ball mill liner
The Ball Mill liner is a piece located inside the ball mill that is used to protect the fuselage while improving ball mill performance. ball mill liner is usually made of steel, metal alloys, rubber, polyurethane, ceramic or composite materials and is installed in different parts of ballmilll. The use of ballmill liner delays the wear process of ballmill body and improves the shelf life of ballmill. Balmil liner can also help reduce ballmill maintenance costs, as without using the liner, ballmilll breaks down much faster.
The Balmil liner is a piece located inside the ballmill that is used to protect the fuselage while improving ballmill performance. Balmil liner is usually made of steel, metal alloys, rubber, polyurethane, ceramic or composite materials and is installed in different parts of ballmilll. The use of ballmill liner delays the wear process of ballmill body and improves the shelf life of ballmill. Balmil liner can also help reduce ballmill maintenance costs, as without using the liner, ballmilll breaks down much faster.
table of contents
The design and manufacture of rubber lines for ball millls is done.
- Rubber Compound
Vulcan Sanat Sepahan Company with more than two decades of experience has been a manufacturer of high quality technical rubber compounds. The company currently produces a wide range of compounds. Advanced technical compounds are used for a variety of rubber rollers and a number of other industrial applications.
- Vulcan Sanat Sepahan Co. builds and develops customized compounds according to customer specifications.
Vulcan Sanat Sepahan Company considers chemical and physical standards as well as process technology such as compressive molding, injection or extrusion to optimize a rubber compound. All custom engineering compounds are based on standard elastomers such as natural rubber, SBR, EPDM, NBR or CM, etc. Is.
Features of Ball Mill Liners
Reduced maintenance
The low-cross-section T-track system eliminates the need for frequent inspections, repairs and tightening of bolts. Rubber on the inner surface of mills (mills) creates a sealing that prevents slurry leakage and erosion from the mill shell. Faster changes and longer wear life with fewer maintenance problems mean availability and efficiency of the mill.
Lower installation cost
Since the weight of rubber and metal mill liners is up to 80% less than steel, they are installed faster, easier and safer.
Health & Security
Rubber liners significantly reduce the production and transmission rate of sound associated with crushing. The risk of compressive damage during installation is reduced due to the lighter weight of liners. Conversion to rubber linings of metal can reduce the number of parts used.
Operational Efficiency
Sepahan Industry Vulcan rubber compounds are specially formulated for maximum tear and resilience resistance, which increases wear life and reduces downtime. Liner sections are customized to fit specific geometry and operating conditions. Reducing the mass of lining systems increases the weight of the charge used, leading to increased productivity.
Reduced maintenance The low-cross-section T-track system eliminates the need for frequent inspections, repairs and tightening of bolts. Rubber on the inner surface of mills (mills) creates a sealing that prevents slurry leakage and erosion from the mill shell. Faster changes and longer wear life with fewer maintenance problems mean availability and efficiency of the mill.
Lower installation cost
Since the weight of rubber and metal mill liners is up to 80% less than steel, they are installed faster, easier and safer.
Health & Security
Rubber liners significantly reduce the production and transmission rate of sound associated with crushing. The risk of compressive damage during installation is reduced due to the lighter weight of liners. Conversion to rubber linings of metal can reduce the number of parts used.
Operational Efficiency
Sepahan Industry Vulcan rubber compounds are specially formulated for maximum tear and resilience resistance, which increases wear life and reduces downtime. Liner sections are customized to fit specific geometry and operating conditions. Reducing the mass of lining systems increases the weight of the charge used, leading to increased productivity.
Installation of ball mill liners
Vulcan Sanat Sepahan Company has been producing a variety of forklifts and shellplates used in ballmillls for mines, tile industry, cement and … It has been able to meet the needs of these industries at a high quality level.
Liners installed inside ball mill
ball mill liner
Application
Crushing can be done in two ways: dry and wet. Dry crushing application is limited because the use of water may be prohibited due to process limitations or may cause changes in chemical composition. Crushing is often done in a wet way. Ore is formed using slurry water.
Lining grinding
In a mineral factory, the grinder body is constantly exposed to abrasion and tearing due to contact with ore. While it requires interchangeable lining to absorb the impact and not allow it to enter the mill body.
Traditionally, linings were made of steel. However, rubber as an alternative has been of global importance in the past three decades in wet crushing application, due to its superior abrasion characteristic. (Shown in the figure below)
Generally, the cost of lining for a range mill is between 10-40% of the total cost of milling operations.
However, choosing the right lining material and designing it is important for the longevity of the liner and the proper grinding efficiency.
Rubber Liner Design
The liner, apart from protecting the mill steel shell from impact and abrasion, effectively requires the transfer of power from the mill body to recharge with cataract and cascading effect. Therefore, lining requires plates and forklifts with appropriate profiles.
