Ball Mill Calculations

Ambuja Cement Rajasthan Limited
Ball Mill Performance & Efficiency

S.
Description
Symbol
Formula
Example
No.
1
Arm of gravity
0.666 * ( 1 - 4 * R2 )1.5
Torque factor matrix
TAN [ 0.5 / R * (1 - 4*R ) ] - [ 2*R * (1 - 4*R )

-1
2 0.5
0.583
Deff
4.18
Centre Distance (from mill centre to media top layer), mts
0.139
Deff
Mill effective diameter, mts
0.578
h/Deff, ratio of centre distance to mill effective diameter
Target
u
Material
Grinding
Coars e/Medium
Cem ent
&
Raw
Meal
Fine
Coal
Power consumption, net
2 0.5
Coars e/Medium
Medium
Pn
kW
Fitting
None
None
Danula
Sonex
None
None
Danula
Danula
None
Danula
Type
Balls
Rods
Balls
Balls
Balls
Cylpebs
Balls
Cylpebs
Balls/Cylpebs
Cylpebs
0.514 * F * u * n * Deff * a
Torque
0.73
0.55
0.75
0.66
0.69
0.73
0.71
0.75
0.69
0.71
175
Grinding media weight, tons
0.73
Torque factor
16
Mill speed, rpm
Deff
4.18
Deff
0.578
Arm of gravity, -
Pn
2538
Target
3
Power consumption, gross
New production rate

(Mill output Vs. Blaine)
Pg
Pn * 100 * 100
Pn
2450
kW
Em * Eg
Em
95
Em
Motor efficiency, %
Eg
95
Eg
Gearbox/girth gear efficiency, %
Pg
2715
Target
4
NPB
tph
Formula-1
OPB
OPB
OB
118
4000

S.
Description
Symbol
Formula
Example
No.
Exp ( ( NB - OB ) * 0.49 / 1000 )
NB
OPB
Old production rate, tph
NPB
OB
Old blaine, cm2/gm
Target
NB
New blaine, cm2/gm
Formula-2
OPB
OPB * ( OB / NB )
New production rate

(Mill output Vs. Residue)
OB
Old blaine, cm2/gm
NPB
NB
New blaine, cm2/gm
Target
( 2 - log ( NR ) )
OPR
150
OR
11.5
NR
9.5
OR
Old residue, %
NPR
138
NR
New residue, %
Target
Scem
2.1
Pu
90
21500 * ( Scem - Sclk )
(at weigh feeder)
tph
Pu * ( 100 - Fgyp )
Scem
Target SO3 content in cement, %
Sclk
0.3
Pu
Gypsum purity, %
Fgyp
4.8
Sclk
SO3 content in clinker, %
GSP
4.52
Fgyp
Free moisture in gypsum, %
MBS
%F
GSP
%Filling
88
OPR
Gypsum set point
Maximum ball size
118
5000
NB
tph
4000
OPR * ( 2 - log ( OR ) )
72
OB
OPB
NPR
mm
1.3
5000
36 * F
0.5
* { ( SG * Wi ) / ( %C * Deff
Target
0.5
)}
0.333
15
Feed size (sieve size in mm which retains 20% material), mm
SG
SG
Specific weight of feed material, gm/cm3
Wi
15
Wi
Bond's work index, kWh/t
%C
75
%C
Mill speed as %critical, %
Deff
5.1
Deff
MBS
90
Target
112.5 - ( 125 * h / Deff )
2.5

S.
Description
Symbol
Formula
Example
No.
%
Free height, mts
Deff
4.155
Deff
%F
37.3
Target
9
Circulation factor
Formula-1
F+G
F
F
Fresh feed rate, tph
Coarse return, tph
Formula-2
10 Circulation load
FF
150
CR
170
2.13
Target
2-3
Rg
54.92
Rg - Rf
Rf
3.52
Rg - Rm
Rm
34.16
Rg
Residue of coarse return, %
2.48
Rf
Residue of fines, %
Target
2-3
Rm
Residue of separator feed, %

C
2.48
CL
148
CL
%
( C - 1 ) * 100
C
Circulation factor, -
Target
11 Separator efficiency
SE
Formula-1
Ro
100
[log(Ro/Rf) - C * log[{Ro+(C-1)*Rg} / {Rf+(C-1)*Rg}]]*100
Rf
3.52
log(Ro/Rf) - C * log[{Ro+(C-1)*100} / {Rf+(C-1)*100}]
2.48
Ro
Residue of fresh feed, %
Rg
54.92
Rf
Residue of fines, %
SE
68.8
Target
Rg
Formula-2 (Fines Efficiency)

