BALL MILL

GRINDING

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

BALL MILL
GRINDING
PROCESS

Ball Mill Grinding

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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Ball Mill Grinding

CASCADING ACTION

Nipping Angle and Particle Size!

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Ball Mill Grinding

CATARACTING ACTION

Crushing by Impact

Ball Mill Grinding

RELEASE POINTS AND GRINDING

Rotation
Rotation

Re le ase Points
Release
points
1

Lift
Lift Zo ne
Zone
Grinding
Grinding
Zone
Zone
1 - Cascading
(tumbling)
1 - Cascading
(tumbling)
2 - Cataracting (free fall - max impact)
2 - Cataracting
(free fall - max. impact
3 - Excessive Lift (impact on liner)
3 - Excessive Lift (impact on liner)

Liners
into charge.
Liners digsdigs
into charge.
Some
Some slipslip
occurs.
occurs

Ball Mill Grinding

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 Mill Grinding

BALL CHARGE - POROSITY

Coarse Balls - Large Voids

Low Retention

Fine Balls - Small Voids

High Retention

Average Ball Weight

Total charge weight / Total number of balls [kg/ball]
Specific Surface Area
Total surface area / Charge weight [m 2/t]
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Ball Mill Grinding

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
where crushing takes
place
For filling ratios less than 0.6
there's steel to steel contact &
no grinding.

Voids where interparticle

grinding takes place

For filling ratios greater than 1.1,

balls are pushed apart, cushioning
impact.

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Ball Mill Grinding

SPEED AND LINERS TYPE

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Ball Mill Grinding

HOW A PARTITION WALL WORKS

Feed End View of Partition
without Grate Segments

Side View of a Partition

3. Material gravity drops

through the center hub
and into the next
compartment.
2. Material is lifted
by mill rotation.

1. Material fills the

chamber, in between
the slotted plates and
blind plates

Material is lifted by
mill rotation and is
then gravity dropped
into the next
compartment.

Gas Flow

BM Load Level

2
Material passes
through the slots
and fills the lifter
chamber.

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BALL MILL

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Ball Mill Grinding

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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Ball Mill Grinding

THE MILL

End
Discharge
Ball mill
with
2
Chamber

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Ball Mill Grinding

THE MILL

Bi-rotator

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Ball Mill Grinding

THE BALL MILL

Intermediate diaphragm
Outlet diaphragm
Reject return Inlet head
C2 liners
C1 liners
chute

Gas + dust
outlet

Fresh feed

Discharge box

Outlet seal
Material discharge

Shell
Central or ventilation ring
Fresh air inlet

Central Ventilation ring grate

Supports

Trunnion

Feed Arrangements
Mill Heads
Mill Bearings
Drive Types
Mill Shell
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Ball Mill Grinding

FEED ARRANGEMENTS

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Ball Mill Grinding

MILL HEADS

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Ball Mill Grinding

MILL BEARINGS - TRUNNION

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Ball Mill Grinding

MILL BEARINGS SLIDE SHOE

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Ball Mill Grinding

MILL DRIVE TYPE GIRTH GEAR

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Ball Mill Grinding

MILL DRIVE TYPE CENTRAL DRIVES

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Ball Mill Grinding

MILL DRIVE TYPE GEARLESS DRIVES

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Ball Mill Grinding

POWER RANGES OF MILL DRIVES

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BALL MILL
INTERNALS

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Ball Mill Grinding

CONTINUOUS LIFT OR STEP LINERS

For first compartments only

Better wear characteristics
Moderate lift
ROTATION

Rotation

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Ball Mill Grinding

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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Ball Mill Grinding

SINGLE WAVE & DUOLIFT LINERS

Early release on
backslope causes
media to slip.

Rotation

For first compartments only

Racing is common, wear life

is short

It has good lift

Duolift is designed for mills

that had lorrain liners before

Negative back slope

induces sliding

Duolift has a small hump in

between lifts to prevent this.
Wearlife is much better.

