PAMANTASAN NG LUNGSOD NG MAYNILA

College of Engineering and Technology

Chemical Engineering Department

BALL MILL
DESIGN PROBLEM
Design an equipment that would reduce the size of the incoming 1338.66 kg of partially
ground alimasag shell with a size of 5 mm from double roll crusher to a particle size within the
range of 0.30-0.40mm.
DESIGN DESCRIPTION
The ball mill is an equipment for grinding materials into fine powder. The grinding takes
place when balls collide with the alimasag shells. Continuous collision will result in finer particle
size of the raw material. The 1338.66 kg of previously ground alimasag shell will be pulverized
to a particle size within the range of 0.30-0.40 mm after it passes through the different
compartments of ball mill. Product size is determined by the size and weight of the ball and the
rotation power of the mill itself. Moreover, ball mill is a tumbling pulverizer in which the steel
balls are classified with the larger balls at the feed end where larger lumps are crushed and the
small balls at the discharge end where the material is finer. (Brown p.38).
The 5.00 mm of alimasag shell feed amounting to 1338.66 kg enters the ball mill, using
the belt conveyor and accompanied by a feed hopper. Ball mills work by allowing balls of heavy
material to fall upon and crush the material being milled. Repeating the action hundreds or
thousands of times results in reducing the material to affine powder (Sponenburgh, 2006). On
the first compartment, the feed will be introduced and the desired particle size will be obtained.
It will then be transferred to the second compartment using the intermediate diaphragm. This
diaphragm has a mechanism that every time the ball mill rotates, it catches the alimasag shell,
leaving the balls and once the material is at the top, it will discharge the feed material to the next
compartment. On the second compartment, smaller size of the balls were placed and used for
further crushing of the alimasag shells. The outlet diaphragm will then transfer the materials to
the discharge through the screwed branching pipe. A ventilating air will be used to regulate the
transfer of the alimasag shells from on compartment to another going to the discharged. A
screen will be installed at the end of the ball mill while the ventilating air will be transported to a
cyclone where small particles will be removed and be collected.
DESIGN SELECTION
Among the types of size reduction equipment, ball mill is selected as it is applicable for
batch processes. Ball mill is also feasible since it grinds the material to particle sizes smaller
than 20 Mesh. The ball mill will act as the secondary crusher for our alimasag shell after the
double roll crusher. Moreover, the feed for ball mill must be 1 to 10 mm only (Couper et. al.).
 PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

Figure : Different size reduction equipment (General Design and Sizing of Comminution
Equipment by Metso, Inc.)
Figure shows several equipment within their corresponding feed particle size. For
conical ball mill, the particle size ranges from 30mm to 2 mm; The rod mills, the size ranges
from 7 mm to 0.5 mm. For ball mills, the particle size ranges from 5 mm to 300 micron.
Therefore, ball mill is selected based on the particle size.

DESIGN PARTS AND ACCESSORIES

Table 9.3 and figure 9.2 show the main parts and function of each part of ball mill.

Figure 9.2: Parts of the Ball Mill

Table 9.3 Parts and Functions of the Ball Mill
Parts Function
This is where the inert gas is introduced to collect the
Air Inlet
suspended particles in the ball mill and to evenly transport
 PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

the feed and materials from each compartment to the

discharge branch pipe
Feed Inlet This is where the feed is introduced
This contains the balls and it has the shell opening where the
Ball Mill Shell
balls must be input.
This will be used to transport the air with particles to the
Inert Gas Outlet
cyclone.
Motor This will be the power source of the ball mill’s rotation
Balls This is the grinding media of the ball mill.
Intermediate This will separate the course grinding process to the medium
Diaphragm and small grinding process.
This will provide the necessary grip for upward lift of the balls
Shell Liner
thus making collisions for size reduction
This will deliver the final size reduced product to the screwed
Outer Diaphragm
branch pipe for alimasag shell collection
 PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

DATA AND ASSUMPTIONS

1. The Alimasag shell feed rate is 1338.66 kg per batch. (Based on Material Balance in Ball
Mill)
2. The bulk density of alimasag shell is 567.9 kg/m3. (Based on Experimentation)
3. The particle size of the inlet feed is in maximum of 5 mm. (Based on Design of Double
Roll Crusher)
4. The desired product particle size is below 0.355 mm. (Based on Experimentation)
5. The mass loading inside the mill is 20% and 30% free space upon rotation (Process
Design by Hess).
6. The ball mill is a perfectly mixed batch air-swept mill.
7. The residence time is 100 min.

