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Powder Technology
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A correlation between Vickers Hardness indentation values and the Bond Work Index
for the grinding of brittle minerals
Malcolm Gent , Mario Menendez, Javier Torao, Susana Torno
Universidad de Oviedo, E.T.S.I.M.O. (School of Mines), Spain
a r t i c l e
i n f o
Article history:
Received 5 September 2011
Received in revised form 19 December 2011
Accepted 25 February 2012
Available online 3 March 2012
Keywords:
Grinding
Bond Work Index
Microindentation
Vickers Hardness
a b s t r a c t
Comminution of materials is an energy intensive and inefcient process where predetermination of energy
consumption for the production of a mineral powder may require lengthy and costly testing. This investigation was conducted to asses an unanticipated correlation between Vickers Hardness (VH) values for crystalline minerals and their comminution energy requirements as expressed by the Bond Work Index (BWI).
Based on preliminary investigations, hardness values of crystalline minerals as measured by the VH test are
interpreted to be affected by their elasticity. A tentative mathematical relation with a high correlation between the VH of liberated, mono-crystalline minerals and their BWI is presented. This relation probably predicts the maximum comminution energy requirements as mineral products for grinding are usually
constituted by particles relatively free of extraneous planes of weakness.
The VH test is proposed as a potential, rapid alternative method for determination of BWI values for the
grinding of minerals. It may also potentially assist in the assessment of energy losses due to excessive grinding of mineral ores.
2012 Elsevier B.V. All rights reserved.
1. Introduction
Considerable research has and continues to be conducted into the
prediction of mill power consumption or production rates for the
comminution of ores/rocks and minerals. Comminution of materials,
especially of mineral resources and products is reported to be energy
inefcient and requiring signicant capital investment. Much of the
published research that has been conducted has been oriented to
the modelling of energy consumption in fragmentation and methods
for the determination of the grinding energy requirements for comminution of specic materials.
There is a large demand for ground mineral powders in many industrial applications and manufacturing processes. This is especially
so in the case of producing ne to very ne mineral powders such
as llers for industrial applications where the associated high energy
consumption is a major cost factor in the production process and as
such requires the evaluation of the grindability of specic mineral
products. The selection of a mineral product to produce a powder is
frequently not dependant on a specic source or exact composition.
As such, there may be signicant differences in the grindability of
one mineral product relative to others that can constitute a critical
factor in the nal production cost of a powder. Despite this, methods
for the prediction of comminution power consumption for such
operations are probably the least developed of the methods for predicting comminution energy requirements.
Testing of a specic mineral or blend of minerals to determine
the required energy consumption for ne grinding is presently
based on lengthy laboratory sample or preliminary industrial scale
batch tests. Determination of specic grinding energy consumption
for the production of mineral powders from new mineral sources developed or when new mineral powder products are to be produced is
essential for determining operating costs. This is especially so in the
case of contract grinding operations where a contractor is not familiar
with the operational costs for the grinding of a mineral or when a
type of mineral product is available from different sources.
The results of investigations presented here were conducted with
the objective of ascertaining if an observed indication of a correlation
between the Vickers Hardness (VH) and the Bond Work Index (BWI)
could be a valid tool for predicting mineral BWI values. This possible
relation was originally observed during analysis of test results of
an investigation conducted by the authors including six mineral
abrasives (Table 1) of semi-equidimensional mineral particles to
evaluate the physical properties required of abrasives for waterjet
cutting (AWC) of ductile materials. The observed relation (Fig. 1) as
expressed in Eq. (1) was found to have a correlation factor (R 2) of
0.7436.
2
Corresponding author at: c/Independencia 13, Oviedo 33004, Spain. Tel.: + 34 985
10 42 37; fax: + 34 985 10 42 45.
E-mail address: gentmalcolm@uniovi.es (M. Gent).
0032-5910/$ see front matter 2012 Elsevier B.V. All rights reserved.
doi:10.1016/j.powtec.2012.02.056
218
Table 1
Composition and mechanical characteristics of mineral sands tested for abrasive waterjet cutting applications.
Test abrasive
Components
(% volume)
Vickers Hardness
(kg/mm2)
Vickers Hardness
St. Dev.
