ball mill liner design

ball mill liner design

There are many different designs and styles of ball mill liners. As with grinding balls local economics and ultimately operating costs determine the best design and material to use. The initial set of liners is rarely the final design selected. Based upon individual experience, mill superintendents develop preferences for liner designs. The following is given as a guideline for the initial set of liners.

For 60 mm (2.5) and smaller top size balls for cast metal liners use double wave liners with the number of lifters to the circle approximately 13.1 D in meters (for D in feet, divide 13.1 D by 3.3). Wave height above the liners from1.5 to 2 times the liner thickness. Rubber liners of the integral molded design follow the cast metal design. If using the replaceable lifter bar design in either metal or rubber the number of lifters should be about 3.3 D in meters (for D in feet* divide 3.3 D by 3.3) with the lifter height above the liners about twice the liner thickness. The use of double wave liners, particularly when using 50 mm (2) or larger balls, may show a loss of 5% or so in the mill power draw until the waves wear in and the balls cannest between the lifters.

When liners, and double wave liners in particular, wear with circumferential grooves, slipping of the charge is indicated, and this warns of accelerated wear. When the top size ball is smaller than 50mm (2.5) and mill speed is less than 72% of critical wear resistant cast irons can be used. For other conditions alloyed cast steel is recommended.Rubber liners are well suited to this same area and not onlyreduce operating costs but can reduce noise levels.

Single wave liners are recommended for larger size balls (50mm/2.5 and larger). The number of the lifters to the circle equals approximately 6.6 D in meters (for D in feet, divide 6.6 D by 3.3). The liners are from 50 to 65 mm thick (2 to 2.5) with the waves from 60 to 75 mm (2.5 to 3) above the liners. The replaceable lifter bar design madeof either metal or rubber in about the same design proportions can be used. There could be a loss in power with rubber particularly if the mill speed is faster than about 72% of critical speed, and the ball size is larger than 75 mm. Because of the impacting from the large balls, single wave liners for ball mills are usually made from alloyed steels or special wear-resistant alloyed cast irons. Because of the difficulty of balancing growth and wear with work hardening manganese steel is used infrequently and then with extreme care to allow for growth.

When a grate discharge is used the grates and wear platesare normally perpendicular to the mill axis while the discharge pans conform to the slope of the mill head. The grates and wear plates are normally made from alloy wear resistant cast steel or rubber. They are ribbed to prevent racing and excessive wear. The dischargers and pans are generally made from either wear resistant cast ironor rubber, or wear resistant fabricated steel.Slot plugging can be a problem in grate discharge mills. Whether the grates are made of metal or rubber the slots should have ample relief tapered toward the discharge side. Total angles 7 to 10 degrees (3.5 to 5 degrees per side) are commonly used. Metal grates often havea small lead-in pocket or recess which can fill in with peened metal rather than have the slot peen shut. With the proper combination of metal internals and rubber surfaces, rubber grates have flexibility that tend to make them self cleaning and yet not fail due to flexing.

Except when using rubber liners, the mill surfaces are covered with a protective rubber or plastic material toprotect the surfaces from pulp racing and corrosion. This is done in wet grinding mills. Since dry grinding mills get hot due to heat from grinding generally rubber liners and rubber materials cannot be used.

Shell liners may be furnished of various materials and of several designs. In each case the material used is the best obtainable, resulting in the lowest cost per ton of ore ground. The liner contours are selected for the specific grinding application and take into consideration liner wear, scrap loss, and mill capacity.

Liners cast of Manganese Steel, Ni-Hard, Chrome-moly, or other similar materials may be of the step type, block type, wave type, or the two-piece plate and lifter construction. These are illustrated on the right. During the past years of building ball Mills various other shapes of liners have been tried, such as the pocket type, spiral liners, etc.; in most cases it is found that these special shapes and designs are not justifiable from the standpoint of economics. They involve additional costs which are not generally recovered from an increased efficiency in milling operation.

Lorain Shell Liners consist of high carbon rolled steel plates accurately formed to the mill shell radius. These are held in place by rolled alloy steel heat treated lift bars. This type liner is carefully engineered for the specific grinding application. Variations in lift bar design and liner plate thickness provide this flexibility of design for application.

