L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 1Krupp Polysius Corp.Process TrainingBall Mill + SEPOL L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page (Krupp Polysius Corp.Mill inletMill dis)argeBall *illing (! ompartmentBall *illing 1! ompartmentDri+e$ntermediate diap)ragm Dis)arge diap)ragmBall mill L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ,Krupp Polysius Corp. Polysius cement mill L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page &Krupp Polysius Corp.Schematic possibilities of ball grindingA 'atarat mo+ement -Grinding beause o* impat and *rition.B 'asade mo+ement -Grinding beause o* *rition.A B L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 5Krupp Polysius Corp.Movement of grinding media in a ball millMo+ement depends on:/Mill speed/Ball )arge/Liner s)ape/Mill diameter L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 0Krupp Polysius Corp.Movement of grinding media in a ball millMill re+olutions: 1 o* ritial speedBall

)arge: 1 o* mill +olume L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 2Krupp Polysius Corp.Ball mill speed/Vcrit: critical speed balls stay on t)e mill 3all due to entri*ugal *oreNO GRINING POSSIB!"#iritD&(!,4 =/Vma$: maximum speed ira 251 o* t)e ritial speedima5D,1!24 =Di6 diameter inside liners L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 7Krupp Polysius Corp.Ball charge1! 'ompartment:oarse balls(! 'ompartment:ball *illing lassi*iedbeause o* liners L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 8Krupp Polysius Corp."$ample for ball si%e distribution for Ball Mills in closed circuit &ith a 'igh "fficiency Separator separator (&ithout pregrinding) L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 10Krupp Polysius Corp.!iner Shape*+lassifying !iners*1(, - .Mill ylinder 'lassi*ying liner9lo3 o* material L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 11Krupp Polysius Corp.!iner shape* !ifting liners *Li*ting linersMill s)ellMill rotation L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 1(Krupp Polysius Corp. Ball fillingT)e *illing le+el o* t)e grinding media is as *ollo3s: .&:-D L 'DG-tons.9P-1.(i i =9P 69illing le+el -1.'D 6')arge density -appro5 &!5 t;m, < 1! 'ompartment. -appro5 &!0 t;m, < (! 'ompartment.Li6#**eti+e grinding lengt)Di6$nside diameter: 6,!1& L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 1,Krupp Polysius Corp.rive po&er re/uirement of ball millsT)e re=uired po3er o* a ball mill depends on:/Mill si>e -diameter% lengt)./Mill re+olution speed/Amount o* ginding media -1./number o* grinding ompartments/type o* material/type o* mill liners/type o* grinding media/type and lengt) o* a pre?drying ompartment -i* appliable. L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 1&Krupp Polysius Corp.+alculation of ball mill po&erGL@ M P =@L G M = L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 15Krupp Polysius Corp."stablishing the po&er re/uirement at the mill shaft1!,0 D -tons. G-A". Pi =GB 3eig)t o* ball )argeDiB internal diameterB ?*ator1!,0B on+ersion *ator *rom CP to D" L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 10Krupp Polysius Corp. Basic c * factor for n 0 12 3 n4rit9illing degree E1F

?*a

tor Em1!5;s,F(?ompartment mill L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 12Krupp Polysius Corp.+ * factor correction+

0 cbasic corr5 speed corr5 Blaine L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 17Krupp Polysius Corp.iD n+*factor correction for speed if n 12 3 n4rit

