Investigation of the effects of ore abrasivity index on ball wear in wet ball milling operations with lab scale tests
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ETİ Bakır C.O. R&D Center
These authors had equal contribution to this work
Publication date: 2026-10-07
Physicochem. Probl. Miner. Process. 2026;62(20th Balkan Mineral Processing Congress 5):241418
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ABSTRACT
The operational costs of a mineral processing plant are largely dominated by energy consumption and the use of consumable materials during the grinding operations. Industrial mills come in various types and sizes, with grinding media such as balls and rods that differ in hardness and properties. Ore characteristics, such as hardness and abrasiveness, influence the wear of these consumables. The selection of appropriate grinding media based on ore abrasivity is therefore critical. This study investigates the wear of grinding media during wet grinding in ball mills made from cast iron at ETİ Bakır Co.’s Samsun plant. A laboratory-scale ball mill and the LCPC abrasivity test were used to assess grinding media wear. Samples from various ores were collected from the company's mines. The relationship between media wear and ore characteristics was analyzed using multi-linear regression frameworks incorporating the LCPC and Bond Wi tests. The study evaluated the effects of different ore types on grinding media wear and determined the relationship between ore abrasiveness and ball wear. Finally, a dimensionless ball wear index model was developed to relate ore characterization parameters to grinding media wear under controlled laboratory conditions.