ball mills in working in cement

ball mill for cement grinding process

ball mill for cement grinding process

MQ series ball mills are mainly used in grinding operations in mining, cement, refractory, chemical and other industries. According to the discharging method, it is divided into MQG series dry type lattice ball mill, MQS series wet type lattice ball mill, MQY series wet overflow type ball mill, MQZ series peripheral discharge type ball mill; according to the type of liner, it is divided into A series (high manganese steel lining). Plate, magnetic lining) standard type and B series (rubber lining, high aluminum lining, silica lining, ceramic lining) energy-saving type; according to the transmission mode is divided into edge drive ball mill and center drive ball mill.

When Ball Mill is working, raw material enters the mill cylinder through the hollow shaft of the feed. The inside of the cylinder is filled with grinding media of various diameters (steel balls, steel segments, etc.); when the cylinder rotates around the horizontal axis at a certain speed, Under the action of centrifugal force and friction force, the medium and the raw material in the cylinder will drop or roll off the inner wall of the cylinder when the gravity of the cylinder reaches a certain height.

When material particle gravity is greater than centrifugal force, they will be crushed due to the impact force. At the same time, during the operation of the mill, the sliding movement of the grinding media to each other also produces a grinding effect on the raw materials. The rest material is discharged through a discharge hollow shaft. Due to the constant uniform feeding, the pressure causes the material in the cylinder to move from the feed end to the discharge end. During wet grinding, the material is carried away by the water flow; during dry grinding, the material is taken away by the airflow drawn out of the cylinder.

When Ball Mill is running, the raw material enters the mill cylinder through the hollow shaft of the feed. The inside of the cylinder is filled with grinding media of various diameters (steel balls, steel segments, etc.); when the cylinder rotates around the horizontal axis at a certain speed, Under the action of centrifugal force and friction force, raw material in the cylinder will drop or roll off the inner wall of the cylinder when the gravity of the cylinder reaches a certain height. When their own gravity is greater than the centrifugal force, they will be crushed due to the impact force. ore. At the same time, during the operation of the mill, the sliding movement of the grinding media to each other also produces a grinding effect on the raw materials. The ground material is discharged through a discharge hollow shaft. Due to the constant uniform feeding, pressure will causes the material in the cylinder to move from feed end to discharge end. During wet grinding, material is carried away by water flow; during dry grinding, raw material is taken away by the airflow drawn out of cylinder.

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cement directory: ball mills

cement directory: ball mills

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coal mill in cement plant | vertical roller mill & air-swept ball mill

coal mill in cement plant | vertical roller mill & air-swept ball mill

Coal mill is also called coal pulverizer or coal grinder. It is a mechanical device used to grind raw coal into pulverized coal powders. The most used coal mills in cement plants are air-swept ball mill and vertical roller mill.

At present, most cement plants use coal as the main fuel in the clinker production process. The standard coal consumed by the new dry process for producing 1 ton of cement clinker is usually between 100 kg and 130 kg, and the fuel cost accounts for about 15% of the cement production cost.

Calcining high-quality cement clinker needs a stable coal powder supply. Therefore, coal powder preparation has become an important part of cement production, and coal mill has also become one of the important equipment in cement plant. The coal mill in a cement plant should be reliable and should be operated with great care, or it is easy to cause safety accidents In the process of grinding, storage, transportation, and burning of pulverized coal, resulting in casualties and equipment damage.

When we manufacture a coal mill, we will comprehensively take into account the production scale, site, raw coal quality, operating conditions and other aspects of the target project for reasonable design, so as to perfectly match the kiln calcination system and meet the requirements of reliability, efficiency, safety, environmental protection and automation.

Ball mill is a traditional coal pulverizer machine, which has been widely used since it was invented. In the cement plant, the new dry process cement manufacturing requires the moisture content of coal powder to be 0.5% ~ 1.5%, while that of raw coal is 1.5% ~ 4.0%. Therefore, the ball mill should have drying function besides grinding. In order to enhance the drying ability, large ball mills are equipped with drying chambers.

During the operation of the ball mill, the raw coal first enters the drying chamber through the feed inlet for drying, and the dried raw coal enters the grinding chamber for grinding and second drying. The pulverized coal is taken out of the mill by hot air.

