BALL MILL

Particle Technology Lab

Submitted by: Husna

ID:2020-CH-10
Submitted to: Dr. Shehzad
Dated: 26 October 2021

Ball Mill
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 TABLE OF CONTENT
Ball Mill......................................................................................................................................................4

1.1. Objectives:............................................................................................................................................4

1.2. Overview:.............................................................................................................................................4

1.3. Apparatus/ Materials:............................................................................................................................4

1.4. Abstract:...............................................................................................................................................5

1.5. Related Theory:....................................................................................................................................5

1.5.1. Introduction:...............................................................................................................................5

1.5.2. Types of Ball Mill:....................................................................................................................5

1.5.2.1.Overflow Type:.........................................................................................................................6

1.5.2.2. Grate-Discharge Type.............................................................................................................6

1.5.2.3. Centre- Periphery Discharge Mill:...........................................................................................7

1.5.3. Working and Construction:................................................................................................................7

1.5.4. Performance Indicators......................................................................................................................8

1. Reduction Ratio................................................................................................................................8

2. Capacity...........................................................................................................................................8

3. Energy Consumption........................................................................................................................8

1.5.5. Factors affecting Performance...........................................................................................................8

1.5.5.1. Feed Characteristics................................................................................................................8

1. Feed rate...........................................................................................................................................8

2. Nature of Material/ Strength of Material:.........................................................................................9

1.5.5.2. Design Parameters...................................................................................................................9

1. Mill Size...........................................................................................................................................9

2. Ball Size...........................................................................................................................................9

3. Types of Liner.................................................................................................................................9

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 1.5.5.3. Operating Parameters.............................................................................................................9

1. Speed of Mill:...................................................................................................................................9

2. Feed Pulp Density:...........................................................................................................................9

3. Volume of Balls:............................................................................................................................10

1.5.6. Applications:....................................................................................................................................10

1.5.7. Limitations:......................................................................................................................................10

1.5.8. Procedure:........................................................................................................................................10

1.5.9. Specifications of Laboratory Ball Mill:............................................................................................11

1.5.10. Observations and Calculations:......................................................................................................11

1.5.11. Graphs:..........................................................................................................................................11

1ST GRAPH:.....................................................................................................................................11

2ND GRAPH: LOG NORMAL DISTRIBUTION LAW:..................................................................12

3RD GRAPH: GAUDIN SCHUMANN DISTRIBUTION GRAPH:................................................13

4th Graph: ROSIN REMMLER DISTRIBUTION GRAPH:.............................................................14

1.5.12. Conclusions:...........................................................................................................................15

1.5.13. Discussions:...................................................................................................................................15

 Discussions on Capacity:.............................................................................................................15

 Discussion on Power Consumption:............................................................................................15

 Discussion on Reduction ratio:....................................................................................................15

1.5.14. References:....................................................................................................................................16

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 Ball Mill

1.1. Objectives:
 To study the various parts of Laboratory Ball Mill with special emphasis on their
functions.
 To perform a grinding test on a given sample.
 To analyze the product by sieve analysis.
 To calculate its reduction ratio by feed size and product size measurement.

1.2. Overview:

Fig 1: Schematic showing Ball mill

1.3. Apparatus/ Materials:

 Laboratory Ball mill
 Rock sample for crushing
 Sieve set (0.85, 0.60, 0.425, 0.30, 0.212 and 0.15 mm)
 Ro-Tap Sieve Shaker

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1.4. Abstract:
The main purpose of this experiment is to study the different parts of laboratory Ball mill,
its parts and its working. Also to examine the product of ball mill by product sieve analysis,
to calculate its reduction ratio and to carry out a grinding test on a given sample and
measure the product size. It is used to grind cement, gypsum and phosphate etc. It works on
the principle of attrition and impact forces. We will study its construction and working, its
operating parameters and the different factors that affects its performance. We will also
draw graphs e.g, cumulative mass percentage passing and retaining, log normal distribution
graph, Gaudinn Schumann and Rosin Rammler graph.

1.5. Related Theory:

1.5.1. Introduction:
Ball mill,also known as tumbling mill is a grinding machine used to grind large quantity of
material into small size using different sized steel balls. The working principle is
impact and attrition. The particles fall from the top of the shell. It is a hollow cylinder which
rotates about its axis. It is filled with balls which are made of stainless steel or rubber material. It
is most suitable for fine grinding. It should have a length to diameter ratio of 1.5 to 1 or less.
They are used to grind cement, gypsum and phosphate etc.

