Ball Mills

BALL MILL BASICS , DESIGN, OPERATION
K.P.PRADEEP KUMAR
1. Introduction
2. Movement of grinding media in a tube
mill
3. Ball charge and ball filling level
4. Components of ball mills (linings,
diaphragms, mill inlet, drive, bearing)
5. Mill ventilation, water injection and
grinding aids
6. Mill investigation
7. Case studies 8. Summar
Cascading
Catracting
Grinding Circuits
L:\DATA\Dept150\Polysius Presentation
and Training\Polysius Training\Grinding\Ball
Page 9
Mill\ballm_sepol_process.ppt 150
Open Circuit mill
closed grinding circuit with circulating air operation
Page 14
closed grinding circuit with direct air operation and fresh air supply for
fine material cooling (single pass)
Page 15
The separator in closed grinding circuit with circulating
air operation. High-pressure grinding roll as primary mill
Page 16
The separator closed grinding circuit with circulating air operation.
High-pressure grinding roll and tube mill in hybrid operation
Page 17
The SEPOL in closed grinding circuit with circulating air operation.
SEPOL after high-pressure grinding roll and tube mill for combination
and finish grinding.
Page 18
Material flows in ball mill circuits
S F(f) 85 -90%
2…3-fold material circulation
Separator collecting
cyclones
S G(g)
Separator
tube mill S A(a) filter
10 -15% sampling for

100% determination of
feed material F Mill fineness
waste air
filter
100%
finished material F
Page 19
Cascading
Catracting
Critical speed of ball mill
Ball Filling level
Diaphragms
Material transport capacity = 5 t/dm2/h
Water Injection
NO INJECTION INJECTION
Water spray INLET/OUTLET
plume
ºC ºC
toe
Slot
Slotblockage
blockage
Dehydratation Innefficiency
Innefficiencyinin
Dehydratationofofgypsum
gypsum
Coating
Coating dedusting
dedustingequipment
equipment
Low
Lowmill
millefficiency
efficiency Temperature
Temperatureoscilations
oscilations
affects ventilation
affects ventilation
•Dehydration of gypsum •Slot blockage

•Coating •Inefficiency in dedusting equipment
•Low mill efficiency •Temperature oscillations affect ventilation
Finish Mill Water Sprays
poor atomization • Poor atomization

= spray lands on load – Loss on Ignition
increases
– Exit air temp high
• Excess atomization
excess atomization
– Discharge material temp
= spray goes into air high
stream • Spray controlled by
nozzle design and air /
water ratio
Illustration of Water Spray Effects
90
80
70
Mill Shell Temp, % Range
60
50
DE Water Spray
Partiton Water Spray
40
Compartment 1 Compartment 2
30
% Distance from Mill Feed End
•Note how much cooler the 1st compartment is

•Discharge end sprays tend to have a mid-compartment hot
spot
Purpose of longitudinal samples
• judgment of grinding efficiency and grinding success along the mill
• An optimal ball mill filling will lead to steadily decreasing residues and
increasing Blaine values
• A not optimal ball filling will lead to areas where residues and Blaine values
romaine unchanged for several feet of the mill.
Page 78
Longitudinal sample (meter sample)
• one sample of approx, 1lb every 1m (approx. 3 ft) of the mill length
• sample should consist of material from outer mill areas and mill center
• sample should be taken approx. 25 mm (1 in) below surface
0m 1m 2m 3m 0m 2m 3m 4m... sampling point

• sieve residues and Blaine values should be taken for each sample
• results are inserted into a diagram
Page 79
Mill Longitudinal Sample (Meter Sample)
Good Example for Longitudinal Sample

10 0 4500
90 4000
80
3500 Bla in e
70 2 2 8 9 µ m = 8 Me sh
3000
60 10 8 9 µ m = 16 Me sh
2500 5 5 5 , 3 µ m = 3 0 Me sh
Residue % 50
40
2000 3 2 1 µ m = 5 0 Me sh
8 6 , 6 µ m = 17 0 Me sh
30 1500
7 2 , 7 µ m = 2 0 0 Me sh
20 1000 4 3 , 2 µ m = 3 2 5 Me sh
10 500
0 0
0 1 0 1 2 3 4 5 6 7 8
Meter sample points / m
Bad Example for Longitudinal Sample

10 0 3500
90 Bla in e
3000 2 2 8 9 µ m = 8 Me sh
80
70 2500 10 8 9 µ m = 16 Me sh
5 5 5 , 3 µ m = 3 0 Me sh
60
2000 3 2 1 µ m = 5 0 Me sh
Residue % 50
8 6 , 6 µ m = 17 0 Me sh
40 1500 7 2 , 7 µ m = 2 0 0 Me sh
4 3 , 2 µ m = 3 2 5 Me sh
30 1000
20
10
500
0 0
0 1 2 0 1 2 3 4 5 6 7 8
Meter sample points / m
Page 80
Material load normal
Chamber I Chamber II
Material level
Chamber I:
Normal material load: approx. 1/3 of the grinding
media surface lies bare and the grinding media
lies next to each other with the material laying
in the space between
Chamber II:
Normal material load: grinding media are just
projecting on the surface or are just covered with
material
Page 82
Material load too low
Material level
Chamber I:
• No material visible over a section
or over the entire length of the grinding
chamber.
Chamber II:
• No material visible on the surface of the
grinding media charge.
Page 84
Material load too high
Material level
Chamber I:
• Large quantities or material above and between
the grinding media no intensive grinding
• Build-up of large material pieces in front of the
intermediate diaphragm
Chamber II:
• Grinding media are covered with a 50 to 100mm
thick material layer
low degree of grinding
Page 89
Ball Filling 1. Compartment
Material load normal Material load too low
Page 91
Ball Filling 2. Compartment
Material load normal Material load too high
Page 92
Torque factor =0.73 for compartment 1
=0.69 for compartment 2
Ball filling
The filling level of the grinding media is as follows:
G(tons)
FP(%) =
π
CD  L i  (D  ) 2
i
4
FP = Filling level (%)

