Introduction:

Ball mill is an efficient tool for grinding materials into fine powder. The ball
mill is used to grind many kinds of mine and other materials. It is widely used in building
material, chemical industry etc. There are two ways of grinding, the dry process and the
wet process. It can be divided into tabular type and flowing type according to different
forms of discharging material.
Both plastic and non plastic raw materials are finally ground
and mixed in a ball mill. Ball mill is a long steel cylinder, lined with quartz, silex, clean or
rubber and supported on hollow grunions. The cylinder is nearly half-filled with the
material to be ground and solid grinding media, which is metal rods in a rod mill, flint
pebbles in a pebble mill and balls of metal, rubber or ceramic in a ball mill.
Purpose of grinding and crushing are1) To decrease the size of materials.
2) To increase the surface area of materials.
3) Make the material free from the matrix.

Working Principle:
The ball mill is horizontal type and tabular running device has
two warehouses. This machine is grid type and its outside runs along gear. The material
enters spirally and evenly warehouse of the milling machine along the input material
hollow axis by input material device. It appears that in the upward movement of side of
the shell. The balls are interlocked and relatively stationary. At the top of their lift at
about the quadrant, the balls cascade down the free surface in free fall and hit the toe of
the slope. It is the jostling and sliding and impacting of the balls, mainly in their
downward path, that causes the comminution of the material in their midst. The material
particles appear to take up positions either as anvils at the toe of the slope where they
are simply struck by the falling balls or as annuli having a common centre at the point of
contact between pairs of balls, so that the particles, the finest being in the annulus of
smallest radius and the coarsest in the annulus of largest radius. In practice, the chance
of finest getting into position would be expected to be small because the coarsest sizes
that are mostly attacked.

Speed of Rotation of Ball mill:

During operation the balls are carried up to a certain height
depending on the speed of the mill, where they break contact with the wall and roll down
to the bottom to be picked up again and recycled grinding is achieved by the rolling of
balls not merely by their impact on falling freely which causes fast wear of the ball and
contamination of the powder. Ultimately when a critical speed is reached, the balls are
carried over and at that condition there is hardly any grinding action and the mill is said
to be centrifuging.

The mill diameter (D) is emperically related to the optimum operating speed (n) as
follows:
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n= 57-40 log D
The point at which the outermost balls loose contact with the wall of the mill
depends on the balance between gravitational and centrifugal forces. Equating these
two forces as shown in the figure, the following relationship is obtained.
Mg Cos = mu2/ (R-r)
Where the speed u is related to the speed of rotation by the following equation,
u= 2n (R-r)
Or
Cos = 4 2n2 (R-r)/g
At the critical speed, =0, Cos =1 and n becomes the critical speed n c and then,
nc = 1/2 [g/R-r]1/2
The most efficient grinding is achieved when the value of is about 45 0,when
the upper balls roll down towards the bottom and the lower ones are carried up. In the
process the moving balls rub against one another.

Construction:
1) Shell: The shells are made from usually mild steel sections welded together.
It is usually fitted with turning at each end which run in bearings; shell thickness is about
10 mm.

2) Lining: The lining of the shell of the ball mill is cast steel or Ni-hard cast iron
with about 75% chromium. The thickness of the lining is 20 mm.
The criteria for ball mill linings are:
a) The material must be most wear resistant.
b) The shape of the pieces must be such that no machine work is necessary.
c) The pieces must be light to handle.
d) It must be possible to reline the shell.
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Ball mill features and benefits:

This machine is made up of feeding part, discharging part,
gear part, transmission part, (decelerator, small transmission gear, generator, electrical
control) and so on. The hollow axis adopts the cast and the lining can replace the
rotating big gear processes in the way of casting rolling gear. T barrel body is wearable
well and bears wearable scale board. This machine runs steadily and works reliably.

Grinding media:
There are many types of grinding media suitable for use in a ball mill with
materials having its own specific properties and its advantages. Common in some
applications are stainless steel balls. While usually very effective due to their high
density and low contamination of the material being processed, stainless steel balls are
unsuitable for some applications, including:
i) Black powder and other flammable materials require non sparking head, antimony,
brass or bronze grinding media.
ii) Contamination by iron of sensitive substances such as ceramic raw materials. In this
application ceramic or flint grinding media is used as ceramic media, are also very
resistant to corrosive materials.
High density alumina media (90-95% Al 2O3) is widely
used in the ceramic industry to grind the bodies, frit glazes and other ingredients. It is
more expensive than silica/ sleek media but is more efficient.

