Experiment 4 Date:17/09/2024
Lab Record
1. Title : Study of the Grinding Process in a Ball Mill: Analyzing Operational Zones
On
and Calculating Average Particle Size and Reduction Ratio of Metalliferous Ore.
Studying operation of ball mill and determination
of average
2. Introduction:size and reduction ratio of grinding a
metalliferous
Run-of-mine ore refers to the ore from the mines, remaining
raw material extracted directly
unprocessed and ungraded. It contains a mix of soil, rock, minerals, contaminants, and
impurities in its natural state. To separate valuable minerals from waste materials or
gangue, size reduction of run-of-mine ore is essential. This process improves the
efficiency of key operations like separation, concentration, and extraction. Additionally,
size reduction enhances the handling and transportation of ore, while optimizing the
performance of processing equipment to ensure more economical and effective ore
processing.
Size reduction is carried out using specialized equipment designed to crush and grind
materials. This step is crucial across various industries, playing a vital role in
manufacturing and processing.
Grinding is a mechanical process used to reduce the size of solid materials by applying
friction, impact, or pressure. It involves breaking down the material into smaller particles
to increase surface area, aiding in further processing or extraction. Grinding is critical for
producing high-precision, durable components in industries such as mining, cement, and
metalworking. By reducing the size of ore particles through mechanical and vibrational
forces, grinding helps liberate economically important minerals from the surrounding
material.
Mills are mechanical devices used to break down materials into smaller sizes. They are
widely employed in industries such as mining, cement production, and chemical
processing to reduce the size of materials like ores.
Submitted by
One common piece of size reduction equipment is the ball mill, a type of grinder. It
consists of a rotating cylindrical shell filled with low-carbon steel balls that grind
Sanidhya Jindal
materials through impact, friction, and attrition as the shell rotates. Size reduction occurs
due to the cascading motion of the grinding media, interparticle collisions, and friction
with the mill wall. Roll Number : 123MM0666
Beyond ball mills, other types of mills include:
Hammer Mills: As the name suggests, hammer mills crush materials into smaller
pieces using hammers. They are widely used for crushing applications (1).
Mineral
Rod Mills: Dressing
Rod mills use Laboratory
long steel rods (MM2363
as grinding media )
and are employed in
coarse grinding, primarily for feed sizes of 45-50mm (2).
Roller Mills: This category includes mills with rotating rollers or fixed rollers with
Department of Metallurgical and Materials Engineering
a rotating table for grinding.
Vibratory Mills: These rely on vibrational forces, rather than rotation, for grinding.
The grinding chamber Institute
National is filled withof
media like balls or,rods,
Technology occupying about 65-
Rourkela
80% of its capacity.
2024-25
Fluid Energy Mills: Material is fed into a high-speed, high-pressure, often high-
temperature jet of air or gas for grinding (3).
Disc Mills: These mills feature either a single rotating disc in a stationary casing or two
discs rotating in opposite directions, making them suitable for rapid, loss-free grinding of
hard, brittle, and fibrous materials (4).
Drum Mills: Drum mills are used for processing larger feed sizes and sample volumes. The
final fineness depends on the media used (5).
Grate Discharge Mills: These mills have a grate diaphragm to control the discharge of
grinding balls.
Pebble Mills: A variation of ball mills, pebble mills use natural pebbles instead of balls to
crush materials.
Tube Mills: Featuring a cylindrical shell longer than its diameter, tube mills are lined with
hard balls to grind materials.
Wet Grinding Mills: These mills operate with materials in a liquid state or slurry (6).
High-Pressure Grinding Mills: These mills use two rollers of the same size rotating
against each other, with material fed between them to form a compressed material bed (7).
Pin Mills: These mills utilize a rotor with rods that propel particles into stationary pins or
surfaces for size reduction (8).
Stirred Mills: Designed for fine and ultrafine grinding, stirred mills provide efficient
solutions across various industries, offering customizable options for different applications
(9).
Fig 1 : Tube Mill
Fig 2 : Hammer Mill Fig 3 : Rod Mill
Fig 4: Pin Mill Fig 5 : Stirred Mill
Fig 6 : Disc Mill Fig 7 : Roller Mill
Fig 8 : Rod Mill Fig 9 : Vibratory Mill
A ball mill is a type of grinding equipment used to reduce the size of materials through the impact
and friction generated by the movement of spherical grinding media (balls) within a rotating
cylindrical shell.
Types of ball mills:
There are different types of ball mills:
According to production mode:
Dry ball mill
Wet ball mill
According to process used:
Dryer mill
Superfine ball mill
Open circuit mill
Closed circuit mill
According to raw materials:
Raw mill
Cement mill
Coal ball mill
Steel slag ball mill
Slag ball mill
Quartz ball mill
Types of balls:
Steel balls: Most common type of mill balls. They are durable, have high density and resistant to
wear and tear.