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Ball Mill Grinding

LORAIN BAR LIFT LINING

2 1/2

1 1/2

Chamber 1

Chamber 2

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Ball Mill Grinding

INSTALLED DUOLIFT LINERS

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Ball Mill Grinding

CLASSIFYING LINERS
Diameter < 4.4m

Diameter > 4.4m

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Ball Mill Grinding

EXAMPLES OF CLASSIFYING TYPE LINERS

CARMAN LINING

SLEGTEN - MAGOTTEAUX TYPE

NATAL (THIN PROFILE TYPE)

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Ball Mill Grinding

RIPPLE TYPE LINERS

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

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Ball Mill Grinding

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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Ball Mill Grinding

PARTITION / OUTLET WALL

DISCHARGE & 2ND COMPARTMENT VIEW

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Ball Mill Grinding

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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Ball Mill Grinding

SLEGTEN ADJUSTABLE PARTITION

Scoop
Assembly

Number of

open scoops
regulates the
material flow

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Ball Mill Grinding

CONTROLLING MATERIAL LEVEL IN C1 & C2

Conventional Material
Transport

Effect of the Material

Flow Control
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Ball Mill Grinding

GRINDING CIRCUITS

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Ball Mill Grinding

OPEN CIRCUIT
Gas
Material

Dust
Collector

Fan

Fresh
Feed
Mill

Finished
Product
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Ball Mill Grinding

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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Ball Mill Grinding

CLOSED CIRCUIT
Fan
Dynamic
Separator

Dust
Collector

Fan
Dust Collector

Static
Separator

Rejects

Fresh
Feed

Finished Product
Mill

Material
Gas

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Ball Mill Grinding

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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Ball Mill Grinding

DESIGN ASPECTS
OF
BALL MILL SYSTEM

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Ball Mill Grinding

THE BALL MILL

Leff C2
Leff C1

2.8 < L/D < 3.2

27% < Length of first
compartment < 35% mill
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 mm

Leff TOT
D

Deff

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Ball Mill Grinding

ABSORBED POWER OF A MILL

SLEGTEN FORMULA :

1.27

rpm
2.379

P = L*
J * Kj * * Fr * d * C
*
4
Vcr
Where : L
rpm
Vcr
Fr
J
Kj
d
C

- Useful Length of mill (m)

- Mill Speed (rpm)
- The critical speed inside liners = (42.3/Fr^0.5)
- Internal Diameter (inside liners) (m)
- Ratio between the apparent ball volume and the internal volume
- (1.36 1.2 * J)
- Apparent density of load (t/m3) : C1=4.5 & C2=4.6
- 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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Ball Mill Grinding

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 Mill Grinding

BALL CHARGE DESIGN C1

Emphasis on crushing and less on grinding

Typical top size:
80 mm if easy to crush, small feedsize
90 mm is the most common
100 mm 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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Ball Mill Grinding

TYPICAL BALL CHARGE FOR C1

Typical Recommendation
40 %

30 %

For Smaller Feed Size

40 %

25 %

20 %
20 %

15 %

10 %
Size
90 / 80 / 70 / 60 mm

Size
90 / 80 / 70 / 60 mm

Bond : Equal Number of Balls

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Ball Mill Grinding

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 = 2 X slot width
E.g. slot width = 8-10 mm; smallest = 16-20 mm

Non-classifying liners limits C2 to 3 sizes

Classifying liners allow a large variety of s
Best Practice Ball Charge Optimization
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Ball Mill Grinding

RELATION BALL SIZE PARTICLE SIZE

90 mm

30 mm

15 mm

40 mm

1 mm

0,1 mm

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Ball Mill Grinding

SLOT DESIGNS
CRITERIA :
C1 Slots
From 6 to 8 mm
C2 Outlet Slots
Larger by at least
2mm than those
of C1 outlet

