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Pag L:\DATA\Dept150\Polysius Pres

Process
e1 Training
entation and Training\Polysiu
s Training\Grinding\Ball Mill
Ball Mill + SEPOL
\ballm_sepol_process.ppt
150 WEI, 140 CD

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Ball mill
e2 entation and Training\Polysiu
s Training\Grinding\Ball Mill
Discharge diaphragm
\ballm_sepol_process.ppt
Intermediate diaphragm 150 WEI, 140 CD
Mill inlet
Mill discharge

Ball filling 2. compartment

Ball filling 1. compartment

Drive

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Polysius cement mill
e3 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Schematic possibilities of ball grinding
e4 entation and Training\Polysiu
As Training\Grinding\Ball MillB
\ballm_sepol_process.ppt
150 WEI, 140 CD

A Cataract movement (Grinding because of impact and friction)


B Cascade movement (Grinding because of friction)

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 5 Movement
entation and Training\Polysiu
of grinding media in a ball mill
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
Movement depends on:
150 WEI, 140 CD

Mill speed
Ball charge
Liner shape
Mill diameter

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 6 Movement of grinding media in a ball mill
entation and Training\Polysiu
s Training\Grinding\Ball Mill
Mill revolutions: % of critical speed
\ballm_sepol_process.ppt
150 WEI, 140 CD
Ball charge: % of mill volume

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e7 entationBall
andmill speed
Training\Polysiu
s Training\Grinding\Ball Mill
Vcrit: critical speed balls stay on the mill wall due to centrifugal force
\ballm_sepol_process.ppt
NO GRINDING POSSIBLE!
150 WEI, 140 CD
42.3
Vcrit
Di

Vmax: maximum speed circa 75% of the critical speed

31.7
Vmax
Di

Di = diameter inside liners

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Ball charge
e8 entation and Training\Polysiu
s Training\Grinding\Ball Mill
1. Compartment:
\ballm_sepol_process.ppt
coarse balls 150 WEI, 140 CD

2. Compartment:
ball filling classified
because of liners

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Example
e9 for ball size distribution
entation for Ball Mills in
and Training\Polysiu
closed circuit with a High Efficiency Separator
s Training\Grinding\Ball Mill
separator (without pregrinding)
\ballm_sepol_process.ppt
150 WEI, 140 CD

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 10 Liner
entation andShape
Training\Polysiu
-Classifying Liners- Mill
s Training\Grinding\Ball
\ballm_sepol_process.ppt
150 WEI, 140 CD

1 < 2
1
2

Flow of material
Mill cylinder Classifying liner

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius
Liner shape Pres
e 11 entation andliners
- Lifting Training\Polysiu
-
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

Mill shell

Lifting liners

Mill rotation

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 12 entation Balland filling
Training\Polysiu
s level
The filling Training\Grinding\Ball Mill
of the grinding media is as follows:
\ballm_sepol_process.ppt
150 WEI, 140 CD
G(tons)
FP(%)

CD L i (D )2
i
4

FP = Filling level (%)


CD = Charge density (approx 4.5 t/m3 1. Compartment)
(approx 4.6 t/m3 2. Compartment)
Li = Effective grinding length
Di = Inside diameter
= 3.14

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Drive power requirement of ball mills
e 13 entation and Training\Polysiu
s Training\Grinding\Ball Mill
The required power of a ball mill depends on:
\ballm_sepol_process.ppt
150
Mill size (diameter, WEI, 140 CD
length)

Mill revolution speed

Amount of ginding media (%)

number of grinding compartments

type of material

type of mill liners

type of grinding media

type and length of a pre-drying compartment (if applicable)

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 14 Calculation
entation of ball mill power
and Training\Polysiu
s Training\Grinding\Ball Mill

\ballm_sepol_process.ppt
150 WEI, 140 CD

P M
L
M G L
G

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
eEstablishing
15 the power
entation requirement
and at the mill shaft
Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD
G (tons) Di c
P (kW)
1.36

G weight of ball charge


Di internal diameter
c c-factor
1.36 conversion factor from HP to KW

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Basic c - factor for n = 75 % nkrit
e 16 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD
c-factor [m1.5/s3]

2-compartment mill

Filling degree [%]


Krupp Polysius Corp.
Pag L:\DATA\Dept150\Polysius Pres
e 17 C - factor
entation correction
and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

