How to make the ball mill more energy-efficient

The ball mill has a simple, compact structure and high reliability. It is an important grinding equipment in metallurgy, chemical industry, cement, ceramics, construction, electric power and other fields.But its disadvantages are also obvious, that is, high energy consumption and high wear resistance.In recent years, with the growth of energy and the decline of energy quality, energy saving and consumption reduction have become a hot topic in ball mill research.

After continuous experience summary, the staff of our company have concluded that the energy-saving and consumption-reducing measures of the ball mill are mainly focused on structural improvement, process parameter optimization, and automatic control.Please see the specific analysis below.

1. Structural improvement

Compared with small and medium-sized mills, the advantage of large-scale equipment is that it can save construction costs and operation and maintenance costs, and simplify equipment configuration and automation requirements.However, its unit energy consumption is higher than that of small and medium-sized specifications, so its specifications are limited in development.

The current research focus is to improve the original equipment and develop energy-saving ball mills, such as continuous ceramic industry, continuous taper ceramic raw materials, rolling bearing type, etc. These new types of machinery and equipment have achieved obvious results in energy saving and consumption reduction.

2. Improve the liner

The liner can play a role in protecting the cylinder body and extending the service life of the equipment.At the same time, its shape can directly control the trajectory of the steel ball in the cylinder.Liners are spare parts that are easy to wear, replace and consume a lot, accounting for more than 60% of the cost of wearing parts.

Changing the material and form of the liner has an important impact on improving operational efficiency.In terms of materials, metal liners, rubber liners, magnetic liners, composite liners, etc. are generally used; the modification forms of liners include cone graded liners, angle spiral liners, etc.

3. The material and shape of the medium

The role of the grinding medium is to produce punching, squeezing, grinding, and grinding effects in the cylinder body, so that the material meets the fineness and grading requirements of the finished product.Poor performance of the grinding medium will lead to poor wear resistance, high unit consumption, and large dosage, which seriously affects the grinding efficiency and accounts for about 30% of the cost of wearing parts.

The grinding medium mainly improves the grinding efficiency by improving its material and shape.In terms of materials, low-chromium white-mouthed cast iron grinding balls, alloy cast iron balls with special alloy pig iron or waste alloy pig iron as the main raw material, have developed relatively quickly because of their low price and moderate wear.In terms of shape, short cylindrical, rod-shaped balls and cylindrical rod-shaped media have high productivity and low unit power consumption compared to traditional steel equipment.

4. Process parameter optimization

The working state of the ball mill is affected by factors such as speed rate, filling rate, ball-to-material ratio, aspect ratio, liner and grinding medium size, and the coupling between the various factors is more complicated.To give full play to the grinding efficiency, attention must be paid to the influence of design and operating parameters.Improper selection of grinding parameters will greatly reduce efficiency and even fail to work properly.

Among the working parameters, the rotation speed rate and filling rate have a significant impact on the working state of the ball mill.The grinding process is the process by which the material gradually becomes smaller from large particles. In different grinding stages, the speed rate and filling rate have different effects on the particle size of the product.In-depth research on the mechanism of the influence of speed rate and filling rate on product particle size can propose a more reasonable grinding process to provide reference, thereby greatly improving work efficiency.

5. Automatic control

The system of a ball mill is a complex system with multiple inputs, multiple outputs, non-linearity, time-varying, large hysteresis and multivariate coupling.The influence of many factors makes it difficult to accurately establish a mathematical model that changes with environmental conditions.Perfect automatic control of it can enable the system to be adjusted to operate at a better working point and reduce energy consumption.

After the above analysis, I believe that everyone has a certain understanding of the energy-saving measures of the ball mill. If you need more help, you can consult our staff.