164LOESCHE Mills For Ores and Minerals E

Loesche-Mills
for
ores and minerals
loesche_Mineralien_ErzProspe_GB_2011.indd 1
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Loesche technology always one step ahead

The company Loesche has more than 100 years of
experience in the comminution of coal, cement raw
material, clinker, slag and minerals. With consistently
new developments, Loesche is always one step
ahead.
Since 1961 Loesche mills have been successfully
used in the ore industry.
1961 Delivery of the first mill for phosphate rock,
LM 12.20, Japan
1967 Commissioning of a Loesche mill, LM 12/850,
for comminution of magnesite, Mitsuhahmi,
Japan
1973 Delivery of the first Loesche mill for comminution of manganese dioxide, LM 9/760,
Thessaloniki, Greece
1976 First use of a Loesche mill for comminution of
baryte, LM 14/1120, Ijmuiden, Netherlands
1987 Installation of a Loesche mill for comminution
of lithium feldspar, LM 13.2, Bikita, Zimbabwe
1993 Delivery of the first Loesche mill for comminution of copper matte, LM 31.2, Magna, USA
1993 Delivery of a Loesche overflow mill for titanium
slag, LM 13.2, Vredenburg, RSA
1998 Installation of up to that point the largest
Loesche mill for comminution of phosphate
rock, LM 50.4, Phalabora, RSA
1999 Delivery of a Loesche mill for the test facility of
Anglo Research for comminution of different
ore types, LM 3.6, Johannesburg, RSA
2001 Delivery of a Loesche overflow mill for
comminution of titanium slag, LM 13.2,
Empagnini, RSA
2006 Commissioning of a Loesche mill for comminution of colemanite, LM 19.2, Bigadic, Turkey
Loesche Mill Type LM 60.4, Ras al Khaima,

United Arab Emirates, 2006
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Loesche grinding technology is a dry milling process which offers significant advantages over conventional crushing and grinding technologies in ore
beneficiation
Low specific energy consumption
Steep product particle size curve
Reduced product overgrinding
In-bed comminution
Selective comminution
Higher degree of liberation of the valuable minerals
Combining of the crushing and grinding process
stages
Rapid response to changes in the feed composition
Optimisation of throughput through online
monitoring
The grinding product has a positive effect on the
downstream processes
Compact design
Loesche grinding technology is particularly suitable
for users:
who aim to increase their recovery of respective
ores and minerals by applying the Loesche grinding technology
who must reduce their operating costs
who are dependent on a limited or expensive
energy supply
who operate or are planning ore processing in
arid regions
who operate obsolete or inefficient grinding
systems
whose processing plants no longer comply with
the ecological requirements
Loesche Mill Type LM 46.4, Lengerich, Germany, 2003
whose space requirement for the building of

complete plants or modernisation of plant parts is
limited
Loesche Mill Type LM 60.4, Ras al Khaima, United Arab Emirates, 2006
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Principle of operation
Loesche grinding technologies allow users to choose
With pure compressive comminution, the introduction
different comminution principles. The spectrum rang-
of shear forces is deliberately avoided.
es from a combination of compressive and shear

stress right through to shear-free grinding, or pure
This is achieved by tapered rollers, whose axes are
compressive comminution.
angled in relation to the horizontal grinding track in

such a way that the roller axis intersects exactly the
The grinding material is comminuted in the Loesche
centre of rotation of the grinding plate with its axis.
mill between the rotating grinding track and the staThe different comminution principles are matched to
tionary grinding rollers.
the respective ore characteristics in order to achieve

optimum mineral liberation.
If an ore reacts positively to shear stress, a combination of compressive and shear is used.
The Loesche patented shear-free grinding is used
where pure compressive comminution is desired.
Through the use of shear-free grinding the percentage of finest grain can be additionally reduced with
regard to the already steep product particle size
curve. At the same time the percentage of medium
There are two basic types of roller axis position in
grain size fractions is increased. Further positive
relation to the centre of rotation of the grinding plate.
effects are additional energy savings and the minimi-
This gives rise to different comminution effects:
sation of wear.
Compressive comminution with shear component

The grinding product altered by shear-free grind-
Pure compressive comminution.
ing can reduce the amount of fines up to 50 % and

Generally speaking, Loesche mills operate with a
thereby result in significant advantages for the down-
compressive comminution system with a shear com-
stream sorting processes.
ponent. This effect is created by tapered rollers,

whose axes are angled below 15 with respect to the
horizontal grinding track. The roller axes do not intersect the centre of rotation of the grinding plate.
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Comparison of the Loesche comminution principles
Accumulated screen underflow [weight %]
100
90
80
Compressive and shear stress
70
Shear-free grinding
60
50
40
30
20
10
0
10
100
1000
particle size [m]
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Advantages of the Loesche grinding process

for ore beneficiation
Grinding is of central importance to the downstream
Monitoring of the grinding forces in combination with
sorting processes. The more complete the mineral
in-bed comminution provides a selective ore com-
liberation of the ground ore, the greater the chances
minution.
of obtaining a good recovery.