C = cbasic corr. speed corr. Blaine

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
C-factor correction for speed if n 75 % nkrit
e
1.1
18 entation and Training\Polysiu
1.09 s Training\Grinding\Ball Mill
1.08
1.07
\ballm_sepol_process.ppt
1.06 150 WEI, 140 CD
1.05
c - factor correction

1.04
1.03
1.02
1.01
1
0.99
0.98
0.97
0.96
0.95
0.94
0.93
0.92
0.91
29.7 30.2 30.7 31.2 31.7 32.2 32.7 33.2 33.7

n Di
Krupp Polysius Corp.
Pag L:\DATA\Dept150\Polysius Pres
e 19 C-factor correction
entation for Blaine
and Training\Polysiu
s Training\Grinding\Ball Mill
Above\ballm_sepol_process.ppt
3500 Blaine:
150 WEI, 140 CD
c decreases as Blaine increases

c is reduced by 0.175% per 100 Blaine

Blaine 3500
CBlaine 1 0.175
10000

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 20 Example
entation drive
and losses
Training\Polysiu
s Training\Grinding\Ball Mill
given: \ballm_sepol_process.ppt
eff. gear box = 96 %
150 WEI, 140 CD

eff. Motor = 96 %

eff. Lines = 99 %

drive efficiency = eff. gear box eff. motor eff. lines

drive efficiency = 0.96 0.96 0.99

drive efficiency = 0.91 = 91 %

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Drive losses
e 21 entation and Training\Polysiu
s Training\Grinding\Ball Mill
The losses due to the drive must be taken into consideration with this calculation.
\ballm_sepol_process.ppt
150 WEI, P(shaft)
140 CD
P(counter)
drive eff.
Drive efficiency:

Ball mill Gear box Motor Counter

P(shaft) eff. gear box eff. motor eff. lines

drive efficiency = eff. gear box eff. motor eff. lines

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 22 Fineness
entationconversion (clinker)
and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
( (Bl2 - Bl1 )
) f
0.49 150 WEI,
= fineness factor
Bl1140 CD
= new Blaine
f e 1000
Bl2 = base Blaine

Wsp = specific work


Wsp (Bl2 )
Wsp (Bl1 ) = power consumption (kWh/t)
f

M2 (Bl2 ) M1(Bl1 ) f M1 = new capacity for new Blaine (t/h)


M2 = base capacity for base Blaine (t/h)

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Example 1: adjustment of capacity (Clinker)
e 23 entation and Training\Polysiu
s Training\Grinding\Ball Mill 2
Conversion of existing system from 3500 to 5000 cm /g (Blaine)
\ballm_sepol_process.ppt
150 WEI,( (35001000-140 0.49 )
5000) CD
f e
0.4795

Base capacity: M2 = 100 t/h @ 3500 Blaine

Therefore: M1 100 t/h 0.4795

47.95 t/h @ 5000 Blaine

Krupp Polysius Corp.


Pag Example L:\DATA\Dept150\Polysius Pres
1: product fineness vs. mill capacity
e 24 entation and Training\Polysiu
Capacity (%)
130%
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
120%
150 WEI, 140 CD
110%

100%

90%

80%

70%

60%

50%

40%

30%
303132 3334353637 3839404142 4344454647 4849505152 5354555657 585960
Blaine ( 100)
Krupp Polysius Corp.
Pag L:\DATA\Dept150\Polysius Pres
Example
e 25 2: adjustment
entation andof mill power consumption (Clinker)
Training\Polysiu
s Training\Grinding\Ball Mill 2
Conversion of existing system from 3500 to 5000 cm /g (Blaine)
\ballm_sepol_process.ppt
150 WEI,( (35001000-140 0.49 )
5000) CD
f e
0.4795

Given: Wsp = 35 kWh/t @ 3500 Blaine


35 kWh/t
Therefore: Wsp
0.4795

73 kWh/t @ 5000 Blaine

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Example 2: adjustment of mill power consumption
e 26 entation and Training\Polysiu
specific work (%)
340% s Training\Grinding\Ball Mill
320% \ballm_sepol_process.ppt
300% 150 WEI, 140 CD
280%
260%
240%
220%
200%
180%
160%
140%
120%
100%
80%
60%
30 3132 3334 3536 37 3839 4041 4243 44 4546 4748 4950 5152 53 5455 5657 5859 60
Blaine ( 100)
Krupp Polysius Corp.
Pag L:\DATA\Dept150\Polysius
KWH/T Shaft Pres
Grindability
e 27 (at milland
entation shaft) as a function of Blaine
Training\Polysiu
250
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
200 150 WEI, 140 CD

