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12 reasons for lower output of ball mill

Date:2019-05-29 14:51     writer:admin     Views:

  The ball mill is mainly responsible for the mill grinding operations, is the key link of the ore dressing process, in the whole mill infrastructure investment and production costs accounted for a considerable proportion.

  At the same time, the ball mill is the "bottleneck" operation link of the whole concentrator, it is directly related to the overall processing capacity of the concentrator, has a significant impact on the economic and technical indicators of the whole concentrator, therefore, to ensure the ball mill output standard is the most important.

  It is a very common problem that the output of the ball mill can not meet the design requirements in the production of the selection plant. Then under what circumstances will the output of the ball mill be substandard?

  1, the ball mill warehouse length ratio design is not reasonable

  The disproportionate length ratio of each warehouse of the ball mill results in the imbalance of coarse and fine grinding capacity of the ball mill, resulting in the phenomenon of fine over coarse or too fine products, and thereby affecting the output.

  Normally, the length ratio of each bin of the ball mill is as follows:

  2, the ball mill ventilation is not good

  Under normal operation of the ball mill, due to repeated impact and friction of the medium in the cylinder, the temperature inside the mill keeps rising, resulting in water vapor produced by the water-containing materials. If the ball mill is not ventilated well, the water vapor cannot be discharged in time, and the water vapor will adhere to the steel ball, resulting in paste or paste grinding phenomenon.

  Therefore, it is necessary to control the amount of ventilation of the ball mill. The passing effect of the ball mill is good, which can not only bring out qualified fine materials in time, but also effectively reduce the over-crushing phenomenon and reduce the temperature of the ball mill.

  3, the ball mill feed unreasonable

  During the operation of the ball mill, uniform feeding is a necessary condition to ensure the normal operation of the ball mill.

  If the ball mill feed too much material, will cause the grinding capacity of the ball mill is insufficient, resulting in saturation, so the need to feed in strict accordance with the feeding standards.

  4, the ball mill into the grinding particle size is too large

  The ball mill into the grinding particle size is too large, the impact and effect of the grinding body is difficult to adapt to, and the ball mill first bin will be broken to increase the amount of steel ball, to enhance the impact and grinding ability, this situation is easy to cause a bin crushing unreasonable situation.

  Under normal circumstances, the ball mill entering the grinding particle size is generally controlled at 15mm is appropriate, for large ball mill, because of the crushing capacity is strong, can adjust the grinding particle size to 25~30mm.

  5, the ball mill into the grinding water is too large

  Ball mill into the grinding material with large water content, grinding body and lining plate will adhere, resulting in paste grinding, will block grate plate, causing full wear phenomenon.

  But containing a small amount of water can effectively reduce the temperature of the ball mill, reduce static electricity, etc.

  Permissible moisture content of grinding material (for reference only)

  6, ball mill steel ball grading unreasonable

  Gradation is to achieve the impact and grinding of different particle size materials, in order to improve the grinding efficiency, so the gradation of ball mill steel ball is very important, the general gradation range of 25%~35%, but the practical application of intermediate in 28%~32%.

  Common ball mill steel grade ratio in economic operation:

  Note: the filling rate of one bin should be >28% when the material's easy grinding performance is poor, or the grinding requirement is fine.

  7, did not timely add steel ball

  The grinding effect and output of the ball mill are restricted by the ball mill's steel balls. However, with the grinding and impact in the cylinder, the ball will be worn out. Therefore, it is necessary to add the ball in time to ensure the consistency of the ball mill's output to the greatest extent.

  8, ball mill grinding material temperature is too high

  Generally, when the temperature of the grinding material in the ball mill is too high, it is easy to reduce the grinding efficiency. When the temperature of the ball mill exceeds 100℃, a layer of air film isolated from each other on the surface of the small particles of the material will be damaged, resulting in adhesion phenomenon.

  In order to reduce the internal temperature of the mill and improve the efficiency of grinding, a small amount of mist water can be sprayed into the flour bin to reduce the internal temperature of the mill to below 50℃.

  9. Temperature inside the cylinder increases

  When the temperature of the ball mill increases, the effective strain of nanomaterials formed by the ball mill decreases and the grain size increases, which significantly affects the mechanical properties of the powder made into the block.

  In addition, no matter the final product of ball mill is solid solution, intermetallic compound, nanocrystalline or amorphous phase, the diffusion problem is involved, and the diffusion is affected by the grinding temperature, so temperature is also an important factor affecting the output of ball mill.

  10. Unreasonable grinding aid dose

  On the premise of not harming the performance of the product, a small amount of grinding aid can be added to the ball mill, which can not only accelerate the crack growth in material crushing, reduce the bond between fine powders, effectively improve the grinding efficiency, but also improve the efficiency of the ball mill under energy saving.

  However, the grinding AIDS of ball mill should be added in accordance with the national standards. The amount of grinding AIDS added in the general cement production process should not exceed 1%. The grinding AIDS of other materials can be inquired through the national standards.

  11. Ball mill "full grinding"

  When the output of ball mill is getting lower and lower, the first thing to consider is whether there is a "full mill", it is the culprit that affects the output of ball mill.

  The causes of "full grinding" include: too much feeding;

  The hardness and particle size of grinding materials become harder and larger.

  Excessive moisture in grinding materials;

  Improper grading of steel balls;

  The compartment or grate is clogged with debris.

  The solution to the problem of "full grinding" : reduce the feeding quantity;

  When the size or hardness of the grinding material changes, it should be adjusted in time.

  Adjust the moisture content of the grinding material;

  Reasonable allocation of large and small steel ball ratio;

  Clearance of clogging material on floor or grate;

  Increase ball mill barrel ventilation.

  12, ball mill working time is too long

  The working time of ball mill has a direct influence on the composition and purity of products.

  At the beginning stage, the particle size decreases rapidly with the extension of time, but after the ball grinding reaches a certain period, even if the ball grinding time continues to be extended, the particle size value of the product does not decrease greatly.

  Different samples have different optimum grinding time.

  On the other hand, the longer the grinding time, the more serious the pollution will be, affecting the product purity.

  The above are the common problems that cause the output of the ball mill not up to the standard. In addition, there are many reasons for the low output of the ball mill. It is one of the ways to improve the output of the ball mill to find and solve the problems in time.

  In addition, it is an effective way to ensure the milling output of the ball mill to complete all operations and daily maintenance of the ball mill in strict accordance with the design requirements of the ball mill.

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