BALL MILLS & SEPARATORS

Ankit Agrawal (AAL)

Samar Sharma (SSA)
Surbhi Bajaj (SBJ)
Yash kalra (YK)
OVERVIEW
 Introduction
 Circuit of Ball Mill
 Mechanism
 Design of Ball Mill
 Energy Consumption
 Variants of Ball mill
 Instrumentation
 Introduction of Air Separators
 Principle
 Forces on a Particle
 Power Requirement
 Separator design
 Types of separators
 Various makes of separators
 Maintenance
WHAT IS A BALL MILL?

 It is a device used for size reduction.

 It can reduce sizes of 1/4 inches to 20-75 micron
 Cylindrical in shape
 Rotates on a horizontal axis
 Partially filled with the material to be ground and the grinding
medium
ADVANTAGES

 It is a well-established technology.
 It is a simple technology not requiring many moving parts.
Hence, it is a robust construction.
 It is possible to re-circulate the ground material and
achieve finer grinding. It is also possible to regulate the
amount of re-circulated product to control final product.
 Apart from grinding ball mills are also used for mixing.
 By using different media in the same drum, we can process
a wide variety of feed.
COMPONENTS OF BALL MILL
OPEN & CLOSED CIRCUIT MILL
OPEN & CLOSED CIRCUIT MILL
 In open-circuit grinding the ball-mill discharge passes
directly to the next processing step without being screened
or classified and no fraction is returned to the ball mill

 In closed-circuit grinding the ground material, undersize,

in the ball-mill discharge is removed either using a screen
or a classifier with the oversize being returned to the mill
for additional size reduction

 The over size material that is returned to the ball mill is

called the circulating load
OPEN & CLOSED CIRCUIT MILL

 Open-circuit ball-mill grinding requires more power than

closed-circuit grinding for products containing similar
amounts of top-size material

 Example, assuming the desired grind size is 90% passing

some specific top size, open-circuit grinding would require
1.40 times the power to achieve similar results as closed-
circuit grinding
GRINDING MECHANISM
 The grinding is primarily done by the grinding media
(balls) by a cascading effect.
 The cylinder is rotated along with the charge and action is
similar to tumbling.
 Due to the centrifugal action of the rotating cylinder,
particles are carried towards the top, after which they
break contact from the wall and fall down. This angle is
called “angle of break”.
GRINDING MECHANISM

 Grinding occurs primarily due to the impact when falling

particles strike the bottom.
 Grinding also occurs (to a lesser extent) by the slipping and
rolling of particles over one another.
 The speed of rotation and angle of break are important
parameters.
CHOICE OF MEDIA

 Initial feed size – Smaller particles cannot break up larger

ones
 Final particle size – For fine grinding, small sized media are
effective
 Density – Heavier and more dense particles give better results
 Hardness – Harder media undergo much less wear and
contaminate the product less
 Other considerations include costs, pH resistance, adsorption
properties that may affect the charge
CHOICE OF MEDIA
 Media should also be chosen according to application.
Typical examples are flint or pebbles (less hard), stainless
steel and metal balls (undergo corrosion), porcelain balls,
some specially designed high density media
 Advantages of using smaller media
 More grinding contacts per revolution
 Provide smaller voids, reducing the chance of agglomeration
 More uniform grinding.
OPTIMAL RUN

 The voids of the media must be covered by the material to

be ground otherwise there will be too much wear of media
and contamination will occur.
 The speed of running typically ranges from 65-80% of the
critical speed.
 Fastest grinding occurs where there is just sufficient
material in a batch to fill all voids and slightly cover the
grinding media.
 This is 25% of the total volume with a half ball charge and
18% with a one-third ball charge.
OPTIMAL RUN

 Batch sizes typically don’t exceed 60% in a conventional

ball mill. And, time taken to grind increases faster than the
batch size.
 Only 1-2% of the energy supplied is actually used in the
fracturing process. The rest is released as heat.
 For this reason, a current of air is passed through the mill
to keep it cool and sweeping out excessive moisture (dry).
CRITICAL SPEED
 Speed at which the contents of the mill would simply ride
over the roof of the mill due to centrifugal action.
 The critical speed (rpm) is given by:

nc = 42.29/√d
Where “d” is the internal diameter in meters.
 Ball mills are normally operated at around 75% of critical
speed, so a mill with diameter 5 meters will turn at around
14 rpm.
DESIGN CRITERIA FOR BALL MILL

