CHAPTER 6

EQUIPMENT DESIGN

6.1 Design of the Conveyor System to Ball Mill

Conveyor belt and metal conveyor systems are the only conveyor systems which will be
used in the Ceramic plant. These conveyor systems allows time efficient transportation of
raw materials, green bodies, and final products, as well as efficient warehousing and
manufacturing distribution.
The conveyor system used to travel raw materials to the ball mill is through conveyor belt
system. This is because, conveyor belts are usually made of rubber compound which
provide optimal abrasion resistance, full resistance to mildew and rot, and high adhesion
between piles and covers.
The belt speed of conveyor belts supported by idlers must not exceed 0.25 m/s with
abrasive materials, and 0.5 m/s with non-abrasive materials. And for conveyor belts
supported by sliders, the belt speed must not exceed 0.13 m/s.
Conveyor Capacity = (B^2)pS/1.085
Where,
B = belt with
Density = density of material
S = belt speed
6.1.1 Feeder Belt Capacity
Cmaximum = (0.8 m)^2 (density of material) (0.5 m/s) /1.085 = kg/s
6.1.2 Belt Conveyor from Feeder Belt to Ball Mill 1
Ccapacity = (MT/24hr) (kg/MT) (1hr/3600s) = kg/s
Distance = m
Power, P = 0.0027(m^0.82)L
6.1.3 Belt Conveyor from Feeder Belt to Ball Mill 2
Ccapacity = (MT/24 lhr) (kg/MT) (1hr/3600s) (kg/MT) = kg/s
Distance = m
Power, P = 0.0027(m^0.82)L
6.1.4 Belt Conveyor from Feeder Belt to Ball Mill 3
Ccapacity = (MT/24hr) (kg/MT) (1hr/3600s) = kg/s
Distance = m
Power, P = 0.0027(m^0.82)L
6.1.5 Belt Conveyor from Feeder Belt to Ball Mill 4
Ccapacity = (MT/24hr) (kg/MT) (1hr/3600s) = kg/s
Distance = m
Power, P = 0.0027(m^0.82)L
6.2 Design of the Ball Mill
Ball mills are cylindrical rotating devices used in grinding and mixing raw materials fed
using aluminum balls, through wet milling process. This process further grinds the raw
materials inside the mill by friction, with 30 percent solid loading and 70 percent loading,
into finer particle size.
The total amount of solid and water loadings are based on the amount of formulated
ceramic slurry, which is kg, are,
M solid loading = kg
M water loading = kg
respectively. Assuming that there is % weight loss due to, the following loadings are
calculated,
6.2.1 Total Solid Loading
M solid loading milled = (kg) – (% weight loss) (kg) = kg
6.2.2 Total Water Loading
M water loading milled = (kg) – (% weight loss) (kg) = kg
6.2.3 Total Outflow Ceramic Slurry Loading
M ceramic slurry = M solid loading milled + M water loading milled = kg
6.3 Design of the Pumps and Pipes
Pipes are usually used as a medium for transporting ceramic slurry and water from one
point to another. The pipes used throughout the plant are PVC pipes; this is because, the
degree of inertness and resistance to corrosion is high. In addition to that, transportation
of ceramic slurry and water would have not been possible without a pump. Pumps used
in this plant are industrial pumps which are usually a heavy-duty process pumps. And the
types of pumps used for industrial purposes typically includes centrifugal pumps and
positive displacement pumps.
6.4 Design of the Screen
In body preparation, materials are allowed to pass through three different micron size
screens. These screens are between the ball mill and slurry tank, and spray dryer and silo
storage area. The screens are used to take the granulated material and separate it into
multiple grades by particle size. Hence, it will be assumed that there is a 3% loss in weight
due to oversize on the screen.
6.5 Design of the Slurry Tank
Slurry tanks are used to mix, store, and age ceramic slurry after milling for several hours
in the ball mill. In this plant, ceramic slurry is stored and aged for 24 hours with a spindle
speed of, before it is pumped to the spray dryer. Moreover, it will be assumed that there
will be a % loss in weight due to the slurry particles left inside the tank.