Day 1 - 5 - BALL Mill Internals - MBu PDF

BALL MILL INTERNALS
Ball Charge, Liners and Diaphragm
Melchior Buhendwa
HTC Global – Operational Support
Cement Production Intense Training
Casablanca, 15th to 19th May 2017
THE BALL MILL INTERNALS
Outlet diaphragm
Intermediate diaphragm
Feed Head Liners
Second Chamber liners
First Chamber liners
Central Screen
Slide (5); 15/5/2017; Ball Mill Internals

BALL MILL INTERNALS – Functions in a nutshell
 Feed Head Liners – Protection; no process role
 1st Chamber Liners – Protection; Impart energy to the balls for effective crushing
 Intermediate Diaphragm – Process role – Fencing; Fineness controller;

material flow regulator; Ventilation
 2nd Chamber Liners – Protection; Impart energy to the balls for effective fine
grinding.
 Outlet Diaphragm – Process role – Fencing; Ventilation;
 Grinding Media – Crushing/Grinding

IMPORTANCE OF MILL INTERNALS!
Operational costs for a 4 m X 15 m Cement mill
Output,TPH 100 Annual running hours 6500
6500X10X53250000
Prodn.in 5 years,MT Power in 5 years,Kw 97500000
SPC, kWh/T 30 GM wear rate, g/T 30

18000
Power cost, €/kWh 0,06
Grinding
media Grinding Grinding
Normal Wt.req.in 5 Total cost Liner tonnage for 5 media cost media Power cost in Power cost
Wt. lifetime Hrs yrs in 5 years Cost/Ton years for 5 years cost/Ton 5 years / ton
Feed Head Liners 10,0 18000,0 18,1 54166,7
369687,5
30X3250000
1st Chamber shell liners
Intermediate diaphragm frame
35,0
10,0
30000,0
60000,0
37,9
5,4
94791,7
27083,3
32500001000000
Grate plates Intermediat diaphragm 5,0 15000,0 10,8 54166,7
Back plates Intermediate diaphragm 5,0 30000,0 5,4 16250,0
2nd Chamber shell liners 55,0 60000,0 29,8 74479,2
Outlet diaphragm frame 8,0 60000,0 4,3 21666,7
Grate plates Outlet diaphragm 5,0 30000,0 5,4 27083,3
Total 133,0 117,2 369687,5 0,11 97,5 126750,0 0,04 5850000,0 1,80
Cost/Ton %
Cost/Ton
Liners 0,11 5,8%
GM 0,04 2,0%
Power 1,8 92,2%
Total 1,95 Liners GM
6% 2%
Liners
GM
Power
Power
92%
All costs in €

Ball Main design criteria
 Design itself is a matter of experience

 Mainy parameters are used for the design of ball mills:
 Material to be ground
 Mill Speed
 Filling degree
 Ratio mill length to diameter
 Length of chambers
 Quantity of grinding media
 Shape of shell liners
 Ect.

Material: Grindability test acc. Zeisel**
120
Slag From Diagram:

100 Clinker
Limestone Values for spec. Energy at 3.000
cm²/g acc. Blaine:
kWh/t
80
Limestone/Trass: 12 kWh/t
60 Clinker: 26 kWh/t
Spec. energy
Slag: 42 kWh/t
40
20 ** Energy consumption at mill

shaft (without mechanical and
0
electrical losses)
1000 2000 3000 4000 5000 6000
Spec. surface acc. Blaine cm²/g

Mill speed
Critical mill speed

Is the speed which is reached when the centrifugal force FC of
grinding media is equal to his gravity force FG. In the case the
grinding ball runs on the mill lining without falling down.
F C = FG
Deff
m* * w²crit = m. g
2
De : Effective mill diameter (inside liners)

m: Mass of grinding ball
w: Angular mill speed
g: Gravity
The critical mill speed ncrit can be expressed as a function of the

mill diameter De
42,3
Slide (5); 15/5/2017; Ball Mill Internals ncrit 
Deff
Mill speed
 The ratio between the mill speed n and the critical ncrit can be
expressed in percentage k.
n
k
ncrit
 Modern ball mills in the cement industry work with a ration k of
round 75% to 76 %.
 Older mills operate between 69% – 73%
 Special case USA: Some ball mills are running with k in the
range of 76% - 80%

