Ball Mill Performance & Efficienc

S. Description Symbol Form

No.
1 Arm of gravity a
FLS - Cement Milling Program - TAN-1 [ 0.5 / R * (1 - 4*R
h
Deff
R
2 Torque factor matrix u
Material Grinding Fi
FLS - Communition Manual - No
No
Coars e/Medium
Da
Cem ent
So
& Raw
No
Meal
No
Fine
Da
Da
Coars e/Medium No
Coal
Medium Da

2 Power consumption, net Pn

FLS - Communition Manual kW F
u
n
Deff
a

3 Power consumption, gross Pg

FLS - Communition Manual kW
Em
Eg

4 New production rate NPB Formula-1

(Mill output Vs. Blaine) tph
Binani Cement Ltd, India
OPB
OB
NB

Formula-2

OPB
OB
NB
5 New production rate NPR
(Mill output Vs. Residue) tph
Binani Cement Ltd, India OPR
OR
 Ball Mill Performance & Efficienc
S. Description Symbol Form
No.
NR
6 Gypsum set point GSP
(at weigh feeder) tph
Simple Mathematical Calculation Scem
Pu
Sclk
Fgyp
7 Maximum ball size MBS 36 * F0.5 * { ( SG * W
FLS - Cement Milling Manual mm F
SG
Wi
%C
Deff

8 %Filling %F
FLS - Communition Manual % h
Deff
 Ball Mill Performance & Efficienc
S. Description Symbol Form
No.
9 Circulation factor C Formula-1
FLS - Communition Manual -

F
G

Formula-2

Rg
Rf
Rm
10 Circulation load CL
FLS - Communition Manual % C

11 Separator efficiency SE Formula-1

FLS - Communition Manual % [log(Ro/Rf) - C * log[{Ro+(C
log(Ro/Rf) - C * log[{Ro+(
Ro
Rf
C
Rg

Formula-2 (Fines Efficiency

Rf
Rm
C

Formula-3 (Coarse Efficienc

Rg
C
Rm
12 Critical speed nc
FLS - Cement Milling Manual rpm Deff
all Mill Performance & Efficiency
Formula Example

0.666 * ( 1 - 4 * R2 )1.5 h 0.583

TAN [ 0.5 / R * (1 - 4*R ) ] - [ 2*R * (1 - 4*R ) ] Deff
-1 2 0.5 2 0.5 4.18
Centre Distance (from mill centre to media top layeR 0.139
Mill effective diameter, mts a 0.578
h/Deff, ratio of centre distance to mill effective di Target -
- -
Material Grinding Fitting Type Torque
None Balls 0.73
- -
Coars e/Medium
None Rods 0.55 - -
Cem ent
Danula Balls 0.75 - -
& Raw
Sonex Balls
None Balls
0.66
0.69
- -
Meal
None Cylpebs 0.73 - -
Fine
Danula Balls 0.71 - -
Danula Cylpebs 0.75
- -
Coars e/Medium None Balls/Cylpebs 0.69
Coal
Medium Danula Cylpebs 0.71 - -
- -
0.514 * F * u * n * Deff * a F 175
Grinding media weight, tons u 0.73
Torque factor n 16
Mill speed, rpm Deff 4.18
Mill effective diameter, mts a 0.578
Arm of gravity, - Pn 2538
Target -
Pn * 100 * 100 Pn 2450
Em * Eg Em 95
Motor efficiency, % Eg 95
Gearbox/girth gear efficiency, % Pg 2715
Target -
Formula-1 OPB 170
OPB OB 3000
Exp ( ( NB - OB ) * 0.49 / 1000 ) NB 3200
Old production rate, tph NPB 154
Old blaine, cm2/gm Target -
New blaine, cm2/gm

Formula-2 OPB 170

OPB * ( OB / NB ) 1.3 OB 3000
Old production rate, tph NB 3200
Old blaine, cm2/gm NPB 156
New blaine, cm2/gm Target -
OPR * ( 2 - log ( OR ) ) OPR 150
( 2 - log ( NR ) ) OR 11.5
Old production rate, tph NR 9.5
Old residue, % NPR 138
all Mill Performance & Efficiency
Formula Example

New residue, % Target -

21500 * ( Scem - Sclk ) Scem 2.1
Pu * ( 100 - Fgyp ) Pu 90
Target SO3 content in cement, % Sclk 0.3
Gypsum purity, % Fgyp 4.8
SO3 content in clinker, % GSP 4.52
Free moisture in gypsum, % Target -
36 * F * { ( SG * Wi ) / ( %C * Deff ) }
0.5 0.5 0.333 F 15
Feed size (sieve size in mm which retains 20% matSG 3
Specific weight of feed material, gm/cm3 Wi 15
Bond's work index, kWh/t %C 75
Mill speed as %critical, % Deff 5.1
Mill effective diameter, mts MBS 90
Target -
112.5 - ( 125 * h / Deff ) h 2.5
Free height, mts Deff 4.155
Mill effective diameter, mts %F 37.3
Target -
all Mill Performance & Efficiency
Formula Example

Formula-1 FF 150
F+G CR 170
F C 2.13
Fresh feed rate, tph Target 2-3
Coarse return, tph

Formula-2 Rg 21.25
Rg - Rf Rf 9.14
Rg - Rm Rm 16.78
Residue of coarse return, % C 2.71
Residue of fines, % Target 2-3
Residue of separator feed, %
( C - 1 ) * 100 C 2.6
Circulation factor, - CL 160
Target -
Formula-1 Ro 100
[log(Ro/Rf) - C * log[{Ro+(C-1)*Rg} / {Rf+(C-1)*Rg}]]*100
Rf 17.68
log(Ro/Rf) - C * log[{Ro+(C-1)*100} / {Rf+(C-1)*100}]C 1.79
Residue of fresh feed, % Rg 83.78
Residue of fines, % SE 80.7
Circulation factor, - Target 70-80
Residue of coarse return, %

Formula-2 (Fines Efficiency) Rf 17.68

( 100 - Rf ) * 100 Rm 46.91
( 100 - Rm ) * C C 1.79
Residue of fines, % SEf 86.6
Residue of separator feed, % Target 70-80
Circulation factor, -

Formula-3 (Coarse Efficiency) Rg 83.78

Rg * ( C - 1 ) * 100 C 1.79
C * Rm Rm 46.91
Residue of coarse return, % SEc 78.8
Circulation factor, - Target 70-80
Residue of separator feed, %
42.3 / Deff0.5 Deff 4.15
Mill effective diameter, mts Pn 20.8
Target -
Processed by - Rupinder Singh