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Survey of Glaze Preparation in Discontinuous Ball Mills and Measurement of Grinding Media Charging by Computer Softwares

This document discusses methods for preparing glazes in discontinuous ball mills and measuring the charging of grinding media. It describes that the amount of grinding media charged should be around 55% of the total ball mill volume. A formula is provided to calculate the weight of grinding media needed based on the ball mill volume and media density. The document also examines using image analysis software to estimate the size distribution of different grinding media, in order to calculate the weight of media charged based on the percentage of each media size. Measuring the actual media height loaded can determine differences from the theoretical calculations.

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52 views4 pages

Survey of Glaze Preparation in Discontinuous Ball Mills and Measurement of Grinding Media Charging by Computer Softwares

This document discusses methods for preparing glazes in discontinuous ball mills and measuring the charging of grinding media. It describes that the amount of grinding media charged should be around 55% of the total ball mill volume. A formula is provided to calculate the weight of grinding media needed based on the ball mill volume and media density. The document also examines using image analysis software to estimate the size distribution of different grinding media, in order to calculate the weight of media charged based on the percentage of each media size. Measuring the actual media height loaded can determine differences from the theoretical calculations.

Uploaded by

alvarezri
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
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CASTELLN (SPAIN)

SURVEY OF GLAZE PREPARATION IN DISCONTINUOUS BALL MILLS AND MEASUREMENT OF GRINDING MEDIA CHARGING BY COMPUTER SOFTWARES
Mohammad Hossein Khodabakhsh Apadana Ceram, Qazvin, Irn

CASTELLN (SPAIN)

1. INTRODUCTION
The purpose of this paper is to describe how the characteristics have evolved of glaze preparation in discontinuous ball mills. When you are using discontinuous ball mills, you must add grinding media to the batch regularly, because the grinding phenomenon during glaze preparation has a valid proportion of grinding media to raw materials in its cycle to optimize the grinding time and size distribution. As is well known, in the first step the characteristics of the ball mills must be measured.

Figure 1. Schematic illustration of a ball mill.

DB= Internal diameter of ball mill with the liner, LB= Length of the ball mill, A= External diameter of ball mill, B= External length of ball mill, DL= Liner diameter. To calculate the real volume of the ball mill the liner diameter must be subtracted from the ball mill diameter. VB = (DB - DL) LB where VB is ball mill volume.

2. GRINDING MEDIA PERCENTAGE IN THE BALL MILL


For continuous ball mills, it is recommended to use grinding media making up about 40 to 45% of ball mill volume; these data being 50 to 55% for discontinuous ball mills (55% in this study). There is approximately 35 to 40% vacancy in the charged grinding media (40% in this study). Therefore, the real volume quantity of grinding media in a ball mill can be calculated by subtracting the vacancy of the space between grinding media from total volume occupied by the grinding media. The real volume of grinding media in a ball mill is 6055% = 33% and is 4055%= 22% of the total volume of the ball mill. This value shows that if we have charged materials less than 22% of the total volume of the ball mill, friction will occur between the grinding media. In the other way, the grinding media were put in the glass with 200 ml volume. By considering the density of the water equal to 1 and
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CASTELLN (SPAIN)

adding water to the glass to fit the container, the density of the grinding media is equal to the weight of water. Grinding media were used in 5 sizes: 2, and inch. By calculating the density, having the volume of the grinding media, the weight of the ball mill can be calculated: W= V D. In this formula, W is grinding media weight, V is grinding media volume, and D is grinding media density. The weight of the slip can be calculated by this formula: Dry weight = (0.45 V Dp) / 100, Water weight = (0.45 V Wp) / 100 where V is real volume of the ball mill, Dp is the dry percentage of materials in a slip (approximately 68~69%) and Wp is water percentage in a slip (31~32%). Slip weight is the sum of the dry weight and water weight. The ball mill cross section can be calculated from: a = 2 A Cos (1-( )), A=0.5 R2[( 0.01745 a )- Sin a], V= [(

p R2)-A] L

Figure 2. Ball mill cross section.

where R is the ball mill radius, h is the height of the empty space in the ball mill and L is the ball mill length. The desired height of the grinding media in the ball mill can be calculated by Microsoft excel software to obtain 55% of total ball mill volume. In this study, the parameters in table 2 are calculated to obtain the suitable grinding media height.

3. SIZE DISTRIBUTION OF GRINDING MEDIA WITH IMAGE ANALYSIS


To obtain the size distribution of the grinding media in a ball mill some images were prepared from ball mill grinding media by high resolution digital camera and
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CASTELLN (SPAIN)

the images was estimated by Adobe Photoshop software to real size distribution approximately. In this method, the total surface and the percentage of each grinding media size was calculated to obtain the weight of the grinding media charge in the ball mill. For ensuring the grinding media size, the size of some used grinding media was measured. Figures 4 to 8 shows measurements for 2 to 1 inch grinding media.

Figura 3.

4. SUMMARY
By comparing table 2 and 3 and manually measuring the height of grinding media in a ball mill, the difference between the practically used ball mill and its theory can be calculated. By measuring the shortage of the grinding media height, the charging content can be estimated. The size distribution of the grinding media can be measured by image analysis to calculate the percentage of each grinding media size.

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