008 Ball Charge Management

Mill Workshop, Holcim Apasco S.A.
July 2006
8. Ball charge management

The production process chain / All processes
Drying Coarse grinding (*) Fine grinding Separating
Ball charge management
Ventilation & cooling
Operation
Control
(*) Includes pregrinding and the grinding in the 1 st chamber

2
HGRS Mill Workshop / Mexico / July 2006 06.07/Geo, OR
Content
 Global supply contracts for grinding media
 Briefly review quality aspects of grinding media
 Ball charge classification requirements
 Guidelines for top up compensation for wear
3
Objectives
 Know the standard practices for ball charge

management and how to apply them
 Learn about the accepted suppliers of grinding media
4
Content
5
Global Supply Contracts
Supplier Expiry Date
 Brockhausen terminated
 Christian Pfeiffer 31.12.2005
 Magotteaux 31.12.2005
 Toyo 31.12.2005
 Vega 31.12.2005
 New contact person at Corporate Procurement:

Stefan Evers
phone: +41 58 858 91 42
fax: +41 58 858 91 19
mobile: +41 79 774 06 87
stefan.evers@holcim.com
6
Purchasing Volumes in 2003
Global Suppliers Volume * %
 Brockhausen 717 t 8.46%
 Christian Pfeiffer 131 t 1.55%
(contract signed in Aug 2003)
 Magotteaux 4,096 t 48.34%
 Toyo 0 0
(contract signed in Jan 2003)
 Vega 2,012 t 23.74%
Others: 1,518 t 17.91%
TOTAL: 8,474 t 100.00%
* Source: Holcim group companies 7

Content
8
Quality parameters for the cement manufacturer
 Visual appearance
 Breakage
 Wear rate
 Net: the one needed for grinding
 Gross: the one paid
 Gross – Net = scrap
9
Visual appearance and breakage
 Visual Appearance  Breakage
 Discuss with ball manufacturer

 Visual control prior to delivery ball operating conditions
acceptance
 Reclaim if > 0.5 - 3 [%] of
 Reclaim if > 1 - 3 [%] of balls breakage per ball size –
with visual defects – depends depends on contract
on contract conditions conditions
10
Possible defects
 Visible  Non visible
 Internal health
 Micro - structure & hardness
Ears  Chemical composition
Inclusion Sucking
Micro -
Claming ? structure
11
Consequences from defects
 Breakage
 Deformation
 Higher net and gross wear

rates
 Deterioration of mill
performance:
 Reduced production
 Reduced mill availability
12
Ball wear and operating conditions
Abrasion
Impact
Corrosion
13
Content
14
What means ball charge management?
As the balls wear
Mill absorbed power reduces Grinding efficiency reduces
So does production So does production
Top up for wear compensation Ball charge classification

15
Ball charge classification on principle
Deformed & broken
balls sorted out
mechanically/manually
Scraps Total
Balls in bucket t 7.2 11.1 25.2 30.7 89.8 6.0 170.0
Balls sampled -- 200 200 200 200 200 0 0 200
Sample weight kg 85.3 38.5 18.2 9.5 4.5 0.0 0.0 2.9
Diam. Equival. mm 47 36 28 23 18 0 0 15
Composition % 4 7 15 18 53 0 0 4 31 [g/ball]
2
Number of balls -- 16'882 57'662 276'923 646'316 3'991'111 0 0 413'793 37.1 [m /t]
200 balls per sample in the second chamber

100.00
50 balls per sample in the first chamber
16
Criteria for ball charge classification
 Visual criteria for ball form classification
(deformed/broken)
Bad
Good
17
Example for a ball charge classifier
18
Ball charge classifier in operation
19
Automatic refilling of the classified ball charge
20
Frequency of ball charge classification
 Standard frequency for ball charge classification
 First chamber  Second chamber

 Once every year  Once every two – three years:
- OPC
- OPC + < 5 [%] MIC
 Once every one – two years:
- Composite cements (>> 5 [%
MIC)
- Slag
- Puzolana
21
Content
22
Ball wear compensation – decrease of the balls
 While a Ø 90 [mm] becomes an Ø 80 [mm] an Ø 80
[mm] becomes a Ø 70 [mm] and so on …
Ø90 [mm]
Ø80 [mm]
Ø70 [mm]
 < Ø 30 – 40 [mm] wear slower than bigger balls

