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By J. P. Gous, M. Tangstad, J. D. Steenkamp

In April of 2013 a 48 MVA submerged arc furnace producing silicomanganese was excavated in South Africa. One of the areas excavated systematically was the furnace taphole. The aim was to obtain a refractory wear profile of the tap-hole area, together with affected hearth and sidewall refractory. Subsequently, thermodynamic modelling was applied to quantify the potential for chemical reaction between refractory and slag and refractory and metal in the tap-hole area.

Jan 1, 2014

By P. L. Ngwenyama, I. Maubane

Soundless chemical demolition agents (SCDAs) are proving to be the future of sustainable and environmental-friendly mining. These expansive chemicals become critical when there is a need to break rock close to communities, environmentally sensitive areas, and critical structures and infrastructure. Unlike explosives, the SCDAs do not generate air-blast, ground vibrations, flyrock, noise, dust, and noxious fumes, which can negatively affect the environment, surrounding communities, sensitive areas, and critical structures and infrastructure. Over the years, several types of SCDA products have been used successfully in the civil and construction industries for the demolition of old and dilapidated buildings near vibrations and environmentally sensitive areas. They have also been used to fragment boulders in the mining and construction industries. However, to date, no study has investigated the applications of soundless chemical demolition on a large-scale in opencast mines. Therefore, this study evaluated whether soundless chemical demolition can break large volumes of in situ rock. This was done by conducting five trials using Nex-Pand soundless chemical demolition agents in four different surface mining sites. Trial 1 was unsuccessful as it was unable to break the rock due to the large confinement between the drilled holes and the use of a hole diameter that was 182% larger than recommended. Trial 2 was a success as it was able to fracture the rock with a crack width that reached 110 mm after 72 hours. Trial 3 generated cracks at the biggest hole diameter of 102 mm. The cracks developed and ceased to increase after 96 hours at a crack width of 100 mm. Trial 4 achieved the smallest crack width due to a very competent rock compared to the other sites. Trial 5 generated cracks at a slower rate than other trials because of the use of Nex-Pand powder at lower ambient temperatures than recommended. These trials proved that soundless chemical demolition agents can replace explosives in areas closer to sensitive infrastructure and communities. This will ultimately enable mines to unlock value and access deposits in these areas.

Jul 23, 2025

By V. Yahorava

Efficient recovery of precious metals from process solutions is essential for improving process economics. Traditionally, precious metals are relatively effectively recovered from waste streams via precipitation or cementation. However, these approaches have a number of drawbacks, including poor water balance, creation of environmentally unfriendly waste streams, and losses of precious metals. Ion exchange technology is an alternative for the recovery of precious metals from waste or low-grade streams. This technology allows the recovery of the precious metals to extremely low levels (micrograms per litre) with relatively high upgrade ratios from the solution onto the resin without major water balance concerns, while the impact on the environment could be minimized or avoided. Research was conducted on the recovery of platinum group metals and gold from different low-grade and waste streams from one of the precious metals refineries in South Africa by means of ion exchange. Various functionalities and matrices (granular and fibrous) of ion exchange materials were evaluated. The results from these studies indicated that in some cases ion exchange could be very effective for the recovery of precious metals, and that the PGM concentration could be reduced to < 1 mg/L. The upgrading ratios of the various PGMs onto the specific fibres were relatively high for the specific streams evaluated, which might in some cases justify incineration of the loaded material instead of stripping and recycling the adsorbent. The cost of direct incineration for one of the waste streams tested would be less than 1% of the value of the PGMs recovered. However, the adsorbent has to be carefully selected and the process design optimized for each specific stream.

Jan 1, 2014

By C. Banff, E. C. F. Hamman, J. Venter

Open pit slope stability analyses for large scale instabilities are often carried out using limit equilibrium, finite element or finite difference computer programs. All of these require empirical estimates of rock mass shear strength when calibrated values are not available, which is a common occurrence. A common method of estimating rock mass shear strength is the Hoek-Brown failure criterion, which often over- or underestimates rock mass shear strength when used in limit equilibrium or elastic linearly plastic slope stability analyses, resulting in published alternative estimates for the coefficients of the Hoek-Brown failure criterion. This paper investigates the differences between limit equilibrium and elastic linearly plastic slope stability analysis based on the Hoek-Brown failure criterion. The investigation consisted of a comparison of 3840 RS2 finite element analysis models completed with strain softening, and 216 Slide2 limit equilibrium models. The models were used to evaluate a methodology to determine equivalent limit equilibrium and elastic linearly plastic shear strength parameters that provide the same stable slope angles and instability back break distances as the more representative strain softening stress analysis methods. This paper presents the methodology and compiles the results into design charts and equations for equivalent limit equilibrium Mohr-Coulomb shear strength parameters, that simplify calibration against actual case studies. The results compare well with older empirical shear strength estimates, however, a detailed calibration of the results against case studies will need to be carried out. The analysis also did not consider pore pressure effects; this is left for future publication.

