute the halk of our present knowledge of somminution “There isnoacceped scientific theory thal x basic to comminution In lect, mechanical, and civil engineering, as well astm man) othe ida activitis, such theories exist and ae extremely help. ful, bu rock is essentially heterogeneous, andthe zone of wexknes that control its breakage are thoroughly diversified. No theory has Yet been dacovered which cam account forthe vaibilty of rock, }ough many attempts have been made Empirical equations tell aothing of the wy uf » phenomenon, but if they are properly derived they can tell uch about the hew, ‘They always represent only an approximation of behavior but neve! 8 law. Ins proper empiical equation a symbol i assigned foreach ofthe variable quantities that obviously affect the relationship. In ‘nding rll these include mull diameter, il spend, and ford rate ‘mong them. Insetting wp and revising an empirical equation the cardinal princi- ple in establishing and modifying its this any change mat be ste ‘sorbed tothe variable which eaused it. A useful empirical equation is rendered useless when a change in any convenient conficient Of ‘aponent is made to make It 0 a parteular set of dala without certainty that the aliered coeficient ‘or exponent i the responsible ‘arabe in the new data. Such indiscriminate revisions have brought the use of empirical equations into some disrepute When existing equations are changed to socommodate new data {is a ood rule to make a change which gives rele intermediate between the mew and the old A halfway point ie ually 2 good choice, ‘TESTING AND CALCULATIONS. Inetficleney of Comminution Present comminstion proceses are grosly ineficien. Methods of breaking rock are sill fundamentally primitive. They consist of Striking Ganpact), squeezing (compression), and cubbing (abrasion Shear) They al ply deformation forces exceding the yield point fad cause fullure along the crystal faces, the incipient cracks, and the other heerogencous zones of weakness The necasary input of Stress indvoes strain energy ito the deformed rock. When this stress {5 removed by breakage the strain energy is eleased as heat thas ‘been determined that from 95 to 9966 of the requied energy input {ie eteaed in the form of wasted heat, and that only 1 to 3% is ‘lla in the formation of my broken snace are. “The possiblity that tome way may be found to break rock with more reuonableeffclency and with ls heat waste i exciting in the extreme. Such a discovery would make lower grade ores avaiable for treatment, add mach wealth to snake ming much less energy-intensive than it & now. Partlle-Sizo Dotermination Evaluation of site reduction opertions requires measurements of parce se The sizeof the feed, the size of the product and the work inpot quired ofl the desired size reduction of a stated tonnage are needed ‘Screen Analyses, The standard method of measuring particle sizes by sievingdetermining what percentage ofa sample wil pass through an opening of sperfed size. The openings are ordinarily Square since the esting sieves are usually made of wire woven in 2 Sauare weave and crimped inte place by passing between closely ‘Raoed ste roll The width athe opening im micrometers, milline- {ro inches ithe spcited size. Tt is usually designated by the laumber of meshes per linear inch, or, in the large sizes, dimensions ‘ofthe opening in inches “Tetng sieves are eranged in a regular series of openings of de- creasing se, The ratio between the succestve sizes is conveniently Set at V7 atbough for closer work the 4/1 is sometimes used. A ‘dey sample to be screen analyzed is weighed and placed on the top ‘fa sens of rete sieves which is agtated by shaking, The amount Fetsned on ich sive is weighed, together with the amount pasting Chrough the finest seve and Fetained on the nested pan underneath, Tne porcmt wegin peng sd the perent cumulative retained on achieve ste are calculated and sometimes plotted. Often the orginal ‘Gey sample s frst sreened wet through a fine screen, usually 200 ‘mcah, and both fractions dried and weighed before finishing the job by rescreening the 200-mesh portion