150
kWh/t

100

50

Range for Clinker


0

2000 4000 6000


Blaine cm2/g

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Infuence of fineness and
e 28 entation and Training\Polysiu
product/slope on the strength
s Training\Grinding\Ball Mill
of the cement
\ballm_sepol_process.ppt
150 WEI, 140 CD

Example:
3500 5000
Blaine Blaine
Product Slope 1 1

Compressive Strength 29 49.5


after 2 days (N/mm2)
Compressive Strength 56 65
after 28 days (N/mm2)

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Ballemill
29 inspection
entation and Training\Polysiu
and audit
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

1. Material level and


distribution

2. Grinding media and


charge

3. Shell liners and


diaphragm

4. Water injection and


grinding aid lances

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 30 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

1. Material Level and Distribution

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 31 Material
entation andload too low
Training\Polysiu
s Training\Grinding\Ball Mill
Chamber I Chamber II
\ballm_sepol_process.ppt
150 WEI, 140 CD

Material level

Chamber I:
No material visible over a section
or over the entire length of the grinding
chamber.

Chamber II:
No material visible on the surface of the
grinding media charge.

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 32 Material
entation andload too high
Training\Polysiu
s Training\Grinding\Ball Mill
Chamber I Chamber II
\ballm_sepol_process.ppt
150 WEI, 140 CD

Material level

Chamber I:
Large quantities or material above and between
the grinding media no intensive grinding
Build-up of large material pieces in front of the
intermediate diaphragm

Chamber II:
Grinding media are covered with a 50 to 100mm
thick material layer
low degree of grinding
Krupp Polysius Corp.
Pag L:\DATA\Dept150\Polysius Pres
e 33 Material
entation andload normal
Training\Polysiu
s Training\Grinding\Ball Mill
Chamber I Chamber II
\ballm_sepol_process.ppt
150 WEI, 140 CD

Material level
Chamber I:
Normal material load: approx. 1/3 of the grinding
media surface lies bare and the grinding media
lies next to each other with the material laying
in the space between

Chamber II:
Normal material load: grinding media are just
projecting on the surface or are just covered with
material
Krupp Polysius Corp.
Pag L:\DATA\Dept150\Polysius Pres
e 34 Ball Filling
entation and1.Training\Polysiu
Compartment
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD
Material load normal Material load too low

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Ball Filling 2. Compartment
e 35 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
Material load normal Material load too high
150 WEI, 140 CD

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 36 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

2. Grinding Media and Charge

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 37 Grinding
entationmedia and charge
and Training\Polysiu
s Training\Grinding\Ball Mill
To be checked: \ballm_sepol_process.ppt
150
Ball size distribution and ballWEI, 140 CD
classification in the 2. compartment
(if mill is equipped with segregation liners)

Shape of grinding balls (worn and/or broken balls) as well as foreign bodies
in the ball charge

Measurement of filling level in the empty mill

Coating of grinding balls

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 38 Measurement
entationofand
filling level in the mill
Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
height above ball charge - h
string above ball charge - s
150 WEI, 140 CD
Free liner plates above ball charge

Di
h Liners

Ball charge

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 39 Example for measurement
entation of filling level
and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
given: h = 2.284 m (height above ball charge)
150 WEI, 140 CD
s = 3.240 m (string above ball charge)

Di = 3.44 m (diameter inside liner)

FP = 21.7 (free liner plates above ball charge

h/ Di s/ Di 360 - (FP x 10)/2


= = =
0.664 0.942 71.5
Fl (see diagram) 29.5% 29.5% 29.5%

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Filling level of ball charge vs. h/Di -, s/Di - and functions
h/Di
e1 40 entation and Training\Polysiu 200
s Training\Grinding\Ball Mill
0.9 h/D\ballm_sepol_process.ppt 180
s/Di i

0.8 150 WEI, 140 CD 160

0.7 140

360 - (FP x 10)/2


0.6 120
s/Di
0.5 100

0.4 80

0.3 360 - (FP x 10)/2 60

0.2 40

0.1 20

0 0
0 5 10 15 20 25 30 35 40 45 50
Ball Filling Level (%)
Krupp Polysius Corp.
Pag L:\DATA\Dept150\Polysius Pres
e 41 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

3. Shell Liners and Diaphragm

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 42 Shell liners
entation andand diaphragm
Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
Shape and150
wearWEI,
of liner140
platesCD