Sep 1, 2025

By R. H. Matjie, J. R. Bunt, A. C. Collins, J. C. van Dyk, C. A. Strydom

South African discard coal fines and K₂CO₃ blends were heated in a laboratory-scale rotary kiln to produce ashes for H₂SO₄ leaching tests. The optimized H₂SO₄ leaching conditions of 6.12 mol.dm³ (M) H₂SO₄, solid to liquid ratios 1:5 and 1:10, and 80°C for 8 hours were used. K₂CO₃ was added to increase the dissolution efficiency of K. The objective was to determine if the Al present in metakaolinite (Al₂O₃.2SiO₂), the Al, K, and Ti in the alumino-silicate glasses, and the Ti in rutile (TiO₂) in the ashes could be selectively dissolved in H₂SO₄. XRF results show that the ashes formed at 700°C dissolved more efficiently (87% Al, 89% K and 23% Ti) compared to the ashes formed at 1050°C. This can be attributed to the presence of Al₂O₃.2SiO₂, K₂CO₃ melt, K₂CO₃ remnants, KAl(SO₄)₂, and K-aluminosilicate glass in these ashes. XRD results indicate that the ashes prepared at 1050°C contained anorthite (CaAl₂Si₂O₈), microcline (KAlSi₃O₈), pseudomullite (Al₂O₃.SiO₂), and silicon spinel (2Al₂O₃.3SiO₂), which are either insoluble or only sparingly soluble in H₂SO₄. These minerals resulted in the lower dissolution efficiencies of Al and K. Based on the high dissolution efficiencies of Al and K for the ashes produced at 700°C, coal fines blended with K₂CO₃ could possibly be utilized as feedstocks for the production of aluminium(III), potassium(I), and titanium(IV) and a sulphate-containing leach liquor. Furthermore, the environmental issues and costs associated with the handling and disposal of large volumes of coal fines will also be resolved.

Aug 2, 2022

By A. Çelik

Wheel loaders are widely used in many sectors due to their mobility, operational flexibility, and low costs. The literature is mainly focused on improving the hydraulic, mechanical, and electronic subsystems of these machines in terms of efficiency or developing strategies for controlling these systems. In this study, the effects of the loader operator and different working conditions on the loading performance were investigated. The study was carried out at the Can Lignite Enterprise (CLI), which is a major coal producer in Turkey. In the study, which lasted approximately four months, a total of 808 measurements were performed to investigate seven different scenarios. The effect of a single parameter on loading performance was investigated in the first six scenarios. The results showed that the biggest impact on loading performance was caused by the operator's experience with 63.4%. On the other hand, the worst and most ideal working conditions determined from the first six scenarios were tested in the seventh scenario. It was tested as a script. The test results showed that the loading performance was 285.5% more effective under the most ideal operating conditions compared to the worst operating conditions. In addition, in the study, the loading performances of five loaders with four different capacities were examined in terms of energy efficiency and it was determined that the Kawasaki 115 work machine, which has a higher model and lower engine operating hours, was more advantageous. In the study, various suggestions were developed in parallel with the research results. The most prominent and easiest to implement of these suggestions is related to the selection of the loader operator.

Nov 27, 2024

By K. Sasaki, S. Kuroiwa, H. Miki, Y. Aoki, T. Hirajima, Y. Orii, G. P. W. Suyantara

