Ball Mill Optimization

The Ball Mill

 The Ball Mill Gas  dust
outlet
Intermediate diaphragm
Outlet diaphragm
Reject return Inlet head C2 liners !ischarge "o#
chute C1 liners

Fresh feed
Outlet seal

$aterial discharge

Shell
Central or ventilation ring
Fresh air inlet
Central Ventilation ring grate
Supports

Trunnion Feed Arrangements

Mill Heads
Mill Bearings
Drive types
Mill hell
March 2004 2
The Ball mill / ATC Process
 The Ball Mill
%eff C2
%eff C1
%eff TOT

! !eff

" #/D $ %atio &et'een ! and (

" #ength o) C*/Total #ength $ ratio &et'een 2+ and 40, e-cept )or &irotators
" Ball diameter in C* )rom *00".0 mm to +0"0 mm 4 / !"*/21 to 2"*/2 / 21
" Ball diameter in C2 )rom 0"(0 mm to 20"*+ mm 2"*/21 / 21 to !/4 / (/31

March 2004 !
The Ball mill / ATC Process
 Conditions of the lifting liners
 Purpose
 ns5ring proper cascading o)
the &alls and hence cr5shing o) Step
material
 General condition of liners
 Plate conditions &rea6s7 chips7
attachments
 Criterion
 Per)ormance sho5ld &e
chec6ed 'hen step 8 40,
o) initial step 'ear90,
 Corrective measure
rotation
 %eplacement

March 2004 4
The Ball mill / ATC Process
 The step si&e 'lifting po(er)
depends on
 Mill rotation speed '*
critical speed)
-irection of rotation  +olume
+olume load
Grinda$ilit, of feed
material

BOLTLESS STEP CHAMBE

! L"#E

 Less material spillage

 Avoids $olt $rea%age

March 2004 (
The Ball mill / ATC Process
 E.ample of $olted liner

March 2004 
The Ball mill / ATC Process
 Effect of dela,ed mill maintenance
 %eplacing 'orn o5t liners in a cement mill
:increase o) the mill o5tp5t ;*(,
:decrease o) the electricity cons5mption
 Delayed replacement o) li)ting liners 8!0,initial
:%es5lts a)ter replacement
 Average cons5med speci)ic energy
" &e)ore /0 %1h2t
" a)ter 34 %1h2t lin%ed to a return to normal mill output

March 2004 +
The Ball mill / ATC Process
 C! and C5 +olume Loading
 Purpose
 ns5re ade<5ate si=e red5ction
Measure on 1/2 step or
 ns5re proper o5tp5t plate transverse center

 6uic% estimate
 Distance &et'een charge and
lo'er part o) the tr5nnion Vertical measurement

 Distance &et'een charge and

lo'er part o) the ventilation screen
 Criterion
Middle
 Bet'een 23, and !4, axis
 Corrective measure
 %eg5lar recharging

March 2004 3
The Ball mill / ATC Process
 C! and C5 +olume Loading
 >-ample )or an over)illed compartment

March 2004 .
The Ball mill / ATC Process
 C! and C5 +olume Loading
 As an e-ample7 'hat is the e))iciency loss associated
to a poor &all vol5me loading ?

1986 1993 Gap

@ol5me loading in C* !0, 2*, "!0,

Mill o5tp5t t/h 3( (. "!0,
6h/t 2+7 !.7* ;42,

March 2004 *0
The Ball mill / ATC Process
 Ball charge conditions in C! and C5
 Purpose
 >val5ating &all charge 'ear
 Detecting a mechanical pro&lem &rea6age o) a diaphragm
sector
 Criteria
 Clean charge no scrap
 %o5nd &alls not de)ormed
and o) s5ita&le si=e
 Corrective measures
 Ball charge sorting in case o)
contamination Clean charge &olluted charge
 C* &all sorting every (000 " +000 h
 C2 &all sorting every *0000 " *4000 h

March 2004 **
The Ball mill / ATC Process
 Material level in C! and C5
 Purpose
 #imit 'ear and ins5re a
good particle si=e
red5ction
 Detecting the presence o)
spit=ers 'aves
 6uic% evaluation
 Material / &all level

