Ball Mill Manufacturers & Suppliers In India
In beneficiation plant, ball mill is the key equipment for grinding materials after they are crushed. This type of grinding machine is equipped with a certain amount of steel balls as the grinding medium inside its cylinder. As professional Chinese ball mill manufacturers in India, ZENITH summarizes some key factors of ball mill in the production process.
Application scope of ball mill
Ball mill is widely used in the production industries of cement, silicate products, new building materials, refractory materials, fertilizers, black and non-ferrous metal beneficiation, and glass ceramics. It performs dry or wet grinding on various ores and other grindable materials.
Main structure of ball mill
Cylinder: bears the weight of itself and lining plate, silo plate, grinding body and materials in the mill (bear static load); withstand the impact force of the grinding body (bear dynamic load). The material of the cylinder is A3 steel plate or 16Mn steel plate, with a thickness of 0.01-0.015 times the diameter of the mill.
Lining plate: protect the cylinder from direct impact and grinding by the grinding body and materials; change the motion trajectory of the grinding body to improve its impact and grinding ability.
Grinding door: replace the lining plate and partition plate; Install and reverse the grinding body; observe the amount of material and grinding balls inside the ball mill. Grinding doors are arranged in a straight line on both sides of the cylinder, staggered arrangement.
Grinding balls (steel balls): Steel balls are the medium for grinding materials in ball mill, and the grinding and peeling effect is generated by the collision and friction between steel balls and materials in the ball mill. During the working process of the ball mill, the reasonable grading of the steel balls is related to the efficiency of the equipment. Only by ensuring a certain proportion of various steel balls can it adapt to the particle size composition of the ground material and achieve good grinding results.
Partition plate: separates the grinding body to gradually reduce the grinding size from front to back, meeting the requirements of the grinding process; screen and analyze materials to prevent large particles from flowing towards the discharge end; control the flow rate of materials inside the ball mill.
Ball mill classification
Generally, ball mill can be divided into dry grinding ball mill and wet grinding ball mill.
During dry grinding, due to the design of the cylinder, there may be blind spots where some materials cannot be pulverized by ball mill. However, wet grinding ball mill also has a weakness compared to dry grinding ball mill, which is that the powder after wet milling needs to be dried to remove moisture or other liquid media, which will increase energy consumption and cost; wet grinding cannot be used for cement production.
Advantages of dry grinding ball mill:
(1) The dry ball mill adopts a grate plate and discharge materials at the end, which is smooth and has no swelling phenomenon. The cylinder does not need to be cooled, with a long service life and low failure rate.
(2) There are auxiliary equipment for dry grinding ball mills, which have changed the original mill structure and integrated the body and chassis. During installation, it can be hung on the foundation plane at once. The main shaft is supported by double row centripetal spherical roller bearings, which can reduce energy consumption by 30%.
Advantages of wet grinding ball mill:
(1) Wet grinding ball mills have higher grinding efficiency and lower requirements for ore moisture content, and can handle ores with high moisture and mud content.
(2) Wet ball mills have fewer auxiliary equipment and simple material transportation devices, resulting in an investment of approximately 5% -10% lower than dry ball mills.
(3) Wet ball milling can not only grind agglomerates into fine particles - circular particles, but also force barren materials and plastic materials to mix evenly.
So both have their own characteristics, and when grinding materials, choose the appropriate grinding method according to needs. As one of the leading ball mill manufacturers & suppliers in India, ZENITH will also recommend suitable ball mill for customers according to the actual production condition.
Operation of ball mill
When starting the ball mill, it is necessary to first debug the equipment, and the starting sequence is: feeding motor, main motor, high-pressure oil pump, and low-pressure oil pump.
At this point, it should be noted that in general, it is not allowed to start the ball mill twice consecutively within an hour.
The sequence of shutdown of the ball mill is as follows: stop the feeding equipment, stop the main motor, automatically start the high-pressure oil pump, stop the low-pressure oil pump after the ball mill stops rotating, stop the high-pressure oil pump according to the bearing temperature, and then (manually) start the high-pressure oil pump every 30 minutes (until the cylinder cools to room temperature).
The spray lubrication device system automatically operates when the main motor is working. Automatically stop when the main motor stops.
Do not start the slow drive device when the main motor is working; do not start the main motor when the slow drive device is working.
If you purchase ball mill from ZENITH, we will provide the detail operation manual and train operators for you! So, do not worry about the operation.
Maintenance of ball mill
During the production process of ball mill, the regular maintenance is very important. Pay attention to the following 4 aspects.
The lubrication of main bearings and motor bearings requires that the lubricating oil (grease) injected must be clean, the sealing must be good, and the oil injection amount should meet the requirements. The lubrication station must add filtered clean lubricating oil for refueling.
All external lubrication systems and main bearings require regular cleaning and oil replacement. The oil change interval is 30 days for the first time and approximately 12 months thereafter, depending on the usage conditions. When replacing with new oil, the inner wall of the oil chamber should be cleaned. Lubricating oil that has deteriorated or is not clean should not be used.
The lubrication of main bearings and small gears requires lubricating oil to have sufficient extreme pressure and wear resistance, good viscosity and temperature resistance, good oxidation stability and thermal stability, good emulsification resistance, good rust and corrosion resistance, and low friction coefficient.
Lubrication of large and small gears:
The lubricant is required to adhere to the tooth surface during the operation of the ball mill and a layer of anti-extrusion and wear-resistant oil film that cannot be removed from the tooth surface must be formed during the entire interval between two refueling operations. Never allow oil and hardness to accumulate at the root of the gear teeth.
The amount of oil used depends on the size of the gears and the adopted oil. It is recommended to have a fuel injection interval of 5-8 minutes, and the best fuel injection time is for the large gear to rotate for 2 cycles.
If kept clean and properly lubricated, the main bearings require minimal maintenance.
The service life of the main bearing is uncertain, and even a short lack of lubricating oil can lead to bearing failure. Good maintenance and correct operation of the lubrication system are guarantees of long service life. The bearing seal should be regularly checked for lubricating grease and wear condition, and any deteriorated or damaged seals should be replaced timely.
Large and small gears
During the first 12 hours of operation of the ball mill at full load, use a temperature measuring gun to check the temperature of the small gear every hour, and use a stroboscope to check the gear tooth surface; check at least once per shift for the next two weeks and once a week thereafter.
If the temperature difference between the two ends of the small gear exceeds 8℃, adjust the small gear. If there is a danger on the tooth surface, stop the ball mill and clean for inspection. At the same time, check the amount of lubricant on the large and small gears and adjust according to the visual results.
The feeding and discharging devices may wear and must be regularly inspected and replaced if necessary.
The lubrication system includes all components for maintaining all operations of the main bearings. Regular add matching lubricating grease to high-pressure and low-pressure pumps. The differential pressure gauge on the oil filter is used to indicate dirty oil filters and should be replaced promptly if necessary.
As a famous ball mill manufacturers & suppliers in India, ZENITH has many customers who have set up production plants in India and we can arrange you to visit the sample line. And there are different types and models of ball mills for you to choose, there is always a suitable one for you!