Selective flotation to separate copper minerals from, for example, Mo- and/or As-bearing minerals is a continuing problem because the selectivity of current systems is imperfect. Selective Cu-As flotation is currently difficult, and the most common Cu-Mo selective flotation method uses NaHS; this must be done in an enclosed system because, under acidic conditions, this method produces hydrogen sulfide. In this paper, some novel alternative flotation processes that use redox reactions are discussed; these methods have a much lower environmental impact. Oxidation and reduction reactions can be used to make copper minerals more hydrophilic and Mo-bearing minerals more hydrophobic. X-ray photoelectron spectroscopy (XPS) analyses indicated that the copper minerals became hydrophilic because hydrophilic iron precipitated and several hydroxides covered the copper minerals’ surfaces, whereas the molybdenum minerals remained hydrophobic because their sulfide surfaces were not covered. Flotation experiments on these minerals after redox treatments indicated that excellent separation of Cu-minerals from Mo-minerals can be achieved. Possible mechanisms for this separation were investigated using detailed surface analyses and thermodynamic calculations. The additives used to initiate the redox reactions are easy to handle and make these new flotation procedures better than current processes because the new methods do not emit effluent gas and because they are commercially viable. Keywords: Flotation; chalcopyrite; molybdenite; oxidation; reduction

Jan 1, 2020

By D. Yu Pleev, V. G. Krivolapov

Mines of Southern Kuzbass working out, basically, coal formations of flat seams. Seams, as a rule, are inclined to self-ignition. Detection at early stages of the centers of endogenous underground fires has great value for safe conducting mountain works. One of methods of detection of an early stage of underground fires in the worked out space is the method of superficial radon survey. In the report the method is de-scribed and examples of superficial radon survey on concrete layers are given.

Jan 1, 2003

By U. König, N. Norberg

Ore mineralogy defines the properties during processing and metal extraction. Fast and frequent monitoring of the mineral content and related process parameters brings value to the mining operation and material processing. Decreasing ore qualities and increasing prices for raw materials require a better control of processed ore and a more efficient use of energy. Traditionally quality control in mining industries has relied on time consuming wet chemistry or the analysis of the elemental composition. The mineralogy that defines the physical properties is often monitored infrequently, if at all. The use of highspeed detectors has turned X-ray diffraction (XRD) into an important tool for fast and accurate process control. XRD data and their interpretation make the difference in the identification of minerals, in describing their distribution in ore bodies and in their beneficiation during processing. The use of statistical techniques such as Partial Least-Squares Regression (PLSR) or Principal Component Analysis (PCA) on XRD raw data has been successfully trialled to determine raw materials and processed ores, in addition to well established methods for mineral identification and quantification. PLSR can be used to correlate process parameters directly from the XRD pattern without investigating the mineral content. Hidden information present in the XRD pattern but not determined with traditional methods can be used to improve the characterisation of the analysed materials. The practical use for the direct determination of process relevant parameters during exploration and ore beneficiation will be illustrated in several case studies from mining and ore processing. Keywords: Geometallurgy, mineral monitoring, X-ray diffraction, process efficiency

Jan 1, 2020

By H. C. Voges

The concentration of cassiterite at Iscor&apos;s Uis Mine is described, and information is given on aspects of the concentration of iron ore at Thabazimbi and Sishen Mines. At Uis, a very Iow-grade tin ore is concentrated by three-stage jigging, spiral concentration, and tabling to give a high-grade concentrate with a recovery of 80 per cent of the tin. A Iow-grade tantalite-columbite concentrate is also produced. The possibility of recovering mica, the use of sluice boxes instead of spirals, and the recovery of cassiterite from minus 45 µm material are being investigated. At the two iron-ore mines, heavy-medium separation is applied to size fractions larger than 0,5 mm. The types of ferrosilicon and the circuits used for the recovery of ferrosilicon from the various dilute-medium circuits are described. The spiral-concentration plant being installed at Thabazimbi for the treatment of the minus 0,5 mm portion of the ore is described.

Jan 1, 1982

By E. P. Preis, R. C. W. Webber-Youngman

The real cost of any mining incident has, empirically, proven to be estimation-driven, rather than factdriven. One of the main reasons for this lies with the complexity of the cost composition of any given mining incident. Incident costs comprise both direct and indirect cost factors, and in many cases the costs associated with these factors are incurred during different time periods following the incident. In this paper we aim to identify the various cost factors arising from mining incidents, provide a thorough understanding of all the potential cost factors identified, and draw general conclusions on the knowledge obtained. Furthermore, recommendations are made on how mining companies could use the results, in order to assist them in calculating the costs of mining incidents. The paper also provides suggestions for further research, with the emphasis on the most significant immeasurable cost factors, namely the costs of implementing job accommodations following an incident, the harm to company reputation, and the decreased productivity due to low worker morale/psychological factors following an incident. If mining companies are aware of and understand which factors could contribute to the cost of any given incident, future planning and incident cost estimations could be easier. It should, however, be noted that although this study provides a comprehensive list of cost factors (and detailed explanations), other unknown cost factors relating to mine incidents could prevail in extreme cases.

