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3 Common Problems and Solutions in Ball Mill Operation

Xinhai 2020-06-24(10:06:21) 369 0

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The stable operation of equipment is an important way to ensure the economic benefit of mineral processing plants. Due to long-term operation, ball mills of most mineral processing plants will cause various problems. They not only affect the normal operation of the whole dressing plant, but also damage the economic benefits of the dressing plant.

So, what are the common problems in the daily operation of ball mill? And how should we solve them when encountering these problems? This article will analyze the causes of three common ball mill problems and propose solutions.

ball mill

1.Ball mill has insufficient processing capacity and easily throws stones

For some ball mills, the feed amount of the mill is far from the design capacity in actual operation. When the feeding amount exceeds a certain limit, ball mill will throw out unground stones at the outlet, and the amount of stones thrown out is large. This not only increases the power consumption of ball mill, but also increases the labor intensity of personnel.

Reason #1: The particle size of the input material is too large (more than the original design value of 20mm)

Too large material particles will bring extra burden to the ball mill. And some super large material particles are not easy to be broken by steel ball, which will reduce the processing capacity of ball mill and increase the power consumption.

Solution: During operation, the operator of the ball mill should closely monitor the particle size of the material on the feeder. If it is found that the particle size of the material exceeds the designed maximum particle size, it shall immediately reduce or stop feeding, and take corresponding measures to ensure that the particle size of the material is qualified.

Reason #2:The supplement of steel balls is insufficient

Due to the long-term operation of ball mill, the steel balls will wear violently, the diameter will be reduced, and the impact force will be correspondingly weakened. When the steel balls in the ball mill are not replenished in time, the processing capacity of the ball mill will be reduced.

Solution: In order to maintain a certain ball filling coefficient and steel ball diameter, qualified steel balls should be added to the ball mill regularly according to the current of the ball mill and the amount of material accumulated by the ball mill.

Reason #3The inner lining of the ball mill is damaged

The perfect cylindrical lining of ball mill can increase the friction coefficient between the steel ball and the lining, which is beneficial to lifting the steel balls and materials and improving the processing capacity of the ball mill. As for the seriously worn lining, there will be a relatively large sliding between the steel ball and the lining. Therefore, more energy will be consumed on the friction between steel balls and the lining plate, instead of being used to lift steel balls, and the processing capacity of the ball mill will be significantly reduced. When the liner of the ball mill is damaged or falls off, you can hear the obvious impact sound.

Solution: If it happens, the ball mill should be stopped as soon as possible, and the damaged liner should be dealt with immediately to avoid large-scale damage of ball mill liner

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2.The slurry is easy to be thrown out from the ball mill outlet

During the ball mill operation, the slurry flows out of the sundry pipe with small stones.

Reason #1: The water-material ratio in ball mill is out of balance

The amount of water flowing through the ball mill barrel is an important parameter in operation, which reflects the carrying capacity of the solid particles in the ball mill. Therefore, the amount of water flowing through the barrel of the ball mill should correspond to the amount of material passing through the ball mill and be controlled within an appropriate range.

The water flowing through the barrel of the ball mill is mainly composed of the carrying water and the underflow of the cyclone. Under normal circumstances, underflow of the cyclone generally remains unchanged, but the premise is to ensure that the underflow grit nozzle of the cyclone is not worn. 

When the underflow grit of the cyclone wears out, the working conditions of the cyclone changed, which will increase the amount of underflow water in the cyclone and reduce the amount of overflow water in the top flow, thereby increasing the amount of water entering the ball mill.

Solution: In normal operation, pay attention to check the wear of the nozzle of the cyclone. Ensure that the water-to-material ratio at the inlet of the ball mill is within the normal range. This can not only ensure that the output of the ball mill is normal, but also reduce the pulp flick at the outlet, thereby reducing the labor intensity of personnel.

Reason #2:The choice of the hole diameter of the outlet cylindrical screen of the ball mill and the cleanliness of the outlet filter

If the ball mill outlet cylinder screen aperture is too large, the coarse material not only easy to increase the wear of the pump and cyclone, and even cause the pump plug. If the diameter of the outlet screen of the ball mill is too small, the filter screen is easy to block and cause the pulp mill to flick at the outlet. In addition, during normal operation, if the slurry concentration is high and the material contains certain impurities (such as wood chips, etc.), the clogging phenomenon of the ball mill outlet cylinder screen will also occur, resulting in the ball mill outlet slurry throwing.

Solution: You should choose the right mesh size and keep the outlet mesh clean.

3.The export of ball mill is easy to throw steel balls

During the ball mill operation, the steel balls flow out of the outlet with small stones.

Reason: The material level in the ball mill is too high

The reason why the steel balls are easy to be thrown out at the outlet of the ball mill is that the material level in the ball mill is too high. The reason for the excessively high material level in the ball mill is that, first, the water-to-material ratio is reduced, which reduces the carrying capacity of the water and causes the material level in the ball mill to increase. Second, the inlet diameter is too large, so that the residence time of the material in the ball mill is increased, which causes the material level in the ball mill to be too high. Third, there are too many steel balls in the ball mill.

Solution: During the operation, the water-to-material ratio, the inlet diameter and the amount of steel balls in the ball mill should be strictly controlled.

Conclusion

The above are the causes and solutions of the three common problems of ball mill. In order to ensure the stable and efficient operation of the equipment, in addition to selecting the type of equipment that conforms to the processing process, daily maintenance and maintenance are more important. Therefore, it is recommended that each mine owner consult the equipment manufacturer with the overall dressing qualification when selecting the ball mill, and choose the equipment suitable for its own process, which guarantees the production efficiency and economic benefits of the entire dressing plant fundamentally.


Ball Mill

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