27390644

Pag L:\DATA\Dept150\Polysius Pres
Process
e1 Training
entation and Training\Polysiu
s Training\Grinding\Ball Mill
Ball Mill + SEPOL
\ballm_sepol_process.ppt
150 WEI, 140 CD
Krupp Polysius Corp.

Ball mill
e2 entation and Training\Polysiu
Discharge diaphragm
Intermediate diaphragm 150 WEI, 140 CD
Mill inlet
Mill discharge
Ball filling 2. compartment
Ball filling 1. compartment
Drive

Polysius cement mill
150 WEI, 140 CD

Schematic possibilities of ball grinding
As Training\Grinding\Ball MillB
150 WEI, 140 CD
A Cataract movement (Grinding because of impact and friction)

B Cascade movement (Grinding because of friction)

e 5 Movement
of grinding media in a ball mill
Movement depends on:
150 WEI, 140 CD
Mill speed
Ball charge
Liner shape
Mill diameter

e 6 Movement of grinding media in a ball mill
Mill revolutions: % of critical speed
150 WEI, 140 CD
Ball charge: % of mill volume

e7 entationBall
andmill speed
Training\Polysiu
Vcrit: critical speed balls stay on the mill wall due to centrifugal force
NO GRINDING POSSIBLE!
150 WEI, 140 CD
42.3
Vcrit
Di
Vmax: maximum speed circa 75% of the critical speed
31.7
Vmax
Di
Di = diameter inside liners

Ball charge
1. Compartment:
coarse balls 150 WEI, 140 CD
2. Compartment:
ball filling classified
because of liners

Example
e9 for ball size distribution
entation for Ball Mills in
and Training\Polysiu
closed circuit with a High Efficiency Separator
separator (without pregrinding)
150 WEI, 140 CD

e 10 Liner
entation andShape
Training\Polysiu
-Classifying Liners- Mill
s Training\Grinding\Ball
150 WEI, 140 CD
1 < 2
1
2
Flow of material
Mill cylinder Classifying liner

Pag L:\DATA\Dept150\Polysius
Liner shape Pres
e 11 entation andliners
- Lifting Training\Polysiu
-
150 WEI, 140 CD
Mill shell
Lifting liners
Mill rotation

e 12 entation Balland filling
Training\Polysiu
s level
The filling Training\Grinding\Ball Mill
of the grinding media is as follows:
150 WEI, 140 CD
G(tons)
FP(%)

CD L i (D )2
i
4
FP = Filling level (%)

CD = Charge density (approx 4.5 t/m3 1. Compartment)
(approx 4.6 t/m3 2. Compartment)
Li = Effective grinding length
Di = Inside diameter
= 3.14

Drive power requirement of ball mills
e 13 entation and Training\Polysiu
The required power of a ball mill depends on:
150
Mill size (diameter, WEI, 140 CD
length)
Mill revolution speed
Amount of ginding media (%)
number of grinding compartments
type of material
type of mill liners
type of grinding media
type and length of a pre-drying compartment (if applicable)

e 14 Calculation
entation of ball mill power

150 WEI, 140 CD
P M
L
M G L
G

eEstablishing
15 the power
entation requirement
and at the mill shaft
Training\Polysiu
150 WEI, 140 CD
G (tons) Di c
P (kW)
1.36
G weight of ball charge

Di internal diameter
c c-factor
1.36 conversion factor from HP to KW

Basic c - factor for n = 75 % nkrit
150 WEI, 140 CD
c-factor [m1.5/s3]
2-compartment mill
Filling degree [%]

e 17 C - factor
entation correction
150 WEI, 140 CD
C = cbasic corr. speed corr. Blaine

