How to Calculate the Production Capacity of a Limestone Grinding Mill

Introduction

Calculating the production capacity of a limestone grinding mill is essential for optimizing operational efficiency and ensuring cost-effectiveness in mineral processing plants. This article provides a comprehensive methodology for capacity calculation, along with technical insights into advanced grinding solutions from ZENITH, a leading Chinese mining machinery manufacturer with over 30 years of industry expertise.

Limestone grinding mill in operation

Key Factors Affecting Production Capacity

Several critical parameters influence the output of a limestone grinding mill:

  • Feed Material Characteristics: Hardness (Mohs scale), moisture content, and input size (typically ≤50mm for most mills)
  • Mill Specifications: Grinding mechanism, power consumption, and classification efficiency
  • Operational Parameters: Rotation speed, grinding pressure, and airflow rate
  • Desired Product Fineness: Ranging from coarse (45μm) to ultra-fine (5μm) powders

Step-by-Step Calculation Methodology

1. Theoretical Capacity Formula

The basic production capacity (Q) can be estimated using:

Q = 60 × C × b × v × n × η

Where:
C = Grinding roller width coefficient (0.85-1.15)
b = Grinding roller width (m)
v = Grinding roller circumferential speed (m/s)
n = Number of grinding rollers
η = Comprehensive efficiency factor (0.6-0.9)

2. Practical Correction Factors

Adjust the theoretical value by considering:

  • Material Work Index (Wi): Bond ball mill grindability test results
  • Moisture Correction: Typically 0.92-1.08 multiplier for 1-8% moisture
  • Circulating Load: 150-250% for closed-circuit systems

Technical diagram of limestone grinding mill components

ZENITH’s Recommended Solutions

1. MTW Series Trapezium Mill

For medium-scale limestone processing (3-45 ton/h), the MTW215G model offers:

  • 50mm max feed size with 10-325 mesh output
  • 280kW main motor power with 315kW fan motor
  • Conical gear transmission (98% efficiency)
  • Curved air duct design reducing energy loss

2. XZM Ultrafine Mill

For superfine limestone powder production (0.5-25 ton/h at 325-2500 mesh), the XZM268 model features:

  • Vertical turbine classifier for precise particle separation
  • 315kW main motor with ≤75dB noise level
  • Special alloy grinding rollers with 3x lifespan
  • Pulse dust collection system exceeding international standards

Case Study: Capacity Optimization

A Malaysian customer achieved 22.5 ton/h output with ZENITH’s MTM160 mill by:

  1. Reducing feed moisture from 6% to 3.5%
  2. Optimizing classifier speed to 82rpm
  3. Implementing automatic pressure adjustment

This resulted in 18% energy savings while maintaining 325-mesh product quality.

ZENITH grinding mill installation at customer site

Conclusion

Accurate production capacity calculation requires both theoretical formulas and practical adjustments. ZENITH’s grinding mills, backed by 30+ years of R&D and global service network, provide reliable solutions tailored to limestone processing needs. Our engineers are available for customized capacity assessments and system optimization.

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