The proportion of steel ball size added to the ball mill should be determined based on factors such as the diameter of the ball mill, ore hardness, ore particle size of the ball mill, steel ball hardness (mass), and ball mill speed. After the model of the ball mill is determined, the speed of the ball mill is also set. The hardness of ore can be measured. The ore particle size of the ball mill is determined by changing the mesh size. Usually, newly installed ball mills have a running in process, during which the amount of steel balls is added for the first time, accounting for 80% of the maximum ball capacity of the ball mill. The proportion of steel balls added can be based on the size of the steel balls (120mm, 100mm, 80mm, 60mm, 40mm). The weight of steel balls added is determined by the quality of the steel balls, which in turn determines the amount of ore consumed per ton. It is best to use new wear-resistant steel balls. The best (high-quality) steel ball addition is calculated based on the amount of ore processed per ton (i.e. adding 0.8 kg per ton of ore). Generally, steel balls need to be used to process one ton of ore (1 kg‐ 1.2 kg). The proportion of steel balls in a ball mill should be determined based on factors such as the effective length of the mill, whether it is equipped with a roller press, the particle size of the feed, the type of lining plate and structure used, the expected sieve residue fineness and ratio table, the amount of chromium balls used, and the rotational speed. The general grading of steel balls is 120mm, 100mm, 80mm, and 40mm. If high chromium balls are used, the manufacturer must be required to add rare earths during production. Why is the amount of steel balls added to the ball mill during the running in process only 80%? After the ball mill is installed, the large and small gears of the ball mill need to mesh, and the processing capacity needs to gradually increase. After the ball mill runs continuously for two or three days, check the meshing of the large and small gears. When everything is normal, open the manhole cover of the ball mill and add the remaining 20% of steel balls for the second time. The addition of small steel balls is only for the first time. Because the reasonable friction generated between steel balls, steel balls and ore, and steel balls and ball mill liners during normal operation of the ball mill will increase wear, resulting in small and medium ball mills turning into small balls. So under normal circumstances, there is no need to add a small ball. The case of adding small balls is when there is no monomer dissociation in the useful mineral particle size, and when the fineness of the grinding machine does not meet the flotation requirements, an appropriate amount of small balls can be added. The steel balls in the ball mill are constantly worn during operation. In order to maintain the ball load filling rate and reasonable ball ratio, and to ensure the stable operation of the ball mill, it is necessary to carry out reasonable ball replenishment to minimize wear and tear.
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