10 effective measures to improve the production capacity of ball mills

In the mineral processing plant, the ball mill is responsible for the task of further grinding the broken material into fine particles, which can be said to play a role in carrying it up and down.Therefore, improving the production capacity of the ball mill is of great significance to the entire mineral processing production line. It can not only improve the grinding efficiency, but also play an active role in the subsequent sorting and dehydration operations.However, there are many ways to increase the production capacity of ball mills. What are the really effective ones?This article introduces you to 10 effective measures to improve the production capacity of ball mills.

1. Pre-crusher to reduce the abrasive particle size

Adding a crusher in front of the ball mill can significantly reduce the particle size of the ground material.At present, in most mineral processing production, the particle size of the ore before entering the ball mill is generally broken to about 25mm by a jaw crusher, which greatly reduces the grinding efficiency of the mineral processing ball mill.If a fine crusher is added in front of the ball mill, the particle size of the ore before entering the mill can be reduced from 25mm to less than 10mm.At this time, the power consumption of a mineral processing ball mill for grinding 1 ton of ore is only about 13KWH. Compared with the original 1 ton of medium hardness ore, the power consumption is about 25KWH, which greatly reduces energy consumption and also reduces the load on the grinding system.

2. Improve the grinding system and improve efficiency

By improving the grinding system, the grinding efficiency can be effectively improved, thereby increasing the output of the ball mill.A reasonable grinding system is related to the process layout, equipment selection, and the grinding capacity of each silo of the mill.The factors that affect the efficiency of the mill include the nature of the grinding material, process parameters, mechanical structure and performance.

For example, we can increase the production capacity of the ball mill by adjusting the steel ball grading method.When the grinding material has a large particle size and hardness, it needs to be hit with a steel ball with a larger ball diameter; materials with small particle size and easy to grind should be hit with a small steel ball; fine materials should be ground with a small steel ball.In addition, the filling rate of steel balls should be controlled between 25% and 35%.Through these measures, the grinding capacity and efficiency of the ball mill can be improved.

3. Add an efficient classifier to ensure quality

The addition of an efficient classifier can select the finished fine powder in time, reduce the grinding rate, and ensure the production quality of the ball mill.The particle size of the ground material is reduced, the powder selection efficiency is improved, and the finished fine powder is selected in time to a large extent, reducing the powder return rate of the finished product and reducing the load on the ball mill.If the system efficiency is low, it will affect the quality of the product.Therefore, high-efficiency powder separator plays an important role in increasing the output of ball mills and ensuring product quality.

4. Formulate reasonable control indicators

Formulate reasonable fineness control indicators for grinding products according to material properties, fineness requirements, etc., which can balance production, quality and consumption.The finer the grinding product, the lower the output of the mill; conversely, the higher the output.Factors such as the nature of the milled materials, the fineness requirements of the milled products, and the grinding process should be comprehensively considered, and reasonable control indicators should be formulated to achieve a balance between output, quality and consumption.

5. Strengthen the ventilation in the mill

Ventilation in the mill is essential, which can take away the fine powder, reduce the temperature, improve the grinding efficiency without affecting the product quality.There is a certain wind speed in the mill, so that the fine powder generated during the grinding process can be taken away by the air flow in time, reducing the buffering effect of the fine powder and improving the grinding efficiency.Generally, the ventilation speed in the mill varies depending on the grinding of different materials, usually 0.3-1.0m/s.When the ventilation is good, the water vapor in the mill is discharged in time, the grate hole of the compartment plate will not be clogged, the adhesion of the grinding body is also reduced, and the temperature in the mill can be reduced, which is conducive to the operation of the mill and the improvement of product quality.

6. Spray water in the mill to control the temperature

Spraying water during grinding can take away heat, prevent the grinding body from being coated, and increase production capacity.Water is atomized and sprayed into the mill with high-pressure air, which effectively takes away the heat in the mill and realizes cooling in the mill.At the same time, water is a surface active substance, which can easily disintegrate the coalescence of particles and prevent the abrasive body from being coated.The amount of water sprayed depends on the temperature of the clinker entering the mill, which accounts for about 1%-2% of the ore volume, and the water sprayed into the mill is completely evaporated without residual water.Water spraying in the mill can increase the production capacity by 5%-10%.

7. Add grinding aids to increase production

Adding a grinding aid can increase the production capacity of the ball mill by about 10%.Generally, triethanolamine is used, and the amount incorporated accounts for 0.04%-0.1% of the grinding material.Grinding aids can improve the wearability of materials and improve grinding efficiency, thereby increasing the output of ball mills.

8. Automatic control of grinding system

The addition of materials is automatically adjusted according to the noise of the ball mill, so that the materials in the mill are kept in good condition and the output is increased.The grinding system is automatically controlled. According to the noise of the ball mill, the electric ear method is used to control the electromagnetic vibration feeder or belt feeder, control the appropriate amount of material in the mill and automatically adjust the uniform addition of the material, so that the amount of material in the mill is always maintained in a good condition, which can increase the output of the mill.

9. Control the particle size of ore feed

The finer the particle size of the ore feed, the higher the production capacity of the ball mill and the lower the energy consumption. The processing capacity can be improved by crushing more and grinding less.After the particle size of the ground material is reduced, the processing efficiency of the ball mill is significantly improved.For example, when the particle size of the incoming material is greater than 25mm, the grinding capacity of the mill increases but the grinding efficiency decreases; the particle size of the incoming material is preferably less than -10mm, and it is better to be less than 5mm when there are conditions. By adjusting the steel ball grading, it is more conducive to improving the grinding efficiency of the mill.

10. Adjust the grinding concentration and fineness

The grinding concentration and fineness affect each other, and can be controlled by adjusting the ore feed water to adapt to different raw ore conditions.Reasonable adjustment of the grinding concentration and fineness can improve the production capacity of the ball mill.According to different raw ore conditions, adjust the amount of ore feed water and control the grinding concentration, so as to achieve the appropriate grinding fineness and improve production efficiency.