Ball Mill Optimization
The Ball Mill
The Ball Mill
Gas + dust
outlet
Intermediate diaphragm
Outlet diaphragm
Reject return Inlet head
C2 liners
C1 liners
chute
Discharge box
Fresh feed
Outlet seal
Material discharge
Shell
Central or ventilation ring
Fresh air inlet
Central Ventilation ring grate
Supports
Feed Arrangements
Mill Heads
Mill Bearings
Drive types
Mill Shell
Trunnion
The Ball mill / ATC Process
March 2004
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)
The Ball mill / ATC Process
March 2004
Conditions of the lifting liners
Purpose
Plate conditions (breaks, chips,
attachments)
Criterion
Step
General condition of liners
Insuring proper cascading of
the balls and hence crushing of
material
Performance should be
checked when step < 40%
of initial step (wear=60%)
Corrective measure
rotation
Replacement
The Ball mill / ATC Process
March 2004
The step size (lifting power)
depends on
Mill rotation speed (%
critical speed)
Volume load
Direction of rotation
Grindability of feed
material
BOLTLESS STEP CHAMBER
1 LINER
Less material spillage
Avoids bolt breakage
The Ball mill / ATC Process
March 2004
Example of bolted liner
The Ball mill / ATC Process
March 2004
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
The Ball mill / ATC Process
March 2004
C1 and C2 Volume Loading
Purpose
Insure adequate size reduction
Insure proper output
Quick estimate
Distance between charge and
lower part of the trunnion
Distance between charge and
lower part of the ventilation screen
Criterion
Between 28% and 34%
Corrective measure
Regular recharging
The Ball mill / ATC Process
March 2004
Measure on 1/2 step or
plate transverse center
Vertical measurement
Middle
axis
C1 and C2 Volume Loading
Example for an overfilled compartment
The Ball mill / ATC Process
March 2004
C1 and C2 Volume Loading
As an example, what is the efficiency loss associated
to a poor ball volume loading ?
1986 1993
Volume loading in C1
Mill output t/h
kWh/t
The Ball mill / ATC Process
30%
85
27,6
March 2004
21%
59
39,1
Gap
-30%
-30%
+42%
10
Ball charge conditions in C1 and C2
Purpose
Criteria
Evaluating ball charge wear
Detecting a mechanical problem (breakage of a diaphragm
sector)
Clean charge (no scrap)
Round balls (not deformed)
and of suitable size
Corrective measures
Ball charge sorting in case of
contamination
Clean charge
C1 ball sorting (every 5000 - 7000 h)
Polluted charge
C2 ball sorting (every 10000 - 14000 h)
The Ball mill / ATC Process
March 2004
11
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
The Ball mill / ATC Process
March 2004
12
Material level in C1 and C2
Criterion
Material level = ball level
over the entire compt.
Corrective measures
Change in the number of
small balls 60 mm (21/2) (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
The Ball mill / ATC Process
Right level
Empty compartment
March 2004
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Controlling material level in C1 and C2
conventional
material
transport
The Ball mill / ATC Process
effect of the
material flow
control
March 2004
14
Ball Charge Classification
Purpose
Adapts the charge granulometry to
that of the material
Criterion
Progressive decrease of the ball size
in C2
Corrective measures
Sorting and optimization of the ball
charge
Replacing liners
Checking the size of slots
6mm intermediate diaphragm
8mm outlet diaphragm
The Ball mill / ATC Process
March 2004
Classified
Unclassified
15
Classifying liners
Diameter <4.4m
Diameter >4.4m
The Ball mill / ATC Process
March 2004
16
Ripple type liner for fine Grinding
Grinding media to be used in 2nd chamber <30mm
The Ball mill / ATC Process
March 2004
17
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.
