Although the kiln is known as the "major energy consumer in the ceramic industry", the power consumption of the kiln only accounts for 1 / 5 of the total power consumption, while the power consumption of the ball mill, as the raw material processing module, accounts for 1 / 3 of the total power consumption, and its energy saving potential is huge. It is reported that there are nearly 10000 40 ton intermittent ball mills in China, which consume a large amount of electric energy and water resources every day.
The energy-saving continuous ball mill has always been the research and development direction of many ceramic machine enterprises in China. In view of the difficulty in achieving standardization of ceramic raw materials in China, it has become an important problem that the industry needs to solve to manufacture a continuous ball mill that is suitable for the formulation process of ceramic raw materials and the production technology of China.
After years of research, the combined continuous ball mill developed by Hunan Xiangtan Yida Electromechanical Equipment Manufacturing Co., Ltd. (hereinafter referred to as "Yida electromechanical") is not only less capital investment and simple operation, but also suitable for the specific process of ceramic production in China.
It is understood that the total investment of Yida electromechanical combined continuous ball mill is no more than 15 million yuan, taking the raw materials of 600 tons per day as an example; Compared with the intermittent ball mill, it not only saves energy and reduces consumption, but also reduces the construction costs such as labor and ball mill foundation, and can recover all the investment costs in five years. Especially compared with similar foreign equipment, the total investment is only about half of that of foreign equipment under the same level, output and quality. "Most of the raw materials of domestic ceramic factories directly enter the intermittent ball mill for grinding from the raw ore; while the combined continuous ball mill requires that the hard materials must be less than 5mm and the soft materials must not exceed 30mm for the raw materials in the ball body." Zhou Bihui, general manager of Yida Electromechanical, explained the process of grinding ceramic raw materials in China.
For this reason, Yida electromechanical combined continuous ball mill has broken through the above technological bottleneck and explored the technology suitable for raw material grinding in China: 1. The hard materials (such as feldspar, dolomite, etc.) in the raw material formula are crushed to more than 80 mesh by Raymond mill or column mill, and are transported to different silos, and are continuously transported to the combined continuous ball mill for grinding through the dynamic proportioning of electronic belt scale; 2. For the soft materials in the raw material formula, a slurry tank and a high-speed slurry mixer are used to put a certain proportion of water into the slurry, and then the slurry after the slurry is mixed is removed through a vibrating screen, and then the slurry and the crushed hard materials are pumped into a combined continuous ball mill for grinding by a slurry pump. To put it simply, the hard raw materials and soft raw materials are treated separately, and then they are fed into the combined continuous ball mill, so that the energy saving effect is better, the output is larger, and the quality is more stable.
After a lot of practice and long-term analysis, Yida electromechanical's combined continuous ball mill not only shines brilliantly in Türkiye, India and other countries, but also summarizes a set of three ball milling processes suitable for the current situation of domestic ceramic raw material formulation.
The first ball milling process
The output of this ball milling process is 20-40 tons / hour, and the energy saving effect is 30% - 35%. This method is relatively stable, with little change to the existing raw material workshop, and it is easier for manufacturers to accept during production. This process retains the grinding process of the traditional batch ball mill, greatly shortens the time of the batch ball mill, and requires less batch ball mills under a certain output. This process is generally suitable for the transformation of old plants, with low investment, high output, stable quality and satisfactory energy saving effect.
The second ball milling process
This kind of ball milling process is relatively ideal. Its biggest feature is that feldspar and other hard materials are dry pulverized by column mill to reach the required mesh (180-300 mesh) before entering the silo. The investment of this dry pulverizing equipment is about 1.5 million yuan (excluding the two section combined ball mill), but its energy saving effect is very significant. Plastic raw materials still use the original intermittent ball mill to grind and then enter the slurry pool. In this way, feldspar powder and plastic slurry enter the two-stage combined continuous ball mill for grinding at the same time in proportion through different metering methods. In this way, the output is extremely high, up to 80 tons of slurry per hour, and the energy saving is up to 40% - 50%. Actually, this paper is reprinted on Huaxia Ceramic network to realize feeding automation and formulation automation, The uncertainty factors of artificial formula and feeding are avoided. This process is the best choice for the enterprise to expand its production. It does not require civil works. The occupied area can be reconstructed in the original workshop, and the investment is relatively small. The third is ball milling process.
