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TTC-6 : Ball Mill Circuit Operation, Simulation, Optimisation and Industrial Case Studies

Lecture 1- Importance of PSD in Ball Mill Circuit Operation and Optimisation.  Product Quality, Power, Throughput and Smooth Operation of Mill and Classifier Depend on PSD.
Lecture 2- Importance of Rosin-Rammler Equation in Obtaining PSD from Sieving Data.  Relevance of Particle Size Analysis Instruments.  How the Easily Measurable Blaine Area can Refine PSD Predictions.  Use of SIZEANAL Software.
Lecture 3- Ball Mill Operation and Control with Cement Mill Example. Constant Blaine vs. Constant Strength Control Concept Integrated with PSD to Maximise Throughput.
Lecture 4- Recycle Load Estimation in Closed-Circuit Grinding Systems.  Inherent Inconsistencies, Method to Overcome and Use of CLASANAL Software.  Industrial Case Studies.
Lecture 5- Importance of Wet Classifiers like Hydrocyclones in Wet Grinding Circuits.  Classification Function Equation Generalized to Dry Classifiers.  Classifier Parameters Estimation Method.
Lecture 6- Ball Mill Circuit Modeling and Simulation.  Rate of Breakage Function (or Selection Function) and Distribution Function.  Transformation Matrix for Open- and Closed-Circuit Systems.
Lecture 7- Effects of Ball Loading, Material Filling, Ball Size Distribution, Diaphragm Settings and Air Ventilation (for Dry Mills) on Throughput, Power, Product PSD, Carryover and Wear Rates.
Lecture 8- Population Balance Model for Determining Exact Ball Size Distribution Inside Chambers.  Its Critical Importance and Utility to Operating Plants.
Lecture 9- Mill Heat Balance.  Critical Importance with respect to One Industrial Case Study.
Lecture 10- Ball Mill Internals Inspection.  Ball Loading and Material Filling Measurements, Chamber Sampling Measurements, Circuit Samples, Implications.
Lecture 11- Industrial Case Studies.  Raw Mill, OPC Cement Mill, PPC Cement Mill, Bauxite Mill Optimisation Results.


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