Course 4 Cement Production

4.2 Ball Mills

Imprint

German Cement Works Association

Research Institute of the Cement Industry
P.O. box 30 10 63, 40410 Duesseldorf, Germany
Tannenstrasse 2, 40476 Duesseldorf, Germany
Phone: +49 211 45 781
Fax: +49 211 45 78296
info@vdz-online.de
www.vdz-online.de

info@elearning-vdz.de
www.elearning-vdz.de

Issued: 7th January 2013

Contents
1 Introduction....................................................................................................... 1
2 Structure and Operation .................................................................................. 2
2.1 Ball Mill Designs................................................................................................ 3
2.2 Influencing Factors in Ball Mills ........................................................................ 5
2.3 Mill Lining.......................................................................................................... 6
2.4 Drive Types in Tube Mills .................................................................................. 8
2.5 Configuration of Ball Mills in Cement Grinding Plants..................................... 10
2.5.1 Open-Circuit Mills.............................................................................................. 11
2.5.2 Closed-Circuit Mills ........................................................................................... 12
2.6 Operating Characteristics of Ball Mills .............................................................. 12
2.6.1 Controlling Ball Mills......................................................................................... 13
2.6.2 Advantages and Disadvantages of Ball Mills ..................................................... 14

3 Health and Safety Practices ............................................................................. 15

i
4 Factors Affecting Operation and Quality....................................................... 17

5 Maintenance and Inspection............................................................................ 18

6 Environmental Protection ................................................................................ 19

7 Questions on Course LB 4.2 Ball Mills ........................................................ 19
Solutions............................................................................................................................... 20
Glossary ............................................................................................................................... 23

Index..................................................................................................................................... 24

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1 Introduction
The amount of electric energy used during the cement production process is
approx. 110 kWh/t more than 56 % of the energy is consumed in the grind-
ing process. Nowadays, mills of varying design are used to grind cement in
grinding plants with different process configurations.

Grinding plants using ball mills have now been used for more than 100 years for grinding
cement and its raw materials.
The type of ball mill used in the cement industry is known as a tube mill. Like tubes, the Tube Mills
lengths of these mills are considerably greater than their diameters.
In contrast, mills with lengths no greater than 1.5 times their diameters are known as drum Drum Mills
mills.

Figure 1.0-1: Modern, Large Ball Mill with Direct Drive .

Although ball mills are characterized by a high level of operational reliability and require Low Efficiency
a low level of maintenance, their poor level of grinding efficiency is the main reason why
more efficient grinding methods have been developed increasingly in recent years.
Vertical roller mills, high pressure roller mills and, more recently, also horizontal roller Alternatives
mills are now used in cement works in addition to the traditional ball mills, and can sub-
stantially reduce the amount of energy used to comminute cement raw materials and ce-
ment.
This online course will first outline the physical principles of grinding in ball mills, the Course Summary
mode of operation and the structure of ball mills. This will be followed by a description of
the most important mill parameters, various drive designs and the operating characteristics.
Lastly, the topics of environmental protection and industrial safety will be discussed with
reference to the operation of ball mills.

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 2 Structure and Operation

2 Structure and Operation

Ball mills are classed as free-fall mills that are filled with grinding media.
The mill feed is comminuted by grinding media that can move freely in the
grinding chamber.

Operating Principle, The mill charge, i.e. grinding media and mill feed, is accelerated during rotation of the
Forces mill as a result of friction against the grinding drum, is pressed against the mill shell by
the centrifugal forces and carried upward in the direction of rotation. The mill charge is
therefore subjected to the influence of centrifugal force and gravity . As soon as gravity
is greater than the centrifugal force, the grinding media and particles of mill feed become
detached from the drum wall and fall downward following a parabolic path (Fig. 2.0-1).

a) rolling b) ball droppingl c) centrifuging

Figure 2.0-1: Movement of Grinding Media in Tube Mills .

Comminution by Shock
During coarse comminution the mill speed or circumferential velocity of the grinding
drum is set so that the falling grinding media fall onto the mixture of mill feed and grinding
media below and comminute the mill feed by shock. During the process the comminuted
material is scattered in all directions. The mill feed is discharged continuously from the
mill outlet. The finer mill feed located there offers less resistance to the coarser particles
than that of the coarse material coming from the inlet. The mill feed therefore moves con-
tinuously towards the outlet. After the impact the grinding media and mill feed particles
must again be accelerated to the speed of the revolving grinding drum. As a result there is
always a fairly large heap of material at the foot of the mill charge during operation.