D = 124.2*(C) + 485.7
L = 85.71*(C) + 185.4
Where
“C” = Capacity of Feed (Tons)
“L” = Length of mill (mm)
“D” = Dia. of mill (mm)

 Volume of Mill is given by

{( π /4) * (D2 * L)}
DESIGN CRITERIA FOR BALL MILL

 The Bulk Volume of balls charge ratio to the volume of mill

is known as “Filling Ratio” ( range 30 – 45 % )
F = (bulk volume of the balls / volume of mill)
 So
bulk volume of balls = ( F ) * {(π/4) * (D2 * L)}

 Size of Balls
D2 { ball } = k * Dp
Where k is a constant ranges from 0.9 to 1.4
 Mass of Balls
Mass of the balls = bulk vol. of balls * bulk density of balls
Bulk density of ball = {(1-ε) * (density of ball)
ENERGY CONSUMPTION AND OUTPUT
oThe power (in kW) required to turn a ball mill (cement mill) is
approximated by:
P = 0.285 d (1.073-j) * m * n
where
“D” = Internal diameter in meters,
“j” = Fraction of the mill volume occupied by media
“m” = Total mass of media in the mill, in tones
“n” = Mill speed in rpm

Energy Required in a ball mill is directly proportional to

• Material Hardness
• Fineness required
 Typical mill power consumption for various degrees of fineness. Actual values vary
according to mill system efficiency and clinker hardness.

• About 1-2% of the energy supplied is used in fracturing particles, and the
remaining energy ends up as heat which has to be dissipated by the mill system
ELECTRICAL ENERGY CONSUMPTION
VRM VS BALL MILL (RAW MILL)

30
25
20
15
10 19
15
5
0
VRM BALL MILL
TYPE OF MILL
 ELECTRICAL ENERGY CONSUMPTION
VRM VS ROLLER PRESS & BALL MILL (CEMENT GRINDING)

40
35
30
25
20
15 32
27 26
10
5
0
VRM RP + BM BALL MILL
TYPE OF MILL
VARIANTS OF BALL MILL
 Drive System
 Wet/Dry Ball Mill
 Multi Chamber Ball Mill
ACCORDING TO DRIVE SYSTEM
 Drives for tube mills can be of most different design. The
following criteria are decisive for the selection:
• Power to be transmitted
• Space requirement
• Type of mill bearing

 Modern drive systems should require only little

maintenance and meet the highest standards as regards
noise emission, temperature- resistance and safety.
GIRTH GEAR DRIVE

up to 6,000 kW
CENTRAL DRIVE

from 2,000 to 8,000 kW

CIRCUMFERENTIAL DRIVE

from 3,000 to 10,000 kW and more

MULTI CHAMBER MILL
Single Chamber overflow Mill:
In the case of this design, the length of
the mill cylinder is maximally utilized.

Single-chamber tube mill with

discharge wall:

•Used for wet grinding and dry

grinding.
•The width of the slots in the
discharge diaphragm determines the
maximal grain size in the mill
discharge material
Two-chamber tube mill

This design is used for wet as well as for dry

grinding.

•The first grinding chamber is normally

equipped with a lifter lining and filled with
coarse grinding media for the preliminary
comminuting of the grinding material.

• Via the width of the slots in the

intermediate diaphragm, the maximal grain
size of the grinding material transferred to the
second grinding chamber is limited.
•The second grinding chamber is filled with
smaller grinding media. The two-chamber tube mill
is the typical mill for grinding systems with
separators.

Three-chamber tube mill

These systems are used for wet as well as for dry

grinding. For dry grinding, in an open circuit, for
wet grinding also in connection with screens or
hydro-cyclones
Two-chamber tube mill with Circumferential
discharge:

This design combines two mills to one tube.

It is used for dry grinding or combined grinding

and drying.

Depending on the plant configuration,one

chamber can be used as preliminary
grinding chamber and the other one, after the
previous separation of the material discharged
from the first chamber,as fine grinding
chamber.

If required, both grinding chambers can be

heated.
Two-chamber tube mill with circumferential
discharge and drying chamber connected in
front:

The preliminary grinding chamber is preceded

by a drying chamber. To achieve an as uniform
distribution of the grinding material over the drying
chamber cross section as possible, the drying
chamber is provided with lifters.
COMPONENTS OF BALL MILL
SHELL LINING PLATES
These plates are specially designed and incorporate contour
features which inject movement into the ball charge during
rotation of the mill.

