In grinding operation, the consumption of steel grinding balls is very large, about 10 times more than that of mill liner. In order to make up for the loss of steel ball and keep the ball load particle size constant in the ball mill, it is necessary to add steel ball regularly according to a certain proportion.

The consumption of ball mill mainly comes from mechanical wear and corrosion wear. They are the irreversible process of "physical mechanical" and "physical chemical" on the solid surface. How to effectively reduce the energy consumption of ball mill under the premise of ensuring the grinding quality of ball mill?

1 change ore grindability

The grindability of the materials fed into the ball mill is one of the reasons that affect the energy consumption of the ball mill. Generally, if the grindability of the materials fed into the ball mill is small, the ore is easy to grind, and the wear of the ball mill is smaller, and the energy consumption is also small; otherwise, the opposite is true.

In the actual production, if it is difficult to grind the ore or the ore requires fine grinding, it can be considered to add certain chemical agents to improve the grinding effect and increase the grinding efficiency in the grinding process when the economic and site conditions permit, or to heat the ore to change the mechanical properties of the whole ore and reduce the mineral hardness. Both methods can effectively reduce the energy consumption of ball mill.

2 reduce the feed particle size

If the size of ball mill is large, the work of ball mill on the material will be larger. To achieve the specified grinding fineness, the workload of ball mill is bound to increase, and then the energy consumption of steel ball will increase.

In order to reduce the power consumption of the ball mill, the feeding particle size of the grinding can be reduced, so it is required that the particle size of the ore crushing product is small, that is to say, "more crushing and less grinding".

3 control the filling rate of steel ball

When the rotation speed of the ball mill reaches a certain degree, the larger the filling rate is, the more times the ball strikes the material, the larger the grinding area and the faster the wear. In addition, if the filling rate is too high, the movement state of the ball mill will be changed, and the impact effect on the large particle material will be reduced. On the contrary, the filling rate is too small and the grinding effect is weak.

At present, the filling rate of steel ball in grinding operation of concentrator is generally 45% ~ 50% for lattice mill and 38% ~ 42% for overflow mill. If according to the actual situation of each concentrator, it is not a reasonable filling rate, so it is necessary to determine the reasonable ball loading through beneficiation test.

4 control ball size and ratio

Because the ball in the ball mill is in point contact with the material, if the diameter of the ball is too large and the crushing force is large, the wear will be too fast, and it is easy to cause the material to break along the direction of the penetration force, affecting the grinding efficiency.

In addition, if the ball filling rate is the same, if the ball diameter is too large, the number of individual steel balls will be small, the probability of crushing will be low, the phenomenon of over crushing will be intensified, and the product particle size will be uneven; if the ball is too small, the crushing force on the ore will be small, and the grinding efficiency will be low. Therefore, reasonable ball size ratio can not only reduce the steel consumption of ball mill, but also effectively improve the grinding efficiency.

5 control grinding concentration

The size of grinding concentration will affect the specific gravity of slurry, the adhesion of materials around the steel ball and the fluidity of slurry. If the grinding concentration is appropriate, the adhesion of the material around the steel ball is good, the impact and grinding effect of the steel ball on the material is also large, and the wear of the steel ball is fast.

In the actual production, the grinding concentration can be controlled by controlling the ore feeding quantity, or supplying water quantity, or adjusting the grading function, etc.

6. Control the rotation speed of ball mill

On the premise of reasonable ball ratio of ball mill, with the increase of rotation speed of ball mill, the steel ball in the barrel will be in the state of falling into the pile. When the rotation speed rate is increased to a certain extent, the useful power will reach the upper limit. At this time, the grinding effect is better, and the wear of ball mill steel ball is more reasonable. The theoretical critical speed rate of ball mill is generally 78-85%. Due to the nature of the material and other factors, it is necessary to determine the rotation speed of the ball mill according to the actual situation.

In addition, the quality of steel balls affects not only the productivity, but also the ball consumption, thus affecting the grinding cost. When selecting steel balls, the first is that the harder the steel balls are, the better the hardness is, but the proper hardness value. If only the ball consumption is considered, the higher the hardness is, the lower the consumption is. But for the productivity of the mill, the productivity increases with the increase of the hardness of the steel balls in a certain range When the hardness exceeds a certain range, the productivity of the mill will be adversely affected, the productivity of the mill will be reduced, and the steel ball will be fragile. Second, the ball density of ball mill is also a problem that can not be ignored.

In the process of grinding, there are many factors that affect the energy consumption of ball mill, and most of them are difficult to make quantitative analysis, only qualitative analysis and judgment. In order to reduce the power consumption of ball mill on the premise of ensuring a reasonable quality index, it is necessary to consider from multiple links, and control each link to achieve the technical and economic indexes and good product quality indexes.

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# Six key points of reducing ball wear of ball mill

*2020-04-03*