84% garnet
14% ilmenite
2% carbonates
43% hessonite garnet
21% grossular garnet
34% plagioclase
2% pyroxene
48% hessonite garnet
38% grossular garnet
13% plagioclase
63% hessonite garnet
16% grossular garnet
20% plagioclase
2% pyroxene
100% zircon
26% garnet
28% pyroxenes
11% amphiboles
10% serpentine
9% carbonates
6% staurolite
5% ilmenite
3% quartz
2% magnetite
2711 HV10
387 HV10
37.0
1799 HV10
616 HV10
32.6
2192 HV10
535 HV10
32.6
2130 HV10
851 HV10
34.0
2823 HV10
2090 HV10
897 HV10
546 HV10
39.5
27.7
Zircon (mono-crystalline)
PRC#3 (a raw mono-crystalline beach sand)
1=P 1=F
BWI (kWh/t)
40
GMA 80
35
TC-K1
TC-TU
TC-C1
30
PRC#3
25
20
15
1500
1700
1900
2100
2300
2500
2700
2900
The BWI test is extensively used factor in designing grinding processes and evaluating grinding conditions. A large number of BWI
values for the comminution of different ores are available but can
vary widely for the same type of ore and generally are not reported
for specic minerals. Berry and Bruce [16] have shown that the BWI
can be determined by grinding samples to evaluate using the same
power consumption as that of a reference sample and comparing
the initial and product grain sizes. This procedure requires that the
product sizes be similar. Other alternative, rapid methods to determine the BWI of materials [17,18] have also been proposed but
have not become well established procedures.
There are a number of other models used or promoted to assess
energy requirements for the industrial comminution of a material.
They include the: Bond Pendulum test [3]; Narayanan and Whitens
rebound pendulum test [19]; JKMRC-Drop Weight Crushing Test
[20]; Ultrafast load cell test [21]; Utah load cell work index [22];
Unconned compressive strength test [23]; Friability test and a powder crush test [24]. However, these are not particularly effective for
predicting energy consumption requirements for very ne grinding
and except for those of the Bond model, values for specic materials
are noticeably lacking in the literature.
3. Theoretical considerations
3.1. The comminution process
The results of studies reporting BWI values are almost invariably
for ores or rocks rather than to grinding of specic minerals. The resistance to comminution of rock or mineral particles depends on the
materials the presence of planes of weakness such as tectonic or thermally induced stresses and joints; and/or petrographic features such
as mineral foliation, minerals grain sizes, form of contacts between
grain boundaries; and/or mineralogical properties such as inclusions
within grains, cleavage plains and the crystal lattice properties. The
signicance of these features on the energy required to fragment a
particle usually varies with its original size, the size of the new particles to be produced and the nature of the materials present. It is reasonable to suppose that in most instances, the degree of energy
required to fragment particles along planes should increase progressively from 1) tectonic or thermally induced stresses, compression
or cooling joints to 2) mineral foliation and strong mineral cleavage
planes, 3) mineral grain boundaries, inclusions within grains and
weak cleavage plains and 4) through non-cleavage plane crystal
lattice structures (i.e. fragmentation of the atomic or molecular
structure).
The comminution of materials into small fragments consists of the
breakage of particles through contact with other particles and/or with
the grinding media, and/or a resistant surface, and/or with solid mill
walls. Modelling of this process is further complicated by the random
nature of the grinding process where any new surfaces generated are
from random impacting of the grinding media or device with a random selection of the particles of varying sizes. In addition, the force
and/or angle of impact relative to any particle plane of weakness
are also random. It is evident that as the size of particles is reduced,
the probability increases that the new particle surfaces produced
being derived from the fragmentation of crystal lattices. Since the
fragmentation of none ductile, mineral crystal lattices should in
general be the most energy intensive of the comminution process,
this should account at least in part for the observation of various authors of a the dependence of the BWI value on the product size (e.g.
[25,26]).
In the comminution of ores and rocks, their resistance to fragmentation in materials of the same composition can vary substantially
with the neness to which they must be ground, the extent or abundance of different types of planes of weakness, sizes of crystals of different types present, their presence or lack of strong cleavage planes.
219
220
70
4. Procedure
Table 2
Compilation of maximum and minimum reported VH and BWI values of minerals.
