Five measures to reduce the wear effect of ball mill steel balls

The wear of ball mill steel balls has always been one of the headaches for many users, and in severe cases, it can also affect the processing efficiency of equipment. So, how can we reduce the wear of steel balls?

1. Control the speed of the ball mill

Under the premise of reasonable steel ball ratio in the ball mill, with the increase of ball mill speed, the steel balls in the cylinder will be in a leaking state and become thrown pile bodies. When the speed rate increases to a certain level, the useful power reaches its maximum value, and the grinding effect is better, and the wear of the ball mill steel balls is also more reasonable. The theoretical critical speed rate of a ball mill is generally 78-84%. Due to material properties and other factors, the ball mill speed needs to be determined based on the actual situation.

2. Regularly clean expired balls

Add new steel ball Excessive failure of balls and an increase in ball breakage rate can lead to an increase in the bearing capacity of the ball mill and an increase in power consumption, which is one of the reasons for high ball consumption. Therefore, it is very important to regularly clean the failed balls and add new steel balls according to the grading.

3. Reasonable grading of steel balls

The size and proportion of steel balls inside the mill vary, with large balls accounting for 30-40%, medium balls accounting for 40%~30%, and small balls accounting for 30%. As the large balls continue to wear down in the later stage, their diameter becomes smaller and smaller. Therefore, it is necessary to regularly add large balls, but attention should be paid to the reasonable ratio. If the proportion of large balls inside the mill exceeds 70%, it will lead to a decrease in the effective area of the grinding balls, which not only increases ball consumption but also affects the grinding efficiency If the proportion of large-diameter steel balls in the grinding process exceeds 70%, it will result in a decrease in the effective area of the grinding balls. We know that the grinding efficiency of a ball mill is determined by the sum of the work done by each steel ball. Too many large balls result in many grinding balls not being able to exert their effectiveness, leading to a decrease in the grinding efficiency of the ball mill.

4. Add grinding aids or perform heating treatment

The grindability of materials is also an important factor affecting the consumption of steel balls in ball mills. In practical production, if difficult to grind materials are encountered, some grinding aids can be added appropriately or the ore can be heated to reduce the hardness of the materials, improve grindability, and also be an effective method to reduce ball consumption.

5. Reduce the particle size of the feed material

The larger the particle size of the ball mill, the greater the work done by the ball mill on the material. In order to achieve the specified grinding fineness, the workload of the ball mill will inevitably increase, and the energy consumption of the steel balls will also increase. To reduce the power consumption of the ball mill, the feed particle size for grinding can be reduced. Therefore, it is necessary to require the product particle size of the crushed ore to be small, that is, to "crush more and grind less".