5/14/2017 BallSampling

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BallChargeSampling

1 Introduc on:

Itisalwaysinteres ngtoknowtheballchargegrada oninsideaballmill.

Reasonsare:

*toseethedierencewiththetheoricalballchargegivenbythesupplierorsomebodyelse

*toadjustthefuturemakeup

*togetagoodideaofthewearoftheballs

*todecideifitis metochangecompletelytheballcharge

*tocheckiftheclassica onisgoodinsecondchamber

Experiencedengineershaveagoodfeelingonlyhavingalookduringthemill'svisitbutresultsofacompletesamplingisbeer

inordertoconvinceotherpeople.

Theproblemnumberoneisthedicultyofthejob.Infactitisveryhardandlongwork...

2 Methodusedintheminingindustry:
Letusrecallthemethodo enusedinwetprocess.
2.1 Toolsneeded:

AtubeinPVCwithadiameterof300mmandalengthof1000mm(thistubemustberesistant,athicknessof810mmisnecessary)
Apieceofwoodisnecessarybetweenthetubeandthehammerduetotheimpact
Abighammertoknockthetubeintotheballcharge
Amagnettoremovetheballsfromtheballcharge
Acordforli ingthemagnetandtheballs
Asolidbuckettocarrytheballsinthelaboratory
2.2 Procedure:
Takethreesamplesalongthemill,therst1metera erthemillinlet,thesecondatthemiddleofthechamberandthethird
1meterbeforethemilloutlet.Thesamplespointswillbeonthemillaxis.Seegurebelow:

Asthesamplingcampaignof3samplestakealong me,theprocedurecanbereducedtoasinglesample
tobetakeninthemiddlethemill
Knockthetubeintotheballchargewiththehelpofapieceofwoodandthehammer(2030cm).
A erthat,removetheballsinsidethetubewiththemagnetlinkedtothecord.
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A erthat,removetheballsinsidethetubewiththemagnetlinkedtothecord.
Puttheballsinsidethebucket.
Normally,thisopera onisrepeated4or5 mesdependingonthefacilitytoenterthetubeintothecharge.
Watchthefollowingdrawings:

Onesampleshouldweighbetween500and600kg
Allthismaterialissentinaroomtobeanalysed
2.3 Comments:

Thismethodisimpossibletoimplementfortherstchamberbecausetheballchargeistoocoarse(ballsfrom90mmto60mm).
Thismethodcouldbeimplementedinthesecondchamber,especiallyinthesecondpartwheretherearenotballsof60,50mm.
Inanycase,itisnecessarytoemptythemillbeforetocarryoutthesamplingcampaign.

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3 Methodtobeusedinthecementmill:
3.1 Toolsneeded:

Asolidbuckettocarrytheballsinthelaboratory
Ashoveltotakethesmallballsinchamber2
3.2 Firstchamber:
Take2samplesintwopointsasshownonthesketchbelow:

Foreachsample,abouttenbucketsof20kgeacharesucient.
Ballsinsurfaceareacceptedduetothedicultytogodeeper.
Ballsaretakenbyhand.
Allthismaterialissentinaroomtobeanalysed
3.3 Secondchamber:
Take4samplesinfourpointsasshownonthesketchbelow:

Foreachsample,aboutvebucketsof20kgeacharesucientforsamples1(1/5)and2(2/5).
Foreachsample,abouttwobucketsof20kgeacharesucientforsamples3(3/5)and4(4/5).
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Foreachsample,abouttwobucketsof20kgeacharesucientforsamples3(3/5)and4(4/5).
Forsamples1/5and2/5,ballsinsurfaceareacceptedduetothedicultytogodeeper.
Forsamples3/5and4/5,taketheballsdeeperifpossible.
Ballsaretakenbyhandif60,50and40mmballs.
Ballsaretakenwithashovelifsmallballs.
Allthismaterialissentinaroomtobeanalysed

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4 Analysisofthesamples
4.1 Allweneed:

Abalance
4.2 Procedure:
Theprocedureherebelowistheoneofthewebsite"www.themininggrindingoce.com"butcanbeappliedherealso.
Theballsareassembledvisuallybysizes.
Thebiggestballs(from90mmto50mm)areweighedonebyone.
Forthelowerdimensions,wewillassembletheballsofthesamesizebylotsinordertosave me.
Theballsfrom50mmto30mmareassembledbylotsof5.A er,eachlotofveballsisweighed.Inthecalcula onlistwhichwill
follow,eachballofonelotwillhavetheaverageweightofthelot(totalweightofthelotdividedby5).
Theballsfrom30mmto15mmareassembledbylotsof10.A er,eachlotoftenballsisweighed.Inthecalcula onlistwhichwill
follow,eachballofonelotwillhavetheaverageweightofthelot(totalweightofthelotdividedby10).
Themedialowerthan15mmareo enscrapsandwillbeweighedtogether.Agoodapproxima onofthenumberofsmallpieces
isenough.
Itisalsointeres ngtocounttheballswhichhaveadefect.Thiscanbeachievedwithballshavingadiametergreaterthan40mm.
Onecanseesomepicturesofthelotsbysizeherebelow:

4.3 Example:
Theexamplebelowistheoneofamonochamberballmillintheminingindustry.
Inthisexample,onlyonesampleinthemiddleofthemillhasbeentaken
Totalweightofthesample:567,9kg
Numberofballs:480
Herebelow,therawlistofthissamplewiththeweightoftheballsandtheballswithdefectinred
























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A ertheweighing,wemustclassifytheballsbycategory.
Forthis,weconverttheweightindiameterandwehavethefollowingcategories(withspecicgravityof7,8kg/dm3):
categories(withspecicgravityof7,8kg/dm3):

Andwehavethefollowingresults:

Importantno ce:Inthissample,therewerenotballsunder40mmandnoscraps.Thereasonwasthatthismillwasalways
workingfullofmaterial.Thepulpwasgoingoutbythedooratmilloutlet.
Normally,achargeattheequilibriummusthaveagrada onfromthetopupsize(here80mm)upto10mm
(whentheballbecomesachipandleavesthemill).
ThismillwasgrindingcopperoreinChile.
Ballmillsintheminingindustrydon'thaveclassifyinglinings.
4.4 Analysisoftheresultsandinterpreta on:
Fortherstchamberofacementmill,themostimportantistoknowif:
*thereisreallytherightpercentageofthebiggestballs(o en90mm)
*thereisabigamountofballslowerthanthesmallestdimension(o en60mm)
Forthesecondchamber,themostimportantistoknowif:
*thereisasa sfyingclassica on(segrega on)oftheballs
4.5 Analysisoftheresultsandinterpreta onoftheexamplehereabove:
theanalysisofaballmillintheminingindustryisrealizedinordertoknowiftheballchargehasreacheditsequilibrium.
Forthosewhoareinterested,theanalysisoftheresultsandaninterpreta onoftheexamplehereaboveisthefollowing:
Inourexample,thetopsizeis80mmandthetopupis100%of80mmdiameterball.
Inordertointerpretthesamplingresults,wehavetocompareitwiththetheory.
Wetakeintoaccountsizeswith5mmintervalas80,75,70,65...etc
Atheoricalchargeattheequilibriumisachargewherealltheintervalshavethesamenumberofballs,exceptthetopsize
whichhasonlyonehalfofinterval(8077,5mm)andthe10mmsize(12,510mm)becauseweconsiderthata10mmballwill
leavethemill
Let'scalculatethetheore calequilibriumchargeasfollows:

Wecalculatethenumberofballsasfollows:
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Wecalculatethenumberofballsasfollows:

whereN=numberofballs

Allthesizeshave68ballsexcept80and10mmdiameterswhichhave34balls
Summarysheet:

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weplot3chartsinordertocomparetherealityandthetheoryandwehave:

Commentsonthecharthereabove(Number):
Wecanseethanthereisadrama cdecreasefrom50mm.
Therearenotballssmallerthan40mm.
Normallywemustndballsupto1015mminsidetheballmill.

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Commentsonthecharthereabove(Weight):
Onthisgraph,wecanseethesamephenomenon.
Thesurface2representsallthesmallerballswhichdon'texist.
Thesurface1compensatesthesurface2(theremustbeequals).

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Thegraphhereaboveisequivalenttothegraph"Weight"
Lastremarkonthissample:9%oftheballsbetween80and40mmhaveadefect.Thispercentageisrela velyhighand
mustbeinves gated
Otherexample:

Intheexamplehereabove,onecanobservethattherealityisclosertothetheory,especiallyfortheweightchart

5 Conclusion
Themethodpresentedhereisnottheonlyexis ng.
Themostimportantistocollectthenecessaryinforma ontoimprovethegrindingperformance.

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