47 NCPMills
47 NCPMills
Suppliers of: Ball Mills Sag Mills Rod Mills Fag Mills Liners Anxillary Equipment Turnkey Project Management
NCP supplies new Grinding Mills and all ancillary equipment to clients across the globe.
Product Range
1. NEW EQUIPMENT Grinding Mills & Communition Circuits 2. REFURBISHED EQUIPMENT Grinding Mills & Comminution Circuit Equipment Crushers & Crushing Plants Thickeners Conveyor Equipment Pump Projects Ventilation Fans Shaft Compressors Mine Winders Power Generation Equipment Cranes The product range offered by NCP includes: ROD MILLS BALL MILLS ROM BALL MILLS SAG MILLS FAG MILLS LINERS GRINDING MEDIA ANCILLARY EQUIPMENT NCP is actively involved with supplying and developing a wide range of mill types with mills being identified by the type of grinding media used. Each type of mill has characteristics that enhance its grinding application and the operational characteristics of each must be evaluated in relation to the objectives of the grinding requirement.
PRroduct Range
Many factors are involved in the selection of grinding media. Including ore hardness, feed size, mill size, mill speed and feed rate. Media selection is important because the cost of media is a major expense in grinding with significant savings available by optimizing the use of grinding media. Media diameter can be selected so as to provide for the best mill performance as well as media shape selection (established shapes are either spherical or cylindrical).
Choice of materials used in grinding media is significant. Grinding balls should be made of forged steel, or cast steel having the same resistance to breakage. Rods should be hot rolled, hot sawed or sheared with standard tolerances and machine straightened. NCP typically undertakes DEM Analysis (Discreet Element Modelling) to determine optimal Liner Design & Mill charge characteristics.
Mill Types
Rod Mills
Rod Mils can accept feed up to approximately 25mm and are generally selected to grind products in the -4mm to -0.5mm range. Grinding action is by line contact between rods which extends the length of the mill. Large feed particles spread the rods at the feed end and in so doing ,allow preferential grinding of the coarse fraction. A minimum amount of fines are created and a relatively uniform sized grading is produced. Rod Mills are usually operated in open circuit. Most rod mill applications involve wet grinding where material is reduced in size from crusher product size to a size suitable for ball mill feed. Rod milling in the size range utilised is more efficient than primary ball milling, in that the desired product is obtained at a lower cost per ton. To avoid breakage or tangling of rods the L/D ratio of rod mills is kept within the limits 1.3/1 to 2/1. 1. Ball Mill - Overflow Discharge: As the name implies, material is discharged from an overflow mill by overflowing the discharge opening. In this type of mill the balls are kept in the mill by keeping the top of the ball charge below the level of the discharge opening. A reverse spiral in the discharge trunnion liner also assists this condition.
OVERFLOW BALL MILL
NCP actively supply the three most common Rod Mill types:
2. Ball Mill - Grate Discharge: This mill type embodies the principle of steep pulp gradient, quick discharge operation. A grate assembly at the discharge end of the mill permits retention of a higher ball charge (45%) than is possible in an overflow mill, which has a practical limit of around 40%. Behind the grates are pulp lifters, which pick up the ground material as it passes through the grates and transports it out of the mill. This quick removal of ground material produces overgrinding especially when operated in closed circuit with a classifier. The classifier removes the particles, which are within the product specification, and returns the oversize back to the mill feed chute.
1. Rod Mill Overflow An overflow mill is constructed with a feed opening at one end and a discharge opening at the other, both on the axis of the mill. Material leaves the mill by overflowing at the discharge end. Used for producing the finer end of the product range.
2. Rod Mill End peripheral discharge (EPD) The end peripheral discharge mills steeper gradient produces shorter retention time and thus a coarser product than the overflow type. Product is discharged through port openings equally spaced around the periphery of the shell at the discharge end. Grinding may be accomplished wet or dry. End peripheral discharge is used to good advantage in damp grinding of coke or steelwork sinter plants.
