14 1 r 1' l ut C\-I~MICAL CORPORAT\ON

L35 East 42nd Street

New York, N.Y. 10011

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CATAL G 101-B
 AN EVOLUTION OF QUALITY PRODUCTS
Broad Experience and Years of Development are reflected in the MARCY MILL
For more than fifty yea rs th e names MINE
AND SMELTER and MARCY have been the
symbol of dependable quality ore milling ma -
chinery, industr ial and mining equipment, and
supplies created for your specific needs. Dur-
ing this period thousands of operators have
exper ie nced continuous economical and un -
equalled service throu gh their use .
No exact date is reco rded as to when the
need first arose for some mechanical means
of reducing particles in size, but considering
that it has been many years, it is perhaps sur-
prising that grinding is still an "art" and not
an "exact science ".
The Mine and Smelter Supply Company,
through its Manufacturing Divisi on , during
these years has continuously accumulated
knowledge on grinding applications. It has
contributed greatly to the grinding process
through the development and improvement of
such equipment.
Just what is grinding? It is the reduction
of lump solid materials to smaller particles by
the application of sheari'lg forces , pressure ,
attrition , impact and abrasion . The primary
consideration . then , has been to develop some
mechanical means for applying these forces .
The modern grinding mill applies power to
rotate the mill shell and thus transmits energy
to some form of media which , in turn , frac -
tures individual particles.
Just how this can best be done reverts to
our history of grinding. In 1914 Mr. Frank E.
Marcy established the " Marcy pr inciple of
THE MINE AND SMELTER SUPPLY
THE ORE & CHEMICAL CORPORATION Main Off ice: Denver 16, Colorado, U .S .A .
235 East 42nd Street 3800 Race St.
New York, N. Y. 10017
El Pa so, Texas 122 East 42nd St., New York
Copyright 1958 by The Mine & Smelter Supply Co. BOTH MARCY AND
gri nd ing". This pr inciple is simply stated
" rapid change of mill content is necessary for
h igh effic iency". This pri nc ip le is incorpo-
rated in all Marcy Mills and has been prove n
in hundreds of operating installations until it
is now gene rall y accepted as a world-w ide
axiom . Since the first Marcy installation oper-
ators of every class. small as well as large.
have shown the ir preference fo r Marcy M ill s.
We point with pride to the grea t number of
large installations throughou t the world where
Marcy Mill s are do ing the gri nd in g. Sma ll
m ills prof it from the experience of these la rge
operations.
Throu gh constant and extensive research .
in the field of g rindin g as well as in the field
of manufacturin g. Mine & Smelter cont inues
to p ioneer. Constantly changing conditions
provide a challenge for the future . Meet ing
this challenge keeps our company youn g and
progressive . This prog ress ive spiri t , with the
knowledge gai ned through the years. assures
top quality equipment for the users of our
mills.
Today Mine & Smelter 's modern manu -
facturing facilities. rigid controls . and close
inspection assure excellence in uniformity of
our products and satisfactory performance
even under the most severe cond it ions.
You are urged to study the follow ing
pages which present a detailed picture of our
facilities and d iscuss the techn ical aspects of
grinding. You will find th is data helpful when
considering the se lection of the grinding equ ip-
ment.
P.O. Box 9041
Sal t Lake Ctty, Utah
MASSCO ARE REGISTER E D T RADE M ARK S Printed in U. S.A.
 Marcy Quality and Service 2- 3

Selection of a Grinding Mill 4- 5

From Theory to Practice 6-13

General Construction 14-19

Method of Discharge 20-21

Drives 22-23

Feeders 22-23
Eight of seve nteen 9 ' x 12' Marcy Rod Mills at Anacondo ,
Montana Rod Mills 24-29

End Peripheral Discharge

Rod Mills 28-29

Center Periphe ral Discharge

Rod Mills 28-29

- Ball Mills 30-33

- Tube Mills

Pebble Mills

Special Applications
34-35

34-35

36-37

Cement Grinding 38-39

Useful Information 40-43

Alphabetical Index 44-45

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1
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MARCY TECHNICA L SERVICE

As a part of our service our staff includes

experienced engineers, trained in the field of
metallurgy, with special emphasis on grind-
ing work. Th is knowl edge, as well as a back-
ground gained fro m intimate contact with
various operating companies throughout the
world, provides a sound basis for consulta-
t ion on your grind ing problems. We take
pride in manufacturi ng Marcy Mills for the
metallurgical , rock products, cement, process.
OVER SO YEARS OF EXPERIENCE and chemical indust ries
It is quite understandable that The Mine
& Smelter Supply Company takes pride in the
quality of its Marcy Mills because of the
tradition established and carried forward in
the history of our company.
Complementing the human craftsmanship
built into these mills, our plants are equipped
with modern machines of advanced design
which permit accurate manufacturing of each
constituent part. Competent supervision en-
courages close inspection of each mill both
as to quality and proper fabrication . Each
mill produced is assured of meeting the high
requ ired standards. New and higher speed
machines have replaced former pieces of
equipment to provide up-to-date procedures.
The use of high speed cutting and drilling
tools has stepped up production , thereby re-
ducing costs and permitting us to add other
refinements and pass these savings on to you,
the consumer.
Each foundry heat is checked metallurgic-
ally prior to pouring. All first castings of any
new design are carefully examined by the use
of an X-ray machine to be certain of uniform-
ity of structure. The X-ray is also used to
check welding work, mill heads, and other
castings. Partial view of Pattern Shop
Each Marcy Mill, regardless of size, is de-
signed to meet the specific grindi ng condi-
tions under which it will be used. The speed
of the mill , type of liner, discharge arrange-
ment, size of feeder, size of bearings, mill
diameter and length, and other factors are
all considered to take care of the size of feed,
tonnage, circulating sand load, selection of
balls or rods, and the final size of gri nd.
All Marcy Mills are built with jigs and tem-
plates so that any part may be duplicated.
A full set of detailed drawings is made for
each mill and its parts. This record is kept
up to date during the life of the mill. This
assures accurate duplication for the replace-
ment of wearing parts during the future years.
Views of our manufacturing plant in Den-
ver are shown on these pages. Other manu-
facturing plants are located in Canada, Eng-
land, Australia, Sweden, South Africa, and
Finland.
 TEST FA CI LITIES
- As an additional service we offer our test-
ing laboratories to chec k your material for
grindability. Since all grind ing problems are
different some basis must be established for
recommending the size and type of grind ing
eq uipment required. Experience plays a great
part in t h is phase; however, to establish more
direct relationships it is often essential to con-
duct individua l grindability tests on the spe-
c ific material involved. To do this we have
established certain definite procedures of lab-
Portion of Foundry
oratory grinding work to correlate data ob-
tained on any new specific material for com-
pa rison against certain standards. Such stand-
ards have been established from conducting
simi lar work on mate rial which is actually
being ground in Marcy Mil ls throughout the
world. The correlation between the resu lts
we obtain in our laboratory against these
standards, coupled with the broad experience
and our company's background, insures the
proper selection a nd recommendation of the
required grinding equipment.
3
 When selecting a gri nd ing mill there are many
factors to be taken into consideration. First let
us consider just what constitutes a grinding mill .
Essentially it is a revolving, cylindrical shaped ma-
chine, the internal volume of which is approxi -
mately one-half filled with some form of grinding
med ia such as steel balls, rods or non-ferrous
pebbles.
Size of feed to a mill may be considered : coarse
( l" to 2"); medium (1/4" to 3/.!"): or fine•(less than
1/4"). Feed may be classified as hard, average or
soft. It may be tough , brittle, spongy, or ductile.
It may have a high specific gravity or a low specifi c
gravity. The desired product from a mill may range
in size from a 4 mesh down to 200 mesh , or into
the fine micron sizes. For each of these properties
a different mill would be indicated.
The Marcy Mill has been designed to carry
out specific grinding work requirements with em-
phasis on economic factors . Consideration has
been given to minimizing shut-down time and to
provide long, dependable trouble•free operation.
Wherever wear takes place renewable parts have
been designed to provide maximum life. A Marcy
Mill, given proper care, will last indefinitely.
Marcy Mills have beer manufactured in a wide
variety of sizes ranging from laboratory units to
mills l2 V2' in diameter, w ith any suitable length.
Each of these mills, based on the Marcy principle
of grinding, provides the most economical grind-
ing apparatus.
Marcy offers you the following advantages:
l . Power requirements and consumption of
liners and media are kept at a minimum.
2 . Superior mechanical construction provides
continuous low cost operations.
3 . They are available in a large selection of
sizes and capacities.
4 . Low pulp level grinding provides an active
effective grinding mass within the mill to
act on particle size reduction only. There
is no wasteful cushioning of grinding action
by high pulp levels.
5. For any given capacity, Marcy Low Dis-
charge Level Mills require less floor space,
lower transportation costs, and minimum
required erection material.
4
ROD M ILLS
For a number of years ball mill grinding
was the only step in size reduction between
crushing and subsequent treatment. Subse-
quently rod mil ls have altered this situation ,
providing in some instances a more econom-
ical means of size reduction in the coarser
fractions . The pr incipal f ield of rod mill usage
is t he preparation of products in the 4-mesh
to 35-mesh range . Under some conditions it
may be recommended for grind ing to about
48 mesh. Within these limits a rod mill is
often superior to and more efficient than a
ball mill . It is frequently used for such size
reduction followed by ball milling to proE:luce
a finished fine grind. It makes a product un i-
form in size with only a minimum amount of
tramp oversize.
The basic principle by which g rinding is
done is reduction by line contact between
rods extending the full length of the m ill.
Such line contact results in selective grind ing
carried out on the largest particle sizes. As a
result of th is selective grinding work the in-
herent tendency is to make s ize reduction
with the min imum production of extreme
fines or slimes.
The rod mill has been found advantageous
for use as a fine crusher on damp or sticky
materials. Under wet grinding conditions this
feed characteristic has no drawback for rod
mill ing whereas under crushing conditions
those characteristics do cause difficulty. Th is
asset is of particular importance in the man-
ufacture of sand, brick, or lime where such
material is ground and mixed w ith just suffi-
cient water to dampen, but not to produce a
pulp. The rod mill has been extensively used
for the reduction of coke breeze in the 8-mesh
to 20-mesh size range containing about l 0%
moisture to be used for sintering ores.

BALL MILLS
Grinding by use of nearly spheri cal shaped
gri nd ing med ia is termed ball milling. Strictly
speaking, such media are made of steel or
iron. When iron contamination is detrimental ,
procel.3in or natura l non-metallic materials are
used and are referred to as pebbles. When ore
particles are used as grindi ng media this is
known as autogenous grinding.
Other shapes of media such as short cyl-
inders, cubes, cones, or irregular shapes have
been used for grinding work but today the
nearl y true sphe rical shape is predominant and
has been found to provide the most economic
form .
In contrast to rod milling the grindi ng
action results from point contact rather than
li ne contact. Such point contacts take place
between the balls and the shell liners, and
between the individual balls themse lves. The
material at those points of contact is ground
- to extremely fine sizes. The present day prac-
tice in ball milling is generally to reduce ma-
terial to 35 mesh or finer . Grinding in a ball
mill is not selective as it is in a rod mill and
- as a result more extreme fines and tramp over-
size are produced.
Ball mills generally operate at slightly
higher speeds than rod mills and thereby im-
- part a cascading action to the gri nd ing media .
Ball mills are genera lly recommended not
only for single stage fine gri nd ing but also
have wide application in regrind work. The
Marcy Ball Mill with its low pulp level is
especially adapted to single stage grinding
as evidenced by hundreds of installations
throughout the world. There are many appli-
- cations in specialized industrial work for
either continuous or batch grinding.
WET AND DRY CRINDINC
Wet grinding may be considered as the
grindi ng of material in the presence of water
or other liquids in sufficient quantity to pro-
-
duce a fluid pulp (generally 60 % to 80 %
solids) . Dry grinding on the other hand is
carried out where moisture is restricted to a
very limited amount (generally less than 5 %).
Most materials may be ground by use of either
method in either ball m ills or rod mi lls. Se-
lection is determined by the condition of feed
to the mill and the requirements of the
ground product for subsequent treatment.
When grinding dry some provision must be
made to permit material to flow through the
mill. Marcy Mills provide this necessary gra-
dient from the point of feed ing to point of dis-
charge and thereby expedites flow .
ADVANTAGES OF WET GRINDING
l . No dust problem.
2 . Damp and sticky feed may be treated.
3. Low power consumption.
4 . Simplified material handling.
5 . Higher mill capac ity.
6 . Size classification is simplified.
ADVANTAGES OF DRY GRINDING
l. Lower steel consumpti.on .
2 . Elimination of dryi ng or filtering f in-
ished product.
FINENESS OF GRIND
The fineness to which material must be
ground is determined by the individual mate-
rial and the subsequent treatment of that
ground material. Where actual physical sepa-
ration of constituent partic les is to be rea l-
ized grinding must be carr ied to the fineness
where the individual components are sepa-
rated. Some materials are li berated in coarse
sizes whereas others are not liberated until
extremely fine sizes are reached.
Occasionally a sufficient amount of valu-
able particles are liberated in coarser sizes to
justify separate treatment at that grind. Th is
treatment is usually fol lowed by regrind ing
for further liberation. Where chemica l treat-
ment is involved , the reaction between a solid
and a liquid, or a solid and a gas. will gen-
erally proceed more rapid ly as the particle
sizes are reduced. The point of most rapid
and economica l change would determine the
fineness of grind required.
Laboratory examinations and grinding tests
on specific materials should be conducted to
determine not only the fineness of grind
required , but also to indicate the size of
commercial equipment to handle any specific
problem.
5

The following few pages are devoted to
the subject "From Theory to Practice" taking
you step by step through some of the vari-
ables encountered in grinding and how each
of these affect your operations.
As previously pointed out, grinding must
still be considered an art and not an exact
science. As a result many theories have been
expounded on the numerous variables which
enter into grinding work. Should it be pos-
sible to reduce all of these variables to a sim-
ple mathematical formula the selection of a
grinding mill would, of course, be simple.
Many approaches to this have been made but
to date a fool-proof formula, both mathe-
matically and practically applicable, has not
been devised. W e must, therefore, take each
variable into consideration on its own merits
and then correlate such ideas into a single
selection. To do this a broad experience and
understanding of the complete subject of
grinding is essential. This is a part of the
problem of your engineers and our own con-
sulting staff. On page 5 two general points
have been discussed briefly — wet or dry
grinding, and fineness of grind. T w o main
categories of grinding equipment, namely rod
mills and ball mills, have also been mentioned.
Whether grinding is to be performed wet
or dry, or in a ball mill or rod m i l l , a choice
must be made between open or closed cir-
cuit. Other factors which require thought are
mill size, speed of mill rotation, moisture con-
tent, retention time, circulating load, type and
sizes of grinding media, mill pulp level, mill
shape, power, and relation between diameter
and length. These all influence operating re-
sults and are evaluated and incorporated in
the selection and design of the Marcy M i l l .
6
A NOTE ABOUT M I L L SHAPE
Marcy mills are essentially cylindrical ir"""
shape and this design has been selected for
very definite reasons.
M i l l capacity is a function of the mill vol —
ume and the load of grinding media. There-
fore to obtain a mill of greatest capacity for
any given space, pure logic dictates a mill
having the greatest volume. W h i l e a square—
section would provide the greatest volume,
smooth continuity of operation and uniformity
of media action must also be considered and
thus a true circle is the only practical answer.—
Should the diameter vary from one end to an-
other there is but one thing which occurs—
reduced volume, or in other words, reduced
capacity. —
The cylinder simplifies mill construction,
resulting in a m i n i m u m amount of mainte-
nance and reflecting in less downtime. Power-
wise, cylindrical mills provide the most eco-
nomical piece of equipment for grinding work.
Floor space for any mill is proportional to the
diameter of the mill and its length. Therefore,
floor space is kept at a m i n i m u m . A m i l l . ~
keeping uniform diameter throughout its full
length obtains maximum volume for a given
floor space.
LENGTH OF M I L L
The relationship of mill diameter to length,
is of considerable importance. Rod mills should
have a length greater than the diameter to
avoid entanglement' of rods. The construction
of ball m'ills is different in that the diameter,
may be larger, equal to, or smaller than the
length.
The selection of mill length is depend-
ent upon the size of feed, size of product a n d '
type of grinding circuit selected. Considera-
tions given a short mill are the reduced floor
space, shorter retention time producing less
fines in the discharge product, and the possi-'
bility of producing a slight amount of tramp
oversize particles. Corresponding conditions
to be expected f r o m a longer mill are greater
floor space requirements, higher capacity'
(closely proportional to mill length), greater
retention time thereby producing a finer mill
discharge product and a greater amount of ex-
treme fines, less tramp oversize in the product."
Since most mill variables act as a function of
the mill length, this consideration is relatively
simple. On pages 10 and 1 1 considerable dis-
cussion is provided on the subject of m i l l "
diameter.
 OPEN AND CLOSED CI RCU ITS
SINGLE A N D TWO-STAGE
GRINDING
The method of operating a grindi ng mill
may be classified into two methods. open cir-
cuit or closed circuit. In open circuit grind-
ing feed enters one end of the mi II at a pre-
determined rate so as to make the desired fin-
ished product during a single pass through
Advantages of ope n circuit grinding:
1. Simplicity of m ill layout.
2. May be used where classifying is not
practical .
3. May be used where contro l o f prod-
uct size is not important.
4 . The use of rod m i l ls will produce an
ideal fine feed for ball mills.
5 . May be used where classi f ier dilutuion
would be objectionable.

-
that mill. In other words there is no size
classi f ication made on the discharge product. Advantages of closed circuit grinding:
One important application is on ores contain- 1. Prov1des a close control of fin ished
ing damp and clay-like material which causes product size.
difficulty in fine crushing. This problem is 2. Mill capacity is greatly increased .
generally solved by wet grinding in a rod 3. Power requirements per ton of f i n-
- mill or in this case it may be called wet fine ished material are lower.
crushing. 4. Less overgrinding or production of ex-
In closed circuit grinding the feed enters t rem e f in es.
one end of the mill and is discharged from Advantages of single stage grinding:
the other end into some type of classifier . 1. Less equipment to purchase. install and
This class ifier is to limit maximum particle mai ntai n .
size removed from the mill circuit. The over-

-
size material is returned to the grinding mill
for additional size reduction. Such material
returhed to the mill is defined as the circulat-
ing load. Classifying equipment may consist
2 . Less floor space requirements.
Advantages of two-stage grinding:
1. Less overgrinding.
2. Provides a simp l ified fine crush i ng

- of vibrating screens on coarse separations for

wet or dry grinding. For wet grinding in the
finer size ranges wet classifiers and/or cy-
clones are employed, generally to make a size
3.

separation from 20 mesh down to 325 mesh.
Under dry grinding conditions air classifiers
are used to make the size classification .
Single stage grinding may be defined as
grinding original feed to finished size in a
single mill . It may o;:>erate in either open cir-
cuit or closed circuit.
Two stage or multiple stage grinding may
- be defined as grinding in two or more u ni t s
with each unit making a step in size reduc-
tion . Each mill may operat e either as open
4.
pla n t and grinding section .
May be used to increase capac i ty of
exist in g single sta ge operation .
Provides an opportunity for recovery
of desirable material between stages
of size reduct ion .
CIRCULATING LOAD
Generally speaking circulating loads for
rod mi ll operation will be less than 200 %.
In most cases it will more closely approach
100% to 120 %. In ball mill operations the
ci rc u lat in g load will vary between 300 % and
1000 % depen ding upon the grind required
and t ype of m aterial . As an average it will

- circuit or closed c i rcuit. app roach 3 50 % .

