Livraison de l'entreprise de broyeur à boulets

Brève description:

1. PAINPOINT DRIVEN OPENING Is your mineral processing operation constrained by inconsistent grind size, usure excessive de la doublure, or unplanned maintenance halting production? These common challenges directly impact your plant’s throughput and profitability. Considérez les coûts: unscheduled downtime for liner replacement can cost thousands per hour in lost production, while inefficient grinding consumes excess power and…

Envoyez-nous un e-mail Télécharger au format PDF

Détail du produit

Mots clés du produit

1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Is your mineral processing operation constrained by inconsistent grind size, usure excessive de la doublure, or unplanned maintenance halting production? These common challenges directly impact your plant’s throughput and profitability. Considérez les coûts: unscheduled downtime for liner replacement can cost thousands per hour in lost production, while inefficient grinding consumes excess power and fails to liberate valuable minerals, reducing recovery rates. Are you managing high energy consumption per ton of processed material? Are your maintenance teams spending more time on reactive repairs than on planned optimization? The reliability and efficiency of your comminution circuit hinge on the core equipment at its heart. Addressing these issues requires a mill engineered not just for capacity, mais pour une durée soutenue, costeffective operation.

2. APERÇU DU PRODUIT

Ce produit est robuste, heavyduty ball mill designed for the continuous grinding of ores and minerals in both greenfield and brownfield processing plants. Il fonctionne sur le principe de l’impact et de l’attrition, where grinding media (billes d'acier) cascade within a rotating cylindrical shell to reduce feed material to a fine slurry or powder.

Flux de travail opérationnel:
1. Présentation du flux: Minerai concassé (<25mm) is conveyed, often with water, into the mill via a trunnion or peripheral feed chute.
2. Action de broyage: The rotating drum lifts the charge of steel balls; as they cascade, they fracture ore particles through impact and shear forces.
3. Réduction de la taille des particules: Material is ground progressively as it travels from the feed to the discharge end.
4. Décharge de boue: The ground product exits as a slurry through discharge grates, which retain grinding media while allowing sized material to pass for further processing. Livraison de l'entreprise de broyeur à boulets

Champ d'application: Ideal for wet or dry grinding in secondary and regrind applications across base metals (cuivre, plomb, zinc), métaux précieux (or), minéraux industriels, and cement clinker.

Limites: Not suitable for primary crushing of runofmine ore. Optimal performance requires correctly sized feed from upstream crushing circuits. Highly abrasive ores will accelerate wear rates, necessitating appropriate material selection.

3. CARACTÉRISTIQUES PRINCIPALES

Coque robuste & Flange Design | Base technique: Analyse par éléments finis (FEA) optimized structure | Avantage opérationnel: Eliminates shell flexing and fatigue cracking under full load, garantir l’intégrité structurelle à long terme | Impact sur le retour sur investissement: Reduces risk of catastrophic failure and extends operational life beyond 20 années avec un bon entretien
Système de doublure avancé | Base technique: Highchrome alloy steel or rubber composites with engineered lifter profiles | Avantage opérationnel: Maximizes grinding efficiency and provides predictable wear life; reduces media consumption | Impact sur le retour sur investissement: Lowers total cost per ton by extending liner service intervals by up to 30% par rapport à l'acier au manganèse standard
Équipement de circonférence & Pinion Drive Alignment | Base technique: Laseraligned during assembly with precisionmachined gear teeth | Avantage opérationnel: Ensures smooth transmission of power with minimal vibration and noise; prevents premature gear tooth pitting | Impact sur le retour sur investissement: Improves energy transfer efficiency by ~5% and reduces drive train maintenance events
Hydrodynamic Trunnion Bearings | Base technique: Oillubricated bearing journals with continuous pressure circulation | Avantage opérationnel: Supports extreme mill loads with minimal friction; includes temperature monitoring for predictive maintenance | Impact sur le retour sur investissement: Virtually eliminates unplanned bearing seizures, a major cause of extended downtime
Entraînement à fréquence variable (VFD) Ready | Base technique: Motor and drive train engineered for VFD integration | Avantage opérationnel: Allows softstarting to reduce grid stress and enables speed optimization for different ore types | Impact sur le retour sur investissement: Lowers peak power demand charges and can improve specific energy consumption by adjusting rotational speed
Integrated Control & Instrumentation Packages | Base technique: Prewired panels for bearing temperature, flux de lubrification, motor amperage, and mill sound monitoring | Avantage opérationnel: Provides operators with realtime data to optimize charge level and detect anomalies early | Impact sur le retour sur investissement: Permet la planification de la maintenance basée sur les conditions, éviter des dommages secondaires coûteux

