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Calcium Carbonate Milling Equipment

Milling machines are used to reduce the size of material by cutting, crushing, or grinding it. The choice of industrial milling equipment depends on the industry and the materials to work with. Besides, there is a significant difference between those aimed to remove layers from metal or other materials workpieces and those designed to reduce particle size for materials that come in bulk.

Milling

Calcium carbonate makes up almost one-twentieth of the earth’s crust. But the abundant mineral is found in many living things, including the human body. However, processing calcium carbonate extracts the multi-purpose material from inorganic sediments, namely limestone, chalk, and marble.

Calcium carbonate

A vertical agitated media mill is used for grinding ultrafine particles, in an agitated (or stirred) grinding media action, such as mineral fillers, glazing raw materials and non-mineral hard materials. It comprises a cylindrical grinding chamber that is filled with grinding beads of a few millimeters in diameter.


<h2>Ideal for mineral fillers, glazing raw materials and non-mineral hard materials</h2>
The ATR vertical agitated media mill from Hosokawa Alpine is a vertical agitated media mill that comprises a cylindrical grinding chamber, with a double-walled mill housing to permit water cooling, that is filled with grinding beads of a few millimeters in diameter.

Because of the small grinding beads, the particle size of the feed material should not exceed 100 µm. The agitator shaft with its arms dips into the bed of material and grinding beads and is set into slow rotation by a gear unit connected to a motor.

Typical used for milling mineral fillers, glazing raw materials, and non-mineral hard materials. Examples: limestone, quartz, zircon sand, talc, ceramic colors and frits, titanium dioxide, etc.

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Vertical agitated dry media mill

A horizontal rotary ball mill drum can be used for grinding of dry hard materials, such as hard minerals for the ceramic, glass or porcelain industry and processing of soft minerals with abrasive properties.


<h2>Dry ultrafine grinding of mineral powders and ceramic raw materials</h2>
The Super Orion ball mills from Hosokawa Alpine are employed for the dry ultrafine grinding of mineral powders and ceramic raw materials. The ball mill is designed for the dry comminution of hard materials, especially for the ultrafine range &lt; 10 µm in circuit with an ALPINE ultrafine classifier.

Ball mills are giant drums that are filled with between 30 and 40% of their volume with freely moving grinding media, in this case balls. The diameter of the balls is between one and several centimeters to suit the application - smaller balls for fine milling results and larger ones for coarser milling tasks.

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Horizontal rotary ball mill drum

Particularly designed for humid, oily, and greasy products.


<h2>Ultrafine pill mill proved to process even sticky materials in a wide chamber housing</h2>
The Contraplex Wide Chamber Mill - Contraplex CW from Hosokawa Alpine is an ultrafine pin mill, with two driven pin discs. Designed aiming to achieve high-power fineness values at a range of approximately 10 to 500 µm.

The fineness can be adjusted by altering the fine pin mill disc speeds. The centrifugal forces acting on both discs allow the processing of humid, greasy, and sticky products, primarily as a result of the utilization of the design within the wide chamber housing.

The feed material stands out for being embrittled by intensive mixing with liquid nitrogen. Ultrafine Pin mills are considered among the most reliable and versatile equipment currently available in the materials processing market. It features a generously dimensioned mill door that can be attached wide-open, for easier cleaning.

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Ultrafine pin mill

With a pre-crusher continuous flakes are made into pieces, before granulation.


<h2>Proper pre-crushing before granulation</h2>
Pre-Crusher type PC from Hosokawa Alpine is a pre-crusher of plates quite suited for the first crushing levels before the granulation and production of clumped materials for free-flowing.

The crushing takes place with counter-rotating grinding rollers which are either equipped with bars or discs, that reach particle sizes up to 30 mm, dust-free coarse crushing in the preliminary crushing of flakes

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Pre-crusher of plates

When you need to produce ultra-fine powders, the milling and drying process employed is what ensures the consistency of your product. To process minerals and chemicals, you need a machine which is powerful, flexible, simple to maintain.


<h2>Versatile and highly efficient milling and drying</h2>
Atritor’s cell mill has been constructed to produce ultra-fine powders. It is able to grind, flash dry, classify and surface coat powders at the same time. Its capacity ranges from 50 kilograms per hour to 15 tonnes per hour, with evaporation rates up to 3,000 kilograms per hour.

The feed can be dosed directly into the machine via a screw feeder or via the inlet air duct. It is then ground in a vertically mounted, multi-stage rotating rotor. Each of the rotor sections is constructed with up to 200 quick-change blades. There is also the possibility for a classifier which is mounted at the discharge section to ensure that oversized feed particles are either discarded or recirculated.

The mill acts as an efficient dryer when the process air is heated using a hot air generator or even waste heat from another process. It can reach an inlet temperature of up to 450ºC. Heat energy from the process can be recovered from the heated air stream and utilized to preheat the intake air. After flash drying, the product is kept cool due to evaporative cooling via the constant exposure of new surface areas of the product created during attrition.

In the case of minerals that require surface treatment, the cell mill provides a range of coatings and surface modifiers that can be added on the side of the machine during the milling process. It has a wide range of applications, from minerals like GCC, clay and limestone to chemicals, dyes, pigments and a wide range of food ingredients and by-products.

