How to optimise a ball charge

Grinding 1/6
PR GRI P07-08 V1

Introduction
ƒ Optimisation of ball charge is an important factor in achieving efficient grinding. A ball mill can only be
optimised for one product hence on mills with several products it should be done for the main product.
ƒ The ball charge cannot be considered in isolation and must be adjusted taking into account the mill
system design including the separator, the design and condition of mill internals.
ƒ Several prerequisites are necessary to ensure the ball charge optimisation is effective.

Indicators and Targets:

ƒ Residue at the intermediate diaphragm
ƒ Cement mill: target < 5% residue on 2mm sieve
ƒ Raw mill: target reach < 5% residue on 4mm sieve
ƒ Material filling level
ƒ Ch 1 - Larger balls are partly visible in the material bed
ƒ Ch 2 - just slightly above the media
ƒ Ball Charge expansion < 3%
ƒ Chamber 1 Specific power consumption
ƒ Cement mill 8-12 kWh/t
ƒ Raw mill 40 – 45 % of total mill power consumption
ƒ Diaphragm slot openings are :
ƒ 6-8 mm in the first compartment
ƒ 8-10 mm in the second compartment

Prerequisites
ƒ Mill feedsize
ƒ Clinker and additives 95% passing 25 mm; 100 % passing 50 mm
ƒ Raw material 95% passing 30 mm; 100 % passing 50 mm
ƒ Good separator performance according to the type.
ƒ No circuit limitations due to:
ƒ Material transport
ƒ Material drying
ƒ Diaphragm opening
ƒ Cement mill ventilation - 1.5 to 2.0 m/s
ƒ Clinker temperature < 70°C

Required Information from Mill Audit Inspection

ƒ Mill feed size
ƒ Ball filling levels, after crash stop and after mill purge
ƒ Material filling levels
ƒ Existing ball gradings
ƒ Liner condition & step height
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PR GRI P07-08 V1

ƒ Material size grading at diaphragms

ƒ Diaphragms condition, slot sizes, presence of gaps (and flow control adjustment if fitted)
ƒ Mill production rate
ƒ Mill motor power absorbed
ƒ Mill dimensions, motor size, mill speed , gearbox size, etc to calculate power

Tools
ƒ Slegten formula for calculating mill power consumption can be used to estimate media requirements for
each chamber.
1 Grinding Domain > Job aids
ƒ Power indicator can be used to calculate the net power for the mill considering fineness and composition
1 BRS database > Indicators > Power Consumption Indicator Finish Mills (PR120X)

In this procedure you may find references to other information (tools, other “How to” procedures, knowledge
documents, etc) which are available from their respective domain of the Web Cement Portal (e.g. Grinding,
Pyroprocessing..) or from the BRS database (indicators).
Access the web cement portal via L.O Group Portal:
1 http://lo.lafarge.com > Access to all intranet sites > Division sites > Cement
 How to optimise a ball charge
Grinding 3/6
PR GRI P07-08 V1

Action Steps

1. Determine & compare

ƒ Determine target production rate & power consumption for the mill from grindability
ƒ Compare with actual mill performance

2. Calculate
ƒ Calculate the actual and theoretical specific power consumption for chamber 1

3. If the actual consumption is less than 8 kWh/t

ƒ If the actual consumption is less than 8 kWh/t most probably there is insufficient power to crush the
material effectively. The mill audit / inspection would reveal excess coarse material and volume expansion
of the ball charge.
ƒ In this case the media quantity of the first chamber needs to be increased by increasing volume loading,
if space is available.
In the case there is insufficient space available for increasing the volume loading, it is advisable to try
a coarser ball charge before considering the increase of the first chamber length.

ƒ In special cases clinkers have been found easier to crush and do not need 8-12 kWh/t so it is worth
making the easier change to the media grading before changing the chamber length

4. If the consumption is greater than 12 kWh/t

ƒ If the consumption is greater than 12kWh/t there is probably excessive power in the first chamber and
energy is being wasted and the target fineness at the diaphragm is exceeded.
A typical sign for wasted energy is that part of the ball charge operates without material and that
there is no volume expansion.

