SUPER-ORION® BALL MILL S.O. M I N E R A L S & M E TA TA L S
PROCESS PR OCESS TECHNOL TECHNOLOGIES OGIES FO FOR R TO TOMORROW MORROW SM
ALPINE MINERALS SUPER-ORION® BALL MILL S.O. & METALS
Sup er-Orion Ball mills - An establ ished con cept w i t h l e a d in g - e d g e r e f i n e m e n t s.
PRINCIPLE OF OPERATION
Ball mills have been the mill of choice for years for ma nufa cturing high-grade mineral pow ders. These lega cy mills a re still popula r due to their low operating and maintenance costs regardless of whether the material displays Mohs hardness values of over 4 or is sof t - such as limesto ne o r ba rite. Because of hard abrasive constituents limestone or barite cause a high degree of wear w ith hig h-speed mills; ho w ever, Super-Orion ba ll mills ensure low -w ea r a nd cost-effective processing.
BALL MILL S.O.
FEATURES
improved w ha t started as a simple ba ll mill
This is the classic stan da rd d esign - a d esign
- Ca s t si d e p la t e s b o l t e d t o a
for the non-metallic mineral sector to a
which
high-tech machine for the mineral powder
t h r o u g h o u t t h e w o r ld o v e r t h e y e a r s - b o t h
industry. The o riginal g rinding p rinciple an d
the design and efficiency have been
the unpa ralleled robustness of t he ma chine
continually
are two features which have not changed,
trend fo r finer and purer products.
Over the years, we have continuously
and
today,
there
are
three
standard designs available.
different
has
proved
itself
in
operation
refined to sat isfy the market
rolled-steel drum w ith integra ted manhole.
- D ri ve v ia r in g a n d p i n io n g e a r w i t h a u t o m a t ic a ll y co n t r o l le d t o o t h lubrication, primary gea ring w ith couplings and high-performa nce gea rbox.
- B e a r in g u n it : j o u r n a l b e a r in g d e si g n e d
SUPER-ORION S.O. CLASSIC DESIGN
as a friction bea ring w ith closed loop oil recirculat ing lubricat ion w ith temperature control.
- Product discharge via ad justable slots l o ca t e d a r o u n d t h e p e r ip h e r y o f t h e drum. Tw o-piece discharg e ho using w ith to p venting connection w ith inspection cover.
B A L L M I L L S . O . - C L ( C O M P A C T LI NE) FEATURES - Completely enclosed w elded design in high-gra de steel. - Direct drive via bearing journal with top-mounted g ea rbox. Moto r conn ected to gea rbox via a V-belt drive. - Product discharge via slots located a round th e periphery of the drum.
BALL MILL S.O.-SF (SUPER FINE) FEATURES - High-tech mill for manufacturing ultrafine fillers. - Special d esign as fo r S.O.-C.L ab ove, a lbeit w ith ad ditiona l features: - Sl o t t e d p a n e l t o se p a r a t e t h e g r in d i n g m e d ia a n d t h e d i sc h a r g e a r e a f r o m t h e e n d p r o d u c t . - Special-design grinding med ia. - High-precision speed con tro l via freq uency con verter. - Loa d cells.
TYPICAL PROCESS FLOW DIAGRAM 1
Feed Silo, Dosing, De dusting
2
Weigh Belt Feed er
3
Drum Magnetic
4
Sam pling Port
5
Ball Mill S.O.
6
Loa d Cells
7
Grinding Aid
8
Grinding Media Refilling
9
Rota ry Va lve
10
Ult ra fin e Classifier ATP
11
Secon da ry Air
12
Throt tle Va lve Pneuma tic Actua ted
13
Automa tic Filter
14
Blower
15
Throt tle Va lve Pneuma tic Actua ted
16
Fine Pro duct, Doub le Flap Va lve
17
Control Cabinet
PROCESS TECHNOLOGIES FOR TOMORROWSM
2 /3
ALPINE MINERALS BALL MILL S.O. IN STEEL & METALS FOR MINERAL FILLERS APPLICATIONS
The ball mill cont inues to b e the m ost p o p u l a r m a ch i n e w h e n i t co m e s t o manu facturin g mineral fillers.