With the slot

flared out,
material can
pass freely
without
jamming

Beyond here, the slot

begins to widen

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Ball Mill Grinding

MILL WATER
INJECTION

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Ball Mill Grinding

Water Injection Only if required

INJECTION
INLET/OUTLET

NO INJECTION

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Ball Mill Grinding

Water Injection Only if required

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Ball Mill Grinding

Water Injection Only if required

Inlet water injection

Diaphragm water injection

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Ball Mill Grinding

Different arrangements to compensate for different trunnions

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Ball Mill Grinding

Different arrangements to compensate for different trunnions

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Ball Mill Grinding

Different arrangements to compensate for different trunnions

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Ball Mill Grinding

BALL MILL
INTERNAL
CONDITION

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Ball Mill Grinding

CONDITIONS OF THE LIFTING LINERS

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

Step

Rotation

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Ball Mill Grinding

VOLUME LOADING C1 & C2

Purpose
Insure adequate size reduction
Insure proper ourput
Quick Estimate
Distance between charge and
lower part of the trunnion
Distance between charge and
lower part of the ventilation
screen
Criterion
Between 28% and 34%
Corrective Measure
Regular recharging

Measure on 1/2
step or plate
transverse center

Vertical
Measurement

Middle Axis

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Ball Mill Grinding

LEVEL MANAGEMENT
Specific Grinding Energy
[kWh/t]

Volume Load vs. Specific Power

25
20
15
10
5
15

20

25

30

35

Volume load [%]

Best Practice Ball Charge Level Management

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Ball Mill Grinding

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
Clean
of suitable size
Charge
Corrective Measures
Ball charge sorting in case of contamination
C1 ball sorting (every 5000 - 7000 h)
C2 ball sorting (every 10000 - 14000 h)

Polluted
Charge

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Ball Mill Grinding

MATERIAL LEVEL IN C1 & C2

Purpose
Limit

wear and
insure a good particle
size reduction
Detecting the
presence of spitzers

Quick Evaluation
Material

Overfilled compartment

/ ball level
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Ball Mill Grinding

MATERIAL LEVEL IN C1 & C2

Criterion

Material level = ball level

over the entire compt.

Corrective Measures

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

Right level

Empty compartment
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Ball Mill Grinding

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
balls have contact
ideal case in 1st comp
but still material between the balls

Too low level (few material in between balls)

high specific energy
wear and breakage on balls and liners
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Ball Mill Grinding

BALL CHARGE CLASSIFICATION

Purpose

Adapts the charge granulometry to

that of the material
Criterion
Progressive decrease of the ball size
in C2
Corrective Measures
Sorting and optimization of the ball
charge
Replacing liners
Checking the size of slots
6mm intermediate diaphragm
8mm outlet diaphragm

Classified

Unclassified

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Ball Mill Grinding

Purpose

VENTILATION SCREENS

Insure gas flow

Preventing balls from passing
between compartments

Good Permeability

General Condition

Cleanliness

Criteria

Maximum permeability
Mechanical behavior with the 90 mm
balls and screen# < 40 mm in C1
Screen# < 15 mm in C2 to prevent 20
mm balls from escaping

Total lack of Permeability

Corrective Measures

Cleaning or replacement
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Ball Mill Grinding

DIAPHRAGM SLOTS

Purpose
Providing outlet for the
material in the
compartments while
retaining spitzers and
balls
Improving ventilation
General conditions
Slot plugging
Peening, Clearances

Scrap

C1 Side
Clearance

Slot
C1 Side
Width Clearance

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Ball Mill Grinding

DIAPHRAGM SLOTS

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

Peened slots

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Ball Mill Grinding

DIAPHRAGM SLOTS
Rotation
Rotation

Slots deformed from

one end

Center

Deformation over slots entire

length
Center

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Ball Mill Grinding

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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Ball Mill Grinding

Material level

SUMMARY

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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Ball Mill Grinding

Target levels for material fineness before the

intermediate diaphragm
Sieve Size
(mm)

Cumulative Residue
(%)

2.3

8 - 14

Basis - sieve about 0.5 - 1 Kg of material if

there are clinker nibs present.
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Ball Mill Grinding

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