japanese industrial ball mill

carbide tool sets, drill bits, router bits | m3tools

M3Tools is one a world leader for industrial quality cutting tools used by woodworking professionals & enthusiasts, architects, sign builders, cabinetmakers, stage & set builders. We offer solutions for woodworking, plastics, aluminum, composite, aviation, boating, recreational vehicles, ski & snowboard industries. Our number one job is to help you advance your business. More about us...

Cemented carbide is a hard material used extensively as cutting tool material, as well as other industrial applications. It consists of fine particles of carbide cemented into a composite by a binder metal. Cemented carbides commonly use tungsten carbide (WC), titanium carbide (TiC), or tantalum carbide (TaC) as the aggregate. Mentions of "carbide" or "tungsten carbide" in industrial contexts usually refer to these cemented composites.

Most of the time, carbide cutters will leave a better surface finish on the part, and allow faster machining than high-speed steel or other tool steels. Carbide tools can withstand higher temperatures at the cutter-workpiece interface than standard high-speed steel tools (which is a principal reason for the faster machining). Carbide is usually superior for the cutting of tough materials such as carbon steel or stainless steel, as well as in situations where other cutting tools would wear away faster, such as high-quantity production runs.

3. Carbide tipped tools last far longer because the carbide chip forming surface resists wear as the chip flows over the tools. This greatly reduces need for costly changes with increased scrap and rework.

American National Standard B94.11M-1993 covers the relevant information relating to drill bits, including sizes, tolerances, nomenclature, and definitions. Below is a summary of some of the key terminology relating to Drill Bits.

2. Back taper is a reduction in the drill bits diameter that occurs from the point of the drill bit to the end of the drill bit body. Most drill bits are machined with a small back taper to prevent the bit from binding in the workpiece when the drill bit becomes worn.

5. Flutes are the grooves that are formed in the drill bit which serve to allow the removal of chips from the hole being cut and to allow cutting fluid to reach the cutting lips of the bit. Flutes are usually helically shaped or straight cut.

6. Overall length is the distance measured from the extreme end of the shank to the outer corners of the cutting lips. Note that this measurement excludes the conical shank end and the conical cutting point at the tip of the drill bit.

Carbide (Carb) is the hardest and most brittle of the drill bit materials. Its used mostly for production drilling where a high-quality tool holder and equipment is used. It should not be used in hand drills or even drill presses. These drill bits are designed for the most demanding and hardest materials.

If you're just starting out, the five essential bits listed above or a quality set can be an excellent place to start. However, there are many more router bits on the market. Here are a few specialty router bits you can buy, as well as how they can be used:

I don't mean that entirely literally. But I think it's best if you buy just a few tools and start using those. As you get more comfortable with what you have it becomes easier to understand what tools you should get next. That way you don't end up buying a workshop full of tools only to find out that you aren't really into woodworking. Let's begin, guys!

industrial manufacturing | industrial info resources

The distribution & warehousing sector covers non-refrigerated/frozen warehousing, general goods warehousing, regional distribution/hubs for manufacturing companies, logistics companies, distribution companies, online retailers, the United States Postal Service, data centers, as well as air-freight companies such as FedEx, UPS and DHL.

The transportation systems sector includes inland & deepwater ports, airports, light rail, commuter rail and freight rail, including maintenance facilities, intermodal terminals, interconnects, rail bridges, substations, microgrids and railyards associated with mass-transit systems.

Reports on the infrastructure sector deal with steam, chilled water, electrical distribution and independent power, including the microgrid needs of educational institutions, hospitals, prisons, military bases and governmental facilities.

The semiconductors & computers sector deals with plants that manufacture computers, printed circuit boards, semiconductors, computer terminals, office machines, resistors and capacitors, connectors, solar panels and electronic components.

The housing, building products & furniture sector covers facilities that manufacture furniture (both home and office), asphalt roofing products, kitchen cabinets, millwork, transformers, household appliances, electric lamps and bulbs, household appliances, mattresses, air conditioning systems, communications equipment, toys, games, sporting equipment, writing instruments, switchgear, current-carrying electric devices and storage batteries, plus more.

The automotive sector includes vehicle assembly plants that produce cars, light trucks, buses and commercial heavy-duty trucks, as well as tier suppliers that produce automotive parts.

The fabricated metal products sector consists of facilities that manufacture wire, metal cans, cutlery, hand saws and tools, sheet metal, architectural and ornamental metal work, bolts, nuts & screws, metal stampings, automotive stamping, industrial valves and valve fittings, small arms and ammunition, steel and wire springs, metal foil and leaf, fabricated metal pipe, and general fabricated metal products.

The heavy manufacturing sector includes facilities that manufacture heavy construction equipment, farm equipment, rail cars & engines, airplanes & airplane parts, turbines & generators, lawn & garden equipment, compressors, pumps, conveyors, military equipment, household and commercial appliances, mining equipment, oil & gas field equipment, food processing equipment, bearings, machine tools, textile processing equipment, transformers and HVAC equipment plus ship and boat building and more.

The plastics & rubber products sector involves facilities that manufacture tires, rubber & plastic hosing, belts, gaskets and seals, rubber goods, plastic film & sheet, laminated plastic products, plastic pipe, bottles, foam products, injection and blow molded products, and assorted plastic products.

The distribution & warehousing sector covers non-refrigerated/frozen warehousing, general goods warehousing, regional distribution/hubs for manufacturing companies, logistics companies, distribution companies, online retailers, the United States Postal Service, data centers, as well as air-freight companies such as FedEx, UPS and DHL.

The transportation systems sector includes inland & deepwater ports, airports, light rail, commuter rail and freight rail, including maintenance facilities, intermodal terminals, interconnects, rail bridges, substations, microgrids and railyards associated with mass-transit systems.

Reports on the infrastructure sector deal with steam, chilled water, electrical distribution and independent power, including the microgrid needs of educational institutions, hospitals, prisons, military bases and governmental facilities.

The semiconductors & computers sector deals with plants that manufacture computers, printed circuit boards, semiconductors, computer terminals, office machines, resistors and capacitors, connectors, solar panels and electronic components.

The textiles sector includes man-made wool, broad-woven fabric mills, carpet & rugs, yarn-spinning mills, non-woven fabric facilities, footwear, and tire cord & fabric products including clothing and more.

The housing, building products & furniture sector covers facilities that manufacture furniture (both home and office), asphalt roofing products, kitchen cabinets, millwork, transformers, household appliances, electric lamps and bulbs, household appliances, mattresses, air conditioning systems, communications equipment, toys, games, sporting equipment, writing instruments, switchgear, current-carrying electric devices and storage batteries, plus more.

The automotive sector includes vehicle assembly plants that produce cars, light trucks, buses and commercial heavy-duty trucks, as well as tier suppliers that produce automotive parts.

The fabricated metal products sector consists of facilities that manufacture wire, metal cans, cutlery, hand saws and tools, sheet metal, architectural and ornamental metal work, bolts, nuts & screws, metal stampings, automotive stamping, industrial valves and valve fittings, small arms and ammunition, steel and wire springs, metal foil and leaf, fabricated metal pipe, and general fabricated metal products.

The heavy manufacturing sector includes facilities that manufacture heavy construction equipment, farm equipment, rail cars & engines, airplanes & airplane parts, turbines & generators, lawn & garden equipment, compressors, pumps, conveyors, military equipment, household and commercial appliances, mining equipment, oil & gas field equipment, food processing equipment, bearings, machine tools, textile processing equipment, transformers and HVAC equipment plus ship and boat building and more.

The plastics & rubber products sector involves facilities that manufacture tires, rubber & plastic hosing, belts, gaskets and seals, rubber goods, plastic film & sheet, laminated plastic products, plastic pipe, bottles, foam products, injection and blow molded products, and assorted plastic products.

ball mill, custom engineering & manufacturing near tollesboro, ky

"Shane Wallingford and his team have become valuable members of our industrial ecosystem. JSB Industrial Solutions has become the single source manufacturer for our hydraulic closing units, the foundation of safety systems when extracting hydrocarbons in the oil and gas industry."

"Shane Wallingford and his team have become our go to supplier for ball mills and ball mill lid replacements... They perform quality work in a timely manner and are always available for one on one conversations when questions or consultations are needed."

small ball mills for sale

Our small-scale miners Ball Mills use horizontal rotating cylinders that contain the grinding media and the particles to be broken. The mass moves up the wall of the cylinder as it rotates and falls back into the toe of the mill when the force of gravity exceeds friction and centrifugal forces. Particles are broken in the toe of the mill when caught in the collisions between the grinding media themselves and the grinding media and the mill wall. In ball mills, the grinding media and particles acquire potential energy that becomes kinetic energy as the mass falls from the rotating shell. Ball mills are customarily divided into categories that are mainly defined by the size of the feed particles and the type of grinding media.

Intermediate and fine size reduction by grinding is frequently achieved in a ball mill in which the length of the cylindrical shell is usually 1 to 1.5 times the shell diameter. Ball mills of greater length are termed tube mills, and when hard pebbles rather than steel balls are used for the grinding media, the mills are known as pebble mills. In general, ball mills can be operated either wet or dry and are capable of producing products on the order of 100 um. This duty represents reduction ratios as great as 100.

