Training of Production Personnel

Operation Area: Cement Grinding

Module: Wear Protection
Units: Ball Charge Management

HGRS CTS Mechanical Process Technology

 Ball charge management

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Holcim Group Support Ball Charge Management 09/02-OR
Ball charge management.ppt
 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

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Holcim Group Support Ball Charge Management 09/02-OR
Ball charge management.ppt
 Top up for ball wear compensation
 1 [t] ball wear = ~ 8 – 9 [kW] mill power loss

Maintain absorbed power through periodic ball top

up!
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Holcim Group Support Ball Charge Management 09/02-OR
Ball charge management.ppt
 Top up for ball wear compensation (Example 1st Chamber)
 Ball net wear rate calculation (1/2)
Scraps
S = 6 [t]

Wear
compensation
WC = 24 [t] Small balls Good balls
SB = 4 [t] GB = 68 [t]

Initial charge Cement production

IC = 80 [t] TC = 750’000 [t]
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Holcim Group Support Ball Charge Management 09/02-OR
Ball charge management.ppt
 Top up for ball wear compensation (Example 1st Chamber)
 Ball net wear rate calculation (2/2)

IC + WC – (GB + SB + S)
Net wear = X 1’000’000 [ gballs / t cement ]
TC

Net wear 1st 80 + 24 – (68 + 4 + 6)

Chamber = X 1’000’000 = ~ 35 [ gballs / t cement ]
750’000

Net wear 2nd Chamber = 20 [ gballs / t cement ]

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Holcim Group Support Ball Charge Management 09/02-OR
Ball charge management.ppt
 Top up for ball wear compensation
HGRS ball charge recommendation first chamber:
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 [m2 / t] 10.2

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Holcim Group Support Ball Charge Management 09/02-OR
Ball charge management.ppt
 Top up for ball wear compensation
HGRS ball charge recommendation second chamber:
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 [m2 / t] 32.8
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Holcim Group Support Ball Charge Management 09/02-OR
Ball charge management.ppt
 Top up for ball wear compensation
 The ball quantity to compensate wear (BWC) depends
on the net wear (NW) and the annual cement production
(ACP).

BWC = ACP x NW x 10^-6 [t/a]

 NW1 = 35 [g/t]  NW2 = 20 [g/t]

 ACP = 750’000 [t/a]  ACP = 750’000 [t/a]
 BWC = 750’000 x 35 x 10-6=  BWC = 750’000 x 20 x 10 -6
=
~ 26 [t/a] 15 [t/a]

31 [%] of initial ball charge weight 9 [%] of initial ball charge weight

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 Top up for ball wear compensation

 Loss in weight ~ 26 [t/a]  Loss in weight ~ 15 [t/a]

 Ball size for:  Ball sizes:

 100 [%] Ø 90 [mm]  15 [%] Ø 50 [mm]
 35 [%] Ø 30 [mm]
 50 [%] Ø 20 [mm]

 Weight for wear comp.:  Weight for wear comp.:

 2.3 [t/a] Ø 50 [mm]
 26 [t/a] of Ø 90 [mm]
 5.3 [t/a] Ø 30 [mm]
 7.5 [t/a] Ø 20 [mm]

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Ball charge management.ppt
 Top up for ball wear compensation

 Weight for wear comp.:  Weight for wear comp.:

 21 [t/a] of Ø 90 [mm]  2.3 [t/a] Ø 50 [mm]
 5.7 [t/a] Ø 30 [mm]
 7.5 [t/a] Ø 20 [mm]

 Frequency:
 1.8 [t/month] or
 2 barrels per month
 Frequency:
Every six months:
 1.2 [t] (1 barrels) Ø 50 [mm]
 2.8 [t] (3 barrels) Ø 30 [mm]
 3.8 [t] (7 barrels) Ø 20 [mm]

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Ball charge management.ppt
 Ball charge classification
Deformed & broken
balls sorted out
mechanically/manually

Scraps Total
Balls in bucket t 8.3 14.1 30.6 41.9 99.1 6.0 200.0
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 21 50 0 0 3 33 [g]
Number of balls -- 19'461 73'247 336'264 882'105 4'404'444 0 0 413'793 36.6 [m2/t]

200 balls per sample in the second chamber

100.00
50 balls per sample in the first chamber
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 Ball charge classification
 Visual criteria for ball form classification
(deformed/broken)

Bad

Good

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 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

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