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What are the main factors affecting the efficiency of ball mills in ore dressing?

Publish Time:

2020-08-10

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In mineral processing, ball mills typically use the compressive and frictional forces between grinding media such as steel balls to grind materials. Ball mills are used in the grinding of iron ore, gold ore, and copper ore, as well as in the metal smelting, ceramics, fine chemicals, cement production, and power generation industries for crushing and pulverizing operations. However, ball mills have long suffered from problems such as high energy consumption, rapid steel wear, and low grinding efficiency.

　　What are the main factors affecting the working efficiency of ball mills in ore dressing equipment?

　　Ore dressing ball mills typically use the squeezing and frictional forces between grinding media such as steel balls to grind materials. They are used in iron ore, gold ore, and copper ore grinding, as well as in metal smelting, ceramic products, fine chemicals, cement production lines, and power plants for crushing and pulverizing operations. However, ball mills have long suffered from high energy consumption, rapid steel wear, and low grinding efficiency.

　　What are the main factors affecting the working efficiency of ball mills in ore dressing equipment? How do these factors arise? How to improve the working efficiency of ball mills in ore dressing equipment?

　　1. Unreasonable matching of grinding media grades and the number of balls loaded. The specifications and loading of grinding media are not selected according to the specific properties of different materials, resulting in a low output coefficient of the ball mill equipment (output coefficient = output/loading), generally between 0.3 and 0.9.

　　2. The ore is not graded according to the energy required for grinding during the grinding process.

　　3. When materials with different physical and chemical properties are mixed and ground, impurities in the materials are not screened, and materials with excessively large volumes are included, such as stones mixed in coal.

　　4. Unreasonable work scheduling and peripheral supporting facilities adjustments. The ventilation performance, drying degree, and pulverizing output are not matched, resulting in unnecessary energy consumption increase.

　　5. The grinding media does not have sufficient wear resistance and strength. After several months of operation, the out-of-round rate increases, and the pulverizing output gradually decreases.

　　Methods and concepts for improving grinding efficiency

　　1. Optimize the grading and loading of steel balls and other grinding media: Based on the specific situation of the particle size distribution of the material, the impact force required for grinding, and the required fineness of the outlet, determine the shape, size, and loading of grinding media of different specifications to improve the grinding speed.

　　2. Optimize the design and placement of the mill liner of the ore dressing equipment to achieve graded grinding: According to the movement law of materials of different particle sizes in the grinding process in the mill, improve the liner combination and operation method to improve the throwing and falling of steel balls and other grinding media and the highest falling point, so that the grinding media self-adjusts along the length direction of the mill according to the particle size distribution specification to achieve positive grading and energy supply.

　　3. Optimization of the operating environment: According to the unique properties of various ores (water content, grindability, electrostatic adsorption, etc.), through multi-faceted and multiple comprehensive experiments, reasonably adjust the mill differential pressure, outlet temperature, material supply, and separation effectiveness of the ore dressing equipment according to the experimental results, establish standardized and regular parameter control standards, and keep the ball mill of the ore dressing equipment in good operation under output.

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Replacement method for cone crusher parts

Cone crushers are one of the main mining machines widely used for ore crushing in various mining areas. The main components of cone crushers include the bowl liner, disc, gear, cone sleeve, eccentric shaft, crushing wall, bearing, etc. After a period of use during the crushing operation, the crusher will inevitably suffer wear and tear or component damage. This will directly affect the progress of the crushing operation, and at this time, these components need to be replaced. Replacement methods for cone crusher components: 1. The cone crusher bowl liner is fastened to the adjusting ring with U-shaped screws, and zinc alloy is injected between them to ensure a tight fit. When newly installing or replacing the bowl liner, the fastening should be checked after 6-8 hours of operation, and the U-shaped screws should be tightened again. 2. Due to friction, the disc wears, affecting the change in the gear gap. To ensure normal gear meshing, shims must be added to the bottom cover, and the thickness of the shims should be equal to the wear of the disc. 3. The cone sleeve and the hollow eccentric shaft must be tightly fitted, and zinc alloy is injected to prevent the cone sleeve from rotating. The zinc alloy must fill all gaps. Due to the hot injection of zinc alloy, the cone sleeve may be deformed. Therefore, the dimensions of the newly installed cone sleeve should be checked, and any inaccuracies should be corrected promptly. When manufacturing spare parts, they should be matched according to the actual size of the inner diameter of the eccentric sleeve to maintain the original fit. 4. The cone crusher wall is fixed to the cone body with a cone head, and zinc alloy is cast between them. After 6-8 hours of operation of the newly installed or replaced cone crusher wall, the fastening should be checked, and any loosening should be tightened immediately. 5. When the cone crusher is working, the ore must be distributed in the middle of the disc. To prevent the crusher from overloading and causing uneven wear of the liner, ore should not be directly loaded into the crushing chamber. The correct ore feeding condition is that the ore is evenly distributed in the crushing chamber by the distribution disc, and the ore fed should not exceed the horizontal level of the bowl liner. 6. When installing the bowl bearing, care should be taken to prevent the steel wire rope from damaging the oil seal ring (support it between the steel wire ropes with hardwood, etc.). During assembly, the supporting spherical surface should be scraped to ensure that the crushing cone and the bowl spherical surface are in contact with the outer circle, and the inner ring should ensure an annular gap of 0.35-0.5 mm. The bowl bushing is fixed to the bowl bearing housing with locking pins filled with babbitt alloy around it to prevent the bowl bushing from rotating along the circumference. The bowl bearing housing is fixed to the housing with a key (pin). If a gap is found between the bowl bearing housing and the housing during operation, it must be dealt with immediately.

