Ball mill grinder is the essential equipment in mineral processing plant, which is also the key equipment in the whole mineral processing plant construction. Therefore the stable operation of ball mill is essential. However, before the official putting into operation, the commission of ball mill grinders is important. A little mistake would lead to the unqualified particle size in products, even reducing the metal recovery rate. How to carry out the commission of ball mill grinders? In this passage, we will introduce you to the process of ball mill grinder commission.
Ball mill grinder installation accomplishment according to the paper, to ensure all the components are at the right position. The complete installation process should be recorded and acceptance passed.
The bush should be installed on the sector block of lower bearing seat according to the rotation direction of ball mill. The bush should be revised according to the axial guide ring. The bearing seat seal should be installed correctly. The junction should be sealed by a sealant.
Ensuring that all the monitoring equipment are well-connected. The flow monitor, pressure switch and temperature sensor are set well. Oil pressure gauge, thermometer, accident button and interlocking device instructions are reliable.
Connecting with reducer and pinion coupling, and installing protecting mask. Start the lubricating oil system and cooling water system. Turn on the power of the ball mill, press the accident button to stop it, and check the main bearing, motor, and gears to determine whether the direction of rotation of the ball mill is correct. If there is no abnormality, start the ball mill to run for 8 hours.
When running empty, if the lubricating oil system is working normally and there is no oil leakage. The ball mill runs smoothly and there is no obvious noise. The vibration value of the main bearing, motor, and pinion does not exceed 0.1mm, and there is no obvious damage or hot phenomenon to all parts. The empty vehicle runs normally.
According to the ratio of ball mill, a certain amount of steel balls are added into the cylinder of ball mill grinder. Steel balls are added in batches. During operation, measure bearing temperature, current, and vibration intensity everywhere. After the installation of the ball mill is completed, start to run with load, add 70% of the specified load into the grinding material, and continue to run for more than 10 hours. During this process, the liner bolt joint should be fastened and check the bolt connection frequently to prevent the loosen.
During running with load, the ball mill grinder should satisfy the following requirements. The vibration of each part does not exceed 0.1mm; The current of the motor has no abnormal fluctuations; The running process is stable; The noise is small; The connecting bolts are tight, and the cylinder has good sealing.
The above is the whole installation and commission process of ball mill grinder. Xinhai Mining established the commission operation management service center to ensure the correct and favourable installation. Xinhai Mining insists on the service idea professional attitude wins the trusts of clients, helping clients to resolve problems and free from worries.
NextXinhai ball mill manufacturers will introduce the running state of the ball mill machine from the structure of the ball mill machine, motion state of ball mill machine and the working principle of the ball mill machine.
The basic composition of the ball mill machine includes a cylindrical barrel, end cover, bearing and transmission ring, etc. The barrel is mounted on a large bearing and placed horizontally. The cylinder body is equipped with the unquantified steel ball or steel rod (25mm-150mm of large steel ball), which accounts for 25%-50% of the effective volume of the whole cylinder body.
In the grinding process of the ball mill machine, the rotation speed of the barrel generally operates from high to low, which can be divided into three motion states: release state, drop state and turnover state.
The dropping state is produced when the ball mill machine is running at a high speed. At this time, the grinding process of the ball mill machine is completed by the impact power, followed by grinding operation.
Turnover state, also known as the centrifugal state, is the state of motion when the speed of the ball mill barrel increases to a certain limit value (critical speed) (in general, the ball mill machine does not work under this state). At this point, all media will rotate with the cylinder rotation and will not fall. There is no grinding action between the material and medium when the ball mill machine is in a centrifugal state.
The working principle of the ball mill machine is also the movement rule of the ball mill machine. The ball mill machine is driven by the motor to rotate, so as to realize the operation between the material in the barrel of the ball mill machine and the steel ball. When the medium inside the cylinder is brought to a certain height with the rotation of the ball mill machine, the medium will fall due to its own weight. At this time, the medium will be violently impacted by the steel ball inside the cylinder, over and over again, and finally the mineral grinding is completed.
These are some aspects of the ball mill machine explained by Xinhai ball mill manufacturers. If you have any questions, please contact us! As one of the most professional ball mill manufacturers, we will customize the most suitable ball mill machines for you.
"Create international brand, based on global market" has been one of the strategic thinking of Xinhai. Xinhai has exported beneficiation equipment to Russia, Mongolia, Kazakhstan, Chile, Brazil, Vietnam, Iran and more than 30 countries.
