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Rod mill

A mill with steel rod as the grinding body loaded in the cylinder

This entry is made by Compilation and application of scientific encyclopedia entries of "Science Popularization China" to examine.

Rod mill^[1] The grinding body loaded in the cylinder is a steel bar Mill. The rod mill is generally of wet overflow type, which can be used as a primary open circuit Grinding It is widely used in artificial stone sand, mineral processing plants and chemical plants power Primary grinding of the department. The mill is mainly composed of motor main reducer , transmission part, cylinder part, main bearing, slow transmission part, feeding part, discharging part, annular seal, thin oil lubrication station, big and small gear spray lubrication, foundation part, etc. The main reducer is parallel shaft and hard tooth surface. Rod mill is asynchronous motor The reducer is connected with the pinion to directly drive the peripheral big gears to decelerate and rotate, and drive the rotary part to rotate. The cylinder is equipped with proper grinding medium - steel bar. Under the action of centrifugal force and friction, the grinding medium will enter the cylinder body continuously from the feeding part and be crushed by the moving grinding medium, The products are discharged out of the machine through overflow and continuous feeding for the next process. Its working principle, structure, type, grinding medium, use, installation and installation precautions are introduced in detail.

Chinese name: Rod mill
Foreign name: Rod Mill
Applicable to: Artificial stone sand, primary grinding of concentrator

Features: Fine sanding, high sanding efficiency
Grinding medium: Steel bar
Discipline: Mining, machinery

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Product Introduction

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The rod mill is decelerated by the motor through the reducer and the surrounding big gear, or by the low-speed Synchronous motor The cylinder is directly driven to rotate by the peripheral big gear reducer. The cylinder body is equipped with appropriate grinding medium - steel bar. Under the action of centrifugal force and friction force, the grinding medium is lifted to a certain height and falls in a state of throwing or discharging. The milled materials continuously enter the cylinder from the ore feeding port, are crushed by the moving grinding medium, and the products are discharged out of the machine through the overflow and continuous ore feeding force for the next process operation^[2] 。

When 80% of the product particle size is required to be less than 2.0% to 0.5mm, the rod mill is generally used. The product particle size of the rod mill is generally not more than 4.7mm at the maximum and not less than 0.4mm at the minimum. The feed particle size of the rod mill is 80% less than 20mm to 4mm, and the maximum feed particle size can also be up to 50mm. Due to the material of the grinding rod and other reasons, the length of the grinding rod should not exceed 6.1 meters, otherwise it will lead to rod disorder and other consequences. Therefore, the specification of the rod unloader has not exceeded the specification of 4.6 × 6.3 meters.

When the ore is fed into the rod mill, the coarse particles are at the ore feeding end and the fine particles are at the ore discharging end. Therefore, the rod group cannot be completely parallel and inclined during operation, which is also a reason that the grinding rod cannot be too long.

The crushing ratio of rod mill is 15:1 to 20:1. The conventional crushing and grinding process of most foreign concentrators is composed of crushers, rod mills and ball mills. In China, few concentrators use rod mills, and the feed particle size of ball mills is high, resulting in large energy consumption, grinding medium consumption, lining plate consumption, etc. As the grinding rod of the rod mill is in line contact, large materials are ground first, which has the selective grinding effect. Therefore, the product size range is narrow, the product size is uniform, there is less over grinding, and the grinding efficiency is high

working principle

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Rod mill is asynchronous motor The reducer is connected with the pinion to directly drive the peripheral big gears to decelerate and rotate, and drive the rotary part to rotate. The cylinder is equipped with proper grinding medium - steel bar. Under the action of centrifugal force and friction force, the grinding medium will continuously enter the cylinder body from the feeding part, and will be crushed by the moving grinding medium, The products are discharged out of the machine through overflow and continuous feeding for the next process.

Main structure

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The mill is mainly composed of motor main reducer , transmission part, cylinder part, main bearing, slow transmission part, feeding part, discharging part, annular seal, thin oil lubrication station, big and small gear spray lubrication, foundation part, etc. The main reducer is parallel shaft and hard tooth surface^[3] 。

type

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There are three types of universal rod mills^[3] :

1. Overflow rod mill;

2. Ore discharging rod mill around the end;

3. Ore discharging rod mill around the center.

Overflow rod mill is the most widely used, and the product size is smaller than the other two. It is generally used to grind the crushed product and then supply it to the ball mill. The product size is 2-0.5mm.

