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| Optimization Practice of Grinding Media Charge and Gradation for Ball Mill in Double Closed-circuit Combined Cement Grinding System#br# |
| Yue Qinghui, Wang Junchao, Pang Zhiyi
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| Jinan Wanhua Cement Co., Ltd. , Jinan Shandong 250205, China |
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Abstract A 5 000t/d cement clinker production line is equipped with a double closed-circuit combined cement grinding system composed of a ?4.2m×13m ball mill and HFCG140-80 roller press. The long-term adoption of the general grinding media charge scheme prioritizing throughput improvement results in high unit power consumption and poor economic operation performance of the system. This paper carries out systematic optimization on the grinding media charge and gradation of the supporting ball mill through a combination of theoretical calculations and field industrial tests. Firstly, the gradation remained unchanged while the grinding media charge of the first and second chambers was adjusted stepwise. Correlation curves between total media charge, system throughput and power consumption were drawn to determine the optimal charge interval. Secondly, aiming to solve the difficulty in cement specific surface area control after reducing total media charge, the average ball diameter of the first chamber and the specification of steel cylpebs in the second chamber were both reduced to boost fine grinding efficiency.After optimization, the total grinding media charge was cut from 210t to 193t, and the system throughput remained stably above 175t/h. The unit power consumption of cement decreased from 26.68kW·h/t to roughly 24kW·h/t, achieving an annual electricity saving of about 230×104kW·h. Meanwhile, the grinding media loss dropped from 20g/t to approximately 15g/t, and the operating current of auxiliary equipment declined by 5%~10%. This optimization scheme can serve as a practical reference for realizing energy-saving and economic operation of double closed-circuit combined grinding systems via adjusting grinding media charge and gradation.
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Received: 15 January 2026
Published: 25 September 2026
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