- r-0-o
F • FEED
D : DISCHARGE
PRIMARY -,
O =OVERSIZE F- MILL - D-
RETURN SANDS
C =CLASSIFIER
t
0
D
I
OPEN CIRCUIT
OR
FINISHED PRODUCT
Two sTAGE : PRIMARY OPEN CIRCUIT
SECONDARY CLOSED CIRCUIT
Ll'-·_ _cLAssiFIER Lc
_ _ _ ____,!
F SINGLE STAGE
F F
!-o~ I
S PLIT O
I- 0 --, I ~

W
~ ~
LD-
iii
(/)
<{

d
LD- L D-
IC SINGLE STAGE
jC
h lc T WO STAGE: BOTH
TWO STAGE:PRIMARY OPEN CIRCUIT MILLS CLOSED CIRCUITED
CLOSED CIRCUIT

TWO STAGE: BOTH MILLS WITH ONE CLASSIFIER

( PRODUCT CLASSIFIED)
CLOSED CIRCUITED WITH
SECONDARY CLOSED CIRCUIT
SEPARAT E CLASSIFIERS

7
 From Theory to Practice

MILL SPEEDS Generally speaking ball mil ls operate within

the range of 50 % to 90% of critical speed.
Proper speed, or most efficient speed, at The average is found to be approximately 75 % .
which mills are to operate depends upon the Pebble Mills have been found to operate more
action desired by the grinding media, the amount efficiently at higher speeds than ball mills.
of media, its size and shape, pe rcentage of solids When reaching the h igher percentages of critica l
in each mill , and shape of liners. In the follow- speed caution must be used and consideration
ing d iscussion we refer to critical speed apply- given the action of the scoop feeder (see
ing to ball mills and peripheral speed referring page 22).
to rod mills. Reference gr~phs giving these When considering rod mills, peripheral
speeds for various mill diameters will be found speeds only should be considered. In the case
on page 9 . of ball milling, with a free moving grinding me-
Critical speed may be considered as the dium , ball paths obtained are based on critical
speed at which an infinite particle will con- speeds. ln a rod mill with a comparatively rigid
tinue its travel around the periphery of the grinding medium, a certain cascading and ro ll
mill , thus becoming part of a flywheel action. of rods are obtained, which does not resemble
Grinding balls actually will not centrifuge at the action of loosely projected ball paths. There-
th is theoretical critical speed s ince they are larger fore to simulate similar rod actions in mi lls of
than an infinite particle and also because of various diameters it is necessary to operate be-
slippage. tween 60% and 98% of critical speed. There-
fore, Critical Speed is misleading if used in con-
The fo llowing table illustrates the action of a junction with rod mi lls. It has been found that
normal ba ll charge at various percentages of critical Marcy low pulp level rod mills show increases
speed. in efficiency as peripheral speeds are increased
%Critical
from 300' per minute to the present practical
Speed 10 20 30 40 so 60 70 80 90 maximum of around 500' per m inute.
Sliding 3 3 3 2 2 2 1 1 To illustrate the comparison between critical
Cascading 1 1 1 2 3 3 2 speeds and peripheral speeds and the misleading use
•Centrifuging 1 1 2 2 3 of critical speed for rod mills, we submit the follow-
ing illustrative table:
1 indicates slight amount, 2 indicates appreciable amount, 3
indicates great amount.
BALL MILLS @ 76% C.S. ROD MILL SPEEDS
The following table illustrates the effect of va ry-
ing the amount of ball charge. M ill
Dia.
Criti-
cal
RPM
At Peri-
pheral I At 330'/ Min. At 470' / Min.
Ball Charge 5 - 15 15-25 25-35 35-45 45-50 Inside Speed 76% Speed Mill % Mi ll %
% (Mill Volume) Liners RPM c.s. Ft. / Min. RPM c.s. RPM C.S.
Sliding *3 * 3 * 2 * 1 * 1 4' 38.3 29. 1 366 26.2 68_4 37.4 97.7
Cascading ** 1 ** 2 * 3 *2 23 .8 44? 18. 1
6 31.3 57.8 24.9 79.5
Centrifuging ** 1 ** 2 *3
8 27. 1 20.6 518 13. 1 48.3 18.7 69. 1
I indicates sl ight amount, 2 indi ca tes appreciable amount 3 19.5 552 11.7
indicates great amount. ' 9 25.6 45.7 16.6 64.8
• effecti ve a t a ll speeds, • * on ly e ffect ive a t highe r speeds. 10 24.2 18.4 578 10.5 43.4 15.0 62.0

SLOW SPEED MEDIUM SPEED HIGH SPEED

Above are three illustrations showing the action of balls in a mill at differ-
ent speeds. The action at medium speeds (around 75% critical speed) is gener-
ally most desirable and efficient for Marcy grate discharge mills.

8
 Theoretically critical speed is t he po int at wh ich ce ntri fu ga l and gravity forces acting
on an infinite particle travel ing on the sh e ll liner offset e ach other or becom e equa l. The
formula used in calculating crit ical speed is shown on the graph be low .
I' I I I

Zl
::::i CRITICAL SPEED
.J
.J = 54.19
w ..
Cs ..JR
- I:
Cl)
w
9
.S.= CRITICAL SPE D IN R.P.M.
R = RADIUS IN FEET INSIDE
Cl)

- z
a::e
~
40%

45%
0 % 60 % 70%

65%
80 %

75 %
90 %

85%
100 %

95%
SHELL LINING.

- w
~
<(4

- 0
_J
_J
~
40 45
10 15 20 25 30 35 50 55

MILL R.P.M.

~
Wl2
w
La..
J,
PERIPHERA L: SPEED
- P. S.= IT X D X R.P. M.

,....... ~8
ii;
~

- a:
w
t-6
w
~
z!:>~P·""·
30 Rf>·""·

- <(
0
_J4
_J
35 R.e·""·
4o R.P.""·
45 R .f>.""·
50 Rf>·"" ·

200 300 400 500 600

FEET PER M INU TE

-
The above graph provides pe riph era l speeds for various mill
diameters. Such speeds are meas ured on th e inside d iame te r
of shell liners.

9
from Theory to Practice
POWER AND CAPACITY
Often grinding capacity and power are used
hand in hand since power is an index to the
potentialities of any grinding mill. The grind
achieved is in direct relation to the power applied
in rotating a mill. This rotation transmits energy
input to the grinding media and energy is con-
sumed in reducing particle sizes. Wh en any
particle is split, producing two or more smaller
part icles , the total surface area of the smaller
particles will be greater than the surface area of
the initial size. Therefore surface area often
is used to express the amount of grinding work
which is performed .
There are two methods of looking at power.
First and easily understood is the reference to
connected horsepower , or the actual consumed
horsepower required to drive the mill. The sec-
ond is bas ing power on the amount of work done .
We prefer to express this as kilowatt hours per
ton of materia l ground . The following formula
contain ing three factors may be found useful in
calculating power consumed per ton of material
ground . Wherever two of the factors are avail-
able , the third may easily be solved .
KWH /ton x tons per 24 hours
HP
17.9
There are several variables in mill horsepower
-the most important has to do with mill diame-
ter. Several of these variables also reflect simi-
larly on capacity. There have been various state-
ments made as to how power and capacity vary
with mill diameter , each using a figure of the
diameter raised to some power, such as 0 3 , 0 2.65 ,
0 2.6, and 0 2 ·5 . For your convenience we have
listed on page 11 a table givi ng these various
diameters raised to the appropriate figures . We
have found in the Marcy low pulp level mills
that the capacity varies closely as the diameter
cubed . The mill power varies closely as the
diameter to the 2.5 power . With overflow type
mills , or high pulp level mills , the theoretical ex-
ponents more closely approach the 2.6 or 2.65
power. The difference lies in the waste of energy
when transmitted through a cushioning deep
quantity of pulp.
Power required in relationship to m ill length
is a straight line function or direct proportion
within limits. In other words each foot of m ill
will require a definite amount of power. Capac-
ity of a mill also varies in the same manner .
Example:
You are operating a No. 86 Marcy Mill con-
suming 245 HP and gri ndin g 500 tons per day
to 65 mesh. What will be the capacity of a
54 Marcy Mill? From the table on pa ge 11 . the
86 diameter cubed is 512; the 54 diameter
cubed is 125 ; the 86 diameter to the 2.5 power
is 181 ; and the 54 diameter to the 2.5 power
is 55 .91 . Such diameters are inside new liners.
Capacity
125 x4
x 500 = 81 tons
512 X 6
Horsepower
55.91 X 4
X 245 = 50 HP
181 X 6
Therefore the 54 mill will have a capacity of
81 tons and wi II consume 50 H P.
Power consumed is a reflection of the fine-
ness of grind. The finer a material is ground the
more power is consumed.
Power consumption is also a reflection of
the amount of media carried within the mill.
The maximum power requirements for any mill
will be when it is 45% to 50 % filled with
grinding media . Above or below this power
drops off. Similarly mill capacity will behave
the same way. Within limits the effect of add-
ing or decreasing grinding media will be pro-
portional to that weight.
Power is again reflected in mill dilution . A
mill carrying a high percentage of solids will
consume less power than a mill carrying a low
percentage of sol ids .
The above refers to wet grinding. Under dry
grinding conditions it has been found that the
power will be between 60 % and 90 % that of
a wet grinding mill. Wet grinding capacity will
be 1 Y2 to 2 times that of dry grinding.
 T ' I I . I . !t-H rl-
3/8"To ,o~:~~rr-=
1 r· ,
I • ~ - 1- Th e ta bl e be low tabulates mill d ia meter in fe e t o r
, ' I ..,._ j-r- inches raised to various expone nt s. Th is table w ill be
found useful in calculat ing power and capaci ty figures .
3~4J:-il 1/ 7 8 I 10 II 12 ~
E
0
DIAMET ER
I - l ifT! 0 Fee t Inches D2S D26 Dl 6S Dl
1- ri-1 !H-I
i

IO~~~i·Jii/4~"~To~3~5~Mt~sihl ~~ I/4"To 150 Mesh - 2 24 5.657 6.061 5.761 8.00

0 27 7.596 8.236 8.576 11 .39
r wz a::c; 28
-
26 1:
6
>- 30 9 .879 10.83 11 .34 15.63
3 4 5 6 7 8 9 10 II 12 ~ffi
fil~
24
22 1
"
33 12.54 13 .87 14.59 20 .80
20
ii 3 36 15.59 17.40 18.38 27 .00
~~ 18
39 19.04
1- u 21 .43 22 .73 34 .33
I 1/2" To 48 Mesh f+ >- <3
a::
16 w
0
42 22 .92 25 .98 27 .66 42 .88
9 00
\W 34587891011 12
0
~ 45 27 .23 31 .07 33 .20 52 .73
zUl
H 1+-l og 44 1 'i.... 4 48 32 .01 36 .77 39 .41 64 .00
3 4 5 6 7 8 9 10 II 12 I- u H-L.f-l- 11 ....
1-1- 42 H\ I - ' :z: 51 37 .24 43 .03 46 .28 76 .77
15 ~~ 40 ~
~
54 42.95 49 .92 53 .83 91.33
Ul 38 r-- ,.-f-4
1/2" To 65 Mesh 1- a:: 114" To 200Mesh r ~ 57 49 . 18 57.47 62 . 13 107 2
II
w 36
:. --
9 a.. 34 5 60 55.91 65 .68 71 . 17 125.0
32 1-- \ 63 63.18 74 .56 81.00 144 .7
30 J.--r- 66 70 .97 84 . 14 91.65 166.4
28l+c-t- - ~- ... 69 79 .30 94 .45 103 . 1 190.1
17S:SstB:;:JIH::EEE~ 26
24
1!- - ~ I 6 72 88 .20 105.5 115.4 216 .0
i I I -f-1 I 8
15,~~~3/~e·~·T~o~eo~Mie~sh~rl :~ r-r I 4 f- 4 1" -t- + !
75
78
97 .68
107 .7
117 .3
129.9
128.6
142.6
244 . 1
274 .6
t 3 4 5 6 7 8 9 10 II 12
345178tl01112 81 118.4 143.3 157.6 30 7.5

- MILL DIAMETER INSIDE

The above graph illustrates how power con-

sumed fo r vario us g rinds changes with ball mi ll
SHELL~Feet 7 84
87
90
93
129.7
141 .5
154 . 1
167 .2
157 .5
172.5
188.5
205 .2
173 .6
190.5
208 .4
227 .3
343 .0
381 . 1
421 .9
465.5

- d iameter. It is noted that as the diameter of the

mi II increases the kilowatt hours consumed per ton
decrease. This shows the advantage of selecting as
large a diameter mil l as possible for any grinding
application . (Curves may be used within limits of
8 96
99
102
105
181.0
195.6
210 .7
226 .5
222 .9
241 .5
260 .9
281.3
247 .4
268 .4
290.4
313 .6
512 .0
56 1.5
614 . 1
669 .9
about 3 or 4 feet d iameter variance.) 9 108 243 .0 302 .6 337 .8 729 .0
111 260 .2 325 .0 363 .3 791.5
Below is a g raph showing the effect on mill 114 278 .2 348 3 389 .9 857 .4
capacity by vary ing the size of feed . As feed size 117 296 .8 372 .8 417 .8 92 6.9
decreases capacity increases : Example : 1" feed 10 120 316 2 398 . 1 446 .7 1000
equals 24 .5 %: Y2" feed equals 43 %. Decreasing 122 3 29 .6 409 . 1 466 .7 1051
feed would increase capacity (43-24.5) 18.5 %. 123 336 .3 424 .4 476 .9 1077
126 357 .3 452 .0 508 .4 1158
129 379.0 480.5 541 .0 1243
11 132 401.4 510 .0 575.0 1331
135 424 .6 540 .9 610 .6 1424
138 448.5 572 .5 647 .0 1521
,.... 141 473 . 1 605 .3 684.7 1623
12 144 498 .9 639 .6 724.4 1728

- ~
~ roc

2c
13
147
150
153
156
159
525 .0
552 .5
580 .6
609 .3
639.0
674 .6
711.0
748.7
787 .2
827.4
764 .7
806 .9
850 .4
895.0
.941 .5
1839
1953
2073
2197
2327
162 669.6 868 .6 989 .3 2460
:to · 165 701 . 1 911.3 1039 2600
! FEED: ZE : INC HES i

,.... fit I :j:!'Eff

i~-
From Theory to Practice
GRINDING MEDIA
The subject of grinding medi a is still con-
troversial. The following information is gen-
eral and based upon facts gathered from many
operations.
General statements can be made and are
worthy of consideration when selecting grind-
ing media . For the best results it has been
found that the smallest diameter ball or rod
which will break down the particular material to
be ground is desirable since greatest surface area
is obtained. From the standpoi nt of economy .
the larger the media the higher will be the liner
consum pt ion and media consumption . The mini -
mum size of grinding balls should be selected
with caution si nce there will be a tendency for
such bal ls to floa t out of the mill in a dense
pulp (this is minimized by the use of a Marcy
grate di sc ha'rge mill) . Also the smaller the media
the quicker it will reac h its reject size .
For the first stage of grinding, media will
generally be in the 4" to 2" size (in some cases
as high as 5") . In secondary finer grinding the
initial charge w ill begin at around 3" and in
the case of balls will grade down to about 3_4".
Extremely fine grindi ng will dictate the use of
1 %" and sma ller balls.
Grinding media is the working part of a mill.
It will consume power whether it is doing grind-
ing work or not. The amount of work which it
does depends upon its size, its material, its con-
struction and the quantity involved . It is, the re-
fore , advantageo us to select the type of grind-
ing media which will prove most econom ical ,
the size of media which will gi ve the best grind-
ing results , and the quantity of media which
will just produce the grind required.
One of the econom ic factors of grinding is
the wear of the gr inding media. This is de-
pendent upon the material used in its manu-
facture, method of manufacture, size of media ,
diameter of mill , speed of m il l, pulp level main-
tained in the mill , rate of feed, density of pulp
ma inta ined , shape of the liner surface, nature
of the feed, and the probl em of corrosion .
In general practice , tonnage rates and
power consumption will be in direct proportion
11
to the specific gravity of the media and approx i-
mately in direct proportion with the amount of
media .
Many shapes of gri nd ing media have been
tr ied over the past years . but essentially there
are only two efficient types of med ia used . These
are the spherical ball and the cylindrical rod .
Other shapes are relatively expensive to manu-
facture and they have shown no appreciable
improvement in grinding characteristics.
It will be found that a seasoned charge will
provide a better grind than a new mill charge.
This, of course , is impossible to determ ine at
the offset, but after continuous operation the
media charge should be checked for size and
weight, and maintained at that optimum po int.
After the charge has been selected, replacement
media should be made at the max imum size
used . In some cases it has been found advan-
tageous to add replacement media of two or
more sizes, so as to maintain more closely the
seasoned ratio.
The original charge to a mill is generally
between 40 % and 50 % of m ill volume for ball
mills and 35 % to 45 % mill volume for rod m ills.
As a general figure rod mills will have a
void space within the charge of around 20 %
to 22% for new rods . In ball m ills the theo-
retical void space is around 42 % to 43% . It
has been found that as grinding rods wear a
4" or 4 Y2" rod will generally break up at about
1 Y2" diameter. The smaller diameter new rods
do not break up as easily and will generally
wear down to about 1". In many applications
it has been found . that grinding efficiency will
increase if rods are removed when they reach
the 1" size , and also if broken pieces of rods
are removed . The Marcy Open End Rod Mill
has the advantage of allowing the quick and
easy removal of such rods.
It is difficult to give figures on med ia con-
sumption since there are so many var iables.
Rods will be consumed at the rate of 0 .2 # per
ton on soft easily ground material up to 2 #
per ton on harder material. Steel consumption
of balls is spread out over an even greater range .
Some indication as to media consumption can
be obtained from power consumed in grindin g.
For example , balls or rods will generally wear
at a rate of about 1 # for each 6 or 7 kilowatt
hours consumed per ton of ore . Liner consump-
tion is generally about one-fifth of the media
consumption .
 GRINDING RODS (NEW)
Approx. Approx. SURFACE SURFACE SURFACE WEIGHT
SIZE VOLUME WEIGHT NUMBER NUMBER AREA AREA PER AREA PER PER
Dia. (Inches) (Cu . ln .) (Pounds) Per Per Each Cu . Ft . Ton UNIT
by Length (Ft.) Each Each Cu. Ft. Ton (Sq. ln.) (Sq . ln.) <Sq . Ft. l SURFACE

1 X 10 94 .2 27 14.6 75 377 .0 5506 196. 1 .0716

11hx 10 147.3 42 9.3 48 471 .2 4404 156.9 .0891
1% X 10 212 .1 60 6.5 33 565 .5 3671 130.7 . 1061
2 x10 377.0 107 3.7 19 754 .0 2753 98 .0 . 1419
2% X 10 589.0 167 2.3 12 942 .5 2202 78.4 . 1772
3 x10 848 .2 240 1.6 8 1131.0 1835 65,4 ·.2122
3 % X 10 1154.5 327 1.2 6 1319.5 1573 56 .0 .2478
4 x10 1507.9 427 0.9 5 1508.0 1376 49 .0 .2832
5 X 10 2356 .2 668 0.6 3 1885.0 1101 39 .2 .3544

FORGED STEEL GRINDING BALLS (NEW)

SURFACE SURFACE WEIGHT
SIZE VOLUME POUNDS WEIGHT NUMBER NUMBE R SURFACE AREA PER AREA PER PER
<Diameter EACH PER EACH Per Pe r AREA, EACH Cu . Ft. TON UNIT
Inches) Cu. ln . Cu . Ft. (Pounds) Cu . Ft. Ton <S.q . ln .) (Sq . ln .) (Sq . Ft .) SURFACE

Y2 .065 280 .019 15099 107851 .79 11858.8 588 .24 .024
3,4 .221 280 .063 4474 31956 1.77 7905 .9 392 . 16 .036
'Va .351 280 .099 2817 20124 2.41 6776 .5 336 . 13 .041
1 .524 280 .148 1887 13481 3. 14 5929 .4 294 . 12 .047
11h 1. 023 280 .290 966 6902 4.91 4743 .5 235 .29 .059
1Y2 1.767 280 .501 559 3994 7 .07 3952 .9 196.08 .071
]3,4 2.806 280 .795 352 2515 9.62 3388 .2 168.07 .083
2 4. 189 280 1.187 236 1685 12.57 2964 .7 147.06 .094
2% 8.181 280 2.318 121 863 19.64 2371 .8 117.65 . 118
3 14. 137 280 4.006 70 499 28 .27 1976.5 98 .04 . 142
3% 22.449 280 6.361 44 314 38A8 1694. 1 84 .03 .165
4 33 .510 280 9.495 29 211 50 .27 1482.4 73 .53 . 189
4 Y2 47 .713 280 13.519 21 148 63 .62 1317.6 65 .36 .212
5 65 .450 280 18.544 15 108 78.54 1185.9 58 .82 .236

- EXAMPLE : Requ ire Initial Ball Charge of 18000# using 2 Y2", 3", 3 Y2" and 4" balls.
Bal l X y * X/ Y % X/Y No. %

- Dia . Wt . Ea .

