Energy Saving Benefit of Rubber Lining Ball Mill


Author: Yang, Marketing Manager of Kosga

Since the 1960s in China, manganese steel (NGMn13) liner has been used for ball mill liner. Many years of practice has proved that manganese steel liner has many disadvantages, such as poor wear resistance, short life, heavy weight, high energy consumption, high noise, low installation and maintenance efficiency, unsafe, high cost and poor economic benefits.

In recent years, some production units use low alloy steel to make lining plate of ball mill. For example, the installation and operation of ball mill in Xiaosigou copper mine in China has many advantages, but it is still not ideal.

Rubber liner is widely used in developed countries of international industry. The reasons why rubber liner can not be popularized and applied in China are as follows: 1. Mill production process is an important link in the grinding process. Lack of awareness of new materials and technologies will affect production. 2. Low depreciation rate of equipment and insufficient funds for renewal.

Rubber liner is made of high molecular compound. Synthetic rubber with high elasticity and excellent wear resistance was selected as the main body, and natural rubber was mixed in a certain proportion to obtain good dispersion, homogeneity of blending and co-vulcanization. According to KOSGA test, vulcanized rubber must have excellent physical and mechanical properties:Tensile Strength MPa≥ 16 、Elongation At Break %≥ 620、Permanent set at break %≤ 15、Hardness Shore A 65±5、Abrasio loss Cm³/1.1km 0.18、RUB.And Steel Density g/C㎡ 1.18、Resilience %≥ 36、Aging of hot air and reduction of tensile %≤ 10 strength

Kosga introduced the production technology of international rubber liner Ball Mill in 1979. By the 1980s, through digestion, absorption and transplantation, Kosga produced rubber liner successfully. It has been operated on more than 400 mills in more than 100 units in China. It shows many excellent performances and receives better economic and social benefits.

1. remarkable power saving effect

The ball mill changed from heavy manganese steel (or low alloy steel) liner to lighter rubber liner, which reduced the mill weight and saved electricity remarkably. Taking the ball mill of 3.6x4m as an example, the weight of each manganese steel liner is 27 t, while that of rubber liner is only about 5 t. The weight of rubber liner is reduced by 22 t, and the power consumption decreases significantly. According to the comprehensive average calculation, the annual electricity saving is 506 500 kw.h and the annual electricity cost is 75975 yuan. The average test results show that each ball mill saves 300 000-600 000 kw. h of electricity per year.

2. Significant wear resistance and long service life

The service life of manganese steel lining plate for ball mill is 53H~6159h. After using rubber lining plate, the service life of manganese steel lining plate is 7795~12000h, which is generally 1.5~2 times longer than that of manganese steel lining plate.

3. Reducing costs and improving economic benefits

1. Compared with manganese steel liner, the operation rate of rubber liner is increased by about 3%-5%, and the cost of concentrate powder per ton can be reduced by 0.31 yuan. The loss of rubber liner is 1727.15 yuan per month, and that of manganese steel liner is 3210.05 yuan per month. The annual cost savings are 17794.80 yuan. Each set of rubber liner is higher than manganese steel liner, but because of the long service life of rubber liner, the cost is greatly reduced.

According to Kosga statistics. The annual lining consumption of non-ferrous metal mine system is about 40,000 T per ton, calculated at 1590 yuan, which saves 63.6 million yuan annually.

Lining materialLife CycleConsumption of fundsAverage loss
Rubber24 months450001875
Manganese steel12 months486004050
Contrast12 months

4. The consumption of steel balls decreases. Taking the ball mill of φ3.6x4m as an example, the consumption of manganese steel liner steel ball is 1157 kg/t raw ore, and the consumption of rubber liner steel ball is 1009 kg/t raw ore. Compared with the two, the consumption of manganese steel liner steel ball is reduced by 0.148 kg/t raw ore. If the annual output of raw ore is calculated as 600,000 tons, the annual saving of steel balls is 88,800 kg, and the annual cost of forged steel balls (9MnSiCr WV) is calculated as 1670 yuan, the annual saving of 148206 yuan can be achieved.

5. Extend the service life of components. Because the ball mill uses rubber liner, which reduces the weight by 5.4 times compared with manganese steel liner, the service life of large gear ring, small gear shaft and other parts is prolonged, and the rubber liner is not easy to leak pulp, which protects the cylinder rest, reduces the shutdown maintenance and other advantages, reduces costs, and increases economic benefits.

6. Manganese steel lining plate is about 200 kg each. Installation and maintenance require the use of machinery. It is labor intensive and often causes accidents such as crushing hands and feet. The rubber lining board weighs about 38kg each, one person can install a whole set of mill rubber lining board, which not only avoids accidents, but also saves a lot of installation time, increases production and improves equipment utilization rate.

7. Reduce Noise and Improve Labor Environment

When the mill is running, the vibration is strong due to the impact of steel balls, liners and minerals, and the noise reaches 94-110 dB. After using rubber liner, the mill can reduce noise by 5-10 dB due to its shock absorption and sound insulation performance, which improves the working environment and protects workers'physical and mental health.

8. Although there are some technical and material problems in using rubber liner instead of manganese steel liner in mill, it has shown the superiority and advancement of rubber liner in ball mill.

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