Measures to reduce power consumption of ball mill in cement plant

1. Measures to reduce power consumption from the perspective of technology:

(1) the design and selection of the mill is the key factor

Generally speaking, replacing small mills with large mills can increase production and save electricity. Replacing low efficiency ball mills with high efficiency mills can also achieve significant energy saving effects, such as vertical mills, roller mills, extrusion mills, high fine mills, etc., whose efficiency is higher than that of ball mills. (ma 'anshan longsheng wear-resistant materials co., LTD.)

(2) reducing the particle size of human grinding materials can reduce the power consumption per unit product. According to statistics, the effective utilization rate of electric energy of crusher is about 30%, while the effective utilization rate of electric energy of ball mill is about 5%. Therefore, the "more crushing, less grinding" process transformation can reduce the power consumption of the grinding system. But the particle size of the grinding material should not be too small, because with the reduction of the particle size of the broken product, the power of the broken unit product is increasing. For certain ores, there is an optimal particle size entering the mill, at which the energy consumption of ore grinding and grinding is the lowest. According to experience, the optimal particle size of human grinding is generally 0.005d (D is the effective inner diameter of the mill barrel).

(3) strengthen material drying, so that the average moisture of the grinding material is 0.5% ~ 1.5%.

When the moisture content of grinding is too high, the phenomenon of pasting balls is easy to appear in the process of operation, but when the moisture content is too low, the phenomenon of electrostatic effect is easy to appear, which affects the output of grinding machine.

(4) strengthen the ventilation in the mill

Strengthen grinding in ventilation, can reduce grinding inside cushion phenomenon, to speed up the velocity of grinding, can rise to increase mill production, on the other hand, can achieve the purpose of collecting amount of fine dust, because of increased production accordingly to reduce the mechanical and electrical consumption, but air quantity will make dust particles increases, which affect the grinding product fineness, adverse to the quality, when the ventilation rate increases to a certain degree, will increase the grinding power consumption per unit product, practice shows that mill maximum output and minimum power consumption within the scope of grinding system is the best ventilation rate.

(5) determine the target value of fineness of grinding materials reasonably in production

In the actual production, no matter for raw materials or cement, if the fineness value of the grinding product is low, it can offset the effect of other measures, thus restricting the increase of the output of the grinding machine, which is adverse to the reduction of power consumption.

(6) the influence of the change of the wear structure on the power consumption

For the liner board of the mill, when the particle size of the mill is small, it is appropriate to select the groove lining board for the first warehouse of the mill, which can make full use of the sliding friction work, increase the contact area between the steel ball and the material, so as to improve the grinding efficiency. For pulverized media, it is better to choose steel forging for raw material grinding and steel ball for cement grinding.

(7) reasonable steel ball loading is beneficial to reducing power consumption

The more steel balls there are in the mill, the larger the contact surface between steel balls and materials. With the decrease of ball diameter, the surface area of steel ball per unit volume increases, so does the output of grinding machine. Generally speaking, in a certain range of mechanical and electrical consumption and steel ball load is proportional to the ball diameter is inversely proportional. However, if the ball is loaded too much, the impact and grinding efficiency between steel balls will be greatly increased and the power consumption will rise. The steel ball diameter is too small, occupying the steel ball clearance, reducing the load, because the output decreases the power consumption increases correspondingly. There is an optimal loading quantity of steel ball with low power consumption per unit in the mill. The specific value should be determined in the test of the optimal loading capacity and ball diameter ratio of the grinding system.

(8) effect of grinding AIDS on reducing power consumption

In the grinding process, adding a small amount of admixtures, can eliminate the phenomenon of fine powder adhesion and aggregation, it can accelerate the material grinding process to improve the grinding efficiency, improve quality, reduce the unit power consumption of grinding plays a role in auxiliary material grinding. In practice, grinding AIDS are best used for grinding cement on large cement mills. Due to the high price of grinding AIDS, their effect on reducing power consumption and increasing output should be compared with the change of cost.

In addition, the addition of coal gangue, fly ash zeolite and other easily grinded materials in the mill is beneficial to increase production and reduce consumption.

2, matching the corresponding feed camera can reduce the power consumption of the ball mill multi-purpose asynchronous motor, it has two major disadvantages:

One is not economic speed regulation; Second, the excitation current is supplied by the power grid, increasing the reactive power, reducing the power factor and wasting power. To improve the power factor of asynchronous motor, the best power saving measure to compensate the reactive power is to replace the feed camera, and the power factor can be increased to 0.99.

3. Measures to reduce power consumption of equipment:

Because the mill is driven by the motor machinery, there are inevitably a variety of transmission losses, reducing these losses is the main purpose of equipment management, first of all, in the installation of equipment to strictly follow the norms, not dislocation and some other installation errors. In order to avoid the energy loss caused by the vibration of the cylinder body, at the same time should maintain good lubrication, reduce the friction loss. The lubricating oil should be clean, with sufficient oil and smooth oil path to ensure the rotating part of the mill system is well lubricated. , on the other hand, due to the ball mill is usually adopts the sliding bearing lubrication, shaft and bearing contact Angle of 75 degrees - 90 degrees, the friction torque is bigger, now little contact Angle (30 to 40 degrees), the new scraping tile method of the large clearance has been successfully applied to the production practice, we know more than many of the large mill adopts a new way, reduce the power consumption effect is more obvious, the principle is to reduce the friction torque, and Φ 2. 4 meters below the small mill can also use rolling bearing instead of sliding bearing, because significantly reduce the friction resistance and reduce the energy consumption of the mill, the use of rolling bearing instead of sliding bearing used in small and medium-sized mill, its technology has become increasingly mature. (ma 'anshan longsheng wear-resistant materials co., LTD.)

4. From the perspective of operation, measures to reduce the consumption of the grinding machine;

(1) within a certain range, mill practical power as output increases, due to the material stock in mill compared with mill self-respect, share is relatively small, grinding mechanical and electrical flow in fully anticipate when no load and full load conditions are less than 10%, so the normal operation, to the rate of increase is not significantly increase the mechanical and electrical consumption, grinding machine should be run under the condition of full load (maximum) of quantificationally.

(2) timely installation of steel balls (new energy-saving grinding technology with less ball gradation), steel balls will gradually wear out during the operation of the mill, resulting in a reduction in output. In order to ensure the output of the mill, it is necessary to adopt steel balls with good wear resistance and timely supplement the steel balls.

In a word, the energy saving and consumption reducing work of ball mill in cement plant is a more complicated project, which requires coordination and cooperation among various departments and majors. Only in this way can better energy saving effect be achieved. (ma 'anshan longsheng wear-resistant materials co., LTD.)