FEATURES
Examples of functional mineral fillers:
the
- Lo w m a i n t e n a n c e c o st s .
- Limesto ne, chalk, marble
Selection of the grinding media is a
- Extremely long service life (over 50 years).
- D o lo m it e
function of the feed material and of the
- Extremely robust.
- Kaolin, calcined kaolin, bent onite
desired
- Low specific energy con sumption .
- Ta lc
s ci e n t i f i c
- B a rit e
methods are applied to the selection of the
An important decision driver for using
Even
ultrafine
products
are
produced
a ball mill as the principal size reduction
direct ly fro m th e mill/classifier circuit.
machine is its enormous flexibility in the
additional
low-wear
end
steel
grinding
product.
know ledge
media.
State-of-the-art a nd
c a l c u la t i o n
med ia type , compo sition a nd size. The use
No
of highly wear resistant materials prevents
is
discoloration; a frequent requirement for
ultrafine range. With the Super-Orion ball
requ ired. This helps to avo id w a ste or
top-quality fillers used in plastics, paints or
mill, fine products such as pap er fillers in
coarse materials for which there is little
paper.
coat ing qua lity (d 80 = 2 µm) as w ell as coarse
market demand.
fillers, e.g. dolomite powder for bitumen
Our mills fo r fillers a re all pla ted w ith high -
fillers (d 97 = 100 µm) can b e prod uced.
gra de steel which is opt imally mat ched w ith
secondary
classification
The values in the ta ble below a re based on prod uction runs w ith medium-ha rd limestone. This informa tion is purely informat ive. Guaran teed values provided only aft er trials are conducted w ith the o riginal feed ma terial. The values refer to m ills ope rat ed in circuit wit h suitab le classifiers.
VARIANT RANG E (STEEL-PLATED M ILL)
= ava ilab le sizes
= o p t io n
Machine size/ 125/ 125/ 125/ 160/ 160/ 160/ 160/ 200/ 200/ 200/ 200/ 200/ 200/ 270/ 270/ 270/ 270/
300/
design
600
125
160
200
160
200
270
330
270
S.O.
S.O.-CL
S.O.-SF
Slotted pa nel
110
160
200
250
0.6
0.8
1.0
1.2
Mo t o r [kW]
22
30
37
55
75
90
330
400
470
530
600
300
400
500
600
250
315
400
340
450
560
630
900
2.7
3.0
3.5
3.7
4.9
6.1
7.4
9.8
3x
2x
500/4
630
630/4 500/4 630/4
Thro ug hp ut [t/h]
o f limest o n e d 70 2 µm ATP-NG cla ssifier
500
315/3 315/4 315/6
Thro ug hpu t [t/h]
o f limest o n e
0.5
0.7
0.9
1.1
1.5
d 97 10 µm ATP cla ssif ier
1.9
2.3
2x
2x
315
400
500
500
630
500
500
500/3 500/3 500/4 500/4
1.8
2.3
3.1
3.8
5.4
6.6
8.0
9.4
10.6
12
13
17
21
26
33
315
315
400
500
630
630
800
800
1000
1000
1000
1250
1250
1500
1500
Thro ug hpu t [t/h]
o f limest o n e d 97 40 µm ASP cla ssif ier
BALL MILL S.O. FOR THE MANUFACTURE OF CERAMIC RAW MATERIALS
The Super-Orion ba ll mill ha s become t he sta nda rd a round the
ag ainst w ear. As a result, the product-cont act compo nents of a ll
w orld for processing ceramic raw ma terials. Comb ined w ith a
suita ble classifier mod els such a s Turbo plex, Stra to plex, an d
classifier, th e b all mill usually forms th e he a rt o f t he pro cess. In spite
Vento plex are prote cted ag ainst w ear w ith ceramic or PU. Particular
o f c e r a m i c r a w m a t e r i a l s h a v i n g a M o h s h a r d n e ss o f b e t w e e n 5 a n d
attention must be paid to the classifying wheel because wear
8, i.e. are extremely abrasive; grinding must be perfo rmed w ithout
increases with the square of the speed (double the speed = four
iron contamination if the colour integrity of the end product is to
times the w ea r). Because of t his, classifying w heels in all cera mic
be e nsured. Becau se of t his, th e ba ll mill is usually lined w ith silex
construction are emplo yed fo r t he ATP Turbo plex classifiers.