Ceramic balls: Made of alumina, zirconia or silicon nitride, making them hard and wear
resistant. They are also chemically inert, so do not react with material being milled.
Grinding media balls: Made of high-chromium steel, having excellent grinding properties. Used
to grind cement, minerals and ores.
Rubber: Used for grinding softer materials such as food items.
Fig 12 : Steel Balls Fig 13 : Rubber Balls
Fig 14 :Ceramic Balls Fig 15 : Grinding Media Balls
(High Chrome Steel)
Zones of a Ball Mill :
In a ball mill, the grinding process occurs in distinct zones, each contributing to the overall size
reduction of the material:
Cataracting Zone: This is the uppermost section of the mill where the grinding media
(balls) are lifted and then fall back onto the ore. In this zone, the media move in a free-
falling motion, generating high-impact forces that contribute to coarse size reduction. The
cascading balls in this zone crush the larger ore particles, producing significant fracture.
Cascading Zone: Below the cataracting zone, the balls move along the inner wall of the
mill, sliding and rolling over one another. This zone generates more frictional forces than
impact, leading to finer grinding. The materials are ground by the attrition forces between
the media and ore, resulting in moderate size reduction.
Grinding Zone: This is the area near the bottom of the mill where the grinding media and
ore particles are compacted. The grinding media here exert compressive forces on the ore,
primarily causing finer particle size reduction. The grinding zone is where most of the
energy is transferred to the material, and the largest amount of grinding occurs.
Slip Zone: This is the lowest part of the mill, where the balls barely move due to low
centrifugal forces. Material in this zone experiences minimal grinding action. Although not
much grinding happens here, the materials are mixed and slowly move toward areas
where more active grinding occurs.
Each of these zones plays a role in the overall efficiency of the ball mill, contributing to both
impact-based and attrition-based size reduction depending on the zone and the operating
conditions.
Balls Used in the Ferrous Industry:
Forged Steel Balls: High-carbon steel balls known for their toughness and used in
grinding iron ore and coal.
Cast Iron Balls: Durable balls made from cast iron, suited for abrasive ferrous ores.
Chrome Steel Balls: Balls with high chromium content, providing excellent wear
resistance in steel and iron processing.
Balls Used in the Non-Ferrous Industry:
Alumina Ceramic Balls: High-purity ceramic balls, ideal for non-ferrous materials like
aluminum.
Zirconia Balls: Extremely durable balls used for fine grinding of non-metallic materials.
Glass Balls: Soft grinding media used where chemical purity is essential.
Tungsten Carbide Balls: Ultra-hard balls for grinding hard non-ferrous materials and
precious metals.
3. Aim of experiment:
The objective is to examine the operation of a ball mill, determine the reduction ratio for a
specific feed size, and evaluate how it varies based on the following factors:
The influence of the number of balls in the mill
The impact of grinding duration
4, Materials, Equipment and Methodology:
Materials and equipment:
Mineral ore sample with initial particle size (initial feed size) of 12.5 mm
Grinding steel balls of 500g weight
A ball mill for grinding ore sample
Test sieves of BSS standards 8 to 300
A sieve shaker machine
Digital balance
Brush (for collecting residue from sieves)
Methodology:
The experiment was conducted four times, varying both the grinding duration (30 minutes and
40 minutes) and the ball-to-ore ratio. The ratios used were 4:1, 8:1, 5:1, and 10:1, where, for
example, a 4:1 ratio signifies 4 balls were used for every unit of ore.
First, 500 grams of the ore sample was prepared, ensuring that the initial average particle size
(feed size) was 12.5 mm.
The sample was manually sieved to ensure a uniform particle size distribution before being
placed into the ball mill along with 4 steel balls. The mill was operated for 30 minutes
After the grinding process, the ore was carefully removed, with attention given to minimize
material loss through the mill's rims or joints. The sample was weighed again to account for any
loss, and the sieve analysis was then carried out.
For sieve analysis, a set of BSS standard sieves (Nos. 8, 16, 36, 52, 72, 100, 150, and 300) was
arranged in descending order, with sieve No. 8 at the top and No. 300 at the bottom. The ground
sample was loaded into the top sieve (No. 8) and placed into a sieve shaker, which was run for
10 minutes—an optimal duration for sieving.
After sieving, the weight of the sample retained on each sieve was measured, and the average
particle size was determined. This data was then used to calculate the reduction ratio.
The process was repeated using the same 4 balls, but with the grinding time extended to 40
minutes. The corresponding data was recorded, and the reduction ratio was recalculated.
The experiment was then repeated for both grinding durations (30 and 40 minutes), with
different ball-to-ore ratios of 8:1, 5:1, and 10:1. The reduction ratios for each case were
determined and recorded.