Mineral/
sample
Minimum
reported
VH
Maximum
reported
VH
Minimum
reported
BWI kWh/t
Maximum
reported
BWI kWh/t
Flourite1
Zircon1
Almandine/pyrope garnet2,1
Cassiterite2
Chromite2
Corundum2
Feldspar2
Grossular garnet2
Hematite2
Ilmenite2
Kyanite2
Magnetite2
Quartz2
Rutile2
175
1991
1530
1239
1036
2500
730
1326
739
501
1020
440
1103
894
200
3319
2711
1467
2000
3000
850
1326
1114
752
1224
110
1260
1106
12.37
11.8
8.9
56.7
11.67
12.38
9.6
10.7
18.87
10.1
6.8
12.12
5.1
39.50
37
11.8
19.3
58.18
12.8
12.38
12.68
16.4
18.87
20.9
22.1
20.2
1
2
In-house data.
Published data.
BWI (kWh/t)
60
50
40
30
20
10
0
0
500
1000
1500
2000
2500
3000
3500
VH (kg/mm2)
Fig. 2. Relation between trends of maximum and minimum reported Bond Work Index
and Vickers Hardness values of minerals.
suggests that there exists a signicant relation between these parameters. This relation of both maximum and minimum sets of values can
be described by Eqs. (3) and (4) which have correlation factors of
R2 = 0.7461 and R2 = 0.9061 respectively.
2
VH
BWI kWh/t
Almandine garnet1
Almandine/pyrope2
Anorthite2
Barite2
Cassiterite2
Chromite2
Corundum2
Dolomite2
Feldspar2
Flourite1
Grossular garnet2
Hematite specular2
Hematite2
Ilmenite2
Kyanite2
Magnetite2
Quartz2
Rutile2
Zircon1
2711
2498
900
173
1171
1036
3000
365
850
200
1326
1114
926
626
1224
110
1260
974
2810
37
26.17
11.67
6.24
11.8
13.4
58.18
11.31
12.8
5.1
12.38
15.4
12.68
11.4
18.87
10.21
12.77
12.12
39.50
1
2
In-house data.
Published data.
221
5. Results
6. Discussion
As indicated in Fig. 3, the selected values indicate a strong correlation between VH and BWI as expressed in Eq. (5). These values include mineral types with a wide variety of physical characteristics
(e.g. soft and relatively ductile, soft and brittle, hard and brittle,
etc.). The data constitutes a very limited set of values but a high correlation (R 2 = 0.9111) is indicated.
All of the halide carbonate and sulphate as well as most of the silicate minerals used for this investigation are characterised as having
cleavage planes. If only the oxide minerals (n = 8) are considered,
the Eq. (6) can be derived with a correlation factor (R 2) of 0.9636.
Without additional data with intermediate values this relation is dubious as it is dominated by the corundum values.
2
Similar relations can be derived for the halide, carbonate and sulphate (n = 3) minerals (Eq. (7)) and the silicate (n = 8) minerals (Eq.
(8)) with correlation factors (R 2) of 0.9980 and 0.9413 respectively.
2
Eq. (7) being based on only three sets of data, the expression of
the relation between VH and BWI for halide, carbonate and sulphate
minerals should be considered as being very tentative. This is especially so as both the VH and BWI values are the lowest of all the
suits of minerals considered and include such a wide variety of mineral groups. If this group is excluded from consideration, the range
in BWI values related to VH values can be expressed as in Eq. (9).
2
Eq. (9) appears valid for oxides and silicate minerals with a VH
greater than 1200. For VH values less than 1200, the range in BWI
values 5 as derived from Eq. (5) appears to be the most indicated
range. These equations will generate slightly larger BWI values than
from Eq. (6) but is considered more indicative of the variation in
values that might be anticipated for a given type of mineral.
70
60
7. Conclusions
BWI (kWh/t)
50
40
30
20
10
0
0
500
1000
1500
2000
2500
3000
3500
VH (kg/mm2)
Fig. 3. Relation between trends of Bond Work Index and Vickers Hardness values and
specic minerals.
222
minerals. The precise basis for the observed relation between VH and
BWI values is uncertain but it is speculated that if the observed relation is developed, it may also form the basis for the eventual capacity
to calculate the energy requirements for the grinding of mineral
blends. It could also contribute towards understanding of energy consumption in mineral ore grinding and energy loss due to over grinding of ores.
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