Coating

Shape of slots

Blocking of slots (if blocked, cleaning is required)

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 43 entationBall
andmill liners
Training\Polysiu
s Training\Grinding\Ball Mill
Ball Mill lifting liners in \ballm_sepol_process.ppt
good Ball Mill classifying liners,
condition 150 WEI, 140 CDcoated
heavily

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 44 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

4. Water and Grinding Aid Injection Lances

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 45 Water injection
entation lances
and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD
lances should be open and clean

no damages from impact

cleaning air in water spray should be checked

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Water spray system
e 46 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
Spray lance in good condition Spray lance totally blocked
150 WEI, 140 CD

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 47 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

5. Intermediate and Discharge Diaphragm

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 48 Intermediate
entation and
and discharge diaphragm
Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD
Diaphragms should be open to assure proper
material and air flow in the mill.

If diaphragms are blocked with worn balls or


material they should be cleaned. If blockage
occurs regularly, broken or worn balls have to be
removed from ball charge.

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius
Diaphragm Pres
e 49 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
Diaphragm not blocked 150 WEI, 140 Diaphragm
CD heavily blocked and
coated with material

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 50 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

Longitudinal Sample

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 51 Longitudinal
entation andsample (meter sample)
Training\Polysiu
s Training\Grinding\Ball
one sample of approx, 1lb every 1m (approx. 3 ft) ofMill
the mill length
\ballm_sepol_process.ppt
sample should consist of material from outer mill areas and mill center
150 WEI, 140 CD
sample should be taken approx. 25 mm (1 in) below surface

0m 1m 2m 3m 0m 2m 3m 4m... sampling point


sieve residues and Blaine values should be taken for each sample

results are inserted into a diagram

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 52 entation
Purpose and Training\Polysiu
of longitudinal samples
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150and
judgment of grinding efficiency WEI, 140success
grinding CD along the mill
An optimal ball mill filling will lead to steadily decreasing residues and
increasing Blaine values

A not optimal ball filling will lead to areas where residues and Blaine values
romaine unchanged for several feet of the mill.

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Mill Longitudinal Sample (Meter Sample)
e 53 entation and Training\Polysiu
s Training\Grinding\Ball
Good Example for Longitudinal Sample Mill
4500
\ballm_sepol_process.ppt
100

90
4000
80

150 WEI, 140 CD 3500 B laine


70 2289 m = 8 M es h
3000
60 1089 m = 16 M esh
2500 555,3 m = 30 M esh
Residue % 50

40
2000 321 m = 50 M esh
86,6 m = 170 M esh
30 1500
72,7 m = 200 M esh
20 1000 43,2 m = 325 M esh

10 500
0 0
0 1 0 1 2 3 4 5 6 7 8

Meter sample points / m

Bad Example for Longitudinal Sample


100 3500
90 B laine
80
3000 2289 m = 8 M esh

70 2500 1089 m = 16 M es h
555,3 m = 30 M esh
60
2000 321 m = 50 M esh
Residue % 50 86,6 m = 170 M esh
40 1500 72,7 m = 200 M esh

30 43,2 m = 325 M esh


1000
20

10
500
0 0
0 1 2 0 1 2 3 4 5 6 7 8

Meter sample points / m

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 54 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

SEPOL

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
SEPOL
e 55 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
Feed Material
150 WEI, 140 CD

Separating Air

Fines

Oversize Material

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
SEPOL SV/x
e 56 entation and Training\Polysiu
DISPERSION PLATE FEED BOX
s Training\Grinding\Ball Mill
AIR GUIDE \ballm_sepol_process.ppt
PLATE ROTOR BLADES
150 WEI, 140 CD GUIDE VANE

AIR INLET DUCT

CYCLONE
SEPARATOR FEED
SEPARATOR REJECTS
REJECT CONE
VENT AIR WITH FINES
FRESHAIR OR CIRCULATING AIR

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
SEPOL SV
e 57 entation and Training\Polysiu
FEED BOX
s Training\Grinding\Ball Mill
DISPERSION PLATE
\ballm_sepol_process.pptROTOR BLADES
AIR GUIDE PLATE GUIDE VANE
150 WEI, 140 CD