Overfilled compartment

March 2004 *2
The Ball mill / ATC Process
 Material level in C! and C5

 Criterion
 Material level 9 &all level
over the entire compt
 Corrective measures
 Change in the n5m&er o)
small &alls 0 mm 2" Right level
*/21 or (0 mm 21 in
C* and
20 mm !/41 or *+ mm
(/31 in C2
 coop ad5stments
 Control o) the circ5lating
load
'mpt( compartment

March 2004 *!
The Ball mill / ATC Process
 Controlling material level in C! and C5

conventional effect of the

material material flow
transport control

March 2004 *4
The Ball mill / ATC Process
 Ball Charge Classification
Classified
 Purpose
 Adapts the charge gran5lometry to
that o) the material
 Criterion
 Progressive decrease o) the &all si=e
in C2
 Corrective measures )nclassified
 orting and optimi=ation o) the &all
charge
 %eplacing liners
 Chec6ing the si=e o) slots
mm intermediate diaphragm


3mm o5tlet diaphragm



March 2004 *(
The Ball mill / ATC Process
 Classif,ing liners

-iameter 7898m

-iameter :898m

March 2004 *
The Ball mill / ATC Process
 ipple t,pe liner for ;fine Grinding<

rinding media to &e 5sed in 2 nd cham&er 8!0mm

March 2004 *+
The Ball mill / ATC Process
 Effect of dela,ed mill maintenance
 Ball sorting done a)ter ! years Too late 9 20000h
 %es5lts a)ter &all charge sorting

= to !0* o5tp5t increase on average )or all prod5cts



Average cons5med speci)ic energy E



&e)ore 35 %1h2t


a)ter 8= %1h2t


March 2004 *3
The Ball mill / ATC Process
 Ho( are the liners and the $all charge>

 ear o) the liners and &all charge has to &e loo6ed a)ter in order to avoid per)ormance losses
Worn out state Normal state* Gap
rinding
energy !. 6h/t !2 6h/t "*3,
Mill o5tp5t ( t/h .2 t/h ;40,

 a)ter the replacing o) liners and &all charge

March 2004 *.
The Ball mill / ATC Process
 +entilation Screens
 Purpose
 ns5re gas )lo' Good permeability
 Preventing &alls )rom passing &et'een
compartments
 General condition
 Cleanliness
 Criteria
 Ma-im5m permea&ility
 Mechanical &ehavior 'ith the .0 mm
!"*/21 &alls and screenG 8 40 mm Total lack of permeability
*"!/41 in C*
 creenG 8 *( mm (/31 in C2 to prevent
20 mm !/41 &alls )rom escaping
 Corrective measures
 Cleaning or replacement

March 2004 20
The Ball mill / ATC Process
 -iaphragm Slots
 Purpose
 Providing o5tlet )or the material
in the compartments 'hile Scrap
retaining spit=ers and &alls
 mproving ventilation
 General conditions
 lot pl5gging
 Peening7 clearances

lot 'idth
C! side clearance
C5 side clearance

March 2004 2*
The Ball mill / ATC Process
 Meas5ring the Diaphragm details

March 2004 22
The Ball mill / ATC Process
 -iaphragm Slots

 Criteria
 C* slots )rom  mm to
3 mm
 C2 o5tlet slots larger &y at least 2 mm than
those o) C* o5tlet
 Corrective measures &eened slots
 Filing and cleaning
 Diaphragm replacement

March 2004 2!
The Ball mill / ATC Process
 Compartment Samples
 Purpose
CO$&*RT$'+T +,1 CO$&*RT$'+T +,2
 rinding amples           

assessment 































C* and C2

          

          

          

 Determining
spit=er locations Charge
-./m
 6uic% evaluation Direction o) rotation
 amples ta6en at ! 5 4
C!
8 3 / ! 5
C5
4 8 3
the discharge end
o) the compartment

March 2004 24
The Ball mill / ATC Process
 E?ual positioning for
sample collection and
media grading 'measure
80 media $alls at each
position)9

March 2004 2(
The Ball mill / ATC Process
 Second cham$er
sample collection using
sieve9

March 2004 2
The Ball mill / ATC Process
 Meas5ring media
diameter 5sing
vernier caliper

