Ten tricks for improving grinding efficiency of ball mill – 1

The low grinding efficiency, low capacity, high energy consumption, and unstable fineness of ball mill are the problems that most of the peers will encounter. How to effectively improve the grinding efficiency of the ball mill is an important issue. Here, we share 10 ways to improve the grinding efficiency of ball mills.

1.Change the grindability of raw ore

The hardness, toughness, dissociation, and structural defects of raw ore determine the degree of grinding difficulty. Small grindability is easy to grind ore, mill lining, and ball wear is also smaller, energy consumption is also small; conversely, on the contrary. The raw ore properties directly affect the productivity of the mill.

In the production, if the more difficult ore or ore requires fine grinding, we can consider to adopt a new treatment process to change the grindability of the ore when the economic and site conditions permit.

One method is to add certain chemical reagents in the grinding process to improve grinding effect and increase grinding efficiency.

Another method is to change the grindability of the ore, for example, the minerals in the ore heating, change the mechanical properties of the whole ore, reduce the hardness.

2.More crushing, less grinding, reduce the particle size into the mill

If the grinding particle size is large, the work that the mill needs to do on the ore will be more significant. To reach the required grinding fineness, the workload of the ball mill will increase, and subsequently, energy consumption and electricity consumption will also increase.

In order to reduce the feed size of grinding, the product size of crushing is required to be small, that is, “more crushing and less grinding. “. The crushing efficiency is higher than the grinding efficiency, and the energy consumption of crushing is lower, about 12% ~ 25% of the grinding energy consumption.

3.Reasonable filling rate

If the ball mill has a certain rotating speed and the filling rate is high, the grinding ball will strike the material more times, the grinding area is large, the grinding effect is strong, but the power consumption is also large, and if the filling rate is too high, the motion state of the steel ball will be easily changed, reduce the impact on large particle materials. On the contrary, the filling rate is too low, and the grinding effect is too weak.

At present, many mines set the filling rate at 45% ~ 50%, which is not strictly reasonable, because the actual conditions of each concentrator are not the same, copying others’data to load the ball can not achieve the ideal grinding effect, depending on the situation.

4.Reasonable size and proportion of grinding ball

Due to the point contact between the grinding ball and the ore in the ball mill, if the ball diameter is too large, the crushing force is also significant, which results in the crushing of the ore along the direction of the penetrating force, rather than along the interface of different minerals with weak binding force. There is no selectivity in crushing, not for grinding purposes.

Besides, under the same ball filling rate, the ball diameter is too large, resulting in too little ball, low crushing probability, increased crushing phenomenon, product granularity is not uniform. The size of the steel ball is too small, the crushing force on ore is too small, and the grinding efficiency is too low.

5.Precisely add grinding balls

In production, the grinding action between steel ball and ore will cause the wear of a steel ball, which will lead to the change of the proportion of steel ball of each size, affect the grinding process, and create the fineness change of grinding products. Therefore needs the reasonable steel ball supplementary system to be able to cause the production to be stable.

The automatic grinding balls charging machine is good to add the balls into the ball mill. The grinding balls are charged by the timer on time after calculating. Welcomed in the mines. 

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