As a grinding equipment, rod mill is widely used in the treatment of various ores and waste slag, including steel slag produced in the steel production process. The steel slag rod mill consists of a cylinder, a transmission system (motor, reducer, gear pair), a main bearing, a feed/discharge device and a steel rod grinding medium. It adopts a wet overflow design and is suitable for the first-level open-circuit grinding of steel slag. It is mainly used for the crushing and grinding of steel smelting waste slag (converter slag, electric furnace slag, etc.), separation and recovery of metallic iron, and processing the remaining slag into building materials (such as steel slag cement, micro powder).

The impact of slag rod mill blockage on production

1. Decreased equipment operation efficiency

The output drops sharply, the discharge port or grate plate blockage directly restricts the material flow, resulting in the accumulation of steel slag in the cylinder, the effective impact space of the grinding medium (steel rod) is reduced, and the production capacity decreases by 30%-50%.

Energy consumption rises abnormally, the cylinder load increases after blockage, the transmission system needs to do extra work to overcome the resistance, the power consumption increases by 15%-25%, and in severe cases, the overload protection shutdown is triggered.

2. Increased equipment wear

Abnormal steel bar loss, material accumulation leads to increased friction between steel bars and steel slag, local overheating accelerates steel bar bending and breaking, the probability of disordered bars increases, and the service life of the medium is shortened.

Damage to liner and transmission parts, abnormal vibration caused by blockage will accelerate fatigue wear of gears, bearings and liner, increase the risk of loosening of cylinder bolts, and increase maintenance costs.

3. Process interruption

Production line coordination is out of balance, blockage forces shutdown and cleaning, resulting in idling or interruption of upstream crushing equipment and downstream magnetic separation, sorting and other processes, and the overall resource processing chain efficiency is reduced.

Material properties deteriorate, steel slag stays in the cylinder for a longer time, and materials with too high humidity may agglomerate and harden, increasing the difficulty of subsequent crushing or grinding.

4. Product quality fluctuations

Particle size distribution exceeds the standard, poor discharge leads to the inability to discharge qualified fine particles in time, the proportion of coarse particles increases, and the fineness of the finished steel slag powder does not meet the standard, affecting the stability of building material admixtures.

The metal recovery rate decreases, the particle size control before magnetic separation fails, the separation efficiency of granular steel and tailings decreases, and the amount of metal resources recovered decreases.

5. Safety hazards and economic risks

Overheating and vibration of equipment, blockage leads to abnormal increase in bearing temperature (up to 60°C or above), the vibration amplitude of the cylinder exceeds the standard, and there is a risk of transmission parts breaking.

Operation and maintenance costs increase, frequent shutdowns for clearing blockages cause waste of man-hours, maintenance manpower, and spare parts replacement costs increase, while delaying delivery cycles and reducing economic benefits.

By optimizing feed particle size control, strengthening discharge system monitoring and other measures (such as patented design of the guide mechanism), blockage can be effectively reduced to ensure the continuity and stability of the steel slag production line.