Individual Assessment Abantas

Republic of the Philippines
Mindanao State University- Iligan Institute of Technology

COLLEGE OF ENGINEERING & TECHNOLOGY
Department of Materials and Resources Engineering & Technology (DMRET)
Tibanga, 9200 Iligan City, P.O Box No. 5644 tel. Nos. (063) 221-4050 local 4130
Direct line (063) 223-2351 Homepage:http://www.msuiit.edu.ph/coe
1
ASSESSMENT:
1. Calculate the reduction ratio obtained.
2. Differentiate a Blake crusher from a Dodge crusher. What type of crusher was
used for our purposes?
Blake crushers and Dodge crushers are two different types of jaw crushers
that are frequently employed in mining and ore processing. The primary distinction is the
swing jaw position. The swing jaw in a Blake crusher is fixed in the upper part of the
crusher, allowing for a larger feed opening and higher production capacity. This design
enables efficient material crushing while reducing the need for frequent adjustments and
ensuring consistent output. A Dodge crusher, on the other hand, has its swing jaw at the
bottom, allowing for a downward pushing motion that aids in the breaking down of larger
rocks into smaller fragments. This downward force is particularly useful when dealing with
tough and abrasive materials. Understanding this distinction is critical as it affects the
operational characteristics and effectiveness of these crushers in various applications and
making informed decisions when selecting the appropriate type for specific mining
operations.
We decided to use a Blake Crusher as the primary crusher in our laboratory
experiment. This decision was made because the Blake Crusher's movable jaw can swing
because it is hinged at the top. Additionally, we fed our material into the crusher's upper
opening. We made sure that the crushing action mainly took place at the top of the crushing
chamber by using this crusher design. This configuration made it possible to process larger-
sized materials effectively because the larger feed opening allowed for their entry into the
crusher. The Blake Crusher was used, and its top-pivoted movable jaw and top feeding
configuration gave us a strong and adaptable crusher that worked well with a variety of
materials and helped us get repeatable and reliable results in our laboratory experiment.
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3. What are the factors which may affect the size of the product?
The size of the product obtained from laboratory experiments can be influenced by a
number of factors. Among these factors are the following:
• Material Properties: The properties of the material being crushed, such as

hardness, brittleness, and moisture content, can impact the size of the product.
Harder materials may require more energy to break down, resulting in coarser
products, while brittle materials tend to produce finer products.
• Feed Size: The initial size of the material being fed into the crusher can
significantly impact the final product size. Larger feed sizes generally result in
larger product sizes, while smaller feed sizes tend to produce finer products.
• Crusher Type: The type of crusher used in the laboratory experiment,
whether it is a Blake crusher or a Dodge crusher, can also affect the product
size. Each crusher has its own characteristics and operating principles that
influence the final output.
• Crusher Settings: The settings and adjustments of the crusher, such as the
gap or discharge setting, can affect the size of the product. A smaller gap
setting generally leads to a finer product, while a larger gap setting produces
coarser output.
• Crushing Chamber Design: The design of the crushing chamber within the
crusher can influence the product size. Variations in chamber geometry, such
as the shape of the crushing surfaces or the presence of concaves or liners, can
affect the final product characteristics.
• Comminution capacity of the crusher. The comminuting capacity of the
crusher sets the pace for material processing. A greater capacity enables a
larger quantity of material to be crushed within a specific timeframe,
potentially yielding a larger final product size, assuming a constant feed rate.
Contrarily, a lower comminuting capacity can limit the amount of material
processed, potentially resulting in a smaller product size.
3
4. Taggart gives the empirical formula for calculating the capacity of crushers as:
T = 0.6LS
T = tonnage capacity
L = the length of the receiving opening, in.
S = the width of the discharge opening, in.
Calculate the tonnage capacity of the crusher used.
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5
6
ASSESSMENT:
1. What is the importance of determining the work index?
Determining the Bond Work Index is critical in crushing and grinding laboratory
experiments. The Bond Work Index is a critical parameter for evaluating the hardness
and grindability of materials, providing critical insights for equipment selection,
process optimization, and design considerations. Researchers and engineers can
identify the most appropriate equipment and operational parameters to achieve the
desired product size efficiently and economically by knowing the Bond Work Index.
This information enables them to reduce energy consumption, optimize grinding
circuits, and make informed decisions about material handling and processing,
ultimately leading to increased efficiency, lower costs, and increased productivity in
crushing and grinding operations.
2. What is circulating load? What is the usual range of circulating load in closed
circuit grinding?
The circulating load is the amount of material that recirculates within a closed
grinding circuit. It denotes the portion of the ground material that escapes the classifier and
returns to the grinding mill for further processing. The determination of circulating load is
critical in grinding experiments as it aids in evaluating the efficiency and performance of the
circuit. A high circulating load indicates suboptimal grinding conditions, such as potential
overgrinding or inefficient classification, which can result in excessive energy consumption
and reduced throughput. A low circulating load, on the other hand, indicates a well-balanced
and optimized grinding circuit, resulting in increased energy efficiency and product fineness.
The typical range of circulating load in closed circuit grinding laboratory
experiments can vary depending on the specific characteristics of the grinding system and
the desired product specifications. However, in closed circuit grinding, the typical range for
circulating load is between 200% and 400%. This means that the amount of material
circulating in the grinding circuit is two to four times the amount of fresh feed. The
circulating load indicates the balance between the amount of material fed into the mill and
the amount discharged. A higher circulating load within this range indicates more material
recirculation, which could indicate a more efficient grinding process with better
classification and less overgrinding.
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3. What are the advantages and disadvantages of increasing the circulating load in
closed circuit grinding?
Increasing the circulating load in closed circuit grinding offers advantages

