ENERGY REQUIREMENT

FOR SIZE REDUCTION

The Bond Third Theory

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References
1. Rowland, C.A. “Selection of Rod Mills, Ball Mills and Regrind
Mills." Edited by Andrew L. Mular, Doug N. Halbe and Derek J.
Barratt. Mineral Processing Plant Design, Practice, and Control.
Englewood: SME, 2001. 710-754.
2. A. Gupta and D.S.Yan, Mineral Processing Design and
Operations-An Introduction, 2016
3. Bond, F. C. "Crushing and Grinding Calculation." British, 1960:
1-14.
4. Rowland, C.A. "Using the Bond work index to measure
operating comminution efficiency." Minerals & Metallurgical
Processing 15, no. 4 (1998): 32-36.

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Energy for Size Reduction - Work Index
 It had been generally observed that in the process of size reduction, as the
size of the particles diminishes the surface area of the particles increases.

 So a measure of size or surface area before and after size reduction would
indicate the extent of energy expended in the comminution process.

 Hence if E was the energy used for a desired size reduction, which resulted
in a change in surface area S, it has been found that
dE =k[SndS] (1)

where k is a constant and a function of the crushing strength of the rock.

n = -2 (Rittenger), n = -1 (Kick), n = -1.5 (Bond)

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Energy for Size Reduction - Work Index
 It has been found that Rittinger's expression, n = - 2 , is more
applicable for coarse size.

 reduction while that of Kick, n = - 1, is more appropriate for

finer size reductions in the region where large surface areas of
particles are exposed as in the case of grinding operations.

 Bond's intermediate value of 1.5 covers almost the entire

range of particles.

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 Energy for Size Reduction - Work Index

 Substituting n = - 1.5 in equation 1 and integrating between feed

particle size, F, and product particle size, P, yields Bond's general
expression for the energy required in size reduction as:

E = 2k(1/P1/2 -1/F1/2) (2)

where k is a constant and a function of ore characteristics.

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The Bond Third Theory
 For size reduction of ore in a CLOSED CIRCUIT
REDUCTION PROCESS, Bond derived the specific
energy for grinding as:
 1 1 
W  10Wi    kWh / t
 P80 F80 

 Where W is the specific power requirement (kWh/t), F80

is 80% passing size of feed in microns, P is 80% passing
size of the product in microns, and Wi is the Bond work
index-a material specific constant. The number 10
indicates 100 m.
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The Bond Ball Mill Standard Test
 Determining Bond’s work index (Bond 1961):
48.95
Wi ,TEST  kWh / t

0.23 0.82  10 10 
A Gbp 
 P F 
 80 80 

Where A = test-sieve size in m, Gbp = net gram product per

mill revolution (g/rev), P80 = 80% passing size of circuit
product, and F80 = 80% passing size of the new feed.

 The Bond work index then defined as the resistance of the

material to crushing and grinding and determined from Bond’s
grindability test or plant operation.
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The Bond Third Theory
 Also suggested the specific grinding energy (W) required
for size reduction in INDUSTRIAL TUMBLING MILLS can
be calculated from mill shaft power (P) and mill capacity
(Q): W=P/Q

 Grinding power determined from work indices works

appropriately in THE RANGE OF ROD MILL AND BALL
GRINDING CONDITIONS, and also for other
conditions by USING BOND’S
CORRECTION/EFFICIENCY FACTORS

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 Relationship between UCS and Bond work
index

Property Soft Medium Hard Very hard

UCS 50-100 100-150 150-250 >250

(MPa)
Bond WI 7-9 9-14 14-20 >20
(kWh/t)

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Perfect/Ideal Conditions For The Bond Work
Index
• From the Bond work index, calculate energy direct as
total energy required from INFINITELY LARGE SIZE to
80% PASSING 100 Microns.
• Rod Mill, wet open circuit grinding in 8-ft (2.44-m) dia mill
• Ball Mill, wet, closed circuit grinding in 8-ft (2.44-m) dia mill.
• Power calculated is at the pinion shaft, which includes mill
bearings and gear pinion losses, but does not include motor
losses or losses in any other drive component, such as
reducers and clutches.
• But as mills got larger and feed changed, there was a need
for “EFFICIENCY FACTORS”.

