Ball Mill Calculations

Ambuja Cement Rajasthan Rajasthan Limited

Ball Mill Performance & Efficiency S.

Description

Symbol

Formula

Example

No. 1

Arm of gravity

0.))) $ * " ! # $ + % ,".5

a

-N -N / 0.5  + $ *" ! #$+ %,0.51 ! / %$+ $ *" ! #$+ %,0.5 1

-

+

*or,ue fa!tor matri

Centre Distan!e "from mi## !entre to media to$ #ayer%& mts

R

0.13'

(i## (i## effe effe!t !tiv ive e dia diam meter eter&& mt mts

a

0.57

R

h)De h)Deff ff&& rat ratio io of !ent !entre re dist distan an!e !e to mi## mi## effe effe!t !tiv ive e dia diame mete ter r

*arget

u Mate rial

2rin3in'

Cement = Ra/ (ea# ine

Coa#

Coarse Coarse))(edium edium (e di um

n 2

.18

Def Deff

Coarse)(edium

o/er !onsum$tion& net

0.583

Deff

h

-

+

h

!"

Fittin' 8on e 8on e Dan u#a
-ype 9a# #s Rod s 9a# #s 9a# #s 9a# #s Cy# $e bs 9a# #s Cy# $e bs 9a##s) 9a##s)Cy Cy#$e #$ebs bs Cy# $e bs

0.5"# $ F $ u $ n $ Deff $ a 

4rinding media /eight& tons

-or 4ue 0. 3 0.5 5 0. 5 0.  0. ' 0. 3 0. 1 0. 5 0.' 0.' 0. 1

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

!

!



15

u

0.3

u

*or,ue fa!tor

n

n

(i## s$eed& r$m

Deff

Deff

(i## effe!tive diameter& mts

a

0.58

a

Arm of gravity& -

Pn

%5

*arget 3

o/er !onsum$tion& gross

e/ $rodu!tion rate "(i## out$ut ;s. 9#aine%

1

.18

-

g

Pn $ "00 $ "00

n

+50

2

Em $ E'

6m

'5

6m

(otor effi!ien!y& 7

6g

'5

6g

4 ea earbo)girth ge gear ef effi!ien!y& 7

P'

%7"5

*arget 

-

-

9 t$h

Formula!"

:9 (PB

:9

118 000

Ambuja Cement Rajasthan Limited


Description

Symbol

Formula

Example

No. 9

Exp * * NB ! (B , $ 0.#  "000 , :9

:#d $rodu!tion rate& t$h

NPB

:9

:#d b#aine& !m+)gm

*arget

9

e/ b#aine& !m+)gm

Formula!%

:9 (PB $ * (B  NB ,

e/ $rodu!tion rate "(i## out$ut ;s. Residue%



000 5000

:9

:#d b#aine& !m+)gm

NPB

9


*arget

R

(P+ $ * % ! lo' * (+ , ,

t$h

* % ! lo' * N+ , ,

8

:R

150

:R

11.5 '.5

:R

:#d residue& 7

NP+

"

R

e/ residue& 7

*arget

-

+.1

u

'0

%"500 $ * Scem ! Scl6 ,

t$h

Pu $ * "00 ! F'yp ,
*arget <:3 !ontent in !ement& 7

0.3

u

4y$sum $urity& 7

gy$

.8

<:3 !ontent in !#in2er& 7

2SP

#.5%

gy$

ree moisture in gy$sum& 7

*arget

0.5

(9<

7

-

R

4<

7i##ing




"at /eigh feeder%

mm

118

:9

4y$sum set $oint

(aimum ba## si>e

-

9

:R



7%


:9

5

".

5000

0.5

0.