Direct classifying after each grinding contact helps to
The Loesche grinding principle is based on in-bed
avoid unwanted overgrinding and to achieve a steep
comminution.
product particle size curve. In addition to the energy

benefits, this has above all positive effects on the
downstream sorting processes.
F
F
With a maximum feed grain size of 150 mm and grinding products up to P80 of 20 m, the Loesche mill
combines the crushing and grinding process stages

in a single aggregate. Accordingly, the Loesche mill
F
can, depending on process management, substitute
two to three crushing and grinding stages. As well

as simplifying process management, the compact
Due to the fact that the particles have many points of
design of Loesche grinding technology reduces the
contact with each other, the grinding force is directed
plant footprint.
through the grinding bed. This results in a better

degree of liberation compared with conventional
In this way, the Loesche mill can be easily planned for
grinding technologies. Online monitoring of the oper-
incorporation in existing plant concepts or, in the case
ating pressure of the grinding rollers and thus of the
of new planning concepts, can reduce the amount of
grinding forces provides a controllable and consistent
surface area used.
product fineness.
Particle size distribution of a Loesche Mill compared to a Ball Mill
100
Accumulative screen throughput [weight %]
90
Loesche Mill
Ball Mill
80
70
60
50
40
30
20
10
0
100
1000
Particle size [m]

6
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The advantages of the Loesche grinding process over
Advantages for the downstream process
conventional grinding systems can be summarised

The use of Loesche grinding technology delivers not
as follows:
only advantages in the grinding process but also in

Controlled grinding; thus specific liberation of
the downstream ore-sorting processes. These advantages can be put down to the grinding characteristics
the valuable mineral
of the Loesche mill and thus the optimised grinding
Selective comminution by means of in-bed
product.
comminution
Minimisation of product overgrinding
Flotation
steeper product particle size curve

minimises the amount of finest grain
Flotation kinetics is improved through the grind-
minimises the amount of coarse grain
ing products
thus improved fine-tuning of downstream

sorting processes possible
The recovery can be increased thanks to the
Higher degree of liberation
improved liberation of the valuable mineral

Improved grade recovery relation
Dry grinding product improves metering and

conditioning of the following downstream process
stages
Degree of liberation
70
Optimum flotation range
Degree of liberation [%]
60
50
SAG +
Ball Mill
40
Loesche Mill
Zn ore
(as example)
30
20
10
0
< 38
38
53
75
106
Particle size m]
Activation of particle surfaces

Energy savings of up to 45% can be achieved
compared with conventional crushing and grinding circuits
The operating costs are reduced by savings on
personnel, energy and grinding auxiliaries
Reduction of specific wear
Use in arid or permafrost regions is possible
The flotation times can be reduced, while

recovery remains the same
Reduced consumption of flotation reagent
thanks to low fines
Dry grinding product provides for precise
metering and conditioning
Reduced mineral surface lining by finest grain
and thus improved collector absorption
Water consumption is reduced

The Loesche grinding process is self-regulating
such that the mill always runs at its optimum
operating point
Improvement in the environmental balance sheet
thanks to conservation of resources
7
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Flotation kinetics
Recovery
[%]
Loesche Mill
Ball Mill
t110 t2
20[min
t
1
30
t2
Retention time [min]; t
Density sorting:
Magnetic separation:
Improved recovery thanks to a better degree of
Higher recovery thanks to coarser feed size
liberation at coarser feed size
Reduced losses of valuable mineral in the finest
Improved concentrate grade thanks to a reduced
particle fraction
amount of finest particles in the feed

Heap and agitator leaching:
Improved ore leaching solution contact thanks
Water management
to higher liberation of valuable material and thus
Reduced water consumption
increased recovery
Reduced problem of slimes during filtration
Improved leaching solution flow through the heap

by reduced amount of fineness
Improved leaching kinetics
Improved recovery of process water thanks

to reduced water absorption at the slimes and
faster sedimentation of the tailings
Grade recovery curve
Recovery
[%]
Loesche Mill
Ball Mill
Concentrate grade [g/t]

8
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Loesche Overflow Mill Type LM 13.2 SP, Namakwa Sands, South Africa, 1993
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Customer benefit and customer satisfaction

Quality and reliability from the outset are the interna-
The cornerstones of our competence include:
tionally recognised advantages of Loesche grinding

plants. Ever since 1928, when the Loesche mill was
Customised plant concepts from planning
first introduced to the market, the principle of the
through to commissioning, based on our own
vertical roller mill with rotating grinding track and indi-
knowledge and experience, paired with custom-
vidually guided rollers has proven to be particularly
er requirements
energy- and resource-conserving.
Individual problem solutions with optimised

process technology
These advantages of the Loesche mill are becoming

increasingly more important in the face of increasing
plant sizes and commitment to more economical use
Close cooperation with suppliers of further

processing equipment according to customer
of resources, such as energy, water, etc.
requirements
Furthermore, because of the high product rates for
Loesche mills the investment costs are significantly
advice on new technical developments
lower compared to smaller grinding plants.

From sales through to aftersales service, from project
Customer service: plant optimisations and
Long-term commitment to deliver spare parts
Certification to EN ISO 9001: 2008.
planning on schedule through to the handover of

plants, Loesche is a competent partner to its customers. Our maxim is:
Every Loesche grinding plant is a reference
plant!
Central grinding plant for granulated blast furnance slag, Loesche Mill Type LM 35 2+2, Rouen, France, 2003
10
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Loesche Mill Type LM 69.6 under construction, Idhan, UAE, 2009
11
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Layout and function of the Loesche mill

Layout
Mill function, airflow mode
The established basic principle of the modular sys-
The ore raw material is fed via an air lock
tem patented in 1970 is used for Loesche mills with
1
via the chute
2
1
two, three, four and six roller modules. Each roller
2 falls
3
4
and
10 11 tabel
12 13
3
4the5 centre
6
7of the
8
9grinding
onto
14
15
16
17
18
20
106 117 12
15 16 are
17 18
19 21 22
4
5 ferrous
8 139 14objects
. Free
foreign
separated
out23
24
25
26
27
28
19
20
22
24
28
10 11 from
12 13the
15 21
16
17 23
18 magnetically
19 25 26 27 before
14 feed
module consists of the grinding roller, a rocker arm
material
reaching
20 21 22 23 24 25 26 27 28
2
3removed
4
5 via
6 a
7 diverter
8
9
the air lock 1 and
that transmits force to the roller by hydraulic spring
gate. A
loading, and the upper end of which the rocker arm is
10 operates
11 12 13
15 16way
17 and
18 19
metal detector
in a14similar
ensures
supported so that it can pivot. Large or small mod-
20 21 22 23 24 25 26 27 28
the separation
of non-magnetic metal parts. The
ules can be used in different numbers (two, three, four
material to be ground moves on the grinding track
and six) in identical mill sizes (grinding table diame-
towards the edge of the grinding table under the
ter). In this way, customer-specific requirements can
effect of centrifugal force and in this way passes
be satisfied on a customised basis.
under the hydropneumatically spring-loaded grinding
2
3
Loesche technology is characterised by the following 1 rollers
7
8 that
9
. 5The6 material
has been drawn in is
features:
10
11 12 13
16 17 bed
18 in
19 the gap between the
14 15
ground
in the
material
Each roller is held by a locally secured rocker
20
21 22 23 24 25 26 27 28
2
3
1 rollers
rollers
and grinding track. The
5
6dis-7
are
10 the
11 1material
12 2 13 3 14
4 15 5 16
placed upwards as they roll over
bed
. 6 17 7 18 8 19 9
arm.
20 2110 2211 2312 2413 2514 2615 2716 2817