C-factor correction for speed if n 75 % nkrit
e
1.1
18 entation and Training\Polysiu
1.09 s Training\Grinding\Ball Mill
1.08
1.07
1.06 150 WEI, 140 CD
1.05
c - factor correction
1.04
1.03
1.02
1.01
1
0.99
0.98
0.97
0.96
0.95
0.94
0.93
0.92
0.91
29.7 30.2 30.7 31.2 31.7 32.2 32.7 33.2 33.7
n Di
e 19 C-factor correction
entation for Blaine
Above\ballm_sepol_process.ppt
3500 Blaine:
150 WEI, 140 CD
c decreases as Blaine increases
c is reduced by 0.175% per 100 Blaine
Blaine 3500
CBlaine 1 0.175
10000

e 20 Example
entation drive
and losses
Training\Polysiu
given: \ballm_sepol_process.ppt
eff. gear box = 96 %
150 WEI, 140 CD
eff. Motor = 96 %
eff. Lines = 99 %
drive efficiency = eff. gear box eff. motor eff. lines
drive efficiency = 0.96 0.96 0.99
drive efficiency = 0.91 = 91 %

Drive losses
The losses due to the drive must be taken into consideration with this calculation.
150 WEI, P(shaft)
140 CD
P(counter)
drive eff.
Drive efficiency:
Ball mill Gear box Motor Counter
P(shaft) eff. gear box eff. motor eff. lines
drive efficiency = eff. gear box eff. motor eff. lines

e 22 Fineness
entationconversion (clinker)
( (Bl2 - Bl1 )
) f
0.49 150 WEI,
= fineness factor
Bl1140 CD
= new Blaine
f e 1000
Bl2 = base Blaine
Wsp = specific work

Wsp (Bl2 )
Wsp (Bl1 ) = power consumption (kWh/t)
f
M2 (Bl2 ) M1(Bl1 ) f M1 = new capacity for new Blaine (t/h)

M2 = base capacity for base Blaine (t/h)

Example 1: adjustment of capacity (Clinker)
s Training\Grinding\Ball Mill 2
Conversion of existing system from 3500 to 5000 cm /g (Blaine)
150 WEI,( (35001000-140 0.49 )
5000) CD
f e
0.4795
Base capacity: M2 = 100 t/h @ 3500 Blaine
Therefore: M1 100 t/h 0.4795
47.95 t/h @ 5000 Blaine

Pag Example L:\DATA\Dept150\Polysius Pres
1: product fineness vs. mill capacity
Capacity (%)
130%
120%
150 WEI, 140 CD
110%
100%
90%
80%
70%
60%
50%
40%
30%
303132 3334353637 3839404142 4344454647 4849505152 5354555657 585960
Blaine ( 100)
Example
e 25 2: adjustment
entation andof mill power consumption (Clinker)
Training\Polysiu
s Training\Grinding\Ball Mill 2
Conversion of existing system from 3500 to 5000 cm /g (Blaine)
150 WEI,( (35001000-140 0.49 )
5000) CD
f e
0.4795
Given: Wsp = 35 kWh/t @ 3500 Blaine

35 kWh/t
Therefore: Wsp
0.4795
73 kWh/t @ 5000 Blaine

Example 2: adjustment of mill power consumption
specific work (%)
340% s Training\Grinding\Ball Mill
320% \ballm_sepol_process.ppt
300% 150 WEI, 140 CD
280%
260%
240%
220%
200%
180%
160%
140%
120%
100%
80%
60%
30 3132 3334 3536 37 3839 4041 4243 44 4546 4748 4950 5152 53 5455 5657 5859 60
Blaine ( 100)
KWH/T Shaft Pres
Grindability
e 27 (at milland
entation shaft) as a function of Blaine
Training\Polysiu
250
200 150 WEI, 140 CD
150
kWh/t
100
50
Range for Clinker

0
2000 4000 6000

Blaine cm2/g

Infuence of fineness and
product/slope on the strength
of the cement
150 WEI, 140 CD
Example:
3500 5000
Blaine Blaine
Product Slope 1 1
Compressive Strength 29 49.5

after 2 days (N/mm2)
Compressive Strength 56 65
after 28 days (N/mm2)

Ballemill
29 inspection
and audit
150 WEI, 140 CD
1. Material level and

distribution
2. Grinding media and

charge
3. Shell liners and

diaphragm
4. Water injection and

grinding aid lances

150 WEI, 140 CD
1. Material Level and Distribution

e 31 Material
entation andload too low
Training\Polysiu
Chamber I Chamber II
150 WEI, 140 CD
Material level
Chamber I:
No material visible over a section
or over the entire length of the grinding
chamber.
Chamber II:
No material visible on the surface of the
grinding media charge.

