03 Ball Mill EDM

Grinding with Ball Mill Systems
EDM
Ball Mill
Ball Mill
2
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
EDM
EDM =
End Discharge Mill
Product discharge
at mill end
4
Elements of Ball Mill - Overview
5
Mill Drive Concepts
D r iv e C o n c e p t s fo r
B a ll m ills
G ir th g e a r D r iv e s G i r t h g e a r u n i ts C e n tr a l d r iv e s
S in g le p in io n c o n c e p t S in g le d r iv e w ith T w o -w a y p o w e r s p littin g
( < 2 '5 0 0 k W ) tw o p in io n s re d u c er
( < 5 '0 0 0 k W ) ( < 6 '0 0 0 k W )
D o u b l e - p i n io n c o n c e p t D o u b le d r iv e w ith P la n e ta r y g e a r r e d u c e r
( < 5 '0 0 0 k W ) fo u r p in io n s (< 1 2 '0 0 0 k W )
(< 1 0 '0 0 0 k W )
6
Example Planetary Gear Drive
Planetary gear reducer concept MAAG
 Two gear stages with three planets
 All shafts with friction bearings
 Pinions, planets surface-hardened Annulus
 Annulus through-hardened
Planets
Gear coupling
Drive arrangement Sun pinions

7
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
8
Potential Technical Problems Drive
Girth gear drives - Fundamental 1. Axial/radial runout

Problems
2. Alignment of the drive trains
5 2 3 3. Uneven power splitting
4. Centre distances variable
5. Face load distribution
1 6. Sealing of the girth gear

7. Girth gear is through hardened
only, fatigue strength is limited
4
 Dynamic behaviour
 A lot of individual rotating
masses risk of resonance
5 6 7 vicinities
 Torsional/structural vibrations
 Pinion shaft bending vibrations
9
Gearboxes
Gear reducer
Polysius Combiflex
Planetary Gear
10
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
11
Potential Problems Drive
Single pinion drive (2’300 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 1
12
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
Feed Arrangements for Ball Mills
(Slurry mill)
Preferred design today
14
Feed Arrangement (Example Step Feeder)
Material feed
Ventilation air
 Advantages
 Good mill ventilation
 Easy to maintain
 Simple design
15
Elements of Ball Mill – Overview (Internals)
External
elements
Mill feed Mill Mill discharge Mill
arrangement Mill head Mill shell bearing arrangement drive
Head Grinding Shell Intermediate Retention Discharge

liners media liners diaphragm ring diaphragm
Internal
elements
16
Overview Internal Elements
A Coarse grinding
compartment
B Intermediate
diaphragm
C Fine grinding
compartment
D Discharge
diaphragm
E Grinding media
F Retention ring
17
Liners for Coarse Grinding
18
Lifting Height Requirements (1st Chamber)
 This criteria has to be
confirmed case by case h0
through evaluation of the
coarse grinding.
 Rule of thumb: h must be
greater than 50 [mm]
1st chamber lining at end of lifetime

h > 0.5 ho
19
Classifying Liner for Fine Grinding (2nd Chamber)
Rotation sense
20
Head Liners
21
Open Diaphragm (Drying Chamber Diaphragm)
22
Intermediate Diaphragm
2nd Compartment
Fine Grinding
Intermediate diaphragm
1st Compartment
Coarse Grinding
23
Function of Intermediate Diaphragm
24
Intermediate diaphragm
 Slot opening in 1st chamber

 Material flow control system
 Centre screen
 Grates in the second chamber
25
Discharge diaphragm
Discharge diaphragm
26
Discharge Diaphragm
27
Material Quality and Application of Shell Liners
Material Chemical Hardness Remarks

Composition (HRC)
Manganese Recommended for small mills.
Steel 12 – 14% Mn 40 Deformation of liners for large
mills (initial surface hardness
20 – 25 HRC)
Low chromium Less deformation than

alloy cast 2 – 3% Cr 40 - 42 manganese liners. Suitable
for large and small mills
liners
High chromium Most used material. Suitable

alloy cast 12 – 15% Cr 50 - 55 for big and small mills (Notch
impact strength 4 – 10 J/cm2)
liners
28
Life Time of Shell Liners
29
Grinding Media
Coarse grinding Ø 90 – 50 [mm]
Fine grinding Ø 50 – 12 [mm]