The ball mill, an intermediate and fine-grinding device, is a tumbling drum with a 40% to 50% filling of balls. The material that is to be ground fills the voids between the balls. The tumbling balls capture the particles in ball/ball or ball/liner events and load them to the point of fracture. Very large tonnages can be ground with these devices because they are very effective material handling devices. The feed can be dry, with less than 3% moisture to minimize ball coating, or a slurry can be used containing 20% to 40% water by weight. Ball mills are employed in either primary or secondary grinding applications. In primary applications, they receive their feed from crushers, and in secondary applications, they receive their feed from rod mills, autogenous mills, or semi-autogenous mills. Regrind mills in mineral processing operations are usually ball mills, because the feed for these applications is typically quite fine. Ball mills are sometimes used in single-stage grinding, receiving crusher product. The circuits of these mills are often closed with classifiers at high-circulating loads.

All ball mills operate on the same principles. One of these principles is that the total weight of the charge in the mill-the sum of the weight of the grinding media, the weight of the material to be ground, and any water in the millis a function of the percentage of the volume of the mill it occupies.

The power the mill draws is a function of the weight of the charge in the mill, the %of volumetric loading of the mill, the %of critical speed, which is the speed in RPM at which the outer layer of the charge in the mill will centrifuge.

For closed grinding circuits producing typical ball mill products, indirect and direct on-line measurements of the product size are available. The indirect means are those which assume that the product size is relatively constant when the feed condition to the classifying unit and the operating conditions in the classifying unit are constant. One example is maintaining a constant mass flow, pulp density and pressure in the feed to the cyclone classifier.

By using math modeling, it is possible to calculate the product size from measured cyclone classifier feed conditions and circuit operating data, thus establishing the effect on the particle size distribution in the product for changes in the variables.

Direct on-line means to measure either particle size or surface area are available for typical ball mill circuit products. These require the means to obtain representative or at least consistent samples from the grinding circuit product stream. These direct means and the calculated product particle size distributions can be used to:

Small variations in the feed size to ball mill circuits generally is not critical to the calculation of operating work index because they make a very small change in the 10F factor. Thus, a computer program can be developed to calculate operating work indices from on-line data with the feed size a constant and with the program designed to permit manually changing this value, as required to take into account changes in feed size resulting from such things as drawing down feed bins, crusher maintenance, work screen surfaces in the crushing plant, etc. which are generally known in advance, or can be established quickly. Developments underway for on-line measurement of particle size in coarser material which when completed will permit measuring the feed size used to calculate operating work indices.

recorded by a data logger, gives continuous means to report comminution circuit performance and evaluate in-plant testing. Changes in Wio indicated on data loggers alert operating and supervisory personnel that a change has occurred in either the ore or in circuit performance. If sufficient instrumentation is available, the cause for a problem can often be located from other recorded or logged data covering circuit and equipment operation, however, generally the problem calls for operator attention to be corrected.

Wio can be used to determine the efficiency of power utilization for the entire comminution section of a mill, and for the individual circuits making up the comminution section. The efficiency of a comminution circuit is determined by the following equation.

Wi is obtained by running the appropriate laboratory tests on a composite sample of circuit feed. Wio is calculated from plant operating data covering the period when the feed sample was taken. Since Wi from laboratory tests refers to specific conditions for accurate efficiency determinations, it is necessary to apply correction factors as discussed in The Tools of Power Power to Wio to put the laboratory and operating data on the same basis.

To-date, there is no known way to obtain standard work index data from on-line tests. Continuous measurement of comminution circuit efficiency is not possible and thus efficiency is not available for circuit control. Using laboratory data and operating data, efficiency can be determined for overall section and individual circuit for evaluation and reporting. Just monitoring Wio and correcting operating problems as they occur will improve the utilization of the power delivered to the comminution circuits.

Samples taken from the chips around blast hole drillings and from broken ore in the pit or mine for laboratory work index and other ore characteristic determinations before the ore is delivered to the mill, can be used to predict in advance comminution circuit performance. Test results can also be used for ore blending to obtain a more uniform feed, particularly to primary autogenous and semi-autogenous circuits.

We sell Small Ball Mills from 2 to 6 (600 mm X 1800 mm) in diameter and as long as 10 (3000 mm) in length. The mills are manufactured using a flanged mild steel shell, cast heads, overflow discharge, removable man door, spur type ring gear, pinion gear assembly with spherical roller bearings, replaceable roller bronze trunnion bearings, oil lubrication, replaceable trunnion liners with internal spirals, rubber liners and lifters, feed spout with wash port, discharge trommel with internal spiral, motor and gear reducer drive, direct coupled to pinion gear, gear guard and modular steel support frame. All ball mills always come withOSHA-type gear guard.

A PULP level sufficiently high to interpose a bed of pulp, partly to cushion the impact of the balls, permits a maximum crushing effect with a minimum wear of steel. The pulp level of theseSmall Ball Millscan be varied from discharging at the periphery to discharging at a point about halfway between the trunnion and the periphery.The mill shell is of welded plate steel with integral end flanges turned for perfect alignment, and the heads are semi-steel, with hand holes in the discharge end through which the diaphragm regulation is arranged with plugs.The trunnion bearings are babbitted, spherical, cast iron, and of ample size to insure low bearing pressure; while the shell and saddle are machined to gauge so that the shells are interchangeable.

Data based on:Wet grinding, single stage, closed circuit operation: feed:( one way dimension); Class III ore. All mills:free discharge, grated type, rapid pulp flow. N. B.for overflow type mills: capacity 80%power 83%. Dimensions :diameters inside shell without linerslengths working length shell between end liners.

The CIW is a Small Ball Mill thats belt driven, rigid bearing, wet grinding, trunnion or grate discharge type mill with friction clutch pulley and welded steel shell. The 7 and 8 foot diameter mills are of flange ring construction with cut gears while all other sizes have cast tooth gears. All these mills are standard with white iron bar wave type shell liners except the 8 foot diameter mill which is equipped with manganese steel liners. The horsepowers shown in the table are under running conditions so that high torque or wound rotor (slip ring) motors must be used. Manganese or alloy steel shell or head liners and grates can be supplied with all sizes of mills if required. Alloy steel shell liners are recommended where 4 or larger balls are used and particularly for the larger sized mills.

Small (Muleback Type) Ball Mill is built for muleback transportation in 30 and 3 diameters (inside liners). A 4 (Muleback Type) Ball Mill is of special design and will be carefully considered upon request. Mankinds search for valuable minerals often leads him far away from modern transportation facilities. The potential sources of gold, silver and strategic minerals are often found by the prospector, not close by our modern highways, but far back in the mountains and deserts all over the world. The Equipment Company has realized this fact, and therefore has designed a Ball Mill that can be transported to these faraway and relatively inaccessible properties, either by the age old muleback transportation system, or by the modern airplane. As a result these properties may now obtain a well-designed ball mill with the heaviest individual piece weighing only 350 pounds.

The prime factor considered in this design was to furnish equipment having a maximum strength with a minimum weight. For this reason, these mills are made of steel, giving a high tensile strength and light weight to the mills. The muleback design consists of the sturdy cast iron head construction on the 30 size and cast steel head construction on the larger sizes. The flanges on the heads are arranged to bolt to the rolled steel shell provided with flanged rings. When required, the total length of the shell may consist of several shell lengths flanged together to provide the desired mill length. Liners, bearings, gears and drives are similar to those standard on all Ball Mills.

This (Convertible) and Small Ball Mill is unique in design and is particularly adapted to small milling plants. The shell is cast in one piece with a flange for bolting to the head. In converting the mill from a 30x 18 to a 30x 36 unit with double the capacity, it is only necessary to secure a second cast shell (a duplicate of the first) and bolt it to the original section.

30 Convertible Ball Mills are furnished with scoop feeders with replaceable lips. Standard mills are furnished with liners to avoid replacement of the shell; however, themill can be obtained less liners. This ball mill is oftendriven by belts placed around the center, although gear drive units with cast gears can be furnished. A Spiral Screen can be attached to the discharge.

This mill may be used for batch or intermittent grinding, or mixing of dry or wet materials in the ore dressing industry, metallurgical, chemical, ceramic, or paint industries. The material is ground and mixed in one operation by rotating it together with balls, or pebbles in a hermetically sealed cylinder.

The cast iron shell which is bolted to the heads is made with an extra thick wall to give long wearing life. Two grate cleanout doors are provided on opposite sides of the shell by means of which the mill can be either gradually discharged and washed, while running, or easily and rapidly emptied and flushedout while shut down. Wash-water is introduced into the interior of the mill through a tapped opening in the trunnion. The mill may be lined with rubber, silex (buhrstone) or wood if desired.

The Hardinge Conical Ball Mill has been widely used with outstanding success in grinding many materials in a wide variety of fields. The conical mill operates on the principle of an ordinary ball mill with a certain amount of classification within the mill itself, due to its shape.

Sizes of conical mills are given in diameter of the cylindrical section in feet and the length of the cylindrical section in inches. Liners can be had of hard iron, manganese steel or Belgian Silex. Forged steel balls or Danish Flint Pebbles are used for the grinding media, depending upon the material being milled.

