Ball Mill Understanding & Optimisation

Grinding with Ball Mill Systems
EDM
Ball Mill
Ball Mill
HGRS
Tikaria_Mill Workshop
SEPT-07
What is a End Discharge Mill (EDM)?

Air outlet
2st Compartment
Intermediate diaphragm
(Fine Grinding)
1st Compartment
(Coarse Grinding)
Mill feed arrangement
Mill discharge
Drive
Gearbox with pinions

Air inlet
3
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EDM
EDM =
End Discharge Mill
Product discharge
at mill end
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Elements of Ball Mill - Overview
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Mill Drive Concepts

Drive Concepts for
Ball mills
Girth gear Drives
Girth gear units
Central drives
Single pinion concept

(< 2'500 kW)
Single drive with

two pinions
(< 5'000 kW)
Two-way power splitting

reducer
(< 6'000 kW)
Double-pinion concept
(< 5'000 kW)
Double drive with

four pinions
(< 10'000 kW)
Planetary gear reducer

(< 12'000 kW)
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Example Planetary Gear Drive

Planetary gear reducer concept MAAG
Two gear stages with three planets
All shafts with friction bearings
Annulus
Pinions, planets surface-hardened

Annulus through-hardened
Planets
Gear coupling
Drive arrangement
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Sun pinions
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Gear Box Internals

Parallel shaft gear reducer (two way power branch)
All gears surface-hardened and
ground
All shafts with roller bearings
Key point::
Face load distribution of the
LS-gear stage
Low speed gear

stage
Bearings with excentric sleeves

to optimise the face load distribution
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Potential Technical Problems Drive

Girth gear drives - Fundamental
Problems
5
1.
Axial/radial runout
2.
Alignment of the drive trains
3.
Uneven power splitting
4.
Centre distances variable
5.
Face load distribution
6.
Sealing of the girth gear
7.
Girth gear is through hardened

only, fatigue strength is limited
Dynamic behaviour
A lot of individual rotating masses

risk of resonance vicinities
Torsional/structural vibrations
Pinion shaft bending vibrations

9
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Gearboxes
Gear reducer
Polysius Combiflex
Planetary Gear
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Potential Damages Drives

Breakage damage (pinions)
Cause: Inadequate transverse
load distribution, brittle material

Fatigue breakage
Initial damage:
Pitting on the pitch line
Secondary damage:
Tooth breakage
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Potential Problems Drive

Single pinion drive (2300 kW)
Breakage failure of the pinion in the
gear reducer
Heavy (active) pitting on the drive
pinion
Possible Cause:
- Inadequate load distribution (1)

- Overload of the tooth flanks (2)
1
2
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Mill Bearing
Advantages slide shoe bearings:
No size and capacity limitation of the
mill
Simple design of wear plates
Far higher limit of gas temperature at
mill inlet (e.g. for drying with heat

generator)
13
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Feed Arrangements for Ball Mills

(Slurry mill)
Preferred design today
14
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Feed Arrangement (Example Step Feeder)

Material feed
Ventilation air
Advantages
Good mill ventilation

Easy to maintain
Simple design
15
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Elements of Ball Mill Overview (Internals)

External
elements
Mill feed
arrangement
Head
liners
Mill head
Grinding Shell
liners
media
Mill shell
Intermediate
diaphragm
Mill
bearing
Retention
ring
Mill discharge
arrangement
Mill
drive
Discharge
diaphragm
Internal
elements
16
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Overview Internal Elements

A
Coarse grinding
compartment
Intermediate
diaphragm
Fine grinding
compartment
Discharge
diaphragm
Grinding media
Retention ring
17
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Liners for Coarse Grinding
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Lifting Height Requirements (1st Chamber)

This criteria has to be
confirmed case by case

through evaluation of the
coarse grinding.
h0
Rule of thumb: h must be
greater than 50 [mm]
1st chamber lining at end of lifetime
h > 0.5 ho
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Classifying Liner for Fine Grinding (2nd Chamber)
Rotation sense
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Head Liners
21
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Open Diaphragm (Drying Chamber Diaphragm)
22
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Intermediate Diaphragm
2nd Compartment
Fine Grinding
1st Compartment
Coarse Grinding
23
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Function of Intermediate Diaphragm
24
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Slot opening in 1st chamber
Material flow control system

Centre screen
Grates in the second chamber
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Discharge diaphragm
Discharge diaphragm
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Discharge Diaphragm
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Material Quality and Application of Shell Liners
Material
Manganese
Steel
Low chromium
alloy cast
liners
High chromium
alloy cast
liners
Chemical
Composition
12 14% Mn
2 3% Cr
12 15% Cr
Hardness Remarks
(HRC)
40
Recommended for small mills.

