Re: how to estimate the wear rate for Ball mill. Ball wear can be measured by weighing an entire charge before and after grinding a known tonnage of materials. With new balls sample of given size can be weighed before and after grinding a given tonnage and, assuming uniform wear per unit of ball surface, the total charge …

It is assumed that ball mill wear occurs in each of three comminution zones, with adhesive wear found in the crushing and tumbling zones and abrasive wear …

Wear Rate Case Study for ZJH minerals' SAG mill grinding media. A gold mining in shandong provice china, first the gold mine adopt 10% percent chrome casting balls, but these balls wear quick (1.34 kg gridning per ton ore), then they change these balls to be our forged steel balls, then the forged balls grinding rate(0.735kg gridning per ton ore)

The energy con sumption for spherical balls was 3.6 Kw after grinding for 420 minutes, producing a 45µm. residue of 4.37% whilst that of cylpebs was 2.6kW after grinding for 295 minutes producin ...

Advanced mill liner wear measurement and prediction services 3 FARO laser scanner Recording liner profiles as 3D cloud point data inside the . mill chamber. ... Lifter wear rate . 12.6 mm/mT; Accumulated tonnage. 3.808 mT. Plate wear rate. 12.3 mm/mT; Average processed tons. 52,500 tonne/day.

Ball Mill Design Parameters. Size rated as diameter x length. Feed System. One hopper feed; Diameter 40 – 100 cm at 30 ° to 60 ° Top of feed hopper at least 1.5 meter above the center line of the mill.

The wear rate of martensitic alloy steel balls was established by charging 20, 76 mm production heat treated Armco MOLY-COP balls to Unit 14 Ball Mill and testing for 534.1 operating hours. Twenty 76 mm pearlitic carbon steel balls, representative of the host charge, were tested concurrently by Climax for control purposes.

The wear rate of grinding media is mainly influenced by various parameters such as pH, solid percentage, throughout, charge weight of balls, rotation speed of mill and grinding time which the relationship between the wear rate and the effective parameters is a highly-nonlinear and coupled multivariable relationship and cannot be expressed by an ...

The Ball Mill Abrasion (BMA) test was developed by the University of Queensland Materials Performance group to simulate the high stress abrasion conditions experienced in production ball mills. It gives …

The example shown in Fig. 1 refers to cast irons tested as grinding balls in a ball mill [2]. Because of different heat treatments one sample has high hardness martensitic matrix while the other presents a low hardness austenitic matrix. The wear rate for the later was much higher because of the subsurface cracking of the carbides, shown in Fig ...

The performance of grinding media in a ball mil l is also measured in terms of its wear rate. Abrasive ores such a s gold and copper produce high wear rates of about 120µm/hr [ 74 ].

Wear is associated with the comminution mechanisms found in the ball charge profile. It is assumed that ball mill wear occurs in each of three comminution zones, with adhesive wear found in the crushing and tumbling zones and abrasive wear arising in the grinding zone. Wear rates are proportional to the energy dissipated in these zones …

The performance of grinding media in a ball mill is measured in terms of wear rate, which is a function of the media composition, hardness, phase structure, and corrosive–abrasive characteristics of the slurry. The wear mechanisms involved in a ball mill are impact, abrasion, corrosion, and erosion. ...

A new method to predict the wear profile of ball mills was proposed. • Wear parameter of ball mills depends on properties of their lifter profiles. • Mill component …

In an endeavor to follow this plan, the attempt has been made to secure reliable data showing the screen analysis of ball charges which have been in steady use for a long period. It … See more

For wet ball mills, the equilibrium size distribution of balls in the mill is a function of the make-up balls added to the mill and the rate of wear of the balls. Second, economic studies of grinding processes [3] show that steel loss of media and liners during grinding is a substantial fraction of the total cost of grinding. Third, in order ...

The performance of grinding media in a ball mill is measured in terms of wear rate, which is a function of the media composition, hardness, phase structure, and …

Ball mills tumble iron or steel balls with the ore. The balls are initially 5–10 cm diameter but gradually wear away as grinding of the ore proceeds. The feed to ball mills (dry basis) is typically 75 vol.-% ore and 25% steel. The ball mill is operated in closed circuit with a particle-size measurement device and size-control cyclones.