The Steel Head Ball-Rod Mill gives the ore dressing engineer a wide choice in grinding design so that he can easily secure a Ball-Rod Mill suited to his particular problem. The successful operation of any grinding unit is largely dependent on the method of removing the ground pulp. The Ball-Rod Mill is available with five types of discharge trunnions, each type obtainable in small, medium or large diameters. The types of discharge trunnions are:

The superiority of the Steel Head Ball-Rod Mill is due to the all steel construction. The trunnions are an integral part of the cast steel heads and are machined with the axis of the mill. The mill heads are assured against breakage due to the high tensile strength of cast steel as compared to that of the cast iron head found on the ordinary ball mill. Trunnion Bearings are made of high- grade nickel babbitt.

Steel Head Ball-Rod Mills can be converted intolarger capacity mills by bolting an additional shell lengthonto the flange of the original shell. This is possible because all Steel Head Ball or Rod Mills have bearings suitable for mills with length twice the diameter.

Head and shell liners for Steel Head Ball-Rod Mills are available in Decolloy (a chrome-nickel alloy), hard iron, electric steel, molychrome steel, and manganese steel. Drive gears are furnished either in cast tooth spur gear and pinion or cut tooth spur gear and pinion. The gears are furnished as standard on the discharge end of the mill, out of the way of the classifier return feed, but can be furnished at the mill feed end by request. Drives may be obtained according to the customers specifications.

Thats one characteristic of Traylor Ball Millsliked by ownersthey are built not only to do a first class job at low cost but to keep on doing it, year after year. Of course, that means we do not build as many mills as if they wore out quicklyor would we? but much as welike order, we value more the fine reputationTraylor Ball Mills have had for nearly threedecades.

Thats one characteristic of Traylor Ball Mills We dont aim to write specifications into thisliked by ownersthey are built not only to do advertisementlet it suffice to say that theresa first class job at low cost but to keep on do- a Traylor Ball Mills that will exactly fit anyanything it, year after year. Of course, that means requirement that anyone may have.

If this is true, there is significance in the factthat international Nicked and Climax Molybdenum, theworlds largest producers of two important steel alloys, areboth users of MARCY Mills exclusively. With international interest centered on increasingproduction of gold, it is even more significant that MARCYMills are the predominant choice of operators in everyimportants gold mining camp in the world.

Ball Mill. Intermediate and fine size reduction by grinding is frequently achieved in a ball mill in which the length of the cylindrical shell is usually 1 to 1.5 times the shell diameter. Ball mills of greater length are termed tube mills, and when hard pebbles rather than steel balls are used for the grinding media, the mills are known as pebble mills. In general, ball mills can be operated either wet or dry and are capable of producing products on the order of 100 pm. This duty represents reduction ratios as great as 100.

The ball mill, an intermediate and fine-grinding device, is a tumbling drum with a 40% to 50% filling of balls (usually steel or steel alloys). The material that is to be ground fills the voids between the balls. The tumbling balls capture the particles in ball/ball or ball/liner events and load them to the point of fracture. Very large tonnages can be ground with these devices because they are very effective material handling devices. The feed can be dry, with less than 3% moisture to minimize ball coating, or a slurry can be used containing 20% to 40% water by weight. Ball mills are employed in either primary or secondary grinding applications. In primary applications, they receive their feed from crushers, and in secondary applications, they receive their feed from rod mills, autogenous mills, or semiautogenous mills. Regrind mills in mineral processing operations are usually ball mills, because the feed for these applications is typically quite fine. Ball mills are sometimes used in single-stage grinding, receiving crusher product. The circuits of these mills are often closed with classifiers at high-circulating loads.

These loads maximize throughput at a desired product size. The characteristics of ball mills are summarized in the Table, which lists typical feed and product sizes. The size of the mill required to achieve a given task-that is, the diameter (D) inside the liners-can be calculated from the design relationships given. The design parameters must be specified.

The liner- and ball-wear equations are typically written in terms of an abrasion index (Bond 1963). The calculated liner and ball wear is expressed in kilograms per kilowatt-hour (kg/kWh), and when multiplied by the specific power (kWh/t), the wear rates are given in kilograms per ton of feed. The wear in dry ball mills is approximately one-tenth of that in wet ball mills because of the inhibition of corrosion. The efficiency of ball mills as measured relative to single-particle slow-compression loading is about 5%. Abrasion indices for five materials are also listed in the Table.

The L/D ratios of ball mills range from slightly less than 1:1 to something greater than 2:1. The tube and compartment ball mills commonly used in the cement industry have L/D ratios 2.75:1 or more. The fraction of critical speed that the mill turns depends on the application, and most mills operate at around 75% of critical speed. Increased speed generally means increased power, but as the simulations presented in Figure 3.26 show, it can also produce more wasted ball impacts on the liners above the toe. causing more wear and less breakage.

There are three principal forms of discharge mechanism. In the overflow ball mill, the ground product overflows through the discharge end trunnion. A diaphragm ball mill has a grate at thedischarge end. The product flows through the slots in the grate. Pulp lifters may be used to discharge the product through the trunnion, or peripheral ports may be used to discharge the product.

The majority of grinding balls are forged carbon or alloy steels. Generally, they are spherical, but other shapes have been used. The choice of the top (or recharge) ball size can be made using empirical equations developed by Bond or Azzaroni or by using special batch-grinding tests interpreted in the content of population balance models. The effect of changes in ball size on specific selection functions has been found to be different for different materials. A ball size-correction method can be used along with the specific selection function scale-up method to determine the best ball size. To do this, a set of ball size tests are performed in a batch mill from which the specific selection function dependence on ball size can be determined. Then, the mill capacities used to produce desired product size can be predicted by simulation using the kinetic parameter corresponding to the different ball sizes.

The mill liners used are constructed from cast alloy steels, wear-resistant cast irons, or polymer (rubber) and polymer metal combinations. The mill liner shapes often recommended in new mills are double-wave liners when balls less than 2.5 in. are used and single-wave liners when larger balls are used. Replaceable metal lifter bars are sometimes used. End liners are usually ribbed or employ replaceable lifters.

The typical mill-motor coupling is a pinion and gear. On larger mills two motors may be used, and in that arrangement two pinions drive one gear on the mill. Synchronous motors are well suited to the ball mill, because the power draw is almost constant. Induction, squirrel cage, and slip ring motors are also used. A high-speed motor running 600 to 1,000 rpm requires a speed reducer between the motor and pinion shaft. The gearless drive has been installed at a number of locations around the world.

steel and metals

The operational environment for bearings is unique to steelmaking, comprisingparticle contamination, water and heat. In addition, the bearings may have to cope withheavyor shock loadsandvibration, operational speedsranging from extremely slow to extremely high, coupled withrapid acceleration anddeceleration. We offer a comprehensive range of bearings for the steel industry, fromstandard bearingsto ourown independently developed, high-capacity specialised bearings.

A typical problem forbearingsinconverters: the swivel bearing cannot be replaced without dismantling the centralwheel. NSK'sultra-large split Spherical Roller Bearingsallow bearing replacement without removing the central wheel of the gearbox, thus reducing maintenance cost and shortening downtimes.

Differentialspeedsin theroller/racewaycontact zonecan cause uneven wear inspherical roller bearingsandtoroidal roller bearings.Spallingandcrackson theracewayof the outer ring are costly as they cause unplanned production stoppages and above-average consumption of bearings. To tackle this problem,NSKhas developeda range of full complementcylindrical roller bearings effective as non-locating position in guide rolls of continuous casting machines.

In order to meet the requirements of steel making equipment and continuous-casting machines, NSK has expanded its range of cylindrical roller bearings. NSK has developed the new NUB series which can reduce the total cost of ownership for continuous casting machine guide rolls>>

NSK offers specific bearings for rolling mills which guarantee higher reliability and longer operational service lives. Sealed bearingsminimise the environmental impact and help reduce grease consumption. Super-Toughsteel(STF series) with optimumheat treatmentpreventscracksand earlyraceway damage. In addition, NSK has developed WTF material (WTF series) for bearings which are exposed towaterinfiltration. Thefour-row extra-capacity sealed-clean taper roller bearings(KVS series) are capacity-optimised, resistant to contamination by foreign matter and now also available with specially formulated grease against water infiltration.

NSK solution for four-row tapered roller bearings in rolling mills. These bearings offer long service life, reduced maintenance cost and increased operational efficiency. Optional we offer: Super TF, WTF, Sealed Clean and new grease AQGRD>>

industrial ball mills: steel ball mills and lined ball mills | orbis

Particle size reduction of materials in a ball mill with the presence of metallic balls or other media dates back to the late 1800s. The basic construction of a ball mill is a cylindrical container with journals at its axis. The cylinder is filled with grinding media (ceramic or metallic balls or rods), the product to be ground is added and the cylinder is put into rotation via an external drive causing the media to roll, slide and cascade. Lifting baffles are supplied to prevent the outer layer of media to simply roll around the cylinder.

