Tongli overflow ball mill adopts air clutch or liquid soft start to realize segmented start of the main motor and cylinder of the ball mill, reduce the installed power, and reduce the starting current from 6.5 times of direct start to 2.5 times. The overflow ball mill uses the rotation of the cylinder to drive the steel balls and ore to collide and rub in the cylinder, so as to achieve the purpose of crushing the ore. Compared with other types of ball mills, the overflow ball mill is equipped with an overflow device at the discharge end, so that the fine-grained product stays in the cylinder for a longer time, thereby achieving a finer grinding effect. The discharge particle size can reach 0.074-0.4mm, which is often used in processes that require fine-grained products. Experimental data shows that the overflow ball mill can grind the ore to a finer particle size within the same grinding time, which is suitable for fine grinding operations.
Efficient Overflow type Ball Mill Grinding Solution
A MACHINE YOU CAN DEPEND ON!
The overflow ball mill produced by Tongli Company adopts air clutch or liquid soft start to realize the segmented starting of the main motor-cylinder of the ball mill, reduce the installed power, and reduce the starting current from 6.5 times of direct starting to 2.5 times.
Overflow ball mills have been widely used in mineral processing, chemical industry, building materials and other industries due to their high efficiency and stable performance. They are an ideal grinding equipment.
The cylinder is generally welded with steel plates, which is sturdy and durable, and is precisely processed to ensure its roundness and stability. Usually a double-bin design is adopted, with the first bin for coarse grinding and the second bin for fine grinding, which improves the grinding efficiency.
Equipped with an overflow device, fine particles can be discharged directly from the mill, while coarse particles remain in the mill for further grinding. This design makes the particle size distribution of the product more uniform. It can effectively control the particle size range of the product and reduce over-grinding.
Model | Inner Diameter (mm) | Effective Length (mm) | Effective Volume (m³) | Working Speed (r/min) | Media Filling Rate (%) | Max Ball Load (t) | Main Motor Power (kW) | Main Motor Poles |
ZJTLY2136 | 2100 | 3600 | 11 | 23.8 | 40 | 20 | 210 | 8 |
ZJTLY2736 | 2700 | 3600 | 20.6 | 18.5 | 40 | 34 | 400 | 32 |
ZJTLY2740 | 2700 | 4000 | 20.6 | 20.5 | 40 | 38 | 400 | 32 |
ZJTLY2745 | 2700 | 4500 | 23 | 20.5 | 40 | 32 | 450 | 32 |
ZJTLY2760 | 2700 | 6000 | 30.4 | 20.5 | 40 | 56 | 630 | 32 |
ZJTLY3245 | 3200 | 4500 | 32.8 | 18.5 | 40 | 61 | 630 | 36 |
ZJTLY3254 | 3200 | 5400 | 39.5 | 18.5 | 40 | 73 | 1000 | 36 |
ZJTLY3260 | 3200 | 6000 | 43.7 | 18.5 | 40 | 81 | 1000 | 36 |
ZJTLY3645 | 3600 | 4500 | 41 | 17.5 | 40 | 76 | 1000 | 36 |
ZJTLY3650 | 3600 | 5000 | 46.2 | 17.3 | 40 | 86 | 1250 | 40 |
ZJTLY3660 | 3600 | 6000 | 55 | 17.3 | 40 | 102 | 1250 | 40 |
ZJTLY3690 | 3600 | 9000 | 83 | 17.3 | 38 | 145 | 1800 | 30 |
ZJTLY3862 | 3800 | 6200 | 64 | 16.8 | 40 | 118 | 1500 | 30 |
ZJTLY4060 | 4000 | 6000 | 70 | 16.8 | 35 | 113.4 | 1500 | 30 |
