Cement ball mills are widely used in cement, silicate products, new building materials, refractory materials, fertilizers, black and non-ferrous metal dressings, and glass ceramics industry. As for types of cement ball mill, there are normal cement ball mill and super-fine cement ball mill.
The material is uniformly fed into the first bin of the cement ball mill by the feeding device through the hollow shaft. The first bin has stepped lining or corrugated lining, which is filled with steel balls of different specifications. The rotation of the cylinder generates centrifugal force to bring the steel ball to a certain height, and balls falling down, will hit and grind the material. After the material reaches the rough grinding in the first bin, it enters the second bin through the single-layer transfer partition. The second bin is embedded with a flat liner with steel balls inside to further grind the material. The powder is discharged through the discharge grid.
As one of leading cement ball mill manufacturers, AGICO Cement can provide high-quality cement ball mill with ultra-low prices, our exports has rich experience in the cement ball mill design, also provide you with good concentrator design technology and processing equipment configuration scheme, we can offer customization service meet various needs from different clients. Our cement ball mills are factory-direct, less human cost and materials cost decide competitive price of cement ball mill.
The cement ball mill has reasonable structure design, simple operation, large handling capacity and low failure rate. The wear-resistant parts are made of ultra-wear-resistant materials, which can reduce the exchange cost of the vulnerable parts and control your production and maintenance cost.
Our cement ball mill adopts advanced technology, reasonable structure design, low maintenance rate; The base is made of channel steel, and the body is made of welded steel plate with good quality and high wear resistance. The inlet head and shaft head of the spiral shaft are provided with pig iron cover, which is safe and reliable to operate, and the failure rate is lower than twice that of other competitors. Please be assured to buy.
Our cement ball mill is more scientific, reasonable in the design of its structure, appearance compared with other manufacturers, ball mill body smaller 1/5, covers less area, infrastructure investment also can reduce 1-20000 yuan, is worth looking forward to and trust!
The company addressed the Facility for a loan and advisory package. The projects engineering team analysed various aspects of investment, primarily the potential for energy savings, financial-technical parameters and risks. With the 30-40 year old grinding mills, engines in poor condition, outdated pressure and voltage indicators with lack of capacitors and a classifier at the production line, the potential for optimisation and savings was substantial.
The $1.5 million investment allowed the company to improve the energy performance and increase reliability of the production cycle. The implemented measures generate $308,000 cost savings per year due to the reduction of electricity consumption by 41 per cent. The investment will repay itself out of energy savings in six years, turning the future cash-flows into company income for years to come. This is not including the operational and maintenance costs reduction, coming from fewer repairs and improved production.
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Casting Steel Ball Manufacturing Process Due to the natural solidification of molten steel, the cast steel balls will inevitably have defects such as loose internal structure and air holes after forming, which will lead to brittle, eccentric wear and out of round phenomena in the use of steel balls. The quality of cast steel ball mainly depends on the content of chromium. In recent years, the price of chromium has gone up all the way and environmental protection and other factors have led to the increasing cost of cast steel ball.
Using high manganese steel as the raw material, using air hammer to install the spherical mold for forging, which has the characteristics of small investment and fast starting, but high dependence on people.
The forged steel ball has all the attributes of forging, so the quality is the best in these kinds of steel ball manufacturing processes. Generally, the steel ball making machine used is air hammer, which has the advantages of small investment and fast starting, but it has strong artificial dependence and low production efficiency.
The surface quality of the forged steel ball, the impact resistance, and the wear resistance are all good, the toughness is strong, and it is not easy to be broken and loss round. We use forging and press methods, which can heat the metal until the temperature reaches 1100C(50C), and use the forging machine to apply pressure to the metal blank to plastically deform it to obtain the forging with certain mechanical properties, shape and size. method.
Through forging, defects such as as-cast looseness caused by metal in the smelting process can be eliminated, optimize the microstructure, and at the same time, the mechanical properties of the forgings are generally better than those of the same materials due to the preservation of the complete metal flow lines.
Forged steel balls are precise in size, high in roundness, high in hardness, and have mechanical properties. It is wear resistant, not easily deformed and broken. It can be fully reflected by the high hardness. The surface hardness is as high as 57hrc to 67hrc, the volume and hardness are as high as 56hrc to 64hrc, the hardness distribution is uniform, the impact toughness is more than 12j/cm2, the breakage rate is low, and the anti-fatigue drop test is more than 20,000 times. The actual damage is caused. The rate is no more than 1%, close to 0.
We have made a comparison between the cast steel ball and our forged steel ball. The results of the two are 0.9kg/t and 0.6kg/t respectively in domestic iron mines. From the data, we can see that using forged steel balls, the consumption of one ton of ore is reduced by 33.3%.
