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TOWERMILL – ADVANTAGES IN WET GRINDING

APPLICATIONS
J Sachweh1

ABSTRACT
The TowerMill, which has now been in existence for no less than 50 years, is one alternative to
the horizontal ball mill and offers several advantages. The TowerMill is widely used in (coal-fired)
electric power plants for the grinding of raw material for the FGD (Flue Gas Desulphurisation)
process involving very high throughputs, very fine product sizes and high availability.
Some companies in the mining industry also looked at the use of such optimised grinding machines
several years ago and found that many of the advantages offered in other industries are transferable
to new applications.
Much development work has been undertaken to improve the TowerMill for new applications and,
as part of that work, tests have also been conducted to make direct comparisons of their performance
with that of ball mills. Grinding tests were performed using the same raw materials and comparable
machine sizes. Some of the results are discussed in this paper, along with a comparison of the
advantages and disadvantages. The conclusion provides an outlook for some worthwhile future
applications.
The test results, which are described and analysed, show that the TowerMill offers significant
advantages in relation to operating costs and operational safety. An example based on the wet
grinding of limestone is presented.
Keywords: wet grinding, agitated media mill, silica, ore, calcium carbonate, TowerMill, ball mill,
energy consumption

INTRODUCTION
Milling operations have become increasingly important for almost every industry in the world. Finer
products are necessary to achieve higher efficiencies in the process and to achieve improvements in
the quality of end products. At the same time it is well known that grinding and milling processes
involve significant amounts of energy consumption, combined with significant costs of maintenance
and wear. Specific production costs are currently rising exponentially with decreasing product size.
It has been reported that grinding or comminution processes are responsible for up to 5 per cent of
total world energy consumption. For this reason, and the fact of constantly rising energy costs, it is
clear that new machines are required in order to be able to keep production costs within economic
limits. This applies not only to energy consumption; the wear and maintenance costs also have to be
reduced for next-generation machines.
Ore and mineral processing companies in particular are very much affected as they have to grind to
ever finer degrees in order to achieve adequate liberation of the target material. For higher production
rates, conventional plants use horizontal tumbling ball mills while accepting the disadvantages of
this old technology.
Ball mills are available in various sizes with some drive motors in excess of 6 megawatts, and these
permit very high flow rates but require considerable floor space and costly foundations and also
involve high energy costs because of the inefficiency of the grinding process. For coarse grinding, the
ball mill is still acceptable but for products in the range under 30 μm, better machines are available.

BACKGROUND
The ball mill is a commonly used solution in the field of wet grinding. It is a mill which is used in
practically all industries, although industry-specific outputs can range from just a few kg per hour to

1. Process Technology, Maschinenfabrik Gustav Eirich GmbH & Co KG, 50 Wallduerner Street, Hardheim 74736, Germany. Email: jens.sachweh@eirich.de

XXV INTERNATIONAL MINERAL PROCESSING CONGRESS (IMPC) 2010 PROCEEDINGS / BRISBANE, QLD, AUSTRALIA / 6 - 10 SEPTEMBER 2010 1197
 J SACHWEH

over 100 tons per hour. Over recent decades the trend has been towards ever increasing requirements
of the end products. With increasing demand, for example, ever higher degrees of fineness have also
been demanded, such that the ball mills are now being pushed to their absolute limits because of a
lack of alternatives. It is frequently the case that very special particle size distributions are required,
which can only be achieved at considerable effort and cost because of a lack of adequate means of
controlling the grinding process.
There is now sufficient knowledge about the function of ball mills and the way in which they work to
enable virtually fully optimised designs to be achieved. In this respect, therefore, the preconditions
are ideal for the existing technology to be used for new and previously unknown applications,
although limits are being reached with increasing frequency.
The degree of fineness that can be reasonably achieved with ball mills is currently in the order
of 20 μm for oversize particles. Even higher degrees of fineness can be achieved with the use of
classifiers, although output is considerably reduced because the working principle involved is subject
to certain physical limits. The main problem with ball mills is the dependency on falling and rolling
balls for the energy input. This means that relatively large grinding balls are required in order to
ensure that sufficient energy is transferred to the product when the grinding media collide, because
this energy is responsible for the grinding results. As a result of the use of large balls, however, there
are relatively few points of contact available between the grinding elements, meaning a low stress
frequency. This phenomenon is countered by using special combinations of grinding balls which are
comprised of small and large balls. In addition, the volumes of the grinding chambers in these mills
are very large because the holding time is naturally longer for higher degrees of fineness, meaning
that larger grinding chambers are required in order to achieve comparable outputs.