DESIGN CONSIDERATIONS

1. The size of balls for finest grinding is 1.5 in, 2 in, and 3 in. (Chemical Process Equipment
Selection and Design by S. Walas, 1st ed., p. 342).
2. The weights for each size of the balls are as follows: 227.2497g for 1.5 in., 538.4142 g
for 2 in, and 1,817.0912 g for 3 in. ball. (Forged Grinding Steel Balls.
https://www.911metallurgist.com/blog/grinding-balls#forged-steel-grinding-balls)
3. The bulk volume occupied by the balls is up to 50% for maximum efficiency (Chemical
Process Equipment – Selection and Design by S. Walas, 3rd ed., p. 372).
4. This critical speed (Nc) is different from actual mill speed. Actual mill speed varies from
65 to 85% of Nc for dry grinding. (Perry’s Chemical Engineering Handbook, 8th Ed. Page
21-64)
5. The work index of alimasag shell 3.08 kWh/t. (Chemical Process Equipment – Selection
and Design by S. Walas, 1st ed., p. 342)
6. The length to Diameter ratio of ball mill ranges from 1.4 to 1.6. We will use the average
which is 1.5 (1.5D=L) (http://www.gomemory.co.za/rr/96951/ball-mill-length-diameter-
ratio.html). The 2 compartment ratio of length ranges has the same ratio of 1.5 of L/D.
(http://www.cementequipment.org/home/cement-grinding-system/mill-shell-optimum-
dimensions/)
7. The materials of construction employed ideally in ball mill and its grinding media is
carbon steel ball. This carbon steel ball can withstand 345 MPa to 485 MPa tensile
strength. (Perry’s Chemical Engineering Handbook, 8th Ed. Page 25-29) Carbon steel is
through-hardened and high density. (Carbon Steel Balls – Grinding Media for your Ball
Mill .http://foxindustries.com/products/grinding-media/carbon-steel-balls/)
8. A safety factor of 20% is required for size reduction equipment which variables include
capacity and power input (Plant Design and Economics for Chemical Engineers by
Peters and Timmerhaus, 5th ed, Table 3-1, p.82).
DESIGN REQUIREMENT
1. Mill Capacity
2. Mill Dimensions
3. Number of Balls
4. Rotor Speed
5. Type of Intermediate and Outer Diaphragm
6. Type of Inner Ball Mill Lining
 PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

7. Ball Mill Thickness

8. Power Requirement of Ball Mill Rotation
 PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

DESIGN CALCULATIONS

1. Mill Capacity
To compute for the total volume of the ball mill:
𝑇𝑜𝑡𝑎𝑙 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑀𝑖𝑙𝑙 = 𝑉𝑡𝑜𝑡𝑎𝑙 = 𝑉𝑓𝑒𝑒𝑑 + 𝑉𝑓𝑟𝑒𝑒 𝑠𝑝𝑎𝑐𝑒 + 𝑉𝑏𝑎𝑙𝑙
Since 30% of the mill is free space and 50% composed of balls (Chemical
Process Equipment – Selection and Design by S. Walas, 3rd ed., p. 372),
VolTotal = Volfeed + 0.30 (VolTotal) + 0.50 (VolTotal)
𝑀𝑎𝑠𝑠
VolFeed =
𝐷𝑒𝑛𝑠𝑖𝑡𝑦
For 20% safety factor:
kg 1 batch
1338.66 𝑥 𝑥 1.2
VolFeed = batch 1.66667 hr
𝑘𝑔
567.9 3
𝑚
VolFeed = 1.6972 𝑚3
VolTotal = 1.6972 𝑚3 + 0.30 (VolTotal) + 0.50 (VolTotal)
VolTotal = 8.4860 m3
USE: VolTotal = 8.49 𝒎𝟑

2. Mill Dimensions
Considering cylindrical ball mill,
𝜋𝐷 2 𝐿
Volume of the Mill =
4

For the design of ball mill,

Since 1.5D = L
𝜋(𝐷)2 𝑥1.5𝐷
8.4860 m3 =
4
D = 1.9313 𝑚
L= 2.8969 m

Use: L = 2.90 m ≈ 9.5144 ft and D = 1.95 m ≈ 6.3976 ft

3. Number of Balls

Using the table provided by Economy Ball Mill Inc. for designing a ball mill,
 PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

A ball mill with L = 10 ft and W = 6 ft contains about 16,500 pounds of balls which
occupies the 50% total volume of the ball mill.
The size of balls for finest grinding is 1.5 in, 2 in, and 3 in. (Chemical Process
Equipment – Selection and Design by S. Walas, 1st ed., p. 342).
16,500
Total weight of each size of ball =
3
Total weight of each size of ball = 5,500 = 2,494.7582 𝑘𝑔
The weight for each size of the balls are as follows: 227.2497g for 1.5 in.,
538.4142 g for 2 in, and 1,817.0912 g for 3 in. ball. (Forged Grinding Steel Balls.
https://www.911metallurgist.com/blog/grinding-balls#forged-steel-grinding-balls)
Number of balls for corresponding sizes:
Number of 1.5 in. ball = 2,494.7582 𝑘𝑔/227.2497x10−3 = 10,978 pieces
Number of 2 in. ball = 2,494.7582 𝑘𝑔/538.4142x10−3 = 4,634 pieces
Number of 3 in. ball = 2,494.7582 𝑘𝑔/1,817.0912x10−3 = 1,373 pieces
Total Number of Balls = 16,985 pieces