Using high manganese steel bar as raw material and using the rolling mill with special spiral hole mould for production, the production efficiency is high, the automation degree is high, but the investment cost is also high.
The bar used for rolling the ball is rolled, so the structure of the ball is relatively uniform. However, the rolling process only shears and rubs the bar, which does not meet the requirements of forging ratio, so it does not have the properties of forging completely. The production equipment used is the production line of steel ball skew rolling mill, which has the characteristics of high production efficiency and full-automatic production.
Although the quality of forged steel ball is good, but ouput is low and rely on much of labor. In order to solve this problem, Anyang Forging Press has developed the technology of forging-rolling by combining forging automation with practical experience of steel ball production. The process combines the characteristics of forging and rolling steel balls, and takes CNC die forging hammer or electric screw press as the core steel ball making machine, matching bar cutting machine, forging manipulator, rounding machine and other equipment to achieve full-automatic and efficient production of forged steel balls.
The Spring Festival holiday has just ended, and Anyang Forging Press's orders have come one after another. All the employees ushered in a full-blown working day. In the various workshops of Anyang Fo......
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Forging is a characteristic material shaping process where material forming takes place by hammering the material into a characteristic shape. Traditionally, all forging processes are manual or powere......
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1. What is an air hammer Air Hammer, also known as Pneumatic Hammer, Power Hammer, is a kind of free forging machine. It is suitable for all kinds of free forging: such as extension, upsetting, punch......
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Before purchasing an ore beneficiation plant, people have lots of concerns: Which equipment I should choose to process my iron ore? Is this ore processing flowsheet best? Can these machines help me remove sulfur in iron ore beneficiation? Would they increase the recovery rate of tailings?
Then how to choose the right ore beneficiation plant depends on a lot of factors including physical properties of raw ore, capacity demands, final ore product requirements, geological situations of ore mines, and so on.
Here Fote Group would love to share valuable information about mining market trends, ways to build a high-quality ore beneficiation plant, and ten different ore processing plants which have been proved successful by our customers. If you have any most pressing questions and concerns, please contact our professional engineers who can make customized solutions according to your actual situation.
Our ore beneficiation plants sale to many countries, such as India, Australia, the USA, the UK, Canada, Switzerland, Philippines, Malaysia, Thailand, South Africa, Sudan, Egypt, Kenya, Indonesia, Nigeria, etc.
Nowadays, with ways of ore processing are getting more and more diversified and intelligent, the investment is not only limited to gold ore beneficiation but enlarged to many other items. From precious metals to coal, and to non-ferrous metals, investors can profit and bring more economic benefits to society.
Over 80 kinds of ores are widely used minerals in the world. Due to large output and high international trade volume, there are the several most common and important ores such as iron ore, copper ore, gold ore, bauxite, coal, lead&zinc ore, nickel ore, tin ore, and manganese ore, etc.
Nothing can replace iron ore in developing infrastructures as well as coal ore in the electricity industry, those ores making a great contribution to countries' economic growth. Gold ore mining ranks in a top position, attracting lots of investment for closed relations between the gold price and currency market.
The screening and crushing process is used to release useful minerals from the gangue. Different types of crushers reduce large sizes of raw ore into smaller ones, then vibrating screen with different mesh would help to get the desired size of ores. During the process, how many crushers need to be installed according to your real situation.
Usually, there are crushers with three crushing stages: primary crushers like jaw crushers, secondary crushers like cone crushers, roll crushers and impact crushers, tertiary crushers like compound crushers and fine crushers. Vibrating screens also have different types: Circular motion vibrating screens, horizontal Screens, high-frequency Screens, and trommel/ drum screens.
Only by crushers cannot get ore products with fine granularity, that's why mill grinding machines necessary in the beneficiation process. The mill grinding process is almost carried out in two consecutive stages: one is dry grinding (coarse grinding) and the other is wet grinding (fine grinding). The key grinding equipment are ball mills and rod mills, and the latter is now mostly used for wet grinding to finally produce fine and uniform ore products.
The beneficiation process is most crucial during the whole plant, helping people extract high value and pure ore concentrate products from ores no matter its grade high or low. The beneficiation process can be carried out in a variety of ways as needed but you ought to select a piece of optimal equipment to avoid inefficiency and waste in the entire process. The most common beneficiation equipment includes flotation machines, electrostatic and magnetic separators, and gravity beneficiation equipment.
Ore drying equipment may appear in any stage of a mineral processing plant (from raw ore-concentrate-finished product). The purpose of drying is to remove the moisture contained in the ore, ensuring the integrity of the product, and maximizing the value. In addition, drying process can also reduce product transportation costs and improve the economic efficiency of storage and processing.