e 32 Material
entation andload too high
Training\Polysiu
150 WEI, 140 CD
Material level
Chamber I:
Large quantities or material above and between
the grinding media no intensive grinding
Build-up of large material pieces in front of the
intermediate diaphragm
Chamber II:
Grinding media are covered with a 50 to 100mm
thick material layer
low degree of grinding
e 33 Material
entation andload normal
Training\Polysiu
150 WEI, 140 CD
Material level
Chamber I:
Normal material load: approx. 1/3 of the grinding
media surface lies bare and the grinding media
lies next to each other with the material laying
in the space between
Chamber II:
Normal material load: grinding media are just
projecting on the surface or are just covered with
material
e 34 Ball Filling
entation and1.Training\Polysiu
Compartment
150 WEI, 140 CD
Material load normal Material load too low

Ball Filling 2. Compartment
Material load normal Material load too high
150 WEI, 140 CD

150 WEI, 140 CD
2. Grinding Media and Charge

e 37 Grinding
entationmedia and charge
To be checked: \ballm_sepol_process.ppt
150
Ball size distribution and ballWEI, 140 CD
classification in the 2. compartment
(if mill is equipped with segregation liners)
Shape of grinding balls (worn and/or broken balls) as well as foreign bodies
in the ball charge
Measurement of filling level in the empty mill
Coating of grinding balls

e 38 Measurement
entationofand
filling level in the mill
Training\Polysiu
height above ball charge - h
string above ball charge - s
150 WEI, 140 CD
Free liner plates above ball charge
Di
h Liners
Ball charge

e 39 Example for measurement
entation of filling level
given: h = 2.284 m (height above ball charge)
150 WEI, 140 CD
s = 3.240 m (string above ball charge)
Di = 3.44 m (diameter inside liner)
FP = 21.7 (free liner plates above ball charge
h/ Di s/ Di 360 - (FP x 10)/2

= = =
0.664 0.942 71.5
Fl (see diagram) 29.5% 29.5% 29.5%

Filling level of ball charge vs. h/Di -, s/Di - and functions
h/Di
e1 40 entation and Training\Polysiu 200
0.9 h/D\ballm_sepol_process.ppt 180
s/Di i
0.8 150 WEI, 140 CD 160
0.7 140
360 - (FP x 10)/2

0.6 120
s/Di
0.5 100
0.4 80
0.3 360 - (FP x 10)/2 60
0.2 40
0.1 20
0 0
0 5 10 15 20 25 30 35 40 45 50
Ball Filling Level (%)
150 WEI, 140 CD
3. Shell Liners and Diaphragm

e 42 Shell liners
entation andand diaphragm
Training\Polysiu
Shape and150
wearWEI,
of liner140
platesCD
Coating
Shape of slots
Blocking of slots (if blocked, cleaning is required)

e 43 entationBall
andmill liners
Training\Polysiu
Ball Mill lifting liners in \ballm_sepol_process.ppt
good Ball Mill classifying liners,
condition 150 WEI, 140 CDcoated
heavily

150 WEI, 140 CD
4. Water and Grinding Aid Injection Lances

e 45 Water injection
entation lances
150 WEI, 140 CD
lances should be open and clean
no damages from impact
cleaning air in water spray should be checked

Water spray system
Spray lance in good condition Spray lance totally blocked
150 WEI, 140 CD

150 WEI, 140 CD
5. Intermediate and Discharge Diaphragm

e 48 Intermediate
entation and
and discharge diaphragm
Training\Polysiu
150 WEI, 140 CD
Diaphragms should be open to assure proper
material and air flow in the mill.
If diaphragms are blocked with worn balls or

material they should be cleaned. If blockage
occurs regularly, broken or worn balls have to be
removed from ball charge.