2.318
Area Eo .

19.64
Wt. / U.1it Surface

.118
.142
of Total

19.2
23 . 1
%X 18000

3456
Balls

1491
balls.

38 .5
4.006 28 .27 4158 1038 26 .8
6.361 1.~ ~ 38.48 . 165 26 .9 4842 761 19.6
~.49_2 u£., 50 .27 . 189 30.8 5544 584 15. 1
* SEE LA ST COL UMNS IN TA BLES ABOVE .614 100.0 18000 3874 100.0

We recommend grindi ng rods having the fol- Rods are to be hot rolled , hot sawed or sheared ,
lowing approximate specifications : with standard tolerance and machine straightened .

Carbon . 85- 1.00%

.60- .90 We have found that a good grade of forged
Manganese
Sulphur .05 Max. steel grinding balls is generally most efficient for
Phosphorous .04 Max . use with our Marcy grate discharge ball m ills .
Sil icon . 10 Max .

13
 General
The Mine and Smelter Supply Company
does not attempt to build a " c h e a p " grinding
mill. Engineering based on long experience
with mill manufacture enters into the pro-
duction of Marcy Mills, w i t h the result that
in field operation this equipment yields the
lowest possible operating costs, maximum op-
erating time, and years of useful service. As
such then it is not an expensive mill.
Every Marcy M i l l is engineered and de-
signed to meet the specific grinding condi-
tions under which it w i l l be used. The speed
of the mill, type of liners, grate openings for
ball mills, size and type of feeder, size and
type of bearings, trunnion openings, mill d i -
ameter and length, as well as many other
smaller factors are all given careful consid-
eration in designing the Marcy M i l l .
Each mill is of proper design, constructed
in a workmanlike manner, and guaranteed to
be free from defects in material or workman-
ship. A l l Marcy Mills are built to jigs and
templates so any part may be duplicated when-
ever required. A l l parts are accurately ma-
chined for fits w i t h close tolerances. Before
shipment each mill is assembled in our shops,
carefully checked and match marked to fa-
cilitate field erection. The mill is given a
heavy coat of paint especially prepared for
this type of machinery and all machined sur-
faces are thoroughly coated w i t h protecting
grease.
A complete set of detailed drawings is
made for each mill and kept in a fireproof
vault. This assures the future supply of per-
fectly f i t t i n g replacement parts for the life of
the mill. Wearing parts embodying the latest
developments are supplied on all orders.
Pages 14-19 are devoted to descriptions of
many of the integral parts composing a Marcy
Mill. The discharge parts and the various
feeders and drives are discussed on pages
20-23.
In these descriptions you will find the
word " M E E H A N I T E " . This is a trade name
for metal castings poured under a licensed
agreement w i t h The Meehanite Metal Cor-
poration. A complete description of its char-
acteristics and inherent nature is found on
page 19.
14
The above heavy duty rolls developed for our own use provides
a true circular shell having close tolerances. This assures perfect
fit for shell liners and heads.
Marcy M i l l shells are fabricated from rolled plate
steel. Under special conditions they can be cast of
Meehanite, steel, or special alloys. The plate steel shells
are rolled accurately to diameter and arc welded accord-
ing to ASME specifications, using a Union Melt Auto-
matic W e l d i n g Machine. This equipment provides an
even flow, uniform strength weld w i t h full penetration.
On each end of the shell are steel flange rings bored
to f i t the shell, set in place and welded to the shell in-
side and out by the Union Melt machine. Large diam-
eter shells are stress relieved under temperature and
atmosphere control after welding is completed. Such
heat treatment relieves any stresses or strains set up
during rolling and welding operations.
The method of attaching the flange rings leaves the
inside surface of the shell free from any pockets or de-
pressions which would cause pulp racing and wear. The
flanges are then machined true w i t h the shell axis and
w i t h each other and counterbored to gauge for male and
female f i t w i t h the separate mill heads. This construc-
tion eliminates any possibility of bolt shearing.
One or t w o manholes are provided in ball mill shells,
designed so that all interior wearing parts can readily
pass through such openings.
Marcy M i l l shells are generally 5 " to 7 " greater in
diameter than the nominal mill diameter figure. In other
words the diameter of a Marcy M i l l is the measurement
inside the average thickness of new liners—not inside
the shell as designated by some manufacturers.
Union Melt Welding Ma-
chine automatically weld-
ing a Marcy Mill Shell.
 HEADS AND TRUNNIONS
Marcy Feed Hea d
Marcy feed and discharge heads are detachable.
cast of Meehanite metal of ample thickness. either
of GA or GC. depending on the size of mill and with
cons.i deration to bending stresses. These heads are
generally ribbed for extra strength and stiffness. Such
ribs terminate near the center of the head in a tru n-
nion seat. A male and female fit to the shell fla nge
ring is provided and the back of the connecting fla nge
is fac ed or spot faced to furnish a true seat for t he
joint connecting bolts.
The head to which the gear will be attached has
a seat or flange with a shoulder turned accurately to
s ize providing a seat for the gear.
All turning and boring is done in one setting to
assure perfect concentrcity.
Smaller Marcy Mills are constructed with separate
trunnions ; larger diameter mills have trunnions cast
,... integral with the heads. Separate tru nn io ns are at-
tached to the heads with bolted flanges for male and
female fit . Flanges are faced and counter bored . All
-
trunn ions are cast of Meehanite metal. turned and
carefully polished . All trunnions have a la rge bear-
ing surface capable of carrying the heavy mill load
and to avoid heating during operation . The outer e nds
of the trunnions are faced and drilled to receive
the trunnion liners. protecting the insi de surface from
wear.
Liner bolt holes are drilled to template and spot
faced on the outside of the head .
FEED HEAD
The feed head has ample depth to contain the
feed head liners. The rod mill feed head is con ical
in shape to give the essential feature of a feed entry
pocket in front of the rods.
BALL MILL DISCHARGE HEAD
This head is of considerable depth providing a
pulp lifting chamber, and is designed to contai n the
discharge grates, clamp bars . and the lifters which
elevate the mill product through the trunnion . See
pages 20 and 21 .
Marcy Disch arge Head showing lifters cast integral w ith head
ROD MILL DISCHARG E HEAD
For rod mill work the discharge head is conical
in shape causing the rods to travel by rotation later-
ally and away from the exceptionally large discharge
opening. The discharge opening is larger than the
in let opening. thus providing the Marcy Low Pulp
Line principle of grindin g.
TRUNNION LIN ERS
The discharge trunn ion liner is cast of Meehan ite
metal and has a wide mouthed bell to conduct the
m ill product away from the mill . with no back dr ip .
The feed end trunn ion liner is also constructed
of Meehan ite and can be furnished of several de-
signs to _meet each specific application . cor normal
closed circu it gri nd ing work a spiral liner is furn is hed
to screw new feed and return sands into the mill.
For spout fed mills a plain tapered liner is generally
furn ished . ~
The mill trunnions are machined with a taper
bored seat to receive the trunn io n liner. Such ar-
ran gement permits the trunnion liner wei ght to be
carried by the seat rather than by the connecting
studs . Th is is of particular importance on the feed
end since the shearing effect of the added feeder
would cause breakage of the feeder connecting bolts.
SPIRAL FEED END
TRUNNION LINER
15
 General Construction

TRU NNION BEARI CS

Swivel type lead-bronze bushed trunnion bearings
a re generally furnished on large diameter Marcy Mills.
The bearing swivels are of Meehanite metal spherically
turned outside and bored and faced inside to receive
the removable bushing. The bushing is bored and
scraped to fit the mill trunnion. The bushing is pro-
vided with end flanges thus assuring that the trunnion
flanges run against a bronze face.
On smaller mills rigid or swivel type bearings sup-
port the mill trunnions. The lower half of such bear-
ings are lined with bronze or a special Marcy babbitt
which is peened in place and bored to fit the trunnion.
In all cases a low bearing pressure is maintained
to assure freedom from overheating, long life and
minimum maintenance. They are designed to provide
support to the mill proper, its media and pulp load.
Trunnion bearings are generally supplied with
seals for use with a circulating oil lubrication sys-
tem. They can be designed to accommodate block BASE AND CAP
grease or oi I with wool waste. These are cast heavy in section of Meehan ite
For special applications trunnion bushings can be metal. Where swivel type bearings are used the base
furnished c-onstructed of Micarta to allow water lubri- is spherically bored inside to gauge to receive such
cation or oi l lubrication. swivels. The bottom of the base is planed to fit a
In mdny d ry grinding applications, or where heat planed top of the trunnion bearing sole plate. The
is developed, the trunnion bearings can be furnished bearing cap is provided with a shroud feature ex-
for water cooling. This system carries away the ex- tending out over drip flanges to protect the bearing
cess heat transmitted through bearings and protects from entrance of dirt or grit.
them. Slotted holes are provided in the base for bolt-
ing the base to the sole plate ; this permits move-
BRONZE BUSHINCS ment of the bearing on the sole plate for adjustment
Marcy Lead Bronze has been found to be the of gear and pinion mesh. Such adjustment is carried
most satisfactory bearing material for large diameter out by the use of set screws.
bearings, affording the greatest protection against
damage of trunn ions. Lead bronze wi ll w ithstand ex- LUBRICANT JACKS
treme heat for a considerable period of time (for ex- A separate hand operated lubricant jack can be
ample in the event of lubrication failure). Such heat furnished to be mounted on the bearing base or at
will cause the lead to sweat out and act as a lubricant some distant point to provide a flow of lubricant prior
itself. This protection eliminates the possibility of to starting mill rotation. This feature assures lubricant
scoring a trunnion and there is no danger, as with being present at the bottom of the bearing and re-
babbitt, of having the trunnions settle in the bearing flects somewhat in reducing bearing wear and shows
and rub on the bearing l>ase. a slight reduction in starting torque.

PINION SHAFT BEARINGS

Pinion shaft bearings are of the SKF anti-friction
type mounted in a common twin bearing assembly.
Bearings are fixed in place so that the pinion shaft
of the mill is always in alignment with the drive com-
ponents. V-belt driven mills are furnished with an
outboard bearing of similar construction.
Also available are bearings of the double rigid
ring oiling type for special applications. Such bear-
ings are cast integral with a heavy twin bearing sole
plate assuring perfect alignment and rigidity. These
bearings are equipped with bronze or babbitted bush-
ings.

16
 GEARS AND PINIONS
Two ge neral c lassifications of geari ng are used for Marcy Mill drives .
These are the spur gear and th e helical gear. Helica l gearin g may be either
of the single helical or double helical (Her rin gbone) design .
SPUR GEARS
These are genera lly furn ished on the smaller diameter mil ls using
V-belt drives o r reducer drives . Spur gears and pinions are cut with teeth
of the ful l depth involute tooth form thus assurin g maximum tooth strength
and long wear ing life. The main gear is cut from a special Meehanite
metal casting and is constructed split and revers ible . The pinion is cut
from a steel for ging bored, keyseated and mounted on the pinion shaft.
The p inion is also reversible .
All spur gears and pinions are careful ly machined and the teeth are
accurately cut to obta in proper tooth profile and spacing. thereby util izing
the maximum potential tooth stren gth and wear rating.
HELICAL GEARS
Helical gears are used for the larger diameter mills which are to be
direct connected to a low speed motor. There are primarily two ma in
reasons fo r use of helical gearing on this drive arrangement . First. in SPUR GEARING
order to permit h igher gear ratios than are obtai nable from a practical
standpoint w ith use of the spur gear. This in turn permits the use of
a higher speed an d less expensive motor. Second ; in order to take advan-
tage of th e smoothe r continuous overlapping tooth action of helical geari ng
so essent ial where the re is no intermediate transmission element such as
a V-belt drive or speed reducer . All helical gears and pinions are cut with
the fu ll depth tooth form . The main gear is cut from a special gear steel
cast ing and is made split and reversible . The pinion , usually integral
with the pinion shaft, is cut from an alloy steel forging and heat treated
prior to cutting the teeth . The pinion shaft is double ended so it is also
reversible.
All Marcy Mill geari ng is designed in accordance with sound engineer-
ing princ iples and at the same time w ith consideration gi ven to th e long
range economics involved . Extremes such as excessively high ratios or
a very low number of teeth in the pin ion are always avoided . Th is is done
to provide allowance for such later changes in power or capacity require-
ments as chan ging the m ill speed through the use of different sized pinions.
Therefore , complete repl acement of the main gea r and pini on is not
required .
Furthermore , all gears and p inions are of ample proportion to with- SINGLE HELICAL GEARING
stand the dynamic overloads encountered in this service and to provide
sat isfactory performance under the conditions peculiar to mill operation .
....
PINION SHAFTS
As mentioned above pin ion shafts used with helical geari ng are usua lly
forged integral with the pinion . For other drives the pin ion shaft is care-
fully turn ed and keyseated to accommodate the pin ion for press f it .
GEAR GUARD
A p late steel gear gua rd , generally in the form of a full ci rcle is fur-
n ished to p rotect t he gear from entrance of dirt or forei gn material. It is
furnished w ith a n inspecti on door and a door to be used for the application
of gear lubr icant. It is made dust resista nt for operations under extremely
dirty and dusty condi t ions. The gear guards are designed to be mounted
independently of the mill proper.

SPECIAL FEATURES
Where spec ific cond itions call for specia l features . th ese can be pro-
vided . For examp le : Splitters for d istri but ing m ill d ischarge to two separate
cl assi fiers ; Rubber lining of heads , shells or feeders fo r resistanc e agai nst
abra sion or corrosion; sectionalizing for transportation restrictions ; special
"""' designs for metal reclaiming work ; discharge trammels and elevators ;
heavy duty scrubber applicatio ns.

17
General Construction

SHELL LINERS
Shell liners may be furnished of various materials and
of several designs. In each case the material used is the
best obtainable , resulting in the lowest cost per ton of ore
ground. The liner contours are selected for the specific
grinding application and take into consideration liner wear, STEP TYPE SHELL LINER
scrap loss, and mill capacity.
Liners cast of Manganese Steel, Ni-Hard, Chrome-moly,
or other similar materials may be of the step type , block
type , wave type, or the two-piece plate and lifter con-
struction. These are illustrated on the right. During the
past years of building Marcy Mills various other shapes of
liners have been tried, such as the pocket type, spiral
liners, etc.; in most cases it is found that these special
shapes and designs are not justifiable frorry the standpoi nt
of economics. They involve additional costs which are not SINGLE WAVE TYPE SHELL LINER
generally recovered from an increased efficiency in mill-
ing operation.
Lorain Shell Liners consist of high carbon rolled steel
plates accurately formed to the mill shell radius. These
are held in place by rolled alloy steel heat treated lift bars.
This type liner is carefully engineered for the specific
grinding application. Variations in lift bar design and liner
plate thickness provide this flexibility of design for appli-
cation .
All shell liners designed for ball mill operations are of
such size and shape that they will easily pass through the TWO PIECE SHELL LINER
manhole opening to facilitate relining operations. In rod
mill work the design is such that they will easily pass
through the large Marcy open end discharge trunnion .
Where cast liners are used, and especially in rod mill
appl ications, we furnish rubber shell liner backing to help
cush ion the impact effect of the media within the mill and
prevent pulp racing. With the Lorain type of liner such
she ll liner backing is not required . For special applications
where severe corrosive cond itions exist a shell Iiner of
special alloys can be furnished and also the interior surface
of the shell can be treated to protect such parts from the BLOCK TYPE SHELL LINER
corrosive conditions.
HEAD LINERS
Head liners are of the segmental type constructed of
Manganese Steel , Chrome modybdenum , or Ni-Hard and
are des igned to pass easily through the manhole opening
or d ischarge opening in the case of rod mills. For ball mill
work ribs are cast with the feed head liners to deflect the
ball mass and minimize wear on the head liner itself.
In grate ball mill work there are no discharge head LORAIN TYPE SHELL LINER
liners. The discharge grates and grate assembly replace
these parts.
LINER BOLTS
Where cast liners are used shell liner bolts and head
liner bolts are made of forged steel with an oval head to
prevent turning and loosening within the liners. These are
held in place with two hex nuts and a cut washer. For
wet grinding applications special waterproof washers can
be furnished .
DOUBLE WAVE TYPE SHELL LINER