All shell liners designed for ball mill operations are of such size and shape that they will easily pass through the manhole opening to facilitate relining operations. In rod mill work the design is such that they will easily pass through the large ball open end discharge trunnion.

Where cast liners are used, and especially in rod mill applications, we furnish rubber shell liner backing to help cushion the impact effect of the media within the mill and prevent pulp racing. With the Lorain type of liner such shell liner backing is not required. For special applications where severe corrosive conditions exist a shell liner of special alloys can be furnished and also the interior surface of the shell can be treated to protect such parts from the corrosive conditions.

Head liners are of the segmental type constructed of Manganese Steel, Chrome molybdenum, or Ni-Hard and are designed to pass easily through the manhole opening or discharge opening in the case of rod mills. For ball mill work ribs are cast with the feed head liners to deflect the ball mass and minimize wear on the headliner itself.

Where cast liners are used shell liner bolts and head liner bolts are made of forged steel with an oval head to prevent turning and loosening within the liners. These are held in place with two hex nuts and a cut washer. For wet grinding applications special waterproof washers can be furnished.

Theeffect of liner design upon mill performance appears to have received little attention. Clearly, the main function of the liner is to form a removable surface to the null body, which may be replaced when seriously worn.

It is also clear however, that the metal plates which serve this purpose may have a surface which ranges from smooth in one which carries an intricate pattern of raised bars or sunken depressions. The merits of the various types do not appear, however, to have been studied.

where smooth liners are those which have projections insufficient to give appreciable keying between the liner and the ball charge, whilst lifter liners are those which are so heavily ribbed as to give rise to appreciable interlocking between the balls and the liners.

Various common types of liners are illustrated in Fig. 6.12. Although these liners have various patterns of projections, or depressions, to give an amount of interaction between the liner and the grinding medium, it would be expected that wear would round the edges. It is doubtful whether, after some time in service, the performance of a mill with these liners differs appreciably from that of a mill with a smooth surface. Liners furnished with heavy lifter bars are also sometimes used and in such a case the locking of the ball charge to the shell must be very effective. Nevertheless, although a few vague general statements to the effect that a lifter mill gives a product with different size characteristics to that of a smooth mill have appeared, the point does not appear to have been widely investigated. It is probable, however, that, on the grounds of differences in the size characteristics of the products, there exists no sound reason for the use of lifters in preference to the normal smooth liners.

It is possible that, when a material with a low coefficient of friction is milled, the charge might slip on a smooth mill shell, with consequent loss of grinding capacity, and in such a case the use of lifter bars might well be the solution. It has also been suggested by one of the authors, Rose, that the use of lifter bars might eliminate the surging of the charge sometimes encountered in mill operation.

An entirely different conception of the duty of the mill liner underlies the design of the studded liner developed by Usines Emile Henricot of Count St. Etienne. These liners, illustrated in Fig. 6.12 and Fig. 6.13, consist of comparatively thin plate liners with uniformly spaced studs on the working surface; these studs being integral with the plate. Provided the spaces between the studs are not allowed to become choked with tramp-iron, etc., the studs furnish a good key between the shell and the charge which, it is claimed, leads to a greater power consumption and to improved grinding. Furthermore it would appear that the studs impose a definite geometrical arrangement in the outer layer of balls which, in turn, brings about a closer packing, throughout the ball mass, than obtains with conventional types of liner. This effect would also lead to improved performance. Evidence of this effect of the studs upon the packing of the charge appears in Fig. 6.13b, for the balls are clearly seen to lie in rows in the mill instead of in completely random array.

An incidental merit claimed for these liners is that the high bearing pressure between the balls and the studs of the liners leads to work hardening of the studs; with a consequential reduction of the rate of metal wear.

The Henricot liners, which have been discussed in a paper by Belwinkel, appear to be the only attempt so far made to influence the grinding characteristics of a mill by means of correctly designed liners. It would therefore appear that there is some room for development in this direction.

types of mill liners cp west palm beach

types of mill liners cp west palm beach

When talking about the ball mills, it involves the steel balls or even the hard pebbles which can break them into fine particles which are purely based on the impact as well as the attrition. A rotating mill comes with the charging with the media and the ore in this is lifted against the perimeter which is present inside of it. Some of the media that are being charged by the rotating mill fall and it impacts the particles of the ore that are located at the bottom of the mill. The rest of the media which is left is made to cascades and, in this process, it can create the breaking of the particle with the help of the attrition.

