Ball Mill Performance & Efficiency

S. Description Symbol Formula Example

No.
1 Arm of gravity a 0.666 * ( 1 - 4 * R2 )1.5 h 0.51
- TAN [ 0.5 / R * (1 - 4*R2)0.5] - [ 2*R * (1 - 4*R2)0.5 ]
-1
Deff 2.9
h Centre Distance (from mill centre to media top layer), mts R 0.176
Deff Mill effective diameter, mts a 0.619
R h/Deff, ratio of centre distance to mill effective diameter Target -
2 Torque factor matrix u - -
Material Grinding Fitting Type Torque
- - -
None Balls 0.73
None Rods 0.55 - -
Coarse/Medium
Danula Balls 0.75 - -
Cement
Sonex Balls 0.66 - -
& Raw
None Balls 0.69
Meal - -
None Cylpebs 0.73
Fine
Danula Balls 0.71 - -
Danula Cylpebs 0.75 - -
Coarse/Medium None Balls /Cylpebs 0.69
Coal - -
Medium Danula Cylpebs 0.71
- -
2 Power consumption, net Pn 0.514 * F * u * n * Deff * a F 79
kW F Grinding media weight, tons u 0.71
u Torque factor n 18.6
n Mill speed, rpm Deff 2.9
Deff Mill effective diameter, mts a 0.578
a Arm of gravity, - Pn 899
Target -
3 Power consumption, gross Pg Pn * 100 * 100 Pn 924
kW Em * Eg Em 95
Em Motor efficiency, % Eg 95
Eg Gearbox/girth gear efficiency, % Pg 1024
Target -
4 New production rate NPB Formula-1(Holderbank) OPB 110
(Mill output Vs. Blaine) tph OPB OB 3450
Exp ( ( NB - OB ) * 0.49 / 1000 ) NB 3350
OPB Old production rate, tph NPB 115.524
OB Old blaine, cm2/gm Target -
NB New blaine, cm2/gm

Formula-2(General) OPB 110

OPB * ( OB / NB )1.3 OB 3450
OPB Old production rate, tph NB 3350
OB Old blaine, cm2/gm NPB 114.288
NB New blaine, cm2/gm Target -

Formula-3(KHD) OPB 110

OPB OB 3450
Exp ( ( NB - OB ) * 0.43 / 1000 ) NB 3350
OPB Old production rate, tph NPB 114.833
OB Old blaine, cm2/gm Target -
NB New blaine, cm2/gm

5 New production rate NPR OPR * ( 2 - log ( OR ) ) OPR 110

(Mill output Vs. Residue) tph ( 2 - log ( NR ) ) OR 11.5
OPR Old production rate, tph NR 9.5
OR Old residue, % NPR 101
NR New residue, % Target -
6 Gypsum set point GSP 21500 * ( Scem - Sclk ) Scem 2.3
(at weigh feeder) tph Pu * ( 100 - Fgyp ) Pu 70
Scem Target SO3 content in cement, % Sclk 1
Pu Gypsum purity, % Fgyp 4.8
Sclk SO3 content in clinker, % GSP 4.19
Fgyp Free moisture in gypsum, % Target -
7(a) Maximum ball size MBS 36 * F0.5 * { ( SG * Wi ) / ( %C * Deff0.5 ) }0.333 F 4
 Ball Mill Performance & Efficiency
S. Description Symbol Formula Example
No.
(If feed size is known) mm F Feed size (sieve size in mm which retains 20% material), mm SG 3
SG Specific weight of feed material, gm/cm3 Wi 17
Wi Bond's work index, kWh/t %C 75
%C Mill speed as %critical, % Deff 3
Deff Mill effective diameter, mts MBS 52
Target -

7(b) Maximum feed size F (MBS *{{(%C * (Deff.)0.5 )}/(SG * Wi)}1/3 * 1/36)^2 MBS 52
(If ball size is known) mm MBS Max. Ball Size, mm SG 3
SG Specific weight of feed material, gm/cm3 Wi 17
Wi Bond's work index, kWh/t %C 75
%C Mill speed as %critical, % Deff 3
Deff Mill effective diameter, mts F 4
Target -

8 %Filling %F 112.5 - ( 125 * h / Deff ) h 1.96

% h Free height, mts Deff 2.9
Deff Mill effective diameter, mts %F 28.0
Target -
9 Circulation factor C Formula-1 FF 150
- F+G CR 170
F C 2.13
F Fresh feed rate, tph Target 2-3
G Coarse return, tph

Formula-2 Rg 21.25
Rg - Rf Rf 9.14
Rg - Rm Rm 16.78
Rg Residue of coarse return, % C 2.71
Rf Residue of fines, % Target 2-3
Rm Residue of separator feed, %
10 Circulation load CL ( C - 1 ) * 100 C 2.6
% C Circulation factor, - CL 160
Target -
11 Separator efficiency SE Formula-1 Ro 100
% [log(Ro/Rf) - C * log[{Ro+(C-1)*Rg} / {Rf+(C-1)*Rg}]]*100 Rf 17.68
log(Ro/Rf) - C * log[{Ro+(C-1)*100} / {Rf+(C-1)*100}] C 1.79
Ro Residue of fresh feed, % Rg 83.78
Rf Residue of fines, % SE 80.7
C Circulation factor, - Target 70-80
Rg Residue of coarse return, %

Formula-2 (Fines Efficiency) Rf 17.68

( 100 - Rf ) * 100 Rm 46.91
( 100 - Rm ) * C C 1.79
Rf Residue of fines, % SEf 86.6
Rm Residue of separator feed, % Target 70-80
C Circulation factor, -

Formula-3 (Coarse Efficiency) Rg 83.78

Rg * ( C - 1 ) * 100 C 1.79
C * Rm Rm 46.91
Rg Residue of coarse return, % SEc 78.8
C Circulation factor, - Target 70-80
Rm Residue of separator feed, %
12 Critical speed nc 42.3 / Deff0.5 Deff 2.9
rpm Deff Mill effective diameter, mts Pn 24.8
Target -
 Ball Mill Performance & Efficiency
S. Description Symbol Formula Example
No.
Processed by - siddhartha kumar
 Ball Mill Performance & Efficiency
S. Description Symbol Formula Example
No.
1 Arm of gravity a 0.666 * ( 1 - 4 * R2 )1.5 h 0.51
- TAN [ 0.5 / R * (1 - 4*R2)0.5] - [ 2*R * (1 - 4*R2)0.5 ]
-1
Deff 2.9
h Centre Distance (from mill centre to media top layer), mts R 0.176
Deff Mill effective diameter, mts a 0.619
R h/Deff, ratio of centre distance to mill effective diameter Target -
2 Torque factor matrix u - -
Material Grinding Fitting Type Torque
- - -
None Balls 0.73
None Rods 0.55 - -
Coars e/Medium
Cem ent
Danula Balls 0.75 - -
Sonex Balls 0.66 - -
& Raw
None Balls 0.69
Meal - -
None Cylpebs 0.73
Fine
Danula Balls 0.71 - -
Danula Cylpebs 0.75 - -
Coars e/Medium None Balls /Cylpebs 0.69
Coal - -
Medium Danula Cylpebs 0.71
- -
2 Power consumption, net Pn 0.514 * F * u * n * Deff * a F 79
kW F Grinding media weight, tons u 0.71
u Torque factor n 18.6
n Mill speed, rpm Deff 2.9
Deff Mill effective diameter, mts a 0.578
a Arm of gravity, - Pn 899
Target -
3 Power consumption, gross Pg Pn * 100 * 100 Pn 924
kW Em * Eg Em 95
Em Motor efficiency, % Eg 95
Eg Gearbox/girth gear efficiency, % Pg 1024
Target -
4 New production rate NPB Formula-1 OPB 110
(Mill output Vs. Blaine) tph OPB OB 3000
Exp ( ( NB - OB ) * 0.49 / 1000 ) NB 3200
OPB Old production rate, tph NPB 100
OB Old blaine, cm2/gm Target -
NB New blaine, cm2/gm

Formula-2 OPB 110

OPB * ( OB / NB )1.3 OB 3000
OPB Old production rate, tph NB 3200
OB Old blaine, cm2/gm NPB 101
NB New blaine, cm2/gm Target -
5 New production rate NPR OPR * ( 2 - log ( OR ) ) OPR 110
(Mill output Vs. Residue) tph ( 2 - log ( NR ) ) OR 11.5
OPR Old production rate, tph NR 9.5
OR Old residue, % NPR 101
NR New residue, % Target -
6 Gypsum set point GSP 21500 * ( Scem - Sclk ) Scem 2.3
(at weigh feeder) tph Pu * ( 100 - Fgyp ) Pu 70
Scem Target SO3 content in cement, % Sclk 1
Pu Gypsum purity, % Fgyp 4.8
Sclk SO3 content in clinker, % GSP 4.19
Fgyp Free moisture in gypsum, % Target -
7(a) Maximum ball size MBS 36 * F0.5 * { ( SG * Wi ) / ( %C * Deff0.5 ) }0.333 F 4.000
(If feed size is known) mm F Feed size (sieve size in mm which retains 20% material), mm SG 3
SG Specific weight of feed material, gm/cm3 Wi 17
Wi Bond's work index, kWh/t %C 75
%C Mill speed as %critical, % Deff 3.24
Deff Mill effective diameter, mts MBS 52.04887
Target -
 Ball Mill Performance & Efficiency
S. Description Symbol Formula Example
No.
7(b) Maximum feed size F MBS *{{(%C * (Deff.)0.5 )}/(SG * Wi)}1/3 * 1/36 MBS 52.04887
(If ball size is known) mm MBS Max. Ball Size, mm SG 3
SG Specific weight of feed material, gm/cm3 Wi 17
Wi Bond's work index, kWh/t %C 75
%C Mill speed as %critical, % Deff 3.24
Deff Mill effective diameter, mts F 3.99741
Target -

8 %Filling %F 112.5 - ( 125 * h / Deff ) h 1.96

% h Free height, mts Deff 2.9
Deff Mill effective diameter, mts %F 28.0
Target -
9 Circulation factor C Formula-1 FF 150
- F+G CR 170
F C 2.13
F Fresh feed rate, tph Target 2-3
G Coarse return, tph

Formula-2 Rg 21.25
Rg - Rf Rf 9.14
Rg - Rm Rm 16.78
Rg Residue of coarse return, % C 2.71
Rf Residue of fines, % Target 2-3
Rm Residue of separator feed, %
10 Circulation load CL ( C - 1 ) * 100 C 2.6
% C Circulation factor, - CL 160
Target -
11 Separator efficiency SE Formula-1 Ro 100
% [log(Ro/Rf) - C * log[{Ro+(C-1)*Rg} / {Rf+(C-1)*Rg}]]*100 Rf 17.68
log(Ro/Rf) - C * log[{Ro+(C-1)*100} / {Rf+(C-1)*100}] C 1.79
Ro Residue of fresh feed, % Rg 83.78
Rf Residue of fines, % SE 80.7
C Circulation factor, - Target 70-80
Rg Residue of coarse return, %

Formula-2 (Fines Efficiency) Rf 17.68

( 100 - Rf ) * 100 Rm 46.91
( 100 - Rm ) * C C 1.79
Rf Residue of fines, % SEf 86.6
Rm Residue of separator feed, % Target 70-80
C Circulation factor, -

Formula-3 (Coarse Efficiency) Rg 83.78

Rg * ( C - 1 ) * 100 C 1.79
C * Rm Rm 46.91
Rg Residue of coarse return, % SEc 78.8
C Circulation factor, - Target 70-80
Rm Residue of separator feed, %
12 Critical speed nc 42.3 / Deff0.5 Deff 2.9
rpm Deff Mill effective diameter, mts Pn 24.8
Target -
Processed by - siddhartha kumar
 Ball Mill Performance & Efficiency
S. Description Symbol Formula Example
No.
1 Arm of gravity a 0.666 * ( 1 - 4 * R2 )1.5 h 0.51
- TAN [ 0.5 / R * (1 - 4*R2)0.5] - [ 2*R * (1 - 4*R2)0.5 ]
-1
Deff 2.9
h Centre Distance (from mill centre to media top layer), mts R 0.176
Deff Mill effective diameter, mts a 0.619
R h/Deff, ratio of centre distance to mill effective diameter Target -
2 Torque factor matrix u - -
Material Grinding Fitting Type Torque
- - -
None Balls 0.73
None Rods 0.55 - -
Coars e/Medium
Cem ent
Danula Balls 0.75 - -
Sonex Balls 0.66 - -
& Raw
None Balls 0.69
Meal - -
None Cylpebs 0.73
Fine
Danula Balls 0.71 - -
Danula Cylpebs 0.75 - -
Coars e/Medium None Balls /Cylpebs 0.69
Coal - -
Medium Danula Cylpebs 0.71
- -
2 Power consumption, net Pn 0.514 * F * u * n * Deff * a F 79
kW F Grinding media weight, tons u 0.71
u Torque factor n 18.6
n Mill speed, rpm Deff 2.9
Deff Mill effective diameter, mts a 0.578
a Arm of gravity, - Pn 899
Target -
3 Power consumption, gross Pg Pn * 100 * 100 Pn 924
kW Em * Eg Em 95
Em Motor efficiency, % Eg 95
Eg Gearbox/girth gear efficiency, % Pg 1024
Target -
4 New production rate NPB Formula-1 OPB 105
(Mill output Vs. Blaine) tph OPB OB 3550
Exp ( ( NB - OB ) * 0.49 / 1000 ) NB 3350
OPB Old production rate, tph NPB 116
OB Old blaine, cm2/gm Target -
NB New blaine, cm2/gm

Formula-2 OPB 105

OPB * ( OB / NB )1.3 OB 3550
OPB Old production rate, tph NB 3350
OB Old blaine, cm2/gm NPB 113
NB New blaine, cm2/gm Target -
5 New production rate NPR OPR * ( 2 - log ( OR ) ) OPR
(Mill output Vs. Residue) tph ( 2 - log ( NR ) ) OR 11.5
OPR Old production rate, tph NR 9.5
OR Old residue, % NPR 0
NR New residue, % Target -
6 Gypsum set point GSP 21500 * ( Scem - Sclk ) Scem 2.3
(at weigh feeder) tph Pu * ( 100 - Fgyp ) Pu 70
Scem Target SO3 content in cement, % Sclk 1
Pu Gypsum purity, % Fgyp 4.8
Sclk SO3 content in clinker, % GSP 4.19
Fgyp Free moisture in gypsum, % Target -
7 Maximum ball size MBS 36 * F0.5 * { ( SG * Wi ) / ( %C * Deff0.5 ) }0.333 F 1.1
mm F Feed size (sieve size in mm which retains 20% material), mm SG 3
SG Specific weight of feed material, gm/cm3 Wi 17
Wi Bond's work index, kWh/t %C 75
%C Mill speed as %critical, % Deff 5.1
Deff Mill effective diameter, mts MBS 25
Target -
8 %Filling %F 112.5 - ( 125 * h / Deff ) h 1.96
% h Free height, mts Deff 2.9
 Ball Mill Performance & Efficiency
S. Description Symbol Formula Example
No.
Deff Mill effective diameter, mts %F 28.0
Target -
9 Circulation factor C Formula-1 FF 150
- F+G CR 170
F C 2.13
F Fresh feed rate, tph Target 2-3
G Coarse return, tph

Formula-2 Rg 60.25
Rg - Rf Rf 6.87
Rg - Rm Rm 37.88
Rg Residue of coarse return, % C 2.39
Rf Residue of fines, % Target 2-3
Rm Residue of separator feed, %
10 Circulation load CL ( C - 1 ) * 100 C 2.39
% C Circulation factor, - CL 139
Target -
11 Separator efficiency SE Formula-1 Ro 37.88
% [log(Ro/Rf) - C * log[{Ro+(C-1)*Rg} / {Rf+(C-1)*Rg}]]*100 Rf 6.87
log(Ro/Rf) - C * log[{Ro+(C-1)*100} / {Rf+(C-1)*100}] C 2.39
Ro Residue of fresh feed, % Rg 60.25
Rf Residue of fines, % SE 80.5
C Circulation factor, - Target 70-80
Rg Residue of coarse return, %

Formula-2 (Fines Efficiency) Rf 17.68

( 100 - Rf ) * 100 Rm 46.91
( 100 - Rm ) * C C 1.79
Rf Residue of fines, % SEf 86.6
Rm Residue of separator feed, % Target 70-80
C Circulation factor, -

Formula-3 (Coarse Efficiency) Rg 83.78

Rg * ( C - 1 ) * 100 C 1.79
C * Rm Rm 46.91
Rg Residue of coarse return, % SEc 78.8
C Circulation factor, - Target 70-80
Rm Residue of separator feed, %
12 Critical speed nc 42.3 / Deff0.5 Deff 2.9
rpm Deff Mill effective diameter, mts Pn 24.8
Target -
Processed by - siddhartha kumar