18
 MEEHANITE METAL
.... Meehanite is th e copyrighted trade name for a
uniform , closely controlled iron cast to ri gid physical
properties . The Mine and Smelter Supply Company
pioneered the use of Meehanite as applied to gri nd-
in g mi II construction.
Because of the uniformity of properties and as-
surance of manufacture according to engineering
specifications, Meehanite metal has been selected
for use in the construction of Marcy Mill heads ,
spur gears. bearings and other castings. Service
perfo rmance durin g the past years has thoroughly
-
justified and demonstrated the soundness of judg-
men t in selecting this material .
COMPARISON OF PROPERTIES
A structural comparison of medium carbon cast
stee l, ordina ry cast iron , and eng ineering types of
Meehanite metal shows considerable similarity be-
tween ord inary cast iron and cast steel. They exhibit
a matr ix consisting of soft, free ferrite with areas
of pearl ite . In addition the cast irons contain a con-
siderable quantity of coarse flake graphite. When
making a direct comparison between a carbon spring
steel and an engineering type Meehanite it is found
that both materials exhibit a high strength , excel-
lent wear res isting, fully pearlitic structure. The
Meehan ite metal, however, contains in addition a
limited contro ll ed amount of short, well distributed
flake graphite whic h is of great importance since it
imparts fre e mac hining qualities as well as casting
soundness , high dampening capacity for resonant
vibrat ions , and freedom from notch sensitivity , par-
.... ticularly under dynamic fatigue stresses.
All meta ls tend to exhibit columnar crystalliza-
tions on changi ng from the liquid to the solid state
and the junction of columnar crystals is a common
cause of structural weakness in steel and other
alloys. In the manufacture of Meehanite the nu-
cleation of crystal growth assures the formation of
an equiaxed crystal structure , free from planes of
internal weakness , shrinks, cracks and columnar
crystal embrittlement .
SOLIDITY, UNIFORMITY AND DEPENDABILITY
- In the manufacture of any metal casting, uni-
form solidity and closeness of grain throughout all
sections are basic essentials for dependable castings
and the el imination or even reduction of shrink is
a major problem with most metals. During the pro-
cess of solidification steel will shrink some 12% .
A soft gray iron casting wi II expand due to the
separation of large amounts of soft flake graphite,
and then contracts during the liquid-solid metal
transformation . This results in expansion voids and
internal porosity. With the mechanism of solidifi-
cation of Meehanite castings the amount of graph-
ite separating approximately compensates for this
liq u id-soli d shrinkage . The significance of these
facts is apparent since the Meehanite casting alone
provides density and solidity when two or more sec-
tions come together.
A design and materials engineer is concerned
with the many property characteristics of metals as
an index of their behavior under service conditions .
Thus the well recognized stress-strain diagram is
often cons ide red . Such a diagram wi II show that
both steel and Mee hanite type GA w ill have true
modulus values where stress is proportional to
strain . There is , however . no true index of mod ulu s
for ordinary cast iron . Steel has a cl early d ef ined
yie ld strength of a little ove r 35 ,000 PSI where very
considerable pla stic deformation occurs without
further load increments. Beyond this yield strength
steel would have little service value . On the other
hand a Meehanite metal casting could withstand
momentarily, overloads beyond th is value without
serious deformation even th ough the ultimate
strength was markedly lower than that of the steel
casting.
SERVICE PERFORMANCE
Several properties which are of particular sig-
nificance to the engineer have been listed . Low
notch sensitivity of Meehanite metal in relation to
the effects of keyways. grooves, sharp fillets or
defective machine finish as stress raisers. in com-
parison with high notch sensitivity of steel is of
major importance with parts subjected to dynamic
stresses. The significance of this property is clearly
defined by data obtained on the marked reduct ion
in fatigue strength of steel when subjected to notch
effects.
The reduction of endurance limit of Mehanite
type GA by induction of a groove or notch amounts
to only about 20% as compared with 50 % reduc-
tion for steel under the same conditions.
Since the fully pearlitic structure of Meehanite
is comparable to that obtained in spring and carbon
tool steels, this engineering iron provides excellent
resistance to abrasion and erosion with the added
advantage of high dampening capacity which is
effective in units subjected to dynamic loading.
Cast steels contain considerable quantities of soft
free ferrite which has low strength and low hard-
ness with poor abr.asion resisting qualities , and also
poor machine characteristics.
As a gear material Meehanite metal is excel-
lent. The high dampening capacity for vibration of
Meehan ite irons prevents buildin g up of resonant
stresses and assures noiseless, smoother operation .
The maintaining of high strength properties with
low coefficient of friction and excellent resistance
to wear assures long life in service while its capac-
ity to resist surface breakdown renders it as an
ideal gear material.
The above statements briefly discuss the main
qualities of Meehanite which are especially im-
portant when considering a material to be used in
the manufacture of grinding mills. In both ball
mill and rod mill operations the heads are stressed
alternately in compression and tension . This con-
dition is produced by rotation and aggravated by
vibration caused by the grinding media . Meehanite ,
due to its controlled structure and uniformly dis-
seminated carbon content has dampen ing qualitieo
which minimize the effect of vibrat ion .
19
 ROD MILLS

MARCY OPE,.., END DISCHARGE

The Marcy Principle of Grinding-"Rapid change

of mill content is necessary for high efficiency."
Marcy Mills have a very large discharge opening or
area and smaller area for incoming feed. The gradient
between the incoming feed opening and the discharge
near the periphery of the shell provides a faster mi-
END PERtPHERAl DISOV.AG£
/"'a t ion of the fines than the oversize particles. In
~eep pulp level mills commonly known as "overflow
mills" this migration can not occur since material
enters and leaves at the same level by displacement
only. Independent tests have shown that regardless
of mi II shape or design , the discharge product of an
overflow mill will be the same no matter at which
end the feed enters.
Marcy low pulp mills benefit from the full im-
pact of the grinding media acting on the ore particles, CENTER PEfUPH(RAL. DISCHARGE

as it falls into the shallow pulp . With a deep pulp

level t~e grinding media is cushioned in the pulp,
thus losing its energy and reducing its grinding ability.
Marcy Mills have shown 25% to 45% more tonnage BALL MILLS
ground and a substantial reduction in power consumed
per ton of material compared size for size with over-
flow mills.
To illustrate the characteristics of various type
mills we have shown the types of discharge for rod
mills and ball mills. There are essentially four types
of rod mill discharge-the overflow type , the Marcy
,rOpen End discharge, the end peripheral discharge , and
1e center peripheral discharge. In the case of ball l.AARCY GRATE CMSCHA.RGE

mills these are the overflow type, semi-grate or inter-

mediate pulp level discharge , and the true Marcy
grate discharge. These specified mills are discussed
in more detail on pages 24-35.
A general statement can be made that the closer
the d ischarge is to the periphery of the shell, the
quicker the material will pass through and less over-
grinding will take place. This is important in both
rod mill and ball mill grinding. First, regardless of SEMI GAATE DISCHARG E

how fine a grind is required , overgrinding is costly

and undesirable. The ideal condition is to remove
the particles as soon as they have reached the opti-
mum size. Secondly, in grinding applications where a
minimum amount of fine material is prefe rred , again
a rapid flow through the grinding mill is required .
These can be accomplished with the Marcy grate for ~ OISCHAA<Z
ball mill operations, or the various Marcy discharge
arrangements for the rod mill.
OVERFLOW TYPE • MIU
r· 1

2.0
- The di scharge end of the conventional Marcy
Open End Rod Mill is virtually open as the name
implies. As a means of controlling splash and to
prevent unruly rods from moving out of the mill a
discharge plug or plug door arrangement is furnished .
The use of th is construction permits pulp to discharge
freely around the annular opening between the plug
and the discharge trunnion liner. By simple removal
of the plug the full large area of the discharge end
may be used for re-rodding , inspection of the mill
when in ope ration , and an easy access to the mill in-
terio r for relining. This large opening does away with
the necessity of manholes for mill entrance as com-
monly employed in the overflow type mill. The plug
door arrange ment is a great time saver during re-
rodding and re- lining operations.
On sma lle r diameter tylarcy Rod Mills a discharge
plug is furnished mounted on the trunnion liner and
extend ing through to line up with the discharge head
liners. T he larger diameter Marcy Mills are furnished
w ith a discha rge housing arrangement independent of
the mill. A hinged door is mounted in this housing
and easily swi ngs in or out of the discharge trunnion
liner. T hese housings are also used to control the di -
rection of discharge pulp flow leaving the mill. Such
flow may be di rected to the left. right, or directly
be low the mi ll centerline.
The d ischa rge housing is of very heavy construc-
tion for strength and rigidly. Maintenance of this
housing is kept at a minimum , the only wearing part Marcy Open End Discharge Housing
being the replaceable Manganese Steel plug door liner.

-- ·----------------------------------------------------------------------------------------------------
The d ischarge end of a Marcy Ball Mill is f itted
with grate sections approximately 3 Y2" thick, made
of special heat treated alloy steel developed for this
particular application. The grate sections have tapered
openings between 1/.1" and Ya" dependent upon the

- specific grind ing application. These are selected to

prov ide the greatest efficiency for any particular job.
The grate sections are held in place by tapered Man-
ganese Steel side clamp bars, a center discharge liner,
and end clamp bars. The discharge grates are very
simple to install and require no attention during opera-
tion . The overall life of the discharge end parts gen-
era lly is greater than that of the feed head liners or
shell liners. The discharge end of the Marcy Ball Mill
has at least ten times the discharge opening area,
through the grate slots, compared to the common
trunn ion overflow type mill. The discharge grates are
designed to run clean and free of any blinding or
choking. The pulp level in the mill may be varied
by merely changing the pulp dilution. There is no
comp li cated mechanical arrangement to compensate The above is a Marcy Mill discharge head with d is-
for pulp level changes. The side clamp bars and center

- d ischarge liner bes ides holding the grate sections in

place , act as a means of stirring up the ball charge
and reduces the amount of wear on the grate sections.
The pulp discharges through the grate slots into a
charge grates, side clamp bars, end clomp bars, a nd
center discharge li ne rs in place. The grates and side
clamp bars are accu rately ground to fit the mac h ined
surfaces of the discha rge head lifters.

lifter compartment in the discharge head , lined with

replaceable wearing parts. This lifting compartment
elevates the discharge pulp up to the level of the
d ischarge trunnion liner opening and spills this against
a deflecting cone which directs it out through the
trunn ion liner.

2.1
 ~-~~~ • • \'I • . '' '
'ft~- ·. _. ·r»~P~-~....-,~~-£:"~J._ ...._1-'- ' ' .. t

V-BELT DRIVE
Drives and Feeders

Several types of drives can be furnished, made up

of various comb inations of gearing, motors and trans-
mission equipment. The correct combination to be se-
lected takes into consideration power requirements, gear
ratings , floor space, interference from other plant equip-
ment and motor characteristics. The ma in types are de-
scribed and illustrated on these pages.
Motors considered are the squirrel cage motor, wound
rotor motor, and synchronous motor. One important ad-
vantage of the synchronous motor is the possible cor-
recting of power factor within your operation , through
its use. When using a synchronous motor we recom-
mend having 200% starting torque, 120% to 130%
pull-i n to rque , and 225 % pull-out torque. These assume
no greate r than a 10 % voltage drop at the motor
term inals.
V-belt or poly-V drives are ge nerally used on
grinding mills consuming 350 HP or less. Where
power exceeds this , drives become so large and
motors become spec ial , resulting in an uneco-
nom ical applicat ion . Generally the driven mill
sheave is of split hub construction to facilitate
field assembly. V-belt drives allow use of higher
speed motors, generally low in initial cost. Motor
speeds should be between 580 and 1160 rpm .
The lower speeds apply to large diameter mills,
the higher speeds to the smaller.

FEEDERS
Each application dictates the selection of proper feed-
ing arrangement. This depends upon whether the grind-
ing w ill be open circu it or closed circuit, and dry grind-
ing or wet gri nding. The size of feed and tonnage rates
are also important factors.
Speed of scoop lip is important. Listed below for
your convenience is a table showing critical speeds for
various radius scoops. Tip of scoop lip speed should not
exceed 90 to 95% of critical speed. Beyond this scoop
efficiency decreases and scoop will have the tendency
to throw material rather than pick it up.
CRITICAL SPEEDS OF SCOOP FEEDERS SCOOP FEEDERS
Radius c. s. Radi us c. 5. Rad ius c. 5. Rad ius c. 5.
Inches (RPM) Inches (RPM) Inches (RPM) Inches (RPM ) The single scoop feede r provides a simple
6 76.8 25 37.5 44 28 .3 63 23 .7 means of picking up and deliver ing the e ntire
7 71.0 26 36.8 45 28 .0 64 23.5
8 66 .3 27 36. 1 46 27 .7 65 23.3 amount of feed to the grinding mill. These feed-
9 62.5 28 35.5 47 27.4 66 23 .1
10 59.3 29 34.9 48 27 . 1 67 23 .0 ers are generally used where the size of feed
11 56.7 30 34.3 49 26.9 68 22.8 will be relat ively fine . The internal construction
12 54.2 31 33.7 50 26.6 69 22.6
13
14
52.1
50.2
32
33
33.2
32.7
51 26.3 70 22.4
22.3
of the feeder is such that a spiral carries the
52 26 .1 71
15 48 .5 34 32.2 53 25.8 72 22 .1 feed into the trunni on liner.
16 47 .0 35 31.7 54 25.6 73 22.0
17 45.5 36 31.3 55 25 .3 74 21.9 The double scoop feeder is furnished of sim-
18 44.2 37 30.9 56 25 . 1 75 21.7 ilar construction but has an additional advantage
19 43.0 38 30.5 57 24.9 76 21.5
20
21
42.0
41.0
39
40
30.1
29 .7
58 24 .6 77 21.3 of maintain ing a balanced and more uniform
59 24 .4 78 21.2
22 40.0 41 29 .3 60 24.2 79 21.1 feed rate to the mill. Th is design also provides
23 39.2 42 28 .9 61 24 .0 80 21.0
24 38.3 43 28 .6 62 23.8 84 20 .5 a counter-balanced rotat ing mass smooth ing out
power peaks and permits handl in g slightly higher
tonnages. Each scoop is prov ided with rep lace-
able Man ganese Steel wearing lips.

2.2
- DIRECT CONNECTED DRIVE SPEED REDUCER DRIVE

-
.....
When power exceeds 300 HP a direct connected
drive is recommended. This drive is also applicable
for lower power requirements if desired . Synchronous
motors are preferred, but in some cases wound rotor
motors may be used. Motor speeds will vary from 225
rpm to 450 rpm .
The motor and pinion shafts are connected to-
gether through a flexible coupling. This drive is the
most compact, resulting in minimum floor space. In
cases where motors must be placed away from the
mill a pilot shaft extension with flexible couplings
can be provided .
This is essentially a direct connected drive
permitting the use of higher speed motors . The
motor shaft is connected to the high speed shaft
of a reducer by a flexible coupling and similarly
the low speed shaft and pinion shaft are coupled .
Gear motors or motor reducers may similarly
be used but such applications are usually re-
stricted to drives under 75 HP.
Any direct connected drive necessitates per-
efct alignment of all rotating shafts. With Marcy
Mills the pinion shaft is fixed in position . Any
gear adjustments are made by moving mill gear
into proper mesh with the pinion .

SPOUT FEEDERS DRUM FEEDERS COMBINATION FEEDERS

This is the simplest form of
feeder consisting of a cylindrical
or elliptical chute supported in-
.... dependent of the mill and pro-
jecting directly into the trunnion
liner. This permits a continuous
flow of material into the mill and
reduces maintenance compared
to other types. This feeder pro-
vides maximum feed capacity to
a mill. It is limited to applica -
tions where sufficient elevation
of feed and any circulating load
.... permits this gravity flow . A spe-
cial trunnion liner is required.
This feeder is genera ll y used This is most often used in
for single pass grinding work. closed circuit grinding. It is gen-
The entire mi II feed enters the
drum via a chute or spout and
erally split for easy access to the
interior and lined with Manga-
an internal spiral carr ies the feed
into the trunnion liner. The drum nese Steel. Original feed enters
feeder may be used in Iieu of a the drum and return classifier
spout feeder when headroom lim- sands are picked up by the scoop .
its d irect spouting. The drum also Either a single or double scoop
provides a convenient method of
arrangement can be furn ished.
adding grindi ng balls to a ball
mill. The drum is ge nera lly lined
with Manganese Steel.

13

Rod Mills
Rod Mills may be considered either
f ine crushers or coarse grinding equip-
ment. They are capable of taking as large
as 2" feed and making a product as fine
as 35-48 mesh . Of particular advantage
is th eir adaptability to handling wet sticky
Feed and discharge heads of Marcy Rod
Mills are conical in shape providin g important
advantages over a mi II with straight heads.
1. They provide the esse ntial feed pocket and
also a space for the pulp to squeeze from the
rod mass . This internal feed pocket permits
coarser pieces of material to roll down to
the toe of the rod load and be absor bed,
minimizing rod spread.
2 . Rods will not tangle or jam.
3 . Wear on head liners is minimized .
4 . The sloping heads tend to align the rods
within the m ill.
5 . Ample space is provided to assist in inspect-
ing and sorting rods when required .
I

ores, which normally would cause diffi- SPECIFICATIONS

culty in crushing operations. Under wet
grinding condi ti'ons of course the prob-
lem of dust is eliminated . Approx. 45 %
Dia . by W eight Rod I. D. Volu me
The grinding action of a rod mill is Length w /o Rods Charge Ave. Mill Shell (Cu. Ft.J
line contact. As mater ial travels from (Feet) Pounds (Tons) HP RPM Inches Mill
the feed end to the discharge end it is
subjected to crushing forces inflicted by 2x4 6,600 1.2 6 38 27 13 .1
the grind ing rods. The rods both tumble 2x6 7 ,900 1.7 8 38 27 19.6
in essentially a parallel alignment and 3x6 19,500 4.4 23 35 43 50. 1
also spin, thus simulating the crushing 3x8 23 ,500 5.9 33 35 43 66 .8
4x 8 34,000 9.3 53 30 54 106
and grinding action obtained from a 4x 10 40 ,600 11.6 30 54 132
66
ser ies of roll crushers. The large feed 5x1 0 SD 46 ,000 14.6 91 28 60 166
tends to spread the rods at the feed end 5x12 SD 50,300 17.5 111 28 60 199
which imparts still an additional action 5x10 60,000 17.5 115 26 Y2 66 200
which may be termed scissoring. As a 5 x 12 63, 000 21.0 138 26Y2 66 240
6x12 SD 88,800 25.0 158 25 72 285
result of this spreading the rods tend to 6x 14 SD 95,300 29.1 185 25 72 332
work on the larger particles and thereby 6x12 90,500 29.7 189 23 78 339
produce a minimum amount of extremely 6x14 97 ,000 34 .8 220 23 78 396
f ine material. 7x 12 SD 95,000 34.9 225 21 Y2 84 398
7x15 SD 120,000 43 .7 285 21 Y2 84 498
The Ma rcy Rod Mill encourages the 7~12 110,000 41.0 264 20 91 467
use of a thick pulp coating both t he 7x15 135,000 51.2 330 20 91 584
8x12 122,000 52.9 340 17]12 102 603
liners and the rods, t hus minim izing steel
8x15 152,000 66 .2 430 17Y2 102 754
consumption . Continuous moveme nt of 9x12 147,500 67 .0 433 15Y2 114 763
the pulp through the rod mass eliminates 9x 15 202 ,000 83 .7 540 15 Y2 114 954
the poss ibility of short circuiting any 10x14 260,000 99 .7 620 14 .0 128 1100
mater ial. The discharge end of the Marcy 10x 16 297,000 114 .0 710 14 .0 128 1257
11x14 310,000 116.7 760 12.7 138 1330
Rod Mill is virtually open and larger in
11x16 347,000 133 .5 865 12.7 138 1521
diameter than the feed end , providi ng a 12x14 380 ,000 138.9 905 11.7 150 1583
steep gradient of mater ial flow through 12x16 434 ,000 158.8 1030 11.7 150 1810
the mill. This is described in more detail
on pages 20 and 21 .
End Per ipheral discharge and center
peripheral discharge rod mills are de-
scribed in detail on pages 28 and 29 .

2.4
-
The following cost advantages should be
considered when evaluating rod mill grinding :
1. Rod Mills use low cost grinding media .
2 . Less power is required since grinding rods
are not cascaded and operate at lower per-
ipheral speeds.
3 . Higher grinding efficiency is obtained since
there is less void space in a rod charge com-
pared to any other grinding media . This also
results in lower steel consumption .
The Marcy Rod Mill is probably the most
flexible type of grinding unit available. The fine-
ness of grind and tonnage may be easily varied
by altering the mill speed. rod charge or dilution .
Under dry grinding conditions the rod mili
product may be altered by varying tonnage . size
of feed, size and quantity of grinding med ia and
the use of peripheral discharge ports .
Normally Marcy Mills are furnished of the

-
4 . Marcy's heavy rigid construction combined
with the Marcy open end feature insures
maximum operating time.
5 . Grinding rods can be kept in maximum work-
two trunnion design . For special applications they
may be furnished of the tire--trunnion or two-
tire construction . These mills can be equipped
with any type of feeder and type of drive . dis-
cussed separately in this catalog.

