1.

MAIN
DESIGN
CEREIA S
1.1 Filling Degree
Filling Degree of Tube Mills
Type of mill Filling Degree
Comp. I Comp. II Comp. III
Single comp. Mill 27 - 33 ---- ---
Two comp. Mill 27 - 33 25 - 30 ---
Three Comp mill 26 - 32 26 - 30 23 - 27
Air swept mill 26 - 30 --- ---
Determining of filling degree
1.2 Mill Speed
Fc = centrifugal force [N]

FG = force of gravity [N]

D = mill diameter
inside liner [m]

M =mass [kg]

ω = angular speed [s ]
G = gravity [ms ]
The Critical Speed
D 2
F - F = m. g - m . . ω crit = 0
i
G C 2
The Critical Angular Speed ωcrit

2.g π . n crit
ωcrit = =
Di 30
The Critical Speed ncri

30 2 .g
n = .
crit π D
i
42,3 -1
ncrit = [ min ]
Di
The Operating Mill Speed n

k -1
n= . ncrit [ min ]
100
n = Operating Mill Speed [min-1]

ncri = Critical Mill Speed [min-1]

k = Ratio n / ncrit [%]

Di = Diameter inside mill lining [m]

The Critical Speed Chart

nc=critical mill speed [min-1]

Practical Values for The Percentage of Critical Speed

Filling degree Type of mill liner % of critical

speed (k)

Low Liner with lifter bars 70 - 71 %

High Smooth liner 74 - 75 %

1.3 The Length To Diameter Ratio
Of Tube Mills Depends on :
Hourly Throughout
Hardness of the material
Open or closed circuit
grinding
Feed size

Grinding System
 The Length To Diameter Ratio λ Of different
mill system:

Type of mill system Ratio λ Remarks

1.Cement mill
Closed circuitmills
Open circuit mills 3.0-3.5
6.0 φ 2.0mills
Large −2.4: : λ=3
λ∼6−3.2
Low λ yields
φ 2.6−3.0 : λ∼5
higher circulating load
φ 3.0−4.0 : λ∼4
φ 4.0 : λ∼3−3.5
Type of mill system Ratio λ Remarks

Ratio similar as for cement mills

2.Slurry mills
Max.length 12-14 m
Type of mill system Ratio λ Remarks

Center discharge mill 2.1-2.7 the lower are applied for

3.RAW mills
two comp.Mill 2.0-2.5 large raw mill

single comp.mill 1.7-2.2

air swept mill 1.5-2
Length of Compartments :

Type of mill % of Total Length

Comp. I Comp. II Comp. III

Two comp. Mill 30 - 35 70 - 65 ---

Three comp. Mill 20 30 50

Center discharge 50 50 ---

mill
 Weight of Grinding Media
π 2 f
Q = Di L i γQ
4 100
Where :

Li :Internal length of the mill or compartment [m]

f : Filling degree [%]
γ : Bulk weight of grinding media It/m3 [t/m3]
Q
Di : Internal mill diameter (inside lining) [m]
Q : Grinding media charge [t]
 The values for bulk densities of the grinding media :

Ball Size Bulk Weight

3
Steel balls 100-60 mm φ 4.4t / m
50-30 mm φ
3
Steel balls 4.6t / m
3
Steel balls 30-20 mm φ 4.8t / m
3
Cylpebs 100-60 mm φ 4.8t / m
Driving Power

Driving Power “N” = Net Power + Power losses

x .DI .Q. .n
N = [ kW ]
30
Driving Power
b = Distance of center of gravity
from the vertical plant through
the axis of rotation [m]

Di = Diameter inside liners

Q = Weight of grinding
media charge [t]

N=speed of the mill [min ]

ω= angular speed [s ]
According to MITTAG :
b = X . Di
M = X . Di . Q
π n
N = M.ω [kW] ω =
30
[S-1]
The Driving power can be written as :
x . Di . Q . π . n
N=
30
For Practical Calculation

N = C. Q. Di. N [kW]
Where :
N = Driving power
Q = Grinding media charge
Di = Mill diameter inside liners
n = Mill speed
c = Power consumption factor
Determining of Power consumption factor c
Practical Calculations

N = c . Q . Di . n ( 4 ) [ kW]
π f
.γ Q
2
Q = . D i . Li . (3) [ t]
4 100
42,3 -1
ncrit = ( 1 ) [ min ]
DI
N = k . nc
100
The formula could be expressed
by one formula :

N = C. Q. Di. n =
π f 42,3 k
. γ Q . Di .
2
c . . Di . LI . .
4 100 Di 100

f k
.γ Q .
2.5
N = 33,22 . C . Li . . Di
100 100
The formula could be expressed
by one formula :

Li
λ=
Di

f k
N = 33,22. C. λ . .γ . . D 3.5
100 Q 100 i
The internal mill diameter
1
3 .5
N . 100 . 100
Di =
33.22 . c . λ . f . γ Q . k

N . 100 . 100 0.286

D =
i 33.22 . c . λ . f . γ . k
Q
Nomograph to calculate the required mill diameter
Example :
Cement mill in open circuit, 100 t/h of
normal cement with a specific surface of
3000 cm2/g ?
Find ?
Mill motor power ?
Nominal mill diameter ?
Total mill length ?
Compartment lengths ?
Total ball charge ?
Fall charge per compartment ?
Mill speed ?
Mill Motor Power

NMS = q= 33 kwh/t 100 t/h = 3300 kw

Assuming total gear efficiency of µG = 0.95 the

Mill motor power

N Ms 3300
N= = ≈ 3500 kW
ηG 0.95
 Assumption

Filling degree f = 30 %

% of Critical Speed k =74 %

Length to diameter ratio λ = 3.5

bulk weight ball charge γ Q = 4.5 t/m3
Grindability curve
Nominal Mill Diameter

Nominal diameter = Inside mill shell D ~ 4.3 m

0 . 286
⎡ N ⎤
D = ⎢ ⎥
. c . λ . f. γ
i
⎢⎣ 33.22 Q . k ⎥⎦
c ~ 0.255
0.286
⎡ 3500 ⎤
Di = ⎢ ⎥ = 4.04m
⎣33.22
. 0.225
. 3.5. 0.3. 4.5. 0.74⎦

DN = D i + lining = 4.04 + 0.26 = 4.3 m