Compared with the vertical roller mill, the advantages of air-swept ball mill are strong adaptability to raw coal quality, simple operation and low investment cost; the disadvantages are high power consumption and high noise.

The working principle of vertical mill is as follows: the material is fed into the mill through the inlet on the top center of the mill and falls on the grinding plate, and the grinding rollers which are driven by the rotation of the grinding plate will crush the material. The fine material is taken away by the high-speed hot air from the bottom to the top, and the coarse material continues to be ground on the grinding plate. The fine material taken away by hot air is separated by the separator on the top of the mill. The pulverized coal with acceptable fineness is discharged from the mill with air, and the unqualified pulverized coal is returned to the mill for further grinding.

energy efficient cement ball mill from flsmidth

energy efficient cement ball mill from flsmidth

You decide whether to operate the mill in open or closed circuit, with or without a pre-grinder and with side or central drive, according to your plant layout and end product specifications. Even the lining types are tailored to your operating parameters.

In addition, the large through-flow areas enable the mill to operate with large volumes of venting air and a low pressure drop across the mill. This reduces the energy consumption of the mill ventilation fan and keeps your energy costs down.

The mill is based on standard modules and can be adapted to your plant layout, end product specifications and drive type. The horizontal slide shoe bearing design enables much simpler foundations and reduced installation height, making installation quicker and less expensive.

Our shell linings are designed to suit the task at hand. In our two-compartment cement mills, the first compartment (for coarse grinding) has a step lining suitable for large grinding media. It protects the shell while ensuring optimum lifting of the mill charge. In the second compartment (and also in our one-compartment cement mills) we use a corrugated lining designed to obtain the maximum power absorption and grinding efficiency. For special applications, we can supply a classifying shell lining for fine grinding in the mill.

In fact, the entire mill is protected with bolted on lining plates designed for the specific wear faced by each part of the mill. This attention to detail ensures both minimal wear and easy maintenance. When a wear part has reached the end of its life, it is easily replaced.

The grinding media are supplied in various sizes to ensure optimum grinding efficiency. The STANEX diaphragm is designed to maximise the effective grinding area, enabling a higher throughput. It is fitted with adjustable lifters to ensure the material levels in each compartment are right. Best of all, the STANEX diaphragm works for all applications, even when material flow rates are high and the mill feed is moist.

The mills are typically driven by our FLSmidth MAAG LGDX side drive - gearing rated to the latest proven AGMA standards. The mill drive is provided with an auxiliary drive for slow turning of the mill. The LGDX includes two independent lubrication systems, one which services the girth gear guard and intakes more dust, and a second which supplies oil for the fast-rotating gearing and bearings and stays clean. If requested, however, the mills can be provided with a central drive: the FLSmidth MAAG CPU planetary gearbox. The mill design differs slightly, depending on whether the side or central drive is chosen.

Each grinding compartment has two man-hole covers to give easy access for maintenance. As there are minimal moving parts, the maintenance requirement is low and simple changes like replacing wear linings and topping up grinding media can be completed quickly and easily. Horizontal slide shoe bearings prevent oil spillages from the casing and offers easy replacement of slide shoes.

Buying a new mill is a huge investment. With over a century of ball mill experience and more than 4000 installations worldwide, rest assured we have the expertise to deliver the right solution for your project. Our ball mill is based on standard modules and the highly flexible design can be adapted to your requirements. The mill comprises the following parts.

The mill body consists of an all-welded mill shell and a T-sectional welded-up slide ring at either end, the cylindrical part of which is welded onto the ends of the shell. The mill shell has four manholes, two for each grinding compartment.

Each slide ring runs in a bearing with two self-aligning and hydrodynamically lubricated slide shoes. One of the slide shoes at the drive end holds the mill in axial direction. In the others, the slide rings can move freely in axial direction to allow for longitudinal thermal expansion and contraction of the mill body.

The slide shoes are water-cooled, and each bearing is provided with a panel-enclosed lubrication unit including oil tank, motorised low- and high-pressure oil pumps, as well as an oil conditioning circuit with motorised pump for heating/cooling and filtration of the oil.