Jan 1, 2021

By G. Coetzer

"Prior to operating a non-recovery coke pilot plant, it was critical to ascertain coal cake stability during the loading of a 1 m3 coal cake into the oven. Various compaction parameters were verified and established on a small laboratory-scale compaction machine to obtain a coal cake of acceptable stability. These parameters include cake density, cake surface moisture, transverse strength (force applied perpendicular to the original compacted coal cake layers), and applied force to the coal cake. This work determined the behavioural characteristics of the coal while being compacted either with a full-sized or a 1/3-sized compaction plate in a 9 kg capacity mould. Two different coals were evaluated, namely Waterberg semi-soft coking coal (sscc) and Oaky North hard coking coal.The target wet cake density of 1 100 kg/m3 (79% of 1 400 kg/m3 relative density) was achieved for Waterberg sscc, with a particle size d50 varying between 0.6 mm and 1 mm, utilizing the 1/3-sized compaction plate in the laboratory-scale set-up, with 11.6% surface moisture and 92.2 t/m2 commercial equivalent applied force. For Oaky North hard coking coal, a wet cake density of 1 189 kg/m3 (85% of 1 400 kg/m3 relative density) was achieved at a surface moisture content of 12.3% and at a lower applied force than that for Waterberg sscc, i.e. 78.5 t/m2.Coal cakes of acceptable strength, and therefore sufficient stability for further processing, were obtained for all materials evaluated during this study.Further studies should be conducted to determine the effect of zeta potential during the compaction of coals.IntroductionExxaro Resources has successfully installed and commissioned a world-class stamp-charging horizontal 1 t electrically-heated pilot-scale coke oven at its Metallurgy Services facility. Prior to operating the coke non-recovery pilot plant, it is essential to ascertain coal cake stability during the loading of a 1 m3 coal cake into the oven. The design of Exxaro’s pilot plant is such that the coal cake is pushed inside the oven by means of a pusher plate, rather than through a ‘spoon’ feed mechanism, such as is found in industrial horizontal coke ovens. The pusher plate loading mechanism dictates that the coal cake should possess high stability and inherent strength during loading into the oven, owing to frictional forces exerted by the oven floor. In order to obtain a coal cake of acceptable stability, various compaction parameters needed to be verified and established on a small laboratory-scale compaction machine."

Apr 1, 2019

By B. Genc, V. J. Mahadeo, S. Ramparsad4, U. Govender

The study was intent on assessing the socio-economic impact of a zinc mine in South Africa through the application of people-centric digital tools using a case study research methodology. The global mining industry is undergoing significant technological shifts to modernize, improve operational sustainability, and align with the environmental, social, and governance (ESG) agenda. While the case study mine is a more modernized mine, continuous improvement around the ‘social’ pillar becomes critical, and to this end application of people-centered digital tools presented as the vehicle to understand community needs and impacts. Despite considerable annual corporate social investment by mines annually, the overall impact or social return on investment is marginally understood. Towards contributing to addressing this gap, digital ESG ‘social-related’ data gathering tools for mines decision-making were developed, including the training-needs assessment tool, community-social needs assessment, small, micro, and medium enterprise (SMME) communications and engagement tool, digital leadership competencies gap assessment tool, and change management blueprint, which further allowed for customization to the mining context. Hence, the novelty of this paper relates to applying digital tools to provide real-time information of the needs of a community, both socially and economically. The findings suggested that these digital tools enabled gathering of information for the establishment of regional and operational baselines towards enabling of social investment returns in relation to socio-economic transformation development interventions. These tools have been applied to a zinc mine context, with lessons and experiences obtained through this study, invaluable to the application of these digital tool in other mines in South Africa. The study was conducted in September 2023 across five host communities, surrounding the zinc mine, in the Northern Cape region, with 120 participants involved in the application of three relevant community-related digital tools, which included the training needs, community-social needs, and SMME communications and engagement tools. It was evident that the digital ESG tools could be used for data gathering for the mine’s informed decision-making and allowed for securing of insights on community needs in near real-time, and further proved practical for community use.