The ore discharging rod mill around the end is generally used for dry grinding, and the product particle size is coarse. This rod mill can also be used for wet grinding. High gradient and good flow rate can be obtained by using the ore discharging rod mill around the end, and the product particle size is 5-2mm.

The central and peripheral ore discharging rod mill can be used for wet and dry type. The product granularity is coarser. The material is fed from both ends of the rod mill. The grinding process is short, and the sand is discharged quickly. The gradient is high, and the product is too fine. This kind of bar mill is mainly used in aggregate industry to produce sand and gravel.

In order to prevent the rod mill from being disordered and tangled, the ratio of the length of the rod mill to the inner diameter of the rod mill is generally recommended to be 1.4 to 1.6. When the ratio is less than 1.25, the possibility of entanglement increases sharply, so it cannot be less than 1.2. When the diameter of the rod mill is greater than 3.8 meters, the working efficiency and quality of the grinding rod should be carefully considered.

The material of the rod mill is generally fed by the funnel. In order to obtain normal flow, the bottom of the feed hopper should be 1.5 meters higher than the center of the rod mill. The rotating speed of the rod mill is generally 60~68% of the critical rotating speed, not more than 70%. The rotating speed of the bench mill can make the rod mill roll in sequence, too high rotating speed will make the grinding rod throw, and too low rotating speed will reduce the output.

The overflow rod mill can be equipped with a rotary screen at the discharge end to remove the broken pieces of the grinding rod and catch the large materials that run out. The discharge end and can be sealed in a small chamber. A door shall be set at the end of the chamber for loading and unloading the grinding rod.

There are two types of rod mill, dry type and wet type, which can be selected by users according to their actual conditions. It can be used after grinding quartz sand, dolomite, monazite and other products Magnetic separator Iron removal.

Grinding medium

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The grinding medium of the rod mill is the grinding rod. It is generally believed that the length of the grinding rod should not exceed 7m, because the long grinding rod is easy to cause winding. Therefore, the length of the rod mill used is not too long, and the diameter of the grinding rod is 75~150mm^[4] 。

The grinding rod shall have enough rigidity and hardness to keep straight without bending during use, and shall not be so brittle that it will not be broken into pieces without being worn to a small enough diameter, but it shall be able to be broken into small pieces for discharge from the rod mill when it is worn to a small enough diameter. If the rod mill is too soft, it is easy to bend when the cylinder rotates. Bending causes premature damage and winding of the grinding rod. The winding of the grinding rod makes it difficult to clean the mill and wastes time.

Process characteristics

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Save power

More than 40% of power is saved compared with older equipment. The particle size of the product is relatively uniform, with less coarse particles and slime. Comparing the particle size characteristics of the products of rod mill and ball mill, the particle size characteristic curve of the products of open circuit rod mill and closed circuit rod mill Ball milling Almost the same.

Uniform discharging and high output

The advanced controllable feeding and discharging rod mill technology is adopted, combined with the grinding materials of actual users, and suitable grinding bodies are used. The traditional ball mill's surface contact is changed to line contact, so that the discharging particle size of Huali sand machine is more uniform and the output is higher, which is suitable for ores with different hardness (Mohs hardness 5.5~12).

purpose

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There are three uses of rod mill^[3] ：

1) In order to prevent the harm caused by over crushing, rod grinding is often used in the gravity or magnetic separation plant of tungsten tin ore and other rare metal ores;

2) When the two-stage grinding process is used, if the first section is grinded from 20~6mm to 3~1mm, and the rod mill is used as the first section grinding equipment, the production capacity is larger and the efficiency is higher. Because the surface area of a certain weight of rod load is much smaller than that of a ball load of the same weight, the productivity and efficiency of rod mill are lower than that of ball mill when performing the second stage of fine grinding;

3) In some cases, it can replace the short head Cone crusher Make small pieces. When dealing with softer or less hard ores (especially ores with high viscosity) and grinding 19-25mm (or even 32mm) ores to 6-10 meshes with a rod mill, the configuration is simpler and the cost is lower than that when the short head cone crusher and the sieve are closed, and the dust removal in the crushing workshop can be simplified. For hard ores, it may be more economical to use a short cone crusher to form a closed circuit with the screen. In the design, the choice of ball mill or rod mill for election must be determined by making plans and comparing them according to specific conditions.