ZJTLY4067 | 4000 | 6700 | 78 | 16.2 | 38 | 118 | 1600 | 30 |
ZJTLY4361 | 4270 | 6100 | 80 | 15.7 | 40 | 144 | 1750 | 30 |
ZJTLY4385 | 4270 | 8500 | 110 | 15.7 | 40 | 205 | 2500 | 30 |
ZJTLY4561 | 4572 | 6100 | 93.3 | 15.1 | 35~38 | 151 | 2200 | 30 |
ZJTLY4564 | 4500 | 6400 | 97 | 15.1 | 30~35 | 134 | 1950 | 30 |
ZJTLY4576 | 4500 | 7600 | 111.7 | 15.1 | 30~38 | 180 | 2200 | 30 |
ZJTLY4669 | 4600 | 6900 | 105.9 | 15 | 38~40 | 185 | 2300 | 30 |
ZJTLY4870 | 4800 | 7000 | 118.9 | 15 | 38~40 | 208 | 2500 | 30 |
ZJTLY4883 | 4800 | 8300 | 138 | 15 | 38~40 | 240 | 3000 | 30 |
ZJTLY5064 | 5030 | 6400 | 121 | 14.4 | 40 | 224 | 2600 | 30 |
ZJTLY5067 | 5030 | 6700 | 123.2 | 14.4 | 40 | 227 | 3000 | 30 |
ZJTLY5070 | 5030 | 7000 | 128.8 | 14.4 | 38~40 | 227 | 3000 | 30 |
ZJTLY5074 | 5030 | 7400 | 136 | 14.4 | 38~40 | 240 | 3300 | 30 |
ZJTLY5080 | 5030 | 8000 | 147.2 | 14.4 | 38~40 | 246 | 3300 | 30 |
ZJTLY5583 | 5500 | 8300 | 182 | 13.7 | 35~38 | 296 | 4100 | 30 |
ZJTLY5585 | 5500 | 8500 | 185 | 13.7 | 35~38 | 300 | 4500 | 30 |
ZJTLY5588 | 5500 | 8800 | 191.5 | 13.7 | 35~38 | 335 | 4500 | 30 |
ZJTLY6095 | 6000 | 9500 | 249.3 | 13 | 38 | 462.6 | 6000 | 30 |
ZJTLY67116 | 6710 | 11570 | 385 | 12.5 | 35~38 | 625 | 2*4700 | 30 |
ZJTLY73115 | 7315 | 11497 | 494.1 | 12 | 38 | 871.2 | 2*675 | 30 |
ZJTLY80120 | 8000 | 12000 | 570.5 | 11.5 | 38 | 1005.8 | 15000 | -- |
The material enters the grinding cylinder of the ball mill through the feed inlet. The feed inlet is usually equipped with a feeding device to uniformly deliver the material into the mill. The cylinder of the ball mill rotates along its axis, and the speed and angle of rotation affect the grinding efficiency. The rotating cylinder drives the internal steel balls and material to move together. Inside the cylinder, a certain number of steel balls are installed. These steel balls are lifted to a certain height as the cylinder rotates. During their descent, the steel balls impact and grind the material through collision and friction, achieving material pulverization.
Within the cylinder, the material continuously collides and rubs against the steel balls, gradually grinding into fine particles. The movement of the material within the cylinder also helps to ensure uniform grinding. The key feature of an overflow ball mill is its discharge system. The discharge end of the mill is equipped with an overflow device (overflow trough) that allows fine material to flow out through this device. The finely ground material flows out from the discharge end of the mill through the overflow device, while the coarse material remains in the mill for further grinding.
This design enables the mill to continuously process material and maintain a good product particle size distribution. The overflow ball mill can be used in conjunction with other equipment (such as classifiers and screening devices) to form a closed or open circuit system. In a closed circuit system, the coarse material is sent back into the mill for further grinding, while the fine material is sent to the next processing stage. In an open circuit system, the fine material is directly discharged from the mill.
