Grinding with Ball Mill Systems
EDM
Ball Mill
Ball Mill
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HGRS Tikaria_Mill Workshop SEPT-07
What is a End Discharge Mill (EDM)?
Air outlet
2st Compartment
Intermediate diaphragm (Fine Grinding)
1st Compartment
(Coarse Grinding)
Mill feed arrangement
Mill discharge
Drive
Gearbox with pinions
Air inlet
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HGRS Tikaria_Mill Workshop SEPT-07
EDM
EDM =
End Discharge Mill
Product discharge
at mill end
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Elements of Ball Mill - Overview
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Mill Drive Concepts
D r iv e C o n c e p t s fo r
B a ll m ills
G ir th g e a r D r iv e s G i r t h g e a r u n i ts C e n tr a l d r iv e s
S in g le p in io n c o n c e p t S in g le d r iv e w ith T w o -w a y p o w e r s p littin g
( < 2 '5 0 0 k W ) tw o p in io n s re d u c er
( < 5 '0 0 0 k W ) ( < 6 '0 0 0 k W )
D o u b l e - p i n io n c o n c e p t D o u b le d r iv e w ith P la n e ta r y g e a r r e d u c e r
( < 5 '0 0 0 k W ) fo u r p in io n s (< 1 2 '0 0 0 k W )
(< 1 0 '0 0 0 k W )
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HGRS Tikaria_Mill Workshop SEPT-07
Example Planetary Gear Drive
Planetary gear reducer concept MAAG
Two gear stages with three planets
All shafts with friction bearings
Pinions, planets surface-hardened Annulus
Annulus through-hardened
Planets
Gear coupling
Drive arrangement Sun pinions
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Gear Box Internals
Parallel shaft gear reducer (two way power branch)
All gears surface-hardened and
ground
All shafts with roller bearings
Key point::
Face load distribution of the
LS-gear stage
Low speed gear
stage
Bearings with excentric sleeves
to optimise the face load distribution
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Potential Technical Problems Drive
Girth gear drives - Fundamental 1. Axial/radial runout
Problems
2. Alignment of the drive trains
5 2 3 3. Uneven power splitting
4. Centre distances variable
5. Face load distribution
1 6. Sealing of the girth gear
7. Girth gear is through hardened
only, fatigue strength is limited
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Dynamic behaviour
A lot of individual rotating
masses risk of resonance
5 6 7 vicinities
Torsional/structural vibrations
Pinion shaft bending vibrations
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Gearboxes
Gear reducer
Polysius Combiflex
Planetary Gear
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Potential Damages Drives
Breakage damage (pinions)
Cause: Inadequate transverse load
distribution, brittle material
Fatigue breakage
Initial damage:
Pitting on the pitch line
Secondary damage:
Tooth breakage
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HGRS Tikaria_Mill Workshop SEPT-07
Potential Problems Drive
Single pinion drive (2’300 kW)
Breakage failure of the pinion in the gear
reducer
Heavy (active) pitting on the drive pinion
Possible Cause:
- Inadequate load distribution (1)
- Overload of the tooth flanks (2) 1
2 1
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HGRS Tikaria_Mill Workshop SEPT-07
Mill Bearing
Advantages slide shoe bearings:
No size and capacity limitation of the
mill
Simple design of wear plates
Far higher limit of gas temperature at
mill inlet (e.g. for drying with heat
generator)
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HGRS Tikaria_Mill Workshop SEPT-07
Feed Arrangements for Ball Mills
(Slurry mill)
Preferred design today
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Feed Arrangement (Example Step Feeder)
Material feed
Ventilation air
Advantages
Good mill ventilation
Easy to maintain
Simple design
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Elements of Ball Mill – Overview (Internals)
External
elements
Mill feed Mill Mill discharge Mill
arrangement Mill head Mill shell bearing arrangement drive
Head Grinding Shell Intermediate Retention Discharge
liners media liners diaphragm ring diaphragm
Internal
elements
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Overview Internal Elements
A Coarse grinding
compartment
B Intermediate
diaphragm
C Fine grinding
compartment
D Discharge
diaphragm
E Grinding media
F Retention ring
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Liners for Coarse Grinding
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Lifting Height Requirements (1st Chamber)
This criteria has to be
confirmed case by case h0
through evaluation of the
coarse grinding.