? *a

tor

orre

tion0!810!8(0!8,0!8&0!850!800!820!870!8811!011!0(1!0,1!0&1!051!001!021!071!081!1(8!2 ,0!( ,0!2 ,1!( ,1!2 ,(!( ,(!2 ,,!( ,,!2 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 18Krupp Polysius Corp.+*factor correction for BlaineAbo+e ,500 Blaine:GH dereases as Blaine inreasesGH is redued by 0!1251 per 100 Blaine0!12510000,500 Blaine1 'Blaine = L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page (0Krupp Polysius Corp."$ample drive lossesgi+en:/e**! gear bo5 6 80 1/e**! Motor 6 80 1/e**! Lines 6 88 1dri+e e**iieny 6 e**! gear bo5 e**! motor e**! linesdri+e e**iieny 60!80 0!80 0!88dri+e e**iieny 60!81681 1 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page (1Krupp Polysius Corp.rive lossesT)e losses due to t)e dri+e must be taAen into onsideration 3it) t)is alulation!e**! dri+eP-s)a*t.P-ounter. =Dri+e e**iieny:Ball mill Gear bo5 Motor 'ounterP-s)a*t. e**! gear bo5 e**! motor e**! linesdri+e e**iieny 6 e**! gear bo5 e**! motor e**! lines L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ((Krupp Polysius Corp.6ineness conversion (clin4er). - 0!&81000. Bl ? -Bl1 (e *=* 6 *ineness *atorBl16 ne3 BlaineBl(6 base Blaine"sp6 spei*i 3orA 6 po3er onsumption -A");t.* . -Bl M . -Bl M1 1 ( ( =M1 6ne3 apaity *or ne3 Blaine -t;).M( 6base apaity *or base Blaine -t;).*. -Bl ". -Bl "( sp1 sp= L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page (,Krupp Polysius Corp."$ample ,7 ad8ustment of capacity (+lin4er)0!&285e *. - 0!&810005000. ? -,500=='on+ersion o* e5isting system *rom ,500 to 5000 m(;g -Blaine.Base apaity: M( 6 100 t;) I ,500 BlaineT)ere*ore: Blaine 5000 I t;) &2!85 0!&285 t;) 100 M1= = L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page (&Krupp Polysius Corp."$ample ,7 product fineness vs5 mill capacity,01&01501001201701801100111011(011,01,0,1,(,,,&,5,0,2,7,8&0&1&(&,&&&5&0&2&7&850515(5,5&555052575800Blaine ( ,99)+apacity (3) L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page (5Krupp Polysius Corp."$ample .7 ad8ustment of mill po&er consumption (+lin4er)'on+ersion o* e5isting system *rom ,500 to 5000 m(;g -Blaine.Gi+en: "sp 6 ,5 A");t I ,500 BlaineT)ere*ore:Blaine 5000 I A");t 2, 0!&285A");t ,5"sp==0!&285e *. - 0!&810005000. ? -,500== L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page (0Krupp Polysius Corp.00170110011(011&0110011701(001((01(&01(001(701,001,(01,&01,0,1,(,,,&,5,0,2,7,8&0&1&(&,&&&5&0&2&7&850515(5,5&555052575800"$ample .7 ad8ustment of mill po&er consumptionspecific &or4 (3)Blaine ( ,99) L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page (2Krupp Polysius Corp.KWH/T Shaft Range for Clinker.29Grindability (at mill shaft) as a function of Blaine.99,29,99299.999:999;999Blaine cm.299 Blaine2999 BlaineProdut Jlope 1 1'ompressi+e Jtrengt) a*ter ( days -K;mm(.(8 &8!5'ompressi+e Jtrengt) a*ter (7 days -K;mm(.50 05 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page (8Krupp Polysius Corp.1! Material le+el and distribution(! Grinding media and )arge,! J)ell liners and diap)ragm&! "ater inLetion and grinding aid lanesBall mill inspection and audit L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ,0Krupp Polysius Corp.1. Material Level and Distribution L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ,1Krupp Polysius Corp.Material load too lo&')amber $ ')amber $$Material le+el')amber $:/Ko material +isible o+er a setion or o+er t)e entire lengt) o* t)e grinding )amber!')amber $$:/Ko material +isible on t)e sur*ae o* t)e grinding media )arge! L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ,(Krupp Polysius Corp.')amber $:/Large =uantities or material abo+e and bet3een t)e grinding mediano intensi+e grinding/Build?up o* large material piees in *ront o* t)e intermediate diap)ragmMaterial load too high')amber $ ')amber $$Material le+el')amber $$:/ Grinding media are o+ered 3it) a 50 to 100mm t)iA material layer lo3 degree o* grinding L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ,,Krupp Polysius Corp.')amber $:Kormal material load: appro5! 1;, o* t)e grinding media sur*ae lies bare and t)e grinding media lies ne5t to ea) ot)er 3it) t)e material laying in t)e spae bet3eenMaterial load normal')amber $ ')amber $$Material le+el')amber $$:Kormal material load: grinding media are Lust proLeting on t)e sur*ae or are Lust o+ered 3it)material L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ,&Krupp Polysius Corp.Ball 6illing ,5 +ompartmentMaterial load too lo3Material load normal L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ,5Krupp Polysius Corp.Ball 6illing .5 +ompartmentMaterial load normal Material load too )ig) L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ,0Krupp Polysius Corp.2. Grinding Media and Carge L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ,2Krupp Polysius Corp.Grinding media and charge To be )eAed:/Ball si>e distribution and ball lassi*iation in t)e (! ompartment -i* mill is e=uipped 3it) segregation liners./J)ape o* grinding balls -3orn and;or broAen balls. as 3ell as *oreign bodies in t)e ball )arge/Measurement o* *illing le+el in t)e empty mill/'oating o* grinding balls L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ,7Krupp Polysius Corp.Measurement of filling level in the mill/)eig)t abo+e ball )arge ? )/string abo+e ball )arge ? s/9ree liner plates abo+e ball )argeLinersBall )arge)Dis L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page ,8Krupp Polysius Corp."$ample for measurement of filling levelgi+en: ) 6 (!(7& m -)eig)t abo+e ball )arge.s 6 ,!(&0 m -string abo+e ball )arge.Di 6 ,!&& m -diameter inside liner.9P 6 (1!2-*ree liner plates abo+e ball )arge ); Di s; Di,00 ? -6P 5 10.;( 666 0!00&0!8&(21!59l -see diagram.(8!51(8!51(8!51 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page &0Krupp Polysius Corp.6illing level of ball charge vs5 h299:999:299laine2289 !" # 8 $e%h1089 !" # 16 $e%h555&3 !" # 30 $e%h321!" # 50 $e%h86&6 !" # 170 $e%h72&7 !" # 200 $e%h43&2 !" # 325 $e%h01020304050607080901000 1 2 0 1 2 3 4 5 6 7 8Meter sample points < mResidue 3 9299,999,299.999.299>999>299laine2289 !" # 8 $e%h1089 !" # 16 $e%h555&3 !" # 30 $e%h321!" # 50 $e%h86&6 !" # 170 $e%h72&7 !" # 200 $e%h43&2 !" # 325 $e%hGood Example for Longitudinal SampleBad Example for Longitudinal Sample L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 5&Krupp Polysius Corp.SEPOL L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 55Krupp Polysius Corp.Jeparating Air Jeparating AirFines Fines9eed Material 9eed MaterialOversize Material Oversize MaterialS"PO! S"PO! L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\ballm_sepol_proess!ppt 150 "#$% 1&0 'D Page 50Krupp Polysius Corp.9M#JCA$M NM '$M'OLAT$KG A$MJ#PAMATNM 9##DJ#PAMATNM M#P#'TJ4#KT A$M "$TC 9$K#JS"PO! SV