The rotation speed of the ball mill directly influences the grinding effect. Typically, the mill's rotation speed should be maintained between 60%-80% of the critical speed. Appropriately increasing the rotation speed can enhance the impact force of the steel balls on the material, improving the crushing efficiency and thus increasing the output.
Maintaining a uniform and stable feed rate is crucial for improving the mill's output. If the feed rate is too low, the material layer inside the mill is thin, leading to poor grinding efficiency; if the feed rate is too high, it can easily cause the mill to overload, reducing the grinding efficiency. Utilizing an automated control system to adjust the feed rate in real-time can optimize the output.
Adjusting the size and proportion of the steel balls based on the material properties can also improve efficiency. Generally, increasing the proportion of smaller steel balls can enhance the grinding efficiency for fine material, while larger steel balls are suitable for coarse grinding. A reasonable mix of steel balls can improve the mill’s crushing efficiency, thereby increasing output.
Optimizing the crushing process before the material enters the ball mill is also important. Pre-treating the material to achieve a suitable particle size can make it easier to grind, thereby increasing the ball mill’s output. Improving the design of the mill’s partition plates and liners can reduce energy loss and enhance the grinding efficiency. For example, using trapezoidal or wave-shaped liners can increase the drop height of the steel balls, enhancing the grinding effect.
Daily inspections of the mill's operating conditions are essential, including checks on rotation speed, vibration, and noise levels. Any abnormalities should be promptly recorded and addressed. Regularly clean the interior and surrounding areas of the mill to prevent material buildup and dust from impacting the equipment's operation.
Periodically check the lubricant oil levels, oil quality, and its viscosity. Based on the equipment usage and manufacturer recommendations, regularly replace the lubricant oil. Inspect all lubrication points (such as bearings and gears) to ensure they are working properly and that the lubrication system is functioning effectively to prevent wear and malfunctions.
Regularly inspect the wear condition of the mill liners. When the liners are severely worn, they need to be replaced to ensure the grinding efficiency and safe operation of the mill. Periodically check the wear and lubrication of bearings and gears. If abnormal sounds or vibrations are detected, the mill should be stopped immediately for inspection and resolution.
Adjust the height and angle of the discharge system (such as the overflow device) as needed to ensure the smooth discharge of materials. Develop a detailed maintenance plan and schedule based on the equipment's usage frequency and manufacturer recommendations to ensure all maintenance tasks are completed on time.
Provide periodic training for operators to ensure they are familiar with the equipment's operating procedures, maintenance methods, and safety precautions. Conduct regular overhauls or inspections according to the equipment's operating time or production requirements, including replacing worn parts and checking the electrical system. If necessary, invite professional technicians to inspect and maintain the equipment to ensure it is in optimal working condition.
Metallic Ores: It is used for grinding various metallic ores such as iron ore, copper ore, lead-zinc ore, etc. It is particularly suitable for fine grinding large chunks of ore to facilitate subsequent beneficiation processes.
Non-metallic Ores: Suitable for processing non-metallic ores like quartz, feldspar, fluorite, etc., to improve the grade and recovery rate of the ores.
Cement Raw Material Grinding: Used for grinding raw materials in cement production, such as limestone, clay, sandstone, etc., helping to enhance the fineness and uniformity of raw materials to meet cement production requirements.
Cement Clinker Grinding: Employed to grind cement clinker into cement powder, increasing the fineness and strength of the cement.
Chemical Raw Material Processing: Used for processing various chemical raw materials like titanium dioxide, sulfates, pigments, etc., finely grinding these raw materials to improve the quality and performance of the products.
Catalyst Grinding: In the production of catalysts, it is used to grind catalyst carrier materials, ensuring the uniformity and activity of the catalysts.
Ceramic Raw Materials: Used for crushing raw materials in ceramic production, such as kaolin, feldspar, quartz, etc., helping to improve the quality and uniformity of ceramic products.
Glass Raw Materials: Employed for grinding raw materials in glass production, such as quartz sand, sodium feldspar, etc., ensuring the uniform fineness of glass raw materials.