- ing condition since worn rods may easily be

withdrawn .

Mill Size FEED 1" 1" 1" 1" 1" Per ipheral
Dia . by GRIND 8 mesh 20 mesh 35 mesh 48 mesh 65 mes h Speed
Length %-200 20-30 30-42 42-55 55-65 65-75 (Feet / M in )
(Feet) Mesh

2x4 24 18 15 12 9 244
2x6 36 27 22 18 14 244
3x6 135 100 80 67 50 359
3x8 180 135 107 89 67 359
4x8 310 235 185 155 116 387
4x10 385 290 230 190 145 387

- 5x10
5x12
5x10
5x12
6x12
545
650
690
835
990
410
490
52i)
625
740
325
390
415
500
590
275
330
345
415
490
205
245
258
310
370
403
403
420
420
432
6x14 1160 870 695 575 430 432
6x12 1180 885 710 585 440 434
6x14 1375 1025 820 680 510 434

- 7x12
7x15
7x12
7x15
8x12
1440
1790
1725
2160
2280
1080
1345
1295
1615
1710
870
1075
1035
1295
1370
715
890
860
1070
1145
535
665
645
805
855
439
439
442
442
440
8x15 2840 2130 1710 1420 1070 440
9xl2 3090 2315 1855 1540 1150 439
9x15 3860 2880 2310 1920 1435 439
10x14 4570 3425 2740 2270 1700 440
10x16 5225 3920 3130 2600 1950 440
11x14 5770 4330 3465 2870 2150 439
11x16 6600 4950 3960 3280 2455 439
12x14 7150 5360 4275 3550 2660 44 1
12x16 8150 6125 4875 4050 3040

The above tables list some of the most common Marcy Open End Rod Mill sizes.

- Capacities are based on medium hard ore with mill operating in closed circuit under wet
grinding conditions at speeds indicated . For dry grinding. speeds and power are reduce
and capacities drop 30 to 50% .

25
 Rod Mills
General Arrangement-Dimensions
MILL
SIZE
A B c D E F G H j K L M N p Q R s T u v w X

• I ,, 1 3'' 3 .. I
8-'lo~" I'' II II II ,,
2x4 4 8.z 27 1-z 82 4.4 224 36 61-z 8

2X6 9-z
I"
1~1o~" 5~ 7-104 9-18
oO I 311 I ':t It 1'1
8-z 27
• 7-zI" 28 " 25.z
I"
8~ II 4f 22f 36
01
61~ II 8
01

I" 1
15r 4r 28 .. 48 " 7~3 .. 98I "
I I ,, 01
3X6 13! 11-'111 " 5.zI" 8-44 9-11 nl • 111 " 14 L" 43" 12 lo 471 . 39'
4 4 4 4 82. 8
0 I II
28" 48" 7~3 98
n u 11

.
01
3x8 13! 13:111 " 5-I " nl • Ill • 14 8-z1 43. 12 .. 47r 39" 15.zI 42I
4 4 2 4 4
tt

13~ 15-Qi6
1 3 M II
5
10·98 12·4i6 14~ 13~
I I 5o • • 16
01
81
1
4~6
11
18 64 "
5" I"
55 ' 8-7~
1
13
I W II
4x8 5 4
' II
128 6-z 4
10 ..
4XI0 13!1.
16
11-~o~
16
• 5 12°-9~·
01 I 5"
14·4i6 142 13!"
2 16" 8r
4'-s" 18
11
64 128
5"
6zI "
7 11
358 55
II I
8-74 13
J W II

1
1i-1o~ 13~ 17~0~ " g• 01
5'-oOI 23~· 54"
I'' I
52" 6~0· 10-1" 15r
0 I II
sx1osc 35! 5 II 1l9I8 14-4j8 1418 131.
2 16
II
8.4 49 ' 7-z
Sx 12SC 35i 14-IO~ 13i6ti 19·0i6,5 .. I
5
II
141"
8
131
2
• 16" 81
4
" 5~o" 23~
1
54
01
49" 12-z
I"
7-z
I II
52
01
6~o" 10- 1" 15r'
SxiO 44
It
13-9
I
•
18 18~ 11 •
H
sf 1i-9
01 1
15 -8f 17~ • 17~ " 16 " 9f 1
5 -6
01
24 68l" 61 131" 71 " 47r 68r lo-g£ 15r
ol
z 2
5~6· 24
1

s8f 51 • 634
301
132
I II
7.z
I"
H

47~ 68~ 10-~ 152

tl I H I ll

6xi2SD 44i 15'-3 " 18.z 21~5z'

I"
8
8" 16-4 18-6.z
I ft I I.
7~6 .. 61r 62 " 21 ~··
8 II
,, c:." I .. I 1"
398 6-0 11-14 18
II

1
6xi4SD 44~ 18'-3 "
01 1''
I" 7~6 " 61~ ••
01 311 U ,5M I II I 11
18.z 2:3-5!"
8
8 18-4" 26-5!'
2
211"
2
22!"
2
16 10" 62 " 21 8 11 39 8 6-o 11-14 18
Ill 3 11 31t ,..
8~514 64
I , .. 11 I II
3" 01 01 II II
6 XI 2 36 8 11-0 2 18 18-11 4 2s4 232 20 9-
4 68 II II

8~5i4 54"
I"
ss ' s'-6' 11~10" ra"
I tl II
20° 9-3"
I ,. II II
6xl4 368 19-0.z 18" 20-111
4
25:i
4
23!"
2 4 6-6 21 II II

MILL
SIZE
A B c D E F G H J K L N p Q R S T u v w
3 II I II I J'' 1 01
7x i2SD 454 21 7-0 6- 04 6 -1 18 II 12 54
~~~
7~0 "
I

6 - 04 6°· 1 18 12 54"
3 II I" 10 I 01
454
0
7- 6
"
15 " 18 " 12 54 7-0
682 68i6
3 II I" 01 II I II
7)( 15 454 682 18" 12 54 7-0

51
t 511 t'' I 0 II
8xl2 6 - 4i6 58j6 6-9 12· 11

6 1 -4~
1

8XI5 51 r'' 6-9

58i6 '
16
II I 3 II I 7 II II Ill
9)(12 55 6-9 4 6 - 88 12 624
11
9xl5 55
3" I I' I II 11
10XI4 73i6 8 -5
I
8-6
01
21 14
01
7-t 1d-o 19-'s "
3 II II
7~1
I 1 01
10XI6 73i6 8-5 8 - 5"
I II 3'' I 01 I I" I II I u
21-3 304 9'-11i' 9 -418 24" 14.zI" 8-9.z 12-0 2 1- 6
11
23-3" 3oio
4
31-
1 I 01 1 I

9-llt 91-4i 24" 14~I" 8-9~ 12 -0

II
2 1-6
I 01

I II 3.. I
1 01 I 01
• l lo
9-11~ 91-4t 24 142 8~-9~· 12- 0
I II I 01
21-6 304 30-1 20 " 36 " 28 I• 12 -6 21-6
I II j I 10 10 1
8~9~· 12-0
11
24° 14~
01 I 01 I 01
23 ·6 304 32-1 20 36 28 12-6 ° 21-6

2.6
 N J-- P- XTX
rF. ~ II
V-Belt
l~=:l.IJ.I
~ '-'= t-::
F--
F=j \ ~
Drive
p
.rnl
~

~El
1/ s~ =
'--

D
I--A B
G
H -E F c--L
..... F=
j

- - -- -
p...
y ~ LJ

r
The above dime ns ions are approximate
M l and for prel iminary use o nl y. Ri ght hand mills
'\ . --e:::::: are shown . Fo r left-hand m ills put drive o n
J
fl 1/ opposite side . Dr ive may al so be loca ted at
discharge end .

--:
~H
,......
~ N N Direct-Connected
~FJ
H F9
~
9~
Drive
--' "--

~
~

~§ l/1~a ~F= =
'-- r-

- I--A

~~
E
j
=
D
B
G
F C L

--

~ __,
Th e above d ime nsio ns are approxima te a nd

- if
_L p
r~
L~ fo r preli m inary use o nly . Ri ght-hand m ills are

?!
s hown. Fo r le ft-hand mil ls put drive o n op-
__j__ 'J:
posite si d e . Drive ma y also be located a t dis-
,I \ cha rge e nd .
Rod Mills
PERIPHERAL DISCHARGE ROD MILLS
END PERIPHERAL DISCHARGE
The Marcy End Peripheral Discharge Rod Mill
is designed to produce a minimum amount of fines
when grinding either wet or dry. Material to be
ground enters through a standard trunnion and is
discharged through port openings equally spaced
around the mill periphery. These ports are in a
separate ring placed between the shell and the dis-
charge head.
Wet Grinding
The construction of the end peripheral dis-
charge mill emphasizes the Marcy principle of
grinding. Due to the steep gradient between the
point of entry and the point of discharge the pulp
flows rapidly through the mill providing a fast
change of mill content with a relatively small
amount of pulp w ithin the grinding chamber.
The sloping or conical shaped feed head pro-
es ample space for a feed pocket to accom-
n .odate large quantities of material and assure
their entrance into the grinding rods. Any type
of feeder listed on pages 22 and 23 can be fur-
n ished for these mi lis; however, since the mi lis
are not usually operated in closed circuit grinding,
the drum or spout feeder is normally preferred .
The pulp discharge from the mill is collected
by a housing around the discharge ring and may
be directed to either side of the mill or immedi-
ately below the mill centerline.
Dry Grinding
No other type of mill is so well adapted to dry
grinding materials to -4 or -8 mesh in single pass
with the production of a minimum amount of
fines. A major factor in dry grinding is the rapid
removal of finished material to prevent cushioning
of the rods. This is accomplislied in the Marcy
End Peripheral Discharge Rod Mill.
The free discharge feature permits the grind-
ing of material having a higher moisture content
)1;Jan with other types of rod or ball mills. Marcy
·ipheral Discharge Mills have found wide appli-
Cdtion in grinding coke and friable non-metallics,
material for glass, pyroborates, as well as gravel to
produce sand. Another application is for grinding
and mixing sand lime brick materials. The rod
action gives a thorough mixture while grinding of
the hydrated lime and sand.
A dust-proof housing is prov ided to deliver the
finished product underneath the mill. Any type of
feeder can be provided but again the drum or spout
type feeder is preferred .
For specifications of Marcy End Peripheral Dis-
charge Rod M ills use table of standard open end
rod mills given on pages 24 and 25. The capacity
of the end peripheral discharge rod mill is slightly
h igher than shown for the Marcy Open End Rod
Mills.
2.8
CENTER PERIPHERAL DISCHARGE
The Marcy CPD (Center Peripheral Discharge)
Rod Mill has been developed to produce sand to
meet U. S. Government or State specifications. It
has also found application in grinding friable n<;>n-
metallics, and industrial materials and ores whtch
tend to slime excessively. Another application is
in the field of " abrasion milling" on ores such as
found on the Mesabi Iron Range . In this latter
application true grinding is not desired , but more
of a surface scrubb ing of the individual particles.
Again w ith th is construction grinding may be
done either wet or dry. In this design , however.
feed enters both ends by means of feeders and is
discharged at the center through rectangular dis-
charge ports equally spaced around the mill per-
iphery. The center discharge openings are gener-
ally contained in a separate ring placed between
shell halves. The ground material is discharged and
directed to either side or directly under the mill
by the use of a discharge ring housing.
In standard rod-milling it will be found that
rods spread apart at the feed end in the amount
of the maximum size of feed entering the mill.
In the Marcy center peripheral discharge mill the
rods are spread at both ends and parallel through-
out the length of the mill. This feature results in
more space between the rods and thereby lessens
the amount of fines produced . Furthermore , fines
are also diminished because the material moves
rapidly through the mill due to the steep gradient
of travel and the distance of travel is reduced by
half. Similarly time of contact with the grinding
media is reduced by half.
Another Marcy center peripheral discharge ad-
vantage is that a cubical shaped particle is pro-
duced. Maintenance is negligible and grinding
media is relatively inexpensive. Other types of sand
manufacturing equipment lose efficiency with wear
and require excessive maintenance . This loss of
efficiency increases rapidly as hardness of feed
increases. The Marcy Center Peripheral Discharge
Rod Mill can be easily maintained at peak oper-
ating efficiency by the periodical addition of rods.
Marcy CPD Rod Mills give a wide range of flex i-
bility to sand plant operation . By changing the
rate of feed , pulp dilution (wet grinding), and d is-
charge port area it is possible to produce and blend
sand of virtually any fineness modulus and main-
tain it within Government specifications.
Unlike many crushers or grinders the CPD Mill
can easily handle wet or sticky material. When
grinding wet, the dust nuisance is completely el im-
inated . For dry grinding applications the mill is
furnished with a dust proof discharge hous ing.
Various items must be considered in computing
the cost of producing manufactured sand . These
include wear on the constituent parts, power con-
sumption, lubrication , labor and general mainte-
 nance. Maintenance of the center peripheral dis-
charge mill is definitely much lower than that of
any other sand manufacturing mach ine . The greater
portion of the wear which takes place is on the
inexpensive high carbon steel rods. Field installa-
tions show an average of less than 1 # per ton of
sand ground as rod consumption , and from 0.08 #
to 0 . 10 # per ton of sand ground as the steel liner
wear. The overall cost of mill operation, exclusive
- of amortization . is generally less than 30c per ton
(year 1958) .
Every possible operating convenience has been
incorporated in the Marcy center peripheral dis-
charge m ill design . On most sizes the trunnions
are carried in large lead bronze bushed bearings.
The interior of the mill is readily accessible through
these large trunnion openings. The peripheral ring
housing is furnished with a door for inspection and
another lower door to facilitate sampling of the
mill discharge. Covers for the discharge ports are
furn ished allowing any variation in discharge area
which might be desired .
Given below are approximate capacities for sev- 5 ' x 12' Marcy CPO Rod M ill in Ca liforn ia
eral sizes of the Marcy center peripheral discharge
mills. Such capacities are expressed in dry tons per
hour , based on _3,4" x 4 mesh screened feed of me-
dium hard gravel. Mill discharge is generally less
than 5 % + 4 mesh in wet open circuit operations.
for dry grinding work reduce the capacities indi-
cated by approximately 30 % to 50 %.

* * Rod RPM
M ill T ons HP HP of Charge, of
Size * Pe r Ho ur To Run Motor Tons Mill

-
2x6 1- 2 7- 9 10 1.7 38.0
3x8 4- 6 25- 30 30 5 .9 35.0
4x10 10- 13 50- 60 60 11.6 30.0
5x12 SD 15- 20 85- 95 100 17.5 28 .0
5x12 22- 28 1 10- 1 15 125 21.0 26 .5
6x12 30- 38 180-197 200 29 .7 23 .0
7x12 40- 45 200-21 5 225 34.9 21.5
8x12 65- 75 325-350 350 52.9 17 .5
9x12 80- 98 41 5-450 450 67 .0 15 .5
10x14 120-140 595-640 700 99 .7 14 .0
11x14 160-190 735-780 800 116.7 12.7
12x14 190-230 880-925 1000 138.9 11.7
*Dimensio ns in feet .
** 45 % Mill volume, new liners and rods. 5' x 1 0 ' Marcy CPO Rod M ill in Pe nnsylva nia

For other specifications see table on pages 24

and 25 pertaining to standard open end rod mills.

-
29

On the previous pages of this catalog we
have discussed grinding in a general way and
have referred numerous times to the Marcy
principle of grinding. To illustrate roughly
th is principle, take a certain weight of crushed
~ re · and grind it with a mortar and pestle until
FIELD EXAMPLES OF QUICK
DISCHARGE CAINS
To illustrate the comparison of the Marcy grate
ciischarge Ball M ill to an overflow type of m ill we a re
showing on page 31 several actual case histories of
installations where the performance of grate disc ha rge
mills versus overflow mills have been p roven . In each
such test, run for long periods of t ime , the ore charac-
teristics and size of feed were ma inta ined identi cal so
that the tests could be compared under like cond it ions.
It will be noted that in each case the grate di scharge
Marcy Mill provided a high increase in tonnage w ith
a lesser increase in power consumption so that the
actual KWH per ton consumed was reduced . From
these field examples you can verify the prev ious state-
ment that an overflow type of mill has somewhere
near 70% the capacity of the Marcy grate mill. These
tests were conducted independently by the actual op-
erating companies involved .
.._.,...__.~~.;..:&·

,I of the ore particles will pass through a

65-mesh screen. Then take a similar sample
SPECIFICATIONS
but th is time grind for a few minutes and
screen at 65-mesh r~moving . the finished ma-
ter ial , then return the oversize particles and Mill Size Approx. 45 % Mill
grind for anot her short period of time and Dia . by Weight Ball I. D. Volume
Length W / 0 Balls Charge Ave. Mill Shell (Cu.
repeat the screening operation. You would (Feet) Pounds (Tons) HP RPM Inches Ft.)
find that t he actual net grinding time required
for the second sample is about half the time 2V2 X 3 4 ,800 .93 6 38. 1 31 V2 14.7
required under the first condition . This same 2V2 X 4% 5 ,900 1.40 9 38. 1 31 V2 22. 1
32 6,300 .82 6 34 .3 38 13.0
process takes place in the Marcy Grate Dis- 34 7,800 1.58 12 34 .3 38 26.0
charge Ball Mill. It must be borne in mind 3 V2 X 4 9,700 2. 12 17 33.6 423,4 33 .6
that it is the classifier which determines the 3V2 X 6 11 ,700 3 . 18 24 33.6 42 3,4 50.4
size of the finished product, not the grinding 43 SD 14,750 2.02 17 31.2 48 32. 1
mill itself. The Marcy Grate Discharge Mill 45 SD 17,500 3.37 28 31.2 48 53 .5
43 18,600 2.58 22 29.9 533,4 40.9
permits a quick discharge of the finished ma- 45 22 ,000 4.29 38 29.9 53 3,4 68 .2
terial into the classifier which makes the de- 54 SD 24,800 4.26 38 28 .5 60 67 .5
sired mesh size separation and returns the 56 SD 28,400 6.36 57 28 .5 60 101. 0
~versize particles to the mill for another pass. 54 25,500 4 .97 47 26 .8 64 V2 78.8
56 29 ,500 7.44 71 26 .8 64 % 11 8.0
Contrary to the usual belief, material does 65 SD 48 ,500 8.57 90 24 .7 76 136.0
67 SD 54,500 11 .97 128 24 .7 76 190.0
not discharge through the grates at the bot-
65 52,000 9 .32 100 24 . 1 79 148.0
tom. In fact it is carried up in the ball load 67 59,900 13 .04 142 24 . 1 79 207:0
so that the greater portion passes out from 75 74 , 100 12.41 143 21.8 91 197.0
the ball load on the upturning side of the 77 79,500 17.39 200 21.8 91 276 .0
mill , in the grate area from about half way 86 112,600 19.00 233 21.0 102 302.0
88 123,300 25.40 308 21.0 102 403 .0
below the centerline of the mill, on up to 97 142,000 28 . 10 400 20.0 114 446 .0
the point where the balls start to leave the 99 161 ,500 36.00 525 20.0 114 572.0
shell on their downward paths. This indicates 10 X 10 215 ,500 53 .30 725 17.9 128 846.0
then that the thick pulp carried in the mill is 10 X 14 269,000 71.60 975 17.9 128 1137.0
well within the ball mass where the actual 11 X 12 280,300 71.80 1040 17.2 138 1140.0
11 X 14 326 ,700 83 .80 1220 17.2 138 1330.0
grinding is taking place. The discharge grates 12 X 12 340 ,900 85.50 1305 16.0 150 1357.0
are not to control the size of particle dis- 12 X 14 397 ,800 99 .70 1520 16.0 150 1583.0
charged , but merely to retain the grinding balls
within the mill , provide the full discharge area
required , and form the steep gradient between
the feed entrance and product discharge.

30
- % Capac ity

- LOCATION

Arizona
Mil l Size
1.0. Shell
Dia. x Length
10 Y2 X 11
10Y2 X 11
DISCHARGE

Overf low
Grate
RPM

16.6
16.6
% C.S.

77 .6
77 .6
HP Tons Per
Input 24 Hrs.
665
700
1610
1850
KWH
Per

7.40
7 .02
%
Cain

15
00
Power
Ton Capacity Increase

5.2
GRIND

12 % +
48 M.
Overfl ow Mill
Compared to
Grote Mill
87

Colorado 6 Y2 X 6 Overflow 25 79 . 1 102 160 11.5 11 % + 65 70

6 Y2 X SY2 Grate 25 79 .1 112 226 8 .9 41.3 9.8 10 % + 65
Idaho 6 Y2 X 4 Y2 Ove rflow 25 79 .1 75 98 13 .7 1 % + 65 77
6 Y2 X 4Y2 Grate 25 79 .1 91 127 12.8 29 .6 21.3 1 % + 65
Mexico 8 X 6 Overflow 22 80 180 660 5. 1 Open 75
8 X 6 Grate 22 80 230 880 4.6 33 .3 22 .3 Circcui.t
Ar izona 8 X 6 Overflow 22 80 197 646 10.89 6 % + 48 70

- Canada
8 X 6
6 h x14Y2
6 Y2 x14y2
Grate
Overflow
Grate
22
24 .5
24 .5
80
81
81
242
323
390
928
1117
1430
9 .34
5.17
4.88
43 .7

28 .0
22 .8

20 .7
5 % + 48
8%
7 % + 65
65 78

Co lorado 9 Y2 X 7 Overflow 19 74 .5 287 900 5 .7 35 % + 100 81.7

9 Y2 X 7 Grate 19 74 .5 338 1100 5.5 22.2 17 .8 35 % + 100
Canada 6 Y2 x12 Y2 Overflow 18.5 59 274 945 5.2 15 % + 65 73.4
6 Y2 X 12~/2 Grate 18.5 59 331 1289 4 .6 36.4 20 .8 15 % + 65

Mill Size FEED 11./.t" 3,1.4" Y2" Y2 " %" %" 1./.t " 1./.t"
Dia . by GRIND 20 mesh 35 mesh 48 mesh 65 mesh 80 mesh 100 mesh 150 mesh 200 mesh
Length %-200 35-40 45-55 55 -65 65-75 75-82 82-88 88 -95 95-98
(Feet) Mesh

2 Y2 X 3 14 11 9 8 6% 5 4 3
2 Y2 x4 Y2 21 17 14 12 10 7 5 Y2 4
32 15 12 10 8 6 Y2 5 4 3
34 29 24 19 16 13 10 8 6
3 Y2 X 4 44 36 30 24 19 15 12 10
3 Y2 X 6 63 52 43 35 27 21 17 14
43 so 44 37 31 25 19 15 12 10
45 so 72 61 51 41 31 25 20 16
43 64 53 45 36 28 22 18 14

,-
45 106 86 75 60 46 36 30 22
54 so 115 95 81 65 50 40 32 25
56 so 171 141 120 97 74 60 48 37
54 145 120 102 82 63 51 41 32
56 21 7 180 153 123 94 76 61 48
65 SD 295 245 205 167 128 103 83 65
67 SD 4 10 340 285 230 175 143 116 90
65 335 275 235 190 150 117 95 73

-
67 460 385 325 260 205 160 130 100
75 510 425 360 290 225 180 145 113
77 700 590 500 400 315 250 202 157
86 885 735 625 500 390 310 250 195
88 1150 960 825 660 510 410 330 255
97 1450 1200 1020 815 635 505 410 315
99 1825 1500 1300 1045 800 640 520 400
10 X 10 2960 2450 2100 1700 1325 1050 850 655
10 X 14

-
3950 3270 2800 2270 1770 1400 1135 875
11 X 12 4425 3660 3130 2530 1955 1570 1270 975
11 X 14 5150 4250 3650 2940 2300 1825 1480 1135
12 X 12 5725 4750 4070 3290 2570 2035 1650 1275
12 X 14 6650 5500 4700 3800 2980 2360 1920

-
1475

. The abov~ . tables list some of the most common Marcy Grate Discharge Ball Mill
s1zes. Capac1t1es are based on medium hard ore with mi ll operating in closed circuit
unde r wet grinding conditions at speeds indicated . For dry grinding , speeds are
reduced and capacities drop between 30% to SO% .

31
 Ball Mills
General Arrangement-Dimensions
MILL
SIZE
A B c D E F G H J K L N p Q R s T u v w X

I'' I~ 7" 11 7 11 9 711 II

7- IOe 9e 6 3" I'' II
2~X3 1o1' 12 11
4 63-z 7-z.
' 5'
-
8
21 II 31-z 10 16 -8 24 " 23 8
5 ''
4 '' 191''
2 30 " 54
3" Ill!." 5' 643 " 24 11 11
4967" 71 11 6: 9 1" 128 5" 27}.4 " 28" 411' 25~ 36 "
10
32 lOiS 16 2 4 38" 10 11 16 6 " 128 4 64 "
II II
72 8-94 12~
II'
s " 12~8
1
3" II" I 7 11 I" 3" II
27~ " 28 " r" I''
I 11
34 10i6 II i6 6-16 8 64 24 38 " 1o'' 16 61 44 252 36 64
4 4
n
I " 01 ,, II ,,
6-5l 712 " 9~118 " 12
II
3" II 7 11 " '
3~X4 8 " 12
11 11
10~ 12 321 I"
64 30 421 10 16 4" 338 51 4 s1
4 372 48 6 - 10
• 1 I" " 12 01 6~ 11
72 II~ 11 48"
II II II
3~X6 7'' 51 I"
11
324I" 37 2I"
II
IOl 12 8 ·5f 8 4 30 10 16 a" 12 338 4 54 6- 10
I Ill II
Ill Ill 11 11 1
192 7-5 " 112 10-1012 98
I" 81" a8~ II
II II
45SD 1o1'
2 7-z 34 14 14 " 4 39
II
40!!
16
I"
54 37~
4
11
48 7-3
'

I Ill II I • II 10 ,, II I II Ill ol
14 "
II ~01 I"
45 1or 8-24 14~ 12- I 14~ 712 34 14 81
4 7~ 39 40 8 5~ 54 37" 48 7-3"
ol ol
3" 6~9~" I" 131-41 Ill II II II II I I' I ll 7'' I ll I" 20"
II
54SD 1o1"
2 214 4 142 8 7-z 37 60 14 14 13 172 402 42i6 62 454 56 8-ol'
2
3" 6~-9~~ , ~~ I II 71 •1 37 II I II II 11
54 1o1"
2 214 4 142 13-4Z 8 12i 2
I"
642 14
II
14 " 13
II
171'
2 49
II
51-z 6.L'
2
I"
454 56 a-9 20
11

1 " II
I 3 11 3" I I'
...>5SD 131"
8
II
23 8 ·4{ 13i 16-34 14
I I ll

9i
oo
50 6!4'' 16 1"
2 21
" 564 114 72 4oil
4 60 " ' I'
9-82 2412
13i' 16-84t '' 14 15~
1
I" II II
I ''
94 54" 6~7''
65 I~ 23 I
21 3"
J." 114 I" 3" 60
11 I t il
564 72 404 9 -82
75
111
182 16
II
114I " 60" 7-7
ol . 16 " 68i6
511
81 1' II 3 11 I lo
6-0 11 ~712
11
26 "
4 524
II I Ill 3 11 1
60 7-7 "
511 II
77 23 16 " 68i6 8-4 II 524 6 -o" 11'-71 ' 26
2
'I 01
7~0
11
10 II 12 62 " 13'-3j' 34
8

M ILL
SIZE
A B c D E F G H J K L N p Q R s T u v w
II 1 1 II 1
17~ I~" 221' 164Ill 72 " 1
10 1' 12
II
21r II~ 0 " 2 1~
11
62" 7~0
01
6 -3~
1 11
86 25 8 4 8· 6 ' 20' 22 21 21r 6 -21 II 13~6"
2 4
lo 101 II' 11 11 11 I • 11
25 " 2781" 13~ 6 ~ II
II
~~~
" I" 62" II'
'
10 " 12 7:0 "
I
88 2 1~ 19-7 8 224 161 4 72 8'- 6 " 20 22 21 21~ 6-5 6-68 13~ 82
3 11 11 ,, 1 11
25 302I '' 11-68
3 7 11
25 18-28 2485' 1.5.4 78
11 II 11
141-6!!"
I II II 11 I ll
96
I
9'- 6 11 20 231 I"36
I I
141 631" 7~6"
2 21 2 6 - 9iij 6 - 102 2 12 2 16
97 25" 30~
II
12~6~ " 25 19-26 24~·
II I 7 tl 3" • I II
9 -6
II
20 36 23!.2 21 2I "
II
6~ 9!!
II
I t'' I" 11
631' ' " 14'--;!!"
8 8 154 78 16 6-102 142 12 2. 7-6 16
1 1 I Ol 11 I "
20-2~ 24~·
; -98 II II
~II I I' ~II Ill 11 6 ~ 3~· 01
8 154 78 "
11
25 3o1" 13 -6i 25 9'-6 " 20 36 231:2 212 7-7~ 7-98
o
12 8~6 16~4!! "
2 8 142 16
11
II II

