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PROCESS TECHNOLOGIES FOR TOMORROWSM
© Hosokawa Alpine 2010. Printed in Germany.
HOSOKAWA ALPINE Aktiengesellschaft P. O. Box 10 11 51 86001 Augsburg GERMANY Delivery address: Peter-Doerfler-Straße 13 – 25 86199 Augsburg GERMANY
Tel.: + 49 821 5906- Fax: + 49 821 5906- E-mail: [email protected]
www.alpinehosokawa.com www.hosokawa.com
Subject to change without notice. All information in this brochure is purely informative and non-binding. Our quotations are authorative with regard to orders.
S u P E R - O R I O N ® b a L L M I L L
T Y P E S S. O. , S. O. - C L C O M P A C T L I N E , S. O. - S F S u P E R F I N E
Hosokawa Alpine is a member of the Hosokawa Micron Group, responding to global needs through emphasis on materials science and engineering. The Group is an international provider of equipment and technology for powder and particle processing, plastics processing and confectionery products. The Group maintains facilities for research, engineering, manufacturing and service in each of the world's major industrial markets.
S.O. 04.10/1(EN)
SuPER-ORION baLL MILL S.O.
a FLExIbLE CONCEPT
A flexible concept: ball mills have been the mill of choice for many years for the manufacture of high-quality mineral powders
Regardless of whether the feed material has a Mohs' hardness value of over 4 or is a soft mineral such as limestone, talc or baryte
- which would nevertheless cause a high degree of wear in high-speed mills because of hard and abrasive constituents - Super-Orion ball mills ensure low-wear and cost-effective processing. We have continuously improved the ball mill over the years from a simple machine for the industrial minerals sector to a high-tech machine for the mineral powder industry. The original milling principle and the unparalleled robustness of the machine have not changed. Today, there are three different standard designs available.
SCHEMATIC
PRINCIPLE OF OPERATION
Ball mills are giant drums that are filled to between 30 and 40% of their volume with freely moving milling media - in this case balls. The diameter of the balls is between one and several centimetres to suit the application - smaller balls for fine milling results and larger ones for coarser milling tasks. The drive sets the milling drum into slow rotation and the bed of milling media is thus activated, i.e. the balls are lifted and then impact back against the bed.
Ball mills are usually operated at 75% of the critical speed. The critical speed is the speed where, mathematically calculated, the
SuPER-ORION S.O. FEATuRES
The classic standard design, which has proved itself in operation throughout the world for decades. Both the design and efficiency are continually improved to pay tribute to new technology and market requirements.
- Cast side plates bolted to a rolled-steel drum with integrated manhole
- Drive via ring-and-pinion gear with automatically controlled tooth lubrication, back gearing with couplings and high- performance gear unit
- Bearing unit: journal bearing designed as a friction bearing with permanent oil- recirculation lubrication and temperature control
- Option: self-aligning roller bearing
- Product discharge via adjustable slots located around the periphery of the drum. Two-part discharge housing with top venting connection and inspection cover
grinding media would centrifuge out, and can be described as follows:
Mills of 2 m in diameter therefore rotate in operation at about 23 revolutions per minute, which corresponds to a peripheral speed of 2.4 m/s. A mill of this size equipped with steel milling media converts approx. 50 kW per m3 of feedstock.
The feed product is fed continuously through the trunnion and is discharged through slots on the opposite side. The discharge rate can be adjusted as a function of the number of open slots. The ground product is transported - often pneumatically
- and is charged to a downstream classifier. The coarse material is returned to the mill together with the feed product.
CASCADING
MOTION
FREE-FALL MOTION
B A L L M I L L S. 0. , S. O. - C L A N D S. O. - S F
SuPER-ORION S.O.-CL
(COMPACT LINE) FEATuRES
- Milling drum of high-grade steel completely in welded design
- Direct drive via trunnion with top- mounted gear unit. Direct motor-gear unit connection via flanged motor
- Drive shaft and trunnion supported in enclosed anti-friction bearings
- Product discharge via slots located around the periphery of the drum
- Mill start-up controlled via frequency converter
- Nominal mill speed can be varied by ± 5% via frequency converter
SuPER-ORION S.O.-SF
(SuPER FINE) FEATuRES
- High-tech mill for manufacturing ultrafine fillers and ceramic materials with d 97 < 10 μm
- Fineness down to d 50 = 0.8 μm
- Design as for S.O.-C.L. above, albeit with slotted panel to separate milling media from the product in the discharge area
- Special milling media
- Option: mill on load cells
nc [1/min] = 42,3 / √ D [m]
Machine size with alu-oxide milling media and alu-oxide lining 155/155 155/195 155/365 195/195 195/265 195/325 195/395 195/495 225/395 225/ S.O. S.O.-CL with slotted panel S.O. - SF Motor kW 30 37 55 55 75 90 110 132 132 160 Throughput t/h of zircon sand d 50 1 μm Classifier ATP
Throughput t/h of aluminium oxide d 50 2 μm Classifier ATP
Throughput t/h of quartz sand d 97 40 μm Classifier ASP
Throughput t/h of feldspar d 97 63 μm Classifier ASP
Machine size with alu-oxide milling media and alu-oxide lining 225/595 265/495 265/595 295/495 295/595 295/695 395/395 395/495 395/595 395/ S.O. S.O.-CL with slotted panel S.O. - SF Motor kW 200 250 315 355 450 500 630 710 900 1120 Throughput t/h of zircon sand d 50 1 μm Classifier ATP
2 x 315/
2 x 315/
2 x 315/ Throughput t/h of aluminium oxide d 50 2 μm Classifier ATP
2 x 315/
3 x 315/ Throughput t/h of quartz sand d 97 40 μm Classifier ASP
Throughput t/h of feldspar d 97 63 μm Classifier ASP
The values in the table below are based on production runs with zircon sand, aluminium oxide, quartz sand and feldspar of medium grindability. This information is purely informa- tive. Guaranteed values only possible after trials have been conducted with the original feed material. The values refer to mills operated in circuit with suitable classifiers.
