2021/5/25 Grinding Media

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Cast Grinding Steel Balls

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Grinding Cylpebs

Forged Steel Grinding Balls

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Rod Mill Grinding Rods

EFFECT OF BALL SIZE AND PROPERTIES ON MILL GRINDING CAPACITY 

Current ball milling theory suggests that grinding capacity is influenced by the size of balls
charged to the mill. In selecting the appropriate ball charge, the first objective is to
determine that ball size which will grind the coarse particles most efficiently. This size should
be the largest ball size charged to the mill. The second objective is to provide the correct
ball size distribution to grind the finer particles in the composite ball mill feed. This objective
may necessitate charging a second, smaller ball size with the maximum ball size. The
practice of charging a pre-determined ratio of two or more ball sizes to a mill is called
rationed ball charging.

Maximum ball size is determined by several factors, including composite feed size, Bond
Work Index, mill speed, mill diameter, and circulating load. An empirical equation was
published by Azzaroni in 1981 to describe the relationship between these variables. The
Azzaroni equation indicates that the correct ball size for the 2.93 m mill is 81 mm. Years of
experience show that a 76 mm ball grinds the coarse particles most effectively.

Ball size distribution is governed by the wear law of the mill and by the wear characteristics
through the cross-section of the balls charged to the mill. With this in mind, it is interesting
to make a qualitative comparison of the ball size distributions which should be generated by
76 mm pearlitic carbon steel balls versus 76 mm martensitic alloy steel balls in the 2.93 m
mills.
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mm pearlitic carbon steel balls used have a relatively flat hardness gradient from
surface to center. Therefore, the inherent wear characteristic of these balls should be nearly
constant during their life in a mill.

Martensitic alloy steel balls are much harder, than pearlitic carbon steel balls throughout
their cross-section. However, 76 mm martensitic balls generally have a hardness gradient.
This gradient reflects varying amounts of soft transformation products such as bainite and
pearlite in the ball micro-structure. The wear rates of these products are higher than that of
martensite at equivalent carbon content. As a result, the inherent wear rate of martensitic
balls increases slightly at the ball becomes smaller. Therefore, for a given ball mill with a

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constant wear law, the resultant seasoned 76 mm martensitic ball chart should contain more
large balls, fewer small : balls, and less surface area than a seasoned charge of 76 mm
pearlitic carbon steel balls. The reduced number of small balls, combined with a lower ball
charge surface area, might explain the 6% lower grinding efficiency of a 76 mm martensitic
ball charge compared to a 76 mm pearlitic ball charge.

We analyzed the ball size distributions resulting from charging 76 mm pearlitic carbon steel
balls versus charging 76 mm martensitic alloy steel balls. This analysis was made using a
computer simulation program that Lorenzetti et al described in 1977 to assess ball size
distributions. Results for the 2.93 mills indicated that the martensitic steel ball charge should
reduce consumption by at least 30%. However, the surface area of the charge should
decrease 5% compared to the pearlitic , steel ball charge because of the hardness gradient
effect described above.

The apparent correlation between lower ball charge surface area and decreased grinding
capacity for martensitic balls warranted further investigation. We recommended a mill test
using a rationed charge of martensitic alloy steel balls. The martensitic balls would reduce
consumption. The rationed charge would increase the surface area of the ball charge.

The following experimental program was developed:

1. Conduct preliminary studies to determine a rationed charge.

2. Conduct a plant test in a 2.93 m production mill.
3. Compare grinding efficiency (tons ground per hour at a given grind) and ball
consumption in the test mill with efficiency and consumption in two adjacent 2.93 m
mills.

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