Rod mill is widely used in metal and non-metal mines and water conservancy and building materials departments to grind various ores or rocks.

Structural differences

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Rod mill Machine structure and Overflow ball mill Basically the same, but with three differences^[4] ：

(1) Steel bars with a diameter of 50-100mm are usually used as grinding media for rod mills, while steel balls are used as grinding media for ball mills. The length of steel bars is 25-50mm shorter than the cylinder, and they are usually made of high carbon steel with a carbon content of 0.8% - 1%; The loading amount of the rod is about 35% - 45% of the effective volume of the rod mill. When viewed with the naked eye, the horizontal plane of the rod is about 100-200mm below the cylinder centerline.

(2) The ratio between the length and diameter of the barrel of the rod mill is generally 1.5-2.0, and the inner surface of the lining plate on the end cover should be a vertical plane. The purpose is to prevent and reduce the chaotic movement, bending and breaking of the steel bar in the barrel, and ensure the regular movement of the steel bar. The ratio of barrel length to diameter of ball mill is small, and in most cases, the ratio is only slightly greater than 1.

(3) The bar mill does not use grid plate for ore discharge, but adopts overflow and open type ore discharge; The diameter of the hollow journal at the discharge end is generally larger than that of the ball mill of the same specification. The rotating speed of the barrel of the rod mill shall be lower than the working speed of the ball mill of the same specification, so that the medium in the barrel can work in the falling state.

Ball mill Analysis of production capacity of ball mill and rod mill

Ball mill and rod mill are both important mining mills, and their production capacity is related to the following factors: ore grindability, particle size of ore feeding and final product, type and size of mill, shape of lining plate, shape, size, proportion, hardness and density of grinding medium, working speed of mill, filling rate of grinding medium, grinding concentration, Sand return amount and working efficiency of classification equipment. Since there are many factors affecting the productivity of the grinding machine, and the factors vary greatly, there is no theoretical formula for accurately calculating the productivity of the grinding machine. Therefore, the production capacity of the mill is generally calculated based on empirical formula and approximate method. There are two commonly used calculation methods: the calculation method of the unit production capacity of the mill according to the ore feeding meter (also called the volumetric meter algorithm) and the calculation method of the grinding power. The volume calculation method is commonly used in China, which is relatively convenient.

Technical performance

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The technical performance of domestic rod mill is listed in the table:

type	Specification and model	Valid Volume m	Cylinder speed r/min	Maximum ball (rod) loading/t	Drive motor	Maximum component mass/t	Quality/t
model	Power/kw	Voltage/v
Overflow rod mill	Φ900×1800	zero point nine	thirty-five point four	two point five		twenty-two	three hundred and eighty	two point zero four	five point three seven
Φ900×2400	one point two	thirty-five point four	three point five five		thirty	three hundred and eighty	two point five five	five point eight eight
Φ1500×3000	five	twenty-six	eight		ninety-five	three hundred and eighty	six point nine two	eighteen
Φ1500×3000 (Intermediate ore discharge)	four point four	twenty-six	thirteen		ninety-five	three hundred and eighty	seven point three six	seventeen point two nine
Φ2100×3000	nine	twenty point nine	twenty-five		two hundred and ten	three hundred and eighty	thirteen point seven seven	forty-two point one eight
Φ2100×3000 (Intermediate ore discharge)	nine	twenty point nine	twenty-five		two hundred and ten	three hundred and eighty	seventeen point five	fifty-seven
Φ2700×3600	eighteen point five	eighteen	forty-six	TDMK400-32	four hundred	six thousand	twenty-four point seven	sixty-eight
Φ2700×4000	twenty point six	eighteen	forty-six	TDMK400-32	four hundred	six thousand	twenty-eight point nine	seventy-three point three
Φ3200×4500	thirty-two point eight	sixteen	eighty-two	TDMK400-36	six hundred and thirty	six thousand	thirty-nine point five	one hundred and eight
Φ3600×4500	forty-three	fourteen point seven	one hundred and ten	TDMK1250-40	one thousand two hundred and fifty	six thousand	forty-six point eight four	one hundred and fifty-nine point nine
Φ3600×5400	fifty	fifteen point one	one hundred and twenty-four	TDMK1000-36/2600	one thousand	six thousand	sixty point seven	one hundred and fifty