Basic criteria for designing rubber lining parts
Rate A/B :
The distance between the two consecutive forklifts at the top can be chosen depending on whether the maximum lifespan, maximum capacity or optimal of the two are taken into account.
Ideal distance for lining two shells (shell)
The number of forklift rows depends on the diameter and type of mill.
For example,
General rule for a ballmilll:
Number of rows = 2* D (mill diameter by foot) ±4
(Depending on the type of mill)
Operating temperature: 70°C>
Slurry pH level: 4 to 7
Please consult if you want these to be above or below the limit.
Forklift Profile
Forklift profiles are mainly selected according to the following:
- a) Speed
- b) Mill diameter
- c) Bullet diameter
The profile is determined as follows. The ideal crushing environment should drop downwards. This section was conducted by studying the simulation software “Ball Trajectory”.
Lining thickness
Choosing the thickness of the liner is very important due to the direct impact on the capacity and power of the tension. In addition, depending on the diameter of the mill, its effect is characterized by an increase in diameter – shown in the table.
The effect of lining thickness on mill capacity
| "4 | "3 | "2 | Lining thickness ------- diameter inside the mill shell |
|---|---|---|---|
|
85.43% |
92.52% |
100% |
6’ Ø |
|
89.11% |
94.44% |
100% |
8’ Ø |
|
91.25% |
95.54% |
100% |
10’Ø |
|
92.76% |
96.37% |
100% |
12’ Ø |
Traction capacity/power is related to ID
Capacity fits ID2.6
Stretching power fits ID2.5
ID= inner diameter of lining
Liner wear rate
Liner wear rate depends on many factors. It is related to some of the main operating parameters shown below.
Effect of liner wear on operational parameters
Minerals and Hardness
Wear liner as a function of feed size
Crushing environment
Effect of different charging volumes on liner shell wear in NCR<78% (g/kWh)
Rate between wear life and speed
Design with simulation software
vulcan uses the latest software models such as Ball Path Trajectory and vulcan soft. The software helps simulate the crushing process with various options of basic design features to predict options that will optimize crushing performance with stretching power and impact spectrum. It also finds easy solutions to crushing problems as the software is connected to liner profiles for operational parameters.
Main components of mill lining
There are various components for completing the mill liner, each designed for a specific task.
Monitoring the performance of the liner during its operation is very important. Vulcan believes in continuous monitoring and improvement. Therefore, vulcan periodically collects liner wear measurements to predict the life of the liner or suggestions for improvement.
Data collection of abrasion liner profile was performed using abrasion gauge design. The data are generated and then entered into the software to generate the liner flow profile by estimating the remaining life.
Visual analysis equally shows the conditions of the liner as real.
However, it’s not so obvious. However, for each case a main recommendation is suggested according to more than 30 years of experience, a period of time for replacement.
Rubber Coated Metal Lining (PM)
The vulcan first introduced the PM lining system in 1989. Extensive interpretation of the tests showed that the rubber coated metal liner has better performance than old liners in primary applications due to its specific impact absorption capacity. This is a way to prepare a combination of rubber and metal in order to observe the requirements of flexibility in crushing application.
Types of liners
Depending on the working conditions, the metal is covered only with lifters or plates. The choice of the type of metal that is worn and its profile also depends on the working conditions. It can be rolled or molded depending on the type of impact resistance properties and wear required.
PM forklifts with rubber plates
Forklift P & Shell Plate Pi
Primary Grinder Application of AG/SAG Mills
Each grinding liner is designed appropriately with working conditions.
fps | mks | Product range | |
52” | 1320 mm | lentgh | Lifter bar (symmetric & asymmetric) |
10” | 250 mm | width | |
16” | 400 mm | height | |
52” | 1320 mm | lenght | Shell plates (symmetric & asymmetric) |
20” | 500 mm | width | |
63” | 160 mm | height | |
Note: Other lengths are available on a demand basis.
| Advantages | Feature |
|---|---|
|
It has a life of 2 to 5 times compared to steel or rubber lining. |
Low wear |
|
Scheduled shutdown. Improved production |
Predictable wear life. |
|
Significant savings when replacing parts |
Different wear patterns have been taken care of in different parts of the mill. |
|
Better protection of the mill body, against corrosion |
Rapid anti-leakage system. |
|
Reduced installation time. Improved production |
Less weight, easier transportation. |
|
Very environmentally friendly |
Reduce noise levels. |
|
Long life of rotating parts |
Less weight on the rotating parts. |
|
Mill availability has been improved due to less maintenance and fewer and shorter stops. |
The secure attachment system ensures screws are not broken. |
Vulcan company PM liner to be installed in ten countries around the world, such as
- Australia
- Canada
- Ghana
- India
- South Africa
- Sweden
Vulcan liner in SAG/AG mill
Mill Size: Dimensions 6.15 m*7.6m
Bullet Size: 125mm
Used Stone: Gold
Rubber lining for continuous and batch mills
The field of grinding function depends very much on the performance of the grinding lines. In the ceramic industry, continuous and batch type mills are used, while stone lining is the most used in the industry. However, rubber has consistently become important as a protection agent against wear and tearing in Bechi mills.
