Quality Horizontal Bead Mill Machine & Bead Mill Machine Factory

The horizontal sand mill has numerous functional components and a complex working principle, requiring extremely high coordination among various components. Now, let's have Anqiu Chunqiang Machinery briefly introduce it to you Main functional components and working principle of horizontal sand mill: ...

The high-speed disperser is a specialized high-speed equipment designed for low-speed stirring, high-speed decomposition, dissolution, and mixing of various liquids of different viscosities and solid powders. Through the rotation of a specially designed impeller at different speeds, it generates ...

Operators and maintenance personnel for horizontal sand mill equipment should be familiar with the equipment's structural performance and the names, specifications, and functions of each component. Operators should lubricate each part according to the requirements indicated on the lubrication ...

Horizontal Grinding Mill Zirconia Grinding Media: Performance and Maintenance I. Key Performance Characteristics High sphericity and roundness with a smooth, pearl-like luster. Excellent toughness and impact resistance, preventing breakage during high-speed operation. The wear resistance of TZP zirconia beads is 30-50 times greater than that of glass beads. Higher density compared to other grinding media, resulting in significantly improved grinding efficiency. This allows for higher solid content in materials or increased material flow rates. Sipur possesses a full range of quality inspection equipment for its zirconia bead products. Technical Specifications: True Specific Gravity: 6.02 g/cm³ Bulk Density: 3.5 - 3.7 g/cm³ Mohs Hardness: 9.0 Material Composition: Zirconia (ZrO₂): 94.8% Yttria (Y₂O₃): 5% Other: 0.2% Features: Extremely low wear loss (at ppm levels). Exceptional hardness, resistant to breakage, suitable for grinding high-hardness materials. Very high density, effectively improving grinding efficiency. Application Scope: Coatings, Inks, Non-metallic Minerals, Electronics, Glazes, Papermaking. II. Causes of Bead Breakage After selecting suitable zirconia beads, proper usage is crucial to minimize breakage and extend the service life of both the grinding media and the mill's contact parts. 1. Causes of Defective Bead Formation Common grinding media like glass beads, zirconium silicate beads, and pure zirconia beads are primarily manufactured using two methods: electric melting and sintering. The beads are formed in hot air, cold air, or an electrolytic bath. If key technical parameters are not properly controlled, the following fragile bead types can be produced: Bubbled Beads Dumbbell-shaped Beads Tailed Beads Flattened (Oval) Beads These beads contain stress concentration zones and are prone to breakage during grinding. Therefore, such beads should be avoided during selection. 2. Distinguishing Normal Wear from Breakage During normal operation, zirconia beads gradually become smaller while maintaining a smooth, rounded surface without sharp edges—this indicates normal wear. Conversely, the presence of beads with sharp edges, fragments, or irregular shapes signifies bead breakage. 3. Root Causes of Bead Breakage Regarding the beads themselves, potential causes include inherent quality issues or the material strength being insufficient for the specific type of sand mill in use. Under normal sand mill operation, zirconia beads are subjected to approximately 1 kg of force. Compared to the compressive strength of glass beads (~5,000 kg) and zirconium silicate beads (~9,000 kg), the force experienced by zirconia beads is negligible. Therefore, the primary causes of bead breakage typically relate to equipment or process conditions, and solutions should focus on these areas.

When purchasing a horizontal sand mill, attention should be paid to the following critical aspects: 1. Material of the Grinding Chamber Many manufacturers use 304 stainless steel for the grinding chamber. However, the nickel content in standard 304 stainless steel (typically 8%) is crucial for corrosion resistance. Some suppliers may use lower-grade variants with only about 4% nickel. This can lead to rusting, especially when processing water-based materials or if the mill sits idle with liquid residue. Rust contamination can cause discoloration in products (e.g., graying of white pigments, darkening of phthalocyanine blue, fading of reds). This discoloration occurs because the chamber wall wears against the grinding media (beads). To minimize this wear when using stainless steel chambers, suppliers often recommend softer media like glass beads or standard zirconium silicate beads. However, for achieving fine particle sizes (e.g., 0.2-0.5μm / 200-500 nm), high-density media like pure zirconia beads are necessary for effective grinding energy. The conflict arises because these hard beads accelerate the wear of a soft stainless steel chamber. Solution: Opt for mills with grinding chambers made from imported wear-resistant alloy steel (e.g., ASSAB tool steel). This allows the use of high-density, high-purity (95%+ ZrO₂) zirconia beads (density ~6.0 g/cm³) without significant chamber wear. Higher bead density provides greater impact force, leading to more efficient particle size reduction compared to lighter glass beads (~2.0 g/cm³) or standard zirconia beads (~2.5 g/cm³). 2. Rotor and Agitator Design Horizontal sand mills primarily feature two agitator designs: Disc-Type: Features smooth chamber walls and a rotor with multiple discs. Grinding media moves primarily in a linear, back-and-forth motion. This design offers limited grinding efficiency and longer processing times for fine grinding. Pin-Type: Features both a rotor and a stationary chamber liner studded with pins (typically made of tungsten carbide). This creates a more intense grinding zone. The media follows a complex path involving both linear and zigzag motions at high tip speeds (e.g., ~12 m/s). This significantly enhances shear and impact forces, leading to much faster and more efficient grinding compared to disc-type mills. 3. Media Separation System This critical component separates the finished product from the grinding beads. It typically consists of a gap separator with a stationary ring (near the mechanical seal) and a rotating ring (in contact with the product slurry). Both are ideally made of tungsten carbide for wear resistance. Gap Adjustment: The separation gap is adjustable based on the target fineness and bead size. For example, to achieve a 200-500 nm grind, a gap of 0.1-0.4mm might be set. Bead diameter should generally be at least 3 times the gap width to prevent blockage. Therefore, for a 0.17mm gap, 0.6-0.8mm beads would be appropriate. A correctly sized separator ensures product purity, high throughput, and efficient grinding. 4. Mechanical Seal and Cooling System Mechanical Seal: High-quality, leak-proof mechanical seals from reputable German brands are essential. These seals should have a long service life (e.g., 8000+ hours) and be self-lubricating, eliminating the need for external oil lubrication which could contaminate the product. The seal flush should use a solvent or water compatible with the product. Cooling: Effective temperature control is vital. A comprehensive four-point cooling system covering the mechanical seal, grinding chamber, front end plate, and shaft is recommended to maintain optimal process conditions and product quality. 5. Production Efficiency A well-designed pin-type mill with a dual-stage pin configuration, paired with high-density zirconia beads, offers significantly higher efficiency. Some models feature a dual-outlet gap system to further enhance output, potentially doubling or more the productivity of conventional mills without compromising product quality. 6. Ease of Operation The main control panel should be centrally located and user-friendly, simplifying operation and parameter adjustments. 7. Ease of Cleaning, Color Change, and Bead Replacement The grinding chamber should have a dead-space-free, self-cleaning design. Features like chamber-mounted wheels or carts allow easy dismantling and maintenance. Ideally, one person should be able to perform tasks like cleaning or replacing beads. 8. Safety and Protection Features The electrical system should use reliable components (e.g., Schneider/Taiwan Shihlin brands). Comprehensive safety interlocks are mandatory, including automatic shutdown in case of over-pressure in the chamber, over-temperature, or motor overload to protect both the equipment and the operator.