Ballm Sepol Process

Pag
e1
Process
Ball Mill
L:\DATA\Dept150\Polysius Pres
entation and Training\Polysiu
Training
s Training\Grinding\Ball Mill
+ SEPOL
\ballm_sepol_process.ppt
150 WEI, 140 CD
Krupp Polysius Corp.
Pag
e2
Ball mill
Discharge diaphragm
Intermediate diaphragm
150 WEI, 140 CD
Mill inlet
Mill discharge
Ball filling 2. compartment

Ball filling 1. compartment
Drive
Pag
e3
Polysius cement mill
150 WEI, 140 CD
Pag
e4
A
B
Schematic possibilities of ball grinding
As Training\Grinding\Ball MillB
150 WEI, 140 CD
Cataract movement (Grinding because of impact and friction)

Cascade movement (Grinding because of friction)
Pag
e 5 Movement
entation
and Training\Polysiu
of grinding
media in a ball mill
Movement depends on:
150 WEI, 140 CD
Mill speed
Ball charge
Liner shape
Mill diameter
Ball charge: % of mill volume
Pag
of grinding media in a ball mill
e 6 Movement
entation
Mill revolutions: % of critical speed
150 WEI, 140 CD
Pag
e7
Vcrit: critical speed
Ball
mill
speed
entation
and
Training\Polysiu
balls stay on the mill wall due to centrifugal force
NO GRINDING POSSIBLE!
150 WEI, 140 CD
Vcrit
Vmax: maximum speed
42.3
Di
circa 75% of the critical speed
Vmax
Di
31.7
Di
= diameter inside liners
Pag
e8
Ball charge
1. Compartment:
150 WEI, 140 CD
coarse balls
2. Compartment:
ball filling classified
because of liners
Pag
Example
for ball
size distribution
for Ball Mills in
e9
entation
closed circuit with
a High Efficiency Separator
s Training\Grinding\Ball
Mill
separator (without
pregrinding)
150 WEI, 140 CD
Pag
e 10
Liner
entation
andShape
Training\Polysiu
-Classifying Liners- Mill
150 WEI, 140 CD
1 < 2
1
Flow of material
Mill cylinder
Classifying liner
Pag
e 11
L:\DATA\Dept150\Polysius
Pres
Liner shape
entation
andliners
Training\Polysiu
- Lifting
150 WEI, 140 CD
Mill shell
Lifting liners
Mill rotation
Pag
e 12
entation Ball
and filling
Training\Polysiu
The filling
of the grinding media is as
follows:
s level
Training\Grinding\Ball
Mill
150 WEI, 140 CD
FP(%)
G(tons)
CD L i (D )
4
2
i
FP
CD
= Filling level (%)

= Charge density (approx 4.5 t/m3 1. Compartment)
(approx 4.6 t/m3 2. Compartment)
Li
= Effective grinding length
Di
= Inside diameter
= 3.14
Pag
e 13
Drive power requirement of ball mills
The required power of a ball mill depends on:
150
WEI, 140 CD
length)
Mill size (diameter,
Mill revolution speed
Amount of ginding media (%)
number of grinding compartments
type of material
type of mill liners
type of grinding media
type and length of a pre-drying compartment (if applicable)
Pag
e 14
Calculation
of ball mill power
entation
150 WEI, 140 CD
L
G
P M
M G L
Pag
the power
requirement
at the mill shaft
eEstablishing
15
entation
and
Training\Polysiu
150 WEI, 140 CD
G (tons) Di c
P (kW)
1.36
G weight of ball charge
Di internal diameter
c c-factor
1.36 conversion factor from HP to KW
c-factor [m1.5/s3]
Pag
e 16
Basic c - factor for n = 75 % nkrit
150 WEI, 140 CD
2-compartment mill
Filling degree [%]
Pag
e 17
C - factor
correction
entation
150 WEI, 140 CD
C = cbasic corr. speed corr. Blaine
c - factor correction
Pag
C-factor correction for speed if n 75 % nkrit
e
18
1.1
1.09
1.08
1.07
1.06
150 WEI, 140 CD
1.05
1.04
1.03
1.02
1.01
1
0.99
0.98
0.97
0.96
0.95
0.94
0.93
0.92
0.91
29.7
30.2
30.7
31.2
31.7
32.2
n Di
32.7
33.2
33.7
Pag
e 19
C-factor
correction
for Blaine
entation
Above\ballm_sepol_process.ppt
3500 Blaine:
150 WEI, 140 CD
c decreases as Blaine increases
c is reduced by 0.175% per 100 Blaine
CBlaine
Blaine 3500
1
0.175
10000
Pag
e 20
eff. gear box
Example
drive
losses
entation
and
Training\Polysiu
150 WEI, 140 CD
= 96 %
eff. Motor
= 96 %
eff. Lines
= 99 %
given:
drive efficiency = eff. gear box eff. motor eff. lines
drive efficiency =
0.96
drive efficiency =
0.91 = 91 %
0.96
0.99
Pag
e 21
Drive losses
The losses due to the drive must be taken into consideration with this calculation.
P(shaft)
150
WEI,
140
CD
P(counter)
drive eff.
Drive efficiency:
Ball mill
P(shaft)
Gear box
Motor
eff. gear box
eff. motor
Counter
eff. lines
drive efficiency = eff. gear box eff. motor eff. lines
Pag
e 22
f e
Fineness
conversion
(clinker)
entation
f
= fineness factor
(Bl2 - Bl1 )
0.49 150 WEI,
Bl1140 CD
= new Blaine
1000
Wsp (Bl1 )
Wsp (Bl2 )
f
M2 (Bl2 ) M1(Bl1 ) f
Bl2
= base Blaine
Wsp
= specific work
= power consumption (kWh/t)
M1 = new capacity for new Blaine (t/h)

