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What are the dimensions of the ball mill you are looking at? 40% ball charge is quite high (unless you are looking at a small mill). A difference (duty vs. maximum) of 5% to 10% is fairly typical and you would likely struggle to perceive an energy efficiency difference between the two operating points.
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Although ball mills can still be found in the regrind circuits in a number of mineral processing plants, their energy consumption is high, and size reduction efficiency is low. The need to grind the ore finer to liberate the minerals and the dramatic increase in the cost of energy in the mid 1970s resulted in more efficient comminution ...
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The ball mill is a key piece of equipment for grinding crushed materials, and it is widely used in production lines for powders such as cement, silicates, refractory material, fertilizer, glass ceramics, etc. as well as for ore dressing of both ferrous and non-ferrous metals. The ball mill can grind various ores and other materials either wet or dry.
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