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The Guinea 6,000t/d gold mineral processing plant was an EPC+M+O project. The design scope covered construction drawings and workshop drawings and involved engineers in the fields of mineral processing, water supply and drainage, power, civil engineering and general layout.
The Malaysia 700t/d gold mineral processing plant was a symbol of Chine-Malaysia cooperation in the mining industry under the policy of The Belt and Road. The raw ore consisted of pyrite, quartz, calcite and mica, with gold being the valuable mineral. It had a gold grade of 4.70g/t, silver grade of 4.63g/t, iron grade of 20.10% and a sulfur grade of 20.55%.
At present, there are thousands of ball mill manufacturers in the market, so how do we choose a suitable one with nice strength and reputation from those ball mill manufacturers? Here, Xinhai gives you some tips for choosing the right ball mill manufacturers.
We know that the ball mill is one of the grinding equipment, and the grinding equipment is the core of the mineral processing plant, and the grinding operation is also a large part of energy consumption. Therefore, in the view of the long-term comprehensive income, it is very important to choose the suitable ball mill machine manufacturers with the reasonable price, strong comprehensive strength, full-equipped after-sales service, high-efficient, and energy-saving ball mill. When choosing the ball mill manufacturers, we should take the following into consideration:
In general, whether an enterprise can go for a long time depends on whether the enterprise has the ability to research and development capabilities. Design and research the new ball mill is the foundation to support the development of the ball mill machine manufacturers. With the rapid development of the times, the new type equipment will quickly seize the market, especially the machinery industry.
For example, Xinhai Mining has a number of innovative technologies in the research and development of ball mill, such as the transmission system with slow transmission system device, hydraulic jacking device, multiple feeding device and discharging methods, large and small gear spray lubrication system, antifriction bearing and sliding bearing, sliding bearing, overall rack, which greatly improve the grinding efficiency of ball mill, and reduce the energy consumption and power consumption of ball mill. Compared with the conventional ball mill, Xinhai ball mill can save more 30% of energy.
In addition, the overall rack of the ball mill enables the whole ball mill to be installed on a whole welding frame, which is connected with the foundation. The installation and commission of ball mill are accomplished in the factory. Just put it on the pre-made foundation at the scene, and find the level and install it firmly. It reduces the engineering quantity and working period, and also convenient for the long-term transportation of equipment.
A complete ball mill is composed of a cylinder, large and small gears, reducer, motor, bearing, bearing support, ball mill bracket and various parts (such as wear-resisting rubber liner, steel ball). In addition to some national standard parts, the ball mill manufactures can provide more spare parts means that the technical strength of ball mill manufacturers is better.
As one of the most professional ball mill manufacturers, Xinhai Mining can provide the ball mill equipment and various basic accessories. But, Xinhai Mining can also configure the motor, reducer, bearing and electrical components from the international brands according to the user requirements. For example, the motor is from ABB or SIEMENS, the reducer is from SEW and Sumitomo, the bearing is from SKF or TIMKEN, the electrical components are from Schneider, ABB or SIEMENS, which not only ensures the efficient and stable operation of the ball mill for a long time, greatly reduces the problem of ball mill, but also saves the investment cost.
The ball mill manufacturers shall be equipped with the ball mill research and development capacities, delivery and shipping, installation and debugging, after-sales service, which indicate that the ball mill manufacturers have a strong production capacity and perfect service system.
Xinhai Mining can not only produce the ball mill equipment by itself, but also has a complete packing and delivery system, on-site installation and debugging service system, which not only guarantees the safe production of the equipment, but also effectively ensures the installation quality and speed of the ball mill. In addition, Xinhai Mining also has the perfect after-sales consulting service and workers training service.
The Above is about how to choose the right ball mill manufacturers. The right ball mill manufacturers can select the suitable ball mill types and equipment parameters according to your plant condition, thus help you to obtain the ideal mineral processing indicator.
[Improvement]: The jack-up device adopts the hydraulic jack-up device independently developed by Xinhai. When the ball mill is in maintenance, only handling the hydraulic station can make the hydraulic jack rise and fall. Compared with the ordinary jack-up device, Xinhai jack-up device is simple, convenient and easy to operate with lower maintenance costs.
The main component is a cylinder with diameter and length at a reasonable proportion. Driven by the transmission device, the cylinder rotates with the materials fed from the cylinder inlet and crushed by the falling impacts and autogenous grinding of the steel balls and ores in the cylinder. Due to the continuously feeding materials, the pressure pushes materials to the outlet and the grinded materials are discharged from the cylinder outlet. Qualified materials flow from the cylinder outlet. In wet grinding, the materials are taken out by the water flow.