The Ball mill / ATC Process
March 2004
18
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 state Normal state*
Grinding
energy
Mill output
*
39 kWh/t
65 t/h
Gap
32 kWh/t
92 t/h
-18%
+40%
after the replacing of liners and ball charge
The Ball mill / ATC Process
March 2004
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Purpose
Good permeability
Cleanliness
Criteria
Insure gas flow
Preventing balls from passing between
compartments
General condition
Ventilation Screens
Maximum permeability
Mechanical behavior with the 90 mm
(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
Total lack of permeability
Corrective measures
Cleaning or replacement
The Ball mill / ATC Process
March 2004
20
Diaphragm Slots
Purpose
Providing outlet for the material
in the compartments while
retaining spitzers and balls
Improving ventilation
Scrap
General conditions
Slot plugging
Peening, clearances
C1 side clearance
Slot width
C2 side clearance
The Ball mill / ATC Process
March 2004
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Measuring the Diaphragm details
The Ball mill / ATC Process
March 2004
22
Diaphragm Slots
Criteria
C1 slots from 6 mm to
8 mm
C2 outlet slots larger by at least 2 mm than
those of C1 outlet
Corrective measures
Peened slots
Filing and cleaning
Diaphragm replacement
The Ball mill / ATC Process
March 2004
23
Compartment Samples
Purpose
COMPARTMENT N1
Grinding
Samples
assessment
(C1 and C2)
Determining
Charge
spitzer locations
0.5m
Quick evaluation Direction of rotation
Samples taken at
C1
1 2
3 4
5 6
the discharge end
of the compartment
The Ball mill / ATC Process
COMPARTMENT N2
March 2004
C2
24
Equal positioning for
sample collection and
media grading (measure
40 media balls at each
position).
The Ball mill / ATC Process
March 2004
25
Second chamber
sample collection using
sieve.
The Ball mill / ATC Process
March 2004
26
Measuring media
diameter using
vernier caliper
The Ball mill / ATC Process
March 2004
27
Compartment Samples
Criteria
<5% retained on 2
to 2.5 mm (or 8
mesh) sieve at the
diaphragm
Progressive
decrease all along
the mill
Corrective measure
Adapting the
charge
granulometry
Changing the
length
The Ball mill / ATC Process
Fineness evolution in the mill
% Cumulated
rejects
100
80
60
40
20
0
10
11
12
Sample Number
40 m
63 m
100 m
200 m
500 m
1 mm
2,5 mm
5 mm
Diaphragm
Diaphragm
Inadequate grinding
Presence of grains
March 2004
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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
The Ball mill / ATC Process
March 2004
29
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
The Ball mill / ATC Process
March 2004
30
GROUP EXERCISE
WHAT CAN YOU SEE ?
What are we looking at ?????
Ask yourself
Slots !!
Gap in
diaphragm.
What?
Where?
Condition?
Older type diaphragm
Back side of intermediate diaphragm
Low permeability
The Ball mill / ATC Process
March 2004
32
Hard faced Scroll at mill inlet
The Ball mill / ATC Process
March 2004
33
Slotted back plates,
this is undesirable
The Ball mill / ATC Process
March 2004
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Very low permeability
The Ball mill / ATC Process
March 2004
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Girth gear drive ,
Bucket elevator mill
The Ball mill / ATC Process
March 2004
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Intermediate diaphragm
Blockage due to excessive heat within mill.
Slot profile is circumferential and is therefore ok.
Central ventilation grid permeability ok
The Ball mill / ATC Process
March 2004
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Outlet side of intermediate diaphragm showing
excessive wear
The Ball mill / ATC Process
March 2004
38
Worn mill feed inlet ,
Plant used initiative until replacement available
The Ball mill / ATC Process
March 2004
39
High wear
Badly blocked and
worn central vent
grid
Media blockage
of radial slots
The Ball mill / ATC Process
March 2004
40
Tramp material,This
often results in slot
blockage.
The Ball mill / ATC Process
March 2004
41
Worn outer ring of inlet head wall liner,
This needs replacing.