With almost 50 years' extensive experience, Fote engineers are professional in integrating, designing, fabricating, commissioning, maintaining, and troubleshooting various beneficiation plants. The company aims to provide customers with the best mining equipment and the most reasonable beneficiation plants. Its final goal is to increase the potential profit that customers can obtain from the ore and enable mining companies to improve the overall profitability.
5TPH low-grade gold ore beneficiation plant in India 10 TPH gold ore beneficiation plant in South Africa 20-35TPH gold ore beneficiation plant in Egypt 10 TPH iron ore beneficiation plant in the USA 10-50TPH copper ore beneficiation plant in Pakistan 50-100TPH manganese ore beneficiation plant in Kenya 150TPH Bauxite ore beneficiation plant in Indonesia 50TPH lateritic nickel ore beneficiation plant in Philippines 200TPH zinc & lead ore beneficiation plant in Nigeria 250TPH chrome ore beneficiation plant in Russia
As a leading mining machinery manufacturer and exporter in China, we are always here to provide you with high quality products and better services. Welcome to contact us through one of the following ways or visit our company and factories.
Based on the high quality and complete after-sales service, our products have been exported to more than 120 countries and regions. Fote Machinery has been the choice of more than 200,000 customers.
Leading supplier of high alloy castings and forgings. There are 4 companies with sales of more than 100 million yuan, across the 4 major areas of wear resistance, heat resistance, corrosion resistance, and machinery
To start with, for better results, the liner should be made up of alloys which are best suited to operating conditions in each plant, are cost-effective and have longer lifetime. However, in order to maintain the good performance of a ball mill, it is necessary to carry out the maintenance work regularly. Replacement of a ball mill liner is one of the things that need to be considered for better performance.
WHEN TO REPLACE A BALL MILL LINER? You do not have to replace a ball mill liner regularly except under particular conditions. The ball mill will usually work for a long time without any damage unless the depth of lining wear is enough to have a serious impact on safe operation and efficiency of a ball mill. If depth of lining wear is serious, you should replace the ball mill liner as soon as possible. This is because a ball mill liner protects the barrel of a ball mill by reducing the friction of abrasive materials and body on it.
WHAT THINGS SHOULD BE CONSIDERED BEFORE REPLACING A BALL MILL LINER? Replacing a ball mill liner is not only a cumbersome task but also, a technical one which requires expertise and high-quality work. Before carrying out this task, you should always take steps for the safety of workers. Additionally, an appropriate ball mill liner replacement will increase the efficiency and working of ball mill for a long time. Moreover, it will also ensure the safety of ball mill.
1. CONSIDER THE SPECIFICATIONS OF BALL MILL LINER Before replacing a ball mill liner, you should consider its specifications such as impact resistance, wear resistance, shape and material of the liner.
2. PROFICIENCY IN OPERATION As mentioned before, replacing a ball mill liner requires both expertise and high-quality work. Therefore, you require a team under an experts supervision who know the installment requirements. In other words, proficiency is required in this operation.
3. SUITABLE ENVIRONMENT FOR REPLACEMENT It is necessary to have a suitable environment for replacement process. Good ventilation system along with suitable temperatures are crucial as the worker will have to enter the ball mill barrel for replacement process. In addition to it, you must circulate the remaining pulp in the ball mill, clean, dust and descale the entire cylinder in order to replace the ball mill liner.
4. PAY ATTENTION TO SAFETY Before removing old mill liner, you should remove the used lining screws. Furthermore, pay attention to the safety of workers so that they may not get injured by ball mill liner.
5. DOUBLE CHECK THE INSIDE AND OUTSIDE OF CYLINDER After replacing the ball mill liner, you should double check the inside and outside of cylinder to confirm that there is no working tools, person and other irrelevant things left in cylinder.
The grinding efficiency is the most important parameter to evaluate machine performance. This article discussed the factors that influence grinding efficiency including article size to mill machinemilling mediumslurry rheological propertiesunderflow ratiolinergrinding aid etc. The mill machine should be automatically controlled at a high level.
Ore grinding is a very important section in concentrators, which provides qualified grain grade materials for the subsequent mining processing operation. Grinding accounts for a great proportion of the basic construction investment of the concentrator, it is also consumed steel and energy high. According to statistics, the energy consumption of the crushing and grinding operation accounts for about 65% ~ 75% of the total energy consumption of the concentrator, and the steel consumption accounts for almost 100%. Therefore, it is of great economic and social benefit to correctly select the grinder mills, optimize the operation and improve the grinding efficiency.
In the most grinding process of the concentrator, the construction investment and production and operation cost of grinding operation is much higher than those of crushing operation, so it is necessary to reduce the grinding particle size as much as possible. The finer the grinding particle size is, the higher the grinding efficiency is, and the lower the steel ball consumption is. At present, more crushing and less grinding is one of the main principles of concentrator design and production. Take a gold mine as an example, reducing ore particle from -15mm to -10mm improve the grinding efficiency from 1150 tons per day to 1500 tons per day, and decrease the steel consumption and electric power consumption by 1.53kg/t to 1.1kg/t and 41.57kWh to 29.2kWh respectively.