As a result the functional unit consisting
of rocker arm
The roller-bearing-mounted rocker arm roller

system is supported and guided
2 in
3
1
precisely
2 11
3
1 10
pedestal with integrated spring assembly.
12
4 13
5
14
6
15
7
7
8 rod
9
spring
20
21 22
23
24
and pistons from the hydraulic cylinder
25
26
18
27
19
28
16
17
8 moved.
9 18 19The piston displaces the hydraulic oil
are
20 12
22 14
23 15
24 16
25 17
26 18
28
10 11
13
19
The facility to raise the rollers serves
as21a starting
from
the27cylinder
into the gas-filled bladder accumu20 21 22 23 24
aid for the mill during startup with
the grinding
25
26 27 28
lator
unit. Nitrogen-filled rubber bladders in the accu-
track filled. It is an integral part of the hydropneu-
mulator units are compressed and act as gas springs.
matic spring assembly.
The gas springs can be set to be harder or softer by
In each case two opposing rollers are connected
selecting the gas pressure in relation to the hydraulic
to a common hydraulic unit (except on 3-roller
operating pressure, depending on the fracture behav-
mills).
iour of the material to be ground.
A virtually parallel grinding gap is maintained for

the entire service life of the grinding parts
The ground material is subjected to centrifugal force
between the grinding rollers and the grinding
and rotates outwards and over the edge of the grind-
plates of the grinding table.
ing table. In the1 area

2 of
3 the
4 louvre
5
6 ring
7
Via the hydraulic system the grinding force can be
which
sur9
10 11
12
187
198
143
rounds the grinding
stream
of
2 132
3 the
4 15
4
5 165
6 17
6
7 hot
8 gas
9
1table
1
20
22
26
28
10
10
11 23
11
12 24
13
12
13
15 27
15
16 of
16
17
14mixture
14
upwards 21
captures
the25
optimised in correspondence with the characteris-
directed
tics of the comminuting ores.
20 20
21 22
21 22
23 23
24
25 25
26 26
27 27
28 28
material and material
as yet
not24completely
2
3
4ground
5
6
1
17
18 18
19 19
ground
7
14
15
16
17
18
24
3
25
4
26
5
27
6
28
7
it11rejects
12 13
14
15
16
17
18
20 21 22 23
coarse
This
2materials.
3
4
5
6 falls
7 into
8 the
9 internal grit return
1
24
25
26
27
28
and conveys this to the classifier
10
20
. 11
12 13
21 22
1
Depending on settings of the classifier

cone
10
and13then
onto16 the
12
17
14 15
11
20 21 22
regrinding.
23
24
25
26
27
10
23
2
grinding
table
18 19
2
1
28
10
11
20
21 22
for
4
12 13
23
19
14
15
16
17
18
24
25
26
27
28
The ground material passes from the classifier and is

1
conveyed
mill with the gas stream
3
4
5 from
6
7the8Loesche
9
10
11
12 . 13
20
21 22
23
14
15
16
17
18
24
25
26
27
28
19
Foreign matter and small amounts

2 of3coarse
4
5 material
6
7
1
fall1 through
21 32 the
43 louvre
54 65 ring
76
into
13 channel
87 10
98 11the
14 15 16
9 12ring
2219 23 24 to
25 the
26
11
13
16
18
19
as10 reject
material.
Scrapers
connected
10 12
11
12 14
13 15
15 17
16 20
17 21
18
14
9
18
27
28
19
20 21
22
24
27
20 table
21 23
22transport
23 25
24 26
25
26 28
27
28
grinding
foreign
matter
into the reject
7
8
9
10
11
12 13
14
15
chute
16
17 18
20
21 22
24
25
26
23
8
17
27
. 19
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1
2
10
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14
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21 22
10
1
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12
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21 11
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4
10
3
13
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21 22
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6 107 20
118 21
129 22
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16 21
17 22
18 23
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1
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1
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10
2
5
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5
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2
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86
97
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7 20 8 219 22
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17 18 19
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16
5
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27 117
28 218 319 4
26 1027 1128 12
2
3
1
20 21 22
10 11 12
2
3
4
1
20 21 22
2
3
4
5
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1
10 11 12 13
10 11 12 13 14 15 16
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The grinding
11 12
2
3 is4driven
5
6by 7an 8electric
9 10 motor
1 table
1
4
13
2019 21 22with
23
via2 an3 elastic
coupling
the17mill18 gearbox
15 16
410 511
612 713 814 9and
27 28
A23segmental
bearing
10 vertical
11 12 output
1320 1421 1522. 16
1724 1825 1926thrust
20 top
21 of
22the
23 gearbox
24 25 26
27 28the
absorbs
at the
grinding forces.
15 function,
16 17 18
14 Mill
24
25
26
27
overflow
mode
19
28
In the case of ores with specific grinding characteristics or coarse comminution, it might be beneficial
to separate the grinding and classifying processes.
Before the mill motor is started, the grinding rollers