M2 = base capacity for base Blaine (t/h)
Pag
Example 1: adjustment of capacity (Clinker)
e 23
s Training\Grinding\Ball Mill 2
Conversion of existing system from 3500 to 5000 cm /g (Blaine)
5000) CD
150 WEI,
( (35001000-140
0.49 )
f e
0.4795
Base capacity: M2 = 100 t/h @ 3500 Blaine

Therefore:
M1 100 t/h 0.4795

47.95 t/h @ 5000 Blaine
Pag Example
Pres
1: product fineness vs. mill
capacity
e 24
Capacity (%)
130%
120%
150 WEI, 140 CD
110%
100%
90%
80%
70%
60%
50%
40%
30%
303132 3334353637 3839404142 4344454647 4849505152 5354555657 585960
Blaine ( 100)
Pag
Example
of mill
power consumption (Clinker)
e 25 2: adjustment
entation and
Training\Polysiu
s Training\Grinding\Ball Mill 2
Conversion of existing system from 3500 to 5000 cm /g (Blaine)
5000) CD
150 WEI,
( (35001000-140
0.49 )
f e
0.4795
Given:
Wsp = 35 kWh/t @ 3500 Blaine
Therefore:
Wsp
35 kWh/t
0.4795
73 kWh/t @ 5000 Blaine
Pag
Example 2: adjustment of mill power consumption
e 26
specific work (%)
340%
320%
150 WEI, 140 CD
300%
280%
260%
240%
220%
200%
180%
160%
140%
120%
100%
80%
60%
30 3132 3334 3536 37 3839 4041 4243 44 4546 4748 4950 5152 53 5455 5657 5859 60
Blaine ( 100)
Pag
Pres
KWH/T Shaft
Grindability
(at milland
shaft)
as a function of Blaine
e 27
entation
Training\Polysiu
250
150 WEI, 140 CD
200
kWh/t
150
100
50
Range for Clinker

0
2000
4000
Blaine cm2/g
6000
Pag
e 28
Infuence of fineness and
product/slope on the strength
Mill
of the cement
150 WEI, 140 CD
Example:
3500
Blaine
5000
Blaine
Product Slope
Compressive Strength
after 2 days (N/mm2)
29
49.5
Compressive Strength
after 28 days (N/mm2)
56
65
Pag
29 inspection
entation
Ballemill
and audit
150 WEI, 140 CD
1.
Material level and