Grinding mill medium is the main factor affecting grinding efficiency. In industrial production, the type, shape, size ratio and filling rate of grinding medium should be determined according to the grain size characteristics, hardness characteristics and product particle size requirements of ore materials.
The medium filling rate is the volume ratio of the medium and grinding cavity, moves in throwing and falling state in a ball mill. The throwing motion medium is used to smash large ore, and the medium of falling movement mainly plays the role of grinding. The filling rate of the fine grinding mill is about 5% lower than that of the coarse grinding. The motion state of the medium in the mill is related to the medium filling rate. There is friction force between the medium and the liner. When the filling rate and the friction force are large enough, the liner can bring the grinding medium to the height of the throwing point. It is also important to note that the medium filling rate should not exceed the limit. By the way, the larger the diameter of the ball mill, the lower the filling rate. For the rod mill, the filling rate is generally 10% lower than that of the ball mill of the same specification.
The grinding efficiency is reflected in the processing capacity of the mill and the fineness of the grinding ore. Large diameter steel ball help reduces grinding time thus improves grinding efficiency, in addition, putting some small steel ball to control the particle fineness effectively. In fact, the steel balls are continuously worn and the straight diameter is gradually smaller, so it is difficult to guarantee the ratio of the diameter of the steel ball to keep a stable level.
In the past few decades, researchers have done much work on finding the best shape of grinding medium. Practice shows that the ball mill can reach the finest grain with a lower cost under the regular grinding task requirements. Ball mill or rod mill, is there any else? Some researchers are focusing on a new type of grinding medium called spherocylinder in which has the combination of ball and rod. Experiments show that the spherocylinder grinding speed of the particle is bigger than 500m is faster than that of the ball mill. Besides, owing to the great features of selective grinding and fine grinding, the spherocylinder mill is definitely a good alternative shape to handle the grinding tasks.
Rheology is the science of studying the flow and deformation of objects. The slurry is often considered to be a fluid, which is deformed under stress. The concentration of slurry, particle shape, and particle size distribution are the important factors affecting the slurry rheological properties. From the analysis of the slurry rheological properties and the grinding speed, it can be seen that the grinding concentration affects the slurry liquidity, ore particle adhesion degree, and grinding efficiency. When the concentration/ thickness is too low, the slurry flows quickly and the adhesion degree on the medium is low, which weakens the impact and grinding force grinding mill apply on the ore material. Contrarily, high concentration, high adhesion may slow the flow speed, cause over grinding thus influence the production capacity. Practices show that only appropriate concentration can fulfill the grinding process at its best. For your reference, the grinding concentration of ball mill should better adjust to 72% 82%.
Regrinding sand is a kind of ore with unqualified particle size but close to qualified after grinding process, which is returned to the mills for regrinding. At usual, the grinding efficiency of the inner cavity is not balanced, the efficiency is gradually decreased from the feeding end to the discharging end because of the uneven distribution of the coarse grain along the axial direction. Based on the crushing theory, increasing the amount of regrinding sand does not increase the power consumption of the mill, but only speed up the slurry flow. In addition, thick and coarse regrinding speeding up the slurry flow can make the coarse grain distributed more evenly, thus improve the steel ball grinding performance and efficiency.
The liner plays the role of protecting the cylinder and end cover of the mill and lifting the grinding medium. The shape and material of liner have a great influence on the steel consumption of grinding. In addition to the traditional manganese steel liner, there are rubber liner and magnetic liner.
The consumption of mill liner accounts for a large proportion of the mineral processing cost. In recent years, some new wear-resistant materials have appeared. Among them, rubber liner has been well popularized because of its wear-resistant, long life, energy saving, noise reduction and so on. Because of the soft material, the rubber liner plays the role of cushioning on the cylinder. In the rough grinding operation, the impact of the steel ball will be cushioned, which reduces the production efficiency of the mill. But in the fine grinding task, the rubber liner can bring its superiority into full play.
The magnetic liner uses the magnetism of liner itself to adsorb a layer of ferromagnetic materials in the cylinder, including magnetic minerals, broken steel balls, etc., to form a protective layer of liner, so as to prevent the liner body from being worn out and prolong the life of the liner. Magnetic liner is mostly used for fine grinding.
Grinding aids are a kind of grinding auxiliaries, which can accelerate plastic deformation, promote crushing process, prevent condensation and adhesion. A small number of grinding aids can improve the grinding efficiency and reduce the power consumption of grinding.
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