4
Overflow mode is selected for such materials.
5 lifted
6
7 hydraulically
8
9
are
from the grinding track. The
10
11
12 mill
13 14
16 be
17started
18 19 at
can15
then
20
21 22
low starting torque not only
In contrast to airflow mode, classifying in overflow
empty, but also partially filled. The grinding parts are
mode takes place not in the classifier directly above
prevented from coming into metallic contact when
the grinding chamber, but in an external classifier. The
the mill is empty or loaded by automatic lifting of the
material is transported via corresponding conveying
rollers via a level control.
routes from the mill to the external classifier.
A so-called auxiliary drive for starting up a filled mill
The material ground by the grinding rollers is
at low revolutions is not necessary!
conveyed by the centrifugal forces of the rotating
23
24
25
26
27
28
grinding table over the dam ring into the ring duct.
As a result of the high circulation of material it is discharged from the ring duct not by means of a scraper,
but instead in a free material flow via sloping chutes.
Hardfacing the grinding tire inside the mill
Maintenance
Worn grinding parts, tires and grinding track segments can be easily and quickly changed.
The rollers are retracted out of the grinding chamber
into a vertical position with a swinging-out cylinder.
Complete rollers, tires and grinding plates are thus
made accessible for lifting gear.
During grinding the grinding parts wear out for the
most part over the entire service life to such a uniform
extent that mill throughput decreases only when the
grinding parts are completely worn. Partial wear can
be compensated for by specific lining in the mill. This
can be realised by removal of the grinding parts or
Service drive
insitu by means of a special welding unit.

Loesche has the necessary expertise for welding
insitu with appropriate welding apparatus.
14
17.09.12 12:31
Combined drying and grinding and classifying

Combined drying and grinding
Ore raw material may be obtained with different moisture contents as a result of the upstream separation
processes. However, when compared with a moist
product, a dry grinding product allows for more exact
grinding process to evaporate the material moisture.

4
12 13
As soon as the ground material leaves the 20

table21for 22
10
11
12 13
14
15
16
17
18
21 22
4
5
23
6
24
7
25
8
26
9
27
28
15
16
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20
3
10
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12 13
14
23
11
12 13
14
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19
Layout:
19
14
24
15
25
in the feed material evaporates spontaneously on

contact with the hot-gas flow.
16
17
18
10 19
11
12 13
15
14
2
3cone
4
Grit
20 21 22 23 24 25 26 27 28
5
6
7
8
91
2
3
4
5
6
the area above the louvre ring, the water contained
Classifying
10
Hot gases can either be used from on site sources or

2
3
1
by using the Loesche hot gas generator.
11
1 20 2 21 3 22 4 23 5 24 6 25 7 26 8 27 9 28
Hot gases are supplied to the combined drying and
10
metering and conditioning to the downstream sorting

process.
2
1 810
7
1
16
10
2
10
2
11
13
15
4 vane
5 14
6assembly
7 16
8 17
9
Guide
93 12
18
19
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
28
11
3 Rotor
4
5 with
6
7
8
9
blades
17
18
19
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
28
11
3
4 Rotor
5
6 shaft
7
8
9
26 127 228
120 3221 4322 5423 6524 7625 8726 9827 928
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
28
2 11
3
4
5 Housing
6
7
8
9
1 10
10
11 13
12 14
13 15
1520 17
16
17 2319
1824 19
14 1016
10 11 12
18
21 13
22
25 17
26 18
27 19
28
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12
15
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2
3
4
5
6 Material
7
8
9 feed chute
1
20 22
21 23
22 24
23
24 20
2521
26
27 24
2825
22 14
23
26 18
27 19
28
20 21
25
13
2 11
32612
4 27
5 28
6 15
7 16
8 17
9
1 10
Product
discharge
10
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
28
11
20
21 22
23
and thanks to appropriate built-in classifier compo-
24
25
26
27
28
nents, it is possible to satisfy these differing demands

Depending on the application, Loesche vertical roller
made of the grain structure.
grinding mills can be operated in so-called airflow or

overflow mode.
The gas/particle flow rising from the mills is directed

1
via a static guide vane assembly
In both modes direct classifying after the grinding

process eliminates the risk of product overgrinding.
sifying chamber. The
17
18
27
28
20
3 the
4
5clas6
to
10 11 mixture
12 13 flows,
14 15 16
gas/solid-matter
21 22
24
25
depending on the flap position, specifically into the

1
space between the guide vane assembly
Airflow mode combines the functions of grinding and
23
concentric-running rotor with
2
1
blades
10
classifying in one aggregate. The air flow uplifts the
11
3
4the 5
and
26
310. 411 512 613 714 815 916
17
18
1220 1321 1422 1523 1624 1725 1826 1927
28
material from the grinding chamber to the classifier. In
20 21 22 23 24 25 26
As it rotates, the rotor accelerates
the supplied
the classifier above the grinding chamber the material
gas/solid-matter mixture tangentially. The centrifugal
ground to spec is separated from the coarse particles
force generated in the process rejects oversized
(grit), which can drop back onto the grinding table to
grain.
19
27
19
28
be comminuted again or can be removed for further

treatment.
The rotor speed and the gas flow with its flow direction determine the desired separation diameter. This
In overflow mode the ground material is discharged
can be adjusted within wide limits.
over the edge of the grinding table and classified

in an external process. The grit is fed back into the
A unique feature of this classifier type is the continu-
grinding chamber. By isolating the classifying process
ous reclassifying of the particle flows rejected by the
from the grinding process, it is possible to provide
rotor. When they fly outwards under centrifugal force
for several classifying or sorting stages in order to
in the annular gap, they are blasted again by the gas
recover intermediate products.
flow directed upwards/inwards. Here agglomerated

particles dissolve in such a way that they follow the
Dynamic Loesche classifier (LSKS)
product flow as individual grains and do not drop as

apparent oversized grains with the grit back onto the
The Loesche LSKS-type caged-rotor classifier oper-
grinding table.
ates with highly selective separation. It produces grain

distributions of both narrow and wide bandwidths. By
varying the process-technology setting parameters
15
17.09.12 12:31
Sizing model series drives