Grinding additives:
Size reduction of solids in grinding process is achieved by subjecting
particles to different stresses; leading ultimately to the fracture of particles. Fracture
may proceed within the particle itself (intra granular fracture) or along the grain
boundaries (intergranular fracture).Usually the first kind of fracture is sufficient for size
reduction process. In general, fracture process involves rupturing of chemical bonds to
create new surfaces.

A lot of investigations have been done to suggest that as much as 20 fold

increase in grinding rate can be obtained by using chemical additives. It has been
documented that liquids, in particular water, play an active role in the process of fracture
and this effect could be enhanced by adding different surface active agents. In addition
to strength properties, material hardness has also been known to be affected by the
surrounding environment. In this regard, the concentration of additive has also been
claimed to be vital to produce maximum effect during grinding. Apart from water, the
other important additives that facilitate the grinding rate are alcohols and phenols (for
quartz), ketones and amines (for cement klinker and limestone) fatty acid (quartz,
limestone, cement klinker).Some other additives like Carbon black, Sodium silicate,
Sodium chloride, Sodium carbonate, Sodium hydroxide, Kaolin, Sodium poly
metaphosphate, Aluminium chloride, Ammonium carbonate have also been listed for
this purpose. It has also been found that some low molecular weight polymers cause
reduction in slurry viscosity to assist the grinding process.

Ball size and composition:

Balls may be shaped as cubes, cylinders, spheres. Nothing has been found
better than spheres. Nothing has been found better than spheres. Spheres wear
regularly and become small which are used in grinding of finer particle than the first one.
The balls introduced into the mills vary from 1 to 6 inch in diameter.
Compositions which have been used include cast iron,
steel flint, porcelain and Tungsten carbide. Cast iron is not satisfactory except for small
balls below 5 cm in diameter because it produces weak and brittle balls and large
difference between the ball sizes cause breakages.
Criterion for the choice of composition depends apart from density and
hardness upon the possibility of the tolerating material in the product. The ball density
should be as greater as possible compared with the material density, because the
operation of the Archimedes principle decreases the effectiveness of the balls by giving
them buoyancy which is greatest where the depth of the material is greatest in
proportion to the diameter of the balls and least in such places as the point of peripheral
discharge where the depth of material is least.

Ball loading and charge of material in

mill:
The optimum filling of the mill for maximum production of new surface
appears to be somewhat more than the complete filling of voids between the balls.
Fineness appears to depend to some extent on the material loading of the mill.
The loading of the balls in the mill to effect maximum rate of new surface is about
50% of the initial volume of the mill. Sufficient loading of balls will prevent oscillation of
charge as well as give maximum rate of production of new surface.

Ball wear:
Wear of the balls appears to depend upon the Filling ratio, V (Bulk volume
of powder /voids between the balls) and is largest when V is smallest.
Wear is minimum, when
i) The Filling ratio (V) is about unity.
ii) The Hardness ratio (H) is either very high or very low.
[Hardness ratio (H) = Surface area/ original surface area.]
iii) The ratio of speed of rotation to the critical speed is least.

Recent developments:
To cope up with the global market, expanding mining groups are tending to
optimize the mill performances to sort out the best operating conditions. For this
purpose, continuous and reliable information about the mill operation is very much
essential. An innovative online tool has been developed to communicate information
about the dynamics prevailing inside the mill. It is able to finely follow the slurry and ball
load levels inside the mill, measuring the critical mill parameters and turns them into
valuable information for the plant engineers for timely decision making and action.