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Bond Equation w/ efficiency
factors
Bond Equation:

Correction Factors (See Rowland, C.A. “Selection of Rod Mills, Ball Mills and Regrind
Mills." Edited by Andrew L. Mular, Doug N. Halbe and Derek J. Barratt. Mineral
Processing Plant Design, Practice, and Control. Englewood: SME, 2001. 710-754):
 EF1: for dry grinding
 EF2: for open circuit Ball Milling
 EF3: Diameter Efficiency Factor
 EF4: Oversized Feed
 EF5: Fineness of grid
 EF6: high or low ratio of reduction Rod Milling (RM)
 EF7: low ratio of reduction Ball Milling (BM)
 EF8: Rod Milling

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EF3: Diameter Efficiency Factor

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True (Plant) Work Index
 The true plant work index value is estimated by
multiplying the test work index value with the product of
the correction factors:

Wi = Wi(test) x EF1 x EF2 x …. EF7 x EF8

 Factors for condition not applicable should be taken as 1.

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Operating Efficiency
The ratio of the work indices is equal to the ratio of energies
required in the test and the plant mills (Rowland, 1998):
OWi Energy equired at plant mill

Wi Energy at test mill

The specific measured power (W)is determined by dividing

the measured power, P, (kW) mill at pinion shaft with the
circuit throughput/production rate, Q, (t/h). Operating work
index, OWi, (kWh/t) is therefore calculated by:
W  P/Q
OWi 
  1 1 
10   
  P80 F  
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Operating Efficiency

• The ratio of the operating work index (OWi) and the

laboratory work index (Wi) indicates a measure of operating
grinding efficiency in the plant:

OWi
Operating efficiency  x100
Wi

• An efficiency of less than 100 shows that the operation of

circuit is efficient, while an efficiency of higher than 100
indicates the operation of circuit is inefficient.

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Advantages of the Bond Test

 Applied for many conditions to a considerable extent of

accuracy because the correction factors used are
established according to a large industrial database.

 it can differentiate the grindability of varying ores in

design stage and ensure the energy utilization of current
operations.

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Drawbacks of the Bond Test
 The Bond sizing method excluded a number of important
aspects: recycle ratio and classifier efficiency, variations of
residence time distributions with mill geometry and
slurry density, lifter design effect, and changes in flow-rate.

 These aspects could lead to different under or overfilling

of the mill, particularly for grate or peripheral discharge
mills that behave a different way from overflow mills.

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Estimation of the OWi

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Ball Mill Power Estimation

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Quiz

1. Apa yang dimaksud dengan Indeks Kerja (lab.

Work Index, Wi,) dan jelaskan kegunaannya
dalam desain/perancangan sirkuit/prosess kominusi
(grinding circuits).

2. Jelaskan bagaimana cara menghitung

Operating/plant Work Index (OWi). Kemudian,
jelaskan juga bagaimana data ini bersama dengan
data Work Index skala lab. dapat digunakan untuk
menentukan efisiensi proses grinding/kominusi.

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Quiz (lanjutan)
3. Berdasarkan pengujian lab., Bond Ball Mill Work
Index untuk bijih tembaga adalah 19.1 kWh/t. Jika satu
ton bijih tersebut direduksi/dihaluskan dengan
menggunakan ball mill dari ukuran umpannya, F80 = 2.5
mm, hingga dihasilkan produknya, P80 = 120
mikrometer.Tanpa menggunakan faktor koreksi,
hitunglah berapa besar energi yang diperlukan.

4. Sama sperti soal no. 3, akan tetpai Jika diameter bagian

dalam ball mill (inside mill)yang digunakan adalah 4
meter, hitunglah berapa besar energi yang diperlukan.
Gunakan diameter correction/efficiency factor (lihat tabel
diameter efficiency multipliers pada slide berikutnya).

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EF3: Diameter Efficiency Factor

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Homework
a) survey of a SAG-ball mill circuit processing ore from
primary crushing showed size reduction of circuit (SAG)
feed F of approximately 165,000 µm to flotation circuit feed
(cyclone overflow) P80 of 125 µm. The total specific energy
input for the two milling stages was 14.6 kWh/t. Calculate
the operating work index for the circuit.
b) Circuit feed samples taken at the same time were sent for
Bond work index testing. The rod mill test gave RWilab of
14.5 kWh/t and a ball mill work index BWilab of 13.8
kWh/t. Accepting that the rod mill work index applies to
size reduction of the circuit feed down to the rod mill test
product P of 1050 µm and that the ball mill work index
applies from this size to the circuit product size, calculate
the standard Bond energy for the circuit.
c) Calculate the combined Wilab and the relative efficiency,
Wilab:Wio. What do you conclude?
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