Dimensioning parameters
The following standard parameters are decisive in the
As well as the standard parameters, further material-
sizing of Loesche mills:
specific properties and factors must be taken into

consideration for sizing Loesche vertical mills for
GRINDING PRESSURE
crushing ore.
This lies between the minimum value for solid fuels

and the maximum value for ores.
MATERIAL MOISTURE
As opposed to grinding stock for example, from the

cement industry, the bandwith of ore properties is
The Loesche mill can process material with mois-
considerably higher. This results in that in sizing the
ture of up to 25%.
mill, the respective properties of the ore are taken into
PRODUCT FINENESS
consideration.
In the case of air-classifying it is possible, depending on the customer requirement, to create prod-
Based on more than 100 years of experience in mill
uct fineness figures of P80 of 500 m to P80 of
construction and thanks to continuous further devel-
20 m.
opment, Loesche has succeeded in designing vertical
DRIVE POWER
mills for the specific requirements in each case. The
The specific energy consumption during the grind-
throughputs are geared towards the properties of
ing test is decisive for gearbox and motor power.
the ore to be ground and the product properties to

be exhibited by the grinding material. Mill sizes with
In the development history of Loesche mills the sizes
throughputs of less than 100 t/h to well in excess of
have been adapted to the constant demand for higher
2,000 t/h are available.
capacity and throughput figures. The modular construction of the mills also enables customer-specific
solutions to be realised by combining standard components.
Model series
The mill sizes are identified according to the outer
effective diameter of the grinding track in decimetres [dm].
The identification is separated by a point followed by a digit. This digit indicates the number
of rollers operating in the mill.
Loesche mills are modular in design. The units of
rollers, rocker arms and rocker-related spring
assembly components with their pedestal are the
modules. They are arranged as required 2, 3, 4
and 6 times around a grinding table.
The number and size of the rollers is dependent
on the required product rate in conjunction with
the Loesche load factor, the product of the
grindability, moisture and fineness factors.
The required gas flow is decisive for sizing the
housings of the mill and the classifier.
16
17.09.12 12:31
Drives
An electric motor is used as the drive. It drives a plan-
A lubrication unit ensures that the gear teeth, the
etary gearbox with bevel gears. The input shaft is
shaft bearings and the segmental thrust bearing are
horizontal, the output shaft operates vertically
supplied with sufficient oil. Filters and cooling systems
upwards. The drive is enclosed at the top by a hori-
condition the oil. Electrical and hydraulic monitoring
zontal output flange. The gearbox contains a seg-
instruments incorporated in the PLC ensure safe
mental thrust bearing which absorbs the grinding
operation.
forces in the housing at the top. Loesche mill gearboxes are developed in cooperation between Loesche
In accordance with todays state-of-the technology
GmbH and well-known gearbox manufacturers. The
the modular construction principle of gearboxes
field service conditions under which the gearboxes
allows further power increases without the need to
must operate are matched to each other. Decades of
develop a new construction concept.
field experience with Loesche mills determine the

design of the (mill) gearboxes and their peripherals
The Loesche mill does not require a motor with
under all climatic conditions.
increased starting torque. Because the rollers are

hydraulically raised, the breakaway torque of the filled
Todays modern gearboxes are, like Loesche mills,
mill amounts to only 40% of the full-load torque. A
modular in design. Torque split provides for a reduc-
standard motor can easily deliver this starting tor-
tion of rotating masses with simultaneous multiple
que.
use of engineering elements in gearboxes of different

sizes and power outputs.
The installed motor power is geared towards the mills

energy demand and is determined in the Loesche
technical centre during the grinding test. The closest
matching commercially available motor is selected
and recommended to the customer.
Loesche mill gearbox
17
17.09.12 12:31
Complete grinding plants

Complete grinding plants
An ore grinding plant is featured on the following
Complete grinding plants incorporate material stor-
page. Grinding plants that use Loesche mills are char-
age hoppers and conveyor systems suitable for the
acterised primarily by their simple design and layout.
ore industry as well as metering elements to the
A grinding plant consists of the following process
Loesche mill. Included downstream of the classifying
stages and components:
processes is a filter system, which features, as well

as the actual filter and the piping system, the product
Material feeding
discharge and process-air circuit assemblies. The

Loesche grinding plant also features components for
Grinding and classifying
metal separation and Loesches own hot gas generators for drying purposes, if these are required for the
Reject/circulation handling
process.
Product separation
Material which has not yet attained the desired product

particle size is returned to the grinding process.
Mill fan
Final product is intermediately stored in the hopper
Hot gas generator (optional)
and is forwarded from there to the downstream

processes.
Process/measuring and control technology
Complete Loesche grinding plant with mill and filter
18
17.09.12 12:31
Overflow and airflow modes

The Loesche grinding plant is incorporated between
the primary crusher and the downstream process in an ore beneficiation plant. There are essentially two different processes for comminuting ores
with the Loesche mill. The difference being whether
the recirculating load is conveyed in an internal or
external circuit.
When the ground ore leaves the grinding chamber
after the grinding process under its own gravitational
force, this is known as overflow mode. When the
material is discharged by means of an air flow via a
classifier, this is known as airflow mode.
The choice of mode is determined by the properties of the material and the objective of the grinding
process.
Airflow mode
Overflow mode
In airflow mode grinding and classifying are combined
Loesche overflow mill
in a single machine (Loesche mill with classifier).