distribution
2.
Grinding media and

charge
3.
Shell liners and

diaphragm
4.
Water injection and

grinding aid lances
Pag
e 30
150 WEI, 140 CD
1. Material Level and Distribution
Pag
e 31
Material
load
too low
entation
and
Training\Polysiu
Chamber I
Chamber II
150 WEI, 140 CD
Material level
Chamber I:
No material visible over a section
or over the entire length of the grinding
chamber.
Chamber II:
No material visible on the surface of the
grinding media charge.
Pag
e 32
Material
load
too high
entation
and
Training\Polysiu
Chamber I
Chamber II
150 WEI, 140 CD
Material level
Chamber I:
Large quantities or material above and between
the grinding media
no intensive grinding
Build-up of large material pieces in front of the
intermediate diaphragm
Chamber II:
Grinding media are covered with a 50 to 100mm
thick material layer
low degree of grinding
Pag
e 33
Material
load
normal
entation
and
Training\Polysiu
Chamber I
Chamber II
150 WEI, 140 CD
Material level
Chamber I:
Normal material load: approx. 1/3 of the grinding
media surface lies bare and the grinding media
lies next to each other with the material laying
in the space between
Chamber II:
Normal material load: grinding media are just
projecting on the surface or are just covered with
material
Pag
e 34
Material load normal
Ball Filling
Compartment
entation
and1.Training\Polysiu
150 WEI, 140 CD
Material load too low
Pag
e 35
Material load normal
Ball Filling 2. Compartment
entation
Material load too high
150 WEI, 140
CD
Pag
e 36
150 WEI, 140 CD
2. Grinding Media and Charge
Pag
e 37
Grinding
and charge
entationmedia
To be checked: \ballm_sepol_process.ppt
150
140 CD
Ball size distribution and
ballWEI,
classification
in the 2. compartment
(if mill is equipped with segregation liners)
Shape of grinding balls (worn and/or broken balls) as well as foreign bodies
in the ball charge
Measurement of filling level in the empty mill
Coating of grinding balls
Pag
filling
level in the mill
e 38 Measurement
entationofand
Training\Polysiu
height above ball charge - h
string above ball charge - s
150 WEI,
140 CD
Free liner plates above ball charge
Di
Liners
Ball charge
s
Pag
for measurement
of filling level
e 39 Example
entation
given: h = 2.284 m
(height above ball charge)
150 WEI,
140 CD
s = 3.240 m
(string above ball charge)
Di = 3.44 m
(diameter inside liner)
FP = 21.7
(free liner plates above ball charge
h/ Di
Fl (see diagram)
=
0.664
29.5%
s/ Di
=
0.942
29.5%
360 - (FP x 10)/2

=
71.5
29.5%
Pag
e1 40
h/D\ballm_sepol_process.ppt
i
150 WEI, 140 CD
Filling level of ball charge vs. h/Di -, s/Di - and functions

s/Di
0.9
0.8
200
180
160
0.7
140
0.6
120
s/Di
0.5
100
0.4
80
0.3
60
360 - (FP x 10)/2
0.2
40
0.1
20
0
0
10
15
20
25
30
35
Ball Filling Level (%)
40
45
50
360 - (FP x 10)/2
h/Di
Pag
e 41
150 WEI, 140 CD
3. Shell Liners and Diaphragm
Pag
e 42
Shell
liners
and
diaphragm
entation
and
Training\Polysiu
Shape and150
wearWEI,
of liner140
platesCD
Coating
Shape of slots
Blocking of slots (if blocked, cleaning is required)
Pag
e 43
liners
entationBall
andmill
Training\Polysiu
Ball Mill classifying liners,
Ball Mill lifting liners in \ballm_sepol_process.ppt
good
heavily
condition
150 WEI, 140
CDcoated
Pag
e 44
150 WEI, 140 CD
4. Water and Grinding Aid Injection Lances
Pag
e 45
Water injection
lances
entation
150 WEI, 140 CD
lances should be open and clean
no damages from impact
cleaning air in water spray should be checked
Pag
e 46
Water spray system
Spray lance totally blocked
Spray lance in good condition
150 WEI, 140 CD
Pag
e 47
150 WEI, 140 CD
5. Intermediate and Discharge Diaphragm
Pag
e 48
Intermediate
diaphragm
entation and
and discharge
Training\Polysiu
150 WEI, 140 CD
Diaphragms should be open to assure proper

