The low efficiency of grinding will cause a lower processing volume, a higher production energy consumption, and unstable product fineness, most mineral processing plants will encounter such a problem. How to improve the grinding efficiency of the ball mill effectively is an important matter. This article summarizes 5 ways to increase the ball mill efficiency.
1, Change the Grinding Degree of Raw Ore
The hardness, toughness, discoloration, and structural defects of the raw ore determine the degree of difficulty of ore-grinding. If the grinding degree is low, then it is easy to grind ore, the wear of the mill liner and steel ball is also less, also followed by the less energy consumption; on the contrary, it takes the opposite. The nature of the raw ore directly affects the productivity of the mill.
In production, if the more difficult ore or ore requires fine grinding, consider using a new process to change the grinding of the ore, subject to economic and site conditions:
One way is to apply certain chemicals to the grinding process which increase the grinding effect and grinding efficacy;
Another approach is to change the grinding possibility of the ore, for example, to heat the minerals which to change the mechanical properties of the entire ore, then to reduce hardness, etc.
2, More Crushing and Less Grinding, Reducing the Grain Size of the In-grinding
The larger the grinding particle size is, the more Power the grinder needs to do for the ore, to reach the specified fineness of the grinding, the workload of the ball mill is bound to increase, followed by energy consumption and power consumption will also increase.
To reduce the feeding size of the ore grinding, it is required the ore - crushing size is small, that is, to "more crushing and less grinding". And the efficiency of ore - crushing is significantly higher than grinding ore, and the energy consumption of the ore-crushing is lower, it is about 12% to 25% of the ore grinding.
3, Adequate Filling Rate
Under a certain speed of ball mill, the larger the filling rate, the more steel balls hit the material, grinding area is larger, grinding effect is stronger, but the power consumption is also larger. It is easy to change the moving state of steel ball when the filling rate is too high, and it will reduce the impact effect on large particles. On the other hand, if the filling rate is too small, the grinding function will be too weak.
At present, many mines set up a fill rate of 45% to 50%, strictly speaking, it is not necessarily so reasonable, because the exact conditions of each plant are not the same, just copying other's data may not achieve the ideal grinding effect, the fill rate should be based on the actual situation.
4, Reasonable Steel Ball Size and Matching Ratio
Because the steel ball touching with the ore as a point inside the ball mill, if the ball diameter is too large, then the grinding force is also too large, it results the material is broken in the direction of penetration instead of the different mineral crystal interface with weak binding force rupture, the broken of material is not selective which does not fit the purpose of ore-grinding.
In addition, in the case of the same filling rate of steel ball, the ball diameter is too large which will reduce the ball in a great number, the probability of crushing will be lowly, which also causes over-smashing intensifies, the product size will be uneven. If the steel ball is too small, then it will cause less crushing force on the ore, the grinding efficiency will be lowly, so the precise of steel ball size and its ratio is very important to grinding efficiency.
5, Control the Steel Ball Precisely
Because of the grinding effect between steel ball and ore will cause the wear of steel ball under grinding, it results in the changes in the ratio of steel balls of various sizes, then influencing the grinding process and causing the change of fineness of grinding products, so a reasonable steel ball replenishment system can make production stable.