1. Reduced Grinding Efficiency
Blockage prevents material from flowing smoothly through the grinding chamber, significantly reducing grinding efficiency. For example, grate blockage can hinder the discharge of qualified material, resulting in over-grinding and increased inefficient energy consumption. When a wet ball mill becomes blocked, slurry fluidity decreases, and processing capacity can be reduced by over 20%.
2. Increased Equipment Wear and Energy Consumption
Long-term blockage increases wear on components such as liners and steel balls, shortening equipment life. Statistics show that grate blockage can increase energy consumption by 15%-30%. Material retention reduces the impact efficiency of the grinding media. In severe cases, it can lead to chain reactions such as bearing overheating and motor overload.
3. Safety Hazards
Blockage can cause abnormal equipment vibration, sudden temperature rise, and even downtime. Case studies have shown that forced operation after a blockage can damage transmission components. In extreme cases, the equipment can cause mechanical damage due to swinging.
4. Impact on Product Quality
Blockage disrupts the gradation balance of the grinding media, resulting in uneven product fineness. For example, if the moisture content of the incoming material is too high, a "cushion" effect can easily form, causing the finished product particle distribution to deviate from the design requirements.
Preventative Measures:
Control the feed particle size (recommended <15mm for wet mill systems) and moisture content.
Regularly inspect the grate and liner wear (liner wear exceeding 30% requires replacement).
Optimize the steel ball grading (recommended three-grade grading, with a fill rate of 35%-40%).
Install online monitoring devices (such as current warning systems and density interlock systems).
