BALL MILL

GRINDING

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 Ball Mill Grinding

LEARNING OBJECTIVES

 At the end of the day the trainee shall be able to :

 Describe the ball mill grinding process

 Describe ball mill internal equipment and

their impact on performance

 Describe the process principles of mill

separations and interpret the Tromp curve

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BALL MILL
GRINDING
PROCESS

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ACTION OF THE BALLS

Crushing is done by :

Cascade effect : the most efficient

grinding by rolling / crushing under pressure
material entering into the charge

Cataract effect : splitting up by impact

balls falling onto particles
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CASCADING ACTION

Nipping Angle and Particle Size!

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CATARACTING ACTION

Crushing by Impact

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RELEASE POINTS AND GRINDING

Rotation
Rotation
Release points
Re le ase Points
3
2
1 1 2 3

Lift
Lift Zo ne
Zone

Grinding
Grinding
Zone
Zone

1 - Cascading (tumbling)
1 - Cascading (tumbling)
Liners
2 - Cataracting (free fall - max impact) Liners digsdigs into charge.
into charge.
2 - Cataracting (free fall - max. impact
3 - Excessive Lift (impact on liner) Some
Some slipslip occurs
occurs.
3 - Excessive Lift (impact on liner)

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GRINDING PROCESS
 Energy transmitted by the Balls
• Mass  Ball sizes, Specific Weight
• Speed  Movement, Mill Speed, Filling, Liners
• Probability  Number, Size, Material Filling,
Contact Type
 Contact  Cataract - Impact, Low Number
of contacts
 Cascading - Friction, High Number
of contacts

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BALL CHARGE - POROSITY

Coarse Balls - Large Voids Fine Balls - Small Voids

Low Retention High Retention

 Average Ball Weight

• Total charge weight / Total number of balls [kg/ball]
 Specific Surface Area
• Total surface area / Charge weight [m2/t]

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GRINDING VERSUS FILLING

 Interparticle grinding occurs when the void

space is properly filled
 The collision of balls causes a momentary
high pressure compression
Nip or Contact points Voids where interparticle
where crushing takes grinding takes place
place
For filling ratios less than 0.6
there's steel to steel contact &
no grinding.

For filling ratios greater than 1.1,

balls are pushed apart, cushioning
impact.

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SPEED AND LINERS TYPE

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HOW A PARTITION WALL WORKS

Feed End View of Partition Side View of a Partition

without Grate Segments

3. Material gravity drops Material is lifted by

through the center hub mill rotation and is
and into the next then gravity dropped
compartment. into the next
compartment.

2. Material is lifted Gas Flow

1 2
by mill rotation.
BM Load Level
1. Material fills the Material passes
chamber, in between through the slots
. the slotted plates and and fills the lifter
blind plates chamber.

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BALL MILL

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THE MILL

Depending on their function

• Raw mill, additions (slag, limestone, ...)
• Cement Mill (pure cement or cement with additions)
• Coal Mill

The more adapted technology will be used

• Air-Swept Mills (material is sorted by air)
• Mill with end discharge - Compound Mill
• Mill with center discharge - Birotator

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 Ball Mill Grinding

THE MILL

Air
Swept
Mill

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THE MILL

End
Discharge
Ball mill
with
2
Chamber

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THE MILL

Bi-rotator

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THE BALL MILL Gas + dust

outlet
Intermediate diaphragm
Outlet diaphragm
Reject return Inlet head C2 liners Discharge box
chute C1 liners
Fresh feed
Outlet seal

Material discharge

Shell
Central or ventilation ring Feed Arrangements
Fresh air inlet Mill Heads
Central Ventilation ring grate
Supports Mill Bearings
Drive Types
Trunnion
Mill Shell

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FEED ARRANGEMENTS

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MILL HEADS

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MILL BEARINGS - TRUNNION

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MILL BEARINGS – SLIDE SHOE

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MILL DRIVE TYPE – GIRTH GEAR