3. Rod Mill Centre peripheral discharge (CPD) Feed is from both ends and is discharged at the centre through discharge ports, equally spaced around the mill periphery. The ports are in a separate ring between the shell halves. The fact that the particles only travel half the mill length makes the CPD rod mill an outstanding unit for coarse grinding and rapid removal of finished material.
SAG Mills
Ball Mills
Ball Mills accept feed that ranges in size from 80% passing 15mm to fine feeds in regrind applications. Products may be as coarse as 0.5mm or as fine as 40 microns or below. Grinding is accomplished with spherical-shaped media generally made of steel. In a ball mill the length may be less than, equal to, or greater than its diameter. A short length mill has a lower retention time and produces a coarser product. Longer mills have a longer retention time and therefore produce a finer grind. Ball mills can be operated in an open circuit but modern practice generally utilises closed circuit operation.
4. Semi-Autogenous Mills (SAG Mills): SAG Mills use semi-autogenous grinding in place of autogenous grinding when the ore does not produce the necessary competent media. Forged steel balls are used to supplement the coarse ore. With this additional load by adding steel balls, more motor power is required and the physical design of the mill requires to be more robust. Most clients envisaging autogenous operation however request their mill be designed to cater for semi-autogenous loads. Ball sizes commonly used are 100 to 120mm. The ball charge is generally in the range of 2 to 12% of the mill volume.
Mill Types
5. Trunnion Supported vs Shell Supported Mills Trunnion supported mills have been proven by many years of operation. NCP/ Osborn have over 180 mills in the field with powers from 2 kW for laboratory use to 3880 kW on production units. NCP also carry shell supported designs for mills >12 ft diameter. Shell supported designs reduce the bending moment on shells by reducing the effective distance between support points. Limitations on trunnion openings is removed, thus shell diameters can be increased.
Cement Clinker Chrome Ore Coal Coke Copper ore Dolomite Feldspar Ferrochrome Ferromanganese
Mill Calculations
A common method used in determining power requirements uses the Bond theory where the following mathematical relationship applies: W= 10 Wi ( 1/P80 - 1/F80 ) where, W = Kilowatt hours per short ton required Wi = The Bond Work Index (Kwh/short ton) P80= Size in microns which 80% of the product passes F80= Size in microns which 80% of the feed passes Wi is usually obtained from laboratory batch tests or records kept from previous tests. The value W can now be metricated by multiplying by 1.1 (Kwh/tonne) and then by the feed rate to give kilowatts at pinion shaft. A series of correction factors are considered when using the Bond method, in the table to the right. As the formulae for correction factor 3 includes the mill diameter a provisional mill size can be selected from the chart below using the power value (1). For this a suitable L/D ratio must be assumed. The final power in kilowatts can be obtained by multiplying the previously calculated value (1) by each applicable correction factor.