Comminution by Friction
In addition to comminution of the mill feed by shock, another type of comminution, pre-
dominantly abrasive comminution, takes place on the slope and inside the heaped mate-
rial, where the grinding media and the mill feed just roll down as a result of the low speed.
This is mainly important for fine grinding.
Coarse and Fine At higher mill circumferential speeds it is possible to obtain greater comminution by
Comminution shock, which is important for coarse comminution, whilst greater frictional comminution
is achieved at lower circumferential speeds. For fine comminution the mass of grinding
media should just circulate with the mill feed. The mills that are only used for coarse
grinding can therefore run somewhat faster than fine grinding mills with the same config-
uration. If coarse and fine grinding are performed in the same mill tube, but in separate
grinding compartments, this is referred to as a compound mill. The desired optimal com-

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 2.1 Ball Mill Designs

minuting effect can be achieved in compound mills by filling the two compartments with
appropriate grinding media charges and by appropriate configuration of the liner plates.
At this point in the online course you would watch an animation of grinding media move-
ment.
The mass and filling factor of the grinding media, the mill rotational speed or mill circum-
ferential speed and the lifting characteristics of the liner plates should be matched to one
another to achieve the desired movement of the grinding media.

At this point in the online course you would be offered the chance to take part in a quiz on
this topic.

2.1 Ball Mill Designs

Ball mills are constructed as single-, double- or multiple-compartment mills. The com-
partments are separated by intermediate diaphragms (Fig. 2.1-1, 2), which prevent mate-
3
rial that is too coarse from passing from the coarse grinding compartment (Fig. 2.1-1, 1)
into the fine grinding compartment (Fig. 2.1-1, 3).
In 2-compartment mills the first compartment covers about 1/3 and the second compart- Division into
ment covers about 67 % of the length of the grinding space. Approximate values for 3- Compartments

compartment mills are: first compartment approximately 20 %, second compartment ap-

proximately 30 % and third compartment approximately 50 % of the length of the grinding
space.

2
1

Figure 2.1-1: 2-Compartment Mill (source: Christian Pfeiffer) .

The (pronounced lambda) ratio of length/diameter of a ball mill is designed so that the Ratios for a Ball Mill

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 2 Structure and Operation

desired fineness of the mill feed is obtained at the mill outlet.

open-circuit mill for cement: = 3 to 4.5

closed-circuit mill for cement: = 3 to 4

closed-circuit mill for raw meal: = 2 to 3

Table 2.1-1: Guide Values for .

Outlet Diaphragm The outlet diaphragm is located at the mill outlet (Fig. 2.1-1, 4). Its functions are to:
 hold back the grinding media
 regulate the filling factor of the mill feed
Intermediate The grinding compartments are separated by intermediate diaphragms (Fig. 2.1-2). The
Diaphragms intermediate diaphragm prevents the oversize material from passing into the fine grind-
ing compartment.

Figure 2.1-2: Diaphragm in a Double-Compartment Tube Mill (Example) .

Influencing Factors The power consumption, throughput, and fineness of the mill feed produced at the mill
outlet of the different mill designs depend on the following parameters:
 Mill:
 diameter, length and compartment division
 rotational speed
 filling factor and size distribution of the grinding media
 lining
 intermediate and outlet diaphragms
 air flow
 Mill Feed:
 grindability of the feed material
 particle size distribution of the feed
 mill feed mass flow
 filling factor of the mill feed
 grinding aids (type and amount added)
Performance Data Ball mills are now built with tube diameters of up to 6.0 m and tube lengths of up to 20.0
m. Their drive ratings may be as high as 10,000 kW. Nowadays there is extensive knowl-

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 2.2 Influencing Factors in Ball Mills

Figure 2.1-3: Single-Compartment Mill (Polysius) .

edge about ways to optimize energy consumption, operating characteristics and the cement
properties produced by mill configuration and selection of its operational parameters.

Large Cement Mill Usual Mill

Tube: 5.0 m x 17.0 m 4.4 x 15.5 m

Throughput: 220 t/h 150 t/h

Fineness: 2,800 cm2/g 2,800 cm2/g

Drive Rating: 6,400 kW 2 x 2,200 kW

Table 2.1-2: Data For the Largest German Cement Mill and Normal Performance Data.

2.2 Influencing Factors in Ball Mills

The grinding media filling factor (pronounced: phi) is the ratio of the bulk volume Grinding Media
occupied by the grinding media to the total volume of a grinding compartment. In Filling Factor

conjunction with the rotational speed, mill diameter and lining it determines the type of
movement of the grinding media and mill feed charge.