1.5.2. Types of Ball Mill:

Ball mills are classified by the nature of the discharge. The following are the three types of Ball
mill:

Ball Mill

Grate-Diascharge
Overflow Type Compartment Type
Type

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 1.5.2.1.Overflow Type:
The overflow type of ball mill is designed to overflow the materials from the trunnion
on the outlet side. It can grind up to to 75–106 µm. It is used when we wanted the
product with high specific surface. It gives product in an open circuit. Mostly, it is
more suitable to fine-grind materials up to the particle sizes from 150 to 200 meshes.

Fig 2: schematic showing overflow type ball mill

1.5.2.2. Grate-Discharge Type

The grate-discharge type of Ball Mill has a grate at the outlet of the shell. It gives
less excessive grinding compared to overflow mills and is best suited to grinds to
150–250 µm. This type of ball mill is used when the grinding energy shall be
concentrated to the coarser particles without production of slime. It is most suitable to
grind materials up to the particle sizes ranging from 60 to 100 meshes.

Fig 3: schematic showing Grate-discharge type ball mill

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 1.5.2.3. Centre- Periphery Discharge Mill:
In this type, feed enters from both sides of chamber and move rapidly. It has a higher capacity and low
reduction ratio. It is used in gold and platinum coating.It has a longer shell, inside of which is com-parted
into 2 to 3 chambers with grates and is most suitable to produce products grinding from coarse particles
of some 25 mm to fine particles of some 200 mesh.

Fig 4: schematic showing Centre-Periphery discharge ball mill

1.5.3. Working and Construction:

The ball mill is mainly composed of a cylindrical barrel with a feeder, large ring gear
and a motor to drive the ball mill. Grinding operation is carried out in the barrel of the
ball mill. The material fed to the rotating barrel is about 60%. It is filled with steel
balls which grinds the particles. The balls occupy 30-50% of mill space. The particles
are subjected to violent impact forces in the medium. The rotating cylinder rotates
along its axis continuously and generate grinding and peeling forces. The particles are
crushed due to the rotation of the cylindrical barrel and also due to the collision of the
particles with themselves and with the steel balls.

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 Fig 5: schematic showing construction of Ball mill

1.5.4. Performance Indicators

1. Reduction Ratio
Reduction Ratio is defined as the feed size by product size. The reduction ratio of
Ball mill is typically up to 15:1 to 20:1. The reduction ratio of Grate Discharge
type mil is more than the ratio of overflow ball mill because it can reduce
materials up to 150–250 µm.

2. Capacity
Capacity is defined as the amount of material treated by mill in unit time. The
capacity of the Ball Mill is 4kg/hr. Mostly in ball mill, power is more significant
than the capacity. The largest ball mill in operation is 8.53 m diameter and 13.41
m long with a motor power of 22MW. The capacity of overflow ball mill is more
than the grate discharge type ball mill.
3. Energy Consumption
Energy consumption of ball mill is defined as the how much energy is required for
material to be grind in one hour. The energy consumption of overflow ball mill is
very high due to its higher capacity it required more energy to operate.

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1.5.5. Factors affecting Performance
1.5.5.1. Feed Characteristics

1. Feed rate
If the feed rate is high, less time will be provided to the particles and they will not be
properly grounded, resulting in low reduction ratio and low capacity and more power
consumption due to high speed.

2. Nature of Material/ Strength of Material:

It is very significant factor that affects the performance. If the material is hard, it will
be difficult to grind that particle. Size is increased but low reduction ratio, low
capacity and more power consumption.
1.5.5.2. Design Parameters

1. Mill Size
Mill size is related to its capacity. If size is large, capacity will be more and if the size
is small, capacity will be less. But due to higher capacity, there will be more power
consumption.
2. Ball Size
Diameter is an important factor in the size of ball. The diameter of balls should not be
less than the top feed size. Otherwise it will not be able to provide enough force. If
the ball size is increased, reduction ratio will increase but capacity will be decreased
because more mass will be occupied by the balls and vice versa. Smaller the ball size,
lesser its reduction ratio and the capacity is increased because smaller size provide
more surface area and provide more grinding inside the mill.