In the overflow mode the classification and grinding
Within the mill and to the classifier the material is
processes are separate. The material is transported
transported via airflow.
from the mill to the classifier via appropriate conveying

systems.
The feed material from the primary crushing stage

is directed after upstream metal separation into the
Prior to feeding the mill, the ore is classified in the
grinding chamber of the Loesche mill. The ground
pre-classifying stage. Ore already according to spec
material is directed with the uprising gas flow into
is separated in the pre-classifier and guided to the
the classifier. The grit drops back onto the grinding
final classifying stage the dynamic classifier. Thereby
table and is comminuted again. Product of sufficient
overgrinding and unnecessary energy consumption
fineness passes the classifier and is separated in the
are prevented. The coarse fractions of the pre-clas-
filter.
sifier and the dynamic classifier are fed to the mill.

After the material has been ground it is discharged
In both processes the finished grinding product is
through the ring duct and re-fed to the pre-classifier,
finally removed from the filters and fed to the down-
thereby the grinding classifying circuit is closed.
stream process via a product buffer.
The final product of the dynamic classifier is sepa-
Both overflow and airflow modes are closed grinding/
rated in the filter.
classifying circuits. By constant separation of the final

product from the grinding process an overgrinding of
the material can be avoided.
19
17.09.12 12:31
20
17.09.12 12:31
21
17.09.12 12:31
Primary crushing stages
Primary crushing stages
22
17.09.12 12:31
Downstream
processes
Loesche overflow mill

1
Feed, crushing plant
Conveyor belt, mill feed
Overbelt magnet
Metal detector
2-way chute
Defective material collector
Conveyor belt, classifier charge
Static classifier
Dynamic classifier
10
Conveyor belt
11
Loesche mill
12
Discharge system
13
Conveyor belt circulation
14
Filter system
15
Filter fan
16
Stack
17
Product discharge
18
Recirculation gas line

with dumper (optional)
Downstream
processes
19
20
Product storage
Loesche airflow mill

1
Feed, crushing plant
Conveyor belt, mill feed
Overbelt magnet
Metal detector
2-way chute
Defective material collector
Gate
Loesche mill
Reject system
10
Conveyor belt, reject system
11
Filter system
12
Filter fan
13
Stack
14
Product discharge
15
Recirculation gas line

with dumper (optional)
16
17
Product storage
23
17.09.12 12:31
Loesche hot gas generator
Construction
High cooling rate of the combustion chamber

prevents thermal overloading of following units.
1
1
1
1
1
1
10
2
10
2
10
2
10
2
10
2
Burner
2
3
11
Fuel
3 12
4
13
5
14
6
15
7
16
8
17
9
18
10
2
20 12
21 13
22 14
23 15
24 16
25 26 18
27 19
28
11
3 Combustion
4
5
6
7 air8 17
9
10
2
20
11
3
21 13
22 14
23 15
24 16
25 17
26 18
27
12
4 Burner
5
6 muffle
7
8
9
28
19
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
28
11
jacket
3
4
5
6 Perforated
7
8
9
casing
23
24
25
26
27 20
28
21 22
23
25
26
20 272128
32
43
54
10
11
12 13
12
19 13
14
15 2016 2117 2218 2319 24
22
24
25
23
65
76
Low16
wear17
14 15
18
19
Short26installation
20 21 22 23 24 25
27 28 times, low weight, small space
requirement. Can be installed in existing plants.
2
3
4
5
6
7
8
9
1
Complete preassembly is carried out also for
6 10 7 11 8 12 9 13 14 15 16 17 18 19
larger LOMA combustion units.
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
28
11
gap
3
4
5
6
7 Annular
8
9
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
28
11
3
4
5
6
7
8 Protective
9
24
21
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
28
11
3
4
5 Spiral
6
7 housing
8
9
2
1
20 12
21 13
22 14
23 15
24 16
25 17
26 18
27 19
28
11
3
4
5
6
7
8
2
3
4
5 control
6
7
8
9
19 Temperature
21 13
22 14
23 15
24 16
25 17
26 18
27 19
28
10 171118
12
gas13outlet
10 Hot
11 12
14 15 16
1 22
chimney stack is not necessary

7 EMERGENCY
9
8An
98
in EMERGENCY-OFF SITUATIONS and when
10 12
11 13
12 14
13 15
15 17
16 18
17 19
18 19
10 11
14 16
starting and stopping.
20 22
21
22
23
24
25
26
27
20 21
2 24
3 25
4 26
5 27
6 28
7 28
8 within
9 a short time for inspection
1 23
Accessible
1
19
26
27
25
26
27
28
28
Loesche hot gas generators are used where hot gases

are required for direct drying, e.g. in the cement, steel,
industrial minerals, ore, wood, cattle food, agri-food
and chemical industries.
10
11
12 13
14
2
3
4
5
6
7
8
9
Mode of operation
17 18 19
11 12 13 14 15 16 17 18 19
The process gas stream which enters the spiral
20 21 22 23 24
27 28
9
2171 2282 2393 244 255 266 277 288
2
3
4
1
2 housing
3
4
5 cools
6
7 both
8
9the protective jacket housing
1
10 11 12 13 14 15 16 17 18 19
14 15
913 the
4 195
6 . as
7 a
8 result
9
1 162 173 18
10 11 12 13 14 15 16 17 18 19 1 2 3 4 5 610 7 11 8 12and
perforated
jacket
of the
20162117221823 1924 25
26
27
20 21 22 23 10
24 112512 26
27 1528
13 14
10
11process
12 28
13 gas
16 17
18interior
19
14 15
flow
pattern.
The
enters
the
of
20 21 22 23 24 25 26 27 28
20 21 22 23 24 25 26 27 28
20 21 22 23 24 25 26 27 28
2the3annular
4
5 gap
6
7
1
the combustion chamber through
10 11 12
16
14 15there
and holes in the perforated jacket,
and13mixes
17
18
27
28
1
16
10
25 26
5 206
15
20
21 22
23
24
25
26
10
11
12 13
14
15
with the hot flue gases from combustion. At the same

