1. ABERTURA ACIONADA POR PAINPOINT

Are you managing grinding circuit inefficiencies that directly impact your bottom line? Common operational challenges with traditional ball mills include excessive liner wear requiring frequent, costly shutdowns, inconsistent grind size affecting downstream recovery rates, and high specific energy consumption driving up operational costs. Unplanned downtime for maintenance can cost tens of thousands per hour in lost production. Are you questioning how to improve mill availability, achieve a more uniform particle size distribution, and reduce your overall cost per ton milled? A purposeengineered ODM ball mill solution addresses these exact pain points.

2. VISÃO GERAL DO PRODUTO

This equipment is a customengineered ODM (Fabricante de design original) ball mill for continuous, heavyduty grinding in mineral processing and industrial milling operations. The operational workflow involves: 1) Feed material introduction via a trunnion or girth gear drive system, 2) Cascading and attrition of grinding media (bolas) within the rotating shell to reduce particle size, 3) Discharge of ground material via peripheral or overflow mechanisms. Its primary application scope is the fine and regrind milling of ores, cement clinker, e minerais industriais. A key limitation is its design for specific feed sizes and moisture content; it is not suitable for primary crushing of large rock feed.

3. RECURSOS PRINCIPAIS

Optimized Liner Geometry | Base Técnica: Análise de Elementos Finitos (FEA) & discrete element modeling (DEM) | Benefício Operacional: Reduces mediaonliner impact stress and promotes efficient orelifter interaction for consistent grind | Impacto do ROI: Até 30% extended liner life, reducing part costs and downtime frequency
Sistema de acionamento de alta eficiência | Base Técnica: Dualpinion or gearless drive (DMG) options with precision alignment | Benefício Operacional: Minimizes power transmission losses and provides smooth, reliable torque delivery under variable load | Impacto do ROI: Os dados de campo mostram 37% improvement in power efficiency versus poorly aligned standard drives
Advanced Material Specification | Base Técnica: Use of highchrome alloy steel or rubber composite liners tailored to ore abrasiveness | Benefício Operacional: Maximizes wear resistance in specific corrosive/abrasive environments your plant faces | Impacto do ROI: Direct reduction in consumable cost per ton of ore processed
Monitoramento Integrado de Condições | Base Técnica: Embedded sensors for vibration, temperatura, and acoustic emission | Benefício Operacional: Enables predictive maintenance by identifying bearing wear or liner failure before catastrophic stoppage | Impacto do ROI: Transforma a manutenção de reativa em planejada, protecting against sixfigure unplanned downtime events
Precision Trunnion & Bearing Design | Base Técnica: Hydrodynamic slide shoe bearings or largediameter roller bearings | Benefício Operacional: Ensures stable rotation under high dynamic loads with minimal friction losses | Impacto do ROI: Increases mechanical availability above 98% and reduces bearingrelated failure risk

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Linha de base padrão da indústria | ODM Ball Mill Solution | Vantagem (% melhoria) |
| : | : | : | : |
| Vida útil do revestimento (Minério Abrasivo) | ~68 months | 1012 meses | +40% |
| Consumo Específico de Energia (kWh/t) | Set as baseline (100%)| 9396% da linha de base| 47% redução |
| Annual Mechanical Availability| 9294%| >96%| +24 pontos percentuais |
| Grind Size Consistency (Variância P80)| ±12%| ±7%| ~40% improvement |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade/Classificação: Customdesigned from 500 kW para 20+ PM; rendimento de 10 TPH acima 1,000 TPH dependendo do projeto do circuito.
Requisitos de energia: Motor configuration tailored to client voltage (por exemplo, 3.3 kV, 6.6 kV, 11 kV). Includes softstart systems.
Especificações de materiais: Shell constructed from rolled and welded hightensile steel plate; liners available in manganese steel, highchrome cast iron, or engineered rubber; grinding media compatibility specified.
Dimensões Físicas: Diameters from 2m to over 8m; lengths variable based on L/D ratio requirements (tipicamente 1.5:1 para 2.5:1).
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C; dusttight construction for indoor/outdoor siting.

6. CENÁRIOS DE APLICAÇÃO

[Copper Concentrator Regrind Circuit] | Desafio: Inefficient regrinding limiting final concentrate grade; excessive cycloning due to poor P80 control. Solução: Installation of a dedicated ODM regrind ball mill with precise discharge sizing controls.| Resultados: Conseguiu um 15% increase in final concentrate grade while reducing recirculating load by 22%, boosting overall plant recovery.
[Produtor de Minerais Industriais] Desafio: High maintenance costs from rapid liner wear processing highly abrasive silicabased material; frequent wholeplant stoppages.| Solution Implementation of an ODM ball mill with composite rubber liners and optimized slurry flow design.| Results Extended liner life by over 50%, enabling alignment with quarterly maintenance schedules and increasing annual throughput by 8%.

7. CONSIDERAÇÕES COMERCIAIS

Equipment pricing is tiered based on drive technology (standard gear vs. dualpinion vs. gearless), especificações de materiais, and control system complexity. Optional features include advanced instrumentation packages, sistemas de lubrificação automatizados, and spare part kits. Comprehensive service packages are available covering installation supervision commissioning multiyear preventive maintenance plans and onsite technical training Financing options including leasetoown agreements and milestonebased payment plans can be structured to align with project cash flow

8.Perguntas frequentes

Q Can your ODM ball mill integrate with our existing grinding circuit classification system?
A Yes engineering specifications include detailed interface requirements for feed conveyors cyclones or screens ensuring compatibility with your current plant layout
Q What is the expected impact on our plant's overall power draw?
A The highefficiency drive system typically results in a net reduction in specific energy consumption per ton milled however total power draw depends on the new mills capacity relative to the equipment it replaces
Q Are spare parts readily available given this is a custom design?
A All critical wear parts are standardized where possible and detailed drawings are provided to clients Guaranteed inventory of key components like liners gears and bearings is part of extended service agreements
Q What commercial terms are typical for an order of this scale?
A Standard terms involve progress payments tied to major manufacturing milestones FOB shipping point with warranty commencing upon commissioning
Q How long does implementation take from order placement to commissioning?
A Lead times vary by complexity but a typical schedule is1014 months for manufacturing followed by23 months for site installationand commissioning supervised by our engineers