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The basic parameters used in ball mill design (power calculations), rod mill or anytumbling millsizing are; material to be ground, characteristics, Bond Work Index, bulk density, specific density, desired mill tonnage capacity DTPH, operating % solids or pulp density, feed size as F80 and maximum chunk size, productsize as P80 and maximum and finally the type of circuit open/closed you are designing for.

In extracting fromNordberg Process Machinery Reference ManualI will also provide 2 Ball Mill Sizing (Design) example done by-hand from tables and charts. Today, much of this mill designing is done by computers, power models and others. These are a good back-to-basics exercises for those wanting to understand what is behind or inside the machines.

W = power consumption expressed in kWh/short to (HPhr/short ton = 1.34 kWh/short ton) Wi = work index, which is a factor relative to the kwh/short ton required to reduce a given material from theoretically infinite size to 80% passing 100 microns P = size in microns of the screen opening which 80% of the product will pass F = size in microns of the screen opening which 80% of the feed will pass

Open circuit grinding to a given surface area requires no more power than closed circuit grinding to the same surface area provided there is no objection to the natural top-size. If top-size must be limited in open circuit, power requirements rise drastically as allowable top-size is reduced and particle size distribution tends toward the finer sizes.

A wet grinding ball mill in closed circuit is to be fed 100 TPH of a material with a work index of 15 and a size distribution of 80% passing inch (6350 microns). The required product size distribution is to be 80% passing 100 mesh (149 microns). In order to determine the power requirement, the steps are as follows:

The ball mill motorpower requirement calculated above as 1400 HP is the power that must be applied at the mill drive in order to grind the tonnage of feed from one size distribution. The following shows how the size or select thematching mill required to draw this power is calculated from known tables the old fashion way.

The value of the angle a varies with the type of discharge, percent of critical speed, and grinding condition. In order to use the preceding equation, it is necessary to have considerable data on existing installations. Therefore, this approach has been simplified as follows:

A = factor for diameter inside shell lining B = factor which includes effect of % loading and mill type C = factor for speed of mill L = length in feet of grinding chamber measured between head liners at shell- to-head junction

Many grinding mill manufacturers specify diameter inside the liners whereas othersare specified per inside shell diameter. (Subtract 6 to obtain diameter inside liners.) Likewise, a similar confusion surrounds the length of a mill. Therefore, when comparing the size of a mill between competitive manufacturers, one should be aware that mill manufacturers do not observe a size convention.

In Example No.1 it was determined that a 1400 HP wet grinding ball mill was required to grind 100 TPH of material with a Bond Work Index of 15 (guess what mineral type it is) from 80% passing inch to 80% passing 100 mesh in closed circuit. What is the size of an overflow discharge ball mill for this application?

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Ore beneficiation equipment, sand making equipment, crushing equipment and powder grinding equipment, which are widely used in various industries such as metallurgy, mine, chemistry, building material, coal, refractory and ceramics.

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