Milling and drying machine for fine powders

Drying and grinding can be an important feature when trying to process products such as raw and refined minerals, organic and inorganic chemicals, food ingredients and waste streams. It is crucial to maintain particle size and consistent quality of the finished product during such processes. You will need an efficient and abrasion resistant attrition solution to pulverise and dry your product into your required particle size.


<h2>A simplified process while drying and grinding ensuring high product quality</h2>
Atritor’s Dryer-Pulveriser is able to grind and dry the product simultaneously. It is an air-swept mill that uses an air stream to efficiently process the product and controls the final particle size. It is able to process feedstocks of up to 50+mm and production capacities from 100kg/h up to 30t/h with evaporation rates up to 6,000 kilograms per hour.

The mill acts as an efficient dryer when the process air is heated using a hot air generator or waste heat from another process. It can reach an inlet temperature of up to 550ºC. Heat energy from the process can be recovered from the heated air stream. After flash drying, the product is kept cool due to evaporative cooling. The output temperature of the product is maintained accordingly to control the moisture content of the product.

The Flash drying grinder for powders is configured with a combination of variable speed rotor, hammer arrangement and fixed pins. Turbulence inside the grinding area creates attrition to reduce the particle size, which can be controlled for simple deagglomeration of the product. An internal classifier configuration can also be used to further control particle size.

The ‘A’-series is constructed with internals that are resistant to abrasion for applications that can cause high amounts of wearing to the equipment. Where the desired amount of evaporation required far exceeds the grinding duty, the ‘B’-series machine of a lighter weight, fully fabricated configuration permitting higher airflows can be used for non-wearing product or duties, as well as for for applications in which stainless steel contact parts may be necessary.

Flash drying grinder for powders

Widely used in the construction industry as filling materials, calcium carbonate is usually made from pulverized limestones. As a result, vibration and noise are typical issues during CaCO3 powder production processes, especially during grinding. Therefore, it is essential to have a classifier milling system to ensure low noise and low vibration while achieving the maximum particle fineness required in CaCO3 powder production.


<h2>Mill for fine grinding and drying of soft to medium-hard minerals</h2>
The Pendulum Mill PM by NEUMAN &amp; ESSER is a roller mill used for fine grinding and drying soft to medium-hard materials such as clay, bentonite, limestone, and many other minerals. It is a robust and durable design of combined grinding, de-agglomeration, drying, and classifying system.

The mill consists of a sturdy cast, mill housing, and a rotor with a crosshead. The grinding roller travels on the rings, whose centrifugal action against the grinding ring reduces the minerals into finer sizes. Rotating shovels guide the particles from the mill bottom to the grinding zone. The air system then transports the ground particles to the classifier, where it rejects coarse particles and sends them back to the mill for further grinding. The speed of the classifier can be adjusted to meet the required particle size and distribution. Finally, a downstream collector receives the particles with the necessary final degree of fineness.

The Pendulum Mill PM can achieve narrow particle size distribution with an upper particle size ranging from 10 μm to 1,000 μm (1,250 to 18 mesh). The mill capacity ranges from 0.5 t/h to 150 t/h and can process up to 35% humidity material.

Grinding and drying of CaCO3

During the early stages of synthesis, generating only limited product quantities can pose a challenge, making realistic milling tests more difficult.


<h2>Formulates chemical reactions for tests in R&amp;D labs and universities</h2>
DYNO<sup>®</sup>-MILL RESEARCH LAB from WAB-GROUP<sup>® </sup>is a bead mill suitable for small batches starting from 100 ml. It enables processing in two modes: continuous passage and circulation mode. The mill can grind media from ø 0.05 - 1.0 mm to a particle size under 100 nanometers.

DYNO<sup>®</sup>-MILL RESEARCH LAB is designed for easy handling: you can detach the entire grinding section from the drive by loosening just three screws. Afterward, disassembling the grinding section requires only a few simple steps. This makes cleaning quick and convenient. Plus, the separate grinding cylinder can undergo sterilization as a whole.

Agitator bead mill for flow chemistry

Atritor (https://www.atritor.com/) has more than 90 years of experience in simultaneous drying and milling solutions for fine powders.

We eat it; we wear it; we plaster it. But, most importantly, we grind it. Calcium carbonate is a pervasive material found in a raft of everyday products. Virtually all industries depend on it, either as a final or an intermediary product. But GCC is not all of a size, and a plurality of applications means different preparation requirements.

Ground calcium carbonate grains can be as coarse as 1,300 microns in poultry feed or as fine as 2 microns in paper coatings.

Milling the limestone to the correct particle size distribution is a test for GCC processing. But addressing this challenge successfully makes the difference between high and low-quality calcium carbonate materials.


<h2>Mastering impact, shear, and attrition to control particle size</h2>
Crushed limestone is turned to powder in a spectacular engineering phenomenon that occurs at a millimetric level. <a href="https://making.com/calcium-carbonate">Calcium carbonate particles</a> are broken down through impact, shear, and attrition.

Imagine you shank to a nanoparticle and were dropped into a limestone-grinding mill. It would feel like a galactic clash. The blades in the equipment break the rocks by the force of impact; the swirling particles shear off against each other; large particles attrite smaller ones flying at different velocities.

But devising this intricate process to produce homogenous grains of accurate dimensions takes expertise with the raw material. