GRINDING MEDIA KNOWLEDGE
Grinding Ball Breakage: Common Causes and Practical Solutions
Identify brittle fracture, spalling and deformation, then trace the problem to media quality or mill conditions.
Classify the failure first
A ball split into large pieces suggests brittle fracture; thin flakes indicate spalling; flattening or excessive ovality points to insufficient hardness or abnormal impact. Photograph fresh surfaces, count each failure type and retain marked samples before investigating.
Check the media batch
Review chemistry, surface and core hardness, hardness gradient, heat-treatment records and impact results for the affected batch. Mixed batches or diameters can hide the source, so link every sample to delivery, package and mill addition records.
Review the mill conditions
Oversized feed, low charge level, worn liners, high mill speed or a sudden ore change can increase impact energy. Empty-mill running and improper ball size distribution also raise collision severity. Compare the failure date with operating logs and liner inspections.
Run a controlled corrective trial
Change one variable at a time. Test a traceable media batch under stable throughput, feed and charge conditions; record additions, broken balls, power, product size and tonnes milled. Agree measurable breakage limits and corrective action with the supplier before the next shipment.