30
Grinding in Ball Mill
Fine grinding (2nd chamber)

Cascading of grinding media
A
A
Coarse grinding (1st chamber)

Cataracting of grinding media
31
Ball filling degree (f)
98
93
Power [%]
85
Typical range
75
20 25 30 35 40 - 45 f [%]
32
Steps of Grinding
Coarse Medium Fine

Grinding Grinding Grinding
33
Coarse Grinding: Parameters for Optimising
Power parameters Efficiency parameters

 Filling degree  Ball charge (filling degree &
 Chamber length composition)
 Mill diameter  Liner design
 Liner design and condition  Intermediate diaphragm settings
 Mill speed  Mill ventilation
34
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
Grinding Media (1st Compartment)
1.Compartment
Ø 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
Grinding Media (2nd Compartment)
 Holcim Standard for OPC > 3’200 [cm2/g], closed circuit
system
2.Compartment
Ø 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
15
Total 200.0 100

Average ball weight [g] 41
Spec. media surface [m2 / t] 32.8
37
Material Quality of Grinding Media
38
Specific Wear Rates of Grinding Media
39
Mill Efficiency
[%R] [cm2/g]
acc. Chamber 1 Blaine
(coarse grinding) Blaine Value
Chamber 2
(fine grinding)
Sieve Residues
mill length [m] [m]
longitudinal sieving graph

40
Lifting Liners Effects
Liner-Lifting : low high

41
Optimum Material Level 1st Chamber
42
Optimum Material level 2nd chamber
43
Mill Ventilation
 Main Tasks Mill Ventilation:

 Material transport
 Cooling
 Removal of fines
 Fluidisation of material
44
Cooling and Heating Possibilities
Product
Air
Dust ladden air
H 2O
Moist additive Hot gases
Hot clinker Cooling air
H2O
Cooling air Product
Hot gases
H 2O H 2O
45
Fine Grinding and Mill Cooling
PROBLEM SOLUTION
 Insufficient mill cooling  Adapted mill cooling,
lead to material playing with:
agglomeration on balls Clinker temperature
and liners  Mill ventilation
 Water injection
 The grinding is not any
more done by balls  Use of grinding aid
against material but by (temporary solution
material against material because expensive)
46
Water Injection Systems
counter current no water

Product injection
1st 2nd Comp. temp. [°C]
130
counter
120
current
110
Air from
Air from co-current
blower blower 100
H2O H2 O
co-current 90
(Double)
Rotary union 80
1st 2nd Comp.
Mill length
H2O 2nd Comp.
H2O 1st Comp.
47

03 Ball Mill EDM

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Grinding with Ball Mill Systems

Intermediate diaphragm (Fine Grinding)

Mill feed arrangement

Gearbox with pinions

Drive arrangement Sun pinions

 All gears surface-hardened and

 All shafts with roller bearings

Low speed gear

Bearings with excentric sleeves

Girth gear drives - Fundamental 1. Axial/radial runout

1 6. Sealing of the girth gear

Far higher limit of gas temperature at

Preferred design today

Head Grinding Shell Intermediate Retention Discharge

1st chamber lining at end of lifetime

 Slot opening in 1st chamber

Material Chemical Hardness Remarks

Low chromium Less deformation than

High chromium Most used material. Suitable

Fine grinding Ø 50 – 12 [mm]

Fine grinding (2nd chamber)

Coarse grinding (1st chamber)

Coarse Medium Fine

Power parameters Efficiency parameters

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

Total 100.0 100

Average ball weight [g] 1667

Holcim Standard for 1st Compartment

Total 200.0 100

mill length [m] [m]

longitudinal sieving graph

Liner-Lifting : low high

 Main Tasks Mill Ventilation:

Hot clinker Cooling air

Cooling air Product

counter current no water

H2O 2nd Comp.

H2O 1st Comp.

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