Normal values are:

 coarse grinding compartment: = 26 to 32 %
 fine grinding compartment: = 24 to 28 %

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 2 Structure and Operation

Mill Feed The mill feed filling factor G gives the proportion of the volume of the voids between
Filling Factor G the grinding media that is filled with mill feed.

Optimal comminution results are achieved if the voids between the grinding media are just
filled with mill feed, i.e. G = 1.0. This corresponds to a ratio of approximately 8 to 10 t
grinding media per t mill feed in the grinding compartment. For a large cement mill with,
for example, approximately 270 t grinding media in the fine grinding compartment this
gives a mill feed mass in the fine grinding compartment of approximately 30 t .
Rotational speed n The rotational speed n of a mill has a substantial influence on the movement of the grind-
ing media and therefore on their comminuting effect.

Critical Speed ncrit The rotational speed at which the balls start to be held against the internal wall of the
mill due to the equilibrium between the centrifugal force and gravity is known as the
critical speed ncrit.

Relative Speed The ratio of the operational speed n to the critical speed is called the relative speed nrel.
6
The relative speed nrel is normally between 0.7 and 0.75 in industrial ball mills for cement.
In this range it is possible to optimize the movement of the grinding media in multiple-
compartment mills for coarse and fine grinding since the proportion of shock and frictional
comminution in the grinding compartments can be regulated by the
 mill rotational speed, the
 geometry of the lining, and the
 size distribution of the grinding media as well as the
 mass of the grinding media
The mill rotational speed and the dimensions of the mill tube cannot generally be influ-
enced by the operator.
Ventilation Ball mills are ventilated. The purpose of ventilation is:
 dedusting of the grinding space
 cooling of the mill feed
 assisting the mill feed transport and therefore, to a small extent, the throughput
The air flow is approximately 0.2 to 1.0 m3/kg relative to the throughput. The limit for the
air velocity in the free cross-section of the grinding compartment is:
 in open-circuit mills: ~1.2 m/s (stp, dry)
 in closed-circuit mills: ~1.4 m/s (stp, dry)
Grinding Aids Grinding aids are used mainly when grinding very fine cement. They have the following
functions:
 decreasing the adhesive forces between the fine mill feed particles, thereby
 increasing the entrainability of the mill feed
 preventing the lining and the grinding media from becoming coated in the fine grinding
compartment
 the ground cement is easier to classify when using grinding aids.
Examples of grinding aids:
 ethylene glycol, addition level 0.02 to 0.08 mass %
 triethanolamine, addition level 0.02 to 0.03 mass %, relative to throughput.

2.3 Mill Lining

The mill lining is generally made of hardened steel. It has two important functions:

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 2.3 Mill Lining

 to protect the mill shell against wear

 to generate appropriate movement of the grinding media charge

coarse grinding fine grinding

compartment compartment

Figure 2.3-1: Liner Plates for the Coarse and Fine Grinding Compartments of a Ball Mill .

The coarse grinding compartment is equipped with a lifting or stepped lining (Fig. 2.3-1
left), while the fine grinding compartment is equipped with a classifying lining (Fig. 2.3-1
right).
The lifters of the lifting lining absorb the inertial forces acting in the circumferential di-
rection and prevent the balls near the wall from sliding down. Fine grinding compartments
also use classifying linings (Fig. 2.3-2) that achieve axial movement of the grinding media
through the use of conical plates that are stepped in the axial direction. They make use
of the effects of centrifugal force, impact and slope that can be attributed to the different
sizes and masses of the grinding media. The large grinding media are deflected towards
the mill inlet and the smaller grinding media are displaced towards the mill outlet so there
is a smooth adaptation to the progress of comminution.This makes it possible to dispense
with additional intermediate diaphragms, and increases in throughput of up to 10 % can
be achieved.

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 2 Structure and Operation

small mill diameter

average mill diameter

large mill diameter

Figure 2.3-2: Classifying Lining for the Fine Grinding Compartment of a Tube Mill .

2.4 Drive Types in Tube Mills

Ball mills are driven exclusively by electric motors. The torque may be transferred to the
mill drum in various ways.
Types of Drive The following different types of drive are used:
 Girth Gear and Pinion Drives (p. 8)
 Central Drives (p. 9)
 Gearless Drives (p. 9)

Girth Gear and Pinion Drive

In this type of drive the power is transferred to the girth gear of the tube mill by one or two
pinions.