Rule of thumb: h must be
greater than 50 [mm]
1st chamber lining at end of lifetime
h > 0.5 ho
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Classifying Liner for Fine Grinding (2nd Chamber)
Rotation sense
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Head Liners
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Open Diaphragm (Drying Chamber Diaphragm)
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Intermediate Diaphragm
2nd Compartment
Fine Grinding
Intermediate diaphragm
1st Compartment
Coarse Grinding
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Function of Intermediate Diaphragm
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Intermediate diaphragm
Slot opening in 1st chamber
Material flow control system
Centre screen
Grates in the second chamber
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Discharge diaphragm
Discharge diaphragm
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Discharge Diaphragm
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Material Quality and Application of Shell Liners
Material Chemical Hardness Remarks
Composition (HRC)
Manganese Recommended for small mills.
Steel 12 – 14% Mn 40 Deformation of liners for large
mills (initial surface hardness
20 – 25 HRC)
Low chromium Less deformation than
alloy cast 2 – 3% Cr 40 - 42 manganese liners. Suitable
for large and small mills
liners
High chromium Most used material. Suitable
alloy cast 12 – 15% Cr 50 - 55 for big and small mills (Notch
impact strength 4 – 10 J/cm2)
liners
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Life Time of Shell Liners
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Grinding Media
Coarse grinding Ø 90 – 50 [mm]
Fine grinding Ø 50 – 12 [mm]
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Grinding in Ball Mill
Fine grinding (2nd chamber)
Cascading of grinding media
A
A
Coarse grinding (1st chamber)
Cataracting of grinding media
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Ball filling degree (f)
98
93
Power [%]
85
Typical range
75
20 25 30 35 40 - 45 f [%]
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Steps of Grinding
Coarse Medium Fine
Grinding Grinding Grinding
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Coarse Grinding: Parameters for Optimising
Power parameters Efficiency parameters
Filling degree Ball charge (filling degree &
Chamber length composition)
Mill diameter Liner design
Liner design and condition Intermediate diaphragm settings
Mill speed Mill ventilation
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HGRS Tikaria_Mill Workshop SEPT-07
Grinding Media
4,4 [t/m3] 4,6 [t/m3] 4,7 [t/m3]
Bulk weight of a grinding media charge in a two chamber mill with
classifiying liner
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HGRS Tikaria_Mill Workshop SEPT-07
Grinding Media (1st Compartment)
[Link]
Ø Ball [mm] Weight [ t ] Percent [%]
90 25.0 25.0
80 35.0 35.0
70 25.0 25.0
60 15.0 15.0
Total 100.0 100
Average ball weight [g] 1667
Spec. media surface [m2 / t ] 10.2
Holcim Standard for 1st Compartment
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HGRS Tikaria_Mill Workshop SEPT-07
Grinding Media (2nd Compartment)
Holcim Standard for OPC > 3’200 [cm2/g], closed circuit
system
[Link]
Ø Ball [mm] Weight [ t ] Percent [%]
50 20.0 10.0
40 20.0 10.0
30 32.0 16.0
25 32.0 16.0
20 42.0 21.0
17 54.0 27.0
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Total 200.0 100
Average ball weight [g] 41
Spec. media surface [m2 / t] 32.8
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Material Quality of Grinding Media
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Specific Wear Rates of Grinding Media
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HGRS Tikaria_Mill Workshop SEPT-07
Mill Efficiency
[%R] [cm2/g]
acc. Chamber 1 Blaine
(coarse grinding) Blaine Value
Chamber 2
(fine grinding)
Sieve Residues
mill length [m] [m]
longitudinal sieving graph
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Lifting Liners Effects
Liner-Lifting : low high
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Optimum Material Level 1st Chamber
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Optimum Material level 2nd chamber
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Mill Ventilation
Main Tasks Mill Ventilation:
Material transport
Cooling
Removal of fines
Fluidisation of material
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HGRS Tikaria_Mill Workshop SEPT-07
Cooling and Heating Possibilities
Product
Air
Dust ladden air
H 2O
Moist additive Hot gases
Hot clinker Cooling air
H2O
Cooling air Product
Hot gases
H 2O H 2O
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HGRS Tikaria_Mill Workshop SEPT-07
Fine Grinding and Mill Cooling
PROBLEM SOLUTION
Insufficient mill cooling Adapted mill cooling,
lead to material playing with:
agglomeration on balls Clinker temperature
and liners Mill ventilation
Water injection
The grinding is not any
more done by balls Use of grinding aid
against material but by (temporary solution
material against material because expensive)
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HGRS Tikaria_Mill Workshop SEPT-07
Water Injection Systems
counter current no water
Product injection
1st 2nd Comp. temp. [°C]
130
counter
120
current
110
Air from
Air from co-current
blower blower 100
H2O H2 O
co-current 90
(Double)
Rotary union 80
1st 2nd Comp.
Mill length
H2O 2nd Comp.
H2O 1st Comp.
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HGRS Tikaria_Mill Workshop SEPT-07