material and air flow in the mill.
If diaphragms are blocked with worn balls or

material they should be cleaned. If blockage
occurs regularly, broken or worn balls have to be
removed from ball charge.
Pag
e 49
Pres
Diaphragm
Diaphragm
Diaphragm not blocked 150 WEI, 140
CD heavily blocked and
coated with material
Pag
e 50
150 WEI, 140 CD
Longitudinal Sample
Pag
e 51
Longitudinal
sample
(meter sample)
entation and
Training\Polysiu
one sample of approx,
1lb every 1m (approx. 3 ft) ofMill
the mill length
sample should consist of material from outer mill areas and mill center
150 WEI, 140 CD
sample should be taken approx. 25 mm (1 in) below surface
0m 1m 2m 3m 0m 2m 3m 4m...
sampling point
sieve residues and Blaine values should be taken for each sample
results are inserted into a diagram
Pag
e 52
Purpose
of longitudinal
samples
entation
150and
WEI,
140success
CD along the mill
judgment of grinding efficiency
grinding
An optimal ball mill filling will lead to steadily decreasing residues and
increasing Blaine values
A not optimal ball filling will lead to areas where residues and Blaine values
romaine unchanged for several feet of the mill.
Pag
e 53
Mill Longitudinal Sample (Meter Sample)
Mill
Good Example for Longitudinal
Sample
4500
4000
3500
150 WEI, 140 CD
3000
100
90
80
B laine
70
2289 m = 8 M es h
60
Residue %
50
40
30
20
10
0
0
2500
2000
1500
1000
500
0
1089 m = 16 M esh
555,3 m = 30 M esh
321 m = 50 M esh
86,6 m = 170 M esh
72,7 m = 200 M esh
43,2 m = 325 M esh
Meter sample points / m
Bad Example for Longitudinal Sample

3500
100
90
80
70
60
Residue %
50
3000
B laine
2500
1089 m = 16 M es h
2000
321 m = 50 M esh
1500
40
30
1000
20
500
10
0
0
Meter sample points / m
2289 m = 8 M esh
555,3 m = 30 M esh
86,6 m = 170 M esh

72,7 m = 200 M esh
43,2 m = 325 M esh
Pag
e 54
150 WEI, 140 CD
SEPOL
Pag
e 55
SEPOL
Feed Material
150 WEI, 140 CD
Separating Air
Fines
Oversize Material
Pag
e 56
SEPOL SV/x
FEED BOX
DISPERSION
PLATE
Mill
ROTOR BLADES
AIR GUIDE \ballm_sepol_process.ppt
PLATE
150 WEI, 140 CD
GUIDE VANE
AIR INLET DUCT
CYCLONE
SEPARATOR FEED
SEPARATOR REJECTS
VENT AIR WITH FINES
FRESHAIR OR CIRCULATING AIR
REJECT CONE
Pag
e 57
SEPOL SV
FEED BOX
Mill
DISPERSION PLATE
\ballm_sepol_process.pptROTOR BLADES
AIR GUIDE PLATE
GUIDE VANE
150 WEI, 140 CD
AIR INLET DUCT
SEPARATOR FEED
SEPARATOR REJECTS
VENT AIR WITH FINES
FRESHAIR OR CIRCULATING AIR
DISCHARGE BEND
REJECT CONE
Pag
e 58
SEPOL Separator
150 WEI, 140 CD
Pag
Completely
opened
air-inlet
(during commissioning)
e 59
entation
andlouvre
Training\Polysiu
Millare being
Louvres
adjusted to wear pattern
at the rotor
150 WEI, 140 CD
separating
air
Air channels
Pag
e 60
Spiral inlet, guide vanes and rotor
Rotor
150 WEI, 140 CD
Air flow
Guide vanes
Air inlet
Pag
Setting of entation
guide vanes
Commissioning)
e 61
and (during
Training\Polysiu
150 WEI, 140 CD
counter-clockwise rotation
clockwise rotation
Pag
Setting of guide vanes (during Commissioning)
e 62
guide vanes Mill
set to largely tangential
position (6065 to the radial)
150 WEI, 140 CD
max. separating air
speed of separator rotor set to suit

the required cement fineness
Pag
e 63
Separator formulas
SA, SF SG [t/h]: separator
SA (a)
150 WEI, 140 CD feed, separator fines,
separator grits
SG (g)
a, f, g: fineness feed,
fines, grits (Blaine or
residue)
SF (f)
Circulation Factor = SA / SF
= (f - g) / (a - g)
Pag
e 64
100 %
Particleand
Size
Distribution
entation
Training\Polysiu
Area Considered at a Tromp
Curve
150 WEI, 140 CD
Rejects
50%
Fines
Feed
X Particle Size, Q - % Passing

