Ball Mill Workshop, South Asia 27thSept -1stOct 2010

2. Cement ball mill system basics

Holcim Group Support Limited 2010

 Systems Overview

Tube mill Tube mill with pregrinding unit Finish grinding system

Roller Press Roller press

Open circuit
Tube mill

Crusher

Close circuit

Vertical roller mill

Vertical mill

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 Ball Mill with Cage-Rotor Separator

Clinker Gypsum Limestone Slag

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 Pre Grinding system
Roller press with slab recirculation

Clinker

Slag
Lst
Gy

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 Vertical roller mill pre-grinder on closed circuit over a screen
6

8
7
2

3
4 10

1 5

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 Roller press in closed circuit over a dynamic separator

2
3

4
8
5
10
7
1

9
KO, DO type / Fines to ball mill inlet 6
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 Roller press in closed circuit over a dynamic separator

2 3

8 10
4

5 7

Fined to separator ball mill (e.g. S3, TC, NO)

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 Roller press in closed circuit over a dynamic separator

2 3

4
1

5 10
7

Final product is a mix of the separator fines of the roller press and the separator fines of the ball mill
(similar to Palavi). 8
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 Finish Grinding System
Vertical roller mill

Gypsum Limestone Slag

Clinker

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 Finish Grinding System
Horizontal roller mill

Gypsum Slag

Clinker

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 Summary of System Comparison

System Pre-Grinding Semi-Finish Grinding Finish Grinding

Equipment Roller Press Vertical Mill Roller Press Vertical Mill Horomill Roller Press
with Static Dynamic
screen Separator
Spec. Energy
[%] -9 -9 -10 -14 -17 -30 -35 -38
Saving
Capacity Increase [%] +30 +30 +40 +100 +100 N/A N/A N/A

Comments: Moderate energy

Low energy savings High energy savings
savings
Only justified for capacity Only justified for For new installations or additional
increrase capacity increrase mill
Complex systems with many pieces of equipment Straight forward systems
New technology grinding equipment requires:
more maintenance skills
more automation and equipment protection (reducers)
more operation skills and eqipment attention

100 % = Ball mill with cage rotor separator

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 Ball Mill EDM

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 High Efficiency Separator - EDM

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 Roller Press

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 2.2 Ball mill basics

Holcim Group Support Limited 2010

 What is a ball mill?

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 Grinding with a ball mill

Fine grinding
(2nd chamber)

Coarse grinding
(1st chamber)

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 Mill feed

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 End discharge mill (EDM)

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 Central discharge mill (CDM)

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 Shell liners for coarse grinding

Rotation sense

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 New Development of Magotteaux X-Lift

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 Intermediate diaphragm

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 Shell classifying liner for fine grinding

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 Outlet diaphragm

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 Grinding media for ball mills
Coarse grinding 90 60 [mm]

Fine grinding 50 17 [mm]

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Fig.4 : Filling degree f in function of free 0,75
height
height h above
h above grinding
grinding media
media charge
charge Di = Mill diameter
Ball filling degree (f) 0,70

0,65
h h
D D 0,60 filling degree [%]
20 25 30 35

D
h h
D

Fig.5 : Alternative way to determine

0,750,75 the free height

Di = Mill diameter Di + d
Di = Mill
h =diameter+ h'
0,70 2
0,70

0,65
0,65

0,60 filling degree [%]

0,60
20 25 f [%] filling degree [%]
30 35
20 25 30 35

Fig.5 : Alternative way to determine 27

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Fig.5 : Alternative way to determine Tube Mill Dimensioning
Kma 5.1.99
Fig.7 : Critical
Mill critical speed mill speed
FC FC =centrifug
FC =centrifugal force [N]
FG =force of g
FG =force ofcritical
Definition gravity [N]
Di =mill diam
Di =mill diameter inside liner
speed: w =angular s
w =angular speed [s-1]
g =gravity [
FG g =gravity [ms-2]
FC = FG

Di
w
42,3 42,3
n crit = n crit = [min -1
]
Di Di
k = speed
k = [%] of critical [%] of critical speed

n =k * nn cri t = k * n cri t [min -1 ]

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