3~ 14~5"J."
11
25 21'-218 24~· • 11 II I ll 1
71- 9~ 01
142I" 12 6-32
t" 01
16~4!!
11
25 1"'1"
. 9 '-6 '1 7 -7rj' 8 ~6
11
99 8 - 4 78 20 36 23!2 212 I
6 16 8 16
" II
II I II ' II • 1 11 i'
35 26 -4~ 30 " 22~ 81 '
II II

32i 47~ 1a'-1o " 20 " 42 102 14 6 ~ 1112 "

I" 11

. 9~0
01 11
IOxiO 10-8 24 20 7 -111 8-o 8
I
17'-7
4
I II ,, 1 I II
10x12 32i" "
47~ 18-10 35 28 - 4 8z. 30 " 2212 81 " 16-a' 20
10
42" 24 20'' 8-2 8 -42
I t'l Ill 11 I
102 14 6 - 11 " 9~0
01
1i-1o"
10XI4 32~6" 474r" 20'- 10 35 " 30-4k 30 " 221' 81 " 10-8
o II
20
10
42" 24
• 20 "
I II
8-2 8-42
I 111 Ill
I~ 14 6~11
11 11 I II
9-0 1 7~ 10"
2
,,
48 22•
II
11
II x12 30~ 42 " 19~ 3 28~31 " 33 11 24 84 11:6" I
II II II
2oi' 8-7"
II I
8~11~4
11 II 1
12-11 "
II II
36 2 20 2 24 24 8 ~ 11 2d-2'
" 21~3 11 II I II ,, Ol
I I Xl4 3oi'
2 42 36 30-31" 33 " 24 " 84" 11 : 6 " 20" 48" 22' 2o1" 8 - 7 8'- 11~" 24' 24" 8:11 "
I
12-11
I
20-2
2 2 4
' ,, 11 •
34 " 11 1
454 20~21''
3"
~ 111''
II
9 ~ 8~
11
12XI2 2 49
33-k' 3o'' 90" 12-6 20 65 28" 22~ 91-4 II 24' 24 10'-6
II
' "
14-6 24-1"
4 2 16
II
3" Ill ,, 11 I 1 I ,,
90" 12-6"
I I" 01
' II
" 5''
24" 24 lo'-6"
I
12XI3 34 454 21 -2-z 49 31-114 331' 30 20 65 28' 22£ I
14-6"
2 2 9-4 9-8i6 24-1
01 I
3"
34 " 454 22-2~· 49 " 32 '- ul"
II
20" 65 " 28" 22~ 9-4" 24" 24' 10-6
I .5 11 II
12XI4 4 331" 14-6 "
o

2 30 90 12-6" 9-8i6 24- 1"

 '-N 1-N-t- P- -X-;

V-Belt
Drive

- '-t- I
- i-A- B +~+------ C - - - - f--l- D
4 •

- -j--- - - E - I
r-::I-
rt-·•

The above dimensions are ap-

proximate and for preliminary use
only. Right hand mills are shown .
H For left hand mills put drive on
opposite side. Drive may also be
'--t- located at feed end. but clearance
of scoop must be considered .

~N+N H:>:dl r. ;-- Direct Connected

4dbP ~--~
t J-111----~IR
1J(
1Th::-t-l:::t-±t-::::!-t-trtW1:Hiffl:t--ti'Rtt-+tr--tl=-IH- Drive
- -t--t-

I~

li
.... ~~ ~
'111---------IIH I

- 1-A-1- B -1-- - - - C
-t-
-----t~-+- D

=t;r-
-
I
w

The above dimensions are ap-

proximate and for preliminary use
only. Right hand mills are shown .
For left hand mills put drive on op-
posite side . Drive may a lso be lo-
cated at feed end . but clearance of
scoop must be considered.

33
 Essentially tube mills and pebble mills may be
considered as ball mills, the basic difference being
that the ratio of length to diameter is greater. Usually
the shell length is between 2 and 5 times the diam-
eter. These mills are primarily used to grind various
materials to 100 mesh and finer . The Marcy Tube
Mill uses iron or steel balls as the grinding media , and
~ers of various metals and alloys.
Where iron contamination is detrimental such as
in the case of grinding Feldspar for porcelain, Corun-
dum, talc , certain clays, chemicals and glass sand,
a pebble mill is indicated. In such cases the mill is
then lined with silex, granite blocks or porcelain, held
in place by special cements. The general construc-
tion of a pebble mill is much lighter since the load
is much reduced. The horsepower requirement, size
for size, is lower than for a tube mill.
Either type of mill may be operated wet or dry . Marcy Tube Mill installed at the Climax Mo-
In wet grinding the tube mill operates in closed lybdenum Corporation , Climax , Colorado.
circuit with a mechanical classifier. In dry grinding
an air separator is used on the finer separations to
classify and return the oversize to the mill. A great
number of these mills will operate in open circuit
on single pass grinding. Feed size is usually limited
to -Ys" in pebble mill grinding and may be increased
Pebble Mills
slightly to about lh" in tube mill grinding. One of
the main applications is in the regrinding of flota-
tion concentrates prior to further treatment.
The use of grates in these long mills for the pur-
~se of increasing the migration of finished product
becoming more and more common . Tests con-
ducted at a Canadian plant have shown 30% to
40% tonnage increase when using grates as com-
pared to an overflow type. L1ttle or no increase
in power or pebble consumption was noticed. Tests
run by Sylvanite Gold Mines in Canada have shown
13% to 25% more -200 mesh produced on a power
basis in a Marcy Grate Tube Mill than produced in
an overflow tube mill. On the basis of mill volume
the grate mill shows 10% to 29% more capacity per
cubic foot than overflow tube mills.
These Marcy Mills are available with a wide
variety of feeders and types of drives. These are
described in more detail on pages 22 and 23. The
general construction of these mills is similar to that
outlined in the section pertaining to Marcy Mill con-
struction.
For special applications these mills can be de-
signed for batch grinding work rather than the nor-
mal continuous grind.

34
 The table below lists a few sizes of Marcy Grate
Discharge Ball-Tube mills with thei r typical capacity
based on wet grinding 8 mesh fee d to 100 mesh in
PEBBLE MILL MEDIA AND LINING
closed circuit with a suita b le classifier. For dry grind-
ing reduce capacity approximately 30 % to 50 %. The lining for pebble mills may be either stand-
ard types of metallic lining, or for the prevent ion of
Size of Approx. 45% Ball Capocity HP RPM iron contamination non-metallic material s can be
Mill Weight Charge Tons Per To HF of used . Such non -metall ic lining material is Ja sper.
(Feet ) Pounds Tons 24 Hours Ru n Motor Mi ll Silex, or other tough , hard natural stone. A recent
4 X 12 32,500 10.3 115 90 100 30 development is the Coors h igh-strength Alum ina ce-
4 X 16 38,500 13 .7 153 120 150 30 ramic m ill lining brick. This has the followin g char-
4 X 20 44 ,500 17 .2 192 150 150 30 acter istics :
5 X ]4 44,300 17 .2 242 170 200 27 Tensile strength-18 ,000 to 20 ,000 PSI
5 X 18 51 .700 22.3 312 225 250 27 Compressive stre ngth-200.000 to 225 .000 PSI

- Flexural strength--45,000 to 46 ,000 PSI

5 X 22 59 , 100 27.3 380 280 300 27
Modulus of elasticity-31 ,900 .000
6 X 10 71 ,000 18.7 329 215 250 24
6 ]4
Hardness, Moh 's Scale-9
X 86 ,200 26 .0 460 296 300 24
Specific Gravity-3.4
6 X 18 101 ,400 33 .6 590 380 400 24
6 X 22 116,600 41.2 723 46 5 500 24 It is avai lable in 1 Y2" thick plain brick. 1 Y2"
thi ck with lifter bar integral, and 2" thick plain .
7 X 12 100,300 29 .8 600 360 400 22 .5
7 X 16 115,500 40 .0 800 480 500 22 .5 Grind ing media may be either pebbles, rock , or
8 10 127 ,800 410
the new developme nt known as Coors Alumina Ce-
X 3 1. 8 725 450 21
8 ]4 143 ,00 0 1000 570
ramic hi gh den sity grind ing med ia. The media charged
X 44.4 6 00 21
8 X 20 165 ,800 63 .4 1450 810 900 21
to a pebble mill should be betwee n 50 % to 55% of
the mill volume. The desirable characteristics of such
grind ing media are that they should be tou gh, hard .
heavy , and resistant to any chem ical action , with the
material to be ground . Pebbl e consumption generally

.-.....................................
averages 2 # per ton with a wide variation of between
Y2# to 9 # per ton . Relat ively smooth lining results
in less media wear , as does maintaining a high cir-
~ cu lating load .