on the fll set of ry sereens. ‘This procedore avoids eors caused by adhesion of fixer to coarser parle, The seis of standard sive sies is iste in Table 3. The Tyler serie isin common wse. The equivalent ASTM mesh sizes ar i ded. The ASTM teres was designed with a regular sequence of ‘tire diameter seme of which are nt availble commercially. ‘Pie Sie Aaalyues, The units of fie size measurement ar the micron or micrometer, the millimcron, and the Angstrom unit. The ‘Bicren, whiten mu oF fy Hoon, Trnonth m, Vem, and Sgsuc it. A human har is about $0p in diam, “The 200-mesh seve with an opening of 74p is now considered asthe basis ofthe size scale, although 73.8 would be more exact. ‘As manufacturing methods improve fier screens are produced. The Sash seve: hich fe itermeste onthe /2 sale, was formerly | ‘much sed: twas manufactured with atwil weave which permited The warp wires to slide, and was consequently not very accurie. Tes caleiated pasing sie of 4 was often actually SOj or more. However, the newer 325mesh seves have a square weave and are Srocn anciyes are a necessary part ofall comminstion studies In sition tthe information, they supply samples of {he partces ofeach size. These canbe analyzed chemically, examined sat fable 2. Extended Teble of Slove Sizee Opening Wie dam. De asty op te 7200 | we an a0 a6 in, 00 as a mee Be ate T5850 sa bia 13390 st Sie py an 3 a con ins ‘ z tse ist ‘ ‘ aan a 8 8 23a a ° 2 16st ry “ 18 1 ss 2 2 = a 3 = = ms s 2 17 0s 8 » Bs a2 5 0 Et tea 1» 100 ie tos ° no 10 oo 0 2 u wa 20 Zo 2 os = 3 a e &, 0 a we ao % 0 185, a0" 130 io 2s These ar apc ies icroscopically for mineral content and unlocking, and otherwise ‘adie varus ways Bonet to procesing the materia ‘Cllodal clay particles are of the order of 1 to 3p. The visible sze limit of an ordinary eicroscope is smaller than Yip It has teen proposed that the rind limiwhich ithe size imi ofthe finest ‘ee parties produced in grinding be Os. "The milmiron. writen Mut, is Moa of, 10-7 em The unit Iusice in the ental structure of quartz and of ber minerals i ‘Bout 510" om, or about 14 mp. regularities in the series of ‘aynal apace tices along which the Snest ental breakages naturally cur, may be at 100 to 1000 times the ental space lattice unit ‘Syese constitute the actual grind limit ofthe materia. “Kn Angstrom unit, writen A, is Mo my or x10" om it ' weed in the measurement of radiation wave lengths. Visible light fanpa fee 400010 TOODA, co about Vp. This imposes the ws, mit of a microscope. X-rays used for crystallographic data range from 150 10 104. Tnformation regarding the site distribution and the characteristics of the sne factions below the limit ofthe finest sere size available {filways desble and often essential. The range may be extended Jom 70 to as small ar Ip This subject has Been studied intensively, tnd'a numberof methods of fine sle analysis have been developed. Tey fall into two groupe: (1) those which determine particle size ‘Ssanbuton directly and thus continue the see sizing sale into the Sher sine and @) thone which measure the surface areas of 2 sample. ‘The methods developed are Usted Inthe following text ‘sae Analyes of Fines. Haulain infrasier ir eutiation con- tinues the sieve size scale down to 9p and supplies samples ofall tise factions. Andreason pipette™ particles sting from suspension inva quid are withdrawe by 2 pipette, 6lered, dried, and weighed. Feller si analyser provide ai elution of selected sae faction ‘Fhe Scientfe Co sr analyzer is similar to Roller. With asedimen- {ation balance particles stl from a liquid suspension onto a balance sate pn. but the resuts ate not lays consistent, Bouyoucot hydromecr? |: method wed in analyzing sols Sertace Area Determination of Fes, Blsine sir permenbilty* measures rate of air fow through 2 compacted sample. Wajner turbidimetr* measures light passage through particles suspended ina iq Particle Shape. Broken rocks ar highly irregula in shape de ending upon their physical characteristics andthe manner in wich they are broken. Attempts have been made 10 evaluate these stape sierences, bu the results have been more