available sizes option
ALuMINIuM
OxIDE
CYLPEBS
ALuMINIuM
OxIDE
MILLING BEADS
Not only is a lined ball mill necessary for processing without iron contamination, but the classifier must also be suitably protected against wear. As a result, the product- contact parts of all suitable classifier models such as Turboplex, Stratoplex and Ventoplex are protected against wear with ceramic or Pu. Particular attention must be paid to the classifying wheel because wear increases with the square of the speed (double the speed = four times the wear). In view of this, ATP Turboplex classifiers are equipped with monobloc ceramic classifying wheels..
The Super-Orion ball mill has also proved itself in operation around the world for processing ceramic raw materials. In combination with a classifier, the ball mill usually forms the heart of the process. In spite of ceramic raw materials with a Mohs' hardness of between 5 and 8 being extremely abrasive, milling must be performed without iron contamination if the colour integrity of the end product is to be ensured. Because of this, the ball mill is usually lined with aluminium oxide and operated with Al 2 O (^3) milling media.
SuPER-ORION S.O. FOR TECHNICaL
CERaMICS aNd CERaMIC RaW
MaTERIaLS (aL 2 O 3 , ZrO, ZIRCONIuM SILICaTE, ETC.)
Particle size μm
Volume %
200 150 100 50 45 20 15 5 4 3 2 1 0,5μm
VARIABLE-SPEED DRIVE
With a special frequency converter version, it is even possible to operate a heavy ball mill at variable speed. And if the S.O.-SF is to be used for milling ultrafine products or if it is planned to change the product often, operation with a frequency converter is particularly advantageous.
LOAD CELL TECHNOLOGY RESuLTS IN
PRECISION PRODuCT LEVEL CONTROL
Modern applications call for exact measurement of the amount of product in the mill. Because of this, an optional accessory offered for our ball mills is the load cell system. This system works with a tolerance of ±25 to 50 kg (dependent on We offer system configurations for a great the mill size), and permits high-precision variety of products and fineness ranges that are optimally tailored to the individual application in each case. The following classifiers are eminently suitable for closed- circuit operation with a ball mill.
VENTOPLEx CLASSIFIER C
Circuit-air classifier for high throughputs. Fineness range approx. d 97 = 32 μm - 200 μm. Low energy consumption.
Since the Alpine Mikroplex spiral air classifier MP was launched on the market in 1948, Hosokawa Alpine has been extremely successful classifiers
TuRBO-TWIN
CLASSIFIER TTC
STaTE-OF-THE-aRT CONTROL aNd
LOad CELL TECHNOLOGy
MICRON AIR CLASSIFIER MS
ultrafine classifier designed as an air- flow classifier (pneumatic product feed). Operating range: approx. d 97 = 15 – 150 μm. High throughput rates.
STRATOPLEx AIR CLASSIFIER ASP
Standard classifier for high throughput rates in the fine to medium-fine separation range of d 97 = 20 – 200 μm. High fines yield at low energy consumption.
TuRBOPLEx uLTRAFINE CLASSIFIER
ATP AND ATP-NG
Single- or multi-wheel classifier for ultrafine classification. Superfine powders in the range d 97 = 3 – 10 μm. In NG design, fineness values to d 97 = 2 μm (d 50 = 0,5 μm) are possible. Operation free from oversized particles over the entire separation range. Integrated coarse material classifier to increase the yield.
TuRBO-TWIN CLASSIFIER TTC
New classifying concept for results in the fineness range to d 50 = 0.5 μm.
Ball mills are usually operated at 75% of the critical speed, i.e. in the fringe area between cascading and free-fall motion.
control and metering via a screen. The user therefore has the possibility of entering and monitoring up to 4 individual limit values direct on screen or via a bus or serial 20-mA TTY interface.
The complete ball mill is bedded on a steel or concrete frame designed to rest on a defined number of load cells. The load cells are integrated into a control unit and determine the total weight of mill, grinding media and product. Subtracting the weight of mill and milling media results in the weight of the product in the mill. This is accomplished with leading-edge electronics in the kg measuring range.
The addition of virgin feed can be controlled with such precision that the mill always operates at optimum load. This means reliable prevention of no-load operation or overfilling, and mill operation is thus exceedingly cost-effective.
t/h
Stratoplex ASP
Ventoplex C
Micron MS
Turboplex ATP multi-wheel
Turboplex ATP single-wheel
Turbo Twin TTC
Particle size d97 / μm
Fines Yield
Turboplex ATP-NG
COMbINaTION WITH CLaSSIFIERS
