Beruflich Dokumente
Kultur Dokumente
Gas + dust
outlet
Intermediate diaphragm
Outlet diaphragm
Reject return Inlet head
C2 liners
C1 liners
chute
Discharge box
Fresh feed
Outlet seal
Material discharge
Shell
Central or ventilation ring
Fresh air inlet
Central Ventilation ring grate
Supports
Feed Arrangements
Mill Heads
Mill Bearings
Drive types
Mill Shell
Trunnion
March 2004
Deff
March 2004
Purpose
Criterion
Step
Performance should be
checked when step < 40%
of initial step (wear=60%)
Corrective measure
rotation
Replacement
March 2004
Direction of rotation
Grindability of feed
material
BOLTLESS STEP CHAMBER
1 LINER
Less material spillage
Avoids bolt breakage
The Ball mill / ATC Process
March 2004
March 2004
- before 60 kWh/t
- after 53 kWh/t linked to a return to normal mill output
March 2004
Purpose
Insure adequate size reduction
Insure proper output
Quick estimate
Distance between charge and
lower part of the trunnion
Distance between charge and
lower part of the ventilation screen
Criterion
Between 28% and 34%
Corrective measure
Regular recharging
March 2004
Vertical measurement
Middle
axis
March 2004
30%
85
27,6
March 2004
21%
59
39,1
Gap
-30%
-30%
+42%
10
Purpose
Criteria
Corrective measures
Polluted charge
March 2004
11
Purpose
Quick evaluation
Overfilled compartment
March 2004
12
Criterion
Corrective measures
Right level
Empty compartment
March 2004
13
conventional
material
transport
The Ball mill / ATC Process
effect of the
material flow
control
March 2004
14
Purpose
Adapts the charge granulometry to
that of the material
Criterion
Progressive decrease of the ball size
in C2
Corrective measures
Sorting and optimization of the ball
charge
Replacing liners
Checking the size of slots
6mm intermediate diaphragm
8mm outlet diaphragm
March 2004
Classified
Unclassified
15
Classifying liners
Diameter <4.4m
Diameter >4.4m
March 2004
16
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17
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18
Wear of the liners and ball charge has to be looked after in order to avoid performance losses.
Worn out state Normal state*
Grinding
energy
Mill output
*
39 kWh/t
65 t/h
Gap
32 kWh/t
92 t/h
-18%
+40%
March 2004
19
Purpose
Good permeability
Cleanliness
Criteria
General condition
Ventilation Screens
Maximum permeability
Mechanical behavior with the 90 mm
(3-1/2) balls and screen# < 40 mm
(1-3/4) in C1
Screen# < 15 mm (5/8) in C2 to prevent
20 mm (3/4) balls from escaping
Corrective measures
Cleaning or replacement
March 2004
20
Diaphragm Slots
Purpose
Scrap
General conditions
Slot plugging
Peening, clearances
C1 side clearance
Slot width
C2 side clearance
March 2004
21
March 2004
22
Diaphragm Slots
Criteria
C1 slots from 6 mm to
8 mm
C2 outlet slots larger by at least 2 mm than
those of C1 outlet
Corrective measures
Peened slots
March 2004
23
Compartment Samples
Purpose
COMPARTMENT N1
Grinding
Samples
assessment
(C1 and C2)
Determining
Charge
spitzer locations
0.5m
Quick evaluation Direction of rotation
Samples taken at
C1
1 2
3 4
5 6
the discharge end
of the compartment
COMPARTMENT N2
March 2004
C2
24
March 2004
25
Second chamber
sample collection using
sieve.
March 2004
26
Measuring media
diameter using
vernier caliper
March 2004
27
Compartment Samples
Criteria
<5% retained on 2
to 2.5 mm (or 8
mesh) sieve at the
diaphragm
Progressive
decrease all along
the mill
Corrective measure
Adapting the
charge
granulometry
Changing the
length
rejects
100
80
60
40
20
0
10
11
12
Sample Number
40 m
63 m
100 m
200 m
500 m
1 mm
2,5 mm
5 mm
Diaphragm
Diaphragm
Inadequate grinding
Presence of grains
March 2004
28
Summary
March 2004
29
Summary
Material level
Material level = ball level over the entire compartment
Ball charge classification :
progressive decrease of the ball size in C2
Diaphragm slots :
first compartment slots: 6mm to 8mm
second compartment outlet slots larger by at least 2mm
than those of first compartment
Ventilation screens
they have to have the maximum permeability to let the
maximum gas flow through the mill while retaining the balls
March 2004
30
GROUP EXERCISE
Gap in
diaphragm.
What?
Where?
Condition?
Low permeability
The Ball mill / ATC Process
March 2004
32
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33
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34
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35
March 2004
36
Intermediate diaphragm
Blockage due to excessive heat within mill.
Slot profile is circumferential and is therefore ok.
March 2004
37
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38
March 2004
39
High wear
March 2004
40
Tramp material,This
often results in slot
blockage.
March 2004
41
25 mm
75 mm
March 2004
42
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43
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44
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45
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46
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48
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49
Deflectors
March 2004
50
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51
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52
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53
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54
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55
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56
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57
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58
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59
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60
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61
Break 15 mins
March 2004
62
50
45
40
% Volume load
35
30
25
20
15
10
H=HEIGHT ABOVE
CHARGE
D= INTERNAL DIA.
March 2004
63
% Volume Load =
400/PI*((0.25*Cos(2*(H/D-0.5)))
-((H/D-0.5)*((H/D-(H/D)^2)^0.5)))
March 2004
64
Apparent
t/m3
Charge density
3.91
H1
Case
H1 Crash Stop
38%
H2
H2 Without Material
4.50
Charge Expansion
%Volume load
March 2004
33%
5%
65
% Cumulative
Residue
1%
1.18 mm
6%
300 um
20%
March 2004
66
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68
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69
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70
= Internal
= 1.073
0.2846 DAWN
Diameter of Mill
-J
W
N
The Ball mill / ATC Process
= Charge
= Mill
weight in Tonnes
speed in RPM
March 2004
71
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72
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73
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74
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75
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76
March 2004
77