Mill cylinders are typically supplied with a cooling jacket on their cylindrical portion for temperature control, especially when processing temperature-sensitive materials. For extreme temperatures, the ends of the cylinder can also be furnished with cooling apparatus.

ball mill, ball grinding mill - all industrial manufacturers - videos

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... LN2 feeding systems, jar and ball sizes, adapter racks, materials low LN2-consumption clearly structured user interface, memory for 9 SOPs programmable cooling and grinding cycles (10 ...

The XRD-Mill McCrone was specially developed for the preparation of samples for subsequent X-ray diffraction (XRD). The mill is used for applications in geology, chemistry, mineralogy and materials science, ...

The Planetary Ball Mill PM 200, engineered by Retsch, is a milling device best suited for mixing and size reduction processes and is also capable of meeting the necessary requirements for colloidal grinding ...

... Micro Mill PULVERISETTE 0 is the ideal laboratory mill for fine comminution of medium-hard, brittle, moist or temperature-sensitive samples dry or in suspension as well as for homogenising of emulsions ...

... , fast, effective. WORKING PRINCIPLE Impact and friction The FRITSCH Mini-Mill PULVERISETTE 23 grinds the sample through impact and friction between grinding balls and the inside wall of the grinding ...

... grinding mills includes being safe throughout. When the mills are quoted we make sure to include any and all safety components needed. Long life and minimum maintenance To help you get the most of your ...

Annular gap and agitator bead mills are used for processing suspensions and highly viscous products in chemicals and cosmetics as well as in the food sector. Studies have shown that annular gap bead ...

... Pneumatic extraction from the surface of the agitated media bed Wet grinding: Separation of suspension from the agitated media by ball retaining device Flexibility Through careful selection of the size and quantity ...

... details; Agitating power: 0,37 kW Total Power Consumption : 1.44 kW Total Weight : 100 kg Metal Ball Size : 6.35 mm Metal Ball Amount : 7 kg Cold water consumption : 10 liters / hour ...

Cement Ball Mill Processing ability: - 200 t/h Max feeding size: - 25 mm Product Fineness: - 0.074-0.89mm Range of application: - limestone, calcium carbonate, clay, dolomite and other minerals ...

... grinds and classifies a product. Vilitek MBL-NK-80 mill is specially designed for grinding valuable materials, which, when grinding, the re-milled fractions are not a commodity product. In particular, this mill ...

Dimensions: Height: 1530 mm Width: 650 mm Length : 1025 mm Description: Ball mills are capable of rapidly producing chocolate, nut pastes (for gianduia), and spreadable creams. It has been ...

used ball mills | ball mills for sale | phoenix equipment

Why buy a brand new ball mill when we have high-quality used and refurbished ball mills for sale? Well-made industrial equipment from top manufacturers maintain their value and save your company or industry substantially.

Ball mills are a fundamental part of the manufacturing industry in the USA as well as around the world. Ball mills crush material into various sizes and extract resources from mined materials. Pebble mills are a type of ball mill and are also used to reduce the size of hard materials, down to 1 micron or less.

Because of their fairly simple design, ball mills and pebble mills are less likely to need costly repairs (unlike other crushing or extraction equipment) making them an attractive option for businesses on a budget.

Unused 24 x 41 Polysius EGL Ball Mill. Steel Lined. Twin 7MW Electric Motor Drives, 14MW/11kV Power Supply Unit. Twin Combiflex Fixed Speed Gear Drive. Auxiliary Drive Motors, Lubrication Unit Fixed Bearing and Lubrication Unit Floating Bearing, Frozen Charge Protection System, Vibration Sensors for COMBIFLEX, Dam Ring, Permanent installed Centrifuge for Fixed Bearing, Closed Circuit Chiller Unit, Insurance and Commissioning Spares, Special Tools. Qty 2 Available.

Used 11.5' diameter X 17' long ball mill. Manufactured by KVS (Kennedy Van Saun). 1000 HP open winding synchronous motor. Features trommel discharge and feed tank. Refurbished in 2013, which included installation of new oil jacking system, oil lube system for Babbitt bearings, new titanium steel water jet-machined discharge grates, and motor refurbishment. Set of new babbit bearings available. Previously operated as a closed circuit dry mill with grinding capacity of 40 metric tons per hour with output fineness of >80% passing 200 mesh. Motor operating speed of 15.8 RPM charged with approximately 78 tons of 1", 2" and 3" steel balls. Last used at a phosphate processing facility and in good condition.

Used 8' x 10' Epworth 200 HP jacketed steel ball mill, approximately 8' diameter x 10' long, jacketed chamber, gear and pinion driven with approximately 200 motor drive, on stands, Serial# K-0845.

Used 175HP Hosokawa Alpine Super Orion Continuous Ball mill. Model 195/495 CLKE. Alumina Oxide lined. 195 cm (76")inner diameter x 495 cm (194") long drum, periphery dry discharge with adjustable discharge openings, enclosed discharge housing, direct driven thru gearbox. 175HP 460 volt motor with VFD motor controller. Serial# C1198474. Built 2012.

Used 6' x 8' Paul Abbe jacketed 100 HP steel ball mill, approximately 6' diameter x 8' long, jacketed chamber, gear and pinion driven with approximately 100 motor drive, on stands.

Unused 5' diameter X 6' long Steel Lined Ball Mill, manufactured by Patterson Industries, Type D, non-jacketed, with AR400 steel liners. Includes 30 HP, 3 phase, 60 Hz, 230-460 V, 1725 RPM motor. Mill drive is integrally coupled to horizontal parallel shafted helical gear reducer. Continuous type, with product feeding through spiral inlet trunnion and exiting through the discharge end trunnion. Features cylinder manway access door for cleaning. Internal volume measures approximately 839 USG (112 CF). Mill shell is lined with (24) 1/4" thick liner plates, each head lined with (8) 3/8" thick pie-shaped liner plates. Mounted on stand with approximately 66" clearance between the mill cylinder and floor. Mills were intended for use in glass particle size reduction but were never installed. Manufactured in 2019, units are still in factory plastic wrap and in new condition. (Qty - 2 available)

Used 5 ft. dia. x 6 ft. (Approx 120 Cu.Ft) Patterson Pebble Mill. Alumina brick lining. On stand with 20 HP motor and gear reduced drive with brake. Bull gear and pinion. Babbit bearings. Door is polyurethane and has a drain with plug.

Used 4' x 5' (345 Gallon Total/210 Gallon Working) Ball Mill. Mfg Steveco. Steel Lining. Jacketed. 20 HP (460V/60Hz/3ph) Gear Reduced heavy duty drive on high stands. Solid door and discharge door.

Used Paul O. Abbe One Piece Ceramic Ball Mill, Model JM-300. Non-Jacketed chamber approximate 24.8" diameter x 39.5" long. Vessel volume 300 liter (79 gallons). Approximate 5" charge and discharge port with cover. Driven by a 3 HP, 3/60/208-230/460 volt 1760 rpm motor with a shaft mounted Sumitomo Model 203E-25 reducer. Approximate 32 rpm drum speed. Includes a control panel with an ABB drive. Mounted on a common carbon steel frame legs. Serial # 0830032JM. Built 2008.

Used 28 Gallon Paul O. Abbe Ceramic Jar / Ball Mill. Approximate 3.7 Cubic Feet. Approximate 20" diameter x 20" straight side. Includes motor and cage. Mounted on a carbon steel frame with safety cage.

Used 30 gallon Paul O. Abbe Jar Mill. Porcelain jar 21" diameter x 18" straight side. Driven by 1hp, 1/60/115/230 volt, 1740 rpm motor thru a reducer, ratio 9.3 to 1. Inlet & outlet with cover and clamp. Mounted on carbon steel legs with a discharge housing. Serial#84876

Used 25 Gallon Norton Chemical Process Products Jar Mill. Porcelain jar 20" diameter x 20" straight side. Driven by 1hp, 3/60/230/460 volt, 1730 rpm motor thru a reducer, no ratio. Inlet & outlet with cover and clamp. Mounted on carbon steel legs with a discharge housing. Serial# AV-83104.

Used 35.30 Gallon Paul O. Abbe Jar Mill. Model 5A Porcelain jar 22" diameter x 20" straight side. Driven by 1hp, 3/60/230/460 volt, 1745 rpm motor thru a reducer, ratio 25 to 1. Inlet & outlet with cover and clamp. Mounted on carbon steel legs with a discharge housing. Serial#A41563.

Unused 24 x 41 Polysius EGL Ball Mill. Steel Lined. Twin 7MW Electric Motor Drives, 14MW/11kV Power Supply Unit. Twin Combiflex Fixed Speed Gear Drive. Auxiliary Drive Motors, Lubrication Unit Fixed Bearing and Lubrication Unit Floating Bearing, Frozen Charge Protection System, Vibration Sensors for COMBIFLEX, Dam Ring, Permanent installed Centrifuge for Fixed Bearing, Closed Circuit Chiller Unit, Insurance and Commissioning Spares, Special Tools. Qty 2 Available.