qualitative than quanta. ‘Rock shape can be defined in the following manner: Dimenion 4 isthe longest dimension ofthe rok being considered. Dimenon 2 os the tongs simension at gat angles to. Dimension Cs the longest dimension at right angles to both 4 and B. {t can be considered that dimension B is meatured by pasage through square hole screens, although round hole openings would bbemore exact Dimension 4 can be considered at measured by pasge Uhrough sated openings Aller 4 and B have been measured dine son C canbe calculated from the specifi gravity, dimension A is much larger than A the rock i said te be scicula of needleshaped. fC much smaller than 8 the cost i fat or tabular. When and C approach close 10 B the rock i said to havea cubical breakage: such rock ofers more resistance to size reduction than rock with 4 much larger or with C moch sel than B The effects of average dimensions 4. B, and’C upon the ‘ase of sze reduction canbe estimated qualitatively, but quanitaive ‘messurements are not commercially available Plotiag Size Analyses. The plate size distribution ofa homoge- ‘nec erushed or ground product should theoretically fllow a regia mathematical lw, and plotting the size analyses may hopefully ti ove that law. The falure to date to discover has contibed ‘really fo the lack of ascent bass for comminution. The tnt [Practical approach to such alae was made by A. O. Gates in 19132 He found that, when the percent weight pasting a given size vas, Plotted on the vertical scale against the ste onthe horzootal vale for any set of data that cam be plated in a sraight line A.M. Gaudin in 1926 confirmed a straight-line plot and developed an equation for it R. Schuhmann in 1940 refined this equation ito Y= 10042)" = 100(2 ad» ® where y is the percent weight passing ste x ue represents ihe ‘ize 100% passes if the line were extended straight, and a isthe slope of the line on logog paper ‘The Gates- Gaudin Schuhmann (or GOS) equation is til the et caprestion available fora regular particle size distribution. Howes, i015 not exact, since the lopog plot almet inearahly shows marie GENERAL ASPECTS OF COMMINUTION orien he oe ins with moe han 85 pig (Fig rs te ete lang ae ber deel ithe i advange raph, bonne ha he ans nahoneel a trond ee OOS epg ar “Te Roun Raritan scones and wield when opel w been ek fone ince Sommer tee stan he pan red gah no ae iMter war pled on bt seo ew pao stat nce othe sat eatoon he re ea alee et atest emt Set heoac hog eT osc tc ithe te ase whcre he OOS pt Sah bes epee salen te corer nat as avant For mace oes ‘Sosa om pet sneer mre evry ha he monet Pree! lepiog pt Matheney of hs lt oe rca mpi fhe poate sd it pe Oty meanings bea fhe carter me he ss Calculation of Work Required ‘The practical evaluation of commination operations requires a ‘elation between the work input required and the size reduction ac complished. Unfortunately. there no scepted theoretical explana” ‘on of ths relationship. ‘The relationship tied here was derived _rmpircally it has considerable practical uty. Ii called the The ‘Theory. that of Ritingee™ beng the fst and that of Kick” being ‘the second in chronological order. ts theoretical basis, thatthe work input varies asthe effective erack length produced tn breakage, is ‘eientically qestionabl. The only method of measuring or eatmat- ing the crack length has been to consider it a8 equivalent 10 the square root of the new surface area produced. ‘The basic Third Theory assumptions ar thatthe work input per {on varies inversely a5 the square root ofthe product particle ameter ins the aquare rot ofthe foe prtcle ducer, the efletive dame: {ers being in proportion tothe Sze in microns which 80% passes. ‘This 80% pasting size i easly determined from GOS or other plots ofthe Seren analysis. It fhirly consistent, since the log-log plot and the log probability plot are usualy approximately straight at this ‘oars sie. This sie ig ebviouly far lergr than the meorage pete Siameter, whichis an indeterminate valuc in any case ‘The size in microns which 80% of the fal product passes is

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