and disadvantages. On the positive side, it enhances grinding efficiency by Increasing
the circulating load can lead to improved grinding efficiency. It helps maintain a
higher material load within the grinding mill, promoting more effective grinding
action and reducing the chance of underutilization of the mill capacity. This can
result in finer particle size reduction, improved product quality, and increased
throughput. It also allows for better control over the particle size distribution,
allowing for improved classification of particles, ensuring that only properly ground
particles are discharged while larger or coarser particles are recirculated for further
grinding. This can lead to a narrower and more consistent particle size distribution in
the final product.
However, there are also drawbacks to consider. One such disadvantage

is the increased energy consumption associated with a higher circulating load. The
additional mass of material being recirculated requires more power for grinding,
resulting in higher operational costs and reduced energy efficiency. Additionally,
there is a risk of overgrinding when the circulating load becomes excessively high.
This can lead to the production of excessive fines, negatively impacting product
quality, increasing energy consumption, and potentially causing difficulties in
downstream processes.
To optimize the grinding process, it is crucial to carefully evaluate the

trade-offs between grinding efficiency, particle size control, and energy consumption.
By striking the right balance and optimizing the circulating load based on specific
process requirements and objectives, the overall performance of the grinding circuit
can be maximized.
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4. Explain how the rod mill grindability test is performed?
The rod mill grindability test is used in laboratories to determine the resistance of
ore or other materials to grinding. Obtaining a representative sample of the material
to be tested is the initial phase in the test. This sample is then finely ground before
being tested. In the laboratory, a rod mill, a cylindrical device that uses steel rods as
grinding media, is set up. The sample is loaded into the mill along with a specific
amount of water, and the mill is rotated for a set amount of time. The grinding action
of the rods breaks down the sample, which is then collected for further analysis.
The amount of material that passes through a specific size sieve determines the
grindability of the material. This test evaluates the grinding process's efficiency and
provides useful information for designing and optimizing grinding circuits in
industrial applications.
5. Can you determine the grindability index using wet grinding? Why?
No, wet grinding is not usually used to determine the grindability index, such as the
Bond Work Index. A test's accuracy and dependability may be impacted by wet grinding,
which involves the use of water or another liquid during the grinding process. When
compared to dry grinding, the water acts as a lubricant, reducing the efficiency of the
grinding process and resulting in different particle size distributions. Additionally, it may
result in modifications to the properties of the material, making it challenging to establish a
consistent grindability index. In order to determine the grindability index in laboratory tests
and industrial applications, dry grinding techniques are frequently used.
10
6. Calculate the Work Index of the ore by using the following formula:
4.45
W = ───────────────
Pi0.22 G 0.82 ( 1/ P1/2 – 1/ F1/2)
W is the work index, Pi the MOG in microns, G the grindability in gms / rev, P the
product size and the F the feed size in microns, both at 80% passing size.
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11
COLLEGE OF ENGINEERING& TECHNOLOGY
ASSESSMENT:
1. Discuss the nature of the grinding action taking place inside the ball mill.
The grinding action inside a ball mill is a dynamic and complex