Properties required by the plates vary along the length of the

mill. For instance, at the inlet region of the mill there is likely to
be less protection of the plates by ground products and the balls
will be of largest size in use and therefore, toughness is of
outmost importance. However, along the length of the mill, in
second and third chambers, the ball size is considerably
smaller and a protective layer of ground material is available
and here wear resistance must be at a maximum.
Effect of Lifters
 Lifters are protrusions on the wall of the mill that
help in lifting the material to a greater height and
increasing the angle of break.

 The effectiveness depends on the shape and

number of lifters.

 Another advantage is that it increases the life of

lining because typically lifter undergo most wear
and are easy to replace.
  Types of Liners:
1. Bolted Lines
2. Boltless Liners

Advantages of Boltless Liners:

1. Output Increased 8-10 %
2. Power Consumption Reduced 8-20 %
3. Repair Decreased 98 %
4. Liner Consumption Reduced 8-20 %
DIAPHRAGM
 FUNCTIONS OF THE DIAPHRAGM:
 Separation of the grinding media fillings of two grinding
chambers or retaining the grinding media in the grinding
chamber in the case of discharge diaphragms.

 Restriction of the maximal grain size of the grinding material

which is transferred from one grinding chamber into the following
one as a function of the slot width.

 Transport from the grinding material from one grinding

chamber into the following one or from the grinding chamber into
the mill discharge.
 Requirement Of Diaphragms:

Ensuring a grinding material level in the grinding chambers

optimal for the grinding process.

As Large free cross section as possible to ensure a sufficient

ventilation in the mills.

Utmost stability and safety of the frames and the fastening

system of the diaphragms.

High Wear resistance and security against fracture of the

slotted plates and back wall plates.
TYPES OF DIAPHRAGMS

A. Intermediate diaphragm
B. Discharge diaphragm
C. Central discharge Diaphragm
D. Central discharge diaphragm
with separation of the material
streams
In Any Grinding Circuit, There Are But A
Few Basic Objectives

• Reduce the size of the incoming feed to produce a final

product.

• Reduce the size of the feed material to a size where valuable

minerals can be liberated and recovered in a subsequent
process.
 Reject much of the undesired material to simplify further
processing.

 Accomplish the above objectives at minimum cost.

The second and third objectives listed, apply to beneficiation of

metallic ores while the other two are characteristic of grinding
circuits in general.
 Due to the complexity of a grinding circuit, it is difficult if
not impossible for an operator to manually achieve the
best results from a circuit.

 Variables within a circuit contribute to make measurement and

control of certain parameters necessary to achieve optimum
performance from the circuit.
These Variables Include
• Ore type changes
• media loading
• liner wear
• pump dilution
• classifier feed pulp density
• reagent additions
• water pressure changes
• pump speed and wear
• sump segregation
• viscosity
• product particle size, etc.
Within A Grinding Circuit There Are A Number Of
Parameters That Can be Measured Among These
Parameters Are The Following:

 Horsepower – can be determined from standard mill amp

meter measurements. Horsepower is dependent upon mill
speed, media load, ore specific gravity, pulp dilution and type
and condition of liners.

 Sound from the mill – Amplitude of mill sound is measured

with non relevant frequencies filtered out. Sound can be an
indicator of mill loading. Eg: Electronic Ear
 Throughput – can be measured with load cells on the mill feed
belt. Throughput is measured as an indication of the quantity of
final product produced. Also, it is a means of determining the
amount lf makeup water to add to a wet grinding application. Eg:
Belt weigher

 Cyclone feed sump level – can be measured using a bubble

tube, ultrasonic measurement, nuclear absorptions
capacitance or differential pressure measurements. Cyclone
sump level is a good indicator of circulating load in a grinding
circuit. Eg: Level sensors
 Mass flow – can be determined by a density measurement from
a magnetic flow meter. Mass flow can be used to regulate
reagent additions and compute mass balances.

 pH – can be measured by standard electrodes. pH can effect

the formation of colloidal suspensions from metallic
hydroxides. Colloidal suspensions can alter density and have a
significant effect upon classification.
 Ball mill head water – can be measured from the pressure
drop across an orifice plate. Mill head water controls pulp density
and affects grinding efficiency. Eg: Pressure sensors

 Density – often measured by nuclear absorption. Density is

significant in classification, flotation, and grinding mills. Eg:
Density Gauges

 Particle size of the classifier product – can be determined by

screen analysis, direct measurement or inferential
technique. Particle size is significant for liberation of valuable
minerals and in establishing the proper trade off between
throughput and recovery to assure best economic operation and
minimizing over grinding to curtail ore beneficiation costs.
 Separator:
 Pressure at Inlet and Outlet .

