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Ball Charge Design Methods for Mills

The document discusses two methods for designing ball charges in finish mills: 1) The Polysius method treats the entire mill as a single compartment and uses an exponential formula to calculate decreasing ball size along the length of the mill. 2) The Slegten method divides the mill into two compartments, using different formulas and ball sizes for each. Larger balls are used at the feed end with ball size decreasing exponentially in the second compartment. Graphs show how the two methods differ in recommended ball size distributions within each compartment and throughout the entire mill length.

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Vishnu Vardhan . C
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© Attribution Non-Commercial (BY-NC)
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6K views12 pages

Ball Charge Design Methods for Mills

The document discusses two methods for designing ball charges in finish mills: 1) The Polysius method treats the entire mill as a single compartment and uses an exponential formula to calculate decreasing ball size along the length of the mill. 2) The Slegten method divides the mill into two compartments, using different formulas and ball sizes for each. Larger balls are used at the feed end with ball size decreasing exponentially in the second compartment. Graphs show how the two methods differ in recommended ball size distributions within each compartment and throughout the entire mill length.

Uploaded by

Vishnu Vardhan . C
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
  • Introduction to Ball Charge Design Methods
  • Polysius Design Method Overview
  • Polysius Ball Charge Formula
  • Ball Sizes and Measurements
  • Polysius Ball Charge Example
  • Slegten Ball Charge Methodology
  • Comparative Analysis: Polysius vs Slegten
  • Slegten vs Polysius Comparison Chart

Grinding Course

Ball Charge Design


Methods
Ball Charge Design Methods
• Polysius for Finish Mills
 A formula that covers the entire mill as though it is a

single compartment mill.

• Slegten For Finish Mills


 Rules for 1st Compartment and “Transition Zone”

 Formula for Remainder of 2nd Compartment


Polysius Ball Charge for Finish Mills

D   96 e  . 13x 

D = Ball Diameter , mm

X = Distance From Feed End of Mill, m


Polysius Ball Charge Design

110.00
100.00
90.00
80.00
Ball Diameter, mm

70.00
60.00
50.00
40.00
30.00
20.00
10.00
0.00
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Distance From Feed End of Mill, m
Ball Sizes

Ball Dia.,mm Ball Dia, inch approx std size, inch


90 3.54 3.5
80 3.15 3
70 2.76 2.75
60 2.36 2.5
50 1.97 2
40 1.57 1.5
30 1.18 1.25
25 0.98 1
20 0.79 0.75
16 0.63 0.625
Example of Polysius Ball Charge
Bulk Density,
Ball Dia, in Mill Length,m % by Vol kg/m3 % by wt.

3.5 1 25.00 4500 25.00

3 1 25.00 4500 25.00

2.75 1 25.00 4500 25.00

2.5 1 25.00 4500 25.00

Total C1 4 100.00   100.00

Partition 0.5      

2 2 21.05 4718 20.52

1.5 1.5 15.79 4788 15.62

1.25 3 31.58 4832 31.53

1 0 0.00 4886 0.00

0.75 3 31.58 4955 32.33

0.625 0 0.00 4999 0.00

Total C2 9.5 100.00   100.00


Slegten Ball Charge For Finish Mills
• Use 90 mm Balls for 20% (by • Fill Remainder of 2nd
wt.) of 1st Compartment Compartment According to:
Charge.

• Use Same number (“n”) of


80,70, and 60 mm Balls for D   33 e  .1x 
Remainder of 1st Compartment
Charge.
• D = Ball Dia., mm
• Use “n” number of 50 and 40
mm Balls in 2nd Compartment.
(Transition Zone) • X = Distance from Transition
Zone, m
Slegten FM Ball Charge Design For Fine
Grinding Zone
y = 33e -0.1x
35
30
25
Ball Dia., mm

20
15
10
5
0
0 1 2 3 4 5 6 7 8
Distance From End Of Transition Zone, m
Compartment 1 - Polysius vs Slegten

Ball Charge Comparison,1st Compartment, 4m Dia by 4


m Length

40.0
Compartment
Charge Mass

30.0
% of 1st

Polysius
20.0
Slegten
10.0
0.0
3.5 3 2.75 2.5
Ball Sizes, inch
Compartment 2 - Polysius vs Slegten
Ball Charge Comparison, 2nd Compartment, 4m Dia. By
9.5 m Length

40.00
Compartment
Charge Mass

30.00
% of 2nd

Polysius
20.00
Slegten
10.00
0.00
2 1.5 1.25 1 .75 .625
Ball Size, inch
Slegten vs Polysius
Comparison of Slegton and Polysius Ball Charges

4
3.5
Ball diameter, Inch

3
2.5
Slegten
2
1.5 Polysius
1
0.5
0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Distance From Mill Feed End, m

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