Ball mill is a kind of grinding equipment commonly used in the concentrator, which accounts for a large proportion in the capital investment and production cost of the whole concentrator. Besides, it also has a great impact on the final economic and technical indicators of the concentrator.
According to the different grinding conditions, the ball mill can be divided into wet ball mill and dry ball mill. Before selecting the type of ball mill, we should know about the difference between the wet ball mill and dry ball mill, then make a targeted choice.
The wet ball mill and dry ball mill are basically the same in shape and component structure. The cylinder is cylindrical. The component structure mainly includes the feeding part, the discharging part, the rotary part, the transmission part (reducer, transmission pinion, motor, electric control), etc.
The difference between the two is that the structure of the wet ball mill is relatively simple, without too many auxiliary accessories, and the horn-shaped discharge port and the double helix built-in ore discharging facilities are more convenient for discharging. The structure and structure of dry ball mill is more complex with straight cylinder discharge port, air suction device, dust pipe and dust collector.
The working principle of the wet ball mill is to use the transmission machinery to drive the barrel for rotating, and the material is fed from the ore feeing port. Under the action of centrifugal force, the steel ball, material and the lining plate in the barrel body strike and grind among them, so as to complete the material grinding. In this process, the wet ball mill needs to be matched with water to achieve the appropriate pulp concentration. The qualified materials are discharged from the discharging port, while the unqualified materials are returned to the wet ball mill for regrinding.
In the operation process of dry ball mill, the material is fed into the hollow shaft from the feeding device, and the hollow shaft sends the material into the first warehouse by the uniform spiral movement. The warehouse is equipped with the ladder lining board (or corrugated lining board) and steel balls with different specifications.
The wet ball mill can achieve continuous production, has the stronger adaptability to the material, large crushing ratio, easy to adjust the abrasive fineness, high grinding efficiency, low water content requirement of the ore and simple material transport device. Its investment cost is about 5%-10% lower than the dry ball mill.
The dry ball mill adopts grate plate forced-discharging mode, its discharging is smoother, and there is no rise grinding phenomenon, the cylinder doesnt need cooling, and the material has the small wear to the on the lining plate and medium in the fine grinding process. Besides, it has long service life and low failure rate. But because of its barrel reasons, the dry ball mill occasionally forms the dead corner, the material in the dead corner is not easy to be ground.
When the material meets the water will not affect the final product quality, the requirements on the selected ore particle size are fine, and the separation requirements are high, then the material can adopt the wet ball mill.
The wet ball mill has a wide range of applications, can be used to treat all kinds of metal and non-metallic minerals, such as gold ore, silver ore, copper ore, iron ore, phosphate ore, molybdenum ore, feldspar ore, fluorite ore, etc.
If the material has physical or chemical reaction with water (such as cement, marble and other building stones), or the material needs to be stored or sold in the form of grinding, the dry ball mill can be considered.
Here are the four major differences between wet ball mill and dry ball mill and how to choose the two. Only by identifying the grinding method suitable for the material, can we ensure the quality and efficient operation of the ball mill. The wet ball mill and dry ball mill have their own advantages, we still make the rational choice according to the properties, characteristics of the material, the requirements for the product and the working environment.
The steel ball is the grinding media of the gold ball mill. In the working process, the steel ball will directly affect the grinding efficiency of the gold ball mill and even the working efficiency and product quality of the whole concentrator.
Below, we will introduce the steel ball in detail from its specification and quantity, material, ratio and grading to help you choose and add the steel ball correctly, so as to improve the grinding efficiency of the gold ball mill.
Generally, the diameter of the steel ball is between 20mm and 125mm. Among them, the diameter of the small steel ball is generally 40mm and a 60mm, the diameter of the medium steel ball is generally 80mm, and the diameter of the large steel ball is 100mm or 120mm. The diameter of the super large steel ball is 130mm-150mm.
Theoretically, when the filling amount of steel ball in the ball mill is 40%, the ball mill can obtain the ideal output. But in the actual production, the filling rate of the steel ball in the ball mill is mostly about 35%, that is, the volume of the steel ball in the gold ball mill is kept slightly below the horizontal centerline of the ball mill.
As the "consumable" in the grinding operation, the wear degree of the steel ball is different due to the different material. At present, the mainstream steel balls of the gold ball mill on the market mainly include casting steel balls and forged steel balls.
