Raw Materials Granulometry:

Sampling Point Sieve %Retained

[mm]
25 12.5 9.5 4.75 2.36 1.18
A Mill Feed Limestone 82.00% 64.4 90.7 94.6 98.1 99.1 99.5
B Clay Mix. 17.37% 12.1 21.6 26.1 38.7 52.6 64.3
C1 Iron Ore 0.43% 0.0 0.9 2.1 8.0 21.1 41.9
C2 Additive 0.20% 7.8 58.5 67.7 75.6 80.7 85.2
C3 Silica Sand 0.0 0.0 0.0 0.3 0.7 6.3
100.0% 54.9 78.2 82.2 87.3 90.7 93.1

Max. Ball Size Calculation:

d80 [µm] ρ [g/cm3] Wi [kwh/t] K Ψ [%] Du [m] Ømax [mm]
Limestone 40000 1.3 10.18 335 74 4.44 96.9
Mix 15000 1.5 7.1 335 74 4.44 55.2
Iron Ore 2300 2.5 12.13 335 74 4.44 30.6

d80 [µm] Mesh: size of the sieveing where 80% of material is Passing
ρ [g/cm3] density of material
Wi [kwh/t] Work Index
K Factor (335 for dry grinding (OC or CC), 350 for wet grinding)
Ψ [%] % of Critical Speed (mill)
Du [m] Effective Di of the mill
Ømax [mm] Maximum Ball size

Ball Charge Distribution:

From to Limestone Granulometry
Material: EB d180: d280: WB: Energy %Passing d280: WB: Energy Diam ton
Limestone 10.18 40 20 6.7 13.8% 45.1% 20 3.01 35.3% 100 - 90 39.6
20 8 13.2 27.4% 17.8% 8 2.35 27.7% 90 - 80 31.0
8 4 14.9 30.9% 12.7% 4 1.89 22.3% 80 - 60 24.9
4 2.5 13.5 27.9% 9.3% 2.5 1.25 14.7% 70 - 50 16.5
48.3 100.0% 100% 112.0
Ball Charge Design
Based On Slegten Method

Steel dens = 7843 kg/m3 (Use 7843 if not known)

!st Compt Bulk Density 4500 kg/m3 (Use 4500 if not known)

bulk Density
Ball Dia,mm Vol,mm3 vol,m3 kg/ball kg/m3 Std Size
90 381,703.51 3.82E-04 2.99 4,579.60 3.5
80 268,082.57 2.68E-04 2.10 4,608.11 3
70 179,594.38 1.80E-04 1.41 4,640.42 2.75
60 113,097.34 1.13E-04 0.89 4,677.73 2.5
50 65,449.85 6.54E-05 0.51 4,721.85 2
40 33,510.32 3.35E-05 0.26 4,775.85 1.5
30 14,137.17 1.41E-05 0.11 4,845.48 1.25
25 8,181.23 8.18E-06 0.06 4,889.60 1
20 4,188.79 4.19E-06 0.03 4,943.60 0.75
16 2,144.66 2.14E-06 0.02 4,997.61 0.625

1st compt length 3 m

1st compt effective dia. 3.7 m
Desired Vol Load 33 %
2nd compt length 6 m
2nd compt effective dia. 3.6 m
Desired Vol. Load 33 %
Partition Length 0.31 m

1st Compt Chg Vol 10.64 m3

1st Compt charge vol./m length 3.55 m3/m
1st compt chg wt 47,900.61 kg 47.9 mt
2nd Compt Charge Vol. 20.15 m3
2nd Compt Charge Vol./m Length 3.36 m3/m

Slegten Ball Charge Based on Std Inch Ball Sizes

The weight % of 3.5 inch balls in the first compartment is normally 20%
Bulk Density
Ball Dia, inch % by wt no Balls mt kg/m3 Volume, m3
1st Compartment
3.5 20.0 3,320 9.6 4,500 2.13
3 34.1 8,979 16.3 4,500 3.63
2.75 26.2 8,979 12.6 4,500 2.79
2.5 19.7 8,979 9.4 4,500 2.10
Total 1st Compt. 100.00 30,256 47.9 10.64

2nd Compartment
Transition Zone
2 4.9 8,979 4.8 4,718 1.02
1.5 2.1 8,979 2.0 4,788 0.43
Total Transition 7.0 17,957 6.9 1.45
Fine Grinding Zone
 1.25 33.0 246,958 32.5 4,832 6.7
1 26.7 390,185 26.3 4,886 5.4
0.75 33.3 1,153,924 32.8 4,955 6.6
0.625 0.0 - 0.0 4,999 0.0
Total Fine Grinding 93.0 1,791,067 91.5 18.70
Total 2nd Compt. 100.0 1,809,025 98.3 20.15

Ball Charge Plot

3.5

3
Ball Diameter, Inch

2.5

1.5

0.5

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Distance From Feed End, m
 bulk Density
kg/ball kg/m3
2.89 4,583
1.82 4,620
1.40 4,641
1.05 4,664
0.54 4,718
0.23 4,788
0.13 4,832
0.07 4,886
0.03 4,955
0.02 4,999

Ball Dia , Inch

3.5
3
2.75
2.5
2
1.5
1.25
1
0.75
0.625

length,m x y
0 3.5
0.6 0.6 3.5
1.0 0.6
0.8 0.6
0.6 0.6
3.0 1.6
1.6
1.6
1.6
0.31 2.4
0.13 2.4
0.43 2.4
Slegten Values 2.4
 2.00 2 3.0
1.60 1.6 3.0
1.97 2.8 3.0
0.00 3.3
5.57 3.6
6.00 3.6
3.6
3.6
3.7
3.7
3.7
3.7
5.7
5.7
5.7
5.7
7.3
7.3
7.3
7.3
9.3
9.3
9.3
9.3
9.3
0.3
1.1
2.0
2.7
11 12 13 14 3.0
3.3
3.7
4.7
6.5
8.3
9.3
Cum Length
0.6
1.6
2.4
3.0
3.6
3.7
5.7
7.3
9.3
9.3

3.5
3
3
3
3
2.75
2.75
2.75
2.75
2.5
2.5
2.5
2.5
2.5
2
2
2
1.5
1.5
1.5
1.5
1.25
1.25
1.25
1.25
1
1
1
1
0.75
0.75
0.75
0.75
0.625
0.625
0.625
 3.5
3
2.75
2.5
2.39275
2
1.5
1.25
1
0.75
0.625