TROMP
CURVE
entation
150 WEI, 140 CD
Separation
Pag
e 65
Fines
Coarse
X Particle Size
TROMP
CURVE
(IDEAL
SEPARATION)
entation
and
Training\Polysiu
150 WEI, 140 CD
Separation
Pag
e 66
Fines
Coarse
Xc Separation Particle Size

Pag
Separation
e 67
100%
100%
90%
80%
Typical Tromp
Curve
150 WEI, 140 CD
Fines
70%
60%
50%
40%
Coarse
30%
20%
10%
0%
10
100
Particle Size (Microns)
1000
Pag
e 68
150 WEI, 140 CD
Grinding Circuits
Pag
The SEPOL in closed grinding circuit with circulating air
e 69
operation
150 WEI, 140 CD
Pag
The SEPOL in closed grinding circuit with direct air operation
e 70
and fresh air supply for fine material cooling (single pass)
150 WEI, 140 CD
Pag
The SEPOL in closed grinding circuit with circulating

71
entation
aire operation.
High
pressure
grinding roll as primary mill
150 WEI, 140 CD
Pag
e 72
operation. Highpressure grinding roll and tube mill in hybrid
Mill
operation
150 WEI, 140 CD
Pag

e 73 SEPOLentation
and
Training\Polysiu
operation.
after high
pressure
grinding roll and tube
Training\Grinding\Ball
Mill
mill forscombination
and finish grinding.
150 WEI, 140 CD
Pag
e 74
Material
flows
in ball
mill circuits
entation
and
Training\Polysiu
150 WEI, 140 CD
23-fold material circulation
Separator
SG(g)
tube mill
SF (f)
85 -90%
collecting
cyclones
SA (a)
10 -15%
100%
feed material F
Mill
waste air
filter
Separator
filter
sampling for
determination of
fineness
100%
finished material F
Pag
e 75
Qconvection,
Q = Heat
Mill
System II
\ballm_sepol_process.ppt Q
Q =Q
150 WEI, 140 CD
Q
Heat balance in ball mill circuits
sepol air
II in
radiation
II out
material
Qconvection,radiation
Qsepol air
Qwater,evaporated
Qfalse air
Qmaterial
Q exit air
Qinlet air
Qmaterial
Qfalse air
Qpower,converted
Qmaterial moisture
QI in = QI out
Qwater spray
System I

Ballm Sepol Process

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Ballm Sepol Process

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Pag

Krupp Polysius Corp.

Ball filling 2. compartment

Krupp Polysius Corp.

Krupp Polysius Corp.

Cataract movement (Grinding because of impact and friction)

Krupp Polysius Corp.

Krupp Polysius Corp.

Ball charge: % of mill volume

Krupp Polysius Corp.

circa 75% of the critical speed

Krupp Polysius Corp.

= diameter inside liners

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

= Filling level (%)

= Effective grinding length

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Filling degree [%]

C = cbasic corr. speed corr. Blaine

Krupp Polysius Corp.

Krupp Polysius Corp.

c is reduced by 0.175% per 100 Blaine

Krupp Polysius Corp.

eff. gear box

drive efficiency = eff. gear box eff. motor eff. lines

Krupp Polysius Corp.

eff. gear box

drive efficiency = eff. gear box eff. motor eff. lines

Krupp Polysius Corp.

Krupp Polysius Corp.

M1 = new capacity for new Blaine (t/h)

Base capacity: M2 = 100 t/h @ 3500 Blaine

M1 100 t/h 0.4795

Krupp Polysius Corp.

Krupp Polysius Corp.

Wsp = 35 kWh/t @ 3500 Blaine

73 kWh/t @ 5000 Blaine

Krupp Polysius Corp.

Krupp Polysius Corp.

Range for Clinker

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Material level and

Grinding media and

Shell liners and

Water injection and

1. Material Level and Distribution

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Material load normal

Krupp Polysius Corp.

Material load too low

Krupp Polysius Corp.

2. Grinding Media and Charge