bricks (see ta ble below fo r variant s). High -gra de f lint stone is used for th e grinding media ; an inexpensive solution w ith respect to t he investm ent costs. For special applicatio ns, ba ll mills are lined w ith aluminium oxide (see page 6 for the variant range) and operated with Al2O 3 grinding med ia. The a lu-oxide lining serves to t riple th e life of the lining. And the wear to the Al2O 3 grinding media brought about by friction is also lower than with conventional grinding media. In order to provide t he opt imal system f or the applicat ion, costs for maintenance, personnel, etc. have to be considered in detail. Not only is a lined ba ll mill necessary for g rinding w ithout iron contamination, but the classifier must also be suitably protected
The values in the t ab le below a re based on p roduction runs with feldspar an d silica sand of medium g rinda bility. This informa tion is purely info rmative. Guaranteed values provided only after trials are conducted with the original feed ma terial. The va lues refer t o m ills operated in circuit w ith suitable classifiers.
VARIANTRANG E: SILEX LINING/
FLINTSTONE GRINDING MEDIA
= ava ilab le sizes
= o p t io n
Machine size/
150/ 150/ 150/ 150/ 190/ 190/ 190/ 190/ 190/ 190/ 190/ 255/ 255/ 255/ 255/ 255/
design
150
190
260
320
190
260
S.O.
S.O.-CL
320
Slotted pa nel Mo t o r [kW]
30
37
45
460
520
590
300
400
500
600
700
45
55
75
90
110
132
160
160
200
250
315
355
1.0
1.3
1.6
2.0
2.4
2.6
3.0
3.2
4.3
5.4
6.5
7.7
ASP cla ssif ier
315
315
315
315
315
400
400
400
500
500
630
630
Thro ug h put [t /h]
0.6
0.8
1.0
1.2
1.4
1.6
1.9
2.0
2.6
3.3
4.0
4.7
315
315
315
315
315
315
315
400
400
500
500
630
Thro ug hput [t /h]
22
390
of feldspar d 97 63 µm
of silica san d d 97 40 µm ASP cla ssif ier
PROCESS TECHNOLOGIES FOR TOMORROWSM
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ALPINE MINERALS BALL MILL S.O. & METALS FOR TECHNICAL CERAMICS (AL2 O3 , ZrO, ZIRCONIUM SILICATE, ETC.)
ALUM INIUM OXIDE GRINDING MEDIA
ALUM INIUM OXIDE CYLPEBS
Volu me (%) Volume [%]
The values in the t ab le below a re based on prod uction runs w ith zircon sand , aluminium oxide a nd silica sand of medium g rinda bility. This informa tion is purely informative. Guaranteed values provided only after trials are conducted w ith the original feed ma terial. The values refer to mills operat ed in circuit w ith suitab le classifiers.
ALUMINIUM OXIDE LINING
WITH ALUMINIUM OXIDE G RINDING MED IA
Part icleDiame Diamete terr (µm) [µm] Particle
= ava ilab le sizes
= o p t io n
Machine size/
155/ 155/ 155/ 155/ 195/ 195/ 195/ 195/ 195/ 195/ 195/ 265/ 265/ 265/ 265/
265/
design
155
195
265
325
195
700
S.O.
