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    Ball Charge Design - V

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    Karan_Agarwal_4807
    The document provides details on raw materials granulometry and ball charge design for a grinding mill. It analyzes the particle size distribution of various raw materials including limestone, clay mix, iron ore, and additives. It then calculates the maximum ball size for each raw material based on parameters like density and work index. Finally, it designs the ball charge distribution for the grinding mill using the Slegten method, specifying ball sizes and weights in two compartments and a transition zone to achieve the desired volume loads.

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    Ball Charge Design - V

    Uploaded by

    Karan_Agarwal_4807
    823 views11 pages
    The document provides details on raw materials granulometry and ball charge design for a grinding mill. It analyzes the particle size distribution of various raw materials including limestone, clay mix, iron ore, and additives. It then calculates the maximum ball size for each raw material based on parameters like density and work index. Finally, it designs the ball charge distribution for the grinding mill using the Slegten method, specifying ball sizes and weights in two compartments and a transition zone to achieve the desired volume loads.

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    Ball Charge Design_v

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    The document provides details on raw materials granulometry and ball charge design for a grinding mill. It analyzes the particle size distribution of various raw materials including limestone, clay mix, iron ore, and additives. It then calculates the maximum ball size for each raw material based on parameters like density and work index. Finally, it designs the ball charge distribution for the grinding mill using the Slegten method, specifying ball sizes and weights in two compartments and a transition zone to achieve the desired volume loads.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    823 views11 pages

    Ball Charge Design - V

    Uploaded by

    Karan_Agarwal_4807
    The document provides details on raw materials granulometry and ball charge design for a grinding mill. It analyzes the particle size distribution of various raw materials including limestone, clay mix, iron ore, and additives. It then calculates the maximum ball size for each raw material based on parameters like density and work index. Finally, it designs the ball charge distribution for the grinding mill using the Slegten method, specifying ball sizes and weights in two compartments and a transition zone to achieve the desired volume loads.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as XLS, PDF, TXT or read online from Scribd
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    At a glance
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    The document discusses raw material granulometry and ball charge design for grinding mills.

    The raw materials discussed are limestone, clay mix, iron ore, additive and silica sand.

    The ball charge is designed using the Slegten method and distributed in two compartments and a fine grinding zone based on the ball diameters and volumes.

    Raw Materials Granulometry:

    Sampling Point Sieve %Retained


    [mm]
    25 12.5 9.5 4.75 2.36 1.18
    A Mill Feed Limestone 82.00% 64.4 90.7 94.6 98.1 99.1 99.5
    B Clay Mix. 17.37% 12.1 21.6 26.1 38.7 52.6 64.3
    C1 Iron Ore 0.43% 0.0 0.9 2.1 8.0 21.1 41.9
    C2 Additive 0.20% 7.8 58.5 67.7 75.6 80.7 85.2
    C3 Silica Sand 0.0 0.0 0.0 0.3 0.7 6.3
    100.0% 54.9 78.2 82.2 87.3 90.7 93.1

    Max. Ball Size Calculation:


    d80 [µm] ρ [g/cm3] Wi [kwh/t] K Ψ [%] Du [m] Ømax [mm]
    Limestone 40000 1.3 10.18 335 74 4.44 96.9
    Mix 15000 1.5 7.1 335 74 4.44 55.2
    Iron Ore 2300 2.5 12.13 335 74 4.44 30.6

    d80 [µm] Mesh: size of the sieveing where 80% of material is Passing
    ρ [g/cm3] density of material
    Wi [kwh/t] Work Index
    K Factor (335 for dry grinding (OC or CC), 350 for wet grinding)
    Ψ [%] % of Critical Speed (mill)
    Du [m] Effective Di of the mill
    Ømax [mm] Maximum Ball size

    Ball Charge Distribution:


    From to Limestone Granulometry
    Material: EB d180: d280: WB: Energy %Passing d280: WB: Energy Diam ton
    Limestone 10.18 40 20 6.7 13.8% 45.1% 20 3.01 35.3% 100 - 90 39.6
    20 8 13.2 27.4% 17.8% 8 2.35 27.7% 90 - 80 31.0
    8 4 14.9 30.9% 12.7% 4 1.89 22.3% 80 - 60 24.9
    4 2.5 13.5 27.9% 9.3% 2.5 1.25 14.7% 70 - 50 16.5
    48.3 100.0% 100% 112.0
    Ball Charge Design
    Based On Slegten Method

    Steel dens = 7843 kg/m3 (Use 7843 if not known)


