Together
to success
since 1997
"INTECH GmbH"
We are interested in cooperation with the manufacturers of ball tube mills, who are looking for an official and reliable distributor to deal with supply & delivery of their equipment to the industrial plants in Russia.
The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your ball tube mills. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.
Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.
Once we become your authorized representative for ball tube mills in Russia, our marketing staff will carry out a market research in order to check the demand for extrusion lines, will submit a market overview for ball tube mills that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your ball tube mills and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.
Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods or for various types of ball tube mills in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for ball tube mills as per Russian and other EAEU countries’ requirements.
Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your ball tube mills into the future projects.
The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.
Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of ball tube mills. They will also provide necessary training and guidance for the customer’s personnel.
Mills of various types and designs are used for material fine grinding. Materials are ground by friction or simultaneously by impacts and friction. There are a lot of different mill types and designs. Ball mills are the most widely used.
Cost efficiency of the grinding process depends not only on mill unit design, but on grinding flow scheme applied in the machine as well.
Mills with closed circuit operation are used for material fine grinding. This grinding flow scheme means that the material entered into the unit is classified by size: from large to small particles. Material with required grinding degree is discharged from the mill as end product whereas larger grain fractions come back into charging hopper for regrinding, thus creating a closed cycle.
Due to closed cycle it can be reached increased mills performance without increasing energy consumption for grinding: product can be taken off portion-wise of required final grain size and product of a larger grain size can be continuously sent for regrinding. During closed-loop operation a full mill discharge is possible, even when not the whole product corresponds to a given grain size.
Ball mills are machines that are widely used for wet, dry, fine and nano grade grinding of medium hard and hard materials. One of the main components of these machines is a rotating cylindrical shell (pipe, drum), interior space of which is filled by 30 - 40 percent with wear resistant, b grinding balls made of steel or very hard porcelain.
Inner cylinder walls transversely divided by perforated bulkheads into chambers, lined with armor wear resistant plates. Each cylinder chamber has many grinding balls of different diameters. Charging product while entering into mill successively passes all chambers with balls and leaves machine in ground state with quite high grinding degree.
During cylinder rotation, the grinding balls and ground product are trapped by cylinder walls; raise up and not reaching the highest cylinder point fall down on filler. Product grinding is carried out due to balls blows falling from above, as well as friction between them and armor cylinder liner.
Ball mill rotation speed adjustment is made up to its cylinder diameter. There should not be over speed as grinding bolls might against cylinder walls under centrifugal forces that just cannot break away from them and fall down. If machine rotation speed is too low, the balls and raw material simply cannot rise up, thus product will not be ground. In case of too large or too low rotation speed a grinding efficiency excessively slumps.
Ball mills with a center discharge are equipped with short drum with steel balls with a diameter of 25 to 175 mm (pieces max 65 mm are fed in). To lift up the grinding balls higher a drum interior is equipped with stepped or wavy surface plates. Ball mill operates both using dry or wet method. Suspension is drained through the hollow journal during wet grinding. By dry grinding a ground material is sucked off by vacuum cleaner or discharged through the journal by gravity.
Grate ball mills are equipped with cylindrical drum with cast end covers. Drum rotates using hollow journals. Grate cover is located close to one of covers in the drum. Ground material as suspension is fed through grate slits, picked up by grate ribs and removed from mill through the journal. Additionally, raw material is fed through the journal by feeder. Some grate holes can be overlapped in order to adjust suspension level in a mill. Grate ball mills are used only for wet grinding.
Tube mills completely grind process material, so that material can be located in a long drum much longer. In this case, power consumption increases, but there is no need to use the classifier. Tube mills are of single-chamber and multi-chamber type. Multi-chamber mills are equipped with partitions that divide chamber into 3-4 compartments. Each compartment contains grinding bodies of different size (decreases in accordance with material grinding). Compartments located the first along ground material movement are filled with balls by 23-30% and latest compartments are filled by 40%.
The mills equipped with silicon plates which do not contaminate material being processed with iron are used for ceramic materials grinding.
Finished material is discharged through the slits located around end wall periphery and then falls into circular groove.
Ball mills that process the product by balls are used for material fine grinding. Both material and balls are placed together in rotating drum of a hollow structure. Steel or silicon balls in a drum collide with material, breaking and grinding it.
