Ball Mill Manual

ENGI 5671: Process Equipment Design I
Laboratory Manual - Ball Mill
Department of Process Engineering
Winter 2015
Contents
1 Study of operational performance of a ball mill 1

1.1 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3.1 Size reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3.2 Critical speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3.3 Particle Size Distribution . . . . . . . . . . . . . . . . . . . . . . . . 2
1.4 Apparatus and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Experimental procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6 Experimental Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6.1 Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6.2 Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.6.3 Discussions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.7 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Sec. 1 Study of operational performance of a ball mill 1
1 Study of operational performance of a ball mill

In this experiment the operational performance of a ball mill will be studied. By comparing
the size distribution of the particles before and after milling, the performance of the mill will
be evaluated. More specifically, the effect of rotational speed on milling performance will be
determined. The critical speed of the mill will be determined theoretically and the milling
operation will be carried out at different fractions of the critical speed. Sieve analysis will
be carried out for separation of the particles and to determine the particle size distribution.
1.1 Objectives
The specific objectives of the experiment are
1. Observe how pyrophyllite or barite is increasingly reduced in size in a continuous
milling process.
2. Determine the degree of comminution dependent on milling time and speed.
3. Perform screen analysis and classify particles according to screen analysis.
4. Determine size distribution of particles.
1.2 Introduction
Ball mills are primarily used for fine grinding and pulverising of dry hard to medium-
hard materials. A ball mill consists of a rotating hollow cylinder, which is filled approx.
50...70%with wear-resistant milling balls (marked as 1 in Figure 1) made of steel or hard
porcelain and the material to be ground (marked as 2). When the container rotates, milling
balls are lifted against the inside wall and fall back onto the material to be ground, crushing
it through friction, shearing and impact.
1.3 Theory
1.3.1 Size reduction

The term size reduction is applied to all the ways in which particles of solids are cut or
broken into smaller particle size out the process industries, solids are reduced by different
methods for different purposes.
1.3.2 Critical speed

The faster the mill is rotated, the further the balls are carried up inside the mill and the
greater the power consumption and the capacity of the mill. If the speed is too high, the
balls are carried over and the mill is said to be centrifuging. Critical speed nc is the rotary
speed beyond which the balls are centrifuging.

2 1.3 Theory
Figure 1: Size reduction process in a ball mill.
r
1 g
nc = (1)
2π R−r
where, g(m/s2 ) is the acceleration of gravity, R(m) is the radius of the mill, and r(m) is
the radius of the grinding elements. nc (1/s) is the critical speed which can not be exceeded,
normally tumbling mills run at 65 to 80% of nc .
1.3.3 Particle Size Distribution

The particle size distribution will be performed using a series of sieves and sieve shaker,
with the smallest mesh at the bottom and the largest at the top. The sample is placed on
the top screen and the stack shaken mechanically for a definite time. The particles retained
on each screen are removed and weighed, and the masses of the individual screen increments
are converted to mass fractions or mass percentages of the total sample. Any particles that
pass the finest screen are caught in a pan at the bottom of the stack.
The results of a screen analysis are tabulated to show the mass fraction of each screen
increment as function of the mesh size range of the increment. Since the particles on any on
screen are passed by the screen immediately ahead of it, two numbers are needed to specify
the size range of an increment, one for the screen though which the fraction passes and the
other on which it is retained.

1.4 Apparatus and equipment 3
1.4 Apparatus and equipment

The CE 245 Ball Mill allows milling experiments for pulverising to be carried out. The
material to be ground is added to a cylindrical container, the milling drum, together with
milling aids such as balls, and the container is then rotated around its centre axis. Milling
takes place by the balls rolling onto the material to be ground in the drum.
The milling result varies depending on the filling level, dimension and speed of the drum,
geometry of the milling bodies and the material to be ground. Ball mills are not only used
for reduction but also for mixing and dispersing products.
Figure 2: Experimental ball mill apparatus.
1 Digital power consumption display in W 9 Loose roller

2 Digital speed display in 1/min 10 Mounting for protection cover
3 Speed adjuster for drive roller 11 Steel container
4 Timer 12 Inspection windows
5 Off button 13 Drive roller
6 On button 14 Height-adjustable feet
7 Master switch 15 Guide rail
8 Emergency STOP switch 16 Box Level

4 1.5 Experimental procedure
1.5 Experimental procedure

1. Record the weight of each empty sieve.
2. Prepare four groups of rock samples, sieve the samples to get the initial grain size
distribution.
3. Calculate the critical speeds for each of the three sizes of containers, with each size
having three sizes of balls. Pick one of the drums, use three groups of the samples for
three different rotary speeds n1,n2,n3, and n3 should be greater than the critical speed
you predicted for the container you are using. The fourth group should be milled at
either n1 or n2, with balls. The experiment setting is shown below:
4. Stop the ball mill at 20 minutes, take the sample to sieve again and record the grain
size distribution.
Table 1: Experimental conditions.
Group # Rotary speed Balls
1 n1 = 0.5nc No
2 n2 = 0.75nc No
3 n3 = nc No
4 n4 = n1 or n2 Yes
1.6 Experimental Results
1.6.1 Data
Weight of the empty sieves as well as that with grains before and after milling should be
noted as shown in the following table.
1.6.2 Results
1. Construct the grain size distribution from the results from each group in weight
percentage. Plot the before and after milling for different conditions.
2. Compare the size distribution between before milling and after milling for each group,
and then interpret the influence from rotary speed to size distribution result.
3. From the size distribution of group3, describe what happens when rotary speed exceeds
critical speed, how is your prediction of critical speed from calculation?

1.7 References 5
Table 2: Sample raw data table.
Weight of empty Weight before Weight after

Mesh #
sieve (g) milling (g) milling (g)
1.6.3 Discussions
1. What conclusions can you can make about the dependence between rotary speed and
the size distribution?
2. What could be the purposes of size reduction?
3. What other possible parameters could also affect the milling result?
1.7 References
1. GUNT, CE245 Ball Mill Equipment Manual
2. Warren L.McCabe, Julian C. Smith, Peter Harriott,, 2005. Unit Operations of

Chemical Engineering, 7th Edition, McGraw-Hill.

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ENGI 5671: Process Equipment Design I

Laboratory Manual - Ball Mill

Department of Process Engineering

1 Study of operational performance of a ball mill 1

1 Study of operational performance of a ball mill

2. Determine the degree of comminution dependent on milling time and speed.

3. Perform screen analysis and classify particles according to screen analysis.

4. Determine size distribution of particles.

1.3.1 Size reduction

1.3.2 Critical speed

ENGI 5671: Process Equipment Design I

Figure 1: Size reduction process in a ball mill.

1.3.3 Particle Size Distribution

ENGI 5671: Process Equipment Design I

1.4 Apparatus and equipment

Figure 2: Experimental ball mill apparatus.

1 Digital power consumption display in W 9 Loose roller

ENGI 5671: Process Equipment Design I

1.5 Experimental procedure

Table 1: Experimental conditions.

Group # Rotary speed Balls

1.6 Experimental Results

ENGI 5671: Process Equipment Design I

Table 2: Sample raw data table.

Weight of empty Weight before Weight after

2. What could be the purposes of size reduction?

2. Warren L.McCabe, Julian C. Smith, Peter Harriott,, 2005. Unit Operations of

ENGI 5671: Process Equipment Design I

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