Action of grinding balls as function of k and f
The optimum action of grinding ball is achieved for f = 30% and

k in the range of 70% to 80%.
Ball throwing
Cataract: smooth rolling of all

the ball layers without throwing Dead Zone
BALL MILL INTERNALS: What is important?
 Design – to stand upto the Process demands
–
Upto 25% impact on efficiency

Chamber configuration
– Lifting profile for 1st chamber liners
– Slot size/configuration, Ventilation, material retention
– Classification effect of the 2nd chamber liners
– Ball charge configuration
 Quality – to stand upto the Maintenance demands

– Metallurgy – different for different parts; Liners/Grates
– Minimum thickness
– Useful lifetime
– Grinding Media quality - Maintenance and Process impact

AGENDA
1. Ball Charge Management
2. Liner types
3. Diaphragm types

Ball Charge Management
 Deciding the Quantity

– Calculation of ball charge quantity
– Calculation of absorbed motor power
 Deciding the pattern

– Feed size and composition/product size/Circuit type/internals
 Deciding the Quality

– Impact/Wear/Corrosion levels
 Characteristics of High Chromium Balls

– Specific weight and mass

Calculation of ball charge quantity

G=  Deff2  Leff  f  MK
4
Deff = effective diameter of chamber in m Deff = D – 2 x liner thickness
Leff = effective grinding length of chamber in m
f = Grinding media filling ratio
MK = bulk density of grinding media in t/m³
Reference values:
For coarse ball charge 1st chamber (90 – 60 mm): MK = 4,5 t/m³
For ball charge 2nd chamber (60 – 20 mm): MK = 4,6 t/m³

Calculation of absorbed power consumption
Method 1:
– Use Absorbed Power Formula

 P = 0.2846 DAWN
- Where D = effective diameter; A = 1,073 – J; W = total media weight in MT; N =
RPM of mill; J = Volume load (Ball charge filling degree) in decimals:
Example 30% = 0,3
 The above formula has accuracy within +/- 6%.
– When calculating power separately for the 2 chambers use

 10 to 12 kWh/T for 1st chamber
 Balance power for the 2nd chamber

Method 2: Mill absorbed Power - Slegten Formula
1.27
P = L* N * J * Kj *
π 2.379
* Deff. * ρ *C
Vcr 4
Where : P : the motor absorbed power (kW)
L : the useful length of mill (m)
N : is mill speed (rpm)
Vcr : is the critical speed inside liners = (42.3/ Deff. ^0.5)
Deff. : internal diameter (inside liners) (m)
J : Volume Loading (filling degree)
Kj : = (1.36 - 1.2*J)
ρ : is the bulk density of load (t/m3)
C : is a constant depending on the material and the liners
= 11.262 - for clinker mill closed circuit with Slegten eq
= 10.70 - for clinker + slag
= 12.16 - for raw mix

Methode 3: Mill power calculation – VDZ Formulas MT22
Formulas for practical calculations of ball mills:
42,3
Critical speed ncrit  in rpm
Deff
n
Mill speed k
ncrit

Quantity of ball charge G=  Deff2  Leff  f  MK [in Tons]
4
Pabs. = c  G  Deff  nR
Mill absorbed power
[in kW]
at mill shaft
L f k D3,5eff
Combination of formulas Pabs  33,22 * c * * * * *
Deff 100 100

Methode 3: Mill power calculation – VDZ Formulas MT22
Pabs. counter = Pabs  1

A
Total efficency A
The total efficiency A = mech * el
Following values can be used:
For mill with girth gear drive: A = mech *  = 0.92 – 0.94
For mill with central drive: A = mech *  = 0.94 – 0,96

Power consumption factor c
The factor c depends on filling degree and ball charge.
1st grinding chamber c1 = (0,31 – (0,00275*fch1))

2nd grinding chamber c2 = (0,3016 – (0,0028*fch2))
fch1: filling degree 1st chamber

fch2: filling degree 2nd chamber


– Volume loading




Deciding the pattern
Size reduction by:

Cataracting motion Cascading motion
Coarse Medium Fine

Grinding Grinding Grinding

Deciding the pattern – 1st Chamber
Cataracting motion
Coarse Medium Fine

Ø 90 – 60 [mm] balls

 Deciding the Pattern (ball charge composition) – First Chamber
– For conventional cement mills an average ball weight of 1,4kg/ball to 2 kg/ball is
used in the 1st chamber. There are several ways to achieve this:
 If the clinker is consistently coarser than 15mm then 40% by weight of 90mm … if clinker
is consistently finer then can reduce the proportion of 90mm media to as low as 15% … if
clinker size variable then better to have 40% 90mm balls.
 Remainder of first chamber media should be split between equal numbers of 60, 70 and
80mm media balls.
 The following would be typical charge grindings for the first chamber of a cement mill with
coarse, medium or fine clinker feed:
Clinker size
Coarse Medium Fine
90mm (%) 40 25 15
80mm (%) 29 36 41
70mm (%) 19 24 27
60mm (%) 12 15 17

 Deciding the Pattern (ball charge composition) – First Chamber
– Rules of thumb:
 In case of new ball charge composition start and new mill shell liners start with
round 75% of balls for each size then ball charge adjustment and optimization to
100% after mill operation/evaluation of operating data and mill axial samples.
 If ball charge composition is known, start with 80 to 85% and adjust to 100% as
explained before.
– These pattern provide an initial guideline; Fine-tuning always by taking

samples axial sample or at least sample at the diaphragm.
– For closed circuit finish mills… targets should be to attain:

 Before intermediate diaphragm: Before discharge diaphragm
- 15 – 25% R 0.5 mm 15 – 25% R 0.09 mm
- max. 5% R 2 mm max. 5% R 0.2 mm

 Deciding the Pattern – Second Chamber
– In the second chamber the primary function of the media is to finely grind
the cement
– The cement must become progressively finer as it progresses from the

intermediate to the outlet diaphragm
– This means that progressively smaller media is required along the length
of the second chamber
– The second chamber might therefore fitted with a classifying lining.

 Deciding the Pattern - Second Chamber
– If the first chamber of the mill is achieving 2,5% residue on 1mm then
there is no requirement for large media in the second chamber of a
cement mill … 1mm particles require media of max size 25mm for
optimum grinding … particles of 0.5mm need media of max size 18mm
for optimum grinding
– If grinding efficiency were the only consideration then very small media
would be used … for fine grinding the surface area of the grinding charge
is the factor determining grinding efficiency … there area 9,000 x 30mm
balls in a tone of media with a surface area of 26m2/t … there are 72,000
x 15mm balls in a tone of media with a surface area of 50m2/t …
meaning grinding efficiency should be more than doubled with 15mm
compared with 30mm media.

Deciding the pattern – 2nd chamber
Cascading motion
Coarse Medium Fine


 Deciding the Pattern - Second Chamber
– As for coarse grinding chamber, in the fine grinding chamber the average
ball weight determines the residue of the product. 28gm/ball for open
circuit and 46gm/ball for close circuit.
– Dam/Curtain consisting of 60/50/40mm balls. This dam is near the
Intermediate diaphragm and ensures that the nips and coarse particles
are broken. Normally it is in range of 15% to 25% of the total ball charge.
– Medium ball charge consisting of 30/25mm balls. It is in the middle of the
2nd chamber and is 25% to 50% of the total ball charge.
– Fine ball charge consisting of 20/17mm balls. It is 30 to 70% of the total
ball charge.
– Balls are better for generation of higher Blaine. Cylpebs are sometimes
used for reducing the residues but at a higher power consumption
(@5%)
 Typical Ball Charge Pattern - Second Chamber
Ball charge of 2nd chamber
Ball Size (mm) Coarse charge % middle charge % Fine Charge (%)
50 10
40 15 10
30 20 25 15
25 25 25 15
20 30 20 30
17 20 40
Total 100 100 100
Avrg. Ball Weight
52 37 28
(g/ball)
Specific Surface (m2/T) 29 33 39
Remember -
These pattern provide an initial guideline … their appropriateness then has
to be checked and fine-tuned by plotting the grinding diagram.


– Volume loading




– This is covered extensively in the metallurgy selection section.