Dec 11, 2024

By B. P. Watson, D. Hoffmann, D. P. Roberts

Potholes on the Merensky and UG2 reefs in the Bushveld Complex occur as near-circular to elliptical depressions or slumps on the reef horizon, normally presenting as severe disruptions which prevent economic extraction. Within the pothole, the reef and other strata may either be attenuated, absent, or highly deformed, this being the result of the overlying hangingwall strata having slumped down. The hypotheses for pothole formation involve several mechanisms, including downward erosion, upward fluid movement, or synmagmatic deformation. When potholes are exposed in mine workings, significant fracturing is often observed. This fracturing is particularly evident in anorthosite rock types. Stress measurements were conducted in a pothole on the Merensky Reef to determine if the fracturing was due to high stress conditions. The paper describes the measurement results and numerical modelling that was done to determine the influence of depth and mining on the stress condition at the site. The results show that high stresses do exist in at least some potholes, and that current formation theories do not adequately explain the measured stresses. In support of understanding the high local stress associated with the pothole, the study explored several rock engineering modelling processes to validate the conditions of the study site and enclosing excavations. A better understanding of the stress conditions in potholes with additional data could lead to more appropriate support design and avoidance of potential rockbursts in these structures.

Jan 1, 2021

By W. K. Brinsden

In August 1965, the late Mr Alan Smith, then Mill Superintendent at Gold Mines of Kalgoorlie (GMK), Australia, asked me to investigate the planting of vegetation on the GMK slimes dams in order to ease the dust problem in urban and industrial areas-a problem that is caused largely by dust from these barren slimes dams. My early sources of information were the comprehensive papers in various issues of the Journal of The South African Institute of Mining and Metallurgy. However, the climate of Johannesburg differs from that of Kalgoorlie. The average Johannesburg rainfall, which falls mostly in summer, is 730 mm, and the average maximum summer temperature is 26°C (top 34°C). The winters are cool, the average maximum being 18°C (low -7°C). Kalgoorlie, on the other hand, receives, on average, 257 mm of sporadic rainfall, has hot dry summers with an average maximum of 35°C (top 45°C), and cool winters with an average maximum of 18°C (low -2°C). My obvious choice was to look at established trees growing on the GMK lease. A number of Athel pines were growing vigorously adjacent to the Oroya mining and geology offices and also on a nearby sand dump. The Athel pine (Tamarix aphylla), which is native to North Africa, Asia, and India, was originally introduced into Australia in 1936 by Mr Essington Lewis, then manager of BHP. His cuttings were planted in Whyalla, where some difficulty had been experienced in finding trees and shrubs that would flourish despite the district&apos;s low rainfall. In August 1965, cuttings of approximately 20 cm length and 1 cm diameter were taken from the GMK trees, stripped of leaves, and placed in jars of water in the sun. When the cuttings had sprouted both leaves and roots, they were planted in local soil in tins (about 20 cm high and 10 cm in diameter), and watered daily. In October 1965, when the new shoots were about 8 cm long, the trees were transplanted onto a lower flat section¬approximately 30 m wide, 30 m long, and 2 m high-of the Trafalgar slimes dam. No additional soil or fertilizer was used, and the trees were planted in their tins, the bases of which had been removed (the tin would eventually rust away). A few common varieties of non-prickly cactus and two native salt bush (spp Atriplex) were also planted, but did not survive, probably because of the acidity of the slime. During the summer of 1965/1966, Kalgoorlie&apos;s rainfall was 88 per cent above the average, and this probably helped the trees to survive. The moisture content was usually about 2,5 per cent from about 10 cm below the surface, and the pH value of the slime (d80 approximately 75 µm) was about 6. The trees were watered twice a week for the first four months and then left untended. By 1974 they had grown to only about 0,7 m, which indicated that their growth in slime was very slow. Other Athel pines were planted on the wall of the dam, but did not survive beyond 1974, probably because of the steep (about 500) slope and the hardness of the walls, which were initially formed by hand-shovelling of the slime as the height of the dam was raised. Five of the six Athel pines planted in 1965, which probably reached maturity (approximately 5 m in height) in 1981-16 years after being planted-have survived. In the early 1980s, waste rock had to be dumped on the dam, but the management of KMA (now KCGM) took care to ensure that the trees were not buried. Trials are being conducted on other tailings dams so that the performance of cuttings taken from the trees on Trafalgar dam can be compared with that of cuttings taken at various sites in Western Australia. It might also be worth while for an attempt to be made to strike cuttings from Trafalgar dam in pots containing different mixtures of soil and slime.