Deformation of liners for large
mills (initial surface hardness
20 25 HRC)
40 - 42
Less deformation than

manganese liners. Suitable
for large and small mills
50 - 55
Most used material. Suitable

for big and small mills (Notch
impact strength 4 10 J/cm2)
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Life Time of Shell Liners
29
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Grinding Media
Coarse grinding 90 50 [mm]
Fine grinding 50 12 [mm]

30
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Grinding in Ball Mill

Fine grinding (2nd chamber)
Cascading of grinding media
A
A
Coarse grinding (1st chamber)

Cataracting of grinding media
31
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Ball filling degree (f)
Power [%]
98
93
85
Typical range
75
20
25
30
35
40 - 45
f [%]
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Steps of Grinding
Coarse
Grinding
Medium
Grinding
Fine
Grinding
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Coarse Grinding: Parameters for Optimising
Efficiency parameters
Power parameters
Filling degree
Chamber length
Mill diameter
Liner design and condition
Mill speed
Ball charge (filling degree &

composition)
Liner design
Intermediate diaphragm settings
Mill ventilation
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Grinding Media
4,4 [t/m3]
4,6 [t/m3]
4,7 [t/m3]
Bulk weight of a grinding media charge in a two chamber mill with

classifiying liner
35
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Grinding Media (1st Compartment)

1.Compartment
Ball [mm]
Weight [ t ]
Percent [%]
90
25.0
25.0
80
35.0
35.0
70
25.0
25.0
60
15.0
15.0
Total
100.0
100
Average ball weight
[g]
1667
Spec. media surface
[m2 / t ]
10.2
Holcim Standard for 1st Compartment

36
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Grinding Media (2nd Compartment)

Holcim Standard for OPC > 3200 [cm2/g], closed circuit
system
2.Compartment
Ball [mm]
Weight [ t ]
Percent [%]
50
20.0
10.0
40
20.0
10.0
30
32.0
16.0
25
32.0
16.0
20
42.0
21.0
17
54.0
27.0
200.0
100
15
Total
Average ball weight
[g]
41
Spec. media surface
[m2 / t]
32.8
37
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Material Quality of Grinding Media
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Specific Wear Rates of Grinding Media
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Mill Efficiency
[%R]
acc.
[cm2/g]
Blaine
Chamber 1
(coarse grinding)
Blaine Value
Chamber 2
(fine grinding)
Sieve Residues
mill length [m]
[m]
longitudinal sieving graph

40
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Lifting Liners Effects
Liner-Lifting :
low
high
41
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Optimum Material Level 1st Chamber
42
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Optimum Material level 2nd chamber
43
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Mill Ventilation
Main Tasks Mill Ventilation:
Material transport
Cooling
Removal of fines
Fluidisation of material
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Cooling and Heating Possibilities

Product
Air
Dust ladden air
H2 O
Hot gases
Moist additive
Hot clinker
Cooling air
H2O
Cooling air
Hot gases
Product
H2 O
H 2O
45
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Fine Grinding and Mill Cooling

PROBLEM
SOLUTION
Insufficient mill cooling
Adapted mill cooling,
lead to material
agglomeration on balls
and liners
The grinding is not any
more done by balls

against material but by
material against material
playing with:
Clinker temperature
Mill ventilation
Water injection
Use of grinding aid
(temporary solution
because expensive)
46
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Water Injection Systems

counter current
1st
Product
temp. [C]
2nd Comp.
no water
injection
130
120
Air from
blower
Air from
blower
H2O
(Double)
Rotary union
110
H2O
co-current
1st
counter
current
100
co-current
90
80
2nd Comp.
Mill length
H2O 2nd Comp.

H2O 1st Comp.
47
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SEPT-07

Ball Mill Understanding & Optimisation

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Ball Mill Understanding & Optimisation

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Grinding with Ball Mill Systems

What is a End Discharge Mill (EDM)?

Gearbox with pinions

Elements of Ball Mill - Overview

Mill Drive Concepts

Girth gear units

Single pinion concept

Single drive with

Two-way power splitting

Double drive with

Planetary gear reducer

Example Planetary Gear Drive

Pinions, planets surface-hardened

Gear Box Internals

Low speed gear

Bearings with excentric sleeves

Potential Technical Problems Drive

Alignment of the drive trains

Uneven power splitting

Centre distances variable

Face load distribution

Sealing of the girth gear

Girth gear is through hardened

A lot of individual rotating masses

Pinion shaft bending vibrations

Potential Damages Drives

Cause: Inadequate transverse

load distribution, brittle material

Potential Problems Drive

- Inadequate load distribution (1)

mill inlet (e.g. for drying with heat

Feed Arrangements for Ball Mills

Preferred design today

Feed Arrangement (Example Step Feeder)

Good mill ventilation

Elements of Ball Mill Overview (Internals)

Overview Internal Elements

Liners for Coarse Grinding

Lifting Height Requirements (1st Chamber)

confirmed case by case

Rule of thumb: h must be

greater than 50 [mm]

1st chamber lining at end of lifetime

Classifying Liner for Fine Grinding (2nd Chamber)

Open Diaphragm (Drying Chamber Diaphragm)

Function of Intermediate Diaphragm

Slot opening in 1st chamber

Material flow control system

Material Quality and Application of Shell Liners

Recommended for small mills.

Less deformation than

Most used material. Suitable

Life Time of Shell Liners

Fine grinding 50 12 [mm]

Grinding in Ball Mill

Coarse grinding (1st chamber)

Ball filling degree (f)

Coarse Grinding: Parameters for Optimising

Ball charge (filling degree &

Bulk weight of a grinding media charge in a two chamber mill with

Grinding Media (1st Compartment)

Average ball weight

Spec. media surface