This kind of ball milling process is fully automatic. From feeding to discharging and hard materials with various formulas are digitally controlled by computer programming. Each key part has monitoring image points. Its basic technological process is: hard materials, feldspar, potassium feldspar, etc. are crushed to a certain number of mesh by column mill, vacuum suction into the silo, and there are as many kinds of silos as there are raw materials, and automatic batching by electronic belt scale through computer programming. The plastic raw materials do not need to be processed. The raw materials directly enter the first bin (large diameter bin) of the combined continuous ball mill through the feeder for slurry grinding, and then automatically enter the second bin of the combined continuous ball mill; Feldspar powder and mud are grinded and mixed in the second and third silos, and then the slurry is discharged from the third silo, and enters the slurry pool through the vibrating screen and iron separator. This new raw material grinding process. The energy-saving effect is particularly remarkable. It saves 50% - 60% of the energy compared with the traditional intermittent ball mill. Moreover, the quality is stable, the floor area is small, the civil engineering is small, the labor force is reduced, and the one-time investment is small, about 15 million yuan. It is very suitable for the construction of new ceramic enterprises.
Why is it that the combined continuous ball mill and three ball milling processes are not only suitable for raw material processing in China, but also achieve such high energy saving effect?
Zhou Bihui introduced that the structure of the combined continuous ball mill is different from that of the intermittent ball mill. The former is the middle discharge, and only half of the pellets and raw materials can be loaded. When the balls are rolling, the movement distance of the pellets increases, and the potential energy increases correspondingly. The greater the impact force of the pellets on the raw materials, the higher the ball milling efficiency; The latter must be filled with pebbles, raw materials and water in proportion. The movement space of the pebbles in the sphere is subject to the resistance of water and raw materials. The potential energy of the pebbles is small, the movement is limited, and the grinding effect of the pebbles is poor.
The loading and unloading methods of combined continuous ball mill and intermittent ball mill are different. The latter must be shut down for manual loading and unloading, and each loading and unloading takes 3-4 hours; The latter is continuous automatic loading and unloading, which greatly saves time.
The grinding time of combined continuous ball mill is different from that of intermittent ball mill. The latter grinds the plastic raw materials and the hard raw materials at the same time. The hard raw materials need to be grinded in the sphere for more than 10 hours, which is time-consuming and electricity consuming; The former treats the plastic raw materials and hard raw materials separately. The plastic raw materials enter the first section of large-diameter continuous ball mill for pulping, and then enter the second section of continuous ball mill. The hard materials quickly grind to 100-300 mesh through the column mill, and then enter the second section of the continuous ball mill. In this way, the plastic raw materials and hard raw materials are grinded in the second and third sections of the continuous ball mill for a short time, so that the plastic raw materials and hard raw materials are grinded in the second The three spheres are uniformly mixed to achieve the same particle size, which not only makes the grinding degree of the slurry uniform, but also improves the slurry quality, shortens the grinding time and improves the grinding efficiency.
Due to the modular design, the combined continuous ball mill occupies less land, and the number of modules can be flexibly adjusted according to the characteristics of raw materials. Different modules can adopt different optimal operation speeds according to their internal raw material granularity, reasonably use energy, improve production efficiency and reduce unit energy consumption. "We can form two, three or four combined continuous ball mills according to user needs." Zhou Bihui said that the equipment can adapt to a variety of ceramic process formulations in China, suitable for flexible and variable small batch production, and can also adapt to relatively stable process requirements and large batch production. "The particle size of the powder ground by the combined continuous ball mill is basically the same, providing a reliable quality assurance for the production of high-grade ceramic tiles."
To sum up, in today's downturn of the ceramic industry, the combined continuous ball mill is not only a scientific and technological tool for the internal rectification and transformation of ceramic enterprises, cost reduction, green production, quality improvement and competitiveness improvement, but also another innovation power for the transformation and upgrading of the ceramic industry.