COMMERCIAL PEBBLES
Pebble No. Size (Inches )
The table below lists a few sizes of Marcy Pebble Minimum Max imum
Mills with their typical capacity based on regrinding 0 1 1V2
8 mesh feed to 100 mesh in closed circu it with a 1 1 -11/4 13_4- 2
2 ]3,4 2 Ys-2 Y2
suitable classifier, using pebbles ; wet grinding. For
3 2% 31/4
dry gri nd reduce capacity approximately 30% to 50 %. 4 3%-3 % 3 3/.t-4 Y2

- Size of
Mill
(Feet)
Approx.
Weight
Pounds
Pebble Capocity
Charge Tons Per
Tons 24 Hours
HP
To
Run
HP
Motor
RPM
of
Mill
5
6
7
3 Y2-4 Y2
33_4-5
4 3/.t-5 Y2
4 -5 Y2
6 -63_4
7 -7Va

-
4 X 12 24,000 3 .7 29 23 30 32
4 X 16 28 ,000 5.0 38 30 40 32 ALUMINA CERAMIC HIGH DENSITY
4 X 20 32 ,000 6.3 40 38 50 32 GRINDING MEDIA
Size No. of Pieces
5 X 14 40 ,500 6 .8 54 39 50 28 Diameter (Inches) Per Cubic Foot
5 X 18 46 ,000 8 .8 64 50 60 28 1 1960
5 X 22 51 ,500 10.8 75 61 75 28 11/4 1000
6 X 10 40,000 7.1 63 43 60 24 1Y2 580
6 14 47 ,500
]3_4 360
X 9 .6 80 61 75 24
6 X 18 55,800 12.8 96 79 100 24 2 245
6 X 22 63 ,000 15. 1 118 97 125 24 2 Y2 120
7 X 12 48,800 11.6 94 72 100 20 Th e above media weighs approximately 135 # per
7 X 16 54 ,000 15 .4 120 100 125 20 cubic foot . It is shipped in 100 # sacks . It is pre-
ground to remove the slightly rough "as fired " sur-
8 X 10 67,300 12.6 112 83 100 18 face .
8 X 14 72,300 17.6 153 117 150 18

- 8 X 20 78,000 25 . 1 220 165 200 18

35
l

RECLAIMING METALS
The Marcy Grate Discharge Ball Mill in con-
junction w ith the W il fley Concentrating table finds
wide application in foundry practice. This equip-
ment is used for recovering metals from ashes,
slag, clinker, furnace linings and cinders.
In brass foundry applications this combination
has often produced results in recovering 99Y2% of
the metal content in the foundry waste. The Marcy
method is not complex nor expensive--only limited
space is required and operation requires no specially
tra ined personnel.
COKE GRINDING
With the advent of finer grinding of iron
ores. improvements in beneficiating such ores, and
changes in pyrometallurgical treatment of ores
comes the requirement of reducing coke to finer
sizes. Marcy has in essence again pioneered in
th is application and developed ·the EPD Rod Mill
to solve this problem .
DRY GRINDING
Marcy Open End , End Periphe,al Discharge ,
CPD Rod Mills and Grate Disc harge Ball Mills are
partic ularly efficient fo r dry grinding. Such ma -
terials as limestone, cement clinker, gravel , phos-
phates, clays, gypsum, oil shale , terra cotta mix-
tures, coal and coke are economically reduced in
size through their use.
Many such applications indicate the use of
open circuit coarse grinding and in such cases the
product will contain only a small amount of over-
size material. Generally such operations are to the
4-20 mesh product size and work is done by the
Marcy Rod Mill.
As product size becomes finer closed circuit
grinding is indicated. Where the finish grind is to
36
Generally, no preliminary crushing need be con-
sidered since the Marcy Mill will handle material
up to 3 Y2" in size. This feed can be shoveled by
hand into the mill feeder or in larger plants auto-
matic feeding can be used . Water is added with
the feed . The pounding action of the balls within
the mill liberates the metallics from waste. The
coarse and fine metallics are not ground or appreci-
ably reduced in size but are clean and d ischarge
thru the special Marcy Grate slots out of the mill
and over an integral trommel. The trommel screen
removes the coarse metallics and the fines pass
thru to the Wilfley Table.
Since the waste material is ground to a slime
these fines quickly pass off the table to waste. The
heavier metallics separate out on the table and
move forward to the concentrate zone to be col-
lected. Such concentrates are about 98% pure
suitable for direct melting in a crucible. Operation
is continuous. One man may operate such a plant.
Coke will contain a variable amount of mois-
ture which critically affects the behavior in trans-
porting and actual size reduction within the rod
mill. Moisture content approximating 12% is most
common . Below this the problems are simplified .
Above 12%, moisture can nearly stop a II grinding
action-Marcy experience will guide your engi-
neers in selecting the proper mill for your specific
conditions.
35 mesh or coarser, screens can be used to ad-
vantage . A typical circuit of this type is shown
to the right on page 37. As grinding becomes finer
Marcy Ball Mills are required and closed circuit
operation is generally recommended. Air separa-
tors do the sizing work as shown in a typ ical cir-
cuit on the left of page 37.
In dry grinding work, principally fine grinding,
size reduction is accomplished predominately by
attrition rather than impact. This is accomplished
by operating such mills at lower peripheral speeds
than under wet grinding applications. Power con-
sumption for any given size mill then is lower al -
though KWH/ton of material treated will be higher
than wet grinding. This reaction is a result of a
differently acting "bed of pulp" and lack of grind-
ing media "coating".
Due to a common "swelling action " of dry
material being ground, the grinding media level is
often reduced to approximately 40-42 % of mill
volume. Dry grinding offers less steel consumption
than its equivalent wet grinding counterpart.
 Sizes and Capacities
Size of
Mill
Diameter
I.D. Shell
L.ength
Nominal
Tons / Hour
CApprox.)
0 ___ =-
32 38" 24" 1-1.5 ---- 190n-o • otno 1 ~ .. , •• ,.,.,.._
---- l oll - • , ., ..
43 48" 36" 2- 2.5
54 60" 52" 4-5
64 Y2 76" 50" 10- 12

M otor M i ll Ball * Wilfley Tables

~ ........ /

H.P. Weight Charge Required

7 Y2 6300# 1200# One
20 14750# 3000# Two
40 24800 # 5000 # Four n
75 47000# 12000# Eight
* N o. 6 or No. 11 -D. Described in Bulletin 64 -A2 . Plan Vitw of Metal Re cla iming Circu it

COKE GRINDING IN MARCY END PERIPHERAL DISCHARGE ROD MILLS

Capacity Tons Per Hour-Open Circuit
M ill Size Grinding Rod. Mill Motor Approx. 12 % Moisture Feed
Diameter Length Speed H .P. 1" Feed 6 Mesh Product 1 V.. " Feed 8 M esh Product

- 5'-0"
5'-6"
6'-0"
6'- 6"
7'-0"
12'-0"
12'-0"
12'-0"
12'-0 "
12'-0"
27

24
22
20
RPM
25 Y2 RPM
RPM
RPM
RPM
125
150
175
200
250
16
19
9
11 V2
13 Y2
8
1o Y2
12 Y2
15
17 Y2
7'-6" 12'-0" 1B Y2 RPM 300 22 20
8'-6" 12'-0" 16 Y2 RPM 350 28 26
,.9-, 6 12'-0" 16 RPM 500 39 36
,.9-,6 15'-0" 16 RPM 600 49 46

ORE
BIN

Closed Circuit W ith Me ch anical

Classifyi ng Syste m

I_ A Cklndler D Prtuuu Gouo•

8 Col llctOf E PrtiiUtl Control Vo iYt
C Rotorr Fudlr N Nuh Vo lvt
0 Ove,. lu Re!ur l'l P Flnls htd Product

.... Closed Circ uit With Air Se parator Syste m

37
 The Marcy principle of grinding is nearly universally
adapted in the cement industry. Grate Discharge
Ball Mills are the rule rather than the exception .
Rod Mills for raw and finish grinding begin to enter
the picture. Larger and larger diameter mills become
common . Lengths tend to shorten . These are in HOME OF MARCY MILLS. Aerial view of manufactur·
reality Marcy Firsts-Marcy Pioneering-The ing facilities, Denver, Colorado.
Marcy principles developed in the ore milling indus-
try applied to the cement industry. This experience become closely parallel . Only close economic study
plus the years of manufacturing know how unques- can determine which process should be used .
tionabl y qualify Marcy for the Cement Industry.
CLINKER GRINDING
RAW GRINDING Cl inker, the discharge product from the kiln , is par-
This phase of grinding may be either the wet or dry tially cooled and broken or crushed to about 3/.J''- 1"
process, the end product going to a kiln . Material as feed to finish mills. Fineness of grind is depen-
ground consists of limestone, cement rock , marl or dent upon the type of cement to be produced. Since
marine shells along with secondary materials usually fineness of grind falls below standard screen size
shale or clay. A typical raw mix consists of 75-85% accuracy, fineness of grind is determined by use of
limestone , 12-25% shale, the balance consisting of a " Wagner" Turbidometer. Desired grind then is
silica or quartzite and iron oxide. Exact proportion- expressed for example as 1750 Wagner. Another
ing is dependent upon their chemical properties be- determination is by a ir permeability surface area
fore and after calcining to cement clinker. For good method termed " Blaine". For close approximation
kiln practice the grind required is 88-92%-200 and comparison the two have the following arbi-
mesh for standard cement, 99% - 200 mesh for trary relation Wagner = Blaine -:- 1.75 . An indi -
high early. Uniform kiln feed size helps reduce ten - cation of Wagner in terms of mesh sizes is pro-
dency to form kiln rings. vided in the followi ng table :
Wagner % - 200 Mesh %-325 Mesh
WET VS. DRY 1000 78-80 62-64
Wet grinding is generally more efficient and permits 1200 82-85 70-72
a balanced feed direct to the grinding mill since a 1400 87-89 76-80
thorough mixing takes place during comminution . 1600 95-98 89-91
Since dust is not prevalent this hazard is eliminated 1800 98-99.8 94-96
and a cleaner plant results. More efficient classifica- 2000 99-99.8 97-98 .5
tion is possible although due to high d ilutions thick- 2300 100 99-99 .8
eners are required to provide about 65% solids for
kiln feed . Where low cost fuel is available, the extra GENERAL INFORMATION
heat required during calcining, to drive off water. Power Raw Grinding
is actually less costly than resorting to less efficient Wet Closed Circuit ....... . 10 - 19 HP Hrs/Ton
dry grinding. 7 - 14 KWH /Ton
Improvements in air separators and more efficient Wet Open Circui t ... ....... 12- 21 HP Hrs/Ton
dust collecting systems have minimized some of 9- 16 KWH/Ton
these problems to a point where present day costs Dry Closed CircuiL ... .... . 13 - 21 HP Hrs/Ton
10 - 16 KWH/Ton
Dry Open Circuit ............ 17- 25 HP Hrs/Ton
13 - 19 KWH/Ton
Power Clinker Grinding
Closed Circuit ·- -····------- --6.4 - 8 HP Hrs/BB L
4 .8 - 6 KWH/BBL
Material Handled
585 - 620 # raw material yields 1 BBL cement
(376#) or average ratio 1.66 : 1.

38
 HOME OF CEMENT. Aerial view of typical cement plant.
This plant now houses three 9 Y:z' x 25', an 8 Y:z ' x 7 ',
three 8 'V2 ' x 6' and one 9'V2' x 9' Marcy Crate Disc harge Installation showing one of (3) 9 Y:z ' x 25' Marcy Ball
Ball Mills and one 9 'V2' x 12' Marcy Open End Rod Mill. Mills at West Coast Cement Plant.

RAW CRINDINC-%" FEED (AVERAGE MATERIAL)

I
Mill
Size
Motor HP
Wet Dry
Mill RPM
Wet Dry
Tons- Rod
Wet
Charge
Dry
Tons- Ball
Charge
Wet Dry
Open Circuit
Wet Dry
I
Capacity - Tons Per 24 Hours
Closed
Wet Dry
!'
Wet
Closed
Dry
6 X 12 200 1SO 23 .0 17 .S 29 .7 27 .7 ·····- ----- - 900 soo 790 440 ----·· ------
7 X 12
8 X 12
2SO
3 SO
200
300
20.0 1S .O
17 .S 13.2
40 .0 38 .3
S3 .0 49.4
------
------
----··
---- --
12SO
1620
71S
900
1100
1420
625
78S
----- -
......
------ I
------ ROD
9 X 1S 600 4SO 1S.S 11.8 83 .7 78.0 ----- - ----- - 2580 1470 2260 1290 ---- -- ------ MILLS
10 X 16
11 X 16
700
900
600
700
14 .0 1O.S
12.7 9 .6
114
133
106
124
------ ------ 4000 1970
4SOO 2300
3SOO 1730
4000 2000
--··· ·
......
-----·
------ ------ -----·
12 X 16 1000 800 11 .7 8 .8 ISS 148 ------ ------ sooo 2700 4400 2380 --·-·· ---- --I
77 200 200 21.8 20 .8 --···· ------ 17.4 16 .8 81S sao 730 52S 36S 263
7 X 10 300 300 21.8 20 .8 ----·- ----- - 25.0 24 .0 1160 83S 1040 7SO S20 375
sso 40S
88
8 X 11
99
300
400
6 00
300
400
soo
21.0 19.S
21.0 19.S
20 .0 18.4
····-·
-----·
--- ---
---- ··
2S.4 24 .6
3S .O 33 .8
36.0 34 .8
122 0
1680 1240
2240 1S30
89 S 1100 810
1510 1100
2000 1380
7SS
1000
sss I
690 BALL
·----- ------
9 X 12 700 700 20 .0 18.4 --···· ---- ·- 48 .0 46 .4 2960 2040 2660 1830 1330 91S MILLS
10 X 10 800 700 17 .9 17.3 ----- - ------ 53.3 Sl.S 3000 2180 2700 1960 13SO 980
10 X 1S 12SO 1000 17 .9 17.3 ------ ----- - 80 .0 77 .2 447S 3275 4000 2940 2000 1470
II X 14
12 X 1S
12SO 12SO
ISO O 1SOO
17.2 16.6
16.0 1S.9
------
-----·
---- --
··--··
83 .8 81.0
107 103
PRODUCTS
4900 3S40
6100 48SO
1 3 -S % + 10M I
4380 3200
S47S 437S
3-S % + 28M I
2200 1600
2720 2200 I
ABOVE 40 %- 200M 46% - 200M 90%- 200M

CLINKER CRINDINC (AVERAGE MATERIAL)

Mill Motor Mill
Rod
Cha rge
Ball
Charge
I
Feed
Size
Product
Size
Open*
Circuit
Feed
Size
Product
Size
Closed*
Circuit
Size HP RPM Tons Tons Capacity Capacity
6 X 12 1SO 17.S 27 .7 ------ 1" 10 Mesh 2S60 1" 20 Mesh 1840
7 X 12 200 1S.O 38 .3 ----- - 1" 10M 3660 1" 2 0M 2640
8 X 12 300 13.2 49.4 ---- -- 1" 10M 4S70 1" 20M 3300
9 X 1S 4SO 11. 8 78 .0 ----- - 1" 10M 7SOO 1" 20M S400 ROD
10 X 16 600 1O.S 106 ----- - 1" 10M 10000 1" 20M 72SO MILLS
11 X 16 700 9 .6 124 ------ 1" 10M 11700 1" 20M 8400
148 1" 10M 13900 I" I
-
12 X 16 800 8 .8 ------ 20M 10000
BELOW-CLOSED CIRCUIT CRIN DINC CAPACITY
77 200 20.8 -----· 16 .8 20 Mesh 1750 870 3,4" 17SO sso
7 X 20 soo 20 .8 -- ···· 48 .0 20M 1750 2320 3,4" 1750 1460
88 3 00 19.S ...... 2 4 .6 2 0M 1750 1410 3,4" 1750 87S

- 8
9
10
10
11
11
X
99
X 2S
X 10
X 2S
X 12
X 30
24 800
soo
12SO
70 0
1SOO
1000
2SOO
19.S
18.4
18.4
17 .3
17.3
16.6
16.6
......
-----·
····--
······
------
---··-
......
7 3 .8
34 .8
96 .S
S1.S
129
70
174
20M
2 0M
20M
20M
20M
20M
20M
1750
1750
1750
1750
1750
1750
17 50
3930
2S80
66SO
38SO
89SO
S360
12450
3,4"
3,4 "
3,4"
3,4 "
3,4 "
3,4"
3/.j ..
17SO
17SO
17SO
17SO
1750
17SO
17SO
2440
1SSO
4000
2280
S300
3240
7SSO
BALL
MILLS

...... 90 20M 3,4"

12
12
X 13
X 36
1SOO
3000
1S.9
1S.9 ······ 24 8 20M
175 0
1750
8200
21000 3,4"
17SO
17SO
46SO
12000 I
* Bbls / 24 Hours Product S1ze. 10 Mesh - 32% 200M, 20 Mesh - 40 % 200M
1750 - Wagner

39
MARCY
DECI MAL EQUI VALENTS OF ONE INCH
1/ 64 .015625 17 / 64 .265625 33/ 64 .515625 49/ 64 .765625
l / 32 .03125 9 / 32 .28125 17 / 32 .531 25 25 / 32 .78125
3/64 .046875 19/ 64 .29687 5 35 / 64 .546875 51 / 6 4 .7968 75
l / 16 .0625 5 / 16 .3125 9/ 16 .5625 13/ 16 .8125
5 / 64 .078125 21 / 64 .328125 37 / 64 .578125 53/ 6 4 .828125

I InfOrmation 3 / 32
7 / 64
I/ 8
9 / 64
.0937 5
.109375
.125
.140625
II / 32 .34375
23/ 64 .359371
3/ 8 .375
25 / 64 .390625
19/ 32 .59375
39/ 64 .609375
5/ 8 .625
41 / 64 .640625
27/ 32
55/ 64
7/ 8
57/ 64
.84375
.859375
.875
.890625
5 / 32 . 15625 13 / 32 .40625 21 / 32 .65625 29/ 32 .90625
11 / 64 . 171875 27/ 64 .421875 43/ 64 .671875 59/ 64 .921875
3/ 16 .1875 7/ 16 .4375 11 / 16 .6875 15/ 16 .9375
13/ 64 .203 125 29/ 64 .453125 45/ 64 .703125 61 / 64 .953125
7/ 32 .21875 15/ 32 .46875 23/ 32 .71875 31 / 32 .96875
15/ 64 .234375 31 / 64 .484375 47 / 64 .734375 63/ 64 .984375
1/ 4 .25 1/2 .5 3/ 4 .75 I 1.