Ripple Liners: Talking about the first one is the ripple liners in which the system of the grinding is the small section that consumes the power mostly present in the processing plant of the mineral. It is responsible for up to 40% of the total consumption of the power in the processing plant operations related to the minerals. So, the selection of the solution which is efficient in nature for the section of the grinding is found to be very important in the mill liners. The providers that look promising usually provide the system of grinding of the ball mill or even the rod mill which is widely used in various types of mineral extraction and has also found its popularity in the electricity, cement, and chemical industries. It can carry out the crushing of either the dry or the wet and is also capable of meeting the demand for sustainable production at a large scale in the mill liners.

Rod Liners: Out of all the cast materials being used for the linings are the Nickel hard, steel made up of the chrome molybdenum, and along with that the steel which is made up of the manganese. The steel plate which has rolled the steel over it has the lifter bats available with it. The rod liners are made to have exposed to the impacts of the severe level. For the duty of grinding, the right selection of the liners is necessary and for that premature breakage is considered.

Shiplap Liners: The shiplap liners are nothing but the plates that have the longitudinal lining for the ball mill in the mill liners and are available in the shape of the wedgelike. The edge which is thin in the density of each wedge lies beneath the edge which is thick in density and it belongs to the preceding plate which is in the direction of revolution. The shiplap liners are simply the liners that get attached to the form that is using the screws of the TEK with the help of the face of the linear spacing of about 12 C-C.

Lifter bars: When the lifter bars are taken as a liner, they are used for the protection of the head of the ball mill in the mill liner from direct impact and along with that the friction is also avoided which is caused by the grinding medium and correspondingly the material. This kind of Mill Liner is found to be excessive in use in all kinds of working conditions so that it can increase the efficiency of the grinding and along with that the production and it might be proved as a reduction in the consumption of the metal.

home-ball mill rubber liners_compound mill rubber liners_ceramic mill rubbe liner - kosga

home-ball mill rubber liners_compound mill rubber liners_ceramic mill rubbe liner - kosga

We focus on quality, competitive prices and on-time delivery, Our team used our knowledge of the Manufacturing process in China, And a supply network of raw materials that we trust and meet Kosgas requirements, Support each customers product requirements from start to finish.

Throughout the process, you will benefit from our supportive services, Our years of experience and our expertise in each product category, We calculate the most competitive prices and provide the highest quality products, We can also replace the raw materials needed for your products.

We focus on quality, competitive prices and on-time delivery, Our team used our knowledge of the Manufacturing process in China, And a supply network of raw materials that we trust and meet Kosgas requirements, Support each customers product requirements from start to finish.

Throughout the process, you will benefit from our supportive services, Our years of experience and our expertise in each product category, We calculate the most competitive prices and provide the highest quality products, We can also replace the raw materials needed for your products.

Kosga Industrial Limited is a global leader in the design & production of consumables for the mineral beneficiation, mining & bulk solids handling industry. Headquartered in Qingdao, China, Kosga offers a range of wear resistant products and services required for mining, mineral processing, screening, grinding, material handling and beneficiation of minerals. Kosgas philosophy is to uphold traditional values through the empowerment of professionals, providing technical and economically unrivalled solutions to complex problems in mining, beneficiation, power, material handling and engineering.

In the mining, mineral processing, screening, grinding, material handling and beneficiation of minerals, it is inevitable to face challenges. Our skilled service personnel have the solutions and products you are looking for and deserve your long-term trust. They are willing to work together with your team to overcome these challenges by providing process solutions and helping you to obtain the maximum operating income.

ball mill liners selection and design | ball mill rubber liner

ball mill liners selection and design | ball mill rubber liner

The ball mill liners are located on the inner surface of the ball mill barrel, which protects the barrel from the direct impact and friction of the grinding media and the material. The ball mill liners material and shape are different which base on requirements. When the grinding media contacts with different shape of ball mill liners, the movement state will also change, thus enhancing the crushing effect on the material. This design of the mill liners effectively improves the grinding efficiency of the ball mill machine, increases production, and reduces metal consumption.

