Review of test methods for abrasive wear in ore grinding

Maintenance costs associated with wear in coal grinding mills operating in Queensland pulverised coal-fired power stations are in excess of $10m per year. In other fuel-ore and mineral-ore processing industries metal wastage through wear and corrosion is also a major component of maintenance cost. The aim of this paper is (1) to define the relevant terminology applicable to abrasive wear and wet-grinding, and (2) to review the more commonly used test methods for examining wear associated with ore grinding. The test methods considered simulate open three-body abrasive wear and were compared in terms of their tribo-mechanical characteristics, general wear theory concepts such as wear coefficient and wear susceptibility, and the correlation of wear rate with pilot-scale and full-scale mill wear rates. The paper also reviews the application of statistical distributions as a means of interpreting wear rate data from laboratory test mills and production mills. A need for improved correlation between laboratory test results and production mill wear rates based on a more fundamental understanding of the wear processes involved was identified. This review outlines a basis for detailed work leading to this end.