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MILL DRIVE TYPE – CENTRAL DRIVES

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MILL DRIVE TYPE – GEARLESS DRIVES

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POWER RANGES OF MILL DRIVES

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BALL MILL
INTERNALS

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CONTINUOUS LIFT OR STEP LINERS

 For first compartments only

 Better wear characteristics
 Moderate lift

ROTATION

Rotation

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The step size (lifting power)

depends on
 Mill rotation speed
(% Critical Speed)

Direction of rotation  Volume load

 Grindability of feed material

BOLTLESS STEP CHAMBER

1 LINER
 Less material spillage
 Avoids bolt breakage

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SINGLE WAVE & DUOLIFT LINERS

Early release on
backslope causes
media to slip.
 For first compartments only
 Negative back slope induces
sliding
 Racing is common, wear life
is short

Rotation
It has good lift
 Duolift has a small hump in
between lifts to prevent this.
Wearlife is much better.
 Duolift is designed for mills
that had lorrain liners before

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LORAIN BAR LIFT LINING

2 1/2”
Chamber 1

1 1/2”
Chamber 2

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INSTALLED DUOLIFT LINERS

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CLASSIFYING LINERS
Diameter < 4.4m

Diameter > 4.4m

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EXAMPLES OF CLASSIFYING TYPE LINERS

CARMAN LINING

SLEGTEN - MAGOTTEAUX TYPE

NATAL (THIN PROFILE TYPE)

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RIPPLE TYPE LINERS

Grinding media to be used in 2nd chamber < 30mm

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BEST PRACTICES ON LINERS

Refer to the Best Practice

“Selection of Shell Liners”

Refer to the Best Practice

“When to Change Shell Liners”

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PARTITION / OUTLET WALL

DISCHARGE & 2ND COMPARTMENT VIEW

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PARTITION / OUTLET WALL

Double wall, full liftered design is the most
common Feed End View of Partition with Grate Segments

Outer Grate Segment

Inner Grate Segment
Center Hub or Cone
Center Screen (Mill Sweep)

Typical Chamber Filling Level

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SLEGTEN ADJUSTABLE PARTITION

 Scoop
Assembly

 Number of
open scoops
regulates the
material flow

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CONTROLLING MATERIAL LEVEL IN C1 & C2

Conventional Material Effect of the Material

Transport Flow Control
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GRINDING CIRCUITS

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OPEN CIRCUIT

Dust
Gas Collector
Material

Fan
Fresh
Feed

Mill Finished
Product
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OPEN CIRCUIT

 Little or no control of fineness

 Not adapted to high fineness
 Possibility of over grinding
 Higher temperature of products
 Broad particles size distribution
 Lower investment costs

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CLOSED CIRCUIT
Fan Fan
Dust Collector
Dynamic Dust
Separator Collector

Static
Separator
Rejects

Fresh
Finished Product
Feed
Material
Mill Gas

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CLOSED CIRCUIT
 Better regularity because of a real control
of the fineness
 High fineness is possible
 Higher flexibility and possibility of
optimisation by product
 Possibility of higher mill ventilation
 Better control of the temperature (cooling
or drying is possible in the separator)
 Higher output, better efficiency
 Narrow particle size distribution
 Higher investment costs
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DESIGN ASPECTS
OF
BALL MILL SYSTEM

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THE BALL MILL

Leff C2
Leff C1
Leff TOT
 2.8 < L/D < 3.2
D Deff
 27% < Length of first
compartment < 35% mill
L
effective length
 First Compartment
Power – 8 to 10 kWh/t
 Ball diameter in C1
from 100-90 mm to 70-
60 mm
 Ball diameter in C2
from 60-50 mm to 20-17
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 Ball Mill Grinding