– Volume loading




Diameter (mm) Weight (gm.) Number of balls per MT Specific surface (m2/MT)
100 4.001 250 7,854

90 2.917 343 8,728
80 2.049 488 9,812
70 1.372 729 11,222
60 864 1.157 13,805
50 500 2.000 15,708
40 256 3.905 19,628
30 108 9.257 26,173
25 63 15.996 31,408
20 32 31.242 39,259
17 20 50.870 46,185
15 14 74.052 52,347

AGENDA
2. Liner types
3. Diaphragm types

Liner Types
1. First Chamber Liners
2. Second Chamber Liners

Liner Types - 1ST CHAMBER SHELL LINERS
 Function
– Prepare the material for 2nd chamber or fine grinding chamber
– Crush particles to less than 5mm size
 Target values (Cement Mills)
- Open Circuit
» R1mm < 2.5%
» R90µ 40 to 50%
- Close Circuit
» R1mm < 5%
» R90µ 40 to 50%

Influence of Liner shape on lifting effect
Both lifting effects might be insufficient for very hard feed….
Lifting effect also depends on the speed of the mill……

 Most Popular Designs
– Step Liners (Plain/Wave)
– Heidelberger (HTC) Profile
– Double Wave / Block type
– Lorraine type
– Modular type – xlift, UVL

 Step Liners
Step & Wave (boltless) Step & Wave (bolted) Plain Step (bolted)
- Good mechanical life (Very Safe)

- Process life can be an issue
- Useful life for OPC around 30000 Hours (4Yrs)

1ST CHAMBER SHELL LINERS
 The step size (lifting power)

depends on
– Size of the mill
– 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
– More homogeneous
construction.

1st chamber lining plates: Type of shapes
Shapes: - Step liners, Duolift, Xlift
all created by Maggotteaux / Belgium
- Heidelberger profile created by Mr. Rock - HeidelbergCement
R1 = 200 – 600 mm
R3 < R2 < R1
Step liners Heidelberger (HTC) profile
-Easy shape, create more fines -High lifting effect, limited slippage
-Earlier lost of lifting effect due to high -Profile stable during wearing
slippage -Carefully manufacturing (casting) needed
-Adjustment of the ball charge required -Sensitive to low filling degree
-Earlier replacement of the liners
Heidelberger (HTC) Profile
• Heidelberg Cement developed special “in-house” profile

• Lifting step increases with wear
• Supports the decreasing media size
(when media wear smaller they need higher lift for same impact)

Design of a liner plate with Heidelberger (HTC) profile
B, H, R, D depends on mill
diameter, material to be ground
(Particle size, art of material),
critical speed of the mill, ect...
B = 60 – 100 mm
H = 90 – 140 mm
R = 200 – 600 mm
D = 45 – 75 mm

1st chamber lining plates
Step liners Heidelberger profile
Norcem Kjopsvik, CM 4 Anneliese Ennigerloh

 Heidelberger (HTC) Profile
HTC Profile (bolted)
- Good process benefit as slippage low and profile can be maintained longer
- Sharp lifting angle means high risk of breakage; choice of alloy important;
filling degree, speed of mill and process parameters very important
- Semi boltless solution can be adopted to take advantage of the system

 Double Wave Liners
Double Wave (Semi boltless)
- Good process benefit as slippage low and profile can be maintained much longer
- High productivity throughout useful life; good profile for hard feed material
- Sharp lifting angle means high risk of breakage; choice of alloy important; filling
degree, speed of mill and process parameters very important
 Some designs that are getting obsolete…
Grooved Lorraine
Volst Alpine
Block
 And beware of some new ones….
Modular

How to avoid excessive wear (within the whole Mill)?
• Never run the mill without material for extended time

• Interlocking to stop mill when feed less than X t/h for more than 10 min.
• Diaphragm adjustments for material level in first compartment
• Internal Material Transport to be observed (Crash Stop)
• Media Charge too coarse = Material Transport too fast (gaps)
• Media Charge too fine = Material Transport too slow (gaps)

Liner Types
1. First Chamber Liners
2. Second Chamber Liners

2ND CHAMBER SHELL LINERS
 Grinding by attrition required – so many design possibilities like

Classifying, Dragpebs, Plain, Grooved etc.
 Most Optimum Design – Classifying or Self Sorting – Why?
– Feed is fine enough – need for adapting the right size of balls to the
material size. Compatible ball charge 15% efficient against mixed.
– Possibility to go wider range of balls and also lower size of balls
– Possible to use big balls (60mm) to handle nibs
– Classifying liners have almost 20% higher material speed
– Ball charge management is easier – sorting/scrap/nibs removal
– Possibility to use extremely hard and wear resistant alloy for very long
useful life