performance comparison

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（1） Performance of rod mill

The particle size characteristics of rod mill products are related to the conditions of rod mill ore. When the rod strikes the ore, it first strikes the coarse particles and then grinds the smaller particles, thus reducing the risk of over crushing. When the rod rotates and rises along the lining plate, coarse particles are sandwiched between them, like bar screens, allowing fine particles to pass through the cracks of the rod, which is also conducive to crushing coarse particles and concentrating coarse particles at the place hit by the grinding medium. Therefore, the product of rod mill is more uniform, and the over crushing is lighter.

（2） Application Comparison of Rod Mill and Ball Mill^[4]

(1) In order to prevent the harm caused by over crushing, rod grinding is often used in the gravity or magnetic separation plant of tungsten tin ore and other rare metal ores;

(2) In some cases, it can replace the short cone crusher for fine crushing. When dealing with softer or less hard ores (especially ores with high viscosity) and grinding 19-25mm (or even 32mm) ores to 6-10 meshes with rod mill, the configuration is simpler and the cost is lower than that when the short head cone crusher is closed to the screen, and the dust removal in the crushing workshop can be simplified. For hard ores, it may be more economical to use a short cone crusher to form a closed circuit with the screen.

The choice of ball mill or rod mill in the design must be determined according to the specific situation and the plan must be formulated and compared.

Other information

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Rod mill Lining plate Waveform, ladder or wedge shape are usually used. Manufacturers with good lining board quality: Zhangjiagang Hengxinda, Luoyang Tiancheng, etc. According to different ore discharging modes, rod mills can be divided into central ore discharging (overflow type) and peripheral ore discharging (open type). The former is widely used, while the latter has stopped manufacturing.

The rod mill grinds ore by the pressure and stripping force of the rod. When the rod strikes the ore, it first breaks the coarse particles, and then grinds the smaller particles; The bars are in line contact with each other, while the balls are in point contact with each other. Therefore, when the bars rotate and rise along the cylinder wall, coarse particles are sandwiched between them, similar to the bar screen, which allows fine particles to pass through the gaps between the bars, which is also conducive to crushing coarse particles and concentrating coarse particles at the place hit by the grinding medium. Therefore, the rod mill has a selective grinding function, and the product size is more uniform, with less over grinding.

Installation process

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1. The mill must be installed in a solid reinforced concrete On the foundation (the concrete mark is not less than 150), if the installation position of the mill is higher than the ground, the concrete mark will correspondingly increase the low area and volume of the foundation. It should be designed by relevant disciplines according to the maximum load on the foundation and the allowable bearing capacity of the foundation soil. The foundation gap of the mill should be filled with slate to avoid the vibration generated during the operation of the mill affecting the foundation of the building, The foundation surface outline size of the installation equipment, if there is no special requirement, should generally be more than 100mm larger than the equipment base outline size, and the foundation must be specially accepted after completion^[5] 。

2. The elevation of the upper plane of the foundation shall be 50-80mm lower than the elevation of the lower surface of the equipment baseplate, so that sizing block (inclined iron) can be placed between the foundation and the baseplate for adjustment.

3. In order to ensure the close connection between the secondary pouring and the original foundation, the foundation surface to be secondary poured must be chipped into pitted surface. The method of chipping pitted surface is to use a flat steel shovel to shovel pits on the foundation surface one by one, with a diameter of about 30-50mm. The distance between pits varies according to the size of the foundation, generally about - 150mm. Notches should be chipped at the corners of the foundation, The purpose is to make the secondary irrigation more firm.

4. After the foundation is checked and meets the design requirements, the benchmark can be buried. The datum point shall be buried as the basis for aligning the equipment position according to the center line when installing equipment; At the same time, it is also necessary to embed datum points as the standard basis for measuring elevation when installing equipment. The reference point is generally located at the position where the elevation is measured, and its elevation is measured according to the zero point of the plant area.