Figure 2.4-1: Girth Gear-Pinion Drive of a Tube Mill, Examples .

 girth gear diameter up to 12 m
 transferrable power
 up to 5000 kW with 1 pinion, unlimited with 2 pinions. 2 motors and 2 gear units are
normally used with 2 pinions.

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 2.4 Drive Types in Tube Mills

Central Drive
- This drive is approx. 50 % more expensive than the drive with a girth gear and 1 pinion;
there are a number of different designs. The transferrable drive power is unlimited.

Figure 2.4-2: Central Drive of a Tube Mill, Examples .

Gearless Tube Mill Drive

In gearless drives there is no separate motor which produces torque that is transferred to
the mill. Instead, the motor components (stator and rotor) form an integral part of the
mill. The rotating mill tube or its extension therefore takes on the function of the rotor.
The torque generation principle remains the same. Electric motors generally generate a
relatively small torque at high rotational speed and this is transformed by appropriate gear
units. Ring motors generate the required torque directly at a correspondingly lower speed.
These are therefore referred to as low-speed motors.
Advantages of the gearless drive are: Advantages
 the rotational speed can be changed continuously within specific limits,
 low space requirement,
 no gear units.
The following may be classed as disadvantages: Disadvantages
 high investment costs, approx. 1.6 to 1.8 times the cost of girth gear and pinion drives,
which become relatively less with increasing power.
The transferrable drive power is unlimited. Use is made of a.c. motors with variable
frequency supplied by a frequency converter that can be installed in a separate area! A
synchronous motor with a frequency of 5.5 Hz is normal for low speeds of 13 15 rpm.
There are two types of design (Fig. 2.4-4): Ring Motor
a) Rotor mounted on a reinforced, extended mill trunnion bearing. Good accessibility both Designs
to the mill and to the motor
b) Specially configured mill shell enclosed by the motor.
The advantages of the design on the mill shell (b) are: Advantages b)
 minimum total length
Disadvantages of design b) may include: Disadvantages b)
 effects of temperature fluctuations may disrupt mill operation
 deformation of the mill cylinder under the load of the mill charge after switching off
 the mill and motor must be specially matched to one another.

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 2 Structure and Operation

10

Figure 2.4-3: Tube Mill with Ring Motor in a Cement Works .

2.5 Configuration of Ball Mills in Cement Grinding Plants

The configuration of the systems for primary, coarse and fine comminution plays an im-
portant part in the grinding of cement. Energy expenditure and grinding results can be
positively influenced by optimization of the mills and other plant components.
When grinding cement a distinction is made between coarse comminution and fine grind-
ing. It is possible to provide a separate arrangement in the form of a primary mill for coarse
comminution and a fine mill, or to use double- or multiple-compartment mills. The ad-
vantages of the separate arrangement are that the mill dimensions and the grinding media
charge and mill speed can be adapted in both cases to the respective required movements
of the grinding media (ball drop or rolling).
Open- and Closed- Ball mills may be operated both as open-circuit mills and as closed-circuit mills. Both
Circuit Mills types of operation will now be explained in greater detail.

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 2.5 Configuration of Ball Mills in Cement Grinding Plants

Rotor Stator

modification 1

Rotor Stator

11
modification 2

Figure 2.4-4: Gearless Tube Mill Drive (Ring Motor), Schematic View .

2.5.1 Open-Circuit Mills

In open-circuit mills or compound mills the primary and fine grinding processes take place
in separate grinding compartments but in the same mill tube (Fig. 2.5-1).

fan
filter
feed hopper

fresh air

finished
product

Figure 2.5-1: Open-Circuit Mill (Compound Mill) .

Advantages of this configuration are: Advantages:

 only one grinding unit,
 simpler system,
 lower maintenance costs,
 simpler control
This configuration has the following disadvantages: Disadvantages:
 better suited only to coarser cements, since specific energy expenditure increases
rapidly with increasing fineness,
 fineness of the finished product can only be adjusted by changing the mass flow of the
feed,

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 2 Structure and Operation

 grinding heat is only removed by the mill air or by injection of water; water injection
is limited by possible loss of strength

2.5.2 Closed-Circuit Mills

In this configuration the ball mill is positioned in a circuit with an air classifier (Fig.
2.5-2). The "grinding circuit" is formed by the ball mill with two grinding compart-
ments, the bucket elevator and one or two classifiers. Dedusting may be carried out down-
stream.

bucket elevator
dynamic fan
classifier
filter
feed hopper

12

finished
product
static classifier
fresh air

tube mill

Figure 2.5-2: Closed-Circuit Mill .

