Crushing operations are one of the most common operations in the powder industry. It is used when huge lumps of material are required to be broken into powder form. In the crushers, metal balls of different sized are made to collide with the large materials. The constant impact of the metal balls result in breaking the larger lumps into smaller pieces and thereby forming smaller sizes of molecules or even powder form of the material.
The type and extent of crushing is determined by the type of grinding media. Grinding medium is the metallic balls that are used inside the crushers. It varies in make, shape and form depending up on the requirements of the end product. The metal balls are even in surface and are smoother on the couture for high impact collisions with the material that is being crushed or powdered. The grinding media is different for different combination of temperature and pressures. Choose us, we are professional Bead Mill Grinding Media Exporters
The grinding media is used in pulverisers, ball mills, cement mills, etc. Mostly its made of steel and alloys of steel. Chromium is added to the steel to make it tougher and increase the hardness. It is made in high pressure environment with different combination of alloys heated and cooled at different temperatures. They are replaced after pre-specified intervals to improve its effectiveness.
Steel Grinding media are also in the form of beads made of steel alloys and hardened steel balls. Chromium is a hard metal and imparts prolonged hardness to the alloy balls. The steel forged models of grinding balls are most popular in crushing industry. These alloys are preferred for contamination free operations. Also, the speed of operations (crushing) is higher in this case. The media is also preferred for operations where no chemical reaction is anticipated between the crushing medium and the crushed material.
The applications of grinding media include grinding of solids, dispersion of liquids, particle size reduction, and raw material homogenization. Mostly used in cement industry, the pulverisers house the chromium rich grinding media. At elevated temperatures and pressures, the steel balls roll constantly and randomly hitting against the lumps of material. The coated surfaces are designed to ensure that they do not react with the materials.
The choice of the specific grinding media depends upon few important factors. They are as follows:
The type of grinding process followed
The type of material to be ground
Type of wear mechanism involved like corrosion, impact or abrasion of the surface
The mechanical, physical & chemical factors governing the crushing mechanism
On a macro level, it is broadly classified into 3 different forms, the grinding balls, grinding rods and beads. The micro segmentation depends upon the manufacturer and standards followed by the manufacturer for the specific industry under consideration.
The usage of grinding media in mining industry is gaining popularity. The hard balls or rods are used for copper, gold, coal and iron ore industry. For harder metals, premium grades are used effectively to serve the purpose. They are subject to intense destruction tests. They have high brinell and Rockwell hardness number coefficients. They metallurgical aspects of the grinding media are specifically designed to counter the practical working conditions inside the crushing machine.
Intense research and development exercises are conducted to improve the reliability and effectiveness of the grinding media. Inside the pulverisers, the time required by the grinding media to execute their function has been a prime cause of concern. The accuracy of prediction is improving due to advancement in the technology. Future holds enormous possibilities for this field to improve.
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