Grinding with Ball Mill Systems

EDM
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Ball Mill
Ball Mill
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What is a End Discharge Mill (EDM)?
Intermediate diaphragm
Mill feed arrangement
1
st
Compartment
(Coarse Grinding)
2
st
Compartment
(Fine Grinding)
Mill discharge
Air outlet
Air inlet
Gearbox with pinions
Drive
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EDM
EDM =
End Discharge Mill
Product discharge
at mill end
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Elements of Ball Mill - Overview
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Mill Drive Concepts
Single pinion concept
(< 2'500 kW)
Double-pinion concept
(< 5'000 kW)
Girth gear Drives
Single drive with
two pinions
(< 5'000 kW)
Double drive with
four pinions
(< 10'000 kW)
Girth gear units
Two-way power splitting
reducer
(< 6'000 kW)
Planetary gear reducer
(< 12'000 kW)
Central drives
Drive Concepts for
Ball mills
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Example Planetary Gear Drive
Planetary gear reducer concept MAAG
Two gear stages with three planets
All shafts with friction bearings
Pinions, planets surface-hardened
Annulus through-hardened
Annulus
Sun pinions Drive arrangement
Planets
Gear coupling
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Gear Box Internals
Parallel shaft gear reducer (two way power branch)
Low speed gear
stage
All gears surface-hardened and
ground

All shafts with roller bearings

Key point::
Face load distribution of the
LS-gear stage

Bearings with excentric sleeves
to optimise the face load distribution
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Potential Technical Problems Drive
Girth gear drives - Fundamental
Problems
Dynamic behaviour
A lot of individual rotating masses
risk of resonance vicinities
Torsional/structural vibrations
Pinion shaft bending vibrations
1. Axial/radial runout
2. Alignment of the drive trains
3. Uneven power splitting
4. Centre distances variable
5. Face load distribution
6. Sealing of the girth gear
7. Girth gear is through hardened
only, fatigue strength is limited
5 2
1
4
5 6 7
3
5 2
1
4
5 6 7
3
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Gearboxes
Polysius Combiflex
Gear reducer
Planetary Gear
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Potential Damages Drives
Breakage damage (pinions)
Cause: Inadequate transverse
load distribution, brittle material
Secondary damage:
Tooth breakage
Initial damage:
Pitting on the pitch line
Fatigue breakage
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Potential Problems Drive
Single pinion drive (2300 kW)
Breakage failure of the pinion in the
gear reducer
Heavy (active) pitting on the drive
pinion
Possible Cause:
- Inadequate load distribution (1)
- Overload of the tooth flanks (2)
1
2
1 2 1 2
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Mill Bearing
Advantages slide shoe bearings:
No size and capacity limitation of the
mill
Simple design of wear plates
Far higher limit of gas temperature at
mill inlet (e.g. for drying with heat
generator)
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Feed Arrangements for Ball Mills
Preferred design today
(Slurry mill)
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Feed Arrangement (Example Step Feeder)
Advantages
Good mill ventilation
Easy to maintain
Simple design



Ventilation air
Material feed
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Elements of Ball Mill Overview (Internals)
Mill feed
arrangement Mill head Mill shell arrangement
Mill discharge
drive
Mill
bearing
Mill
Grinding
media
Shell Intermediate
ring
Retention
Internal
elements
elements
External
liners diaphragm
Discharge
diaphragm liners
Head
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Overview Internal Elements
A Coarse grinding
compartment
B Intermediate
diaphragm
C Fine grinding
compartment
D Discharge
diaphragm
E Grinding media
F Retention ring
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Liners for Coarse Grinding
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7 8 9
10
11
12
13
14
66
70
75
h
0
h
h > 0.5 ho
Lifting Height Requirements (1
st
Chamber)
This criteria has to be
confirmed case by case
through evaluation of the
coarse grinding.
Rule of thumb: h must be
greater than 50 [mm]


1st chamber lining at end of lifetime
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Classifying Liner for Fine Grinding (2
nd
Chamber)
Rotation sense
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Head Liners
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Open Diaphragm (Drying Chamber Diaphragm)
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Intermediate Diaphragm
1
st
Compartment
Coarse Grinding
2
nd
Compartment
Fine Grinding
Intermediate diaphragm
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Function of Intermediate Diaphragm
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Intermediate diaphragm