process that involves multiple mechanisms. As the mill rotates, the grinding media,
typically steel balls, are lifted and then cascade down, colliding with the ore or other
materials present. This grinding action can be described as a series of steps: the
impact of the grinding media on the particles initiates size reduction by causing
deformation, fracture, and breakage. The continuous impacts lead to further crushing
and abrasion of the material, resulting in the production of smaller fragments.
Additionally, shear forces and attrition occur as the particles slide, rub, and wear
against each other and the grinding media and mill liners. The movement of the
grinding media can be characterized as cascading or cataracting, where in cascading,
the media roll or slide, while in cataracting, they are lifted and thrown into the air,
generating more intense impacts. It also involves a combination of impact,
compression, and attrition forces, all of which contribute to particle size reduction.
As the grinding media cascade through the mill, they collide with the ore particles,
causing stress and fracture and reducing particle size. Furthermore, compression
occurs when grinding media and particles are subjected to high pressure regions, such
as between two balls or the medial and mill's walls. The pressure from the
compression causes the particle to deform and break, thereby reducing its size.
Understanding these grinding mechanisms, along with factors like
mill speed, grinding media size and quantity, feed rate, and material properties, is
crucial for optimizing the grinding process and achieving the desired particle size
distribution in various industrial applications.
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2. Differentiate a ball mill from a rod mil in terms of not only the physico-
mechanical properties but also on energy consumption, grinding action, operating
details, etc.
Ball mills and rod mills are common types of grinding machinery used in ore
grinding and mineral processing operations. Despite their similarities, they differ
significantly in terms of their physical and mechanical characteristics, consumption,
grinding action, operating specifics, and other factors.
Ball mills have a cylindrical shell that contains spherical grinding media, such as
steel balls, in regard to physico-mechanical properties. Rod mills, on the other hand, have a
cylindrical shell with round steel rods as the grinding media. Furthermore, ball mills have a
larger diameter than rod mills, which results in higher capacity and more efficient grinding.
Rod mills are better suited for grinding long materials due to their higher length-to-diameter
ratio.
In terms of consumption and efficiency, rod mills use less energy than ball mills to
perform the same grinding task. This is because rod mills' lower specific energy
consumption is caused by the grinding media's larger surface area. Additionally, rod mills
are thought to be more effective at reducing particle size to the desired level. Less
overgrinding and finer particle sizes are produced as a result of line contact between the rods
and the ore particles during the grinding action in rod mills.
Moreover, Both rod mills and ball mills have different operating specifications. In
order to facilitate efficient grinding and guarantee adequate impact forces, ball mills are
typically run at higher speeds. The material is introduced at one end, and the ground product
is discharged at the other, using controlled feed and discharge systems. As opposed to this,
rod mills have a continuous feed and discharge system where material is fed through a
hollow shaft and the ground product is continuously discharged.
Ball mills are frequently used for fine grinding and can be used in both wet and dry
environments, making them adaptable. On the other hand, rod mills are typically used for
coarse grinding and are better suited for wet grinding operations.
It is essential to comprehend these distinctions between ball mills and rod mills in
order to choose the best grinding machinery, optimize the grinding procedure, and achieve
the desired particle size distribution in a variety of mineral processing applications.
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3. Predict the nature of the product when the balls are used as grinding media for a
rod mill. Explain your prediction.
The nature of the product is anticipated to have specific properties when balls
are used as the grinding media in a rod mill. First off, compared to the impact and crushing
action of balls in a ball mill, a rod mill using balls as media grinds materials relatively more
gently. It is believed that the rolling and sliding motion of the balls along the length of the
rod mill is what causes this mild grinding action. The product produced by a rod mill using
balls as the grinding media will therefore probably have a finer particle size distribution.
In a rod mill, the balls' rolling and sliding motion encourages a more
controlled and gentle grinding environment. As a result, there is less ore particle breakage
and less fines production. In comparison to a ball mill, the product is anticipated to have a
narrower size distribution and a higher proportion of larger-sized particles. The balls'
rounded shape also helps to increase the effectiveness of the grinding action by reducing the
likelihood of overgrinding and ensuring a controlled particle size reduction procedure.
Furthermore, the liberation of valuable minerals from the ore can be
improved by using balls as grinding media in a rod mill. Reduced impact forces and a
gentler grinding action preserve the integrity of the mineral particles by limiting excessive
breaking and the production of fine particles. This improved liberation can be particularly
advantageous in applications involving mineral processing where the recovery of valuable
minerals is a key goal.
Thus, it is anticipated that when balls are used as grinding media in a rod
mill, the finished product will have a finer particle size distribution, a greater proportion of
larger-sized particles, and better mineral liberation. It is crucial to remember that the precise
product characteristics depend on a number of variables, including the ore properties, the
size and makeup of the balls, and the rod mill's operational circumstances.
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Republic of the Philippines

Mindanao State University- Iligan Institute of Technology

1. Calculate the reduction ratio obtained.

• Material Properties: The properties of the material being crushed, such as

Calculate the tonnage capacity of the crusher used.

1. What is the importance of determining the work index?

Increasing the circulating load in closed circuit grinding offers advantages

However, there are also drawbacks to consider. One such disadvantage

To optimize the grinding process, it is crucial to carefully evaluate the

4. Explain how the rod mill grindability test is performed?

The grinding action inside a ball mill is a dynamic and complex

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