Casting steel balls are mainly low chromium casting steel ball, medium chromium casting steel ball and high chromium casting steel ball, whose hardness, impact value and breakage rate are related to the metallographic structure of steel. The higher the chromium content, the better the wear resistance of the steel ball.
Forged steel gold ball mills mainly include low carbon alloy steel ball, medium carbon alloy steel ball, high manganese steel ball, rare earth chromium molybdenum alloy steel ball. The impact toughness of the forged steel ball is large, not easy to deform, but the crushing rate is low.
When first enabled, the gold ball mill needs the large, medium and small steel ball for matching, and the steel mill ball for the first time should be added to 80% of the amount limit that the ball mill manufacturer of ball mill suggests. Because the gears of the ball mill need mesh after the installation, and the processing capacity of the ball mill is increased gradually, then the ball mill operator needs to observe the condition of gear meshing in two or three days. If all is going well, the ball mill operator can open the hole cover to add the remaining 20% of steel ball.
Usually, the small steel balls are used only in the first addition. When the ball mill is running normally, there will be reasonable friction between the steel ball and the steel ball, the steel ball and the ore, the steel ball and the lining plate of the ball mill, which makes the wear increase. The large steel ball is ground into small, and the medium steel ball is ground into the small steel ball, so there is no need to add the small steel ball under normal circumstances. However, if the particle size of the useful mineral does not realize the monomer separation, and the grinding fineness of the ball mill cannot meet the separation requirements (especially the flotation separation requirements), the appropriate amount of small steel balls can be added into the gold ball mill.
In addition, the ball mill steel ball is constantly worn in the operation, the ball mill operator must regularly make up the steel ball and maintain the load filling rate of the steel ball and reasonable ratio.
Determine the grading scheme of the steel ball usually starts from the first warehouse (namely the coarse crushing warehouse). For the multi-bin ball mill, the grading of the first bin is particularly important. According to the cross-gradation principle, the minimum diameter of the steel ball in the previous bin determines the maximum diameter of the steel ball in the next bin. It can be seen that the grading of the steel ball in the first warehouse actually dominates the grading of the steel ball in the other warehouses.
The upper limit of the ball diameter is determined according to the upper limit of particle size of the grinding material. The average diameter of the steel ball is determined according to the average particle size of the grinding material.
The composition proportion of each specification steel ball is set according to the proportioned principle of "small at both ends and large in the middle" for the grinding body and the distribution characteristics of material size,.
Calculate the average ball diameter of the mixed steel ball, and compare with the original average ball diameter of the steel ball, add the steel ball according to the proportion of the ball size. If the deviation is large, it is necessary to set the composition proportion of various steel balls and rematch the balls until the deviation is small.
The secondary grading method means to only select two different diameters of ball mill steel balls for grading. The diameter of the large steel ball depends on the particle size of the grinding material, and the diameter of the small steel ball depends on the size of the space between the large steel balls.
Usually, the diameter of small steel ball should be 13%-33% of the diameter of large steel ball. Generally, the small steel ball accounted for 3%-5% of the mass of large steel ball, and the incorporation amount of small steel ball shouldnt affect the filling rate of large steel ball in principle.
These are the main aspects of the steel ball involved in the grinding process: specifications and quantity, material, ratio and grading. For the concentrator, the selection and application of the steel ball involve many technical problems, it is suggested that the mine owners carefully analyze their own actual situation, determine the suitable steel ball for the concentrator through consulting the professional gold ball mill manufacturers, thus avoiding the unnecessary economic losses.
[Improvement]: Overflow type ball mill is equipped with slow transmission system. When the ball mill starts, the low-speed slow transmission runs first, and the high-speed main motor drive system runs later, which not only saves energy, but also reduces the impact on the ball mill equipment and the grid system.
Principle of theoverflow ball mill: the main component is a cylinder with diameter and length at a reasonable proportion. Driven by the transmission device, the cylinder rotates with the materials fed from the cylinder inlet and crushed by the falling impacts and autogenous grinding of the steel balls and ores in the cylinder. Due to the continuously feeding materials, the pressure pushes materials to the outlet and the grinded materials are discharged from the cylinder outlet. Qualified materials flow from the cylinder outlet. In wet grinding, the materials are taken out by the water flow. There are backpitch impellers in the hollow shaft, which can make the balls and coarse ores in the overflow return to the mill. With a simple structure, higher operation rate, and rolling bearing, the energy conservation is significant.