Advantages: Advantages of this configuration are:

 The mill is shorter, the grinding media are coarser, the mill output material is coarser,
fine material is separated in the classifier. Greater fineness can therefore be achieved.
Coarse material is fed back to the mill.
 Fineness can be controlled by adjustable air classifiers. Short response times.
 Severe heating of the mill feed, especially in large mills, is reduced by approximately
10 20 K by cooling in the classifier.
 At greater finenesses there is lower specific energy expenditure than with open-circuit
grinding.
Disadvantages: It has the following disadvantages:
 Closed-circuit grinding plants are more complicated and more susceptible to break-
down than open-circuit mills.
 More space is required.
 Higher investment costs, inc. buildings approx. 30 25 % more.

2.6 Operating Characteristics of Ball Mills

Different control methods are used depending on the operating characteris-
tics of the ball mill. These methods differ depending on the mode of opera-
tion of the mill (open-circuit mill or closed-circuit grinding plant).

Electric Ear, Grinding A system known as an electric ear that measures the level of grinding noise generated
Noise is generally used to control ball mills.

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 2.6 Operating Characteristics of Ball Mills

Special circumstances arise during the operation of ball mills when grinding soft or moist
materials. The specific problems are explained in greater detail in the following units.

2.6.1 Controlling Ball Mills

Throughput and Mass Flows

If the grindability of the mill feed remains constant, the fineness at the mill outlet will Mass Flows
depend mainly on the throughput mass flow (or circulating mass flow). In an open-
circuit mill, and with constant grindability, it would therefore be sufficient to keep the
flows constant to obtain a finished product of constant fineness.
In closed-circuit grinding plants the coarse classifier material must also be taken into con-
sideration in addition to the fresh material feed. The coarse material mass flow mG is
determined for this purpose. If the proportion of coarse material decreases then the supply
of fresh material mF is increased according to the following rule:
13
throughput mass flow = mF + mG = constant.

However, since the mill can cope more easily with the coarse material that has under-
gone primary grinding than the fresh material, the controller is set in such a way that only
an additional 1/3 to 1/2 a tonne of fresh material is introduced if there is a decrease in
coarse material of 1 tonne.
The mill throughput is composed of the fresh material supplied and the recycled classi- Throughput, Coarse
fier material (coarse material). The amount of coarse material is 2 to 3 times the amount of Material, Fresh Material

fresh material depending on the mode of operation. For example, a mill with a throughput
of 100 t/h is fed 25 to 30 t/h of fresh material and 70 to 75 t/h of coarse material. During
stable operation the amount of material discharged from the mill (finished product) corre-
sponds to the amount of fresh material. In this instance the mill filling factor remains the
same.

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 2 Structure and Operation

Rule of Thumb: coarse material + fresh material = constant

If the amount of coarse material decreases by a tonne, then it would seem at first glance
that a tonne of fresh material must be introduced in accordance with the rule: "coarse
material + fresh material = constant". However, the control strategy is designed to take
long-term considerations into account. If a tonne of fresh material is introduced then
there is more material in the cycle. This is recycled and leads to an increase in the
amount of coarse material. Since the amount of coarse material is 2 to 3 times the feed
rate, it will also increase with time by 2 to 3 t/h before a stable state is reached again.
The amount of fresh material and finished product is then + 1 t/h and the circulating
mass flow is + 2-3 t/h. The total amount of fresh material and coarse material therefore
deviates by up to 3 t/h from the desired value.
If only 1/2 or 1/3 of a tonne more is introduced (depending on the amount of coarse
material) then the flow of coarse material will in turn increase by 1 t/h and the original
state is achieved again (approximately). If this is done accurately, the state will now
differ by precisely the 1/3 t/h of additional fresh material that has been introduced.
The following would be an exact example: coarse material = 3 x fresh material; with
14
one tonne decrease: + 0.25 t/h more of fresh material; leads to 0.75 t/h more of coarse
material. As a result, the tonne decrease has now been offset (0.25 + 0.75). However,
this only represents a simple control strategy and changes as precise as this are not
possible in the context of real process fluctuations.
This is the reason for the simple "rule of thumb". This will achieve the condition "coarse
material + fresh material = constant" after a certain time, even if there is an initial
deviation.