23
Wear rate calculation on principle
Scraps
S = 1 [t]
Wear
compensation Small balls Good balls
WC = 24 [t] SB = 3 [t] GB = 79 [t]
Initial charge Cement production

IC = 80 [t] CP = 700’000 [t]
24
Net and gross wear rate
IC + WC – GB
Gross wear = x 1’000’000 [ gball / tcement ]
CP
80 + 24 – 79
Gross wear = x 1’000’000 = 35.7 [gball / tcement ]
700’000
IC + WC – (GB + SB + S)
Net wear = x 1’000’000 [gball / tcement ]
CP
80 + 24 – (79 + 3 + 1)
Net wear = x 1’000’000 = 30.0 [gball / tcement ]
700’000
25
Ball wear compensation – quantity calculation
 The ball quantity to compensate wear (WC) depends on
the net wear rate (NW) and the annual cement
production (CP).
WC = CP x NW x 10-6 [t/a]
 NW1 = 30 [g/t]  NW2 = 20 [g/t]
 CP = 700’000 [t/a]  CP = 700’000 [t/a]
 WC = 700’000 x 30 x 10-6 =  WC = 700’000 x 20 x 10-6 =
= ~ 21 [t/a] = 14 [t/a]
26 [%] of initial ball charge 8 [%] of initial ball charge weight

weight
26
Ball wear compensation - top up 1st compartment
Biggest ball size
1. Compartment
Ø Ball [mm] Weight [ t ] Percent [%] Wear comp. [%]
90 20.0 25.0 100.0

80 28.0 35.0
70 20.0 25.0
60 12.0 15.0
Total 80.0 100

Average ball weight [g] 1667
Spec. media surface [m 2 / t] 10.2
27
Ball wear compensation - top up 2nd compartment
3 balls sizes required
2.Compartment
Ø Ball [mm] Weight [ t ] Percent [%] Wear comp. [%]
50 17.0 10.0 15.0

40 17.0 10.0
30 27.2 16.0 35.0
25 27.2 16.0
20 35.7 21.0 50.0
17 45.9 27.0
15
Total 170.0 100

Average ball weight [g] 41
Spec. media surface [m 2 / t] 32.8
28
Balls characteristics
29
Ball wear compensation - frequency
 Frequency to be adapted for each chamber
 Regular production intervals and checking the free height

- e.g 2 [t] every 60’000 [t] for the 1st chamber
- e.g ~7 [t] every 350’000 [t] for the 2nd chamber

 Regular time intervals (e.g. 2’000 [h])
 Mill motor absorbed power
- 1 t ~ 10 kW
30
Ball wear compensation – organisation (example)
Mahlkugelfüllungen
Letzte MK-Neufüllung: 17.12.1999 Letzte Mühlenstürzung: 10.12.1999
Kammer 1: MK-Sorten Magotteaux-Maxichrom + GST Kammer 2: MK-Sorten Magotteaux-Maxichrom + GST

Ø [mm] [g/Kugel] [Kugel #] % Gewicht Tonnen Ø [mm] Kugel #/t m²/t m² % Gewicht Tonnen
90 3000 2900 26% 8.70 60 1125 12.72 0.00 0% 0
85 2527 0 0% 0 56 1384 13.63 0.00 0% 0
80 2107 3939 24% 8.30 51 1832 14.97 0.00 0% 0
76 1807 0 0% 0 50 1944 15.27 78.78 9% 5.16
70 1412 6376 26% 9.00 44 2852 17.35 0.00 0% 0
68 1294 0 0% 0 40 3797 19.08 190.84 17% 10.00
60 889 8999 24% 8 37 4797 20.63 0.00 0% 0
30 8999 25.45 270.23 18% 10.62
28 11069 27.26 0.00 0% 0
25 15551 30.53 519.08 30% 17.00
23 19971 33.19 0.00 0% 0
20 30373 38.17 566.41 26% 14.84
17 49457 44.90 0.00 0% 0
22213.95 100% 34.00 1625.34 100% 57.62
Zusätzlich zugefüllte Tonnen seit letzter aktueller Neugattierung in Tonnen