4. AVANTAGES CONCURRENTIELS

5. SPÉCIFICATIONS TECHNIQUES

Capacité & Notation: Sizes from 1MW to over 10MW drive power; débit de 5 TPH à plus 250 TPH en fonction de la conception du circuit.
Exigences d'alimentation: Moteurs haute tension (3.3kV 11kV standard); complete with starter system recommendations.
Spécifications matérielles: Coque construite à partir de tôles d'acier doux laminées (limite d'élasticité minimale 355 MPa). Les tourillons sont en acier forgé. Revêtements disponibles en fonte chromée (CRH >62), caoutchouc, or composite materials.
Dimensions physiques: Diamètres de 2m à plus de 5m; longueurs de 3m à plus de 15m. Les conceptions tiennent compte des contraintes d’expédition.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +50°C. Bearing lubrication systems include heaters/coolers as required.

6. SCÉNARIOS D'APPLICATION

Expansion du concentrateur de cuivre – Goulot d’étranglement du débit

Défi: An existing plant’s aging ball mills could not achieve the finer grind size required for new ore zones without sacrificing throughput, creating a recovery bottleneck.
Solution: Installation of one new largediameter ball mill configured as a secondary grinder in closed circuit with hydrocyclones.
Résultats: Achieved target P80 grind size of 150 microns while increasing circuit throughput by 18%. Copper recovery improved by an estimated 1.5 percentage points due to better mineral liberation.

Gold Processing Plant – Reliability & Coûts d'entretien

Défi: Frequent liner failures in two parallel ball mills caused unpredictable downtime every three months at significant cost in lost production and emergency labor.
Solution: Replacement mills featuring advanced liner systems with boltless rear fastening designs were installed during a planned shutdown.
Résultats: Liner changeout time reduced from five days per mill down to three days due to simplified design field data shows liner life extended consistently beyond seven months under identical conditions.

7. CONSIDÉRATIONS COMMERCIALES

Our ball mills are offered under clear commercial frameworks designed for capital project planning:

Niveaux de tarification: Based on drive power rating (2MW 6MW / Mega Mill Range). Each tier includes progressively enhanced structural components.
Fonctionnalités facultatives & Forfaits:

Grinding Media Charging System
Inmill Camera System
Advanced Process Control Interface Package
Kits de pièces de rechange (initial fill)
Onsite Supervision of Installation & Mise en service

We offer comprehensive service agreements covering scheduled inspections parts supply priority technical support remote monitoring diagnostics financing options including leasetoown structures are available through accredited partners subject to credit approval.

FAQ

1.Q What level of preparation is required at my site before delivery?
A Foundations must be designed poured cured according to our detailed civil drawings provided postorder A suitable crane capable of lifting the heaviest single piece typically the girth gear assembly must be available Electrical substation capacity must be confirmed

2.Q How does this equipment integrate with my existing classification circuit cyclones screens?
A Our engineering team will review your existing circuit layout We ensure feed discharge connections cyclone underflow arrangements are compatible We can also provide interface control recommendations

3.Q What is the expected timeline from order commissioning?
A For standard sizes lead time is typically six nine months including manufacturing sea freight delivery Site assembly commissioning require an additional eight twelve weeks depending on site readiness crew size Livraison de l'entreprise de broyeur à boulets

4.Q What warranty coverage is provided?
A We offer an eighteenmonth warranty from commissioning against defects in materials workmanship Critical components like girth gears trunnion bearings carry specific performance warranties outlined in the commercial agreement

5.Q Can you supply all necessary ancillary equipment motors starters lubrication systems?
A Yes we provide complete package solutions including motor gear reducer if required lubrication console starter panels This singlesource responsibility ensures system compatibility simplifies procurement

6.Q How do you determine optimal specifications like length diameter ratio media load?
A Our process engineers perform lab tests on your ore sample using Bond Work Index other methods We then use proprietary simulation software model best configuration based on target grind size throughput

Balises: Livraison de l'entreprise de broyeur à boulets