5. Laying Foundation bolt Before installation, the rust and oil on the foundation bolt shall be removed, but any grease on the thread shall prevent rust. Check whether the bolt and nut are well matched, and whether the position of the foundation bolt conforms to the general equipment drawing and foundation drawing.

6. Fastening of foundation bolts

A washer must be added below the nut of the anchor bolt. The anchor bolt should be locked with a locking device. Spring washers or double nuts can be used. The anchor bolt can be tightened only after the concrete reaches 75% of the design strength.

7. Main bearing

The installation of the main bearing must meet the foundation strength of more than 75%, and can be installed on the foundation only after passing the inspection. The bearing baseplate shall be cleaned before installation, and the vertical and horizontal center lines shall be marked on the upper surface of the bearing baseplate as the datum line for installation and alignment, then the foundation bolts and baseplate shall be installed on the same foundation, the sizing block shall be placed on the baseplate, and the baseplate shall be adjusted to the correct position.

Bottom of bearing baseplate and secondary pouring cement mortar Generally, the contact surface may not be metalized, but the flatness of the base plate must be ensured, because generally Cold rolled steel plate Surface roughness It can reach about Ra3.2, and the surface roughness of hot rolling is generally about Ra6.3-12.5. The cushion block can be made of 25 * 100 steel plate, the length shall not be greater than the bottom plate width, the main bearing bottom plate shall not be less than 8, and the rest of the bottom plates shall be reduced as appropriate. The adjusting pieces can be made of steel plates of different thicknesses, subject to no more than 2 pieces on each cushion block.

8. The relative elevation of the two main bearing baseplates is generally measured with a liquid communicator or a theodolite, and the allowable difference is 0.5mm, and the feeding end is ensured to be higher than the discharging end. The elevation and levelness of the bearing baseplate should be measured at the same time, and the elevation and levelness should be measured while measuring the height of the scale.

9. Place the bearing pedestal on the bearing baseplate so that the center lines of the two coincide. Pay attention to the observation hole at the lower part of the bearing pedestal towards the outside. The contact surface of the bearing pedestal and the bearing baseplate should be evenly contacted along its periphery. The local clearance should not be greater than 0.1mm. The length of the non contacting edge should not exceed 100mm, and the cumulative total length should not exceed one fourth of the circumference. Otherwise, it shall be handled. Before the installation of the bearing bush, check the fit between the bearing bush surface and the cylinder end cover journal, and the fit between the bush back and the bearing bush base. There should be no pinch phenomenon, and there should be a proper gap between the bush mouth.

10. Before installing the upper cover, connect the cooling water pipe of the main bearing for hydraulic test. The test pressure is 0.4-0.6MPa, and the test time is 30 minutes. There should be no leakage.

11. Before installing the swivel, the end cover must be checked to repair the damage on its upper surface. Such as rust, scratches, etc. At the same time, remove the burrs, flash and anti rust paint on the joint surface. If assembly cannot be carried out immediately after cleaning, a layer of anti rust grease should be coated on the processing surface and packaged.

12. Before installing the rotary part on the bearing, pre install the gear lower cover in the rotary part in place. For the assembled rotary part, measure its total length and the length of the two journal centers, and compare with the center distance of the bearing seat. If it does not meet the requirements, modify the foundation. Before installing the slewing part on the main bearing, the inner part of the main bearing and the journal should be thoroughly cleaned. When installing the cylinder, it is absolutely prohibited to tie the wire rope on the journal. To avoid scratching the journal surface, try to prevent dust and sundries from falling on the bearing surface during installation. When the journal falls and is about to contact the bearing surface, the cylinder (5-10mm) stops falling. At this time, use diesel to wash the bearing surface and journal once, then add a little lubricating oil to it and drop the journal on the bearing surface. Be careful not to damage the pad mouth.

13. After the cylinder is installed in the main bearing, it shall be checked. The bus bars on the two journals shall be at the same level, and the elevation deviation shall not exceed 1mm. The feeding end shall be higher than the discharging end. At the same time, the clearance in the axis direction on both sides of the journal and the pad surface shall be measured. The clearance near the cylinder end is 2.5mm.

14. Before the secondary pouring of the foundation, the foundation bolts shall be tightened, and the oil stain, paint and rust on the bearing pedestal and sizing block shall be removed. After the oil and dust on the foundation are cleaned and cleaned with water, the pouring can be started.