    !st Compt Bulk Density 4500 kg/m3 (Use 4500 if not known)

    bulk Density
    Ball Dia,mm Vol,mm3 vol,m3 kg/ball kg/m3 Std Size
    90 381,703.51 3.82E-04 2.99 4,579.60 3.5
    80 268,082.57 2.68E-04 2.10 4,608.11 3
    70 179,594.38 1.80E-04 1.41 4,640.42 2.75
    60 113,097.34 1.13E-04 0.89 4,677.73 2.5
    50 65,449.85 6.54E-05 0.51 4,721.85 2
    40 33,510.32 3.35E-05 0.26 4,775.85 1.5
    30 14,137.17 1.41E-05 0.11 4,845.48 1.25
    25 8,181.23 8.18E-06 0.06 4,889.60 1
    20 4,188.79 4.19E-06 0.03 4,943.60 0.75
    16 2,144.66 2.14E-06 0.02 4,997.61 0.625

    1st compt length 3 m


    1st compt effective dia. 3.7 m
    Desired Vol Load 33 %
    2nd compt length 6 m
    2nd compt effective dia. 3.6 m
    Desired Vol. Load 33 %
    Partition Length 0.31 m

    1st Compt Chg Vol 10.64 m3


    1st Compt charge vol./m length 3.55 m3/m
    1st compt chg wt 47,900.61 kg 47.9 mt
    2nd Compt Charge Vol. 20.15 m3
    2nd Compt Charge Vol./m Length 3.36 m3/m

    Slegten Ball Charge Based on Std Inch Ball Sizes


    The weight % of 3.5 inch balls in the first compartment is normally 20%
    Bulk Density
    Ball Dia, inch % by wt no Balls mt kg/m3 Volume, m3
    1st Compartment
    3.5 20.0 3,320 9.6 4,500 2.13
    3 34.1 8,979 16.3 4,500 3.63
    2.75 26.2 8,979 12.6 4,500 2.79
    2.5 19.7 8,979 9.4 4,500 2.10
    Total 1st Compt. 100.00 30,256 47.9 10.64

    2nd Compartment
    Transition Zone
    2 4.9 8,979 4.8 4,718 1.02
    1.5 2.1 8,979 2.0 4,788 0.43
    Total Transition 7.0 17,957 6.9 1.45
    Fine Grinding Zone
    1.25 33.0 246,958 32.5 4,832 6.7
    1 26.7 390,185 26.3 4,886 5.4
    0.75 33.3 1,153,924 32.8 4,955 6.6
    0.625 0.0 - 0.0 4,999 0.0
    Total Fine Grinding 93.0 1,791,067 91.5 18.70
    Total 2nd Compt. 100.0 1,809,025 98.3 20.15

    Ball Charge Plot

    3.5

    3
    Ball Diameter, Inch

    2.5

    1.5

    0.5

    0
    0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
    Distance From Feed End, m
    bulk Density
    kg/ball kg/m3
    2.89 4,583
    1.82 4,620
    1.40 4,641
    1.05 4,664
    0.54 4,718
    0.23 4,788
    0.13 4,832
    0.07 4,886
    0.03 4,955
    0.02 4,999

    Ball Dia , Inch


    3.5
    3
    2.75
    2.5
    2
    1.5
    1.25
    1
    0.75
    0.625

    length,m x y
    0 3.5
    0.6 0.6 3.5
    1.0 0.6
    0.8 0.6
    0.6 0.6
    3.0 1.6
    1.6
    1.6
    1.6
    0.31 2.4
    0.13 2.4
    0.43 2.4
    Slegten Values 2.4
    2.00 2 3.0
    1.60 1.6 3.0
    1.97 2.8 3.0
    0.00 3.3
    5.57 3.6
    6.00 3.6
    3.6
    3.6
    3.7
    3.7
    3.7
    3.7
    5.7
    5.7
    5.7
    5.7
    7.3
    7.3
    7.3
    7.3
    9.3
    9.3
    9.3
    9.3
    9.3
    0.3
    1.1
    2.0
    2.7
    11 12 13 14 3.0
    3.3
    3.7
    4.7
    6.5
    8.3
    9.3
    Cum Length
    0.6
    1.6
    2.4
    3.0
    3.6
    3.7
    5.7
    7.3
    9.3
    9.3

    3.5
    3
    3
    3
    3
    2.75
    2.75
    2.75
    2.75
    2.5
    2.5
    2.5
    2.5
    2.5
    2
    2
    2
    1.5
    1.5
    1.5
    1.5
    1.25
    1.25
    1.25
    1.25
    1
    1
    1
    1
    0.75
    0.75
    0.75
    0.75
    0.625
    0.625
    0.625
    3.5
    3
    2.75
    2.5
    2.39275
    2
    1.5
    1.25
    1
    0.75
    0.625

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