CALCULATION
1. IMPORTANT INFORMATION AND FORMULAE
A. Volume of the ball: Volume of the feed = 8:1
B. Actual volume of the ball = 55% of the bulk volume of the ball
C. Around 50%volume occupied by balls and feed i.e. volume of the ball and feed
=50% volume of the ball mill.
D. Volume of the ball mill: D2 L /4 (assuming shape of the ball mill to be cylinder)
Where , D = Inner diameter of the ball mill
And

L = Length of the ball mill

E. According to Bond law: P /T =0.3162 W i(1/Dpb -1/Dpa)

. Where, P= power in KW-hr
.
T= Capacity of the ball mill in ton / hr
.
Wi=Work index
.
Dpb=Size of the pdt
.
Dpa=Size of the feed
F.Optimum speed of rotation = 57 40 logD
Where, D= Mill diameter
G. Critical speed = 1 /2(g /R-r)
Where , R = Radius of Ball mill
.
.
r =Radius of each ball

2. DETERMINATION

OF THE DIMENSION OF THE BALL MILL

A. Density of quartz= 2.65 gm/cm3

.
=2.65103 kg/metre3
.
=2.65 ton/metre 3
B. Ball mill capacity = 1.2 ton/hr
.
=1200 kg/ hr
We, consider, about 8% extra material must be added with the feed.
Hence extra added material =81200100 kg =96 kg
As feed rate =1200kg/hr
Therefore total weight of the feed =(1200+96) =1296 kg

C. Volume of the feed = Weight of the feed /density of feed

.
=1296 kg/2650 kg/metre =0.489 metre3
D. As the volume of the ball = 8 volume of the feed
=80.489 metre3
=3.912 metre 3
E. Actual volume of the ball =55% bulk volume of the ball
=553.912 /100 metre3
= 2.15 metre3
F. Total volume of the ball and feed =(2.15 + 0.489) metre 3
= 2.64 metre 3
G. As the volume of the feed and ball = 50% volume of the ball mill
Therefore volume of the ball mill = 2.64100/50 = 5.28 metre3
H. We know , volume of ball mill = D2L/4
= D21.5D/4 metre3
So now

(As L:D =1.5:1)

D21.5D/4 = 5.28
D 3 =5.284/1.5 metre3
D =1.65 metre

Therefore diameter of the ball mill (D) =1.65 metre

Hence length of the ball mill(L) = 1.651.5 = 2.47 metre

3. ENERGY CALCULATION
A. Average feed size (Dpa) = 20 mm
75% of product size (Dpb) = 45 micron(or passes through 325 mesh B.S shieve)
= 4510-3 mm
Now Bond Law ,

P/T = 0.3162Wi(1/Dpb 1/Dpb)

P = 0.316214.41.2(1/0.045 - 1/20) KW-hr (Wi for

quartz=14.4, T=1.2ton/hr)
P = 5.46 (4.71 0.22) KW-hr
P = 24.51 KW- hr
P = 32.86 hP (1 hp = 746 watt)
Hence we have used a motor of 35 hp, because some energy is lost in operating
the parts of the ball mill.

4. CALCULATION OF OPERATING SPEED AND CRITICAL

SPEED
A. Optimum operatin speed = 57 40 logD (D = diameter of ball mill)
Now D = 1.65 metre
= 165 cm
=165/2.54 = 64.96 inch
D = 64.96/12 = 5.41 feet
R =5.41/2 =2.71 feet
Hence optimum operating speed =57 40log 5.41 rpm
= 57 28.44 rpm
= 28.56 rpm
Therefore critical speed = 1/2(g/R r)
mm =0.1066 feet

where r = radius of each ball =65/2

= 1/23.14( 32.15/2.71-0.1066) rpm (where g= 32.15

2

ft/sec )
=0.04531 rpm

5. NO OF BALLS REQUIRED
A. Actual volume of ball = 55% bulk volume of ball
= 553.912/100 =2.15 metre 3
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Radius of each ball =65/2 =32.5 mm

=32.510 -3 metre
So Volume of single ball = 4/3(32.510-3)3 metre3
=1.410 -4 metre3
Therefore no of balls = 2.15104/1.4 = 15357

CALCULATION
1. IMPORTANT INFORMATION AND FORMULAE:
A. Volume of the Ball: Volume of the Feed = 8:1
B. Actual volume of the Ball = 55% of the bulk volume of the Balls.
C. Total space occupied by Balls and Feed = 50% of volume of the Ball mill.
D. Volume of the Ball mill= D2L /4 (Assuming shape of the Ball mill to be
cylindrical)
Where , D = Inner diameter of the Ball mill
And

L = Length of the Ball mill

E. According to Bond law: P /T =0.3162 Wi (1/Dpb -1/Dpa)

. Where, P= Power in KW-hr
.
T= Total Capacity of the Ball mill in ton / hr
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.
Wi=Work index
.
Dpb=Size of the Product
.
Dpa=Size of the Feed
F. Optimum Speed of Rotation = 57 40 logD
Where,

D= Mill diameter

G. Critical speed = 1 /2 (g /R-r)

Where, R = Radius of Ball mill
.
.
r =Radius of each Ball

2.