4. Rotor Speed

From Perry’s Chemical Engineering Handbook, 8th Ed. Page 21-64 using
equation 21- 90, the critical speed of the ball mill is represented as

42.3
Nc =
√𝐷
42.3
Nc =
√1.9313

Nc = 30.4380 𝑟/𝑚𝑖𝑛
 PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

This critical speed is different from actual mill speed. From Perry’s Chemical
Engineering Handbook, 8th Ed. Page 21-64, actual mill speed varies from 65 to 80% of
Nc for dry grinding. Using 72.5% of Nc

Actual Speed = 30.4380 𝑟/ min 𝑥 0.725

Actual Speed = 22.0675 𝑟/𝑚𝑖𝑛

𝑼𝒔𝒆: 𝑨𝒄𝒕𝒖𝒂𝒍 𝑺𝒑𝒆𝒆𝒅 = 𝟐𝟐. 𝟎𝟔 𝒓/𝒎𝒊𝒏

5. Type of Intermediate and Outer Diaphragm

The intermediate and outer diaphragms separate the two compartments of the ball mill.
Both diaphragms are cross-flow rotating cage separator. There is a center screen
installed. (Mill Diaphragms by Christian Pfeiffer)

6. Type of Inner Ball Mill Lining

There are several types of Ball mill liners. The first compartment that includes the
coarse grinding using the 3 in. balls of the ball mill. These are:

It must have has a lining of double wave since it has the highest lifting power.
(Grinding with Ball Mill Systems by Holcim Co.)

The second compartment that includes the medium and fine grinding using the 2
and 1.5 in. balls of the ball mill.
 PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

It must have has a lining of step liner with structure since it was the second
liner with the greatest lifting power. (Grinding with Ball Mill Systems by Holcim Co.)

7. Ball Mill Thickness

The thickness of mill shell ranges from 1/100 to 1/75 of the mill diameter, depending
on the diameter and length of the mill. (http://www.cementequipment.org/home/cement-
grinding-system/mill-shell-optimum-dimensions/)

Table shows that at range 1.60-2.00 m the shell thickness is 20 mm. Since the
diameter of the ball mill is 1.9313 m, therefore:

𝑼𝒔𝒆: 𝑻𝒉𝒊𝒄𝒌𝒏𝒆𝒔𝒔 = 𝟐𝟎 𝒎𝒎

8. Power Requirement of Ball Mill Rotation

Equation 12.3 from Chemical Process Equipment – Selection and Design by S.
Walas, 3rd Ed. p. 339, can be used to determine the power consumption for the size
reduction mechanism in kilowatts.
1 1
W = 10Wi ( − )
√𝑑 √𝑑𝑖
Where: d = final product particle diameter (𝜇𝑚)
di = initial particle diameter (𝜇𝑚)
Wi = working index
1 1
W = 10 x 3.08( − )
√0.355𝑥103 √5𝑥103
W = 1.1991 kW or 1.6080 hp
𝑼𝒔𝒆: 𝑷𝒐𝒘𝒆𝒓 𝑪𝒐𝒏𝒔𝒖𝒎𝒑𝒕𝒊𝒐𝒏 = 𝟏. 𝟔𝟓 𝒉𝒑
 PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

DESIGN SPECIFICATION
BALL MILL
Operating Data
Number of Units 1
Method of Operation Batch
Materials of Construction Carbon Steel
Residence Time 100 min
Materials Handled Alimasag shells
Actual Capacity 8.49 m3
Feed 5 mm to 0.355 mm
Particle Size (Available from supplier:
0-25 mm)
Ball Mill Data
Proposed Existing
Diameter 1.95 m Up to 2.00 m
Length 2.90 m Up to 4.50 m
No. of Balls
1.5 in 10,978 -
2.0 in 4,634 -
3.0 in 1,373 -
16,985 (16500 lb/ Ball Loading:
Total Number of Balls
7.484 t) Up to 18.6 t
cross-flow -
Intermediate Diaphragm rotating cage
separator
Inner Ball Lining
First Compartment Double wave -
Step Liner with
Second Compartment -
Structure
Shell Thickness 20 mm -
Actual Mill Speed 21.73 r/min Up to 27.2 r/min
Up to 180 kW
Power Requirement 1.65 hP
(AC Motor)
Existing Equipment
Jiangxi Hengcheng Mining
Equipment Co., Ltd.
Supplier (https://www.alibaba.com/product-
detail/Factory-steel-ball-mill-prices-
for_60778778192.html/ )
China (Mainland)|Manufacturer,
Supplier Address
Trading Company
 PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

DESIGN CONFIGURATION
BALL MILL
 PAMANTASAN NG LUNGSOD NG MAYNILA
College of Engineering and Technology
Chemical Engineering Department

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