ABSORBED POWER OF A MILL

SLEGTEN FORMULA :
1.27
rpm π 2.379
P = L* * J * Kj * * Fr * d * C
Vcr 4
Where : L - Useful Length of mill (m)
rpm - Mill Speed (rpm)
Vcr - The critical speed inside liners = (42.3/Fr^0.5)
Fr - Internal Diameter (inside liners) (m)
J - Ratio between the apparent ball volume and the internal volume
Kj - (1.36 – 1.2 * J)
d - Apparent density of load (t/m3) : C1=4.5 & C2=4.6
C - Constant depending on the material and the liners
= 11.262 – For clinker mill closed circuit with Slegten equipment
= 10.70 – For Clinker + Slag
= 12.16 – For raw mix

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NET AND GROSS MILL POWER

Normal values for the ratio Net/Gross power
0.90 Normally for old and inefficient mills
0.92 Polysius Combiflex Drive
0.93 Girth gear driven mill
0.94-0.95 Modern central drive mill
Unexpected values
0.88 High power losses possibly due to mill
chambers running empty.
0.97-1.00 Low power losses possibly due to charge
expansion and/or build up of clinker nibs
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BALL CHARGE DESIGN – C1

 Emphasis on crushing and less on grinding
 Typical top size:
• 80 mm Ø if easy to crush, small feedsize
• 90 mm Ø is the most common
• 100 mm Ø in rare cases; very hard, coarse feed
 Coarser ball charges, gives good crushing
capability but:
• Too porous - shorter retention
• Less surface, less grinding
• Can result in poor preparation for second chamber
if you overfeed (usually forced to underfeed)
• Extra wear
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TYPICAL BALL CHARGE FOR C1

Typical Recommendation For Smaller Feed Size

40 %
40 % 25 %

20 %
30 %
15 %
20 %
10 %
Size Size
Ø 90 / 80 / 70 / 60 mm Ø 90 / 80 / 70 / 60 mm

Bond : Equal Number of Balls

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BALL CHARGE DESIGN – C2

 Top size depends on how much preparation is done
in the first chamber. Recommendation : 30 ... 40 mm
 Smallest size depends on the discharge grate slot
size
• Practical rule of thumb; smallest Ø = 2 X slot width
• E.g. slot width = 8-10 mm; smallest Ø = 16-20 mm
 Non-classifying liners limits C2 to 3 sizes
 Classifying liners allow a large variety of Ø’s
 Best Practice “Ball Charge Optimization”
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RELATION BALL SIZE – PARTICLE SIZE

90 mm 30 mm 15 mm

40 mm 1 mm 0,1 mm

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SLOT DESIGNS

CRITERIA :
C1 Slots – With the slot
flared out,
 From 6 to 8 mm material can
pass freely
C2 Outlet Slots – without
jamming
 Larger by at least
2mm than those
of C1 outlet Beyond here, the slot
begins to widen

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MILL WATER
INJECTION

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Water Injection – Only if required

INJECTION
NO INJECTION
INLET/OUTLET

ºC ºC

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Water Injection – Only if required

ºC ºC

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Water Injection – Only if required

Inlet water injection Diaphragm water injection

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Different arrangements to compensate for different trunnions

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Different arrangements to compensate for different trunnions

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Different arrangements to compensate for different trunnions

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BALL MILL
INTERNAL
CONDITION

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CONDITIONS OF THE LIFTING LINERS

 Purpose
Insuring proper cascading
of the balls and hence
crushing of material Step
 General Condition of Liners
Plate conditions (breaks,
chips, attachments)
 Criterion
Performance should be
checked when step < 40% Rotation
of initial step (wear=60%)
 Corrective Measure
Replacement

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VOLUME LOADING – C1 & C2

 Purpose
 Insure adequate size reduction
 Insure proper ourput Measure on 1/2
step or plate
 Quick Estimate transverse center
 Distance between charge and
lower part of the trunnion
 Distance between charge and Vertical
Measurement
lower part of the ventilation
screen
 Criterion Middle Axis
 Between 28% and 34%
 Corrective Measure
 Regular recharging

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LEVEL MANAGEMENT
Volume Load vs. Specific Power
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Specific Grinding Energy