CD = Charge density (approx 4.5 t/m3 – 1. Compartment)
(approx 4.6 t/m3 – 2. Compartment)
Li = Effective grinding length
Di = Inside diameter
π = 3.14
Page 115
Example 1: adjustment of capacity (Clinker)
Conversion of existing system from 3500 to 5000 cm2/g (Blaine)
( (3500 - 5000)
 0.49 )
f =e 1000
= 0.4795
e =2.72
Base capacity: M2 = 100 t/h @ 3500 Blaine
Therefore: M1 = 100 t/h  0.4795
= 47.95 t/h @ 5000 Blaine
Page 119
Example 1: product fineness vs. mill capacity
Capacity (%)
130%
120%
110%
100%
90%
80%
70%
60%
50%
40%
30%
303132 3334353637 3839404142 4344454647 4849505152 5354555657 585960
Blaine ( 100)
Page 120
Example 2: adjustment of mill power consumption (Clinker)
Conversion of existing system from 3500 to 5000 cm2/g (Blaine)
( (3500 - 5000)
 0.49 )
f =e 1000
= 0.4795
Given: Wsp = 35 kWh/t @ 3500 Blaine
Therefore: 35 kWh/t
Wsp =
0.4795
= 73 kWh/t @ 5000 Blaine
Page 121
Infuence of fineness and
product/slope on the strength
of the cement
Example:
3500 5000
Blaine Blaine
Product Slope 1 1
Compressive Strength 29 49.5

after 2 days (N/mm2)
Compressive Strength 56 65
after 28 days (N/mm2)
Page 122
Classifiers
Particle size distribution
Tromp Curve
Particle Size Distribution
Area Considered at a Tromp Curve
100 %
Rejects
50%
Fines
Feed
X – Particle Size, Q - % Passing
Page 126
TROMP CURVE
Separation
Fines
Coarse
X –Particle Size
Page 127
TROMP CURVE (IDEAL SEPARATION)
Separation
Fines
Coarse
Xc – Separation Particle Size
Page 128
Separation Typical Tromp Curve
100%
90%
80%
Fines
70%
60%
50%
40%
30% Coarse
20%
10%
0%
1 10 100 1000
Particle Size (Microns)
Page 129
Heat balance in ball mill circuits
Q = Heat
System II
Qconvection, Qsepol air
QII in = QII out
radiation
Qmaterial
Qsepol air Qconvection,radiation
Qmaterial Qwater,evaporated
Qfalse air
Q exit air
Qinlet air
Qmaterial
Qfalse air
Qpower,converted
Qmaterial moisture QI in = QI out
Qwater spray
System I
Page 130
Maintenance optimisation
Since a cement cooler is an additional piece of equipment cooling by water and air is favored.
Spraying water into a finish mill for cooling is a common procedure. However, the problem is to find
the right amount of water.
What most people do not know is that too much water can even increase the mill exit temperature
and in the worst case can build up
water in the mill, condensate in mill and mill vent duct and cementate the filter bags.
For estimation purposes, the amount of water should not exceed 2-3 % of the fresh feed rate.
Air is used for cooling in the mill and the separator w/o cyclones. The air velocity in the mill is
based on the open area above the ball
charge and should not exceed
•2 m/s when grinding to 3000 Blaine
•5 m/s when grinding to 3500 Blaine
The max. airflow through the separator depends on the size and is also described in the
operation manual.

Ball Mills

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BALL MILL BASICS , DESIGN, OPERATION

10 -15% sampling for

•Dehydration of gypsum •Slot blockage

poor atomization • Poor atomization

% Distance from Mill Feed End

•Note how much cooler the 1st compartment is

• judgment of grinding efficiency and grinding success along the mill

• sample should be taken approx. 25 mm (1 in) below surface

0m 1m 2m 3m 0m 2m 3m 4m... sampling point

• results are inserted into a diagram

Good Example for Longitudinal Sample

Meter sample points / m

Bad Example for Longitudinal Sample

Meter sample points / m

Material load normal Material load too low

Material load normal Material load too high

FP = Filling level (%)

Conversion of existing system from 3500 to 5000 cm2/g (Blaine)

Base capacity: M2 = 100 t/h @ 3500 Blaine

Therefore: M1 = 100 t/h  0.4795

= 47.95 t/h @ 5000 Blaine

Given: Wsp = 35 kWh/t @ 3500 Blaine

= 73 kWh/t @ 5000 Blaine

Compressive Strength 29 49.5

Area Considered at a Tromp Curve

X – Particle Size, Q - % Passing

Xc – Separation Particle Size

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