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Dimension of Mill

The document provides information on determining key parameters for tube mills used in grinding processes. It discusses filling degree, mill speed as a percentage of critical speed, length to diameter ratio, grinding media weight, and driving power calculations. Formulas are presented to calculate critical mill speed, operating speed, media charge, and motor power based on mill diameter, length, filling degree, speed, and material properties. An example is worked through to determine the required motor power and nominal mill diameter for a cement mill processing 100 tons per hour of cement.

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Piyush Kumar
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78 views33 pages

Dimension of Mill

The document provides information on determining key parameters for tube mills used in grinding processes. It discusses filling degree, mill speed as a percentage of critical speed, length to diameter ratio, grinding media weight, and driving power calculations. Formulas are presented to calculate critical mill speed, operating speed, media charge, and motor power based on mill diameter, length, filling degree, speed, and material properties. An example is worked through to determine the required motor power and nominal mill diameter for a cement mill processing 100 tons per hour of cement.

Uploaded by

Piyush Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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1.

MAIN
DESIGN
CEREIA S
1.1 Filling Degree
Filling Degree of Tube Mills
Type of mill Filling Degree
Comp. I Comp. II Comp. III
Single comp. Mill 27 - 33 ---- ---
Two comp. Mill 27 - 33 25 - 30 ---
Three Comp mill 26 - 32 26 - 30 23 - 27
Air swept mill 26 - 30 --- ---
Determining of filling degree
1.2 Mill Speed
Fc = centrifugal force [N]

FG = force of gravity [N]

D = mill diameter
inside liner [m]

M =mass [kg]

ω = angular speed [s ]
G = gravity [ms ]
The Critical Speed
D 2
F - F = m. g - m . . ω crit = 0
i
G C 2
The Critical Angular Speed ωcrit

2.g π . n crit
ωcrit = =
Di 30
The Critical Speed ncri

30 2 .g
n = .
crit π D
i
42,3 -1
ncrit = [ min ]
Di
The Operating Mill Speed n

k -1
n= . ncrit [ min ]
100
n = Operating Mill Speed [min-1]

ncri = Critical Mill Speed [min-1]

k = Ratio n / ncrit [%]

Di = Diameter inside mill lining [m]


The Critical Speed Chart

nc=critical mill speed [min-1]


Practical Values for The Percentage of Critical Speed

Filling degree Type of mill liner % of critical


speed (k)

Low Liner with lifter bars 70 - 71 %

High Smooth liner 74 - 75 %


1.3 The Length To Diameter Ratio
Of Tube Mills Depends on :
Hourly Throughout
Hardness of the material
Open or closed circuit
grinding
Feed size

Grinding System
The Length To Diameter Ratio λ Of different
mill system:

Type of mill system Ratio λ Remarks

1.Cement mill
Closed circuitmills
Open circuit mills 3.0-3.5
6.0 φ 2.0mills
Large −2.4: : λ=3
λ∼6−3.2
Low λ yields
φ 2.6−3.0 : λ∼5
higher circulating load
φ 3.0−4.0 : λ∼4
φ 4.0 : λ∼3−3.5
Type of mill system Ratio λ Remarks

Ratio similar as for cement mills

2.Slurry mills
Max.length 12-14 m
Type of mill system Ratio λ Remarks

Center discharge mill 2.1-2.7 the lower are applied for

3.RAW mills
two comp.Mill 2.0-2.5 large raw mill

single comp.mill 1.7-2.2


air swept mill 1.5-2
Length of Compartments :

Type of mill % of Total Length

Comp. I Comp. II Comp. III

Two comp. Mill 30 - 35 70 - 65 ---

Three comp. Mill 20 30 50

Center discharge 50 50 ---


mill
Weight of Grinding Media
π 2 f
Q = Di L i γQ
4 100
Where :

Li :Internal length of the mill or compartment [m]


f : Filling degree [%]
γ : Bulk weight of grinding media It/m3 [t/m3]
Q
Di : Internal mill diameter (inside lining) [m]
Q : Grinding media charge [t]
The values for bulk densities of the grinding media :

Ball Size Bulk Weight


3
Steel balls 100-60 mm φ 4.4t / m
50-30 mm φ
3
Steel balls 4.6t / m
3
Steel balls 30-20 mm φ 4.8t / m
3
Cylpebs 100-60 mm φ 4.8t / m
Driving Power

Driving Power “N” = Net Power + Power losses

x .DI .Q. .n
N = [ kW ]
30
Driving Power
b = Distance of center of gravity
from the vertical plant through
the axis of rotation [m]

Di = Diameter inside liners


Q = Weight of grinding
media charge [t]

N=speed of the mill [min ]


ω= angular speed [s ]
According to MITTAG :
b = X . Di
M = X . Di . Q
π n
N = M.ω [kW] ω =
30
[S-1]
The Driving power can be written as :
x . Di . Q . π . n
N=
30
For Practical Calculation

N = C. Q. Di. N [kW]
Where :
N = Driving power
Q = Grinding media charge
Di = Mill diameter inside liners
n = Mill speed
c = Power consumption factor
Determining of Power consumption factor c
Practical Calculations

N = c . Q . Di . n ( 4 ) [ kW]
π f
.γ Q
2
Q = . D i . Li . (3) [ t]
4 100
42,3 -1
ncrit = ( 1 ) [ min ]
DI
N = k . nc
100
The formula could be expressed
by one formula :

N = C. Q. Di. n =
π f 42,3 k
. γ Q . Di .
2
c . . Di . LI . .
4 100 Di 100

f k
.γ Q .
2.5
N = 33,22 . C . Li . . Di
100 100
The formula could be expressed
by one formula :

Li
λ=
Di

f k
N = 33,22. C. λ . .γ . . D 3.5
100 Q 100 i
The internal mill diameter
1
3 .5
N . 100 . 100
Di =
33.22 . c . λ . f . γ Q . k

N . 100 . 100 0.286


D =
i 33.22 . c . λ . f . γ . k
Q
Nomograph to calculate the required mill diameter
Example :
Cement mill in open circuit, 100 t/h of
normal cement with a specific surface of
3000 cm2/g ?
Find ?
Mill motor power ?
Nominal mill diameter ?
Total mill length ?
Compartment lengths ?
Total ball charge ?
Fall charge per compartment ?
Mill speed ?
Mill Motor Power

NMS = q= 33 kwh/t 100 t/h = 3300 kw

Assuming total gear efficiency of µG = 0.95 the


Mill motor power

N Ms 3300
N= = ≈ 3500 kW
ηG 0.95
Assumption

Filling degree f = 30 %

% of Critical Speed k =74 %

Length to diameter ratio λ = 3.5


bulk weight ball charge γ Q = 4.5 t/m3
Grindability curve
Nominal Mill Diameter

Nominal diameter = Inside mill shell D ~ 4.3 m


0 . 286
⎡ N ⎤
D = ⎢ ⎥
. c . λ . f. γ
i
⎢⎣ 33.22 Q . k ⎥⎦
c ~ 0.255
0.286
⎡ 3500 ⎤
Di = ⎢ ⎥ = 4.04m
⎣33.22
. 0.225
. 3.5. 0.3. 4.5. 0.74⎦

DN = D i + lining = 4.04 + 0.26 = 4.3 m

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