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The Ball-Mill Filter Screen is a perforated metal mesh component engineered for particle classification in ball mill pulverizers, manufactured via laser drilling technology—this process ensures aperture edge smoothness (no burrs > 0.01mm) to avoid particle attrition and screen wear. It controls feed and product particle sizes, ensuring downstream processing efficiency—critical for applications requiring <10μm final particle size such as cement clinker grinding and mineral processing. Constructed from wear-resistant metal, it endures abrasive media impact (e.g., steel balls, ore particles) in mining and cement production, outperforming traditional woven wire screens by 3-5 times in service life.
Precise Aperture Control: Aperture sizes from 1.0mm to 3.8mm with 0.1mm tolerance, matching 50-mesh (300μm) feed requirements. The 1.0mm aperture is used for fine grinding of limestone (target particle size 5-10μm), while the 3.8mm aperture suits coarse grinding of iron ore (20-50μm). Laser drilling ensures 100% aperture consistency, avoiding oversize particles that damage downstream equipment.
Durable Construction: 0.2-1mm thick metal sheets (304 stainless steel optional) resist wear for 12+ months in continuous use. For high-abrasion applications (e.g., granite ball mills), 1.2mm thick Mn13 wear-resistant steel is available, extending service life to 18+ months. The screen’s reinforced edge (2x thickness of the main body) prevents tearing at the installation interface.
Customizable Dimensions: Length and width tailored to mill models, with maximum production capacity of 1000 m²/month. For example, it can be customized to 4m×2m size for Φ5.0×15m large ball mills, and 1m×0.8m for laboratory-scale Φ1.2×2.4m mills. Hole pattern (square, round, hexagonal) is also customizable—hexagonal holes increase open area by 15% vs. square holes.
High Filtration Efficiency: Captures 95% of particles exceeding target size, reducing rework rates. In a cement plant, it reduced oversize clinker particles (＞80μm) from 10% to 2%, improving cement fineness and compressive strength (28-day strength increased by 3 MPa).
Mining: Ore grinding classification in gold and copper mines. In a gold mine’s ball mill system, it ensures 99% of ore particles are < 75μm, maximizing leaching efficiency and gold recovery rate (up by 4%).
Cement Industry: Clinker powder control in cement production lines. For Portland cement production, it maintains clinker particle size distribution (30-60μm accounting for 60%), improving cement hydration activity and reducing setting time by 15 minutes.
Coal Processing: Pulverized coal filtration for power plant boilers. It ensures pulverized coal fineness (R90 < 15%, R200 < 5%), enhancing combustion efficiency in boilers—field tests show a 2% reduction in coal consumption per ton of steam.
Q: Which aperture suits 300μm feed size?
A: 50-mesh (300μm) screens are standard for this feed specification. For applications requiring stricter control (e.g., pharmaceutical excipient grinding), a 60-mesh (250μm) screen can be used to prevent oversize particles, with a minor flow rate reduction (＜5%).
Q: How often should it be replaced?
A: Typical service life is 6-8 months, depending on abrasive intensity. In low-abrasion limestone mills, it can last 12 months; in high-abrasion iron ore mills, replacement every 4-5 months is recommended. Regular inspection (every 2 weeks) for aperture blockage or edge wear is advised.
Q: Can it withstand high temperatures?
A: Yes, it operates stably up to 200°C in cement mill applications. For cement clinker mills with outlet temperatures up to 180°C, 304 stainless steel screens maintain structural integrity without thermal deformation. For temperatures exceeding 200°C (e.g., ceramic powder grinding), heat-resistant alloy (e.g., Haynes 282) screens are available, with a maximum temperature of 1200°C.
Q: How to install the screen to avoid misalignment?
A: The screen is equipped with positioning pins and bolt holes that match the ball mill’s discharge port. Align the pins with the mill’s guide slots, then fasten with high-strength bolts (8.8-grade or above) to ensure flatness error ≤ 0.5mm. Misalignment can cause uneven wear, reducing service life by 30%.
