In the cement and mineral grinding industry, energy costs account for a significant portion of production expenses. While the Ball mill has been a reliable grinding workhorse for decades, it is also known for its relatively high energy consumption compared to newer technologies like the tongli vertical roller mill.
For plants running older mills, replacing them outright isn’t always financially feasible. Instead, retrofitting your existing ball mill with modern efficiency upgrades can drastically cut wasted energy, reduce operational costs, and improve sustainability. Brands like Cementl now offer innovative retrofit solutions that deliver measurable savings without full equipment replacement.
Why Ball Mills Waste Energy
The Ball mill works by rotating a drum filled with steel balls, which fall and crush the material. While effective, the design has inherent energy losses:
- Excessive friction between the grinding media and liner surfaces.
- Inefficient grinding motion — much of the movement doesn’t directly contribute to material size reduction.
- Overgrinding of fine particles, wasting energy that doesn’t improve product quality.
Compared to a tongli vertical roller mill, which uses compression grinding, a ball mill often requires more power to achieve the same level of fineness.
Retrofit Fix #1 – High-Efficiency Separator Installation
A major source of energy waste in older ball mills is poor separation of fine and coarse particles. Without efficient classification, fines are overground and coarse particles remain in circulation.
Solution: Upgrade to a high-efficiency separator.
- Reduces overgrinding and reprocessing.
- Improves product uniformity.
- Cuts power consumption by up to 20%.
Cementl offers separator retrofit packages that integrate with your existing mill, giving results similar to a tongli vertical roller mill in terms of particle classification.
Retrofit Fix #2 – Advanced Liner and Grinding Media Design
Traditional steel liners and spherical grinding media aren’t optimized for energy efficiency. The wrong combination increases friction and wear while failing to transfer grinding energy effectively.
Solution: Install energy-optimized liners and media.
- Liner shape improves ball trajectory for better impact efficiency.
- Media size optimization reduces wasted motion.
- Wear-resistant materials extend lifespan and lower maintenance costs.
Cementl’s liner technology is engineered to minimize energy losses and can be tailored for different material hardness levels.
Retrofit Fix #3 – Variable Frequency Drive (VFD) Control
Most older ball mills operate at fixed speeds, regardless of load or material conditions. This wastes energy during low-demand periods.
Solution: Add a Variable Frequency Drive (VFD).
- Adjusts mill speed in real time based on load.
- Prevents unnecessary over-rotation during partial loads.
- Cuts electricity usage while maintaining throughput.
This level of control brings the Ball mill closer in energy efficiency to a tongli vertical roller mill, which inherently adjusts grinding pressure and airflow to match demand.
Ball Mill vs Tongli Vertical Roller Mill: Energy Perspective
While retrofitting improves ball mill efficiency, the tongli vertical roller mill still holds a natural advantage in energy consumption due to:
- Compression grinding instead of impact.
- Integrated drying and grinding in one system.
- Better particle classification within the mill body.
However, a fully retrofitted ball mill can close the energy gap significantly, especially when replacing the entire system is not an option.
The Cementl Advantage
Cementl specializes in both traditional ball mill retrofits and new tongli vertical roller mill installations. Their engineering teams provide:
- Energy audits to identify specific inefficiencies.
- Custom retrofit kits for separators, liners, and drives.
- Performance monitoring to track savings post-installation.
Whether you choose to retrofit or fully transition to a vertical roller mill, Cementl offers solutions that align with both budget and performance goals.
Estimated Energy Savings from Retrofitting
| Retrofit Upgrade | Typical Energy Reduction |
| High-Efficiency Separator | 10–20% |
| Optimized Liners & Media | 5–10% |
| VFD Control | 5–15% |
| Combined Retrofit Package | 20–35% |
For plants producing hundreds of thousands of tons per year, even a 20% cut in grinding energy can result in substantial savings and lower CO₂ emissions.
Final Thoughts
The Ball mill will remain a cornerstone of cement grinding for many plants, but its reputation for energy waste doesn’t have to be permanent. With strategic retrofits — high-efficiency separators, advanced liners, and VFD controls — you can slash energy consumption and extend the life of your mill.
And if you’re ready for the next step in efficiency, the tongli vertical roller mill from Cementl offers a complete system upgrade with unmatched energy performance. Either way, the goal is clear: less wasted energy, lower operating costs, and a more sustainable cement production process.