S.O.-CL
110
132
160
160
0.4
0.4
265
325
Slo t t e d p a n e l Motor [kW]
30
37
45
55
55
75
90
Th ro ug hput [t /h]
395
465
0.3
525
595
300
200
400
500
600
250
345
355
400
0.6
0.8
0.9
1.1
of zircon sand d 50 1,2 µm ATP cla ssif ie r
200/4
Th ro ug hput [t /h] o f
315/3 315/3
0.5
0.7
315/3 315/6 315/6 315/6
0.8
1.1
1.4
1.6
2.0
aluminium oxide d 50 2 µm 3x ATP cla ssif ie r Th ro ug hput [t /h]
315/3
315/3 315/6
315/6
315/3
0.7
1.0
1.2
1.4
1.7
2.0
2.2
2.4
3.2
4.0
4.8
5.7
315
315
315
315
315
400
400
400
500
500
630
630
of silica sa nd d 97 40 µm ASP cla ssif ier
BALL MILL S.O. - STATE-OF-THE-ART CONTROL AND LOAD CELL TECHNOLOGY Our stat e-of-the-art PLC unit com bined w ith t he opt ional load cell technolog y, converts th e robust ball mill wit h its proven grind ing system in to an extrem ely flexible hig h-t ech system .
LOAD CELL TECHNO LOG Y RESU LTS IN VARIABLE-SPEED DRIVE
PRECISION PRO DU CT LEVEL CONTROL
Ball mills a re usually opera ted a t 75% of t he
Current-day applications demand exact
are integrated into a control unit and
critical speed, i.e. in th e fringe a rea be tw een
measurement of the amount of product in
d e t e r m in e t h e t o t a l w e i g h t o f t h e b a l l m il l
cascad ing a nd free-fall. This is oft en ref erred
the mill for optimum grinding efficiency.
with mill, grinding media and product.
to a s the “ ang le of break” . With a specially
Because of this, an optional accessory
Subtracting the weight of the mill and
designed frequency converter, it is even
offered for our ball mills is the load cell
grinding media results in the weight of
possible to operate a heavy ball mill at
system which permits control and precise
prod uct in the mill. This is ma na ge d by
variable speed. And if the S.O.-SF is to be
m e t e r in g o f t h e f e e d p r o d u c t v ia a t e r m in a l
state-of-the-art
used for g rinding ultraf ine products or if it is
w ith a t olerance of ± 25 kg. This provides
m e a s u ri n g r a n g e .
planned to change the product frequently,
the user with t he possibility of ent ering and
operation with a frequency converter is
monitoring up to 4 limit values entered
Th e
particularly advan ta geo us.
d i re ct a t t h e w e ig h i n g t e r m in a l o r v ia a b u s
controlled w ith such precision tha t t he mill
o r seria l 4-20 mA TTY int erf a ce. The
a l w a y s o p e r a t e s a t o p t i m u m l o a d . Th i s
complete ball mill is located on a steel or
means that no-load operation or overfilling
concrete frame designed to rest on a
is reliably prevented, and the mill operates
def ined nu mbe r of loa d cells. The loa d cells
in an exceedingly cost-effective manner.
a ddition
electronics
of
v i rg i n
in
the
kg
feed
can
be
CASCADING MOTION
FREE-FALL MOTION
LOAD CELLS
MILL DRIVE
PROCESS TECHNOLOGIES FOR TOMORROWSM
6 /7
HOSOKAWA ALPINE Aktiengesellschaft &Co. OHG P.O. Box 10 11 51 D - 86001 Aug sburg, G erma ny Delivery a dd ress: Peter-Dörfler-Straße 13 – 25 D - 86199 Aug sburg, G erma ny
Phone.:
+ 4 9 (0 ) 8 21 / 59 06 -2 79
Fa x:
+ 4 9 (0) 821 /59 06-610
E-ma il:
minera l@a lpine.h osoka w a.co m
www.alpinehosokawa.com
Subject to change without notice. All informa tion in this brochure is purely informative and non-binding. Our quotat ions are authoritative with rega rd to orders.
Hosokaw a Alpine is a memb er of the Hosokaw a Micron Group, responding to globa l needs throug h empha sis on mat erials science and e ngineering. The Group is an internationa l provider of eq uipment and technology for powd er a nd pa rticle processing , plastics processing a nd con fectio nery produ cts. The e 1 / 3 0 . 1 1 s l l i M l l a B
Group maintains facilities for research, engineerin g, manufacturing and service in each of th e wo rld's major industrial markets.
© Hosokaw a Alpine 2003. Printed in Germa ny.