Slot opening in 1
st
chamber
Material flow control system
Centre screen
Grates in the second chamber
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Discharge diaphragm
Discharge diaphragm
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Discharge Diaphragm
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Material Quality and Application of Shell Liners
Material Chemical
Composition
Hardness
(HRC)
Remarks
Manganese
Steel 12 14% Mn 40
Recommended for small mills.
Deformation of liners for large
mills (initial surface hardness
20 25 HRC)
Low chromium
alloy cast
liners
2 3% Cr 40 - 42
Less deformation than
manganese liners. Suitable
for large and small mills
High chromium
alloy cast
liners
12 15% Cr 50 - 55
Most used material. Suitable
for big and small mills (Notch
impact strength 4 10 J/cm2)
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Life Time of Shell Liners
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Grinding Media
Coarse grinding 90 50 [mm]
Fine grinding 50 12 [mm]
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Grinding in Ball Mill
Coarse grinding (1
st
chamber)
Cataracting of grinding media
Fine grinding (2
nd
chamber)
Cascading of grinding media
A
A
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Ball filling degree (f)
f [%] 20 40 - 45 30
75
P
o
w
e
r

[
%
]

85
93
98
25 35
Typical range
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Steps of Grinding
Coarse
Grinding
Medium
Grinding
Fine
Grinding
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Coarse Grinding: Parameters for Optimising
Power parameters
Filling degree
Chamber length
Mill diameter
Liner design and condition
Mill speed

Efficiency parameters
Ball charge (filling degree &
composition)
Liner design
Intermediate diaphragm settings
Mill ventilation
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Grinding Media
Bulk weight of a grinding media charge in a two chamber mill with
classifiying liner
4,4 [t/m3] 4,6 [t/m3] 4,7 [t/m3]
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Grinding Media (1
st
Compartment)










1.Compartment
Ball [mm] Weight [ t ] Percent [%]
90 25.0 25.0
80 35.0 35.0
70 25.0 25.0
60 15.0 15.0
Total 100.0 100
Average ball weight [ g ] 1667
Spec. media surface [m2 / t ] 10.2
Holcim Standard for 1
st
Compartment
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Grinding Media (2
nd
Compartment)
Holcim Standard for OPC > 3200 [cm2/g], closed circuit
system
2.Compartment
Ball [mm] Weight [ t ] Percent [%]
50 20.0 10.0
40 20.0 10.0
30 32.0 16.0
25 32.0 16.0
20 42.0 21.0
17 54.0 27.0
15
Total 200.0 100
Average ball weight [ g ] 41
Spec. media surface [m2 / t] 32.8
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Material Quality of Grinding Media
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Specific Wear Rates of Grinding Media
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Mill Efficiency
[%R]
acc.
[cm
2
/g]
Blaine
mill length [m]
longitudinal sieving graph
[m]
Blaine Value
Sieve Residues
Chamber 1
(coarse grinding)
Chamber 2
(fine grinding)
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Lifting Liners Effects
Liner-Lifting : low high
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Optimum Material Level 1
st
Chamber
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Optimum Material level 2
nd
chamber
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Mill Ventilation







Main Tasks Mill Ventilation:
Material transport
Cooling
Removal of fines
Fluidisation of material
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Cooling and Heating Possibilities
Cooling air
Cooling air
Moist additive
Hot clinker
Hot gases
H2O H2O
H2O
Product
Product
Air
Dust ladden air
H2O
Hot gases
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Fine Grinding and Mill Cooling


SOLUTION
Adapted mill cooling,
playing with:
Clinker temperature
Mill ventilation
Water injection
Use of grinding aid
(temporary solution
because expensive)
PROBLEM
Insufficient mill cooling
lead to material
agglomeration on balls
and liners
The grinding is not any
more done by balls
against material but by
material against material

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Water Injection Systems
80
90
100
110
120
130
Product
temp. [C]
Mill length
counter
current
no water
injection
co-current
Air from
blower
Air from
blower H2O H2O
H2O
H2O
1st 2nd Comp.
1st 2nd Comp.
2nd Comp.
1st Comp.
(Double)
Rotary union
counter current
co-current