5. Results:
Table 1: Ball to ore ratio: 4:1, grinding time: 30 minutes
Sl. No. Sieve no Sieve size Arithmetic Weight Weight of
(BSS)(mm) mean (d) retained sample (n x
(mg)(n) d)
1 8 2.411 1.8 294.6 532.342
2 16 1.204 0.812 1.6 1.3
3 36 0.425 0.362 3.2 1.152
4 52 0.3 0.256 3.8 0.969
5 72 0.212 0.181 7 1.260
6 100 0.150 0.128 9.4 1.198
7 150 0.106 0.0795 27.6 2.180
8 300 0.053 0.053 145.8 7.727
9 Pan 4.8
10 total 497.8 548.128
Table 2: Ball to ore ratio = 4:1, grinding time: 40 minutes
Sl. No. Sieve no Sieve size Arithmetic Weight Weight of
(BSS)(mm) mean (d) retained (n) sample (n x
d)
1 8 2.411 1.8 378.4 683.958
2 16 1.204 0.812 1 0.812
3 36 0.425 0.362 2.6 0.936
4 52 0.3 0.256 5.6 1.428
5 72 0.212 0.181 8.6 1.548
6 100 0.150 0.128 8.8 1.122
7 150 0.106 0.0795 29.2 2.3068
8 300 0.053 0.053 61.6 3.2648
9 Pan 0.6
10 total 496.4 695.375
Table 3: Ball to ore ratio: 5:1, grinding time: 30 minutes
Sl. No. Sieve no Sieve size Arithmetic Weight Weight of
(BSS)(mm) mean (d) retained (n) sample (n x
d)
1 8 2.411 1.8 21.2 34.566
2 16 1.204 0.812 0.6 0.6516
3 36 0.425 0.362 2.6 0.9425
4 52 0.3 0.256 3.4 0.8704
5 72 0.212 0.181 9.4 1.7014
6 100 0.150 0.128 21 2.688
7 150 0.106 0.0795 124.8 9.1216
8 300 0.053 0.053 275.8 14.6174
9 Pan 34
10 total 493 65.94
Table 4: Ball to ore ratio: 5:1, grinding time: 40 minutes
Sl. No. Sieve no Sieve size Arithmetic Weight Weight of
(BSS)(mm) mean retained (n) sample (n x
d)
1 8 2.411 1.8 373.2 675.36
2 16 1.204 0.812 0.8 0.6496
3 36 0.425 0.362 0.6 0.2172
4 52 0.3 0.256 1 0.256
5 72 0.212 0.181 2.4 0.4344
6 100 0.150 0.128 4.4 0.5632
7 150 0.106 0.0795 26.8 2.1306
8 300 0.053 0.053 81 4.293
9 Pan 1.2
10 total 491.4 683.904
Table 5: Ball to ore ratio: 8:1, grinding time: 30 minutes
Sl. No. Sieve no Sieve size Arithmetic Weight Weight of
(BSS)(mm) mean retained (n) sample (n x
d)
1 8 2.411 1.8 266.4 481.518
2 16 1.204 0.812 1.2 0.974
3 36 0.425 0.362 0.4 0.144
4 52 0.3 0.256 2 0.550
5 72 0.212 0.181 4 0.720
6 100 0.150 0.128 7.6 0.969
7 150 0.106 0.0795 79.2 6.256
8 300 0.053 0.053 130 6.890
9 Pan 6.2
10 total 497 497.982
Table 8: Ball to ore ratio: 10:1, grinding time: 40 minutes
Sieve no Sieve size Arithmetic Weight retained Weight of sample
(BSS)(mm) mean (d) (n) (n x d)
8 2.411 1.8 252.6 411.86
Table 6:16
Ball to ore ratio:1.204 0.812
8:1, grinding time: 40 minutes 0.4 0.3258
36 0.425 0.362 0.6 0.2175
52
Sl. No. Sieve no 0.3 Sieve size 0.256 Arithmetic 0.6
Weight 0.1536of
Weight
72 0.212 (BSS)(mm) 0.181 mean 1.8
retained 0.3258(n x
(n) sample
100 0.150 0.128 4 0.512
d)
1 150 8 0.106 2.411 0.0795 1.8 28.2327.4 2.2419
591.775
2 300 16 0.053 1.204 0.053 0.812 179.8 0.8 9.5294
0.649
3 36 Pan 0.425 0.362 12.8 2.4 0.864
4 52 Total 0.3 0.256 480.8 5.2 425.166
1.326
5 72 0.212 0.181 6.8 1.224
Calculations:
6 100 0.150 0.128 10 1.275
7 150 0.106 0.0795 33.2 2.622
Ball
8 to ore ratio:
3004:1 - 0.053 0.053 101.2 5.363
9 Pan 1.6
10 Grinding time: 30 minutes: total 488.6 605.1
Average particle size = ∑(n ×d )÷ ∑n=548.128 ÷ 497.8=1.10 mm
Reduction
Table 7: Ballratio = maximum
to ore ratio: 10:1,particle
grindingsize ÷ average
time: particle size = 12.5 ÷ 1.1 = 11.36
30 minutes
No.