Measuring Grinding Noise

If the mill loading changes then the grinding noise will also change immediately. The
grinding noise can be measured using the electric ear . The measurement cannot be
converted precisely enough into the mill feed filling factor so it is only used as a prelimi-
nary warning for the flow rate control system. The electric ear is also used to shut down
the feed equipment if the noise level falls below a certain limit that indicates that the mill
has filled up.
Changes to the mill loading have a particular impact on the mill feed filling factor in the
coarse compartment; the electric ear is therefore located there, on the ball drop side (loud-
est grinding noise). Modern designs of the electric ear measure the frequency spectrum of
the noise emitted and supply detailed information on the operating state of the mill via a
downstream frequency analysis system.
Since the grindability of the feed material fluctuates (more greatly with raw material than
with cement clinker; but the requirements for uniformity of fineness are greater with ce-
ment), fineness must also be monitored in addition to the flow rate control.

2.6.2 Advantages and Disadvantages of Ball Mills

Wide Particle-Size Distribution

The product ground in ball mills generally has a relatively wide particle-size dis-
tribution . It is advantageous to operate the ball mill in a circuit with a classifier,
particularly with materials that are easy to grind and are susceptible to agglomeration,
and also in order to produce greater finenesses. Recycle ratios between 1.1 and 6.0 can

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 be established depending on the grindability of the mill feed and the desired product
fineness.
High Level of Availability
Ball mills are relatively easy to operate in a stable state. Maintenance and repair costs
as well as investment costs are relatively low. Operational reliability as well as avail-
ability of ball mills are high. They are therefore still the most frequently purchased
grinding units.
Low Efficiency
Compared to other mill types, ball mills exhibit the highest specific energy consump-
tion and the lowest energy efficiency. This amounts to only approximately 24 to 32
cm2/J depending on the hardness of the mill feed and the desired grinding fineness.
Noise
Ball mills also emit the most noise and must therefore be operated inside closed build-
ings with special aeration and ventilation equipment in accordance with environmental
legislation.
Cooling Requirement
15
In many cases, especially in large mills and when the clinker is hot, the cement pro-
duced in ball mills must be cooled in the grinding circuit or after grinding because
almost all the electricity supplied to a ball mill is converted into heat and most of this
is transferred to the mill feed (Fig. 2.6-1).

classifier

filter
exhaust air
cooling air/hot gas

cooler
cement

fresh material cooler

cooling air/hot gas
ball mill

Figure 2.6-1: Flow Diagram of a Grinding Plant with Ball Mill and Various Devices for Cooling the Mill
Feed .

Moist interground additions can also be dried, to a limited extent, by using hot gas instead Drying
of air and by utilizing the grinding heat. However, as the mill size increases the drying
capacity of the mill air decreases. It is therefore expedient, including for reasons of quality,
to pre-dry the mill feed in special driers if there is a large proportion of moist mill feed.

3 Health and Safety Practices

Personal protective equipment (PPE) must be worn when working on or in reaction vessels
or conveyors within a grinding plant of any type. This protective equipment consists of
 protective clothing
 hard hat
 gloves
 protective goggles

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 3 Health and Safety Practices

 protective breathing mask

 safety harness
Reaction vessels are generally:
 mill tubes
 vertical roller mill housings
 high pressure roller mill housings
 classifiers (static and dynamic)
 cyclones
 fabric filter housings
 electrostatic precipitator housings
 pipelines
Conveyors are generally:
 bucket elevators
 conveyor screws
 chain conveyors
16  bucket conveyors
 belt conveyors
 Sicon conveyors
 hopper discharge devices (e.g. Saxlund)
 conveying and metering belt weighfeeders
 thrust feeders
 disc feeders
 rotary feeders
 loosening equipment in working hoppers
 specialist machinery (such as screens or Mogensen Sizers)
The following measures must be taken before and during work:
 Production supervisors and managers give and receive information regarding any work
taking place.
 Once work has been performed and completed this must be communicated by the
workers who carried out the work.
 All mill drives must be isolated on the high-voltage side before access. This must be
recorded.
 The operating safety of auxiliary drives used for positioning must be checked before
use.
 Fans, conveying and discharging equipment, metering machines, classifiers and crush-
ers must be disconnected on all poles and be secured against reconnection. The worker
responsible prevents reconnection by arranging padlocks on the switches of the repair
switch boxes and these are removed once work is completed.
 Safety lookouts must be used where necessary.
 Radio equipment or intercoms should be used if visual contact with a safety lookout
cannot be ensured.
 Different surfactants/grinding aids are used to combat the tendency for agglomeration
of mill feed in tube ball mills and to improve dispersion of the feed in classifiers.
The necessary handling instructions detailed in the relevant safety data sheets must be
observed.
 Stearic acids and Mesamol are used as air-entraining agents in hydrophobic cement.
The instructions given in safety data sheets must be observed.
 Water injection is used in tube ball mills for many reasons:

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  conditioning of the exhaust gas for electrostatic precipitators after cement mills;
water injection is therefore relevant to the environment.
 cooling the cement to temperatures below 60 C; water injection is therefore rele-
vant to health and safety at work.
 combating agglomeration during cement grinding in tube ball mills; water injection
is therefore relevant to quality and output.
 Water injection is used in tube ball mills for many reasons: Use of Water
 the conditioning of the exhaust gas for electrostatic precipitators after cement mills
is environmentally relevant,
 the cooling of the cement to temperatures below 60 C is relevant to health and
safety at work,
 combating agglomeration during cement grinding in tube ball mills is relevant to
quality and performance.