Diaphragm Pres
Diaphragm not blocked 150 WEI, 140 Diaphragm
CD heavily blocked and
coated with material

150 WEI, 140 CD
Longitudinal Sample

e 51 Longitudinal
entation andsample (meter sample)
Training\Polysiu
one sample of approx, 1lb every 1m (approx. 3 ft) ofMill
the mill length
sample should consist of material from outer mill areas and mill center
150 WEI, 140 CD
sample should be taken approx. 25 mm (1 in) below surface
0m 1m 2m 3m 0m 2m 3m 4m... sampling point

sieve residues and Blaine values should be taken for each sample
results are inserted into a diagram

e 52 entation
Purpose and Training\Polysiu
of longitudinal samples
150and
judgment of grinding efficiency WEI, 140success
grinding CD along the mill
An optimal ball mill filling will lead to steadily decreasing residues and
increasing Blaine values
A not optimal ball filling will lead to areas where residues and Blaine values
romaine unchanged for several feet of the mill.

Mill Longitudinal Sample (Meter Sample)
Good Example for Longitudinal Sample Mill
4500
100
90
4000
80
150 WEI, 140 CD 3500 B laine

70 2289 m = 8 M es h
3000
60 1089 m = 16 M esh
2500 555,3 m = 30 M esh
Residue % 50
40
2000 321 m = 50 M esh
86,6 m = 170 M esh
30 1500
72,7 m = 200 M esh
20 1000 43,2 m = 325 M esh
10 500
0 0
0 1 0 1 2 3 4 5 6 7 8
Meter sample points / m
Bad Example for Longitudinal Sample

100 3500
90 B laine
80
3000 2289 m = 8 M esh
70 2500 1089 m = 16 M es h
555,3 m = 30 M esh
60
2000 321 m = 50 M esh
Residue % 50 86,6 m = 170 M esh
40 1500 72,7 m = 200 M esh
30 43,2 m = 325 M esh

1000
20
10
500
0 0
0 1 2 0 1 2 3 4 5 6 7 8
Meter sample points / m

150 WEI, 140 CD
SEPOL

SEPOL
Feed Material
150 WEI, 140 CD
Separating Air
Fines
Oversize Material

SEPOL SV/x
DISPERSION PLATE FEED BOX
AIR GUIDE \ballm_sepol_process.ppt
PLATE ROTOR BLADES
150 WEI, 140 CD GUIDE VANE
AIR INLET DUCT
CYCLONE
SEPARATOR FEED
SEPARATOR REJECTS
REJECT CONE
VENT AIR WITH FINES
FRESHAIR OR CIRCULATING AIR

SEPOL SV
FEED BOX
DISPERSION PLATE
\ballm_sepol_process.pptROTOR BLADES
AIR GUIDE PLATE GUIDE VANE
150 WEI, 140 CD
AIR INLET DUCT
SEPARATOR FEED DISCHARGE BEND

SEPARATOR REJECTS
VENT AIR WITH FINES REJECT CONE
FRESHAIR OR CIRCULATING AIR

SEPOL Separator
150 WEI, 140 CD

Completely
e 59 opened air-inlet
entation andlouvre (during commissioning)
Training\Polysiu
s Training\Grinding\Ball Millare being
Louvres
adjusted to wear pattern
150 WEI, 140 CD at the rotor
separating
air
Air channels

Spiral inlet, guide vanes and rotor
\ballm_sepol_process.ppt Rotor
150 WEI, 140 CD
Air flow
Air inlet
Guide vanes

Setting of entation
e 61 guide vanes
and (during Commissioning)
Training\Polysiu
150 WEI, 140 CD
counter-clockwise rotation
clockwise rotation

Setting of guide vanes (during Commissioning)
guide vanes Mill
set to largely tangential
position (6065 to the radial)
150 WEI, 140 CD
max. separating air
speed of separator rotor set to suit

the required cement fineness

Separator formulas
SA, SF SG [t/h]: separator
SA (a)
150 WEI, 140 CD feed, separator fines,
separator grits
a, f, g: fineness feed,
fines, grits (Blaine or
SG (g)
SF (f) residue)
Circulation Factor = SA / SF
= (f - g) / (a - g)

e 64 Particleand
entation Size Distribution
Training\Polysiu
Area Considered at a Tromp
100 %
Curve
150 WEI, 140 CD
Rejects
50%
Fines
Feed
X Particle Size, Q - % Passing

e 65 TROMP
entation CURVE
150 WEI, 140 CD
Separation
Fines
Coarse
X Particle Size

e 66 TROMP CURVE
entation (IDEAL
and SEPARATION)
Training\Polysiu
150 WEI, 140 CD
Separation
Fines
Coarse
Xc Separation Particle Size