When mill machine rotation speed increases, the centrifugal force and balls elevation angle also increases. This angle increases until the sum of balls weights will not exceed the centrifugal force value. Then balls fall down at a certain curve. If centrifugal force becomes too large, the balls will rotate together with mill, and material will not be crushed. Therefore, it is expedient to determine the number of mill machine rotations wherein balls will fall from the maximum height and at a maximum fall speed.
Thus, the maximum number of drum rotations is defined as follows provided that the ball is at a point m.
Ball is under forces acting in different directions. In this case, centrifugal force is equal to
C = m·ω²·r = (G·ω²·r)/g
and component value of ball weight force is
P = G·sin(α)
where,
G – ball weight in kgf;
w – angular drum rotation speed;
D – drum diameter in m;
n – rotations per minute;
C – centrifugal force, measured in kgf.
The armor with stepped (waves) surface but not smooth is used to reduce balls sliding. Thus, when rotation speed is calculated as above by the given formula, the required balls rise is reached.
Balls weight should provide the grinding of enough large material pieces being charged. As balls fall from different heights, sometimes it is difficult to calculate the work they perform precisely. A correct ratio between balls and charged material pieces size should be fulfilled in order to achieve ball mill operational effectiveness. If ground product contains a lot of large pieces, they will not be ground, bunching between the balls, thereby interrupting mill operation. In this case you should reduce material pieces size to be ground or increase the amount of balls, thus reducing the mill efficiency.
Therefore it makes sense to use smaller balls. Diameter should not be less than required value. For example, balls of diameter less than 65 mm are rarely used. Grinding efficiency and mill capacity depend on drum ball filling, which should not exceed 25-40% of the drum volume.
Mill capacity varies with the drum diameter as well as with the ratio between drum diameter and its length. If drum length is small, the grinding will be coarser. In order to achieve more fine grinding one should return large number of material back to mill, which thus is overloaded. If drum length is sufficiently large, the grinding will be performed at its front and its rest part will be inactive though consuming energy. There is no optimal ratio between drum length and diameter but it is usually taken as: L: D = 1.56 – 1.64. Mill efficiency affected by many other factors such as degree of drum filling with balls, balls size, armor shape, rotation speed during drum rotation, grinding fineness, ground material coarse fraction humidity and size, timely removal of final products.
Ball mills differ from other mill types by high energy consumption, i.e. while running with no load a mill with balls consumes the same amount of energy as fully charged mill. So mill operation with part load is considered as unprofitable.
Drum design depends on ball mill types. There are cylindrical, tubular and conical ball mills.
Cylindrical mills have the drums with a diameter of 0.9 – 2.7 meters. The larger fraction of material ground, the greater must be the drum. Drums are filled with steel or silicon balls. Steel balls have a diameter of 20 - 185 mm and silicon balls - 70 - 100 mm. Balls are evenly spaced along entire mill length. Cylindrical mills for large products grinding should have a small length.
Tube ball mills have the balls more durably affecting the product to be ground. Drums of such mills are typically greater in length.
A drive shaft on the ends is equipped with milled ledges and low spots, which are in turn put in sleeves. Such design prevents mills axial displacement to the gearbox or electric motor.
Conical ball mill has a body consisting of 2 cones, between which a short cylindrical section is located.
Conical mill is a modified cylindrical ball mill that is quite advisable, as certain proportionality between effort made and useful resistance can be reached. Large balls of conical mill placed deeper in cylindrical part of the body and ball size towards discharge part gradually decreases.
A diagram of conical mill equipped with air separator is given below. Air fed to mill by fan carries away ground material into air separator where coarse fractions return to mill through the pipe by gravity. Final material discharged from cyclone separator and returns to air fan through the pipe. Excess air is vented into the atmosphere via pipe.
Balls are used as a grinding mechanism clamped between two rings. Lower ring is rotating and upper one is fixed. Lower ring and springs pressure transmitted through the upper ring put the balls into motion. Packing nut adjusts spring tension. Pressure distribution between the springs is uniform making the balls wearing more proportional. Ground material fed to the mill chamber through the duct, thrown to the periphery and ground between the rings and balls putting out where the airflow throws it into the separator.
Mill is powered by electric actuator with V-belt drive. Maximum size of material ground fraction is 25 - 40 mm.
Other equipment
Upon becoming the official distributer of agitators (mixing equipment), our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (agitators (mixing equipment)) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.
We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.
We are always open for cooperation, so let’s move forward together!