Metal Powder Production: Used for grinding various metal powders like aluminum powder, copper powder, etc., for metal material processing and synthesis.
Fine Grinding of Metallurgical Ores: In metallurgical processes, used for the fine grinding of metallurgical ores to enhance smelting efficiency and product quality.
Food Raw Material Crushing: Utilized for grinding various food raw materials such as grains, beans, etc., to improve the fineness of food raw materials and meet production process requirements.
Pharmaceutical Raw Material Processing: Used for grinding pharmaceutical raw materials to a fine powder state, enhancing the solubility and bioavailability of drugs.
Waste Treatment: Used for crushing and processing industrial waste, slag, etc., helping to recycle waste and reduce environmental pollution.
Sewage Treatment: In sewage treatment processes, used for grinding and processing sludge, improving the treatment effect.
Material Discharge Issues:
Possible Causes: The discharge system might be clogged, the overflow device design could be suboptimal, or the material may be too sticky and wet
Solutions:
Inspect and clean the discharge system to ensure there is no blockage.
Adjust the height and angle of the overflow device to optimize discharge efficiency.
Control the moisture content of the material or preprocess sticky materials to ensure smooth discharge.
Mill Overload:
Possible Causes: Excessive feed rate, high material hardness, excessive load of steel balls, or too long grinding time.
Solutions:
Adjust the feed rate to maintain a uniform and stable input.
Assess the hardness of the material and adjust the specifications and quantity of the steel balls accordingly.
Adjust the grinding time appropriately to avoid prolonged overload operation.
Poor Grinding Performance:
Possible Causes: Worn steel balls, overly large material particles, inappropriate rotation speed, or worn mill liners.
Solutions:
Regularly replace or replenish worn steel balls and optimize their specifications and proportions.
Adjust the feed particle size to ensure the material is suitable for grinding.
Adjust the mill's rotation speed to keep it within the optimal range.
Inspect and replace the mill liners to ensure they are in good condition.
Abnormal Temperature:
Possible Causes: Excessive mill speed, poor lubrication, or overheating of the material.
Solutions:
Adjust the mill's rotation speed to avoid excessive speed leading to temperature rise.
Check the lubrication system to ensure there is adequate lubrication oil and that it is functioning properly.
Control the material temperature to prevent high temperatures from affecting the equipment.
High temperatures can lead to a decrease in the viscosity of lubricating oil, thereby reducing lubrication effectiveness and accelerating equipment wear. In high-temperature environments, the components of the ball mill may experience thermal expansion, which can affect the normal operation of the equipment. Additionally, excessive temperatures can cause the motor and electrical components to overheat, increasing the risk of failure.
In high-humidity environments, materials may absorb moisture, increasing their stickiness and leading to material buildup inside the mill or discharge difficulties. Moisture can also cause corrosion of the equipment's electrical and mechanical components. A damp environment can cause rust or corrosion inside the mill, thereby shortening the equipment's lifespan.
Seasonal climate changes can lead to fluctuations in temperature and humidity, affecting the operational stability of the equipment. Under extreme climatic conditions (such as extreme heat or cold), special maintenance and adjustment measures may be required. Understanding the impact of the climate environment on the overflow ball mill and taking appropriate countermeasures can effectively maintain the normal operation of the equipment, extend its lifespan, and improve production efficiency.
The main raw materials are limestone, clay and iron.
Byproduct of blast furnace smelting,Admixture for cement and concrete.
Used for power generation and industrial fuel,ball mill can grind coal into powder to improve combustion efficiency.
It is a carbonate rock with calcite as its main component.
Commonly used in construction and decoration materials, grinding can enhance its physical properties.
Used in construction and medical materials, it can be made into gypsum board after grinding
Used in iron smelting, the raw ore can be ground to improve smelting efficiency.
The main source of copper extraction, it can be ground to improve ore dressing efficiency.
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