4 Factors Affecting Operation and Quality 17

The production operation is determined by: Operation
 time availability of the plant
 output availability of the plant, i.e.:
 safeguarding of product quality
 minimization of energy use
 wear and corrosion
The above factors are interrelated and determine:
 the efficiency of the production plant,
 the influence on possible emissions,
 the influence on output,
 the influence on energy consumption.

Time Availability of the Plant, Maintenance and Inspection

The availability index is influenced by scheduled preventive maintenance:
 Basic repairs are carried out annually.
 Downtime is planned weekly for immediate repairs.
 Damage and unforeseen breakdowns necessitate immediate repairs.
Ensuring quality and securing a high standard of environmental compatibility. Objective:

Output Availability
Measures to safeguard output availability affect:
 the safeguarding of product quality
 the minimization of energy consumption
 the minimization of wear and corrosion
This basically means that:
 the comminution elements in tube ball mills, as in vertical roller mills and high pres-
sure roller mills, must always be maintained in their intended condition,
 the grinding media filling factor in tube ball mills must be checked and corrected
periodically,
 regular measures must be carried out to safeguard the classifying efficiency of different
types of classifier,

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 5 Maintenance and Inspection

 optimum use of grinding aids is ensured,

 water injection is regularly optimized as a function of clinker temperature, and
 measures are taken to assess the condition of the plant.
Grinding plants can be operated reliably and with a high level of availability if the above
measures are carried out diligently and the personnel are well-trained or the plants are
automated, thus minimizing wear.

Comparison of Grinding Systems

Grinding System Energy Expenditure Applicability of Cements

open-circuit mills high universal

tube ball mills operating in closed average universal

circuit

high pressure roller mills operating low universal

in conjunction with tube ball mills
18
high pressure roller mills operating very low for specific applications
in closed circuit

vertical roller mills low for specific applications

Table 4.0-1: Comparison of Energy Consumption and Applicability of Grinding Systems.

5 Maintenance and Inspection

Ball mills are very low maintenance due to their simple structure and are characterized
by their high level of availability. However, regular maintenance should be scheduled in
order to ensure operational reliability.
Wear The parts that are most subjected to wear in ball mills are
 the grinding balls (Fig. 5.0-1) and
 the mill lining.

Figure 5.0-1: Worn Balls of a Ball Mill .

Charge The state of the charge should be checked at regular intervals. Well-worn and possibly
broken grinding media impair the comminuting performance of the mill and increase the
specific energy requirement. The reduction in ball size must be offset by replenishment
with suitable balls.
Lining The mill lining is checked at considerably longer intervals than the charge. Internal repair

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work generally involves turning the mill, which is a complicated procedure. Depending
on design, mill linings have service lives of several years.
Mill bearings and gear units must also be inspected regularly, particularly with regard to Bearings and Gear
the dust loading in mill buildings. Units

6 Environmental Protection
Ball mills emit very high levels of noise. They must therefore be operated inside closed Noise
buildings having special aeration and ventilation equipment in accordance with environ-
mental legislation.
Dust-laden airflows are produced when operating grinding plants. The majority of the Dust
dust is removed from the air in cyclone separators and added to the finished product. Any
remaining pollution must be removed using appropriate filter systems. Further information
on this topic can be found in the corresponding course.

19
7 Questions on Course LB 4.2 Ball Mills
You can test your knowledge by answering the following questions.