 Temperature Monitoring at:

1. Motor winding
2. Bearing
3. Gear Box
4. Separator Inlet and Outlet.

 Flow Measurement.
Electronic Ear
The Fill Level of the Ball Mill is optimized according to the
production requirements.

The fill level is measured by an electronic ear.

This captures a broad spectrum of frequencies which simplifies

the filtrating of external sources such as neighboring mills.

The ear measures and memorizes the frequencies of each mill.

Salient Features:

 Enable optimization of mill operation.

 Eliminates excessive dependence on the operator.

 Precautionary measures can be taken before jamming occurs.

 Suitable for double and single chamber mills.

 Helps in close circuiting and automation of the mills.

LATEST DEVELOPMENT

INSTRUMENTED BALL FOR BALL MILLS

 This technology relates to measuring and determining the

internal dynamics and kinematics of a ball within an
operating ball mill.

 The novel device is an instrumented ball capable of

recording data from an industrial mill. A variety of sensors,
including accelerometers, gyros, strain gauges, microphones,
thermocouples, wear sensors, etc. form the instrument
package.
The data collected by the instruments within the ball allow the
determination of the force, the moments and the rotational kinetic
energy as a function of time.

This technology will allow for Verification and Tuning of the models.

Thus , with better models , the operation parameters will improve

leading to Steel and Energy savings for ball mill operations.

This technology will help the mining industry optimize its milling
performance through:

1. Increase energy efficiency.

2. Reduced ball consumption through optimized ball to rock
ratio.
3. Improved equipment life.
4. Reduction of operation costs, and better design of balls and
liners.
AIR SEPARATORS
AIR SEPARATORS
 Definition
 It is the division of a given material stream into
two separate streams using air as a carrying
medium.
PRINCIPLE
 Action of an air current of a certain velocity upon
a mass particle is proportional to the surface
presented by this particle to the air current. Thus
to the square of mean dimension of the particle.
 Action of force of gravity upon a mass particle is
proportional to the volume. Thus to the cube of
mean dimension of particle.
PRINCIPLE
 If these two forces are concurrent, the force of
gravity will prevail over the effect of air current
as particle dimension increases.
FORCES ON A PARTICLE
1. Centrifugal force, Fc
2. The force of ascending air current, Fd.
3. The force of gravity, Fg.

Fd
Fc
Fg
 The distribution plate must impart sufficient amount
of centrifugal force to through the particle in
separating zone before the new feed is received.
 As heavier and large particles are thrown outwards
their Fc is decreased therefore they settle by the action
of gravity.
DIAGRAM
 Fine particles are lifted by the ascending air currents and pass
between the blades of both auxiliary and main fan into the outer
separator cone, which is also called fines cone.

 Underneath the separating zone there are air return vanes.

 The main fan moves the air from fines cone into the separating
zone through grating of vanes.

 The separation of fines in the outer separator is due to decrease in

their velocity as well as change in direction of air current.
 The auxiliary fan acts against the intake air current caused by
the main fan. This counter action can be controlled by number of
blades of auxiliary fan.

 Horizontal control valves make it possible to change the cross

section of ascending air current for fine adjustment.

 The separator finish product is judged by the amount of coarse

particles in the fine.

 The finer the particle size of finish product, the lower the
separator’s production capacity.
POWER REQUIREMENT
 Quality of separator feed.
 The circulating load.

 Desired fineness of the finished products.

Figures in magnitude vary from 2Kwh/t-6Kwh/t.