20
[kWh/t]

15

10

5
15 20 25 30 35
Volume load [%]

Best Practice “Ball Charge Level Management“

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BALL CHARGE CONDITIONS IN C1 & C2

 Purpose
 Evaluating ball charge wear
 Detecting a mechanical problem
(breakage of a diaphragm sector)
 Criteria
 Clean charge (no scrap)
 Round balls (not deformed) and
of suitable size Clean Polluted
Charge Charge
 Corrective Measures
 Ball charge sorting in case of contamination
 C1 ball sorting (every 5000 - 7000 h)
 C2 ball sorting (every 10000 - 14000 h)

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MATERIAL LEVEL IN C1 & C2

 Purpose
 Limit wear and
insure a good particle
size reduction
 Detecting the
presence of spitzers

 Quick Evaluation Overfilled compartment

 Material / ball level

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MATERIAL LEVEL IN C1 & C2

Criterion
 Material level = ball level
over the entire compt.
Corrective Measures Right level
 Change in the number of
small balls 60 mm or 50
mm in C1 and 20 mm or
17 mm in C2
 Scoop adjustments
 Control of the circulating
load Empty compartment

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MATERIAL LEVEL
 Maximum level (Ball charge is covered with material)
fine material

coarse material
balls have contact

balls loose contact

ideal case in 2nd comp.

very critical in 1st comp.

 Normal level (Material is found in between balls)
fine material

coarse material 69

balls have contact

 Ball Mill Grinding

BALL CHARGE CLASSIFICATION

Purpose
 Adapts the charge granulometry to Classified
that of the material
Criterion
 Progressive decrease of the ball size
in C2
Corrective Measures
 Sorting and optimization of the ball Unclassified
charge
 Replacing liners
 Checking the size of slots
• 6mm intermediate diaphragm
• 8mm outlet diaphragm

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VENTILATION SCREENS
Purpose Good Permeability
 Insure gas flow
 Preventing balls from passing
between compartments
General Condition
 Cleanliness
Criteria
 Maximum permeability
 Mechanical behavior with the 90 mm Total lack of Permeability
balls and screen# < 40 mm in C1
 Screen# < 15 mm in C2 to prevent 20
mm balls from escaping
Corrective Measures
 Cleaning or replacement

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DIAPHRAGM SLOTS
Purpose
Providing outlet for Scrap
the material in the
compartments while
retaining spitzers and
balls
Improving ventilation
General conditions C1 Side Slot C1 Side
Slot plugging Clearance Width Clearance

Peening, Clearances

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DIAPHRAGM SLOTS

Criteria
C1 slots from 6 to 8 mm Peened slots
C2 outlet slots larger by
at least 2 mm than those
of C1 outlet
Corrective Measures
Filing and cleaning
Diaphragm replacement

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DIAPHRAGM SLOTS

Rotation
Rotation

Slots deformed from

one end

Deformation over slot’s entire

length
Center Center

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SUMMARY
Conditions of Lifting Liners
 Performance has to be looked at if step < 40%
of initial step (wear=60%)
Volume Loading : 28% to 34%
Ball Charge Conditions :
 Clean, round shape and suitable size for the
compartment
 C1 has to be sorted every 5000 to 7000 h
 C2 has to be sorted every 10000 to 14000 h

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SUMMARY
 Material level
 Material level = ball level over the entire compartment
 Ball charge classification
 Progressive decrease of the ball size in C2
 Diaphragm slots
 First compartment slots : 6mm to 8mm
 Second compartment outlet slots larger by at least 2mm
than those of first compartment
 Ventilation screens
 They have to have the maximum permeability to let the
maximum gas flow through the mill while retaining the
balls

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Target levels for material fineness before the

intermediate diaphragm

Sieve Size Cumulative Residue

(mm) (%)
2.3 5
1 8 - 14

Basis - sieve about 0.5 - 1 Kg of material if

there are clinker nibs present.
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