8
9
time the flame and hot flue gases are kept away from
16the17perforated
18 19 jacket.
20
21 22
24
25
26
23
27
28
The perforated jacket combustion system developed
Heating media
by Loesche in the mid 1960s consists of a com-
bustion chamber of heat resistant steel with burner

muffle, and is well known in the market under the
19
Natural gas, bio gas, coke gas, blast furnace gas

and other low calorific value gases
Light and heavy oils, wood and lignite dust
name LOMA Hot Gas Generator. The LOMA Hot Gas

Generator has been used worldwide for decades in
LOMA Hot Gas Generator units are constantly being
many different types of thermal processes for opti-
developed and conform to current technical stan-
mization.
dards. More than 600 hot gas generators (of this type)
have been commissioned for a heat flow of between
Design and operation:

LOMA combustion unit type
LF 25 with a natural gas burner,
2005
100 kW and 64,000 kW.
The combustion chamber consists of heat resistant steels no refractory brickwork is necessary
When starting up the hot gas generator heat
losses are minimised since it is not necessary to
heat up refractory brickwork. A start at full load is
therefore possible.
Very good thermal shock resistance and rapid
load changes with only a short delay
17.09.12 12:31
Loesche rotary vane feeder
Feeding of Loesche mills can be carried out via a rotary

vane feeder in order to prevent infiltration air ingress
into the mill interior.
Material is fed continuously from above via the inlet
hopper into every vane pocket of the slowly rotating
vane feeder. In order to reduce wear from the abrasive
feed stock the peripheral speed is low and the filling
level limited to 40%. Adjustable sealing strips on the
rotor prevent any large gaps between the wearing plate
of the housing and the rotor. The material is discharged
downwards into the feed chute of the mill.
Hot gas can be passed through the inside of the rotary
feeder to prevent material caking. It is easy to dismantle for maintenance purposes.
25
17.09.12 12:31
The Loesche test facility

for raw materials testing,
Research and Development
Calibrated standard grinding tests for
mill sizing
Three well equipped laboratory LM 3.6 grinding mills

are available in the Loesche test plant for performing
standard grinding tests.
Loesche has many years of experience in designing

grinding mills. The most important prerequisite for correctly designed grinding mills is an exact knowledge of
the physical properties of the materials to be ground.
The most important characteristic values of a material
to be ground are the Loesche grindability factor and
the specific power demand in relation to a defined
fineness. Depending on the geological formation of
the material to be ground, materials with highly different properties are found in nature, even with materials
which appear visually to be similar.
Fully-automatic
operation with PLC
Loesche Mill Type LM 3.6, laboratory mill
Technological development through

practical laboratory grinding tests
One of the first steps in introducing new technologies
is the practical laboratory test.
Within the framework of our research and development projects the following actions are carried out:
New materials for grinding of future market
Analysis possibilities
Pure density determination with gas pycnometer
Determination of mass-related surface according to Blaine
Grain size analysis with Cilas laser granulometer
Sieve analyses with Alpine air-jet screening method
Sieve analyses with Retsch vibrating sieves
Grindability according to Hardgrove
Grindability according to Zeisel
Microscopy with Zeiss Stemi SV11
Drying ovens for moisture determination
Coal testing (Cfix, volatile matter, ash content)
requirements are examined

Optimised mill settings for special products are
determined
Plant components and process configurations are
optimised
New wear materials and concepts are tested
Our test plant is constructed in such a way that
various modes of operation and plant process configurations can be simulated in the tests.
26
17.09.12 12:31
Loesche worldwide presence
Loesche is an export-oriented company run
ding technologies and preparation processes
The services of our subsidiaries and agen-
by the owner, which was established in 1906
for the benefit of our customers. Their com-
cies are of key importance for analysis,
in Berlin. Today the company is internatio-
petence is mainly due to our worldwide infor-
processing and solving specific project
nally active with subsidiaries, representatives
mation management.
problems for our customers.
and agencies worldwide.

This ensures that current knowledge and
Our engineers are constantly developing
developments can also be used immediately
new ideas and individual concepts for grin-
for our own projects.
Loesche GmbH
Hansaallee 243
40549 Dsseldorf
Tel. +49 - 211 - 53 53 - 0
Fax +49 - 211 - 53 53 - 500
Email: loesche@loesche.de
www.loesche.com
Peoples Republic of China

Loesche Mills (Shanghai) Co., Ltd.
No. 568, Jinhong Road
(near No. 555, Chunhe Road)
Baoshan District,
201901 Shanghai, P. R. China
Tel. +86 - 21 - 5180 6100
Fax +86 - 21 - 5180 6101
Email: info@loesche.cn
Brazil
Loesche Equipamentos Ltda.
Rua Mxico 119 sl. 1908
20031-145 Rio de Janeiro, Brazil
Tel. +55 - 21 - 22 40 79 00
Fax +55 - 21 - 22 20 94 40
Email: loesche@terra.com.br
Germany
Loesche Automatisierungstechnik GmbH
Zum Pier 52
44536 Lnen
Tel. +49 - 231 - 98 70 10
Fax +49 - 231 - 98 70 10 - 20
E-mail: info@loesche-automation.de
www.loesche-automation.de
Loesche ThermoProzess GmbH
Uechtingstrae 19 / Gebude D9
D-45881 Gelsenkirchen
Tel. +49 - 209 - 36 17 22 - 110
Fax: +49 - 209 - 36 17 22 - 180
+49 - 209 - 36 17 22 - 190
www.loesche-tp.de
India
Loesche India Pvt. Ltd.
D - 83, Sector - 2
Noida - 201301
U.P., India
Tel. +91 - 120 - 40 18 500
+91 - 120 - 24 44 205 - 207
Fax +91 - 120 - 40 18 590 - 91
+91 - 120 - 24 43 327
Email: loesche@loescheindia.com
www.loescheindia.com
Loesche Mills (Shanghai) Co. Ltd.