Used 11.5' diameter X 17' long ball mill. Manufactured by KVS (Kennedy Van Saun). 1000 HP open winding synchronous motor. Features trommel discharge and feed tank. Refurbished in 2013, which included installation of new oil jacking system, oil lube system for Babbitt bearings, new titanium steel water jet-machined discharge grates, and motor refurbishment. Set of new babbit bearings available. Previously operated as a closed circuit dry mill with grinding capacity of 40 metric tons per hour with output fineness of >80% passing 200 mesh. Motor operating speed of 15.8 RPM charged with approximately 78 tons of 1", 2" and 3" steel balls. Last used at a phosphate processing facility and in good condition.

Used 8' x 10' Epworth 200 HP jacketed steel ball mill, approximately 8' diameter x 10' long, jacketed chamber, gear and pinion driven with approximately 200 motor drive, on stands, Serial# K-0845.

Used 175HP Hosokawa Alpine Super Orion Continuous Ball mill. Model 195/495 CLKE. Alumina Oxide lined. 195 cm (76")inner diameter x 495 cm (194") long drum, periphery dry discharge with adjustable discharge openings, enclosed discharge housing, direct driven thru gearbox. 175HP 460 volt motor with VFD motor controller. Serial# C1198474. Built 2012.

Used 6' x 8' Paul Abbe jacketed 100 HP steel ball mill, approximately 6' diameter x 8' long, jacketed chamber, gear and pinion driven with approximately 100 motor drive, on stands.

Unused 5' diameter X 6' long Steel Lined Ball Mill, manufactured by Patterson Industries, Type D, non-jacketed, with AR400 steel liners. Includes 30 HP, 3 phase, 60 Hz, 230-460 V, 1725 RPM motor. Mill drive is integrally coupled to horizontal parallel shafted helical gear reducer. Continuous type, with product feeding through spiral inlet trunnion and exiting through the discharge end trunnion. Features cylinder manway access door for cleaning. Internal volume measures approximately 839 USG (112 CF). Mill shell is lined with (24) 1/4" thick liner plates, each head lined with (8) 3/8" thick pie-shaped liner plates. Mounted on stand with approximately 66" clearance between the mill cylinder and floor. Mills were intended for use in glass particle size reduction but were never installed. Manufactured in 2019, units are still in factory plastic wrap and in new condition. (Qty - 2 available)

Used 5 ft. dia. x 6 ft. (Approx 120 Cu.Ft) Patterson Pebble Mill. Alumina brick lining. On stand with 20 HP motor and gear reduced drive with brake. Bull gear and pinion. Babbit bearings. Door is polyurethane and has a drain with plug.

Used 4' x 5' (345 Gallon Total/210 Gallon Working) Ball Mill. Mfg Steveco. Steel Lining. Jacketed. 20 HP (460V/60Hz/3ph) Gear Reduced heavy duty drive on high stands. Solid door and discharge door.

Used Paul O. Abbe One Piece Ceramic Ball Mill, Model JM-300. Non-Jacketed chamber approximate 24.8" diameter x 39.5" long. Vessel volume 300 liter (79 gallons). Approximate 5" charge and discharge port with cover. Driven by a 3 HP, 3/60/208-230/460 volt 1760 rpm motor with a shaft mounted Sumitomo Model 203E-25 reducer. Approximate 32 rpm drum speed. Includes a control panel with an ABB drive. Mounted on a common carbon steel frame legs. Serial # 0830032JM. Built 2008.

Used 28 Gallon Paul O. Abbe Ceramic Jar / Ball Mill. Approximate 3.7 Cubic Feet. Approximate 20" diameter x 20" straight side. Includes motor and cage. Mounted on a carbon steel frame with safety cage.

Used 30 gallon Paul O. Abbe Jar Mill. Porcelain jar 21" diameter x 18" straight side. Driven by 1hp, 1/60/115/230 volt, 1740 rpm motor thru a reducer, ratio 9.3 to 1. Inlet & outlet with cover and clamp. Mounted on carbon steel legs with a discharge housing. Serial#84876

Used 25 Gallon Norton Chemical Process Products Jar Mill. Porcelain jar 20" diameter x 20" straight side. Driven by 1hp, 3/60/230/460 volt, 1730 rpm motor thru a reducer, no ratio. Inlet & outlet with cover and clamp. Mounted on carbon steel legs with a discharge housing. Serial# AV-83104.

Used 35.30 Gallon Paul O. Abbe Jar Mill. Model 5A Porcelain jar 22" diameter x 20" straight side. Driven by 1hp, 3/60/230/460 volt, 1745 rpm motor thru a reducer, ratio 25 to 1. Inlet & outlet with cover and clamp. Mounted on carbon steel legs with a discharge housing. Serial#A41563.

Phoenix Equipment is a global supplier of used ball mills. We have new, used and reconditioned ball mills from leading manufacturers, including: Paul O. Abbe Retsch Epworth Patterson Netzsch Newell Dunford Marcy Denver FL Smidth Nordberg Allis Chalmers Metso Hardinge Kurimoto Iron Works Kobe-Allis Chalmers Stevenson Fuller-Traylor Steveco Western Machinery Marion Machine Makrum and more. Ball mills are used in a wide-range of industrial applications: cement processing, paint dyes and pigmentation processing, coal and ore processing, chemical processing and pyrotechnics, and many others. Ball milling has several key advantages over other systems: cost of the grinding medium and installation is generally low works for batch or continuous operation (as well as closed-circuit grinding) suitable for a wide range of materials simple design ensures less repairs Whether you are in the market for a used ball mill for your business or you have a pre-owned ball mill youd like to sell, USA-based Phoenix Equipment can help. Contact us today to learn more about what Phoenix can do for you. Related equipment: Agitators, Screen/Separators, Kilns and Calciners, Scales and Extruders. Fill out our quick and easy quote form for more information about our Ball Mills inventory.

Ball mills are used in a wide-range of industrial applications: cement processing, paint dyes and pigmentation processing, coal and ore processing, chemical processing and pyrotechnics, and many others.

Whether you are in the market for a used ball mill for your business or you have a pre-owned ball mill youd like to sell, USA-based Phoenix Equipment can help. Contact us today to learn more about what Phoenix can do for you.

Phoenix Equipment buys and sells used chemical process equipment and plants for relocation. Our industry focus includes process plants and machinery in the chemical, petrochemical, fertilizer, refining, gas processing, power generation, pharmaceutical and food manufacturing industries. We have extensive experience acquiring processing plants and process lines that require the execution of complex dismantlement, demolition and decommissioning projects. Based in Red Bank, New Jersey, USA, we have team members located in China, India, Germany and relationships throughout the world.

Why Use Phoenix for Your Plant Dismantling & Plant Relocation Needs A Common Plant Liquidation Scenario Your company has made the tough decision to close a plant. This plant was running for years, and the company paid a lot to have it built, paid everyones salaries, and maintained or even modernized all of the production assets over the plants life but the plant needs to be sold off for one reason or another. Your company has called upon you to recover as much dollar as you can to help keep the organization alive, and better yet, healthy, in what is a constant battle in the marketplace. Youve either: Have spent months, maybe even years trying to find a buyer that would operate the plant in place, without any success, while the plants assets lose value every passing day. Or, you cant sell it to another company, as you are one of the few suppliers of the product the plant makes, and you dont want to create a competitor, or improve a competitors position. Or, the plant is on leased propert

Hydrogenation: Major Applications Hydrogenation is a billion-dollar industry. Hydrogenating means to add hydrogen to something. According to Haldor Topsoe, hydrogenation comprises 48% of total hydrogen consumption, 44% of which is for hydrocracking and hydrotreating in refineries , and 4% for hydrogenation of unsaturated hydrocarbons (including hardening of edible oil) and of aromatics, hydrogenation of aldehydes and ketones (for instance oxo-products), and hydrogenation of nitrobezene (for manufacture of aniline). Hydrocracking & Hydrotreating Industrially, hydrotreating and hydrocracking are performed in down flow trickle bed reactors, where the gas and the liquid feed are sent concurrently through a fixed bed plug flow reactor. Although the flow pattern in the reactor can be reasonably approximated, the observed kinetics in such a trickle bed reactor are quite often affected by minor unplanned oscillations in the flow. How the gas and liquid collide and mix together affects the end prod

Thermoplastics A Focus on Polyethylene & Polypropylene Thermoplastics are a class of polymers, that with the application of heat, can be softened and melted, and can be processed either in the heat-softened state (e.g. by thermoforming) or in the liquid state (e.g. by extrusion and injection molding). Over 70% of the plastics used in the world are thermoplastics, and the two most commonly used thermoplastics are both olefins, compound made up of hydrogen and carbon that contains one or more pairs of carbon atoms linked by a double bond. These two olefins are polyethylene and polypropylene. Polyethylene Polyethylene is a tough, light, flexible synthetic resin made by polymerizing ethylene, chiefly used for plastic bags, food containers, and other packaging. It may be of low density or high density depending upon the process used in its manufacturing. It is resistant to moisture and most of the chemicals. It can be heat sealed and is flexible at room temperature (and low temperature), and in additional to its material properties,

grinding mill design & ball mill manufacturer

All Grinding Mill & Ball Mill Manufacturers understand the object of the grinding process is a mechanical reduction in size of crushable material. Grinding can be undertaken in many ways. The most common way for high capacity industrial purposes is to use a tumbling charge of grinding media in a rotating cylinder or drum. The fragmentation of the material in that charge occurs through pressure, impact, and abrasion.