The stationary steel plate inlet duct leads the venting air into the mill. It is equipped with a manually operated throttle valve and a pressure monitor to adjust the pressure at the inlet end, thus preventing dust emission from the inlet. The feed chute is lined with bolted-on wear plates and slopes down through the air duct to the mill inlet opening.

The more control you have over the mill, the better your grinding efficiency is likely to be. Our ball mills include monitoring systems to continuously measure the material and air temperatures as well as the pressure at the mill exit. The venting of the mill is adjusted by a damper in the inlet to the mill fan. And the material fill level is continuously monitored by means of sensors. For ball mills operating in closed circuit, the circulation load is monitored by weighing the flow of reject material from the separator. These measures ensure you achieve optimum mill performance, giving you the quality, efficiency, safetyand reliability that you need.

FLSmidth provides sustainable productivity to the global mining and cement industries. We deliver market-leading engineering, equipment and service solutions that enable our customers to improve performance, drive down costs and reduce environmental impact. Our operations span the globe and we are close to 10,200 employees, present in more than 60 countries. In 2020, FLSmidth generated revenue of DKK 16.4 billion. MissionZero is our sustainability ambition towards zero emissions in mining and cement by 2030.

use cement ball mill grinding cement clinker | cement ball mill operation

use cement ball mill grinding cement clinker | cement ball mill operation

Cement ball mill is a kind of cement grinding equipment commonly used in cement plants. It is mainly used for grinding materials in cement clinker section. Cement ball mill is widely used in cement production, silicate products, new building materials, refractories, fertilizers, black and non-ferrous metal mineral processing, glass, ceramics, and other industries. It is the ideal grinding equipmentfor cement clinker, limestone, gypsum, slag,ore,and othergrindable hardness materials.

In the process of cement production, cement raw meal is calcined in a rotary kiln to obtain cement clinker. After the cement clinker is cooled, adding an appropriate amount of gypsum and additives. Put the mixture into cement mill and grinding to the appropriate particle size, so as to obtain the finished cement products.

As one of cement ball mill manufacturers with many years of research and development experience, not only our cement ball mill price is reasonable, but also the cement ball mill operation is simple and with high-level automation.

Moreover, the cement ball mill has strong adaptability to materials and a large crushing ratio, which can conveniently control the fineness of the abrasive materials. These advantages make cement ball mill widely used in cement manufacturing, metallurgy, chemical industry, mining and other fields.

As an expert in the cement ball mill manufacturers, the cement ball mill we produced adopts the advanced internal powder selection special compartment structure, which can effectively accommodate the storage of small-sized grinding media, thus greatly improving the overall grinding efficiency of the cement mill. Increased production capacity while achieving the goal of reducing energy consumption.

The 3.813 cement ball mill with double-sliding structure solves the problem of the similar product the discharge end slide bearing temperature is too high to operate continuously, which ensures the equipment can run continuously and stably for a long time and makes a new technical breakthrough in the field of double slide ball mill.

As a ball mills supplier with 22 years of experience in the grinding industry, we can provide customers with types of ball mill, vertical mill, rod mill and AG/SAG mill for grinding in a variety of industries and materials.

how to improve cement ball mill performance in closed circuit grinding system

how to improve cement ball mill performance in closed circuit grinding system

There are many factors that may affect the ball mills working efficiency and product quality during the operation. In this article, we will discuss the measures that can improve the ball mills performance.

The particle size of the feed material is an important process parameter that restricts the grinding efficiency of the ball mill. Due to the different physical and chemical properties and microhardness of the materials (the grindability of materials in raw meals decreases in clinkers), the clinker discharged from the cement kiln must be pretreated to reduce its particle size so as to increase the output and reduce the power consumption of the ball mill.

From table 1 we can learn that if the particle size of the feed material is reduced from 25 mm to less than 2 mm, the mill output can be increased by at least 60%, which is relatively consistent with the actual production.

There are two methods for clinker pretreatment: pre-crushing and pre-grinding. 1) The pre-crushing uses a crusher to crush the clinker before grinding, which can reduce the diameter of clinker particle to 5 ~ 8mm. 2) The pre-grinding adds a roller press to the cement grinding system. In this system, the clinker is extruded circularly, dispersed and separated, and becomes powder with diameter less than 2 mm;

The gradation of grinding media is also an important factor in improving the efficiency of ball mills. A reasonable gradation can only be calculated after analyzing the performance of the mill, the property of the feed material, and equipment layout in the closed-circuit grinding system.