Jan 1, 1991

By A. Modi, C. Li, R. Kabwit, W. Y. Xinchao, R. Joshi

The KIMIN copper project can treat 1.7 million dry t/a copper-cobalt ore. It has three mills in operation, two using conventional milling in water and the third in raffinate. We introduce the project process circuit and the capital and operating costs of using the raffinate process compared with conventional milling in water. There is a capital saving of approximately 11.5% for major equipment by removing the pre-leach thickener. In addition, it also achieves an annual operating cost saving of USD 2.1 million due to an increase in 49% of acidic raffinate recycled and reduction in lime consumption. The features of CITIC’s new duplex stainless-steel ball mill ,as the key equipment of the system, are also introduced

Jan 1, 2023

By P H. Ferreira

The mechanisation of mine development is becoming increasingly important in our South African and Southern African mines with increased emphasis on safe and efficient mining. Raise, blind and shaft boring offer mechanised solutions for excavations such as:- [reef raises stope boxholes and shaft ore passes ventilation passes and shafts chairlifts large vertical hoisting shafts (in excess of 1200 metres in depth) angled hoisting shafts (from small to large diameter bored holes)] These techniques will be discussed with reference to relevant applications and the author?s comparison between conventional drill and blast techniques.

Jan 1, 2005

By T. Uysal

The increasing demand for rare earth elements (REE) in highly strategic sectors such as hybrid electric vehicles, renewable energy, communication technologies, and the defense industry has made REE production methods important. In recent years, studies on REE have increased rapidly; however there are many studies on REE, there are not enough studies in the literature on the economics of the beneficiation process. RE ores are generally leached after beneficiation by gravity, magnetic and flotation methods. In this study, direct leaching, attrition scrubbing and leaching, and flotation and leaching methods are evaluated economically based on the data for the Mountain Pass (MP) facility. According to the sensitivity analysis performed as a function of capital cost (CAPEX), operating cost (OPEX), and rare earths oxides (REO) recovery, REO recovery has the biggest effect on the process economies. Although the flotation method entails additional investment and operating costs, transportation and operating costs are significantly reduced result of the higher grade and recovery. The flotation method is more profitable, with larger NPV and IRR values and a shorter payback period.

Jul 2, 2022

By V. A. Myazin, M. V. Korneykova, A. V. Svetlov, V. G. Minenko, D. V. Makarov, A. L. Samusev

The paper discusses the treatment problem of mine (waste) water for enterprises of the Russian Arctic. The wide range of relevant pollutants, financial resources, the availability of land for the construction of a treatment plant, waste generated during the treatment process are some of the factors controlling current and future process design solutions. All mining operations have adopted water treatment and water quality monitoring solutions, however there is no single approach to the problem and each industry participant operates within the scope of its available resources. The range of existing and emerging methods is extensive — from using constructed wetlands for the deposition of mineral nitrogen compounds in settling ponds, reagent deposition and chemical coagulation in exhausted mine workings, and filtering dams on the surface to retrofitting existing mine drainage treatment plants with the adoption of the electrochemical coagulation process. Methods of wastewater treatment from heavy metals, oil products, and nitrogen compounds are demonstrated in the example of two industrial facilities in the Murmansk region. It was found that the use of electrochemical coagulation provides effective treatment of mine water from NO3, NO2, Ni, Fetotal and petroleum hydrocarbons (the degree of purification from 50.5-99.7%), the use of phytotreatment system provides wastewater treatment from ammonium ions and nitrite ions by 53-84%, nitrate ions - by 22%. Keywords: Industrial water treatment, treatment flowcharts, settling ponds, constructed wetlands, reagent sedimentation, chemical coagulation, electrochemical coagulation

Jan 1, 2020

By R. V. Peche

Since 1952, Bond’s equation has been used as a standard to predict the specific energy of grinding for a given duty. The Bond’s equation considers that the exponent is constant for all conditions. Hukki, in 1961, pointed out that the exponent is a function of the particle size, and concluded that the Bond’s equation applies successfully for an intermediate range of sizes; out of this range the Bond’s equation leads to high error as demonstrated in this paper. More recently, in 2004, S. Morrell presented a new formula in which the exponents vary with the feed and product size. This paper is based on Hukki’s approach and presents a new general formula, in which the exponent varies only with the feed particle size. This new equation has been proven in 82 observable cases in Peru and other countries around the world, involving ball mills and vertimills in different configurations over a wide range of feed and product sizes, work indices and mill diameters; in most cases, the predicted value has an error less than 10% with regards to the observed value and no need for any correction factor. Keywords: Grinding, specific energy, particle size, work index, variable exponent

Jan 1, 2020