Mining is a crucial stage in the beneficiation industry, directly impacting the overall cost and efficiency of the beneficiation plant. The energy consumption of the beneficiation plant's grinding operations accounts for 45% to 55% of the total energy consumption in the plant, and production costs make up 40% to 60% of the total cost of the beneficiation plant. Therefore, exploring methods to reduce grinding energy consumption holds significant practical importance. Currently, beneficiation plants commonly use ball mill sand-making equipment and have tried new energy-saving measures, achieving considerable economic benefits.
1. The lattice ball mill replaces the overflow ball mill. Compared to the overflow ball mill, the lattice ball mill not only has a lower pulp level at the discharge outlet and a faster pulp passing speed, but also reduces over-crushing of ore, allowing for the loading of more steel balls and larger steel balls. Additionally, it can also utilize smaller balls. Due to the presence of a lattice at the discharge end, the small steel balls are not carried out of the drum by the pulp, creating an optimal working condition. The output of the lattice ball mill is 20% to 30% higher than that of the same-sized overflow ball mill, with an energy saving of approximately 25%.
2. The friction coefficient of the roller bearing is lower, resulting in less power consumption overcoming the friction resistance compared to sliding bearings. Additionally, under normal operating conditions, the roller bearing does not require a main bearing replacement for 10 years, saving on maintenance costs and increasing the ball mill's operational efficiency.
By replacing the conventional clutch with a pneumatic clutch, the segmented starting of synchronous motor ball mills can be successfully achieved, enabling the motor to start without load. When the speed stabilizes, the ball mill can be started by engaging the clutch. As a result, the motor's starting time is shortened, starting becomes easier, the impact of the starting current on the power grid is reduced, and the installed power of the mill is also decreased.
4. Rubber lining is a high-wear-resistant non-metallic material. Practice shows that after using rubber lining plates, the unit energy consumption of wet grinding mills is reduced by about 10%, and the production capacity increases by about 5%. Additionally, the service life of rubber lining is generally 2 to 3 times longer than that of alloy lining. It is worth mentioning that the excellent wear-resistant rubber obtained through wet formula design combined with nano-composite dispersion technology has superior wear resistance, with a service life 3 to 4 times longer than that of ordinary rubber. In addition to reducing energy consumption, rubber lining also reduces the noise of ball mill sand-making machines, significantly improving the working environment for workers.
