# How to Reduce the Loss of Steel Balls in the Ball Mill?

As the grinding medium of the ball mill, the steel ball of the ball mill continuously collides and rubs with the material and the barrel of the ball mill during the grinding process. Therefore, the consumption of all the wearing parts of the ball mill is particularly large. Compared with another wearing parts ball mill liner, the consumption of steel balls is almost ten times that of the liner. Although the large consumption of steel balls is an inevitable phenomenon in the grinding operation, under the condition of ensuring the normal operation of the ball mill, properly controlling the consumption of steel balls to avoid excessive ball consumption is also one of the effective ways to control the cost of grinding.

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**1. Regularly clean up the failed balls and add new steel balls**

Too many failed balls and an increase in the rate of broken balls will increase the bearing capacity of the ball mill and increase power consumption. This is one of the reasons for high ball consumption. Therefore, it is very important to regularly clean the failed balls and add new steel balls according to the gradation.

**2. Reasonable filling rate of steel balls**

The steel balls added to the cylinder of the ball mill account for 30-40% of the cylinder volume. When the speed of the ball mill reaches a certain level, the higher the filling rate, the more times the steel ball hits the material, the larger the grinding area, and the faster abrasion. In addition, if the filling rate is too high, it will also change the motion state of the steel ball of the ball mill and reduce the impact. The striking effect of large particles. On the contrary, if the filling rate is too small, the grinding effect is weak.

**3. Reasonable steel ball grading**

The size and proportion of the steel balls in the mill vary. The large balls account for 30-40%, the medium balls account for 40%-30%, and the small balls account for 30%. Later, as the large balls continue to wear, the diameter increases. The smaller the size, the larger balls should be added regularly, but the reasonable ratio should be paid attention to. If the proportion of the larger balls in the mill exceeds 70%, the area of the grinding balls will decrease, which will not only increase the ball consumption, but also affect the grinding efficiency. If the large-diameter steel balls in the mill account for more than 70%, the area of the grinding balls will decrease. We know that the grinding efficiency of the ball mill is calculated by the sum of the work done by each steel ball. Too many large balls cause many grinding balls to fail to exert their effectiveness, and it is an inevitable result that the grinding efficiency of the ball mill decreases.

**4. Grinding aids can be added or heating treatment for difficult-to-grind materials**

The grindability of the material is also an important factor affecting the consumption of steel balls in the ball mill. In actual production, if you encounter difficult-to-grind materials, you can appropriately add some grinding aids or heat the ore to reduce the hardness of the material and easy to grind, which is also an effective way to reduce ball consumption.

**5. Reduce the feed size**

The larger the particle size of the ball mill is, the greater the work done by the ball mill on the material. In order to achieve the specified grinding fineness, the workload of the ball mill will inevitably increase, and consequently, the energy consumption of the steel balls will also increase.

In order to reduce the power consumption of the ball mill, the feed particle size of the grinding can be reduced. Therefore, the product size of the crushed ore must be small, that is, "more crushing and less grinding".

**6. Reasonable grinding concentration**

The size of the grinding concentration will affect the specific gravity of the slurry, the degree of adhesion of the material around the steel ball and the fluidity of the slurry. If the grinding concentration is high, the adhesion of the material around the steel ball is good, the impact and grinding effect of the steel ball on the material is also large, and the steel ball wears faster.

In actual production, the grinding concentration can be controlled by controlling the amount of ore, or the amount of make-up water, or adjusting the classification effect.

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**7. Control the speed of the ball mill**

Under the premise that the ball mill steel ball ratio and reasonable, the ball mill speed increases, the steel balls in the cylinder will fall into a falling state and become a falling pile. When the speed of rotation increases to a certain value, the useful power reaches the maximum value. The mine effect is better, and the steel ball wear of the ball mill is also more reasonable.

The theoretical critical speed of the ball mill is generally 78-84%. Due to the nature of the material and other factors, the speed of the ball mill needs to be determined according to the actual situation.