How to manage the ball charge level

Grinding

PR-GRI P07-04 V1.0

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Introduction
Ball charge level management is a basic part of ball mill optimisation.
Keep ball charge load at the target level with regular top-ups
The mill motor kW can also give a good picture of the ball charge load change. If available, follow this
value on a weekly basis.

Objectives
To reduce specific energy consumption (minus 5% of kWh/t was achieved in some cases by proper ball
charge management)

To adjust ball mill output to the production needs

Prerequisites
Already optimised ball charge distribution and ball charge load, in case of product portfolio change reoptimisation is necessary

See the rule of thumb values for ball charge load to achieve either min. kWh/t or max. production:
Minimum kWh/t
(non sold-out market)
1st compartment

26-28 %

2nd compartment

28-30 %

3rd compartment

28-30%

The maximum filling level needs to be adapted to the mill trunnion opening and diaphragm ventilation
diameter.

Measure ball charge level every 1 to 3 months.

Tools
Free height measuring tool (you can use just a steel measuring tape).

1 Job Aids > Volume load calculation spreadsheet

Procedure Template developed by

How to manage the ball charge level

Grinding

PR-GRI P07-04 V1.0

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Action Steps
1.

Purge the mill

Purge the mill completely (10 minutes maximum)
Safety measures: Be sure safety requirements are met for the internal mill inspection (lock-out/tagout/try-out procedures).

2.

Enter the mill and measure free heights

Enter the mill and measure free heights along the centreline of the mill, from the top of the ball
charge to the top of the mill.

Measure on a flat part of ball charge. Dont measure from high/low spots.
For the top of the mill, measure to an average liner thickness.
Measure the heights at the minimum of:

3 locations in the 1st compartment

4 locations in the 2nd/3rd compartment
Distribute locations evenly throughout the compartment.

3.

Check internal diameter of the mill

Check the internal diameter of the mill during a mill internal inspection (only if this value is not at
disposal).

4.

Calculate the ball charge load

Calculate the ball charge load based on mill diameter and free height measurement.

1 Volume load calculation spreadsheet

5.

Add balls to get back to the ball charge target

Add balls to get back to the target ball charge load or mill absorbed power
Usually, the biggest balls (for a given compartment) are used to fill-up the mill.
Keep good records of top-ups

1 Job Aids > Volume load calculation spreadsheet

1 Job Aids > Ball charge design spreadsheet

Procedure Template developed by