Secondary Grinding Ball Mills experience 1-2 years of liner life, depending on tonnage/ball size. Normally Lifter to Plate ratio is 1:2.Tertiary Grinding Ball Mills experience up to 4 years of liner life. Since, all the mills are unique in their operation and the practical sense in which they run, we do wear measurement during every shutdown.

From this experiment we got following result: 0.002389 MWh/t. Now using standard formula we can calculate grinding media wear rate: Wear Rate (g/kWh) = 0.042 * H * D^0.67 * η. H=Hardness in Mohs Scale. D=Diameter of Ball (mm) η=Efficiency Factor (decimal) Factors affecting wear rate of grinding media.

plant ball mill's grinding efficiency (Fig. 1). The functional performance parameters "mill grinding rate through the size of ... wear rate in a continuously operating mill. Slurry …

In a ball mill, the gradation of its grinding media directly affects its output, production quality, and grinding media wear rate. When the ball mill is running, the material is both being impacted and ground by the grinding media. Obviously, in unit time, the more contact points between grinding media and material, the easier grinding will be ...

The greater the hardness of the material, the faster the wear rate of the ball mill liner and steel balls, which may cause equipment damage or even safety accidents in severe cases. In addition, the wear of the ball mill liner is also related to the steel balls. The size and quantity of the steel balls will affect the service life of the ball ...

1.. Case descriptionA Brazilian power plant consumes mineral coal with high ash contents to feed four turbines to generate 450 MW.Four ball mills, 4.2 m in diameter, are fed with crushed coal with maximum size of 25 mm and up to 20% humidity, to deliver the material ground to sizes less than 0.075 μm.Each ball mill is fed at a rate of 70 t/h …

Research highlights DEM used to simulate the dynamics of ball motion in an industrial scale ball mill. Energy distributions with progressively worn lifter geometry profiles were simulated. A basic wear model based on detailed DEM output data is proposed. DEM simulated energy data was utilised to predict breakage rates of fine particles. A simplified …

In this study, we investigates the application of three powerful kernel-based supervised learning algorithms to develop a global model of the wear rate of grinding …

These Discharge Grates also incorporate as an integral part, a liner between the lifters and steel head of the ball mill to prevent wear of the mill head. By combining these parts into a single casting, repairs and maintenance are greatly simplified. ... EFi, used and fo is the feed rate of new ore to the mill. The power calculated from ...

Thus it appears that the ball wear is, very roughly, proportional to both rate of production of surface and to power input to the mill. This also implies that the rate of …

Experiments and simulation results in a laboratory-scale planetary ball mill verify that the particle wear model can predict the increasing trend of particle wear rate with mill speed, and has good accuracy at high mill speed. In the experiments, the grinding bowl is filled with liquid water to isolate the air and cool the grinding balls, and ...

It gives accurate predictions of the service life of wear resistant alloys in mill liner and grinding media applications. In this paper the BMA test methodology was applied to investigate the wear rates of four grades …

Estimated/Approximate Rubber Liner Wear Life/Rate Cost. In a Ball Mill (particularly) the wear rate or wear life of Rubber depends much on the Ball Size/Diameter used in that mill. The grinding media size which itself is much of a function of the ore/material P80 feed size into that mill. The other primary and addition factor …

The ball charge wear, on the other hand, increases due to the 12 0 higher levels of energy rates distributed in the impact zones of tumbling and crushing (see Fig. 14). Figure 16 shows that wear is dependant on the ball 80 mill filling percentage. The wear rate increases with increasing ball mill filling percentage.

Ball mill specifications [23] Anill ^'mill Balls Initial ball size Size of balls added Ball charge mass Daily charged added 4.3 m 5.0 m Steel, specific gravity 8.5, 600 HB 0.1 m 0.1 m 110 t 2.0 t Using this algorithm, the mill specifications found in Table 1 and the mill rate calculations of r. 22, it was possible to obtain the results ...