ƒ In the short term the media loading can be reduced, in the longer term the length of the first chamber
could be reduced.
ƒ However, before deciding on this latter step is advisable to first try a finer media grading just in case the
clinker is especially hard to crush and need +12kWh/t.

5. If 1st chamber power consumption is in range or excess coarse material at

diaphragm
ƒ In the case that the first chamber power consumption is in range and or excess coarse particles are found
at the intermediate diaphragm then it indicates that the media grading is too fine.
ƒ In this case it is necessary to increase the proportion of 90mm. Use of 100mm should normally be
avoided to prevent excessive liner wear. However, 100mm balls could be an advantage in some
situations as a short term solution e.g. to help overcome excessive mill feedsize or to offset the effect of
badly worn liners.

The use of 100 mm balls has to be discussed with the liner supplier.

Procedure Template developed by

 How to optimise a ball charge
Grinding 4/6
PR GRI P07-08 V1

6. If the 1st chamber power consumption is in range & material filling level is
low
ƒ In the case that the first chamber power consumption is in range and the material filling level is low it
indicates that the media grading is too coarse and the proportion of 60mm could be increased.

7. Intermediate diaphragm condition

ƒ The good condition of the intermediate diaphragm is important in making the first chamber assessment
since if it’s not in good condition it will affect material transport in the chambers.
ƒ Big slot openings will increase the accumulation of nibs in the second compartment. The slot openings in
the second compartment have to be bigger than the openings of the first compartment to prevent
further accumulation.

8. Transition zone
ƒ In the case that coarse material is passed into fine grinding from chamber 1 it is necessary to add some
40mm media for 2mm material and 50mm media for coarser grains.

9. Fineness of 2nd chamber charge

ƒ The second chamber charge should be as fine as possible to provide a high grinding surface area, but still
to remain permeable to avoid excessive hold up of the material

10 Changes to media load

Any changes to media load should be done in small steps to avoid overloading the mill drive.

Procedure Template developed by

 How to optimise a ball charge
Grinding 5/6
PR GRI P07-08 V1

Appendix

Example of ball gradings

In the case of a new product or new mill where there is no pre-existing experience the following
example of gradings can be used :

1. Closed Circuit Cement Mill

Chamber 1 Chamber 2
coarse fine coarse fine
Ball sizes [mm] weight weight Ball sizes [mm] weight weight
[%] [%] [%] [%]
90 40 21 (Transition zone) 40 10
80 29 38 30 25 15
70 19 25 25 25 15
60 12 16 20 20 30
17 20 40
Average ball weight [kg/ball] 1,83 1,63 Average ball weight [g/ball] 47 34
Specific surface [m²/t] 32 37
With high circulating loads, as with oversized separators the coarser grading for the second chamber
is more suitable to help maintain charge permeability

2. Open Circuit Cement Mill

Chamber 1 Chamber 2
coarse fine weight
Ball sizes [mm] weight weight Ball sizes [mm] [%]
[%] [%]
90 40 21 30 10
80 29 38 25 10
70 19 25 20 20
60 12 16 17 60

Average ball weight [kg/ball] 1,83 1,63 Average ball weight [g/ball] 30
Specific surface [m²/t] 39

Procedure Template developed by

 How to optimise a ball charge
Grinding 6/6
PR GRI P07-08 V1

3. Raw Mill
Chamber 1 Chamber 2
coarse coarse fine
Ball sizes [mm] weight Ball sizes [mm] weight weight
[%] [%] [%]
90 40 60 20
80 29 50 30 30
70 19 40 30 30
60 12 30 20 40

Average ball weight [kg/ball] 1,83 Average ball weight [g/ball] 260 186
Specific surface [m²/t] 18 21

Up to 50% 90mm can are used on some mills.

Procedure Template developed by