1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Gérez-vous des opérations de broyage où une finesse de produit incohérente conduit à des lots rejetés ?? Are unscheduled maintenance stops for liner changes and bearing failures causing costly production halts? Do your energy costs for milling consume an unsustainable portion of your operational budget? Each hour of unplanned downtime and each percentage point of energy waste directly erodes your plant's profitability. How can you achieve precise particle size control while extending operational campaigns and reducing total cost of ownership? The solution lies in selecting a white label ball mill engineered not just to grind, mais pour optimiser.

2. APERÇU DU PRODUIT

This product is a white label industrial ball mill, a robust piece of mineral processing and grinding equipment designed for continuous or batch operation. Its core function is the reduction of material particle size through impact and attrition.

Flux de travail opérationnel:
1. Présentation du flux: Raw or precrushed material is fed into the mill's inlet trunnion.
2. Action de la chambre de broyage: The chamber, partiellement rempli de moyens de broyage (billes en acier ou en céramique), rotates. Lifter bars elevate the media and charge, which then cascade and tumble, fracturing the material.
3. Classement des tailles & Décharge: Ground material travels through the mill; finer particles exit via discharge grates at the opposite end, while coarser material remains for further comminution.

Champ d'application: Ideal for grinding ores, clinker de ciment, silicates, fertilizers, and other industrial minerals in secondary and tertiary stages. Convient aux processus de meulage humides et secs.

Limites: Non conçu pour le concassage primaire de grosses matières premières. Optimal efficiency requires proper feed size control and appropriate selection of media type/size.

3. CARACTÉRISTIQUES PRINCIPALES

Modular Shell & Système de doublure | Base technique: Boulonner, segmented highchrome or manganese steel liners | Avantage opérationnel: Enables rapid replacement of worn sections during planned maintenance stops, minimizing downtime by up to 40% par rapport aux systèmes soudés. | Impact sur le retour sur investissement: Reduces labor costs for liner changes and increases mill availability for production.

Precision Trunnion Bearing Assembly | Base technique: Engineered hydrodynamic or roller bearings with integrated sealing solutions | Avantage opérationnel: Provides reliable support under high dynamic loads, preventing catastrophic failure and reducing vibrationrelated stress on the gearbox. | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements, cutting replacement part costs and preventing associated production losses.

Entraînement à fréquence variable (VFD) Intégration | Base technique: Direct control of motor speed and torque via solidstate power conversion | Avantage opérationnel: Allows operators to finetune mill speed for optimal cascading action based on charge volume and desired grind, improving specific energy consumption. | Impact sur le retour sur investissement: Field data shows potential for 515% energy savings versus fixedspeed drives across variable load conditions.

Conception optimisée de la grille de décharge | Base technique: Computermodeled aperture geometry and wear profile | Avantage opérationnel: Ensures efficient expulsion of ground material while retaining grinding media, maintaining a consistent charge level and preventing overgrinding. | Impact sur le retour sur investissement: Contributes to stable product fineness (P80) and reduces media consumption.

Système de lubrification centralisé | Base technique: Automatisé, programmable greasing points for pinion gear and trunnions | Avantage opérationnel: Delivers precise lubricant amounts at scheduled intervals, eliminating manual greasing errors and ensuring critical surfaces are protected. | Impact sur le retour sur investissement: Lowers risk of premature wear on highcost components like girth gears.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | This White Label Ball Mill Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Temps d'arrêt pour changement de revêtement | 2436 hours per full change | 1624 hours with modular system | ~33 % plus rapide |
| Consommation d'énergie spécifique (kWh/t) | Ligne de base = 100% (varie selon le matériau)| Optimisé via VFD & dynamique de charge| Jusqu'à 12% réduction réalisable |
| Disponibilité opérationnelle (Annuel) | ~9294% (y compris les arrêts prévus)| Cible >95% through reliability design| 13 augmentation en points de pourcentage |
| Consommation des médias (g/t) | Materialdependent baseline| Reduced by controlled discharge & profil de doublure| 510% improvement typical |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: À partir de l'échelle pilote (50L) to industrial production models up to 20,000L effective volume.
Exigences d'alimentation: Puissances moteur de 15 kW à 2500+ kW, compatible avec les normes de tension mondiales (380V10kV). VFD is recommended.
Spécifications matérielles:
Coquille: Fabricated from rolled mild steel plate.
Doublures: Fonte chromée (27% Cr), Acier au manganèse, or rubber options.
Options multimédias: Forged/highcarbon steel balls; ceramic balls available.
Dimensions physiques: Conçu sur mesure par capacité; drive configuration can be central or girth gear & pinion.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +50°C. Dusttight construction available for dry milling applications.

