Half filled with grinding media is helpful

Half filled with grinding media is helpful

For the most efficient results, the Mill should be at least half filled with grinding media. Some operators prefer to go a little beyond the halfway mark to compensate for wear. There is no objection to this and we have been suggesting a limit of about 5 percent.
In steel ball grinding, many operators, especially in the paint industry, are satisfied to run with a smaller ball charge ranging as low as one-third the volume of the Mill. They find the smaller charge gives them the required grind within allowable limits of grinding time and the extra space gives them more loading room.
There is no objection to this practice when the grinding cycle falls within the desired working limits. Where speed of grind is of utmost importance, larger ball charges ranging up to the recommended 50% for other types of grinding media are advisable. The logic in this system is best illustrated as follows:
Steel balls are one of the most popular sizes, and there are 36 of these per pound. In a 54x 60 Steel Ball Mill, for example, the difference between the weight of a one-third and one-half ball charge is 3,970 pounds, or 103,220 balls. The steel ball is another very popular size and, as there 53 of these per pound, the difference would amount to 200,410 balls. It s therefore, reasonable to expect (and experience has proven this to be true) that any addition above the minimum limits prescribed can only result in increased grinding efficiency. This improvement is usually related to the surface area of the media involved.
It is not true that a one-half ball charge consumes proportionately more power than a one-third ball charge. The difference in weight between the tow charges is about 50% but the center of gravity of the larger is nearer the center of rotation of the Mill. Consequently, the power required to turn the larger charge only runs between 15 and 20% more.
The grinding efficiency of the one-half charge is considerably greater than for the one-third and, therefore it ca be expected that power consumption per gallon output will actually be less than with the smaller charge.
Grinding media should be periodically checked. Reduction in the quantity and size of the grinding media will result in poor grinding. We suggest a maximum schedule of once every six months, but any established procedure should be decided by individual experience. In some cases, where abrasive materials are involved, once a month is not too often and, in a few cases, even shorter intervals are indicated.
A simple method for checking is to have a rod cut indication the distance from the top of the grinding media to the underside of the manhole opening and use this for checking the depth of the charge.
When grinding enamel frit, wear to the porcelain balls is quite excessive because to the abrasive nature of the frit. Consequently, many operators have been able to closely determine the ball wear per batch and, when a batch of frit is loaded for grinding, a quantity of new balls is added equaling the weight lost during the previous grind. However, even with this system, we still advise an occasional check with the measuring rod because there is no positive guarantee that all balls will wear the same.
We also advocate dumping the charge once a year, or as often as experience indicates, and removing any grinding media found to be excessively worn or damaged.

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