Sl. GrindingSieve
time:no40 minutes:
Sieve size Arithmetic Weight Weight of
(BSS)(mm) mean retained (n) sample (n x d)
Average
1 particle size
8 = ∑ (n ×d )÷ ∑ n=695.375
2.411 ÷ 496.4=1.4
1.8 mm 10 16.305
2 16 1.204 0.812 0.2 0.1629
Reduction
3 ratio = maximum
36 particle
0.425 size ÷ average
0.362 particle size =
0.6 12.5 ÷ 1.4 = 8.92
0.2175
4 52 0.3 0.256 1.6 0.4096
Ball5 to ore ratio: 72 5:1 - 0.212 0.181 5.2 0.9412
6 100 0.150 0.128 17 2.176
7 Grinding time:150 30 minutes: 0.106 0.0795 149 11.8455
8 300 0.053 0.053 283 15
Average
9 particle size = ∑ (n ×d )÷ ∑ n=65.94
Pan ÷ 493=0.1337 mm 14.2
10 total 480.6 47.056
Reduction ratio = maximum particle size ÷ average particle size = 12.5 ÷ 0.1337 = 93.49
Grinding time: 40 minutes:
Average particle size = ∑ (n ×d )÷ ∑ n=683.904 ÷ 491.4=1.39 mm
Reduction ratio = maximum particle size ÷ average particle size = 12.5 ÷ 1.39 = 9.01
Ball to ore ratio: 8:1 -
Grinding time: 30 minutes:
Average particle size = ∑(n ×d )÷ ∑n=497.982 ÷ 497=1.001 mm
Reduction ratio = maximum particle size ÷ average particle size = 12.5 ÷ 0.1001 = 12.47
Grinding time: 40 minutes:
Average particle size = ∑(n ×d )÷ ∑n=605.1 ÷ 488.6=1.24 mm
Reduction ratio = maximum particle size ÷ average particle size = 12.5 ÷ 1.24 = 10.08
Ball to ore ratio: 10:1 -
Grinding time: 30 minutes:
Average particle size = ∑(n ×d )÷ ∑n=47.056 ÷ 480.8=0.097 mm
Reduction ratio = maximum particle size ÷ average particle size = 12.5 ÷ 0.097 = 128.66
Grinding time: 40 minutes:
Average particle size = ∑(n ×d )÷ ∑n=425.166 ÷ 480.8=0.8842 mm
Reduction ratio = maximum particle size ÷ average particle size = 12.5 ÷ 0.8842 = 14.13
6 .Discussion:
The results allow us to discern the impact of both grinding time and the ball-to-ore ratio on the
reduction ratio.
When the grinding time is set to 30 minutes, the reduction ratio exhibits considerable variation
depending on the ball-to-ore ratio. Specifically, the reduction ratios are lower for the 4:1 and 8:1
ratios but significantly higher for the 5:1 and 10:1 ratios.
However, when the grinding time is extended to 40 minutes, the reduction ratios display far less
fluctuation across different ball-to-ore ratios. As the number of balls increases, the reduction
ratio rises in a more consistent and linear fashion.
This suggests that, with longer grinding durations, the reduction ratio follows a more
predictable and systematic trend. The irregular patterns observed in the 30-minute trials likely
indicate experimental errors or inconsistencies in the procedure.
7. Conclusion:
In this experiment, the operation of a ball mill was analyzed, with an emphasis on studying how
the ball-to-ore ratio and grinding duration influenced the reduction ratio.
A metalliferous ore sample with an initial particle size of 12.5 mm was selected. To ensure
uniformity, the sample underwent manual sieve analysis, confirming a consistent particle
distribution. The ball mill was then operated under varying conditions of ball-to-ore ratios and
grinding times, and the resulting reduction ratios were calculated.
Four ball-to-ore ratios were tested: 4:1, 5:1, 8:1, and 10:1, with grinding times of 30 and 40
minutes for each ratio. The results showed considerable variation in reduction ratios for the
different ball-to-ore ratios after 30 minutes of grinding. However, when the grinding duration
was extended to 40 minutes, the reduction ratios exhibited a more consistent and progressive
increase.
Although the experiment posed potential sources of error, meticulous care was taken to
minimize material loss. Precautions were implemented to prevent spillage from machine joints
and to ensure proper handling during the opening and closing of the mill, as well as throughout
the sieve analysis.
8. References :
Following are the websites traversed for preparing this record:
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Last accessed: 5/10/2024
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Last accessed: 7/10/2024
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