The grinding mill liners are the main wearing part of the ball mill equipment. The ball mill liner replacement should in time when the lining plate is excessively worn. Therefore, the selection and design of mill liners have always been of great concern to users.

As one of professional ball mill liners manufacturers, we summarize the main functions of the three-point ball mill liners. It mainly involves the protection of the barrel and the control of the grinding medium.

The mill liner is installed inside the ball mill barrel, separating the grinding media from the barrel, effectively buffering the direct impact of the grinding media on the barrel. Therefore, the barrel is protected, and the service life of the barrel and the entire ball mill equipment is prolonged. The ball mill liners are embedded with the barrel, and at the same time, the rigidity of the barrel is enhanced.

Due to the special shape of the grinding mill liner surface, the grinding media contacts the grinding mill liners, and the huge friction force drives the steel ball upward. The steel ball is lifted to a certain height and dropped, while impacting and grinding materials.

Angle spiral grinding mill liner and cone classification liner have automatic classification function, which can make grinding media of different quality in the cylinder carry out reasonable forward classification along the axial direction of the mill and the change of material size. The automatic grading ball mill liners enable the larger steel balls in the barrel to be concentrated at the feed end to crush larger materials, while the smaller steel balls are concentrated at the discharge end to crush smaller materials.

Different ball mill equipment is suitable for different grinding materials, and the type of grinding mill liners selected will also be different. For example, is the rod mill liners the same as the sag mill liner design? Which type of cement mill liner should be used to grind cement in order to reduce the frequency of ball mill liner replacement as much as possible?

According to the material classification, the common ball mill liners mainly include high manganese steel mill liners, alloy steel mill liners, rubber mill liners, ceramic mill liners and magnetic mill liners.

The mainstream ball mill liners materials currently used in the market are alloy steel and rubber. Alloy steel mill liner is wear-resistant and impact-resistant. Alloy steel has good physical and chemical properties due to its alloy properties, and its service life is more than twice that of high-manganese steel. The ball mill rubber liner has a high wear resistance index, high rebound rate, and high abrasion resistance and tear strength. It also has the advantage of reducing noise.

According to different grinding requirements, ball mill liners are roughly divided into 9 types, which are wedge-shaped, corrugated, flat-convex, flat, stepped, elongated, rudder-shaped, K-shaped ball mill rubber liner and B-shaped ball mill rubber liner. These 9 kinds of grinding mill liners can be classified into two categories: smooth grinding mill liner and unsmooth grinding mill liner.

The smooth grinding mill liner has a large sliding property, has a strong grinding effect, and is suitable for fine grinding processes. The friction of the unsmoothed grinding mill liner is large, which can improve the material and steel ball very well, and has strong agitation effect, so it is more suitable for rough grinding process.

As a ball mills supplier with 22 years of experience in the grinding industry, we can provide customers with types of ball mill, vertical mill, rod mill and AG/SAG mill for grinding in a variety of industries and materials.

ball mill liners

ball mill liners

Ball mill linersfrom Multotecmaximise the lifespan and performanceof your ball mill, with a selection of rubber and rubber composite liners available. Refined through ongoingdesign improvements, our ball mill linersmaximise uptime and service intervalswhile providing animproved crushing of the ore.

Our ball mill liners are the result of state-of-the-artsoftware-drivendesigns with industry-leading inspection data, achieving an optimal charge trajectory and rate of wear life for your ball mill. We ensure your ball mill liners are fitted with precise levels of workmanship, facilitating maximum mill uptime for increased production. Our ball mill liners are available in a wide range of dimensions, designs and profiles. They can be tailored to the specific application requirements of your mineral processing operation, with different rubber formulations and attachment system materials available. With these options, Multotec ensures your ball mill liner can tolerate corrosive levels of acidity and diesel.

Our ball mill liners solutions can be fitted with MultoMet composite lifter bars, shell plates and head plates. The MultoMet range utilises Hardox 500 wear-resistant steel, attached to the leading edges of the lifter bar array and embedded within shell plates and head plates, ensuring maximum abrasion and impact resistance.