March 2004 2+
The Ball mill / ATC Process
 Compartment Samples
@ineness evolution in the mill
 Criteria * Cumulated reects
 8(, retained on 2 *00

to 2( mm or 3 30

mesh sieve at the 0

diaphragm 40
 Progressive 20

decrease all along 0

the mill * 2 ! 4 (  + 3 . *0 ** *2
Sample #um$er
 Corrective measure
 Adapting the 40 Im ! Im *00 Im 200 Im (00 Im
* mm 27( mm ( mm Diaphragm Diaphragm
charge
gran5lometry Inade0uate grinding
 Changing the &resence of grains
length

March 2004 23
The Ball mill / ATC Process
 Summar,

 Conditions o) li)ting liners


Per)ormance has to &e loo6ed at i) step 8 40, o) initial step 'ear90,
 @ol5me loading $ 23, to !4,
 Ball charge conditions $

Clean7 ro5nd shape and s5ita&le si=e )or the compartment

C* has to &e sorted every (000 to +000 h

C2 has to &e sorted every *0 000 to *4 000 h

March 2004 2.
The Ball mill / ATC Process
 Summar,
 Material level
Material level 9 &all level over the entire compartment


 Ball charge classi)ication $

progressive decrease o) the &all si=e in C2


 Diaphragm slots $
)irst compartment slots$ mm to 3mm


second compartment o5tlet slots larger &y at least 2mm



than those o) )irst compartment

 @entilation screens
they have to have the ma-im5m permea&ility to let the


ma-im5m gas )lo' thro5gh the mill 'hile retaining the &alls

March 2004 !0
The Ball mill / ATC Process
GOP EEC"SE

1HAT CA# DO SEE >

 1hat are (e loo%ing at >>>>>

As6 yo5rsel)
Jhat?
ap in lots LL Jhere?
diaphragm JCondition?

Klder type diaphragm

Bac6 side o) intermediate diaphragm

#o' permea&ility

March 2004 !2
The Ball mill / ATC Process
 Hard )aced croll at mill inlet

March 2004 !!
The Ball mill / ATC Process
 lotted &ac6 plates7
this is 5ndesira&le

March 2004 !4
The Ball mill / ATC Process
 @ery lo' permea&ility

March 2004 !(
The Ball mill / ATC Process
 irth gear drive 7
B5c6et elevator mill

March 2004 !
The Ball mill / ATC Process
 ntermediate diaphragm
Bloc6age d5e to e-cessive heat 'ithin mill
lot pro)ile is circ5m)erential and is there)ore o6

Central ventilation grid permea&ility o6

March 2004 !+
The Ball mill / ATC Process
 K5tlet side o) intermediate diaphragm sho'ing
e-cessive 'ear

March 2004 !3
The Ball mill / ATC Process
 orn mill )eed inlet 7
Plant 5sed initiative 5ntil replacement availa&le

March 2004 !.
The Ball mill / ATC Process
 High 'ear

Badly &loc6ed and

'orn central vent
grid

Media &loc6age
o) radial slots
March 2004 40
The Ball mill / ATC Process
 Tramp material7This
o)ten res5lts in slot
&loc6age

March 2004 4*
The Ball mill / ATC Process
 orn o5ter ring o) inlet head 'all liner7
This needs replacing

2( mm

+( mm

March 2004 42
The Ball mill / ATC Process
 orn classi)ying liner
n 2nd cham&er

March 2004 4!
The Ball mill / ATC Process
 Badly )itting head 'all
liners

March 2004 44
The Ball mill / ATC Process
 ndesira&le slots &loc6ed 'ith
mall media

Cham&er 2 side o) intermediate diaphragm

March 2004 4(
The Ball mill / ATC Process
 @ery small ventilation grid )itted
ith 2 s5pport &ars d5e to past
damage
March 2004 4
The Ball mill / ATC Process
 Central ventilation grid
Bloc6ed 'ith tramp material
>ntered 'ith the mill )eed

Circ5m)erential
slots

March 2004 4+
The Ball mill / ATC Process
 Note the ne' mesh )itted on
Kther side

Damaged ventilation grid

March 2004 43
The Ball mill / ATC Process
 %ipple liner in 2nd cham&er

March 2004 4.
The Ball mill / ATC Process
 De)lectors

Kld type o) material transportation

March 2004 (0
The Ball mill / ATC Process
 Flo' control mechanism o) modern intermediate
Diaphragm 7 Ocoops1 Ad5sta&le &y rotation

ood ventilation grid

March 2004 (*
The Ball mill / ATC Process
 OBloc6ing o))1 in order
To control )lo'