6. SCÉNARIOS D'APPLICATION

MidSized Copper Concentrator Plant

Défi: The existing ball mill circuit produced inconsistent grind size, impacting flotation recovery rates. Energy costs were exceeding forecasts due to inefficient load management.
Solution: Implementation of a white label ball mill with VFD control and optimized discharge grates tailored to the ore's abrasion index.
Résultats: Achieved a more stable P80 grind size (±5 micron variance), contribuer à un 2% increase in copper recovery. The VFD enabled loadbased power adjustment, yielding an 8% réduction de la consommation énergétique spécifique.

Industrial Minerals Producer Calcium Carbonate

Défi: Frequent downtime for liner changes in a dry grinding application was disrupting justintime delivery schedules to paint manufacturers.
Solution: Installation of a white label ball mill featuring a quickchange modular liner system designed for abrasive dry materials.
Résultats: Liner replacement time decreased from 32 heures pour 20 heures par événement. This increased annual plant availability by approximately 60 heures, allowing fulfillment of tighter delivery windows without expanding inventory holding costs.

7. CONSIDÉRATIONS COMMERCIALES

Our white label ball mills are offered in clear pricing tiers based on drum diameter, puissance motrice, et spécification du matériau:

1. Niveau standard: Core mill assembly with standard liners and bearings.
2. Niveau de performances: Includes VFD drive system, upgraded highchrome liners, centralized lubrication.
3. Niveau personnalisé: Engineered solutions with specific dimensions, special coatings/liners (par ex., alumina brick), or fully integrated control systems.

Les fonctionnalités optionnelles incluent des capteurs avancés de surveillance de l'état (vibration,température), automated lubrication systems extended beyond standard points,and custom paint/finish specifications.Service packages range from basic commissioning support to comprehensive multiyear maintenance agreements with guaranteed parts availability.Financing options including leasing structures are available through partners to assist with capital expenditure planning.

8.FAQ

T1:What level of technical support is provided during commissioning?
A dedicated project engineer will supervise installation alignment provide operational training for your crew,and assist with initial performance tuning against your specified benchmarks

Q2 Can this white label ball mill integrate with our existing PLCbased plant control system?
Yes.The drive system can be configured with standard communication protocols(Profibus Modbus TCP/IP )to allow remote start/stop speed monitoring,and alarm integration into your central control room

Q3 What is the typical lead time from order placement to delivery?
Lead times vary by model complexity.For standard configurations in our Performance Tier lead times typically range from weeks depending on current manufacturing capacity

Q4 How does the operational noise level compare?
With properly maintained girth gear enclosures precisioncut gearing,and stable bearing assemblies industry testing demonstrates external noise levels typically remain below dB(UN) at one meter meeting common workplace regulations

Q5 Des garanties de performance sont-elles offertes?
Yes.We provide mechanical performance guarantees covering workmanship materials Additionally we can collaborate on process performance guarantees based on agreedupon feed specifications test conditions

Q6 What are the key factors in determining optimal liner material selection?
The choice between highchrome manganese steel rubber depends primarily on your application's abrasiveness impact characteristics corrosion potential( wet grinding )and desired service life versus initial cost Our engineers will analyze your operating data make a recommendation

Q7 La formation des opérateurs est-elle incluse?
Comprehensive training covering safe operation routine maintenance checks troubleshooting common issues basic liner inspection procedures is included as part of every commissioning package Documentation includes detailed operation maintenance manuals