The choice of mill design depends on the particle size distribution in the feed and in the product wanted. Often the grinding is more economic when executed in a primary step, followed by a secondary step, giving a fine size product.

C=central trunnion discharge P=peripheral discharge R=spherical roller trunnion bearing, feed end H=hydrostatic shoe bearing, feed end R=spherical roller trunnion bearing, discharge end K=ring gear and pinion drive

Type CHRK is designed for primary autogenous grinding, where the large feed opening requires a hydrostatic trunnion shoe bearing. Small and batch grinding mills, with a diameter of 700 mm and more, are available. These mills are of a special design and described on special request by allBall Mill Manufacturers.

The different types of grinding mills are based on the different types of tumbling media that can be used: steel rods (rod mills), steel balls (ball mills), and rock material (autogenous mills, pebble mills).

The grinding charge in a rod mill consists of straight steel rods with an initial diameter of 50-100 mm. The length of the rods is equal to the shell length inside the head linings minus about 150 mm. The rods are fed through the discharge trunnion opening. On bigger mills, which need heavy rods, the rod charging is made with a pneumatic or manual operated rod charging device. The mill must be stopped every day or every second day for a few minutes in order to add new rods and at the same time pick out broken rod pieces.

As the heavy rod charge transmits a considerable force to each rod, a rod mill can not be built too big. A shell length above 6100 mm can not be recommended. As the length to diameter ratio of the mill should be in the range of 1,2-1,5, the biggest rod mill will convert maximum 1500 kW.

Rod mills are used for primary grinding of materials with a top size of 20-30 mm (somewhat higher for soft materials). The production of fines is low and consequently a rod mill is the right machine when a steep particle size distribution curve is desired. A product with 80% minus 500 microns can be obtained in an economical manner.

The grinding charge in a ball mill consist of cast or forged steel balls. These balls are fed together with the feed and consequently ball mills can be in operation for months without stopping. The ball size is often in the diameter range of 20-75 mm.

The biggest size is chosen when the mill is used as a primary grinding mill. For fine grinding of e.g. sands, balls can be replaced by cylpebs, which are heat treated steel cylinders with a diameter of 12-40 mm and with the same length as the diameter.

Ball mills are often used as secondary grinding mills and for regrinding of middlings in concentrators. Ball mills can be of the overflow or of the grate discharge type. Overflow discharge mills are used when a product with high specific surface is wanted, without any respect to the particle size distribution curve. Overflow discharge mills give a final product in an open circuit. Grate discharge mills are used when the grinding energy shall be concentrated to the coarse particles without production of slimes. In order to get a steep particle size distribution curve, the mill is used in closed circuit with some kind of classifier and the coarse particles known as classifier underflow are recycled. Furthermore, it should be observed that a grate discharge ball mill converts about 20% more energy than an overflow discharge mill with the same shell dimensions.

Ball mill shells are often furnished with two manholes. Ball mills with small balls or cylpebs can produce the finest product of all tumbling mills. 80% minus 74 microns is a normal requirement from the concentrators.The CRRK series of wet grinding ball mills are tabulatedbelow.

No steel grinding media is used in a fully autogenous mill. When choosing primary autogenous grinding, run of mine ore up to 200-300 mm in size is fed to the mill. When using a crushing step before the grinding, the crusher setting should be 150-200 mm. The feed trunnion opening must be large enough to avoid plugging. The biggest pieces in the mill are important for the size reduction of middle size pieces, which in their turn are important for the finer grinding. Thus the tendency of the material to be reduced in size by pressure, impact, and abrasion is a very important question when primary autogenous grinding is proposed.

When autogenous grinding is used in the second grinding step, the grinding media is size-controlled and often in the range of 30-70 mm. This size is called pebbles and screened out in the crushing station and fed to the mill in controlled proportion to the mill power. The pebble weight is 5-25% of the total feed to the plant, depending on the strength of the pebbles. Sometimes waste rock of high strength is used as pebbles.

Pebble mills should always be of the grate discharge type. The energy that can be converted in a mill depends on the total weight of the grinding charge. Consequently, pebble mills convert less power per mill volume unit than rod and ball mills.

High quality steel rods and balls are a considerable part of the operating costs. Autogenous grinding should, therefore, be considered and tested when a new plant shall be designed. As a grinding mill is built to last for decades, it is more important to watch the operation costs than the price of the mill installation. The CRRK series of wet grinding pebble mills are tabulated below.

Wet grinding is definitely the most usual method of grinding minerals as it incorporates many advantages compared to dry grinding. A requirement is, however, that water is available and that waste water, that can not be recirculated, can be removed from the plant without any environmental problems. Generally, the choice depends on whether the following processing is wet or dry.

When grinding to a certain specific surface area, wet grinding has a lower power demand than dry grinding. On the other hand, the wear of mill lining and grinding media is lower in dry grinding. Thus dry grinding can be less costly.

The feed to a dry grinding system must be dried if the moisture content is high. A ball mill is more sensitive to clogging than a rod mill. An air stream through the mill can reduce the moisture content and thus make a dry grinding possible in certain applications.

Due to the hindering effect that the ball charge gives to the material flow in dry grinding, the ball charge is not more than 28-35% of the mill volume. This should be compared with 40-45% in wet grinding. The expression used for this phenomenon is that the charge in a dry grinding mill is swollen.

Big dry grinding ball mills are often two-compartment mills, with big balls in the first compartment and small balls or cylpebs in the second one. An extra grate wall is used to separate the two charges.

The efficiency of wet grinding is affected by the percentage of solids. If the pulp is too thick, the grinding media becomes covered by too thick a layer of material, which hinders grinding. The opposite effect may be obtained if the dilution is too high, and this may also reduce the grinding efficiency. A high degree of dilution may sometimes be desirable in order to suppress excessive slime formation.

The specific power required for a certain grinding operation, usually expressed in kWh/ton, is a function of both the increase in the specific surface of the material (expressed in cm/cm or cm/g) and of the grinding resistance of the material. This can be expressed by the formula

where c is a material constant representing the grinding resistance, and So and S are the specific surfaces of the material before and after the grinding operation respectively. The formula is an expression of Rittingers Law which is shown by tests to be reasonably accurate up to a specific surface of 10,000 cm/cm.

When the grinding resistance c has been determined by trial grinding to laboratory scale, the net power E required for each grinding stage desired may be determined by the formula, at least as long as Rittingers Law is valid. If grinding is to be carried out not to a certain specific surface S but to a certain particle size k, the correlation between S and k must be determined. The particle size is often expressed in terms of particle size at e.g. 95, 90 or 80% quantity passing and is denoted k95, k90 or k80.

where E =the specific power consumption expressed in kWh/short ton. Eo = a proportionality and work factor called work index k80p = particle size of the product at 80% passage (micron) k80f =the corresponding value for the raw material (micron)

The value of Eo is a function of the physical properties of the raw material, the screen analyses of the product and raw material respectively, and the size of the mill. The value for easily-ground materials is around 7, while for materials that have a high grinding resistance the value is around 17.

Eo is correlated to a certain reduction ratio, mill diameter etc. Corrections must be made for each case. The simplest method of calculating the specific power consumption is test grinding in a laboratory mill, and comparison of the results with a known reference material. The sample is ground in batches for 3, 6,12 minutes, a screen analysis is carried out after each period, after which the specific surface is determined. A good estimate of the grinding characteristics of the sample can be obtained by comparison of the specific surfaces with corresponding values for the reference material.

When the net power required has been determined, an allowance is made for mechanical losses. The gross power requirement thus arrived at, should with a satisfactory margin be utilised by the mill selected.

The critical speed of a rotating mill is the RPM at which a grinding medium will begin to centrifuge, namely will start rotating with the mill and therefore cease to carry out useful work. This will occur at an RPM of ncr, which may be determined by the formula

where D is the inside diameter in meters of the mill. Mills are driven in practice at a speed corresponding to 60-80% of the critical speed, the choice of speed being influenced by economical considerations. Within that range the power is nearly proportional to the speed.

The charge volume in the case of rod and ball mills is a measure of the proportion of the mill body that is filled by rods or balls. When the mill is stationary, raw material and liquid should fill the voids between the grinding media, in order that these should be fully utilized.

Maximum mill efficiency is reached at a charge volume of approximately 55%, but for a number of reasons 45-50% is seldom exceeded. The efficiency curve is in any case quite flat about the maximum. In overflow mills the charge volume is usually 40%, while there is a greater choice in the case of grate discharge mills.

For coarse grinding in rod mills, the rods used have a diameter of 50-100 mm and their lengths are approx. 150 mm below the effective inside shell length. Rods will break when they have been worn down to about 20 mm and broken rods must from time to time be taken out of the mill since otherwise they will reduce the mill capacity and may cause blockage through piling up. The first rod charge should also contain a number of rods of smaller diameter.

It may be necessary to charge the mill with rods of smaller diameter when fine grinding is to be carried out in a rod mill. Experience shows that the size of the grinding media should bear a definite relationship to the size of both the raw material and the finished product in order that optimum grinding may be achieved. The largest grinding media must be able to crush and grind the largest pieces of rock, while on the other hand the grinding media should be as small as possible since the total active surface increases in inverse proportion to the diameter.