Shell Plates Shell plate thickness can vary, which helps both in balancing mill capacity as well as extending ball mill liner life. For arduous milling applications, or where drilling patterns produce shell plates that are too wide, thus exposed to high wear, shell plates with Hardox strips can be utilised. Lifter Bars Available in a range of profiles and dimensions, lifter bars increase the efficiency of the milling operation by maximising the agitation of the ore. The impact and abrasion resistance of these bars is maximised by Hardox 500 steel along the leadings edges of these components. With a high-quality attachment system, lifter bars are easy to install to the ball mill liner. Head Plates We custom-design head plates according to each ball mill to ensure maximum performance and lifespan. Most commonly, our head plates are built from high-quality, specially-formulated rubber. In arduous ball mill applications, Hardox strips can be fitted to the head plates to increase their operational life. Grate Plates Grate plates are available in a range of aperture sizes and configurations. Internal frames are designed for different mill loads, and it is possible to use semi-overflow designs in order to control the pulp level in the mill. Different options for extending plate life exist as required by your application, such as built-in MultoMet lifter bars. Pulp Lifters Manufactured with a rubber-lined fabricated steel base, our pulp lifters use high-quality designs that ensure a correct volumetric flow of the pulp. Rubber wear plates designed to be bolted onto the high-wear areas of the ball mill liner improve the performance life of your mill. Central Cones These components assist in the controlled discharge of the material, maintaining mill capacity across the operation. Cones are provided in segments, which are then assembled inside the mill. This enables easier handling and manageability. Trunnion and Bell Mouth Liners Manufactured with a fabricated steel base that is then rubber lined. Loose steel-reinforced rubber liners are also used in larger trunnions. Filling and Support Segments Extend the wear liner to the corners of your ball mill andscrubber, enabling a clean, smooth lining across the ball mill liner.

high quality mill liners manufacturer | qiming machinery

high quality mill liners manufacturer | qiming machinery

Qiming Machinery is a leader in the design, manufacture, and supply of mill liners for mineral processing and quarrying industries. We offer our customers complete wear liner solutions for mills that increase performance, equipment availability, and lower maintenance costs. Our mill liners are also tested to withstand the acidity level of different elements that may be present in the milling process. Longer milling life to your machine means fewer expenses and more profit or income to your company.

Qiming Machinery mill liners are subjected to different combinations of impact and abrasion, as they are used in SAG/AG, ball or rod mills. Our wear parts are manufactured to the highest standards of quality and delivery, ensuring high levels of reliability for our customers. Also, our mill liners wear parts that add value to customers processes through customized designs.

When choosing any type of mill liners for your mill plants, think long-term. Qiming Machinerys parts help keep your mill plants working at peak performance because they are made to fit and function for just that.

SAG is an acronym for semi-autogenous grinding. SAG mills are autogenous mills that also use grinding balls like a ball mill. SAG mill is usually used to grind large pieces into small pieces, especially for the pre-processing of grinding circuits, thus also known as primary stage grinding machine.

AG is short for the autogenous mill. it combines with two functions of crushing and grinding, uses the ground material itself as the grinding media, through the mutual impact and grinding action to gradually reduce the material size.

Ball mill is a fine grinder. A horizontal or vertical rotating cylinder is filled partially with the balls of ceramics, small rocks, and balls made from stainless steel. The ball charge of a SAG mill is about 29% to 30%. By friction and influence of tumbling balls inside the rotating cylinder grinds the raw material to the required fineness. The internal machinery of the ball mill grinds the raw material into the powder-like material, And if extreme fineness and refinery are required then rotation goes on to continue.

The role of a ball mill liner is to give the mill heads protection against wear and tear thus increasing their lifetime and creating optimal grinding efficiency. Qiming Machinery can design and supply mill liners for all types of ball mill.

Rod mills are very similar to ball mills, except they use long rods for grinding media. The rods grind the ore by tumbling within the mill, similar to the grinding balls in a ball mill. To prevent the conditions leading to rod charge tangling, the length to diameter ratio is maintained at 1.4 to 1.6. Rod mills accept feed up to about 50 mm (2 in.) and produce a product in the size range of 3000 to 270 mm (4 to 35 mesh). Grinding action is by line contact between the rods extending the length of the mill. Rods tumble and spin in roughly parallel alignment simulating a series of roll crushers. This results in preferential grinding of coarse material and minimizes the production of slimes.