AIR INLET DUCT

SEPARATOR FEED DISCHARGE BEND


SEPARATOR REJECTS
VENT AIR WITH FINES REJECT CONE
FRESHAIR OR CIRCULATING AIR

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
SEPOL Separator
e 58 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Completely
e 59 opened air-inlet
entation andlouvre (during commissioning)
Training\Polysiu
s Training\Grinding\Ball Millare being
Louvres
\ballm_sepol_process.ppt
adjusted to wear pattern
150 WEI, 140 CD at the rotor

separating
air

Air channels

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Spiral inlet, guide vanes and rotor
e 60 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt Rotor
150 WEI, 140 CD

Air flow
Air inlet
Guide vanes

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Setting of entation
e 61 guide vanes
and (during Commissioning)
Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

counter-clockwise rotation

clockwise rotation

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Setting of guide vanes (during Commissioning)
e 62 entation and Training\Polysiu
s Training\Grinding\Ball
guide vanes Mill
set to largely tangential
\ballm_sepol_process.ppt
position (6065 to the radial)
150 WEI, 140 CD
max. separating air

speed of separator rotor set to suit


the required cement fineness

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Separator formulas
e 63 entation and Training\Polysiu
s Training\Grinding\Ball Mill
SA, SF SG [t/h]: separator
\ballm_sepol_process.ppt
SA (a)
150 WEI, 140 CD feed, separator fines,
separator grits

a, f, g: fineness feed,
fines, grits (Blaine or
SG (g)
SF (f) residue)

Circulation Factor = SA / SF

= (f - g) / (a - g)

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 64 Particleand
entation Size Distribution
Training\Polysiu
s Training\Grinding\Ball Mill
Area Considered at a Tromp

100 %
\ballm_sepol_process.ppt
Curve

150 WEI, 140 CD

Rejects

50%

Fines

Feed

X Particle Size, Q - % Passing

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 65 TROMP
entation CURVE
and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD
Separation
Fines

Coarse

X Particle Size

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 66 TROMP CURVE
entation (IDEAL
and SEPARATION)
Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD
Separation

Fines

Coarse

Xc Separation Particle Size

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Separation Typical Tromp
e 67 entation and Training\Polysiu
100%
100% Curve
s Training\Grinding\Ball Mill
90% \ballm_sepol_process.ppt
80% 150 WEI, 140 CD
Fines
70%

60%

50%
40%
30% Coarse

20%
10%
0%
1 10 100 1000
Particle Size (Microns)
Krupp Polysius Corp.
Pag L:\DATA\Dept150\Polysius Pres
e 68 entation and Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

Grinding Circuits

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
The SEPOL in closed grinding circuit with circulating air
e 69 entation and Training\Polysiu
operation
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
The SEPOL in closed grinding circuit with direct air operation
e 70 entation and Training\Polysiu
and fresh air supply for fine material cooling (single pass)
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
The SEPOL in closed grinding circuit with circulating
aire operation.
71 entation
High and Training\Polysiu
pressure grinding roll as primary mill
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
The SEPOL in closed grinding circuit with circulating air
e 72 entation and Training\Polysiu
operation. Highpressure grinding roll and tube mill in hybrid
s Training\Grinding\Ball
operation
Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
The SEPOL in closed grinding circuit with circulating air
e 73 SEPOLentation
operation. and
after high Training\Polysiu
pressure grinding roll and tube
mill forscombination
Training\Grinding\Ball Mill
and finish grinding.
\ballm_sepol_process.ppt
150 WEI, 140 CD

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
e 74 Material flows
entation in ball
and mill circuits
Training\Polysiu
s Training\Grinding\Ball Mill
\ballm_sepol_process.ppt
150 WEI, 140 CD
SF (f) 85 -90%
23-fold material circulation

Separator collecting
cyclones
SG(g)
Separator
tube mill SA (a) filter

10 -15% sampling for


100% determination of
feed material F Mill fineness
waste air
filter

100%
finished material F

Krupp Polysius Corp.


Pag L:\DATA\Dept150\Polysius Pres
Heat balance in ball mill circuits
e 75 entation and Training\Polysiu
Q = Heat
s Training\Grinding\Ball Mill
System II
Qconvection,
\ballm_sepol_process.ppt Q sepol air
Q =Q 150 WEI, 140 CD
II in II out Q material
radiation

Qsepol air Qconvection,radiation


Qwater,evaporated

Qmaterial Qfalse air


Q exit air

Qinlet air
Qmaterial
Qfalse air
Qpower,converted
Qmaterial moisture QI in = QI out

Qwater spray
System I
Krupp Polysius Corp.

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