The ball mill has a simple and compact structure and high reliability. It is an important grinding equipment in the fields of metallurgy, chemical industry, cement, ceramics, construction, and electricity. However, its disadvantages are also obvious, that is, high energy consumption and high iron loss. In recent years, with the growth of energy and the decline of energy quality, energy saving and consumption reduction have become a hot spot in ball mill research.

After continuous experience summary, our company staff concluded that the measures for energy saving and consumption reduction of ball mills are mainly concentrated in structural improvement, process parameter optimization, automatic control, etc. Please see the specific analysis below.

1. Structural improvement

Compared with small and medium-sized mills, the advantage of large equipment is that it can save construction costs and operation and maintenance costs, simplify equipment configuration and automation requirements. However, its unit energy consumption is higher than that of small and medium specifications, so its specification development is limited.

The current research hotspot is to improve the original equipment and develop energy-saving ball mills, such as ceramic industry continuous type, ceramic raw material continuous cone machine, rolling bearing type, etc. These new machines and equipment have achieved obvious results in energy saving and consumption reduction.

2. Improvement of lining

The lining can protect the cylinder and extend the service life of the equipment. At the same time, its shape can directly control the movement trajectory of the steel ball in the cylinder. The liner is a spare part that is easy to wear, has a large replacement and consumption, and accounts for more than 60% of the consumption of wearing parts.

Changing the material and form of the liner has an important impact on improving operating efficiency. In terms of material, metal liner, rubber liner, magnetic liner, composite liner, etc. are generally used; the modified forms of the liner include conical graded liner, angle spiral liner, etc.

3. Material and shape of the medium

The function of the grinding medium is to produce punching, squeezing, grinding and grinding in the cylinder, so that the material can reach the finished product fineness and grading requirements. Poor performance of the grinding medium will lead to poor wear resistance, high unit consumption, and high dosage, which seriously affects the grinding efficiency and accounts for about 30% of the consumption of wearing parts.

The grinding medium mainly improves the grinding efficiency by improving its material and shape. In terms of material, low-chromium white cast iron grinding balls and alloy cast iron balls with special alloy pig iron or waste slag alloy pig iron as the main raw materials have developed rapidly due to their low price and moderate wear. In terms of shape, short cylindrical, rod-shaped balls and cylindrical rod-shaped media have higher productivity and lower unit power consumption than traditional steel equipment.

4. Process parameter optimization

The working state of the ball mill is affected by factors such as rotation rate, filling rate, ball-to-material ratio, aspect ratio, liner and grinding medium size. The factors are coupled with each other and are relatively complex. To give full play to the grinding efficiency, it is necessary to pay attention to the influence of design operating parameters. Improper selection of grinding parameters will greatly reduce efficiency or even fail to work normally.

Among the working parameters, the rotation rate and filling rate have a significant impact on the working state of the ball mill. The grinding process is a process in which the material gradually becomes smaller from large particles. In different grinding stages, the influence of the rotation rate and filling rate on the product particle size is also different. In-depth research on the influence mechanism of the rotation rate and filling rate on the product particle size can provide reference for a more reasonable grinding process, thereby greatly improving work efficiency.

5. Automatic control

The system of the ball mill is a complex system with multiple inputs, multiple outputs, nonlinearity, time-varying, large lag and multi-variable coupling. The influence of many factors makes it difficult to accurately establish the mathematical model as it changes with environmental conditions. Perfect automatic control can adjust the system to operate at a better working point and reduce energy consumption.

After the above analysis, I believe that everyone has a certain understanding of the energy-saving measures of the ball mill. If you need more help, you can consult our company staff.