A crushed mineral whose largest particles pass a screen with 25 x 25 mm apertures shall be ground to approx. 95% passing 0.1 mm in a 2.9 x 3.2 m ball mill of 35 ton charge weight. In accordance with Olewskis formula

Grinding media wear away because of the attrition they are subjected to in the course of the grinding operation, and in addition a continuous reduction in weight takes place owing to corrosion. The rate of wear will in the first place depend on the abrasive properties of the mineral being ground and naturally also on the hardness of the grinding media themselves.

The wear of rods and balls is usually quoted in grammes per ton of material processed (dry weight) and normal values may lie between 100 and 1500 g/ton. Considerably higher wear figures may however be experienced in fine wet grinding of e.g. very hard siliceous sand.

A somewhat more accurate way of expressing wear is to state the amount of gross kWh of grinding power required to consume 1 kg of grinding media. A normal value in wet grinding is 15 kWh/kg.The wear figures in dry grinding are only 10-30 % of the above.

where c is a constant which, inter alia, takes into consideration the mean slope a of the charge, W is the weight in kp of the charge n is the RPM Rg is the distance in metres of the centre of gravity from the mill centre

W for rod and ball mills shall be taken as the weight of the rod or ball charge, i.e. the weight of the pulp is to be ignored. For pebble mills therefore W is to be calculated on the basis of the bulk weight of the pebbles.

It should be pointed out that factor c in the formula is a function of both the shape of the inner lining (lifter height etc.) and the RPM. The formula is however valid with sufficient accuracy for normal speeds and types of lining.

The diagram gives the values of the quantity Rg/d as a function of the charge volume, the assumption being that the charge has a plane surface and is homogeneous, d is the inside diameter of the mill in metres. The variation of the quantity a/d, where a is the distance between the surface of the charge and the mill centre, is also shown in the same figure.

In order to keep manufacturing costs at a minimum level, Morgardshammar has a series of standard mill diameters up to and including 6.5 m. Shell length, however, can be varied and tailor made for each application. The sizes selected are shown on the tables on page 12-13 and cover the power range of 200-5000 kW.

Shells with a diameter of up to about 4 m are made in one piece. Above this dimension, the shell is divided into a number of identical pieces, bolted together at site, in order to facilitate the transport. The shell is rolled and welded from steel plate and is fitted with welded flanges of the same material. The flanges are machined in order to provide them with locating surfaces fitting into the respective heads. The shells of ball and pebble mills are provided with 2 manholes with closely fitting covers. The shells have drilled holes for different types of linings.

Heads with a diameter of up to about 4 m are integral cast with the trunnion in one piece. Above this diameter the trunnion is made as a separate part bolted to the head. The head can then be divided in 2 or 4 pieces for easy transport and the pieces are bolted together at site. The material is cast steel or nodular iron. The heads and the trunnions have drilled holes for the lining.

Spherical roller (antifriction) bearings are normally used. They offer the most modern and reliable technology and have been used for many years. They are delivered with housings in a new design with ample labyrinth seals.

For very large trunnions or heavy mills, i.e. for primary autogenous grinding mills. Morgardshammar uses hydrostatic shoe bearings. They have many of the same advantages as roller bearings. They work with circulating oil under pressure.

The spherical roller bearing and the hydrostatic shoe bearing take a very limited axial space compared to a conventional sleeve bearing. This means that the lever of the bearing load is short. Furthermore, the bending moment on the head is small and as a result of this, the stress and deformation of the head are reduced. Ask Morgardshammar for special literature on trunnion bearings.

Ring gears are often supplied with spur gears. They are always split in 2 or 4 pieces in order to facilitate the assembly. Furthermore, they are symmetrical and can be turned round in order to make use of both tooth flanks. The material is cast steel or nodular iron. They are designed in accordance with AGMA.The ring gear may be mounted on either the feed or the discharge head. It is fitted with a welded plate guard.

The pinion and the counter shaft are integral forged and heat treated of high quality steel. For mill power exceeding about 2500 kW two pinions are used, one on each side of the mill (double-drive). The pinion is supported on two spherical roller bearings.

The trunnion bearings are lubricated by means of a small motor- driven grease lubricator. The gear ring is lubricated through a spray lubricating system, connected to the electric and pneumatic lines. The spray nozzles are mounted on a panel on the gear ring guard.

In order to protect the parts of the mill that come into contact with the material being ground, a replaceable lining of wear-resistant material is fitted. This may take the form of unalloyed or alloyed rolled or cast steel, heat treated if required, or rubber of the appropriate wear resistant quality. White cast iron, unalloyed or alloyed with nickel (Ni-hard), may also be used.

The shape of the mill lining is often of Lorain-type, consisting of plates held in place between lifter bars (or key bars) of suitable height bolted on to the shell. This system is used i.e. of all well-known manufacturers of rubber linings. Ball mills and autogenous mills with metal lining also can be provided with single or double waved plates without lifter bars.

In grate discharge mills the grate and the discharge lifters are a part of the lining. The grate plates with tapered slots or holes are of metal or rubber design. The discharge lifters are fabricated steel with thick rubber coating. Rubber layer for metal linings and heavy corner pieces of rubber are included in a Morgardshammar delivery as well as attaching bolts, washers, seal rings, and self-locking nuts. A Morgardshammar overflow mill can be converted into a grate discharge mill only by changing some liner parts and without any change of the mill. Trunnion liners are rubber coated fabricated steel or cast steel. In grate discharge mills the center cone and the trunnion liner form one piece.

Scoop feeders in combination with drum feeders are used when retaining oversize from a spiral or rake classifier. As hydrocyclones are used in most closed grinding circuits the spout feeders are used most frequently.

Vibrating feeders or screw feeders are used when charging feed to dry grinding mills. Trommel screens are used to protect slurry pumps and other transport equipment from tramp iron. Screens can have perforated rubber sheets or wire mesh. The trommel screens are bolted to the discharge trunnion lining.

Inching units for slow rotation of the mills are also furnished. Rods to the rod mills are charged by means of manual or automatic rod charges. Erection cradles on hydraulic jacks are used when erecting medium or big size mills at site.

A symbol of dependable quality ore milling machinery manufacturing, industrial and mining equipment, ball mills and rod mills as well as supplies created for your specific needs. During this period thousands of operators have experienced continuous economical and unequalled service through their use.As anindustrial ball mill manufacturer and supplier, we havecontinuously accumulated knowledge on grinding applications. It has contributed greatly to the grinding process through the development and improvement of such equipment.

Just what is grinding? It is the reduction of lump solid materials to smaller particles by the application of shearing forces, pressure, attrition, impact and abrasion. The primary consideration, then, has been to develop some mechanical means for applying these forces. The modern grinding mill applies power to rotate the mill shell and thus transmits energy to some form of media which, in turn, fractures individual particles.

Through constant and extensive research, in the field of grinding as well as in the field of manufacturing. Constantly changing conditions provide a challenge for the future. Meeting this challenge keeps our company young and progressive. This progressive spirit, with the knowledge gained through the years, assures top quality equipment for the users of our mills.

You are urged to study the following pages which present a detailed picture of our facilities and discuss the technical aspects of grinding. You will find this data helpful when considering the selection of the grinding equipment.

It is quite understandable that wetakes pride in the quality of our mills.Complementing the human craftsmanship built into these mills, our plants are equipped with modern machines of advanced design which permit accurate manufacturing of each constituent part. Competent supervision encourages close inspection of each mill both as to quality and proper fabrication. Each mill produced is assured of meeting the high required standards. New and higher speed machines have replaced former pieces of equipment to provide up-to-date procedures. The use of high speed cutting and drilling tools has stepped up production, thereby reducing costs and permitting us to add other refinements and pass these savings on to you, the consumer.

Each foundry heat is checked metallurgically prior to pouring. All first castings of any new design are carefully examined by the use of an X-ray machine to be certain of uniformity of structure. The X -ray is also used to check welding work, mill heads, and other castings.

Each Mills, regardless of size, is designed to meet the specific grinding conditions under which it will be used. The speed of the mill type of liner, discharge arrangement, size of feeder, size of bearings, mill diameter and length, and other factors are all considered to take care of the size of feed, tonnage, circulating sand load, selection of balls or rods, and the final size of grind.

All Mills are built with jigs and templates so that any part may be duplicated. A full set of detailed drawings is made for each mill and its parts. This record is kept up to date during the life of the mill. This assures accurate duplication for the replacement of wearing parts during the future years.

As a part of our service our staff includes experienced engineers, trained in the field of metallurgy with special emphasis on grinding work. This knowledge, as well as a background gained from intimate contact with various operating companies throughout the world, provides a sound basis for consultation on your grinding problems. We take pride in manufacturing rod mills and ball millsfor the metallurgical, rock products, cement, process, and chemical industries.