TYPES OF SEPARATOR DESIGN
 1st generation HEYD or Sturtevant
separators
 2nd generation Cyclone separator

 3rd generation QDK or High

Performance cage
rotor separator
TYPES OF SEPARATOR DESIGN
 1ST GENERATION SEPARATOR

Circulating fan
Separation Chamber
Auxiliary fan
Precipitating Chamber

Distribution plate
Circulating Fan
Tailing Cone
TYPES OF SEPARATOR DESIGN

 2nd Generation Separators

TYPES OF SEPARATOR DESIGN
 3rd Generation Separator
COMPARISON
TYPES OF SEPARATORS
 Grit Separator
 Mechanical separators
 High efficiency cyclone separators
 Dynamic classifiers
TYPES OF SEPARATORS
 Grit Separators
TYPES OF SEPARATORS
 Grit Separator
 Used to de-dust mill air sweep.
 Have no moving parts.
 Effect separation by cyclonic air flow induced by guide
vanes.
 Dust separation:-
 Radial settings of vanes gives minimum.
 Tangential settings of vanes gives maximum.
TYPES OF SEPARATORS
 Mechanical Separators
TYPES OF SEPARATORS
 Mechanical separators
 The traditional classifier of mill product.
 Has a rotating dispersion plate.
 Coarse particles either fall directly from the dispersion
plate or are rejected between auxiliary fan blades and
the control valve.
 Operating adjustments
 Number of auxiliary fan blades.
 Clearance between blades and control valve.
 Position of main fan blades.
TYPES OF SEPARATORS
 High efficiency cyclone separator
TYPES OF SEPARATORS
 High efficiency cyclone separator
 Introduced to improve on the mechanical separator’s
low efficiency in fines recovery.
 Material is fed onto a rotating dispersion plate, whence
it is dispersed into classifying air stream & then sucked
by tangential inlet ducts.
 Loading is up to about 2.5 kg feed/m3 air flow.
 Horizontal vortex formed classifies particles between
centrifugal force and inward air flow.
 Increasing rotor speed increases fineness.
TYPES OF SEPARATORS
 Dynamic Classifiers
TYPES OF SEPARATORS
 Dynamic Classifiers
 Used integrally with roller mill.
 Involves upward flow of dust entrained air into a
segregating area above grinding table.
 With decreasing air velocity coarse particles fall back
while fines leave with exhaust.
VARIOUS MAKES
 Turbo Separator Turbopol (Polysius)
VARIOUS MAKES
 Turbo Separator
 It is furnished by an auxiliary fan driven by separate
drive arrangement.
 A Special feeding arrangement to improve the
separation process by uniform distribution of separation
feed from distribution plate in circular separating space.
 Sizes= 3200-8500mm dia.
 Maximum capacities= 160t/h of cement with fineness of
2800 cm2/gm Blaine and for raw mix 200t/h with a
fineness 12% residue on 88 micron.
VARIOUS MAKES
 Cyclone air separator (KHD Humboldt Wedag AG)
VARIOUS MAKES
 Cyclone air separator
 Possible to achieve fine product capacities upto 500
metric t/h.
 The cross current separation process with distribution
plate and auxiliary fan.
 According to manufacturers:-
 Specific load of separating zone can be increased.
 Variation in the separation feed (circulating load) do not
affect fineness of separator product.
 This circulating load is reduced to the capacity of
centrifugal system, the separation runs without vibration.
 The blower located outside works better than the fan
located inside separator.
VARIOUS MAKES
 Separator with external blower : SKET/ZAB
VARIOUS MAKES
 Separator with external blower
 Combination of a speed controlled air separator with
principle of instrumental splitting of separation &
precipitation process.
 Similar features as cyclone separator.
VARIOUS MAKES
 Cyclone air separator (Krupp polysius)
VARIOUS MAKES
 Cyclone air separator
 The material is introduced laterally into the separator
by an air slide & is uniformly distributed in the
separating chamber.
 Air generated by external mounted blower separates the
fines & coarse by various forces.
 The separating zone has a higher loading capacity than
that of turbopol separator.
 Specific power consumption is higher than that of
Turbopol separator due to the separation in external
cyclone.
VARIOUS MAKES

 O-Sepa air separator

VARIOUS MAKES
 O-Sepa air separator
 Developed by Onoda Cement Co. Ltd., Tokyo Japan.
 Provides sharp classification & mill system energy
saving.
 Material is fed by chutes directly on the distribution
plate over the rotor.
 The primary & secondary air create a vortex in the
separating zone of separator.
 Adjustments can be made for desired product size by
adjusting the rotor speed.
MAINTENANCE
 Lubrication of separator bearings.
 Lubrication and tightness of gear box.
 Guide vanes
 Timely maintenance of separator cone.
 Proper functioning of fans.
 Continuous Monitoring
o Temperature
o Power
o Current
o Speed
o Position
o Pressure
THANK YOU