module and tracked crushing plant iron ore malaysia formulas ball mill

Here’s a comprehensive overview of module and tracked crushing plants for iron ore in Malaysia, along with relevant ball mill formulas for processing:

—

1. Module and Tracked Crushing Plants for Iron Ore (Malaysia)
# Key Components:
– Primary Crusher: Jaw crusher or gyratory crusher (for large iron ore lumps).
– Secondary/Tertiary Crushers: Cone crushers or impact crushers (to reduce size further).
– Screening Units: Vibrating screens to separate fines and oversize material.
– Tracked Mobility: Enables easy relocation in mining sites (e.g., Metso Lokotrack, Sandvik Mobile Crushers).

# Advantages in Malaysia:
– Adaptability to remote iron ore sites (e.g., Pahang, Terengganu).
– Reduced infrastructure costs vs. fixed plants.
– Quick setup for short-term mining projects.

# Iron Ore Crushing Flow (Typical):
1. Blasted Ore → Primary Crushing (≤250 mm) → Screening.
2. Oversize → Secondary Crushing (≤50 mm) → Tertiary (if needed).
3. Final product (~10–30 mm) fed to ball mill for grinding.

—

2. Ball Mill Formulas for Iron Ore Processing
# (a) Critical Speed (Nₐ):
The rotational speed at which grinding media centrifuges:
\[
N_c = \frac{42.3}{\sqrt{D – d}} \quad \text{(rpm)}
\]
– \(D\) = Mill diameter (m)
– \(d\) = Grinding media diameter (m)

Operational Speed: Typically 65–75% of \(N_c\).

# (b) Power Consumption (Bond’s Law):
\[
P = W_i \left( \frac{10}{\sqrt{P_{80}}} – \frac{10}{\sqrt{F_{80}}} \right) \times C
\]
– \(W_i\) = Bond Work Index (kWh/t; ~13–16 for iron ore).
– \(P_{80}\) = 80% passing size of product (µm).
– \(F_{80}\) = 80% passing size of feed (µm).
– \(C\) = Correction factors (e.g., mill type, efficiency).

# (c)