CORRECTION FACTOR 2, CF2 (open circuit ball milling) Reference % Passing 50 60 70 80 90 92 95 98 Correction Factor 2 1.035 1.05 1.10 1.20 1.40 1.46 1.57 1.70
CF5 = P80 + 10.3 1,145 P80 If P80 > 74 m then CF5 = 1,0
CORRECTION FACTOR 6, CF6 (ratio of reduction, rod milling) Optimum Reduction Ratio: Rr0 = 8 + 5L D1 Reduction Ratio, Rr = F80 P80 CF6 = 1+ (Rr - Rro)2 150
Ferrosilicon Flint Fluorspar Gold Ore Graphite Iron ore Magnetite Lead Ore Lead Zinc Ore Limestone Manganese Ore Mica
Nickel Ore Phosphate Fertilizer Phosphate Rock Potash Ore Pyrite Ore Quartzite Quartz Silica Silica Sand Silica Carbide Silver Ore Slag Slag, Iron blast furnace Sodium Silicate Tin Ore Titanium Ore Uranium Ore Zinc Ore
10.13 8.88 8.90 12.18 12.77 13.53 16.46 26.17 17.30 15.76 12.16 13.00 10.81 11.88 17.93 12.42
CORRECTION FACTOR 4. (oversized feed) CF4 = Rr + (Wi - 7) (F - F0) 80 Rr where Rr = F80 P80 F0 (Ball milling) = 4000 13/W i F0 (Rod milling) = 16,000 13/W i If F80 < F0 then CF4 = 1,00 if F80 < F0
ID Shell m (ft)
Mill Type % Charge
% Critical Speed (Ball)
1,68 (5- 6) Over Flow 40 79,2 27,1 25,8 405 Rod 40 Grate 45
2,00 (6- 6) Over Flow 40 77,7 24,3 22,7 425 Rod 40 Grate 45
2,30 (7- 6) Over Flow 40 76,6 22,2 20,4 449 Rod 40 Grate 45
2,60 (8- 6) Over Flow 40 75,5 20,5 18,5 465 Rod 40 Grate 45
3,20 (10- 6)
3,66 (12- 0)
4,27 (14- 0)
4,57 (15- 0)
4,88 (16- 0)
5,49 (18- 0)
6,10 (20)
7,00 (23)
ID SHELL
Mill Type % Charge % Critical RPM Rod FPM Length m (ft)
Over Flow 40
Rod 40
Grate 45 72,9
Over Flow 40
Rod 40
Grate 45 71,7
Over Flow 40
Rod 40
Grate 45 71,2
Over Flow 40
Rod 40
Grate 45 70,7
Over Flow 40
Rod 40
Grate 45 69,5
Over Flow 40
RPM Rod PFM LENGTH m (ft) 0,914 (3) 1,22 (4) 1,83 (6) 2,44 (8) 3,05 (10) 3,66 (12) 4,27 (14) 4,88 (16) 5,49 (18) 6,10 (20) 6,70 (22) 7,31 (24) 7,92 (26) 8,53 (28) 9,14 (30) 9,75 (32) 10,36 (34) 10,97 (36) 11,58 (38) 12,20 (40) 8 10 15 7 9 14 9 13 12 18 11 16 21 25 33 48 64
15,9 499
16,5
14,8 535
14,9
13,2 560
14,3
13,0 592
13,8
12,8 623
12,7
0,914 (3) 1,22 (4) 42 56 70 84 45 60 75 76 102 127 67 90 112 134 157 91 114 137 151 189 135 168 201 235 269 163 196 228 214 268 321 189 27 284 331 379 426
(1) Power values shown are for Rod & Ball charges (2) Sizes marked - Are suitable for AG, SAG or Run of Mine units. Powers on application. (3) Powers for AG, SAG & Run of Mine sizes within the range in (1) above are also available on application.
220 264 308 352 363 435 508 321 386 450 514 578 643 348 406 464 522
472 567 662 756 418 502 585 669 753 836 920 518 592 666 740
800 934 1067 1200 707 825 943 1061 1179 1297 1415 1532 733 837 942 1047 1370 1566 1762 1957 1212 1386 1559 1732 1903 2078 2252 2425 2598 1359 1510 1862 2094 2327 2560 1648 1854 2060 2266 2472 2678 2884 3090 3296 1659 1843 2194 2468 2742 3017 3291 1942 2185 2428 2670 2913 3156 3398 3640 2217 3321 3690 2939 3266 3593 -
1,863 (6) 2,44 (8) 3,05 (10) 3,66 (12) 4,27 (14) 4,88 (16) 5,49 (18) 6,10 (20) 6,70 (22) 7,31 (24) 7,92 (26) 8,53 (28) 9,14 (30) 9,75 (32) 10,36 (34) 10,97 (36) 11,58 (38) 12,20 (40)
2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 3 3.1 3.2
PO Box 9411 Edenglen 1613 South Africa Tel: +27 87 353 6791 Cell: +27 82 889 8881 +27 82 462 9249 Fax: +27 86 743 7580 projects@newconcept.co.za www.newconcept.co.za
All information supplied herein is subject to change without notice. E&OE
N1109/12397/B1