Dry Mills Training Seminar.pptVIP

Alumina Balls or Cylinders What is the Optimum Mill Charging Level? Mills reach maximum grinding ability at 50% charge volume. Power draw decreases as the center of gravity moves closer to the mill center. Optimum mill charge level is 40- 45% of mill volume. Minimal ball consumption occurs at 35 to 40% of mill charge volume. Optimally Charged Ball Mill (Alumina) Optimally Charged Ball Mill (Silex Flint) Typical Alumina Ball and Flint Pebble Consumption Rates Consumption Rate for Silica (2% retained on 200 mesh) Typical Unit Cost (USD) Unit Production Cost (USD) Flint Pebbles 6 kg per ton $0.20 per kg $1.20 per ton Alumina Ball 0.90 kg per ton $1.90 per ton $1.70 per ton What are the Advantages of Flint Pebbles? Flint pebbles give lower grinding media unit production costs. Since pebble are 98% silica increased Al2O3 content of the flour is negligible. What are the advantages of Alumina Grinding Media? Alumina provides 30-40% more production capacity for the same mill volume due to the higher S.G. of alumina (3.6) as compared to flint pebbles (2.6). Higher mill capacity rates can reduce operational costs through a more efficient milling system with lower energy consumption and reduced labor costs. Offset a large capital cost if a ball mill has no spare capacity. Storage and handling of alumina is much easier as charging volumes are only 10% of flint pebbles. Alumina or Flint Pebbles? If mill utilization rates are low then continue to use flint pebbles for a mill that is already charged with flint. If additional milling capacity is required then switch the mill to alumina balls or cylinders ensuring mill drive is adequate for the heavy media. Types of Iron Free Mill Linings Silex Lining Alumina Bricks Alumina Lining Sub Liner for Alumina Lining Worn alumina bricks can be more easily removed. Sub-liner acts as a final protection for mill shell. Lining can be thoroughly worn off in places before needing to re-l