3. Types of Liner
Liner of ball mill is made of high-quality wear resistant material with high strength, wear
resistance and long working life. Liners protect the machine from excessive wear and tear
and expands its life time.Smooth linings result in much abrasion, and hence a fine grinds,
but with high metal wear, which will affect the surface of mill.

1.5.5.3. Operating Parameters

1. Speed of Mill:
The speed of mill is a very important factor. If the speed is high, centrifugal force will
be too much that the particles will not be grounded properly as particles and ball will
stick only to the sides of cylinder and center-hollowed. If speed is low, balls continue
to roll over each other and attrition forces will be reduced and the particles will not be
grounded properly. It will decrease the reduction ratio and also the capacity and
power consumption will be increased. Therefore, there should be an optimum/critical
speed at which particles will be grounded properly.

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 42.3
Critical Speed= rev/min
√ D −d

2. Feed Pulp Density:

For feed pulp density, %age solids method is mostly used. The higher feed pulp
density higher the reduction ratio but if we keep on increasing pulp density, it will
become slurry type and can’t flow properly and so capacity will be decreased also the
power consumption.
Ms+ Mw
Feed pulp density=
Vs+Vw

3. Volume of Balls:
The optimum volume of balls is 45-50% of the shell. If the volume is greater than 50%,
there will be larger wear and tear, grinding efficiency will reduce, energy consumption
will increase and also reduction ratio is increased. If the volume of balls will be greater,
then the weight of mill will be increased and it will consume more power. Product size
will be deduced so reduction ratio will also be decreased and in result low capacity.

1.5.6. Applications:
1. It produces very fine particles of the size of 10 micron and less.
2. Product fineness is adjustable, uniform and high qualified.
3. It is widely used in powder-making production line.
4. It has a large capacity and crushing ratio.
5. It has a good sealing performance and can be adapted to different working conditions.
6. It can also grind abrasive material.
7. It consumes less power so energy saving, cost effective and high capacity.
8. Can grind various ores and other materials with dry type and wet type.
9. Ball mill is mainly used in mineral ore plants, cement industry, chemical plants, silicate
products, building material, glass and ceramic industry.

1.5.7. Limitations:
 Contamination of product may happen due to high wear and tear between balls
and mill.
 It is a very noisy machine if the cylinder is made of metal.
 The milling time is long. So it is less efficient mill.
 Feed size range is wide in mill
 Not easy to get thinner end product
 It is difficult to clean after using it.

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1.5.8. Procedure:
 Study laboratory ball mill machine and its each part.
 Switch on the machine and understand the function of each part.
 Examine the feed size and the average maximum size in it.
 Feed the material slowly.
 Switch off the machine and take the product and weight it.
 Transfer and shake the product in a machine called Ro-Tap sieve shaker for 20
minutes.
 Switch off sieve-shaker and recover the retained weight on each sieve.
 Record the retained weight for each sieve and minus pan weight from it.
 Calculate the reduction ratio of the machine for the test performed.

1.5.9. Specifications of Laboratory Ball Mill:

Table 1: Specifications of Lab Ball Mill:

Name of Machine Ball mill

Motor Power 1/4 hp (Gear reducer)
Motor RPM 1425
Mill RPM 42
Capacity 4 kg/hr.
Ball Material Alloy Steel
Drum Material Cast Iron
Total weight of Balls 3550 gram

1.5.10. Observations and Calculations:

Feed mass: 700g.
Product Sieve Analysis:
Table2: Observations and calculations from the experiment

Sr. no. Sieve aperture size (mm) Individual mass (g) Cumulative mass
percentage
Passing Retaining Geometric Measured Percentage Passing Retaining
mean
1 9 4.760 6.545 130 13.13 86.87 13.13
2 4.760 2.380 3.366 68 6.87 80 20
3 2.380 0.710 1.300 106 10.70 69.3 30.7
4 0.710 0.250 0.421 212 21.41 47.89 52.11
5 0.250 0.147 0.192 85 8.59 39.29 60.7
6 0.147 0.088 0.114 202 20.40 18.88 81.1
7 0.088 0.01 0.030 187 18.88 0 100

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1.5.11. Graphs:
1ST GRAPH:
In this graph, there is a plot of geometric mean on x axis any cumulative mass passing and
retaining on y-axis. Actually there are two curves, one is of passing cumulative mass percentage
verses geometric mean and the other one is retaining cumulative mass percentage with geometric
mean. These curves will meet at a point. This is d50 point. It shows the accuracy of the graph. In

Plot Between Geometric Mean and Cumu-

lative mass passing and retained
100
90
Mass % passing and retaining

80
70
60
50
40
30
20
10
0
0 0.5 1 1.5 2 2.5 3 3.5 4
Geometric Mean (mm)
Retaining Passing
this way, we have also found out the values of d10, d25, d50 and d75.