DETERMINATION OF THE DIMENSION OF THE BALL MILL:

A. Density of Sodium feldspar = 2.60 gm/cm 3

.
=2.60103 kg/metre3
B. Feed rate = 1.6 ton/hr
=1600 kg/hr
.
We consider, about 8% extra material must be added with the Feed.
Hence, Extra added material = (81600)/100 kg =128 kg
As Feed rate =1600kg/hr
Therefore, Total weight of the Feed = (1600+128) kg =1728 kg
C. Volume of the Feed = Weight of the Feed /Density of Feed
.
=1728 kg/2600 kg/metre3
=0.6646 metre 3
D. As the Volume of the Ball = 8 Volume of the Feed
= (80.6646) metre3
= 5.3168 metre 3
According to packing efficiency, 55% of the bulk volume of the Ball is the Actual
Volume of the balls.
E. Therefore Actual Volume of the Ball = 55% bulk volume of the Ball
= (555.3168)/100 metre3
= 2.9242 metre3
F. Total volume of the Ball and Feed = (2.9242 + 0.6646) metre 3
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= 3.5888 metre 3
G. As the volume of the Feed and Ball = 50% of volume of the Ball mill
Therefore, Actual volume of the Ball mill = (3.5888100)/50 metre3= 7.1776
metre3
H. We know, Volume of Ball mill = D2L/4
= D21.4D/4 metre3

(As L: D =1.4:1)

D21.4D/4 = 7.1776

So now,

Or, D 3 = 6.5277
Or, D =1.87
Therefore, Diameter of the Ball mill (D) =1.87 metre
Hence, Length of the Ball mill (L) = 1.871.4 metre = 2.62 metre

3. ENERGY CALCULATION:
A. Average Feed size (Dpa) = 20 mm
80% of product size (Dpb) = 75 micron (or passes through 200 mesh B.S sieve)
= 7510-3 mm
Now, Bond Law:

P/T = 0.3162Wi (1/Dpb 1/Dpb)

P = 0.316211.851.6(1/0.075 - 1/20) KW-hr (Wi for

Sodium feldspar=11.85 KW-hr/t, T=1.6ton/hr)
P = 5.995 (3.65 0.22) KW-hr
P = 20.56 KW- hr
P = 27.56 hp (1 hp = 746 watt)
Hence we have used a Motor of 30 hp, because some energy is lost in operating the
parts of the Ball mill.

4. CALCULATION OF OPERATING SPEED AND CRITICAL SPEED:

A. Optimum Operation Speed = 57 40 logD (D = Diameter of Ball mill)
Now, D = 1.87 metre
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= 187 cm
=187/2.54 inch = 73.62 inch
D = 73.62/12 feet = 6.135 feet
R =6.135/2 feet =3.068 feet
Hence, Optimum Operating Speed =57 40 log (6.135) rpm
= 57 31.51 rpm
= 25.49 rpm
=0.4248 rps
Therefore, Critical Speed = 1/2 (g/R r)
=70/2 mm =0.115 feet

Where, r = Radius of each Ball

= 1/23.14( 32.15/3.068-0.115) rpm (where g=

2

32.15 ft/sec )
=0.5251 rps
=31.51 rpm.

5.

NO OF BALLS REQUIRED:

A. Actual volume of Ball = 55% Bulk volume of Ball

= (553.912)/100 metre 3
=2.15 metre 3
Radius of each Ball =70/2 mm =35 mm
=3510 -3 metre
So, Volume of single Ball = 4/3 (3510-3)3 metre3
=1.810 -4 metre3
Therefore, No of Balls = (2.9242104)/1.8 = 16245

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