Vertical ball mill

Vertical ball mills are suitable for grinding and dispersing coarse, hard, or pseudoplastic materials. Materials ground by vertical ball mills have uniform and fine particle sizes. Vertical ball mills can also mix several materials very uniformly. Working principle The grinding media are driven by the stirring shaft to perform forced mechanical shearing and grinding. The material is pumped from the bottom filter screen and pipeline of the grinding cylinder to the top of the grinding cylinder, allowing the material and media to fully contact and grind, completing one cycle until the required fineness is reached. Equipment advantages Vertical ball mills integrate material classification and grinding. The grinding media impact is intense, suitable for high-viscosity, difficult-to-grind materials such as high-abrasion carbon black. Compared with other ball mills, it has the following advantages: 1. Strong ventilation and drying capacity, using kiln tail waste gas to dry the moisture in the raw materials; 2. No dead corners in the grinding cylinder, good homogeneity, less equipment, simple operation; 3. Special stirring shaft structure, increasing the media collision rate, improving the grinding frequency; 4. Convenient production adjustment and control, strong adaptability to various performance raw materials; 5. Double-layer cylinder body, special cooling circulation path, good cooling performance, fast discharge, easy cleaning; 6. Less system leakage, reducing the specifications, investment, and power consumption of the electrostatic precipitator for treating waste gas. Use and maintenance 1. Place the equipment flat on the prepared foundation and fasten it with bolts. 2. Before starting, check whether all rotating parts are flexible, whether the motor electrical wiring terminals are firm and reliable, and whether the reducer is filled with lubricating oil. 3. Clean promptly after shutdown to prevent material drying, solidification, and affecting the next start-up. 4. After the machine is installed, do not start the machine before adding the grinding media. A ball mill is a key equipment for further crushing materials after they have been crushed. It is widely used in the production of cement, silicate products, new building materials, refractory materials, fertilizers, ferrous and non-ferrous metal ore dressing, and glass ceramics, for dry or wet grinding of various ores and other grindable materials. Test operation After the ball mill is installed and inspected and qualified, it can be subjected to a no-load test run. The test run of the ball mill should be carried out by a skilled ball mill operator and strictly follow the ball mill safety operating procedures. (1) The continuous running time of the no-load operation is not less than 12-24 hours. Any problems found during operation should be solved promptly. (2) After the no-load test run is normal, the load test run can be carried out. The load test run should be carried out in stages. During the load operation, the feeding should be adjusted according to the discharge situation to avoid unnecessary wear and tear of the steel balls and cylinder lining. 1. Add appropriate materials and 1/3 of the steel balls (refer to the ball mill general drawing for the maximum ball loading) and run for 12-24 hours. 2. Add up to 2/3 of the steel balls and run for 24-48 hours. 3. According to the discharge situation of the ball mill, the output of qualified products, and referring to the actual ball loading of similar ore dressing plant ball mills, determine the reasonable ball loading of this ball mill and conduct a test run for at least 72 hours. (3) The increase in the above load and the duration of the test run should be determined based on the running-in situation of the large and small gears and reducer gears (temperature rise, noise, tooth surface contact, etc.). Before the tooth surface contact accuracy reaches the design requirements, full-load operation is not allowed. (4) During the test run, the cooling and lubrication systems should work normally. The main bearing, transmission bearing, and reducer temperatures should be normal. (5) After running for 24-48 hours with 2/3 of the steel balls, all bolts should be checked and tightened again. (6) The test run work should carefully record all items.

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Heilongjiang Ouxinte Mining Machinery Equipment Co., Ltd. is a sales company integrating the research and development, production, and sales of mining machinery. The company has more than 40 offices or dealerships in more than 20 provinces and cities in China, and its products are sold to more than 40 countries and regions, including Chile, Australia, New Zealand, Sweden, the United Kingdom, France, Germany, Greece, Russia, Kazakhstan, the United Arab Emirates, South Africa, Ethiopia, Japan, South Korea, and Taiwan. The company adheres to the principle of market orientation, focusing on product quality and customer satisfaction. It implements full-process quality tracking and monitoring from production to after-sales service, and has cultivated a team of technical development and production management personnel. Its management philosophy and rigorous management measures ensure product quality and advantages. We warmly welcome domestic and foreign merchants to contact us by mail, phone, or in person to discuss business. We will provide you with excellent service.

Application scope of jaw crusher in mining

Jaw crushers are widely used in mining, metallurgy, construction, and other fields. They are mainly used for coarse crushing of various ores and rocks, especially suitable for medium and large-scale mines and construction waste crushing.

Adhering to market orientation and focusing on product quality

The company has more than 40 offices or dealerships in more than 20 provinces and cities in China, and its products are sold to more than 40 countries and regions, including Chile, Australia, New Zealand, Sweden, the United Kingdom, France, Germany, Greece, Russia, Kazakhstan, the UAE, South Africa, Ethiopia, Japan, South Korea, and Taiwan.

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Address: Sheli Village, Taiping Village, Sheli Original Steel Plant, Acheng District, Harbin City

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