 Classifying liners - principle
– Liners cascade bigger balls more vigorously than smaller balls
– Works better if L/D > 2
– The segregation of the media occurs when the larger balls fall
onto the sloped surface of the plates they pick up enough
energy to ‘bounce’ backward.
– The lighter, smaller balls, work their way to the outlet end of the
mill, thus classification takes place
Flow Direction
Large Ball Small Ball

Large Small
More Mass Ball
Less Mass
Ball
More Impulse Less Impulse
More Deflection Less Deflection
Liner
Mill Shell
PRINCIPLE OF CLASSIFYING LINERS

 Classifying Liners
Classifying liner Mill Dia. > 4.4m Classifying liner Mill Dia. < 4.4m
- Best process and maintenance solution for second chamber
- Easy for ball charge management
- Useful life for OPC more than 60000 Hours (10Yrs)

2ND CHAMBER SHELL LINERS – Classification in action
Outlet end
Krivyi Righ, CM1: 2nd Chamber
Inlet end

 Variations of the Classifying design
Lifting Classifying
Conveying Classifying
Thin Classifying

2ND CHAMBER SHELL LINERS - Ripple type (Dragpebs)
 Used in 2nd chamber for Grinding media < 30mm in FLS mills
- For maximum loading

- Combidan diaphragm
- Danula rings in open circuit

2ND CHAMBER SHELL LINERS – trapezium type (Russian)
 Used in 2nd chamber for Grinding media < 30mm
- Poor power use - For maximum loading

- Protection of shell not full proof
AGENDA
2. Liner types
3. Diaphragm types

Diaphragm types
Diaphragms
chamber 1
chamber 2
• separation of the mill body into two

chambers with different process
conditions
• transfer of ground material with a
certain particle size from …
 from chamber 1 to chamber 2
 from chamber 2 to the mill discharge

DIAPHRAGM TYPES

Diaphragm types
1. Intermediate Diaphragms
2. Discharge Diaphragms
3. Drying Chamber Diaphragms

Intermediate Diaphragm types
1. Conventional Diaphragms
1. FLS
2. Polysious
3. KHD
4. Other OEMs
2. Material Flow Control

1. Estanda
2. Christian Pfeiffer
3. Slegten – Magotteaux/Vega
4. Some OEMs
3. Other – Combidan (FLS)

Main Components of a classic Intermediate diaphragm
1 diaphragm segment
6
3
2 supports
5 2
3 clamping ring
4
1 4 wearing plates, slotted
5 central opening & grid
6 adjustable lifter

INTERMEDIATE DIAPHRAGM – How it works
Feed End View of Diaphragm Side View of Diaphragm

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
chamber, in between
the slotted plates and
. blind plates
Material passes
through the slots
and fills the lifter
chamber.

INTERMEDIATE DIAPHRAGM – How it works
- Material passes through slots into hollow sections

- Mono-Directional Scoops lift material
- Material slides down and passes through opening into center hole
- Mill sweep gas flow carries Material into 2nd Comp.
- Centre hole needs to provide enough area to allow sufficient, not too
fast gas flow
INTERMEDIATE DIAPHRAGM – How it should work….
 In 1st Chamber the ball charge is very coarse and the permeability is high.
Hence there is no material at the end of the 1st Chamber.
 Flow Control Diaphragm helps in good retention of the material and thereby
increasing the crushing efficiency in the 1st Chamber.
 Maximum efficiency corresponds to the maximum power.
 The difference in efficiency of Flow Control and

Conventional diaphragm is 15 %. Since L1 is 30% of the
total length, efficiency of the mill with Flow Control
Diaphragm is 5 % higher.

INTERMEDIATE DIAPHRAGM – Controlling material level
Conventional Material Effect of Material Flow Control

Transport

Intermediate Diaphragm – Christian Pfeiffer

Intermediate Diaphragm - SLEGTEN
 Magotteaux/Vega
– Scoop Assembly
– Number of open
scoops regulates
the material flow

Intermediate Diaphragm - SLEGTEN
Q = S X h = constant
Intermediate Diaphragm : FLS Combidan
• 5 to 8mm screen behind the blind plates

• Principle of recirculation of coarse
• Since Blind plates – higher hardness/carbides/life
• Maintenance of screen is very difficult.
• Breakage in screen disturbs the performance.
• Ventilation generally poor

Intermediate Diaphragm – Central Screen
Good permeability
No
(Estanda)
permeability
Good permeability
Low
(Slegten)
permeability
Good Permeability
(Pfieffer)

Intermediate Diaphragm – Slot configuration
Vertical slots:
Tangential slots:
Plugging but also
Good material
material transfer
transfer; self
low; no self
cleaning possible.
cleaning
Circumferential Perforated slots:

slots: Good Poor permeability
material transfer; of slots.
difficult to cast.