) $ F $ 8 * S2 $ 9i ,  * :; $ Deff , <



15



eed si>e "sieve si>e in mm /hi!h retains +07 materia#%& mm

<4

3

<4

<$e!ifi! /eight of feed materia#& gm)!m3

i

15

i

9ond?s /or2 inde& 2h)t

7C

5

7C

(i## s$eed as 7!riti!a#& 7

Deff

5.1

Deff


MBS

0

*arget

-

""%.5 ! * "%5 $   Deff ,

h

+.5



Description

Symbol

Formula

Example

No. 7

h

ree height& mts

Deff

Deff


:F *arget

'

Cir!u#ation fa!tor

C

Formula!"

-

F=2 F 

resh feed rate& t$h

4

Coarse return& t$h

Formula!%

10

Cir!u#ation #oad

<6

7. 150

CR

10

;

%."

*arget

+-3

5.'+

+' ! +f

Rf

3.5+

+' ! +m

Rm

3.1

Rg

Residue of !oarse return& 7

;

%.#

Rf

Residue of fines& 7

*arget

+-3

Rm

Residue of se$arator feed& 7 C

+.8

;>

"#

* ; ! " , $ "00 C

Cir!u#ation fa!tor& -

*arget 11

.155



Rg

CL 7

Formula!"

7

-

Ro

100

/lo'*+o+f, ! ; $ lo'/8+o=*;!",$+'<  8+f=*;!",$+'<11$"00

Rf

3.5+

lo'*+o+f, ! ; $ lo'/8+o=*;!",$"00<  8+f=*;!",$"00<1

C

+.8

Ro

Residue of fresh feed& 7

Rg

5.'+

Rf

Residue of fines& 7

SE

).

C


*arget

Rg


Formula!% *Fines Efficiency, * "00 ! +f , $ "00

0-80

Rf

3.5+

Rm

3.1



Description

Symbol

Formula

Example

No. C

+.8

Rf

Residue of fines& 7

* "00 ! +m , $ ;

SEf

5."

Rm

Residue of se$arator feed& 7

*arget

0-80

C

Cir!u#ation fa!tor& Rg

5.'+

Formula! *;oarse Efficiency, +' $ * ; ! " , $ "00 ; $ +m

1+ Criti!a# s$eed

+.8

Rm

3.1

Rg


SEc

C


*arget

Rm

Residue of se$arator feed& 7 #%.  Deff 0.5

n! r$m

C

Deff


Deff Pn *arget

1

e/ $rodu!tion rate "(i## out$ut ;s. 9#aine%

R

Formula!"

:9

t$h

5. 0-80

.15 %0. -

118

(PB

:9

000

Exp * * NB ! (B , $ 0.#  "000 ,

9

5000

:9


:9

:#d b#aine& !m+)gm

9


Formula!%

NP+

:9 (PB $ * (B  NB , ".

7%

118

:9

000 5000

:9


9

:9

:#d b#aine& !m+)gm

NP+

9






Description

Symbol

Formula

Example

No. +

e/ <$e!ifi! $o/er !ons. "s$. $o/er ;s. 9#aine%

Formula R

E *S"  S,n

E"

2h)*C 61

1 New production rate (Mill output Vs. Blaine)

NPR

6

:#d s$e!ifi! $o/er

<1

5000

<1

e/ 9#aine

<

000

<

:#d 9#aine

n

n

(i## e$onent for !#ose !2t @ 1.3

E"

#.##

OPB

118

OB

4000 000

Formula OPB * ( OB / NB ) 1.3

OPB

Old production rate, tph

NB

OB

Old !laine, c"#$%"

NPR

NB

New !laine, c"#$%"

Formula

NPR

3+.5

6

tph

# New &peci'c power cons. (sp. power Vs. Blaine)

e/ s$e!ifi! $o/er

E1

E (S1 / S)n

1.3

88



Description

Symbol

Formula

Example

No.

h$*+ 1

New speci'c power



-#.



Old speci'c power

&1

000

&1

New Blaine

&

4000

&

Old Blaine

n

1.-

n

Mill eponent /or close ct  1.-

E1

43.44





100 3000 3500 1.++1



Ball Mill Calculations

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