25 mm
75 mm
The Ball mill / ATC Process
March 2004
42
Worn classifying liner
In 2nd chamber
The Ball mill / ATC Process
March 2004
43
Badly fitting head wall
liners
The Ball mill / ATC Process
March 2004
44
Undesirable slots blocked with
Small media
Chamber 2 side of intermediate diaphragm
The Ball mill / ATC Process
March 2004
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Very small ventilation grid fitted
With 2 support bars due to past
damage
The Ball mill / ATC Process
March 2004
46
Central ventilation grid
Blocked with tramp material
Entered with the mill feed
Circumferential
slots
The Ball mill / ATC Process
March 2004
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Note the new mesh fitted on
Other side.
Damaged ventilation grid
The Ball mill / ATC Process
March 2004
48
Ripple liner in 2nd chamber
The Ball mill / ATC Process
March 2004
49
Deflectors
Old type of material transportation
The Ball mill / ATC Process
March 2004
50
Flow control mechanism of modern intermediate
Diaphragm , Scoops. Adjustable by rotation.
Good ventilation grid
The Ball mill / ATC Process
March 2004
51
Blocking off in order
To control flow.
The Ball mill / ATC Process
March 2004
52
Small media contamination
In 1st chamber
The Ball mill / ATC Process
March 2004
53
Dannular ring , these become safety issues
The Ball mill / ATC Process
March 2004
54
Mill inlet showing no area for air inlet
The Ball mill / ATC Process
March 2004
55
Intermediate diaphragm 1st chamber
Showing sectioned plates (desired) , radial
Slots (undesired) and badly fitting
The Ball mill / ATC Process
March 2004
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Step chute inlet , good area
For airflow
The Ball mill / ATC Process
March 2004
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Sonic ear used for control
The Ball mill / ATC Process
March 2004
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Broken head wall liners
Caused by over tightening
Of bolts
The Ball mill / ATC Process
March 2004
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Step chute feeder
Water injection nozzle
The Ball mill / ATC Process
March 2004
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Removable vent grid
Gap size may be wrong
The Ball mill / ATC Process
March 2004
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Break 15 mins
The Ball mill / ATC Process
March 2004
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50
45
40
% Volume load
35
30
25
20
15
10
H=HEIGHT ABOVE
CHARGE
D= INTERNAL DIA.
0.50 0.55 0.60 0.65 0.70 0.75 0.80 0.85
RATIO H/D
Ball mill volume load =estimation
The Ball mill / ATC Process
March 2004
63
VOLUME LOAD FORMULA
H = HEIGHT ABOVE CHARGE (M)
D = MILL INTERNAL DIAMETER INSIDE LINING (M)
% Volume Load =
400/PI*((0.25*Cos(2*(H/D-0.5)))
-((H/D-0.5)*((H/D-(H/D)^2)^0.5)))
The Ball mill / ATC Process
March 2004
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Changes in apparent volume load
due to charge expansion
H1 = Height above charge -Mill Crash Stop
H2 =
Height above charge - Mill Run Out
Apparent
t/m3
Charge density
3.91
H1
Case
H1 Crash Stop
38%
H2
H2 Without Material
4.50
Charge Expansion
The Ball mill / ATC Process
%Volume load
March 2004
33%
5%
65
Target levels for material fineness
before the intermediate diaphragm
Sieve size
2.36 mm
% Cumulative
Residue
1%
1.18 mm
6%
300 um
20%
Basis - sieve about 0.5 - 1 Kg of material if
there are clinker nibs present.
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March 2004
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Mill power calculation
- DAWN Formula
NETT KW =
Where
= Internal
= 1.073
0.2846 DAWN
Diameter of Mill
-J
(Where J = Fractional Volume Load i.e. if VL = 30% then J = 0.3)
W
N
The Ball mill / ATC Process
= Charge
= Mill
weight in Tonnes
speed in RPM
March 2004
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Net and Gross mill power
Normal values for the ratio Net/Gross power
0.90
Normally for old and inefficient mills
0.92
Polysius Combiflex Drive
0.93
Girth gear driven mill
0.94 -0.95 Modern central drive mill
Unexpected values
0.88
High power losses possibly due to mill
chambers running empty.
0.97 - 1.00 Low power losses possibly due to charge
expansion and/or build up of clinker nibs.
If unexpected values occur : review the mill data
The Ball mill / ATC Process
March 2004
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