Ø [mm] 04.01.2000 27.06.2000 Ø [mm] 04.01.2000 27.06.2000
90 60
85 56
80 1.00 51
76 Rückwiegung und spez. Verschleiss 2000
50
70 44
90 mm 80 mm 70 mm 60 mm 50 mm 40 mm
68 40 0.95
3.46 t 12.26 t 7.04 t 5.40 t 0.96 t 0.00 t
60 1.06 2.50 37
Prod 01/00 - 12/00* 121770 t Summe 29.12 t
30 0.85
28 gestürzt MK-Verlust Schrott Gesamtverl. spez. MK-Verlust spez. Gesverl.
25 33.76 t 3.90 4.80 t
1.65 4.64 t 9.44 t 39.42 77.52
23 Rückwiegung nach Sortierung K2 [t] 2000
20 60 mm 3.70 50 mm 40 mm 30 mm 25 mm 20 mm
17 k.A. k.A. k.A. k.A. k.A. k.A.
2.06 2.50 0.00 0.00 Prod 01/00 - 12/00* 7.60 3.45
121770 t 0.00 0.00
Summe 61.10 t
gestürzt MK-Verlust Schrott Gesamtverl. spez. MK-Verlust spez. Gesverl.
Gesamtsumme: K1 38.56 K2 68.67
65.50 t 3.17 t 4.40 t 7.57 t 26.03 62.17
31
Key messages
1. Control your supplier by making samples of his

delivery – “every plant gets the supplier it deserves”
2. Top up your mills regularly – use the opportunity of

monthly inspections
3. Classify your ball charges regularly – once a year 1st

compartment, every 2 years the 2nd as a rule of the
thumb
32

008 Ball Charge Management

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Mill Workshop, Holcim Apasco S.A.

8. Ball charge management

Drying Coarse grinding (*) Fine grinding Separating

Ball charge management

Ventilation & cooling

(*) Includes pregrinding and the grinding in the 1 st chamber

 Global supply contracts for grinding media

 Briefly review quality aspects of grinding media

 Ball charge classification requirements

 Guidelines for top up compensation for wear

 Know the standard practices for ball charge

 Global supply contracts for grinding media

 Briefly review quality aspects of grinding media

 Ball charge classification requirements

 Guidelines for top up compensation for wear

 New contact person at Corporate Procurement:

* Source: Holcim group companies 7

 Global supply contracts for grinding media

 Briefly review quality aspects of grinding media

 Ball charge classification requirements

 Guidelines for top up compensation for wear

 Discuss with ball manufacturer

 Higher net and gross wear

 Global supply contracts for grinding media

 Briefly review quality aspects of grinding media

 Ball charge classification requirements

 Guidelines for top up compensation for wear

Mill absorbed power reduces Grinding efficiency reduces

So does production So does production

Top up for wear compensation Ball charge classification

200 balls per sample in the second chamber

 First chamber  Second chamber

 Global supply contracts for grinding media

 Briefly review quality aspects of grinding media

 Ball charge classification requirements

 Guidelines for top up compensation for wear

 < Ø 30 – 40 [mm] wear slower than bigger balls

Initial charge Cement production

26 [%] of initial ball charge 8 [%] of initial ball charge weight

Biggest ball size

90 20.0 25.0 100.0

Total 80.0 100

3 balls sizes required

50 17.0 10.0 15.0

Total 170.0 100

 Regular production intervals and checking the free height

- e.g ~7 [t] every 350’000 [t] for the 2nd chamber

Kammer 1: MK-Sorten Magotteaux-Maxichrom + GST Kammer 2: MK-Sorten Magotteaux-Maxichrom + GST

Zusätzlich zugefüllte Tonnen seit letzter aktueller Neugattierung in Tonnen

1. Control your supplier by making samples of his

2. Top up your mills regularly – use the opportunity of

3. Classify your ball charges regularly – once a year 1st

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