Soft rock lining
It has been observed that when converting a batch mill 6’*6′ with a thickness of 125 silix lining to thin rubber lining, the capacity increases to about 30%. In addition, soft liners usually require high mill speed for sufficient efficiency of crusher mill versus rubber liner with lifters. For soft lining, the best result was determined at 60% critical speed, which causes additional slippage between lining and charging, which increases energy consumption as well as wear of both lining and crushing environment.
| Tego lining | Stone lining | parameters |
|---|---|---|
|
kg 2300 |
9000 kg |
Weight of lining |
|
7.4 cu.m. |
6.12 cu.m. |
Available mill volume |
|
3 days |
20 days |
Time required for installation |
|
43 kwh/f |
69 kwh/f |
Power consumption |
|
400 kg/h |
240 kg/h |
Mill capacity |
|
10 hrs. |
12 hrs. |
Batch time |
Head lining with forklift
Soft lining type head with fixed master
According to the crushing theory,
Power=P is the capacity=C and D is the effective diameter of the mill in meters.
Batch vulcan mill lining is suitablely made and can be used for head strength, semi-pit head or headgear.
Lining for continuous grinder
Continuous grinder is the most suitable investment for the ceramic industry, making it possible as an automated manufacturing process. The crushing technique continuously reduces labor costs, requires less space (50%), power (25%) and fuel (15%) and less, and eliminates idle time periods for loading and unloading. Vulcan linings are designed for continuous mills, which are designed, width, height and distance, as well as plate thickness suitable for forklifts. The first lining chamber was designed to obtain optimal impact crushing performance. Usually here pebble is used as a crushing environment. The second and third chambers in continuous milling are usually designed for abrasion/secondary crushing. A diaphragm coated with rubber is placed between two compartments to obtain proper screening.
| Advantages | Feature |
|---|---|
|
Increase capacity |
Less lining thickness. |
|
Reduce slippage. Reduced power consumption/ tone crusher
|
Lining profile.
|
|
Increase mill availability time
|
Less time during installation.
|
|
Better protection of the mill body against corrosion
|
Faster anti-leakage system.
|
|
Scheduled shutdown. Improved production
|
Predictable wear pattern
|
|
Improving the life of rotary mill parts also reduces the risk of damage during installation.
|
Less lining weight
|
|
Environmentally friendly
|
Low noise levels.
|
Rubber Mill Lining
Vulcan introduced specialized rubber lining technology in 1976. By then steel had been accepted as lining materials. As a result of the powerful integration of technology alongside a vast database, more than 30 years of on-site experience and more than 350 installations, vulcan has provided a solution, today in the field of abrasive strength of the mill liner, it has provided solutions for optimal crushing for mineral process factories around the world.
Apart from the design, the uniqueness of vulcan rubber lining is in the formulation of the compound, which is designed in the R&D section and maintained through quality assurance.
Ball Mill with Rubber Liner
fps | mks | Product range | |
52” | 1320 mm | lentgh | Lifter bar (symmetric & asymmetric) |
10” | 250 mm | width | |
16” | 400 mm | height | |
52” | 1320 mm | lenght | Shell plates (symmetric & asymmetric) |
20” | 500 mm | width | |
63” | 160 mm | height | |
Note: Other lengths are available on a demand basis.
Application
- Secondary/Repeat Crushing
- Washing/Cleaning Drum
Each grinding liner is designed appropriately with working conditions.
| Advantages | Feature |
|---|---|
|
Longer life, lower liner cost, tone grinder
|
Less wear
|
|
More access. More operation capacity
|
Less time during installation
|
|
Scheduled shutdown. Improved production
|
Predictable abrasion pattern
|
|
User-friendly during installation
|
Easier transportation
|
|
Environmentally friendly, reducing noise pollution
|
Noise Reduction
|
|
Better protection of the mill body against corrosion
|
Faster anti-leakage system
|
|
Longer life of rotary parts
|
Less weight in rotary parts
|
|
Predicting and improving liner life
|
Customized wear measurement
|
Vulcan liner in ball mill
Mill Size: 5.2 m *10.6 m
Bullet Size: 30mm
Mill speed: 70% critical speed
Used Stone: Iron
Liner in scrubber (cleaner)
Scrubber size: 6.1*11.5 mØ Length
Speed: 55% critical speed
Stone Used: Gold
Installation & Service
Vulcan has an installation and full service unit that provides experienced personnel with installation services anywhere in the world.
Online Order Registration ball mill liner
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