5 Dongzhimen South Street
Room 817-818, CYTS Plaza
Dongcheng District,
100007 Beijing, P. R. China
Tel. +86 - 10 - 5815 6205
Fax +86 - 10 - 5815 6220
Email: info@loesche.cn
Russia
OOO Loesche
Berezhkovskaya Naberezhnaya 16a/2
P.O. Box 97, 121059 Moscow
Russian Federation
Tel. +7 - 495 - 988 50 81
Fax +7 - 495 - 988 60 86
Email: info@loesche.ru
www.loesche.ru
Socialist Republic of Vietnam
Loesche GmbH Viet Nam
Representative office
60 Nguyen Dinh Chieu Str.
Dakao Ward, Dist. 1
HCM - Ho-Chi-Minh City,
Tel. +84 - 8 - 39 10 45 62
Fax +84 - 8 - 39 10 45 26
E-Mail: mai.lam@loesche.vn
South Africa
Loesche South Africa (Pty.) Ltd.
55 Empire Road, Empire Park, Block C
2193 Parktown, South Africa
Tel. +27 - 11 - 482 29 33
Fax +27 - 11 - 482 29 40
Email: loesche4@global.co.za
Spain
Loesche Latinoamericana S.A.U.
Condesa de Venadito 1, Planta 4
28027 Madrid, Spain
Tel. +34 - 91 - 458 99 80
Fax +34 - 91 - 457 10 17
Email: loesche@loesche.es
www.loesche.es
United Arab Emirates
Loesche Middle East FZE
P.O. Box 262 622
Jebel Ali, Dubai, U.A.E.
Tel. +971 - 4 - 886 59 11
Fax +971 - 4 - 886 59 22
Email: info@loesche.ae
United Kingdom
Loesche Energy Systems Ltd.
2, Horsham Gates
North Street
Horsham, RH135PJ, United Kingdom
Tel. +44 - 1403 - 223 101
Fax +44 - 1403 - 223 102
Email: loesche@loesche.co.uk
USA
Loesche America, Inc.
20170 Pines Boulevard, Suite 301
Pembroke Pines
Florida 33029, USA
Tel. +1 - 954 - 602 14 24
Fax +1 - 954 - 602 14 23
Email: webmaster@loescheamerica.com
www.loescheamerica.com
Please visit our homepage at

www.loesche.com
for up-to-date information on
our overseas companies.
25
25
1200181_LOES_huettensand_Zement_reprint_09/2012_V2.indd 25
25.09.12 10:32
Colemanite, Turkey
Phlogopite
Tremolite
Diposide
Bronite, USA
Si-Ca-Ti-OXide
Diposide
Banded Iron Ore Formation, Brazil
Phosphate Rock under direct light

microscope
Chalcopyrite, Chile
50 m
Stranskiite, Namibia
50 m
Apatite, RSA
20 m
Titanium Slag, RSA
50 m
Baryte, Germany
20 m
Expanded Clay, Germany
50 m
2 m
Dolomite, Russia
10 m
Bentonite, Libya
10 m
Clay, Germany
Pictures originated at the electron microscope laboratory of Bauhaus-Universitt Weimar
Apatite
Aragonite, Italy
164_LOESCHE Mills for ores and minerals_ EN 500

09/2012 Printed in Germany
Phosphate Rock, RSA
17.09.12 12:31

164LOESCHE Mills For Ores and Minerals E

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Loesche-Mills

Loesche technology always one step ahead

Loesche Mill Type LM 60.4, Ras al Khaima,

Loesche Mill Type LM 46.4, Lengerich, Germany, 2003

whose space requirement for the building of

With pure compressive comminution, the introduction

different comminution principles. The spectrum rang-

of shear forces is deliberately avoided.

es from a combination of compressive and shear

This is achieved by tapered rollers, whose axes are

angled in relation to the horizontal grinding track in

The grinding material is comminuted in the Loesche

centre of rotation of the grinding plate with its axis.

tionary grinding rollers.

the respective ore characteristics in order to achieve

grain size fractions is increased. Further positive

relation to the centre of rotation of the grinding plate.

effects are additional energy savings and the minimi-

This gives rise to different comminution effects:

Compressive comminution with shear component

Pure compressive comminution.

ing can reduce the amount of fines up to 50 % and

thereby result in significant advantages for the down-

compressive comminution system with a shear com-

stream sorting processes.

ponent. This effect is created by tapered rollers,

Comparison of the Loesche comminution principles

Accumulated screen underflow [weight %]

Compressive and shear stress

particle size [m]

Advantages of the Loesche grinding process

Monitoring of the grinding forces in combination with

sorting processes. The more complete the mineral

in-bed comminution provides a selective ore com-

liberation of the ground ore, the greater the chances

of obtaining a good recovery.

avoid unwanted overgrinding and to achieve a steep

product particle size curve. In addition to the energy

combines the crushing and grinding process stages

can, depending on process management, substitute

two to three crushing and grinding stages. As well

Due to the fact that the particles have many points of

design of Loesche grinding technology reduces the

contact with each other, the grinding force is directed

through the grinding bed. This results in a better

In this way, the Loesche mill can be easily planned for

grinding technologies. Online monitoring of the oper-

incorporation in existing plant concepts or, in the case

ating pressure of the grinding rollers and thus of the

of new planning concepts, can reduce the amount of

grinding forces provides a controllable and consistent

surface area used.

Particle size distribution of a Loesche Mill compared to a Ball Mill

Accumulative screen throughput [weight %]

Particle size [m]

The advantages of the Loesche grinding process over

Advantages for the downstream process

conventional grinding systems can be summarised

only advantages in the grinding process but also in

the valuable mineral

of the Loesche mill and thus the optimised grinding

Selective comminution by means of in-bed

steeper product particle size curve