( 100 - Rf ) * 100
70-80
Rf
3.52
Rm
34.16

S.
Description
Symbol
Formula
Example
No.
( 100 - Rm ) * C
59.1
Residue of fines, %
SEf
Rm
Target
70-80
Circulation factor, Rg
54.92
2.48
Rm
34.16
95.9
Rg * ( C - 1 ) * 100
C * Rm
Rg
SEc
Target
Rm
nc
rpm
2.48
Rf
Formula-3 (Coarse Efficiency)
12 Critical speed
42.3 / Deff0.5
Deff
Deff
4.15
Pn
20.8
Target
New production rate

NPR
Formula-1
OPB
tph
70-80
118
OPB
OB
4000
Exp ( ( NB - OB ) * 0.49 / 1000 )
NB
5000
OPB
OB
Old blaine, cm2/gm
NB
New blaine, cm2/gm
Formula-2
OPB * ( OB / NB )
NPR
72
OPB
118
OB
4000
OPB
NB
5000
OB
Old blaine, cm2/gm
NPR
NB
New blaine, cm2/gm
1.3
88

S.
Description
Symbol
Formula
Example
No.
2
New Specific power cons.

(sp. power Vs. Blaine)
Formula
NPR
E1
E (S1 / S)n
kWh/TC
1 New production rate

NPR
New specific power
32.5
Old specific power
S1
5000
S1
New Blaine
4000
Old Blaine
1.3
Mill exponent for close ckt = 1.3
E1
43.44
OPB
118
Formula
tph
2 New Specific power cons.

(sp. power Vs. Blaine)
E1
OPB * ( OB / NB )1.3
4000
5000
OPB
NB
OB
Old blaine, cm2/gm
NPR
NB
New blaine, cm2/gm
Formula
NPR
OB
E1
E (S1 / S)n
88

S.
Description
Symbol
Formula
Example
No.
kWh/TC
E1
New specific power
32.5
Old specific power
S1
5000
S1
New Blaine
4000
Old Blaine
1.3
Mill exponent for close ckt = 1.3
E1
43.44
100
3000
3500
1.221

Ball Mill Calculations

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Ball Mill Calculations

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Ambuja Cement Rajasthan Limited

Ball Mill Performance & Efficiency

Torque factor matrix

TAN [ 0.5 / R * (1 - 4*R ) ] - [ 2*R * (1 - 4*R )

Centre Distance (from mill centre to media top layer), mts

Mill effective diameter, mts

h/Deff, ratio of centre distance to mill effective diameter

Power consumption, net

Grinding media weight, tons

Mill speed, rpm

Mill effective diameter, mts

Power consumption, gross

New production rate

Gearbox/girth gear efficiency, %

Ambuja Cement Rajasthan Limited

Ball Mill Performance & Efficiency

Old production rate, tph

Old blaine, cm2/gm

New blaine, cm2/gm

New production rate

Old blaine, cm2/gm

New blaine, cm2/gm

21500 * ( Scem - Sclk )

(at weigh feeder)

Target SO3 content in cement, %

SO3 content in clinker, %

Free moisture in gypsum, %

Old production rate, tph

Gypsum set point

Maximum ball size

Old production rate, tph

Feed size (sieve size in mm which retains 20% material), mm

Specific weight of feed material, gm/cm3

Bond's work index, kWh/t

Mill speed as %critical, %

Mill effective diameter, mts

112.5 - ( 125 * h / Deff )

Ambuja Cement Rajasthan Limited

Ball Mill Performance & Efficiency

Free height, mts

Mill effective diameter, mts

Fresh feed rate, tph

Coarse return, tph

Residue of coarse return, %

Residue of separator feed, %

[log(Ro/Rf) - C * log[{Ro+(C-1)*Rg} / {Rf+(C-1)*Rg}]]*100

log(Ro/Rf) - C * log[{Ro+(C-1)*100} / {Rf+(C-1)*100}]

Residue of fresh feed, %

Residue of coarse return, %

Formula-2 (Fines Efficiency)

Ambuja Cement Rajasthan Limited

Ball Mill Performance & Efficiency

Residue of separator feed, %

Residue of coarse return, %

Residue of separator feed, %

Formula-3 (Coarse Efficiency)

Mill effective diameter, mts

New production rate

Exp ( ( NB - OB ) * 0.49 / 1000 )

Old production rate, tph

Old blaine, cm2/gm

New blaine, cm2/gm

Old production rate, tph

Old blaine, cm2/gm

TAN [ 0.5 / R * (1 - 4R ) ] - [ 2R * (1 - 4*R )

[log(Ro/Rf) - C * log[{Ro+(C-1)Rg} / {Rf+(C-1)Rg}]]*100

log(Ro/Rf) - C * log[{Ro+(C-1)100} / {Rf+(C-1)100}]