CONVERSION TABLES
DIRECT REVERSE DIRECT
___..
FACTOR CONVERT FACTOR
+--- ___..
FACTOR CONVERT

Area length
40.46 Acres to Ares .0247157 30.48 Feet to Centimeters .03281
43560 Acres to Sq. Ft. .000022956 .3048 Feet to Meters 3.2808
247.1 Acres to Sq. Kil ometers .0040469 2.54 Inches to Centimeters .3937
.0015625 Acres to Sq. Miles 640 .0254 Inches to Meters 39.3701
160 Acres to Sq. Rods .006250 25400 Inches to Microns .00003937
4840 Acres to Sq. Yards .0002066 25.4 Inches to Millimeters .03937
1076.391 Ares to Sq. Feet .0009290304 25400000 Inches to Millimicrons .00000003937
.0001 Ares to Sq. Kilometers 10000 1000 Inches to Mils .001
.1 55 Sq. Centimeters to Sq. ln. 6.4516 1.6093 Miles to Kilometers .6214
.0001 Sq. Centimeters to Sq. Meters 10000 .9144 Yards to Meters 1.0936
100 Sq. Centimeters to Sq. Millimeters .01
144 Sq. Feet to Sq. Inches .006944444 Power
.09290304 Sq . Feet to Sq. Meters 10.76391 .0000303 Foot Lbs./min. to H.P. 33000
.00000003587 Sq. Feet to Sq. Miles 27878400 .0226 Foot Lbs./min . to Watts 44.25
92903.04 Sq. Feet to Sq. Millimeters .000010764 .001818 Foot Lbs./ sec. to H.P. 550
.003673094 Sq. Feet to Sq. Rods 272 .25 1.356 Foot Lbs./ sec. to Watts .7375
.111111111 11 Sq. Feet to Sq. Yds. 9 746 Horse Power to Watts .001341
.0064516 Sq. Inches to Sq. Meters 1550.016
645.16 Sq. Inches to Sq. ~illimeters .00155 Volume
1000000 Sq. Inches to Sq. Mils .000001 28326.14 Cu. Ft. to Cu. Centimeters .0000353
.0000255 Sq. Inches to Sq. Rods 39204 1728 Cu . Ft. to Cu. Inches .0005787
.0007716 Sq. lnct1es to Sq. Yards 1296 28.32614 Cu . Ft. to Cu. Decimeters .035314
.386108 Sq. Kilometers to Sq. Miles 2.590 .0283261 Cu . Ft. to Cu . Meters 35.314
1000000 Sq. Meters to Sq. Millimeters .000001 .0370370 Cu. Ft. to Cu. Yards 27
1.1959899 Sq. Meters to Sq. Yards .83612736 28.3173 Cu. Ft. to Liters .035314
30.25 Sq. Rods to Sq. Yards .0330578 16.387 Cu. Ft. to Cu. Decimeters .061024
.016387 Cu. In to Cu . Meters 61.0239
.0000214 Cu. ln. to Cu. Yards 46656
.0043290 Cu. ln. to Gallons 231
.764526 Cu. Yds. to Cu. Meters 1.308044
3.7851 Gallons to Liters .2642
1.000027 Liters to Cu. Decimeters .999973
Energy
.001285 Foot Pounds to British Thermal Un its 778 Weight (Avoirdupois)
1.356 Foot Pounds to Joules .7375 1016.05 Long Tons to Kilograms .0009842
.1383 Foot Pounds to Kilogram Meters 7.233 28.3495 Ounces to Grams .035274
4.186 Gram Calories to Joules .2388 453.6 Pounds to Grams .0022046
.000947 Joules to Rritish Thermal Units 1055 .4536 Pounds to Kilograms 2.2046
107 Joules to Ergs .0093458 .0004461 Pounds to Long Tons 2240
.10198 Joules to Kilogram Meters 9.8117 .0005 Pounds to Tons 2000
3.4126 Watt Hours to British Thermal Unit .293 907 .18 Tons to Kilograms .0011023

THICKENING T ANK Flota tion Concentrates 5 to 12 sq. ft . per 24 hr. ton of solids
REQ UIREM ENTS Slimes (Cyanide Plant) 3 to 10 sq . ft . per 24 hr. ton of solids
Easy Settling Ore 3 to 6 sq . ft . per 24 hr. ton of solids
Difficult Sett ling Ore 10 to 40 sq . ft . per 24 hr. ton of sol ids
 MILL FORMULAS
To estimate Circu lat ing Load of closed circuit operation of Ball Mill and Classifier having tons original feed and
screen analys is of products :
X equals tons classifier sands
T equals tons original feed X = T(F - D )
D equals % -200 Mesh in mill discharge D-S-
F equals % -200 Mesh in classif ier overflow

- S equals % -200 Mesh in classifier sands

If screen analyses are accurate any other mesh may be used , or better . solve for several meshes and get
average fi gure .
Ext racti on from assays of Heads , Concentrates and Tailings : Ratio of Concentration .
E =
(H - T ) 100 C R =
C-T
(C- T ) H H -T
C_r.a::.. m
Amount of Reagent used : - -=-=-=--= ---=s.:/_
. . M~i n;...,....,..- * / T on o f 0 re
= . ,.
.315 x tons per 24 hrs.

MILL WATER REQU I REMENTS WATER FACTS

Cyanid e Circuits .............. 1 - 3 Tons per ton ore Cal . Water equals 8 .33 -tf equals 3 .785 liters
Flotat ion Circ u its ...... .. ...... 3 - 5 Tons per ton ore Ton water equals 240 gals . equals 908 .49 liters
Tab le Circu its ............. ..... 5 - 7 Tons per ton ore Cu . Ft. water equals 7 .48 gallons
J ig and Table C i rcuits ...... 6 - 10 Tons per ton ore
Tab le a nd Amalgamation Tons Water per 24 hours
Circuits ........ ....... .. ..... .. 8- 12 Tons per ton ore Cal. per minute
6
W ATER I N PI PES (Gallons per minute)
- Nominal Dia . of Pipe , D= Pipe Dia . D
at 6 ft . per
sec . maximum 3 1/2 8 .2 14 .6 23 33 58 91 130
4
233
5
365
2/ U.S. g. p.m. x 0 .41 at 4 ft . per
\ velocity in ft . per sec . sec . nor mal 2 Y2 5 .5 9 .8 15 22 39 61 87 156 245

PULP CALCULATIONS
w equals weight of a given volume of water
Ws equals weight of an equal volume of dry solids Ws Wp
Cs = W-(Wp -Ws) Cp = -w--
Wp equals weight of an equal volume of pulp , o r by

- Gs
Gp
wetting solids to make water level equal
equals specific gravity of solids
equals specific gravity of pulp Cp- 1 Cubic Ft . 32.038
Ws = CsW Cs - 1
s equals percent of solids in pulp per ton Cp
s = 100 Cp -_! X Cs Tons of dry sol ids per foot depth for D2 (Cp-1 lCs
Cs- 1 cp- rou nd tanks of diameter . D (in feet) . 40 .8 (Cs- 1)

TEMPERATURE
Centigrade -The freezing point of water is 0 ° .
The boiling point of water is 100° . The Cen-
tigrade scale is divided into 100 equal de-
grees between these points.
Fah re nh eit-The freezing point of water is 32 ° .
The boiling point of water is 212 ° . The Fahr-
enheit scale is divided into 180 equal degrees
between these points. The same gradation
above or below is used and when tempera-
tures drop below the zero point a minus sign
that figure by 5 and divide by 9 . To convert
Cent igrade into Fahrenheit multiply degrees
by 9 and divide by 5 . then add 32.
Reaumur Scale-The freezing ,::oint of water is
0 ° . The boiling r:;oint of water is 80 ° . The
Reaumur scale is divided into 80 equal de -
grees between these points . To convert Fahr-
enheit into Reaumur subtract 32 and multiply
that by 4 and divide by 9 . To convert Centi -
grade into Reaumur multiply by 4/5 .

- is pre-fixed . To convert degrees Fahrenheit

into Centigrade subtract 32 , then multiply

41
 AREAS AND CIRCUMFERENCES OF CIRCLES
Dia . Area Cir. Dia . Area Cir. Dla. Area Cir. Dia. Area Cir. Dia. Area Cir.

0 .0123 .3926 7 38.485 21.99 21 346.36 65 .97 45 1590.4 141.4 73 4 185.4 229.3

I
0 .0491 .7854 V2 44 .179 23 .56 V2 363.05 67.54 46 1661 .9 144 .5 74 4300.8 232 .5
0 .11 04 1.178 8 50.265 25 .13 22 380.13 69. 11 47 1734.9 147.7 75 44 17.9 235. 6
0 .1 963 1.570 V2 56.745 26 .70 397.61 70.69 48 1809.5 150.8 76 4536 .5 238 .7
0 .3067 1.963 9 63 .617 28 .27 23 Y2 415.48 72 .26 49 1885.7 153.9 77 4656.6 241.9
0 .4417 2.356 V2 70.882 29.84 V2 433 .74 73 .83 50 1963.5 157 .1 78 4778 .4 245 .0
/8 0 .60 13
0.7854
2 .748
3.141
10
V2
78 .54
86.59
31.41
32.99
24
V2
452 .39
471.44
75.40
76 .97
51
52
2042 .8
2123 .7
160.2
163.4
79
80
4901 .7
5026.5
248 .2
25 1.3
254 .5

~
0 .9940 3 .534 11 95 .03 34.55 25 490.87 78 .54 53 2206 .1 166.5 81 5153 .0
1.227 3.927 103.87 36.13 26 530.93 81 .68 54 2290 .2 169.6 82 5281.0 257 .6
1.485 4.320 12 V2 113. 10 37.70 27 572.50 84 .82 55 2375 .8 172.8 83 5410.6 260 .7

~
1.767 4.712 V2 122.72 39.27 28 615.75 87.96 56 2463 .0 175.9 84 5541 .8 263 .9
2 .074 5.105 13 132.73 40 .84 29 660.52 91.11 57 2551.8 179.0 85 5674.5 267 .0
2.405 5.498 V2 143.14 42.41 30 706.86 94 .25 58 2642.0 182.2' 86 5808.8 270 .2
2 .761 5 .890 14 153.94 43 .98 31 754 .77 97 .39 59 2734 .0 185.-4 87 5944 .7 273.3
2 3.141 6.283 V2 165.13 45 .55 32 804 .25 100.5 60 2827.4 188 .5 88 6082. 1 276 .5
6221 . 1 279 .6
~·
3 .976 7.069 15 176.71 47.12 33 855 .30 103.6 61 2922 .5 191.6 89
~361.7 282.7
~
4 .909 7.854 Y2 188.69 48 .69 34 9C7.92 106.8 62 3019.1 194.8 90
5 .940 8 .639 16 201 .06 50.26 35 962 .11 109.9 63 3117.2 197.9 91 6503 .8 285 .9
3 7 .069 9 .425 V2 213 .82 51.8 36 1017.9 113.1 64 3217 .0 201.1 92 6647 .6 289 .0
6792 .9 292 .2
~·
8 .296 10.21 17 226.98 53.41 37 1015.2 116.2 65 3318.3 204 .2 93
94 6939 .8 295 .3
~
9 .621 11 .00 V2 240.53 54.9 38 1134.1 119.4 66 3421.2 207 .3
11 .045 11.78 18 254.47 56.6 39 1194.6 122.5 67 3525.7 210.5 95 7088 .2 298.4
4 12.566 12.57 Y2 268 .80 58.1 40 1256.6 125.7 68 3631.7 213.6 96 7238 .2 301 .6
V2 15.904 14.14 19 283 .53 59.6 41 1320.3 128.8 69 3739.3 216 .8 97 7389 .8 304.7
5 19.635 15.71 V2 298 .65 61.2 42 1385.4 I 31.9 70 3848.5 219 .9 98 7543 .0 307.9
Y2 7697.7 311.0
~Uc
23.758 17.28 20 314.16 43 1452.2 135.1 71 3959.2 223 . 1 99
6 28 .274 18.85 V2 330.06 44 1520.5 138 .2 72 4071 .5 226 .1
V2 33.183 20 .42

Electrical Abbreviations
A. C. Alternating Current K.V .A. Kilo-volt amperes
D.C. Direct Current K.W . Kilowatts
E Electromotive force in volts p Power
Eff. % Effic iency P.F. Power factor
H.P. Horsepower R Resistance in ohm:;
I Current in amperes

OHMS LAW
KW = EX I X P.F. (Si ngle phase A.C. l
E E 1000
E = IR I =~ R = 1-
KW
I K.V .A. = P.F.
KW =Ex 1000 (D .C. only)

KW = 1.73 X EX I X P.F.
(3 phase A.C. )
p F = Watts KW
1000 · · Volts x Am peres KVA

2xExlxP.F. KW = .746 X HP HP = 1.34 X KW

KW = 1000 (2 phase A.C.)

CURRENT INPUT PER LINE (AMPERES PER MOTOR)

HP X 746 2 X EX Eff. X P.F.

For D.C. I= For 2 Phase A.C. I=
EX Eff. HP X 746
HP X 746 I- HP X 746
For Single Phase A.C. I = EX Eff. X P.F. For 3 Phase A.C. - 1.73 X EX Eff. X P.F.
 -
SCREEN DATA TYLE R SCALE U. S. BUREAU OF STA NDARDS
Openings Dia mete r of Ope nings
MESH Inches Mi llimeters Wire - Inches Inches M icrons

1. 050 26 .67 .1 49 1 25 ,400

.7 42 18 .85 . 135 .75 19 ,100
.525 13 .33 . 105 .5 12,700
.371 9 .423 .092 .375 9 ,520
3 .263 6 .680 .070
4 . 185 4 .699 .065 . 187 4,760
5 .157 4 ,000
6 . 131 3.327 .036 . 13 2 3 ,360
8 093 2 .362 .032 .0937 2 ,380
10 .065 1.651 .035 .07 87 1,680
12 .0661 1,4 10
14 .046 1. 168 .025 .0555 1, 190
16 .0469 1,000
20 .032 8 .833 .0 172 .0331 840
25 .0280 710
28 .0232 .589 .0125 590
35 .0164 .417 .0122 .0197 4 20
48 .0116 .295 .0092
50 .0 117 297
60 .0098 250
65 .0082 .208 .0072 210
70 .0083
80 .0069 . 175 .0056 .0070 177
100 .0058 . 147 .0042 .0059 149
120 .0049 125
150 .0041 . 104 .0026 105
200 .0029 .074 .0021 .002 9 74
270 .0021 .053 .0016 .0021 53
325 .0014 .0014 .0017 44
400 .0015 .038 .0010 .0015 37

Microns Theoretical Mesh Microns Theoretical Mesh Microns Theoretical Mesh

22 .0 673 9 .3 1590 2. 8 5 ,280
18.5 800 7.8 1898 1.64 9 ,030
13. 1 1130 5 .5 2690 1.16 12 ,7 80
11. 0 1346 3 .9 3800 .82 18 ,000

CONCRETE FOUNDATIONS An accurate determination by experimentation

Adequate foundations for any heavy equipment,
and in particular Marcy grinding mills, are extremely
important to assure proper operation of that equip-
ment. Any slight settling of foundations will cause
bearing and gear misalignment, resulting in excessive
wear and higher maintenance costs. It has been
found that concrete foundations on a weight basis
should be approximately 1 Y2 times the total weight
of the grinding mill with its grinding med ia.
Allowable bearing pressure between concrete
footings and the soi I upon which the foundation rests
should first be considered . The center of pressure
must al~ays pas~ through the center of the footing .
F~undat 1ons . subject to shock should be designed
w1th less un 1t pressures than foundat ions for station-
ary loads. High moisture content in soils reduces the
amount of allowa ble pressure that that material can
and close examination should be made to check the
exact soi I characteristics.
Portland cement mixed with sand and aggregate
in the proper proportions has come to be standard
practice in making concrete . For general reference
cem.ent is usually ~hipped in sacks conta ining one
cub~c foot of matenal. A barred usually consists of 4
cu?lc feet . Cement will deteriorate with age and will
qu1ckl y absorb moisture so it should be stored in a
cool , dry place. The sand and gravel used should be
carefully cleaned for best results to be sure of m ini-
mizing the amount of sedimentation in that material.
Concrete may be made up in different mixtures
having different proportions of sand and aggregate .
These are expressed in parts- for example a 1:2 :4
mixture indicates one bag of cement, 2 cubic feet
of sand , and 4 cubic feet of gravel . We recommend

r: support. The fo llow ing f igures may be used for quick a mixture of 1:2 :3 for ball mill and rod m ill founda -
foundation calculations : tions . The proper water to sand ratio should be care-
fully regulated since excess water wi II tend to weaken
BEARING LOAD IN TONS the concrete even more than corresponding variat ions
TYPE OF MATERIAL PER SQUARE FOOT
Soft Cla y 1 - 2
in other material ratios. Between S Y2 to 8 Y2 gallons
r Dry Sand 1Y:z- 3 Y2 of water to a sack of cement is usually recommended ,
Dry thick Cla y 3 - 6 !he lov.:-er amount to be used where higher stre ngth
Soft Rock 5 - 9 IS requ1red or where the concrete will be subject to
Grave l and Coarse Sand 7 - 10
Hard Rock (partia lly broken ) 15 - 20
severe weathering condit ions.
Hard Rock (slightly broken ) 20 - 30
Hard Rock (i n na tural surroundings) Up to 200

4
 Pages
Length of mill 6 . 10
Liner backing 18
Liner bolts 18
Liners 18. 35
Lorain liners 18
Lubricant jacks 16
Lubrication 16

Pages
Adjustment of gear and p inion 16
Advantages of the Ma rcy M i ll 4 , 24 , 25 , 31
Areas of circl es 42
Ball charge 8 , 12, 13 , 30
Ball Mills 5 , 30
Balls 5 , 12, 13
,aearings 16
ushings 16
Capacity 10 , 11 , 12, 25 , 28 , 31, 35
Cement grinding 38 , 39
Center Peripheral Discha rge 20 , 28
Circulat ing load 7 , 30 , 41
Circumference of Ci rc les 42
Classification 7 , 30
Closed circuit grind ing 7
Coke grinding 36 , 37
Concrete facts 43
Combination feeders 23
Construction 2, 14
Conversion tables 40
Critical speed 8, 9 , 22
Decimal equivalents 40
Diameter 10 , 11 ; 24 , 30
Dilution 10 , 23 , 25
Dimensions 27 , 33
Direct connected d ri ve 23
Discharge 20 , 3 1
Discharge head 15
rrives 22 , 23
rum feeder 23
Dry grinding 4 , 5, 10 , 25 , 28 , 36 , 37
Electrical fo rmulas 42
End peripheral discharge 28
Extraction 41
Feed characteristics 4 , 11' 34
Feed head 15
Feeders 22 , 23
Fine crushing 7 , 23
Fineness of grind 4 , 5 , 10 , 11 ' 25 , 30 , 34
Foundations 43
Gears 17
Grates 21, 30 , 34
Grinda bilit 3, 6
Grindi ng media 5, 10 , 12, 13 , 35
Hand of mill 27
Head liners 18
Heads 15
Helical gears 17
Herringbone gea rs 17

44
 Pages
Manufacturing facilities 2
Manufacturing methods 2 , 14
Marcy principle of grinding 1, 4, 20, 30 Pages
Media 5 , 10, 12, 13 , 35
Meehanite 14 , 19 Mill dimensions 27 , 33
Metal reclaiming 3 6 , 37 Mill selection 3. 4
Microns 43 Mill sizes 24 , 30 , 34
Mill weights 24 , 30 , 34
Motors 22
Open circuit grinding 7
,.. Open end rod mills
Overflow mills
21
20 , 31
Overgrinding 4 , 5 , 20
Pebble mills 34 , 35
Pebbles 35
Peripheral discharge 20 . 28
Per ipheral speed 8, 9 . 25
Pinions 17
Pinion shaft ):{
Pinion shaft bearings
Power 10. 11 . 12 , 24 , J I
Pulp calculat ions 41
Pulp level 20 , 30
Ratio of concentration 41
Reagent consumption 41
Regrinding 5 , 34
Rod charge 12. 24
Rod mills 4 , 23 . 24
Rods 12, 13
Rubber lining 17
Sand grinding 28
Scoop feeder 22
Screen data 43
Shape of mill 6 , 28
Shell 14
Shell liners 18
Single hel ical gears 17
Single stage grind ing 5, 7
Special features 17
Speed reducer drive 23
Speeds 5. 8. 24 .
Spout feeders
Spur gears 17
Steel consumption 12. 28
Technical serv ice 2
Temperature 41
Testing facilities 3
Thickening 40
Trunnion bearings 16
Trunnion liners 15
Trunnions 15
Tube mills 34 , 35
Two-stage grinding 7
Tyler screen s ize 43
V-belt drives 22
Volume 24
Water facts 41
Wet grinding 4 . 5, 10 , 28

45
 JHE ORE & CHEMICAL CORPORATION
235 East 42nd Street
New York, N.Y. 10017

MINE AND SMELTER SUPPLY CO.

MANUFACTUR ING DIVISION

Executive Offices and Main Plant:

3800 Race St., P.O. Box 9041
Denver 16, Colorado

Branch Offices:
Albuquerque, New Mexico; 701 Haines Ave, N.W.
El Paso, Texas ; 1515 Eleventh Ave.
New York City, N.Y.; 122 East 42nd Street
Salt Lake City, Utah; 375 West 21st Street
San Jose, Calif.; 1636 Nord Lane
Tucson, Ariz. ; P.O. Box 849

Main Export Office:

Denver, Colorado, U.S.A.

Cable Address:
MINTERPLY

Please write our Denver, Colorado office for names and addresses
of our fore ign licensed manufacturers and sa les agents .

Prin ted in U.S.A.