As an additional service we offer our testing laboratories to check your material for grindability. Since all grinding problems are different some basis must be established for recommending the size and type of grinding equipment required. Experience plays a great part in this phase however, to establish more direct relationships it is often essential to conduct individual grindability tests on the specific material involved. To do this we have established certain definite procedures of laboratory grinding work to correlate data obtained on any new specific material for comparison against certain standards. Such standards have been established from conducting similar work on material which is actually being ground in Mills throughout the world. The correlation between the results we obtain in our laboratory against these standards, coupled with the broad experience and our companys background, insures the proper selection and recommendation of the required grinding equipment.

When selecting a grinding mill there are many factors to be taken into consideration. First let us consider just what constitutes a grinding mill. Essentially it is a revolving, cylindrical shaded machine, the internal volume of which is approximately one-half filled with some form of grinding media such as steel balls, rods or non-ferrous pebbles.

Feed may be classified as hard, average or soft. It may be tough, brittle, spongy, or ductile. It may have a high specific gravity or a low specific gravity. The desired product from a mill may range in size from a 4 mesh down to 200 mesh, or into the fine micron sizes. For each of these properties a different mill would be indicated.

The Mill has been designed to carry out specific grinding work requirements with emphasis on economic factors. Consideration has been given to minimizing shut-down time and to provide long, dependable trouble-free operation. Wherever wear takes place renewable parts have been designed to provide maximum life. A Mill, given proper care, will last indefinitely.

Mills have been manufactured in a wide variety of sizes ranging from laboratory units to mills 12 in diameter, with any suitable length. Each of these mills, based on the principles of grinding, provides the most economical grinding apparatus.

For a number of years ball mill grinding was the only step in size reduction between crushing and subsequent treatment. Subsequently smaller rod mills have altered this situation, providing in some instances a more economical means of size reduction in the coarser fractions. The principal field of rod mill usage is the preparation of products in the 4-mesh to 35-mesh range. Under some conditions it may be recommended for grinding to about 48 mesh. Within these limits a rod mill is often superior to and more efficient than a ball mill. It is frequently used for such size reduction followed by ball milling to produce a finished fine grind. It makes a product uniform in size with only a minimum amount of tramp oversize.

The basic principle by which grinding is done is reduction by line contact between rods extending the full length of the mill. Such line contact results in selective grinding carried out on the largest particle sizes. As a result of this selective grinding work the inherent tendency is to make size reduction with the minimum production of extreme fines or slimes.

The small rod mill has been found advantageous for use as a fine crusher on damp or sticky materials. Under wet grinding conditions this feed characteristic has no drawback for rod milling whereas under crushing conditions those characteristics do cause difficulty. This asset is of particular importance in the manufacture of sand, brick, or lime where such material is ground and mixed with just sufficient water to dampen, but not to produce a pulp. The rod mill has been extensively used for the reduction of coke breeze in the 8-mesh to 20-mesh size range containing about 10% moisture to be used for sintering ores.

Grinding by use of nearly spherical shaped grinding media is termed ball milling. Strictly speaking, such media are made of steel or iron. When iron contamination is detrimental, porcelain or natural non-metallic materials are used and are referred to as pebbles. When ore particles are used as grinding media this is known as autogenous grinding.

Other shapes of media such as short cylinders, cubes, cones, or irregular shapes have been used for grinding work but today the nearly true spherical shape is predominant and has been found to provide the most economic form.

In contrast to rod milling the grinding action results from point contact rather than line contact. Such point contacts take place between the balls and the shell liners, and between the individual balls themselves. The material at those points of contact is ground to extremely fine sizes. The present day practice in ball milling is generally to reduce material to 35 mesh or finer. Grinding in a ball mill is not selective as it is in a rod mill and as a result more extreme fines and tramp oversize are produced.

Small Ball mills are generally recommended not only for single stage fine grinding but also have wide application in regrind work. The Small Ball millwith its low pulp level is especially adapted to single stage grinding as evidenced by hundreds of installations throughout the world. There are many applications in specialized industrial work for either continuous or batch grinding.

Wet grinding may be considered as the grinding of material in the presence of water or other liquids in sufficient quantity to produce a fluid pulp (generally 60% to 80% solids). Dry grinding on the other hand is carried out where moisture is restricted to a very limited amount (generally less than 5%). Most materials may be ground by use of either method in either ball mills or rod mills. Selection is determined by the condition of feed to the mill and the requirements of the ground product for subsequent treatment. When grinding dry some provision must be made to permit material to flow through the mill. Mills provide this necessary gradient from the point of feeding to point of discharge and thereby expedites flow.

The fineness to which material must be ground is determined by the individual material and the subsequent treatment of that ground material Where actual physical separation of constituent particles is to be realized grinding must be carried to the fineness where the individual components are separated. Some materials are liberated in coarse sizes whereas others are not liberated until extremely fine sizes are reached.

Occasionally a sufficient amount of valuable particles are liberated in coarser sizes to justify separate treatment at that grind. This treatment is usually followed by regrinding for further liberation. Where chemical treatment is involved, the reaction between a solid and a liquid, or a solid and a gas, will generally proceed more rapidly as the particle sizes are reduced. The point of most rapid and economical change would determine the fineness of grind required.

Laboratory examinations and grinding tests on specific materials should be conducted to determine not only the fineness of grind required, but also to indicate the size of commercial equipment to handle any specific problem.

ball mill - retsch - powerful grinding and homogenization

Ball mills are among the most variable and effective tools when it comes to size reduction of hard, brittle or fibrous materials. The variety of grinding modes, usable volumes and available grinding tool materials make ball mills the perfect match for a vast range of applications.

RETSCH is the world leading manufacturer of laboratory ball mills and offers the perfect product for each application. The High Energy Ball Mill Emax and MM 500 were developed for grinding with the highest energy input. The innovative design of both, the mills and the grinding jars, allows for continuous grinding down to the nano range in the shortest amount of time - with only minor warming effects. These ball mills are also suitable for mechano chemistry. Mixer Mills grind and homogenize small sample volumes quickly and efficiently by impact and friction. These ball mills are suitable for dry, wet and cryogenic grinding as well as for cell disruption for DNA/RNA recovery. Planetary Ball Mills meet and exceed all requirements for fast and reproducible grinding to analytical fineness. They are used for the most demanding tasks in the laboratory, from routine sample processing to colloidal grinding and advanced materials development. The drum mill is a type of ball mill suitable for the fine grinding of large feed sizes and large sample volumes.

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Incorporated with modern features, we manufacture and export a quality tested range of Ball Mills. Using high-end quality mils steel and other metals these mills are manufactured as per international quality standards. Known for its high efficiency and outstanding performance, our mills are suitable for grinding hard minerals to power fines. These Ball Mills are also used to grind clinker for cement manufacturing, minerals, silicates and calcium bauxites.

Ball mills are primarily used for grinding materials in mineral, refractory, cement and chemical industries. Also, these are fine for silicates and some other materials that can be ground into fines. It may have wet process or dry process.

Working PrincipalBall mill is basically a horizontal cylinder, used to grind the material with the help of a rotating cylinder harmonious to steel grinding balls or ceramic balls. The cylinder revolves at an appropriate speed, letting the balls to grind or disperse the materials in a uniform manner. Depending upon the mill diameter, rotation is normally between 4 to 24 rotations per minute. Also the concept is like: bigger the diameter, slower the rotation. The mill centrifuge point is called as Critical Speed, and ball mills mostly function at 65% to 75% of the critical speed.

In general the ball mills are utilized to grind material 1/4 inch and better, 20 to 75 microns down to the particle size. Also, to have excellent efficiency with the ball mills, they must be functioned in closed circuit system. Some of the classifiers for assorting the discharge from ball mills are screens, cyclones and air-classifiers.

The ball mills are generally separated into two or three chambers along its length. And the chambers are separated by diaphragms. All chamber provides grinding to a specific size, subsequent chamber forms particle size finer in diameter.

Hardened Grinding Media which is steel forged is perfect for milling and dispersion process. The steel balls or ball mill media is suitable for speedy and contamination free milling, grinding of solids, etc. Alloy steel media is highly suitable for crushing and mixing hard materials due to its optimum hardness and high relative density. It is also fine for high pressure and impact grinding / crushing acts. Grinding applications are performed with the use of stainless steel balls and other shapes where no iron impurity is permissible, especially in food productions.

Generally, Mill liners are made from high chromium steel or manganese steel, and are selected on the basis of hardness and type of the material to be ground. Also, the design and thickness of the liners effect the grinding efficiency in Ball Mills, etc.Closed Circuit MillCirculating load and classification efficiency play a major role on the efficiency of closed circuit ball mill. These two factors are basically interconnected and hard to specify in the practice. In reducing the energy consumption in milling, the role of classification seems to be neglected. Ball mill works efficiently by making a coarse product, and precise fractions of this then being set-apart. Proportion of the mill-exit materials returned to the inlet. Also, it is essential for system efficiency that minimal amount of finished-product materials is returned to the inlet. Latest separators are effective in making a precise size and provide reduction of energy consumption and safety as well.

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Our organization has gained recognition as the affluent manufacturer and supplier of a qualitative range of Ball Mill. This mill consists of cylindrical shell that rotates on a horizontal axis, mounted on a sturdy structure. Our clients can avail this mill in different specifications in accordance with their specific demands.