The size of the grinding media is calculated based on the grinding capacity of the mill and the size of the feed material. Because of the complex movement of the grinding media and the material in the mill, and because the actual production situation of each cement plant is different, it is difficult to determine a universally applicable grading rule. Only through long-term production practice can we get the appropriate gradation scheme.

The gradation of grinding media is constantly changing in the process of mill operation, and the wear law of different size of grinding media is also different. Therefore, the supplementary of grinding media can only keep the loading capacity relatively balanced, but can not keep the gradation consistent.

The stable grinding process largely depends on the material of grinding medium. Different materials of grinding media lead to different wear consumption. If the hardness and wear resistance of the grinding media are poor, it is easy to deform and crack during the operation, which not only affects the grinding efficiency and blocks the grate gap, but also makes the partition device difficult to discharge material, and finally leads to the deterioration of the mill operation. Therefore, improving the quality of the grinding media is an effective way to ensure the long-term stable operation of the mill, otherwise, no matter how reasonable the grading scheme is, it is difficult to ensure that the expected grinding effect can always be achieved.

Once the grinding media and other equipment is properly selected for the grinding system, then the gradation can be determined according to the particle size of the feed material. However, no matter how reasonable the grading scheme is, it is always relative.

The ball bearing height of ball mills can be different due to different specifications, diameters, rotating speeds and liner forms of the ball mills. And the potential energy produced by different height of the ball is completely different. Therefore, the reasonable grinding ball diameter should not only match with the mill specifications, but also adapt to the liner form of the mill.

Large size mills with lifting liner bring grinding balls to higher heights and generate stronger impact force, so the diameter of grinding balls can be smaller. The ball diameter should be different according to the aging degree of the inner liner: new liners bring grinding balls to higher height, so the ball size can be smaller.

It can be seen from the experiment that when a grinding ball with a diameter of 70 mm falls freely from the height of 40 cm, its potential energy can completely crush a clinker particle with a diameter of 25 mm. Therefore, the minimum ball diameter should be selected on the premise of sufficient impact energy to increase the number of grinding balls, increase the impact times of balls on materials, and improve the grinding efficiency.

Table 2 and table 3 show the relationship between the material particle size and the grinding ball diameter for reference only. When determining the ball diameter, it is necessary to adjust it according to the cement plants own situation.

85tph cement ball mill put into operation in indian cement plant

85tph cement ball mill put into operation in indian cement plant

Demand for the project came from customers of cement factory in India. Customers need to purchase cement ball mill for cement clinker grinding. Through communicating with customers, we provide them with reasonable solutions. Combined with the daily output of cement and grinding precision requirements of cement plant, a cement ball mill with output of 85t/h can meet the production requirements. Through design and manufacture, field installation and commissioning, 85t/h cement ball mill has been officially put into production. After a period of running-in, the cement ball mill can now reach the maximum output of 85 tons per hour. The successful completion of 85t/h cement ball mill project provides customers with good cement clinker grinding services, which not only saves production costs for customers, but also improves their production efficiency.

The cement grinding is arranged after the cement raw meal calcination process. Cement raw meal is calcined in rotary kiln. Carbonate and other main components are further decomposed rapidly and a series of solid-state reactions occur, and the particles of various minerals are formed, namely cement clinker. After cooling, the clinker is fed into the cement ball mill for grinding. The cement ball mill grinds the cement clinker particles to a suitable particle size, forms a certain particle level, increases the hydration area, accelerates the hydration speed, and meets the requirements of cement slurry coagulation and hardening.

85t/hcement ball millis a new type of high yield grinding equipment developed and produced by AGICO. It can be produced in a single machine or in parallel, increasing the total production per unit time. The cement ball mill specification is 4.213, and the maximum amount of built-in grinding steel ball is 224 tons, which can guarantee the grinding fineness of the material under the premise of large output.

As a ball mills supplier with 22 years of experience in the grinding industry, we can provide customers with types of ball mill, vertical mill, rod mill and AG/SAG mill for grinding in a variety of industries and materials.

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