The Ball-Mill Filter Screen is a perforated metal mesh component engineered for particle classification in ball mill pulverizers, manufactured via laser drilling technology—this process ensures aperture edge smoothness (no burrs > 0.01mm) to avoid particle attrition and screen wear. It controls feed and product particle sizes, ensuring downstream processing efficiency—critical for applications requiring <10μm final particle size such as cement clinker grinding and mineral processing. Constructed from wear-resistant metal, it endures abrasive media impact (e.g., steel balls, ore particles) in mining and cement production, outperforming traditional woven wire screens by 3-5 times in service life.
Precise Aperture Control: Aperture sizes from 1.0mm to 3.8mm with 0.1mm tolerance, matching 50-mesh (300μm) feed requirements. The 1.0mm aperture is used for fine grinding of limestone (target particle size 5-10μm), while the 3.8mm aperture suits coarse grinding of iron ore (20-50μm). Laser drilling ensures 100% aperture consistency, avoiding oversize particles that damage downstream equipment.
Durable Construction: 0.2-1mm thick metal sheets (304 stainless steel optional) resist wear for 12+ months in continuous use. For high-abrasion applications (e.g., granite ball mills), 1.2mm thick Mn13 wear-resistant steel is available, extending service life to 18+ months. The screen’s reinforced edge (2x thickness of the main body) prevents tearing at the installation interface.
Customizable Dimensions: Length and width tailored to mill models, with maximum production capacity of 1000 m²/month. For example, it can be customized to 4m×2m size for Φ5.0×15m large ball mills, and 1m×0.8m for laboratory-scale Φ1.2×2.4m mills. Hole pattern (square, round, hexagonal) is also customizable—hexagonal holes increase open area by 15% vs. square holes.
High Filtration Efficiency: Captures 95% of particles exceeding target size, reducing rework rates. In a cement plant, it reduced oversize clinker particles (＞80μm) from 10% to 2%, improving cement fineness and compressive strength (28-day strength increased by 3 MPa).
Mining: Ore grinding classification in gold and copper mines. In a gold mine’s ball mill system, it ensures 99% of ore particles are < 75μm, maximizing leaching efficiency and gold recovery rate (up by 4%).
Cement Industry: Clinker powder control in cement production lines. For Portland cement production, it maintains clinker particle size distribution (30-60μm accounting for 60%), improving cement hydration activity and reducing setting time by 15 minutes.
Coal Processing: Pulverized coal filtration for power plant boilers. It ensures pulverized coal fineness (R90 < 15%, R200 < 5%), enhancing combustion efficiency in boilers—field tests show a 2% reduction in coal consumption per ton of steam.
Q: Which aperture suits 300μm feed size?
A: 50-mesh (300μm) screens are standard for this feed specification. For applications requiring stricter control (e.g., pharmaceutical excipient grinding), a 60-mesh (250μm) screen can be used to prevent oversize particles, with a minor flow rate reduction (＜5%).
Q: How often should it be replaced?
A: Typical service life is 6-8 months, depending on abrasive intensity. In low-abrasion limestone mills, it can last 12 months; in high-abrasion iron ore mills, replacement every 4-5 months is recommended. Regular inspection (every 2 weeks) for aperture blockage or edge wear is advised.
Q: Can it withstand high temperatures?
A: Yes, it operates stably up to 200°C in cement mill applications. For cement clinker mills with outlet temperatures up to 180°C, 304 stainless steel screens maintain structural integrity without thermal deformation. For temperatures exceeding 200°C (e.g., ceramic powder grinding), heat-resistant alloy (e.g., Haynes 282) screens are available, with a maximum temperature of 1200°C.
Q: How to install the screen to avoid misalignment?
A: The screen is equipped with positioning pins and bolt holes that match the ball mill’s discharge port. Align the pins with the mill’s guide slots, then fasten with high-strength bolts (8.8-grade or above) to ensure flatness error ≤ 0.5mm. Misalignment can cause uneven wear, reducing service life by 30%.