Cut Sizes:

Cut size is the point at which passing and retaining curves intersect each other and it is always
d50.

d10= 0.1mm

d25= 0.15mm

d50= 0.5mm

d75= 2.1mm
Reduction ratio:

We can determine the reduction ratio by this formula:

Reduction ratio=80 % passing feed ¿¿ 8 0 % passing product ¿ ¿ ¿¿

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Reduction ratio= 13/4.760

Log-Normal Plot =2.73109

0
10
20
2ND 30 GRAPH: LOG
NORMAL
% Passing 40
50
60
70
80
90
100
0.01 0.1 1 10 100
Aperture Size, mm

DISTRIBUTION LAW:
In the 2nd one, cumulative passing mass percentage is on y axis and aperture size on x axis but on
a logarithmic scale. From d50, mean distribution or median diameter is obtained. Standard
deviation refers how much particles are close to the average value.
Standard deviation= d84 – d50

3RD GRAPH: GAUDIN SCHUMANN DISTRIBUTION GRAPH:

In the 3rd graph, we plot aperture passing size on y-axis and cumulative passing mass percentage
on x-axis but both on a logarithmic scale. After that we add trend-line which shows the slope or
trend of that particular data and to connect a series of values together. Then the equation of
trend-line is compared to get the constants. The equation for slope/ trend-line for this graph is:

Equation of slope=y= 7.126+ 45.529

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 Gaudin Shumann
100
f(x) = 7.12598051665772 x + 45.5287325348198

Cumulative % Passing
10

1
0.01 0.1 1 10 100

Aperture Size, µm

Equation of Slope:
Equation of slope=y= 7.126+ 45.529
Gaudian Schumann distribution =a log x+ constant
Comparing equation of slope and Gaudian Schumann distribution:
a = 7.126
Constant=45.529

4th Graph: ROSIN REMMLER DISTRIBUTION GRAPH:

In the 4th one, aperture size is on x axis and log of cumulative mass percentage on y axis.it is
suitable for finely grounded particles. It is known as Rosin Rambler distribution. This curve
gives us the size distribution within measured particle size range. Parameters involved are
measured by comparison with the curve of equation the equation is given as:
Rosin Rammler Distribution = y = log log(1OO/R) = b log x+ constant

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 Rosin-Rammler
-1.5 -1 -0.5 0 0.5 1
0
f(x) = 0.506267609266082 x − 0.325119411012364
-0.2
log(log(100/R))
-0.4
Rosin-Rammler
-0.6 Linear (Rosin-Rammler)

-0.8

-1

-1.2
Retaining size

Equation of Slope:

Y= 0.5063x - 0.3251

Rosin Rammler Distribution = y = log log(1OO/R) = b log x+ constant

Comparing both equations we have
b = 0.5063
constant = -0.3251

1.5.12. Conclusions:
In this report, the reduction ratio which can obtain is 2.73109.

1.5.13. Discussions:
Ball mill can reduce energy consumption by 30%, capacity increased by 15-20%.
 Discussions on Capacity:
Capacity is defined as the amount of material treated by mill in unit time. The formula for
capacity of a ball mill is:
PM
Q= t/h
E
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Where

PM = the mill power (kW)

E = the energy (kWh/t)

 Discussion on Power Consumption:

Power consumption is the amount of energy required to crush tons of material per hour. The
formula for power consumption of a ball mill is:
PM = mill capacity * (diameter)n
Where n can be between 0.3-0.5.

 Discussion on Reduction ratio:

It is defined as the ratio of 80%product size to 80%feed size. It is 0.7 fraction of original feed.
Reduction ratio tells us that to which extent the original particle is being crushed. It is also
basically parameter of crushing:
Reduction ratio= 80% original product size/ 80% original feed size
Where
80% feed size = 0.7×largest size of feed
80% product size = size of product at 80% cumulative passing mass percentage

1.5.14. References:
 Mineral Processing Technology, B. A. Wills (8th Edition)

 Ashok Gupta, Denis S. Yan - Mineral Processing Design and Operations. An Introduction-
Elsevier (2016)

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