March 2004 (2
The Ball mill / ATC Process
 mall media contamination
n *st cham&er
March 2004 (!
The Ball mill / ATC Process
 Dann5lar ring 7 these &ecome sa)ety iss5es

March 2004 (4
The Ball mill / ATC Process
 Mill inlet sho'ing no area )or air inlet

March 2004 ((
The Ball mill / ATC Process
 ntermediate diaphragm *st cham&er
ho'ing sectioned plates desired 7 radial
lots 5ndesired and &adly )itting

March 2004 (
The Ball mill / ATC Process
 tep ch5te inlet 7 good area
For air)lo'

March 2004 (+
The Ball mill / ATC Process
 onic ear 5sed )or control

March 2004 (3
The Ball mill / ATC Process
 Bro6en head 'all liners
Ca5sed &y over tightening
K) &olts

March 2004 (.
The Ball mill / ATC Process
 tep ch5te )eeder

ater inection no==le

March 2004 0
The Ball mill / ATC Process
 %emova&le vent grid
ap si=e may &e 'rong

March 2004 *
The Ball mill / ATC Process
 Brea6 *( mins

March 2004 2
The Ball mill / ATC Process
 50

45

40

5
d
a 0
o
l
e 
25
m
lu
o 20
+
* 15

10 'IGT *3OV'
C*RG'
5
! I+T'R+*% !I*.

0!50 0!55 0!"0 0!"5 0!#0 0!#5 0!$0 0!$5

AT"O H2-

Ball mill volume load estimation

March 2004 !
The Ball mill / ATC Process
 +OLME LOA- @OMLA
H  HE"GHT ABO+E CHAGE 'M)

-  M"LL "#TE#AL -"AMETE "#S"-E L"#"#G 'M)

 , @ol5me #oad 9
 400/P02(Cos2H/D"0(
 "H/D"0(H/D"H/D20(

March 2004 4
The Ball mill / ATC Process
 Changes in apparent volume load
due to charge e.pansion
H!  Height a$ove charge FMill Crash Stop

H5  Height a$ove charge F Mill un Out

%pparent &'ar(e density &ase )Volume load

t/m

!*1 +1 &ras' ,top $)

+1 +2

+2 -it'out Material )

4!50

&'ar(e .xpansion 5)

March 2004 (
The Ball mill / ATC Process
 Target levels for material fineness
$efore the intermediate diaphragm

,ieve sie ) &umulative

esidue
2!" mm 1)

1!1$ mm ")

00 um 20)

asis  sieve about 0!5  1 3( of material if

t'ere are clinker nibs present!

March 2004 
The Ball mill / ATC Process
 March 2004 +
The Ball mill / ATC Process
 March 2004 3
The Ball mill / ATC Process
 March 2004 .
The Ball mill / ATC Process
 March 2004 +0
The Ball mill / ATC Process
 Mill po(er calculation
F -A1# @ormula

#ETT 1  095=8/ -A1#

-'ere -  "nternal -iameter of Mill

 !904 FI
A

'1here I  @ractional +olume Load i9e9 if +L  40* then I  094)

1  Charge (eight in Tonnes

#  Mill speed in PM

March 2004 +*
The Ball mill / ATC Process
 #et and Gross mill po(er
#ormal values for the ratio #et2Gross po(er
09J0 #ormall, for old and inefficient mills
09J5 Pol,sius Com$ifle. -rive
09J4 Girth gear driven mill
09J8 F09J3 Modern central drive mill
ne.pected values
09== High po(er losses possi$l, due to mill
cham$ers running empt,9
09J F !900 Lo( po(er losses possi$l, due to charge
e.pansion and2or $uild up of clin%er ni$s9

"f une.pected values occur K revie( the mill data

March 2004 +2
The Ball mill / ATC Process
 March 2004 +!
The Ball mill / ATC Process
 March 2004 +4
The Ball mill / ATC Process
 March 2004 +(
The Ball mill / ATC Process
 March 2004 +
The Ball mill / ATC Process
 March 2004 ++
The Ball mill / ATC Process