A SOLUTION
A logical solution to the problem had in fact been found many years ago, namely the use of very small
grinding elements, which results in a dramatic increase in the number of points of contact and a
larger active grinding chamber volume. However, an alternative method for transferring the energy
to the grinding balls has to be found. One potential solution was the use of an agitator for setting
the grinding balls in motion, and this led to the development of the machine group called agitated
media mills. This process started with a simple agitating vessel containing sand which served as the
grinding media. The sand was set in intensive motion and had a liquid suspension pumped through
it, with the effect that it was ground in the process. As developments progressed, a variety of different
forms of agitator became established and the grinding chamber became ever smaller relative to the
size of the drive, which ultimately led to the use of a ring channel, with the rotor being virtually
smooth or fitted with small pins. These ring gap mills allow the tiniest of grinding balls of <200 μm
in size to be used, making extremely high degrees of fineness possible.
The resulting very high energy densities in the grinding chamber led to totally new requirements for
the wear elements and the cooling systems, and there were extensive developments here. However,
problems still remain even to this day because of the functioning principles involved, and these
problems are dealt with in different ways by the different machine manufacturers. Examples include
in particular the seals which seal the grinding chamber against the agitator, or the material discharge
devices which must hold back the grinding balls but allow the product to pass.
With only a few exceptions, most agitated media mills today are relatively small and achieve nothing
like the throughput ranges of ball mills. There is an increasing demand, however, for the use of mills
higher than 1 MW, which only makes sense with mills which are capable of meeting the requirements
involved and which can be run with reasonable operating costs.

THE TOWERMILL
The TowerMill represents a subgroup of the agitated media mills group and is characterized by an
energy input to the grinding chamber at the lower end of the spectrum and the use of grinding balls
of between 10 and 20 mm in size. This means that much higher degrees of fineness can be achieved
than with a ball mill, but the limit is approx. 10 to 20 μm based on the coarsest grains left. This degree
of fineness is perfectly adequate for many applications, particularly for ores, the desulphurisation of
flue gases and a wide range of mineral materials. The essential thing here is the ability to produce
large volumes of material with a low specific energy requirement and low maintenance costs.

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TOWERMILL – ADVANTAGES IN WET GRINDING APPLICATIONS

Figure 1 shows the layout of a TowerMill. Here it can be seen that the function of the “agitator”
is provided by a twin screw which rotates in the centre of a very high grinding chamber. The mill
drive is positioned above the grinding chamber and for construction reasons it is relatively high,
which was the original reason for the name given to this type of mill. The drive is designed to allow
peripheral speeds of between 2 and 4 m/s in order to ensure that sufficient energy for grinding is
transferred to the grinding balls. The screw-shaped design of the agitator makes it possible to achieve
optimised motion inside the mill. At the centre of the mill the grinding balls are moved upwards and
the space becoming vacant at the bottom is filled by other balls falling from the top to the bottom,
which in the process carry with them the raw material filled from the top. The greatest pressure is
at the base, which means that the bulk of the crushing takes place in that area. There is therefore an
intensive circulation of balls in the TowerMill, which guides the flow of material and crushes it in the
process as well, of course. Figure 2 provides a graphic representation of this characteristic motion. It

Gear Reducer
Drive motor

Upper housing
C oars e clas s ifier

Access door Screw with Liners

G rinding Media
Mill s hell (main body)

C oncrete F oundation

Shell grid liner

S crew F light Liner

S crew Tip Liner

FIG 1 - TowerMill design.

Raw material & Cyclone underflow

process water
to the cyclone

Coarse
underflow

Movement of grinding balls

Slurry

FIG 2 - TowerMill for wet grinding.

XXV INTERNATIONAL MINERAL PROCESSING CONGRESS (IMPC) 2010 PROCEEDINGS / BRISBANE, QLD, AUSTRALIA / 6 - 10 SEPTEMBER 2010 1199
 J SACHWEH

F loor space saving:

5 0-- 7 0% Space cut down

T owerMill Ball Mill

FIG 3 - Floor space comparison with ball mill.

TowerMill Ball Mill

MILL SHELL Static Dynamic

Noise (dB-- A) 85 dB-A 105 dB-- A

Low cost High cost

Foundation (Static load) (Dynamic load)

Safety guard Not required R equired

FIG 4 - Foundation comparison with ball mill.

is possible to influence the speed of ball circulation and the energy input with the design of the screw
and the choice of speed.
The design of the TowerMill allows for a very compact plant design because it only requires a very
small set-up area. Figure 3 shows the space requirements in schematic form. In addition to the space
requirements in themselves, the foundations for a TowerMill are also far more favourable because the
loads involved are of a purely static nature. The ball mill, by contrast, requires foundations designed
to accommodate dynamic loads and the tolerances for the securing of the bearing blocks are much
narrower, which is also reflected in the costs. This is illustrated in Figure 4.

KEY OPERATING PARAMETERS

Operators of ball mill grinding systems often criticise the fact that with existing plants it is only
possible to influence the grinding results with considerable effort and expense. The energy input

XXV INTERNATIONAL MINERAL PROCESSING CONGRESS (IMPC) 2010 PROCEEDINGS / BRISBANE, QLD, AUSTRALIA / 6 - 10 SEPTEMBER 2010 1200
TOWERMILL – ADVANTAGES IN WET GRINDING APPLICATIONS

can only be influenced within narrow limits, such that the only variable that can be influenced to
any great extent is the throughput, and this is dependent on the set feeding rate of the raw material.
The size and filling level of the grinding balls can only be influenced with considerable effort and
expense because much larger volumes of grinding balls are used than in the TowerMill. This problem
is less dramatic in the case of new plants which are designed to meet the precise requirements of
the product, but if a switch to other end products or new raw materials is made, there are no means
available of influencing the product quality. This is where the key advantages of the TowerMill
become apparent, because the speed of the agitator can be adjusted to the optimum speed for new
products. The speed can be adjusted across a wide range without having a negative impact on the
operation of the mill. It is also much easier and, of course, less costly to adjust the grinding ball filling
rate because of the smaller volume of balls. In addition to the ability to influence product quality by
means of the mill parameters, another important point about the TowerMill is that it can be quickly
adapted to changes in wider conditions. A typical example is provided by large plants, for example,
which have to run with widely fluctuating throughputs depending on the nature of upstream and
downstream processes. In other mills this would automatically lead to a change in product quality,
which can have negative consequences.
The main influencing variables in relation to the TowerMill are as follows:
• Screw speed
• Throughput rate
• Ball size
• Ball filling level
• Product viscosity; concentration of solids
• Grinding ball material and density
• Screw geometry
• Recirculation mass flow

GRINDING SYSTEMS
Typical TowerMill grinding systems, such as those required for the FGD process, for example, are
often installed in combination with a classifier. Figure 5 shows an example of such a system. Here the
material to be ground is fed directly into the mill, with the bulk of the process water also being fed in
at the same point. The bulk of the material is then drawn into the grinding balls and ground in the
process. Only a small amount of the raw material leaves the mill directly together with the material
O/F

Process Water

Feed

Hydrocyclone
Unit

Main Drive
Following process
U/F
W eigh Feeder Products
Coarse
New Feed

O/F

Pump Pump
U/F Pump

Product Slurry Tank

TowerMill
Hydrocyclone Feed Tank

FIG 5 - TowerMill: Grinding system.

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 J SACHWEH

High pre s s ure

grinding roll R e grind Mill
De wate ring
P re -crus he d C yclone
cyclone
ore

S tockpile

3mm R oughe r
R e claim conv e yor s cre e n Magne tic
S e paration
0.7mm G rinding mill
s cre e n

C O NC . T owe r Mill

C O NC .

Inte rme diate

T AIL
Magne tic
S e paration

T AIL

C le ane r
Magne tic
C oars e tails C O NC .
S e paration
cyclone T AIL

T ails
T hicke ne r C once ntrate
De wate ring
T hicke ne r
s cre e n

P roce s s wate r
T o T ails
C oars e tailings S torage tank T o C onc. S torage
Dis pos al
s tockpile

FIG 6 - Grinding system for iron ore.

which has already been ground and enters the coarse classifier, which separates out the unground
material so that it can be pumped to the bottom part of the mill. The coarse classifier overflow then
runs to an intermediate hopper which feeds the hydrocycloning plant. This means that the setting
required for the cyclone can be selected independently, which ensures that the hydrocycloning plant
works to optimum effect. The underflow of the cyclone is then returned to the mill’s coarse classifier
and therefore finds its way back to the mill to be ground further. Depending on the settings of the
cyclone, the underflow may be relatively viscous and require occasional dilution at this point in
order to ensure that the material is effectively conveyed to the mill. Some of the process water may
therefore be fed in here if required.
In addition to the plants in which the TowerMill is the only mill used, there are also other plants
in which the TowerMill is downstream of other conventional mills. This is the case, for instance,
in iron ore plants, where the TowerMill is only used for the final stage of crushing. Figure 6 shows
an example of such a system. In these types of plants for the grinding of ores there are always mills
upstream of the TowerMill. Only in the final stage of superfine grinding, where the throughputs
involved are much lower because large amounts of ferrous-free rock have already been removed in
the preliminary stages, is a TowerMill used. A ball mill in the same place would involve far more effort
and expense. The TowerMill would also be suitable, for example, for the second stage of grinding, but
the sizes currently available are still not big enough. Typical ore grinding systems have throughputs
in the region of >200 t/h at the start of the first stage of grinding. The TowerMill cannot yet fully
handle such levels of throughput. The biggest mill currently available works with 1.2 MW.

OPTIMISATION OF THE LABORATORY SCALE

Pilot system
In order optimise the technology and make adaptations to new tasks, a test centre system was
installed which allows investigations to be carried out under practical production conditions and
with extensive parameter variations. Figure 7 shows the system in schematic form. Raw material
and water is supplied automatically, which enables the concentration of solids to be precisely set and
provides guaranteed stable operating parameters for the mill. The drive for the mill is frequency-
controlled and the power consumption of the mill drive is permanently measured and recorded. The
KW5 mill for the grinding system is shown in Figure 8. This mill has an installed output of 15 kW
and an effective grinding chamber capacity of 470 l. The recirculation mass flow is set with the help
of a controllable peristaltic pump. Valves for sampling make it possible to analyse the degree of
grinding fineness of the product in the recirculation flow, the product being pumped into the mill at

XXV INTERNATIONAL MINERAL PROCESSING CONGRESS (IMPC) 2010 PROCEEDINGS / BRISBANE, QLD, AUSTRALIA / 6 - 10 SEPTEMBER 2010 1202
TOWERMILL – ADVANTAGES IN WET GRINDING APPLICATIONS

FIG 7 - Pilot system.

FIG 8 - TowerMill: Test centre.

the bottom. The system does not yet have a cyclone system installed because at present the objective
is restricted to the investigation and optimisation of the mill alone.
Dependency of degree of grinding fineness on specific energy input
Extensive series’ of tests were conducted in order to determine the influence of the various grinding
parameters associated with the TowerMill when used for the grinding of silica sand. The results of
this investigation are summarised in Figure 9, where the d50 is applied via the specific energy. Subject
to the variables selected, a range of curves are produced here as shown in the double logarithmic
chart, which allow interesting conclusions to be drawn when compared.
At a fixed screw speed it is almost irrelevant whether the specific energy is influenced via the
throughput (almost constant screw output) or via the variation of the ball filling level (screw
output not constant). Both curves lie on top of each other and are shown by a joint curve in the
aforementioned chart.
A reduction in the speed of the screw leads to a major reduction in the specific energy requirement,
with the curves for the throughput and the ball filling level shifting in parallel to the left.
The knowledge of this relationship makes it possible to achieve a reliable design for the required
mill after performing just a few grinding tests. In addition, it is also possible to easily predict the
effects of a desired, or in most cases undesired variation in a parameter under production conditions.

XXV INTERNATIONAL MINERAL PROCESSING CONGRESS (IMPC) 2010 PROCEEDINGS / BRISBANE, QLD, AUSTRALIA / 6 - 10 SEPTEMBER 2010 1203
 J SACHWEH

100

grinding of s ilic a s and

80

ball s ize 15 mm
60
Mas chinenfabrik G us tav E irich G mbH & C o K G
P os tfach 1160
D-74736 Hardheim

40
x3(Q = 50.00 % ) / μm

20

(x,y) = (W-s pec (throughput), x3(Q = 50 % )) 3,5 m/s

(x,y) = (W-s pec (ball level), x3(Q = 50 % )) 3,5 m/s
(x,y) = (W-s pec (mean), x3(Q = 50 % )) 3,5 m/s
10 (x,y) = (W-s pec (s crew s peed), x3(Q = 50 % ))
(x,y) = (W-s pec (throughput), x3(Q = 50 % )) 2,1 m/s
8.0
8.0 10 20 40 60 80 100 200
W -spec / kW h/t

FIG 9 - Specific energy influenced by speed, throughput and ball level.

Investigations of the influence of ball size

One of the main influencing variables affecting grinding results in the TowerMill is the selection of
the ball size because the ball size determines the number of points of contact between the grinding
elements and is therefore responsible for the crushing results. The ball size and screw speed have
to be coordinated with each other in order to ensure that the grinding process requires only low
energy input and is also low wearing. Given that the level of knowledge was previously incomplete
in this regard, extensive investigations were undertaken to establish an understanding of the
interrelationships involved. In addition to the ball size, the shape of the grinding media was also
changed in one test. In this case, 12 × 12 mm cylindrical pebbles were used.
The results are summarised in Figure 10, where, as in the previous section, the d50 is applied via the
specific energy. All the tests were conducted with a constant throughput and the specific energy is
varied by means of the screw speed.
32

31
30 c omparis on of ball s ize
29
(x,y) = (W-s pec, x3(Q = 50 % ))-20 mm
28 (x,y) = (W-s pec, x3(Q = 50 % ))-15 mm
27 (x,y) = (W-s pec, x3(Q = 50 % ))-12x12 mm (cylpebs )
(x,y) = (W-s pec, x3(Q = 50 % ))-10 mm
26
(x,y) = (W-s pec, x3(Q = 50 % ))-6-8 mm
25

24
x3(Q = 50.00 % ) / μm

23

22
21
20

19
18

17
16

15
14
13 grinding of s ilic a s and
12
11 Maschinenfabrik Gustav Eirich GmbH & Co KG
Postfach 1160
10 D-74736 Hardheim
9
8
24 26 28 30 32 34 36 38 40 42 44 46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82
W -spec / kW h/t

FIG 10 - Influence of ball size.

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TOWERMILL – ADVANTAGES IN WET GRINDING APPLICATIONS

It is apparent that a reduction of the ball size in the 6 mm to 20 mm range leads to a significant
improvement in degree of fineness. For an identical energy requirement, therefore, it is possible to
achieve a higher degree of fineness with small balls. Below a ball size of 10 mm the grinding results
are also better, but the screw speed requires more attention because at a low speed the transfer of
energy between two grinding balls is no longer sufficient to crush the material.
It was observed that a limit was approached at higher levels of specific energy for all balls. The
larger the ball, the coarser the maximum degree of fineness that can be achieved, although it should
be noted that this effect is observed with other ball mills as well, of course.

COMPARISON WITH BALL MILLS

In order to compare the TowerMill with the conventional ball mill, laboratory tests were conducted
on a throughfeed ball mill with roughly the same grinding chamber volume as the TowerMill used,
making it ideally suitable for comparison purposes. Identical raw material with the same volume
concentration of solids was used in both mills. The material used was limestone which had been pre-
crushed and screened to approx. 600 μm. Also of critical importance for the comparison was that
the ground products were analysed using the same methods and with identical equipment in order
to eliminate any sources of error from the measuring systems. All the samples were dried before
the analysis and then screened on an air jet screen in order to ensure that the coarse fraction was
precisely measured. Laser granulometry was only used to measure the fine fraction < 63 μm because
as a measuring method it is well known for considerable inaccuracies for coarser grain size ranges
>63 μm.
The ball mill was run with a grinding media material composition of 10 - 20 mm. The ball filling
level is 24.5 per cent and the speed of the mill is 71 per cent of the critical speed. The ball mill has
rubber armouring and eight lifters.
Figure 11 shows the dependency of the d50 and d80 on the specific energy for both mills in comparison.
The specific energy in this case was varied by varying the throughput.
In comparison with the TowerMill, an exponential function also applies, in broad terms, to the ball
mill as well, which results in a curve in the double logarithmic chart for the device. This makes it very
easy to compare the two mills. Intersections can be seen in the curves, which mark the sensible area
of application of each mill on the basis of the specific energy requirement. For example, both mills
have roughly the same energy requirement at d50 = 15 μm. For higher throughputs or lower specific
energy, preference should be given to the ball mill. For higher degrees of fineness, on the other
hand, the TowerMill is clearly superior. For example, where d50 = 4 μm it enables energy savings of
80

grinding of limes tone

60
c omparis on of ball mill and T owerMill

Mas chinenfabrik G us tav E irich G mbH & C o K G

40 P os tfach 1160
D-74736 Hardheim
x3(Q = 50 & 80 % ) / μm

20

10

(x,y) = (W _spec, x3(Q = 50 % ))-ball mill

(x,y) = (W _spec, x3(Q = 80 % ))-ball mill
(x,y) = (W - s pec, x3(Q = 50 % ))-T owerMill
(x,y) = (W - s pec, x3(Q = 80 % ))-T owerMill
2
8.0 10 20 40 60 80 100 200
W -spec / kW h/t

FIG 11 - Comparison of ball mill and TowerMill.

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 J SACHWEH

30 per cent to be achieved. The same analysis can be made for d80. Here, however, the intersection
shifts more in the direction of higher specific energy, ie the use of the ball mill can only be justified
up to d80 = 15 μm – at higher degrees of fineness preference would have to given to the TowerMill.
The fact that the intersection of the curves for d80 is at higher levels of energy than for d50 suggest that
the TowerMill should be given preference for fine grinding. The apparent disadvantage will also be
compensated for by the fact that the TowerMill is very often operated with downstream cyclones and
that there is seldom a requirement for the final fineness to be adjusted in the case of a single passage
and no classification.
The comparison only applies, of course, to the raw material examined and would be different for
other products. The tendential curves and also the overlap in terms of area of application of both
mills is, in principle, always to be expected in the form shown.

CONCLUSIONS
The history and the results presented here provide confirmation that the TowerMill is ideally suitable
for wet fine grinding. In the fineness range at which the ball mill can only be used with difficulty,
the TowerMill permits low-cost preparation. In addition to the advantages in energy terms it also
offers other advantages related to the principle of construction involved, which have a direct impact
on production costs. The ongoing development project will make it possible to achieve further
improvements in the performance of existing TowerMills and also possibly enable the series to be
further expanded into ranges above 2 MW. This would then open up new areas of application for ore
processing in particular.

REFERENCES
Jankovic, A, 2005. A review of regrinding in fine grinding technology – the facts and myths, Metso Minerals
Process Technology Asia-Pacific.
Jankovic, A, 2000. Fine grinding in Australian minerals industry, Journal of Mining and Metallurgy-
Collection of Papers, Section A: Mining, 36(5 - 6), Bor, Yugoslavia. pp 51 - 61.
Jankovic, A, 2001. Media stress intensity analysis for vertical stirred mills, Minerals Engineering, vol 14.
Special issue from MEI Conference Comminution 01, Brisbane - Australia, pp 1177 - 1186.
Kaneyasu, T, 1991. Production of ultra-fine cement in the TowerMill, Zement-Kalk-Gips – No. 7/1991,
pp 343 - 344, Tokio, Japan.
Mori, S, Shibayama, A and Hara, T, 1997, Development of a TowerMill for fine grinding, Proceedings of the
XX IMPC, pp 61 - 69, Aachen, Germany.
Nitta, S and Hashiguchi, N, 2006. TowerMill for fine grinding, Sales presentation, Nippon Eirich Co., Ltd.
Shibayama, A, Mori, S and Bissombolo, A, 2000, Studies on comminution mechanism of the dry TowerMill
KD-3, Proceedings of the XXI IMPC, pp C4/44 - 52, Rome, Italy.
Shibayama, A and Mori, S, 1999. A history of the TowerMill pulverizer. Journal of Resources Processing
Society of Japan, 46(1):24 - 30.

XXV INTERNATIONAL MINERAL PROCESSING CONGRESS (IMPC) 2010 PROCEEDINGS / BRISBANE, QLD, AUSTRALIA / 6 - 10 SEPTEMBER 2010 1206