Question 7.0 A:
1. At what rotational speeds are tube mills operated (absolute and relative speeds)?
Explain your choice of speed.
2. What is the efficiency of a tube mill? Why is the efficiency so low?
3. Explain the difference between open-circuit grinding and closed-circuit grinding.
4. What is the usual length/diameter ratio of a tube mill with two compartments for
cement grinding?
5. What is the ratio between the compartment lengths of a double-compartment ce-
ment mill?
6. What are the functions of the mill lining?
7. What grinding media filling factor is normally selected in the two grinding com-
partments of a cement mill? Give reasons for your answer.
8. What is the purpose of ventilation of a tube mill for cement?
9. What is the air rate relative to the mill throughput?
10. Which grinding aids do you know?
11. What are the purposes of grinding aids?
12. Which specific health and safety practice measures are necessary when working on
and, in particular, in a tube mill?
13. Name the environmental protection measures to be taken when operating tube mills.
Explain your reasons!
Solutions see p. 20

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 7 Questions on Course LB 4.2 Ball Mills

Solutions
Solution for 7.0 A:
1. absolute rotational speed = 0.75 x n critical .
critical rotational speed = speed at which the grinding ball mass is held against the
tube wall during mill operation.
relative rotational speed = 0.70 to 0.78
2. Very low! Less than 1.0 % based on energy consumption for comminution of indi-
vidual particles
Reason: very high energy losses
3. a) open-circuit grinding:
mill discharge material + dust = finished product
b) closed-circuit grinding:
mill discharge material = classifier feed,
coarse classifier material is fed back to the mill;
20 fine classifier material + dust = finished product
4. L/D ratio = 3 to 4
5. First compartment: 33%
Second compartment: 67%
6. a) to protect the mill shell against wear
b) to generate appropriate movement of the grinding media charge
7. a) coarse grinding compartment: 26 to 32 %
b) fine grinding compartment: 24 to 28%
Reason: together with other factors, to generate appropriate movement of the grind-
ing media during grinding
8. a) cooling the mill feed
b) dedusting the grinding space
c) assisting the transport of the mill feed and therefore the throughput
9. a) open-circuit mills: 1.2 m/s
b) closed-circuit mills: 1.4 m/s
10. ethylene glycol,
triethanolamine
11. a) to break down the adhesive forces between fine mill feed particles
b) to increase the flow properties of the mill feed
c) to prevent the lining and the grinding media in the fine grinding compartment
from becoming coated
d) to improve the classification process
12. a) inform production supervisors and managers
b) the worker responsible must isolate all drives on the high-voltage side and secure
them against reconnection; this must be documented!
c) the operational safety of auxiliary drives must be checked before use
d) fans, incoming and discharge conveying equipment, classifiers and crushers must
be disconnected at all poles and secured against reconnection
e) safety lookouts must be used where necessary
f) the instructions given in safety data sheets for grinding aids must be observed!
g) once work has been completed this must be reported by the workers who carried
out the work
h) the workers responsible must release the plant for use again once the work has
been completed

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13. a) noise protection is necessary since tube mill operation generates a great deal of
noise
b) prevent dust emissions by
 dedusting tube mills and conveying routes
 sealing all sections of plant
Questions see p. 19

21

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Glossary
air classifier
Classifying machine for dry dust collection or pneumatic classification at low particle sizes (approximately 0.1
2 mm).
ball mill
Tube mill that uses balls as grinding media. If required, the mill can be divided into different grinding chambers,
in which grinding balls with different diameters are used in the individual chambers.
centrifugal force
Physical force that acts upon a body moving along a curvilineal path
classifying lining
Lining that is used for fine grinding. It classifies the grinding media, i.e. the size of the grinding media is adapted
to the progress of comminution along the grinding path.
coarse material mass flow
Material that, owing to its size, remains in the mill circuit and is not discharged. Classification into fine and
coarse material is carried out by a classifier.
electric ear
Technical system for measuring and analyzing grinding noise 23
gravity
Force that acts on a body within a gravitational field. For example, it makes objects fall to the ground. The
gravitational force at the earths surface is called gravity.
grinding media filling factor
The grinding media filling factor is the ratio of the bulk volume occupied by the grinding media to the total
volume of a grinding compartment. Together with rotational speed, mill diameter and lining it determines the
type of movement of the grinding media and mill feed charge.
mill feed filling factor
The mill feed filling factor gives the proportion of the void volume between the grinding media that is filled with
mill feed.
particle size distribution
The frequency distribution of different particle sizes. A combination of different degrees of fineness is known as
a wide particle size distribution or a wide particle range.
throughput mass flow
Amount of material that passes through a mill per unit of time (for example tonnes per hour). Calculated from
the fresh and coarse material mass flows.

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 Index

A
air classifier 12

B
ball mill 1

C
centrifugal force 2
classifying lining 7
coarse material mass flow 13

E
electric ear 12, 14

G
gravity 2
24
grinding media filling factor 5

M
mill feed filling factor 6

P
particle size distribution 14

T
throughput mass flow 13

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