15. The proportion of cement mortar used for secondary pouring is 1:2 (cement mark is 525). During pouring, special attention shall be paid to filling the lower part of the bearing pedestal with cement mortar. During pouring, tamping shall be carried out without gaps.

16. Before the transmission part installs the big gear on the cylinder, it should check whether the lower gear cover is installed, and check the gear cover. If any leakage is found, it shall be removed immediately and its interior shall be cleaned.

17. Clean the big gear and the cylinder. After installation, the flange end face of the big gear and the cylinder end face should closely fit. If there is a gap, it should not be greater than 0.15 mm.

18. The clearance between the big gear and the mating surface shall not be greater than 0.1mm.

19. After the big gear is installed on the cylinder, the end face runout of the big gear is not more than 0.35mm/m pitch circle diameter, and the radial runout of the big gear is not more than 0.25mm/m pitch circle diameter

20. When installing the coupling or clutch, the dimensions of the matching parts such as diameter, length, keyway, chamfer and interference shall be checked in advance. During the hot installation, oil bath or iron box shall be used to heat to the specified temperature. Open fire roasting is strictly prohibited. The coaxial error of each transmission shaft to be connected shall not be greater than 0.2mm. The gap between the two halves of the coupling shall be as specified.

21. The backlash of big and small gears after assembly is 1.02-2.04mm.

22. The contact spot of big and small gears shall not be less than 45% along the tooth height and 60% along the tooth length.

matters needing attention

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one Bar sander The installation location of bar sander is closely related to the crusher. The installation location of bar sander is different depending on the crushing site. Generally, it is installed in the plant or in the open air.

2. Before the installation of the bar sander machine, count according to the packing list, check whether various parts are damaged during transportation, and whether the parts and spare parts are complete.

3. Adjustment of the machine Before leaving the factory, the manufacturer has operated for hours in the factory, and all parts are normal. However, after the bar sander is installed in place on site, a comprehensive inspection should still be carried out to check whether the lubricating oil pipe is firmly connected. Before the test run, it should add oil again, and add Mobil special grade vehicle lubrication.

4. Check the connection of all parts, which should be firm and reliable. Carefully check whether there is any foreign matter on the impeller. If there is, it should be removed in time. Check whether the motor wiring is correct and the voltage is normal.

5. Before installing the belt, start the motor first, and the rotation direction should be consistent with the sign direction of the sander, that is, from the feed port, if the impeller rotates counterclockwise in the opposite direction to the sign direction, adjust the motor wiring, Make its rotation direction consistent with the label direction. For the double motor driven spindle assembly and the motors on both sides, use the same amount of triangular tape to connect with the spindle assembly respectively. The tension force of the triangular tape on both sides should be adjusted to be the same and straight.

Reasonable and correct installation of bar sander can not only improve its working efficiency, but also effectively protect the expensive bar sander, extend its service life and create more value for enterprises

maintain

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The main grinding medium in the rod mill body is steel rod, which is the origin of its name. The machine consists of five parts: cylinder, feeding, discharging, main bearing and transmission^[5] 。

How should the rod mill be maintained?

Generally, the rod mill is a kind of grinding equipment that operates for 24 hours. After power on, the material machine will feed continuously. Under the action of the speed reducer, the motor drives the cylinder to rotate. The steel bar and materials in the cylinder will move together under the action of centrifugal force and friction force. When they reach the highest point, they will fall under their own gravity. Removal of final crushed minerals

Maintenance is a way to effectively extend the service life of the machine, so in order to create long-term economic value, the rod mill should pay attention to maintenance during use. We suggest that when the mill runs continuously for one month, all the lubricating oil should be discharged, the machine should be thoroughly cleaned, and then new oil should be poured in, and the habit should be maintained regularly. In addition, check the lubrication and oil level of each part according to the operating specifications. During the long-term operation of the mill, Drive bearing The heating is normal, but the temperature should not be higher than 55 ℃ to avoid the strike caused by burned parts.

Whether it is a rod mill or a ball mill, maintenance is a regular and regular work, and the working attitude directly affects the extremely long service life and working efficiency. It is recommended that relevant personnel make records, summarize the rules, and reasonably arrange overhaul and medium maintenance.

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