Grinding with ball mill systems

5. Ball charge management

Ball charge management

Ball charge

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Ball charge management

As the balls wear

Mill absorbed power reduces

Grinding efficiency reduces

So does production Top up for wear compensation

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So does production Ball charge classification

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Top up for ball wear compensation (1/5)

While a 90 [mm] becomes an 80 [mm] an 80

[mm] becomes a 70 [mm] and so on

90 [mm]

80 [mm]

70 [mm]

< 30 40 [mm] wear slower than bigger balls

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Top up for ball wear compensation (2/5)

Replace the missing balls

90 [mm]

80 [mm]

70 [mm]

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Top up for ball wear compensation (3/5)

First chamber:

Biggest ball size

1. Compartment
Ball [mm] Weight [ t ] Percent [%] Wear comp. [%]

90 80 70 60

20.0 28.0 20.0 12.0

25.0 35.0 25.0 15.0

100.0

Total Average ball weight Spec. media surface

80.0 [g] [m2 / t]

100 1667 10.2

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Top up for ball wear compensation (4/5)

Second chamber:

3 balls sizes required

2.Compartment
Ball [mm] 50 40 30 25 20 17 15 Total Average ball weight Spec. media surface 170.0 [g] [m2 / t] 100 41 32.8 Weight [ t ] 17.0 17.0 27.2 27.2 35.7 45.9 Percent [%] 10.0 10.0 16.0 16.0 21.0 27.0 50.0 35.0 Wear comp. [%] 15.0

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Top up for ball wear compensation (5/5)

Frequency

Regular production intervals Regular time intervals (e.g.: targeting a constant absorbed power for the mill motor)

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Net & gross wear rate calculation

Scraps S = 1 [t]

Wear compensation WC = 24 [t]

Small balls SB = 3 [t]

Good balls GB = 78 [t]

Initial charge IC = 80 [t]

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Cement production TC = 700000 [t]

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Net & gross wear rate calculations

Gross wear = IC + WC GB TC Gross wear = 80 + 24 78 700000 X 1000000 = 37.1 [ g ball / t cement ] X 1000000 [ g ball / t cement ]

Net wear =

IC + WC GB - SB - S TC

X 1000000 [ g ball / t cement ]

Net wear =

80 + 24 78 - 3 - 1 700000

X 1000000 = 31.4 [ g ball / t cement ]

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Top up for ball wear compensation

The ball quantity to compensate wear (BWC) depends

on the net wear (NW) and the annual cement production (ACP).
BWC = ACP x NW x 10^-6 [t/a]

NW1 = 30 [g/t]

NW2 = 20 [g/t]

ACP = 700000 [t/a] BWC = 700000 x 30 x

ACP = 700000 [t/a] BWC = 700000 x 20 x 10^-6 =

x 10^-6 =

= ~ 21 [t/a] 26 [%] of initial ball charge weight

= 14 [t/a] 8 [%] of initial ball charge weight

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Ball charge classification (1/4)

Deformed & broken balls sorted out mechanically/manually

Balls in bucke t t Balls sam pled -Sam ple w eight kg Dia m . Equival. m m Com position % Number of balls --

7.2 200 85.3 47 4 16'882

11.1 200 38.5 36 7 57'662

25.2 200 18.2 28 15 276'923

30.7 89.8 200 200 9.5 4.5 23 18 18 53 646'316 3'991'111

0 0.0 0 0 0

Scra ps Tota l 6.0 170.0 0 200 0.0 2.9 0 15 0 4 31 [g] 0 413'793 37.1 [m2

200 balls per sample in the second chamber

100.00

50 balls per sample in the first chamber

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Ball charge classification (2/4)

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Ball charge classification (3/4)

Visual criteria for ball form classification

(deformed/broken)

Bad

Good
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Ball charge classification (4/4)

Standard frequency for ball charge classification

First chamber

Second chamber

Once every year

Once every two three years: Once every one two years:
- Composite cements (>> 5 [% MIC) - Slag - Puzolana - OPC - OPC + < 5 [%] MIC

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Ball charge operating cost

USD/tcemnt e Purchasing Electrical energy Classification 0.05 1.30 4.40 0.03 0.05 1.38 - 4.50
50 [g/t] gross wear 40 [kWh/t] Standard frequency

Classification costs are 1-4 [%] of energy costs. Therefore sensible to classify the charge at standard intervals.
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