This is used for grid liners and generally smaller mills. Its great advantage is that it works hardens under stress, yet the substrate remains tough and can withstand extreme impact without fracture. Its primary disadvantage is that it spreads with impact, so solid liners begin to squeeze together and become extremely difficult to remove, and can damage a mill shell if the stress is allowed to build up to an extreme level.

Low Carbon Chrome Moly Steel (300 to 370BHN):Was generally used for mill liners (AG, SAG, and Ball) prior to the movement to higher carbon content steels. It has excellent wear characteristics with some impact resistance, generally now used for discharge grates where slightly better impact resistance is required compared to the higher carbon chrome-moly steels or for thinner section liners.

High Carbon Chrome Moly Steel (325 to 380BHN):This steel is now considered the main material used for SAG mill liners. There are a number of variations with either different carbon or chrome contents. The variations tend to have a bearing on the size of the liner and its section thickness. There is ongoing development within this area as the size of the liners is outstripping the properties provided by the standard high chrome-moly steels.

Chrome Moly White Irons (600 to 700BHN) WI:This casting material is considered to be the ultimate developed and used to date for abrasion resistance in Milling. It is commonly used in cement mills and some of the largest Ball Mills in the world and where performance has not been bettered to date.

The use of this type of material generally began with Rod Mills and Ball Mills, where impacts were considered low enough for this brittle yet highly abrasive resistant wear material to perform well. However, it is now considered obsolete in light of the use of high chrome irons and chrome-moly white iron.

High chromium alloy cast iron generally refers to the alloy white cast iron with the chromium content of 12% 30% and carbon content of 2.4% 3.6%. It is characterized by the microhardness hv1300 1800 of M7C3 eutectic carbide, which is dispersed on the matrix of martensite (the hardest structure in the metal matrix) in the form of a broken network and isolated shape, which reduces the splitting effect on the matrix.

Qiming Machinery is the leading manganese steel, chromium steel, alloy steel, and heat-resisting steel manufacturer in China. We manufacture crusher wear parts, shredder wear parts, mill liners, apron feeder pans, and other wear parts for customers.

ball mill liner function | wear parts for industry | qiming casting

ball mill liner function | wear parts for industry | qiming casting

Ball mill is a major equipment in the production of power plants, cement plants, mines, chemical industry, metallurgy and other industries, the liner is one of the components of the mill, the main role is to protect the cylinder, the cylinder from the grinding body and Material direct impact and friction, help to improve the mill grinding efficiency, increase production and reduce metal consumption. As the liner in the harsh conditions of long-term conditions, maintenance and replacement of considerable volume, not only requires human, material and financial resources, but also a direct impact on productivity.

Ball mill liner plays a major role in protecting the inner wall of the anchor windlass. Different shapes of the ball mill lining plate can improve the grinding effect of the ball mill and improve the working efficiency of the ball mill. 1, flat ball mill liner, the surface smooth, suitable for installation in the fine grinding warehouse. 2, the pressure of the type of ball mill liner, suitable for coarse grinding warehouse, for low speed ball mill. 3, ladder-type ball mill liner, ladder liner is better than the pressure liner, suitable for installation in the coarse grinding warehouse. 4, small corrugated liner crest and pitch are small, suitable for fine grinding and coal mill. 5, end cover liner installed in the grinding head cover or cylinder cover to protect the end cover from wear and tear. 6, ring groove liner in the lining of the T surface for casting a circular groove, after installation to form a circular groove, suitable for multi-warehouse grinding of the first and second positions, dry, wet grinding Machine can be. 7, grading liner, grinding mill for the ideal state should be large particles of material with a large diameter grinding body to impact and crush, that is, in the direction of the mill feed with large diameter grinding body, with the material The direction of the material to the gradual reduction of the grinding body should be sequentially reduced.

Qiming Casting is one of the largest manganese steel, chromium steel, and alloy steel foundry in China. Products include crusher wear parts, Crusher spare parts, mill liners, shredder wear parts, apron feeder pans, and electric rope shovel parts.

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