Ball Mill Optimization

The Ball Mill

The Ball Mill
Gas + dust
outlet
Intermediate diaphragm
Outlet diaphragm
Reject return Inlet head C2 liners Discharge box
chute C1 liners
Fresh feed
Outlet seal

Material discharge

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

Trunnion

Post Sevilla - Module 2

5
 The Ball Mill

Leff C2
Leff C1
Leff TOT
D Deff

- L/D : Ratio between 3 and 5

- Length of C1/Total Length : ratio between 27 and 40% except for birotators
- Ball diameter in C1 from 100-90 mm to 70-60 mm (4 / 3-1/2” to 2-1/2 / 2”)
- Ball diameter in C2 from 60-50 mm to 20-17 mm (2-1/2” / 2” to 3/4 / 5/8”)

Post Sevilla - Module 3

5
 Conditions of the lifting liners

Purpose
Insuring proper cascading of the
balls and hence crushing of Step
material
General condition of liners
Plate conditions (breaks, chips,
attachments)
Criterion
Performance should be checked
when step < 40%
of initial step (wear=60%) rotation
Corrective measure
Replacement

Post Sevilla - Module 4

5
 Effect of delayed mill maintenance

Replacing worn out liners in a cement mill

increase of the mill output +15%
decrease of the electricity consumption
Delayed replacement of lifting liners (<30%initial)
Results after replacement
Average consumed specific energy
- before 60 kWh/t
- after 53 kWh/t linked to a return to normal mill output

Post Sevilla - Module 5

5
 C1 and C2 Volume Loading

Purpose
Insure adequate size reduction
Measure on 1/2 step or plate
Insure proper output transverse center

Quick estimate
Distance between charge and lower
part of the trunnion Vertical measurement

Distance between charge and lower

part of the ventilation screen
Criterion
Between 28% and 34% Middle
axis
Corrective measure
Regular recharging

Post Sevilla - Module 6

5
 C1 and C2 Volume Loading

Example for an overfilled compartment

Post Sevilla - Module 7

5
 C1 and C2 Volume Loading

As an example, what is the efficiency loss associated to

a poor ball volume loading ?

1986 1993 Gap

Volume loading in C1 30% 21% -30%
Mill output t/h85 59 -30%
kWh/t 27,6 39,1 +42%

Post Sevilla - Module 8

5
 Ball charge conditions in C1 and C2

Purpose
Evaluating ball charge wear
Detecting a mechanical problem (breakage of a diaphragm sector)
Criteria
Clean charge (no scrap)
Round balls (not deformed) and
of suitable size
Corrective measures
Ball charge sorting in case of
contamination
C1 ball sorting (every 5000 - 7000 h)
Clean charge
C2 ball sorting (every 10000 - 14000 h) Polluted charge

Post Sevilla - Module 9

5
 Material level in C1 and C2

Purpose
Limit wear and insure a good
particle size reduction
Detecting the presence of
spitzers (waves)
Quick evaluation
Material / ball level

Overfilled compartment

Post Sevilla - Module 10

5
 Material level in C1 and C2

Criterion
Material level = ball level
over the entire compt.
Corrective measures
Change in the number of
Right level
small balls 60 mm (2-1/2”)
(or 50 mm (2”)) in C1 and
20 mm (3/4”) (or 17 mm
(5/8”)) in C2
Scoop adjustments
Control of the circulating load

Empty compartment

Post Sevilla - Module 11

5
 Ball Charge Classification
Classified
Purpose
Adapts the charge granulometry to that of
the material
Criterion
Progressive decrease of the ball size in
C2
Corrective measures Unclassified
Sorting and optimization of the ball
charge
Replacing liners
Checking the size of slots
6mm intermediate diaphragm
8mm outlet diaphragm

Post Sevilla - Module 12

5
 Effect of delayed mill maintenance

Ball sorting done after 3 years (Too late = 20000h)

Results after ball charge sorting
8 to 10% output increase on average for all products
Average consumed specific energy ;
before 52 kWh/t
after 48 kWh/t.

Post Sevilla - Module 13

5
 How are the liners and the ball charge?

Wear of the liners and ball charge has to be looked

after in order to avoid performance losses.
Worn out stateNormal
state* Gap
Grinding
energy 39 kWh/t 32 kWh/t -18%
Mill output 65 t/h 92 t/h
+40%

* after the replacing of liners and ball charge

Post Sevilla - Module 14

5
 Ventilation Screens
Purpose
Insure gas flow Good permeability
Preventing balls from passing between
compartments
General condition
Cleanliness
Criteria
Maximum permeability
Mechanical behavior with the 90 mm Total lack of permeability
(3-1/2”) balls and screen# < 40 mm
(1-3/4”) in C1
Screen# < 15 mm (5/8”) in C2 to prevent 20
mm (3/4”) balls from escaping
Corrective measures
Cleaning or replacement

Post Sevilla - Module 15

5
 Diaphragm Slots

Purpose
Providing outlet for the material
in the compartments while Scrap
retaining spitzers and balls
Improving ventilation
General conditions
Slot plugging
Peening, clearances

Slot width
C1 side clearance
C2 side clearance

Post Sevilla - Module 16

5
 Diaphragm Slots

Criteria
C1 slots from 6 mm to
8 mm
C2 outlet slots larger by at
least 2 mm than those of Peened slots
C1 outlet
Corrective measures
Filing and cleaning
Diaphragm replacement

Post Sevilla - Module 17

5
 Compartment Samples

Purpose
COMPARTMENT N°1 COMPARTMENT N°2
Grinding assessmentSamples X X X X X X X X X X X

(C1 and C2) X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

Determining X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

X
X

spitzer locations X X X X X X X X X X X

Quick evaluation Charge

0.5m
Samples taken at the
discharge end of Direction of rotation C1 C2
the compartment 1 2 3 4 5 6 1 2 3 4 5

Post Sevilla - Module 18

5
 Compartment Samples
Fineness evolution in the
Criteria mill
%Cumulated rejects
<5% retained on 2 to 100
2.5 mm (or 8 mesh) 80
sieve at the 60
diaphragm 40

Progressive decrease 20
all along the mill 0
1 2 3 4 5 6 7 8 9 10 11 12
Corrective measure
Sample Number
Adapting the charge
granulometry 40
µm
1
63
µm
2,5
100
µm
5
200
µm
Diaphragm
500
µm
Diaphragm
Changing the length mm mm mm
Inadequate grinding

Presence of grains

Post Sevilla - Module 19

5
 Summary

Conditions of lifting liners

Performance has to be looked at if step < 40% of initial step
(wear=60%)
Volume loading : 28% to 34%
Ball charge conditions :
Clean, round shape and suitable size for the compartment
C1 has to be sorted every 5000 to 7000 h
C2 has to be sorted every 10 000 to 14 000 h

Post Sevilla - Module 20

5
 Summary

Material level
Material level = ball level over the entire compartment
Ball charge classification :
progressive decrease of the ball size in C2
Diaphragm slots :
first compartment slots: 6mm to 8mm
second compartment outlet slots larger by at least 2mm than
those of first compartment
Ventilation screens
they have to have the maximum permeability to let the
maximum gas flow through the mill while retaining the balls

Post Sevilla - Module 21

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