Intermediate Diaphragm – Slot Design of Grate Plates

Diaphragm types

Discharge Diaphragm
What is the function of the outlet Diaphragm?
- Keep media in 2nd Compartment

- Allow ground material to leave 2nd Comp.
- Control the material flow out of the 2nd Comp.
- Provide enough open area for the mill aeration
without over-speeding the gas / over-”sucking” the
slots
- Typically not adjustable
- Slots need to be larger than in Intermediate
Diaphragm to allow large Particles from 1st Comp.
to leave 2nd Comp.
- Provide support for water injection

Discharge Diaphragm
 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

Discharge Diaphragm – Central Discharge Mills (Dopple
Rotator)
Drying 1st comp. 2nd comp.

comp.
Drying Chamber Diaphragm Double outlet diaphragm

Discharge Diaphragm
Slot profile for Grate Plates

Diaphragm types

Drying Chamber Diaphragm
 Grate plates only on the grinding Chamber side
– Careful about the slot size and orientation
– Careful about the axial load on the frame
 Central Screen to have proper openings to allow bigger
feed sizes to enter the grinding chamber

for better building…..
Thank You!

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BALL MILL INTERNALS

Ball Charge, Liners and Diaphragm

Slide (5); 15/5/2017; Ball Mill Internals

 Feed Head Liners – Protection; no process role

 Intermediate Diaphragm – Process role – Fencing; Fineness controller;

 Outlet Diaphragm – Process role – Fencing; Ventilation;

 Grinding Media – Crushing/Grinding

Slide (5); 15/5/2017; Ball Mill Internals

SPC, kWh/T 30 GM wear rate, g/T 30

Slide (5); 15/5/2017; Ball Mill Internals

 Design itself is a matter of experience

Slide (5); 15/5/2017; Ball Mill Internals

Slag From Diagram:

20 ** Energy consumption at mill

Slide (5); 15/5/2017; Ball Mill Internals

Critical mill speed

De : Effective mill diameter (inside liners)

The critical mill speed ncrit can be expressed as a function of the

Slide (5); 15/5/2017; Ball Mill Internals

The optimum action of grinding ball is achieved for f = 30% and

Cataract: smooth rolling of all

Upto 25% impact on efficiency

 Quality – to stand upto the Maintenance demands

Slide (5); 15/5/2017; Ball Mill Internals

1. Ball Charge Management

Slide (5); 15/5/2017; Ball Mill Internals

 Deciding the Quantity

 Deciding the pattern

 Deciding the Quality

 Characteristics of High Chromium Balls

Slide (5); 15/5/2017; Ball Mill Internals

Slide (5); 15/5/2017; Ball Mill Internals

– Use Absorbed Power Formula

– When calculating power separately for the 2 chambers use

Slide (5); 15/5/2017; Ball Mill Internals

Slide (5); 15/5/2017; Ball Mill Internals

Formulas for practical calculations of ball mills:

Slide (5); 15/5/2017; Ball Mill Internals

Pabs. counter = Pabs  1

The total efficiency A = mech * el

Following values can be used:

For mill with girth gear drive: A = mech *  = 0.92 – 0.94

For mill with central drive: A = mech *  = 0.94 – 0,96

Slide (5); 15/5/2017; Ball Mill Internals

1st grinding chamber c1 = (0,31 – (0,00275*fch1))

fch1: filling degree 1st chamber

Slide (5); 15/5/2017; Ball Mill Internals

 Deciding the Quantity

 Deciding the pattern

 Deciding the Quality

 Characteristics of High Chromium Balls

Slide (5); 15/5/2017; Ball Mill Internals

Deciding the pattern

Size reduction by:

Coarse Medium Fine

Slide (5); 15/5/2017; Ball Mill Internals

Deciding the pattern – 1st Chamber

Coarse Medium Fine

Slide (5); 15/5/2017; Ball Mill Internals

Slide (5); 15/5/2017; Ball Mill Internals

– These pattern provide an initial guideline; Fine-tuning always by taking

– For closed circuit finish mills… targets should be to attain:

Slide (5); 15/5/2017; Ball Mill Internals