Abstract
Zircon sand, as an important industrial raw material, is widely used in ceramics, refractory materials, casting and nuclear industry. The high requirements for particle size and purity during its processing make grinding and classification key links. Ball mill + classifier production line has gradually become the core technology of zircon sand processing due to its high efficiency, energy saving and precise classification capabilities. This article focuses on the application principle, technical advantages and actual cases of ball mill + classifier production line in zircon sand processing.
Processing characteristics and challenges of zircon sand
Zircon sand (chemical formula: ZrSiO₄) is a natural zirconium silicate mineral with high melting point (about 2550℃), high hardness (Mohs hardness 7.5) and excellent chemical stability. However, its dense structure and toughness lead to the following problems in traditional crushing and grinding processes:
· Low grinding efficiency: Conventional equipment is prone to increased energy consumption and increased equipment wear due to the high hardness of zircon sand.
· Difficulty in particle size control: Downstream applications (such as ceramic glazes) require uniform particle size distribution (usually D97≤45μm), but ordinary grinding equipment is difficult to achieve high-precision classification.
Therefore, how to achieve the combination of efficient grinding and precise classification becomes the key to improving the processing quality of zircon sand.
Process flow of ball mill + classifier production line
The ball mill and classifier production line consists of a ball mill, classifying equipment (such as an air classifier), a dust removal system and an automatic control system. The process flow is as follows:
① Coarse crushing and pre-grinding
The raw materials are initially crushed to less than 5mm by jaw crusher or impact crusher;
② Ball mill fine grinding
The ball mill further crushes materials to the micron level through the impact and grinding action of steel balls/ceramic balls in the cylinder.
Based on the characteristics of zircon sand, wet or dry grinding can be adopted. Wet grinding can reduce dust pollution but requires subsequent drying; dry grinding avoids oxidation through inert gas protection.
③ Dynamic and precise classification
After grinding, the material enters the air classifier, where efficient separation of coarse particles and fine powder is achieved through the balance of centrifugal force and aerodynamics. The classification accuracy can reach D97±2μm, and multi-level particle size control can be realized by adjusting the speed of the classifying wheel or the air volume.
④ Collection and dust removal
Qualified fine powder is collected by cyclone separator or bag filter, and ultra-fine powder is recycled to ensure dust-free emission.
Technical advantages of ball mill + classifier production line for processing zircon sand
— High efficiency and energy saving, improving production efficiency
◈ The ball mill and classifier are interconnected to form a closed-loop system. After grinding, the materials are screened by the classifier, and unqualified coarse particles are directly returned to the ball mill for reprocessing, reducing invalid material retention and increasing production efficiency by more than 30%.
◈ The ball mill adopts variable frequency speed regulation technology to dynamically adjust the rotation speed according to the hardness of zircon sand, reducing the unit energy consumption by 25%-30% compared with traditional processes.
◈ Avoid “over-grinding”: The classifier accurately controls the qualified particle size, reducing the energy waste caused by over-grinding.
— Precise classification with strong particle size control capability
◈ The classification accuracy of the air classifier can reach D97±2μm, meeting the strict requirements of ceramic glazes (D97≤45μm), electronic-grade powders (D50≤10μm), etc.
◈ The dynamic classification technology ensures a narrow particle size distribution of the product, increasing the qualified product rate to over 95% and significantly reducing the amount of returned material.
— Low-pollution process to ensure high purity
◈ The ball mill uses ceramic liners and zirconia/alumina grinding media to replace traditional steel liners and steel balls, avoiding the introduction of metal impurities such as iron and manganese. The iron content of the finished product can be controlled below 0.02%.
◈ The fully enclosed production line, integrated with a dust removal system, ensures the dust emission concentration is ≤10mg/m³. This meets environmental protection standards and reduces workshop pollution simultaneously.
◈ In dry grinding, inert gases, e.g: nitrogen, are introduced to prevent zircon sand from reacting with oxygen at high temperatures, making it suitable for high-end application scenarios sensitive to oxidation (such as nuclear industry application).
Practical application cases
Máquinas de pó épico de Qingdao Co., Ltd. is a professional manufacturer specializing in powder processing equipment, with decades of production experience and technical expertise.
Nosso products include:
Equipamento de moagem: Moinho de bolas, jet mill, air classifier mill, moinho de rolos, etc.
Classificação de equipamentos: Inclui 5 tipos de classificador de ar – HTS, ITC, CTC, MBS e TDC.
Equipamentos de modificação de superfície: Modificador de moinho de pinos, modificador de moinho de três rotores e modificador turbo-mill, etc.
Equipamento auxiliar: Control cabinet, filtro de bolsa, ventilador de sucção, etc.
Our ball mill + classifier production line is widely used in the processing of non-mineral powders. It has advanced technology, reliable quality and is widely praised by consumers.
Actual case from Pó épico
Raw Material Condition
Raw material：Zircon sand
Mohs hardness：8
Bulk density ： 2,700kg/m3
Moisture： < 0.2%
Feed size： 99% ≤ 3mm
Production Requirement
D95 45 µm：2200kg/h +/- 5%
D95 75 µm：3000kg/h +/- 5%
Our solution
Ball mill with ceramic liner: Φ2.2m × 6m + Air classifier ITC-3
In this case, our ball mill + classifier production line performed well, met the requirements of customers and laid a good foundation for subsequent cooperation
Conclusão
The ball mill + classifier production line provides a reliable technical solution for zircon sand processing through the synergy of efficient grinding and precision classification. If you are purchasing zircon sand processing equipment or other powder processing equipment, please contact Epic Powder. We will have a professional team to follow up the whole process, from technical consultation, solution design, to equipment installation and commissioning, operator training, as well as equipment maintenance and technology upgrades.
Contato Epic Powder, e deixe que nosso equipamento especializado capacite seu processamento de pó – para maior eficiência e economia de energia.