Separation Typical Tromp
100%
100% Curve
90% \ballm_sepol_process.ppt
80% 150 WEI, 140 CD
Fines
70%
60%
50%
40%
30% Coarse
20%
10%
0%
1 10 100 1000
Particle Size (Microns)
150 WEI, 140 CD
Grinding Circuits

The SEPOL in closed grinding circuit with circulating air
operation
150 WEI, 140 CD

The SEPOL in closed grinding circuit with direct air operation
and fresh air supply for fine material cooling (single pass)
150 WEI, 140 CD

The SEPOL in closed grinding circuit with circulating
aire operation.
71 entation
High and Training\Polysiu
pressure grinding roll as primary mill
150 WEI, 140 CD

operation. Highpressure grinding roll and tube mill in hybrid
operation
Mill
150 WEI, 140 CD

e 73 SEPOLentation
operation. and
after high Training\Polysiu
pressure grinding roll and tube
mill forscombination
Training\Grinding\Ball Mill
and finish grinding.
150 WEI, 140 CD

e 74 Material flows
entation in ball
and mill circuits
Training\Polysiu
150 WEI, 140 CD
SF (f) 85 -90%
23-fold material circulation
Separator collecting
cyclones
SG(g)
Separator
tube mill SA (a) filter
10 -15% sampling for

100% determination of
feed material F Mill fineness
waste air
filter
100%
finished material F

Heat balance in ball mill circuits
Q = Heat
System II
Qconvection,
\ballm_sepol_process.ppt Q sepol air
Q =Q 150 WEI, 140 CD
II in II out Q material
radiation
Qsepol air Qconvection,radiation

Qwater,evaporated
Qmaterial Qfalse air

Q exit air
Qinlet air
Qmaterial
Qfalse air
Qpower,converted
Qmaterial moisture QI in = QI out
Qwater spray
System I

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What are some of the components of a ball mill?

What are some of the components of a ball mill?

Pag L:\DATA\Dept150\Polysius Pres

Krupp Polysius Corp.

Ball filling 2. compartment

Ball filling 1. compartment

Krupp Polysius Corp.

Krupp Polysius Corp.

A Cataract movement (Grinding because of impact and friction)

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Vmax: maximum speed circa 75% of the critical speed

Di = diameter inside liners

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

FP = Filling level (%)

Krupp Polysius Corp.

Mill revolution speed

Amount of ginding media (%)

number of grinding compartments

type of mill liners

type of grinding media

type and length of a pre-drying compartment (if applicable)

Krupp Polysius Corp.

Krupp Polysius Corp.

G weight of ball charge

Krupp Polysius Corp.

Filling degree [%]

C = cbasic corr. speed corr. Blaine

Krupp Polysius Corp.

c is reduced by 0.175% per 100 Blaine

Krupp Polysius Corp.

drive efficiency = eff. gear box eff. motor eff. lines

drive efficiency = 0.96 0.96 0.99

drive efficiency = 0.91 = 91 %

Krupp Polysius Corp.

Ball mill Gear box Motor Counter

P(shaft) eff. gear box eff. motor eff. lines

drive efficiency = eff. gear box eff. motor eff. lines

Krupp Polysius Corp.

Wsp = specific work

M2 (Bl2 ) M1(Bl1 ) f M1 = new capacity for new Blaine (t/h)

Krupp Polysius Corp.

Base capacity: M2 = 100 t/h @ 3500 Blaine

Therefore: M1 100 t/h 0.4795

47.95 t/h @ 5000 Blaine

Krupp Polysius Corp.

Given: Wsp = 35 kWh/t @ 3500 Blaine

73 kWh/t @ 5000 Blaine

Krupp Polysius Corp.

Range for Clinker

2000 4000 6000

Krupp Polysius Corp.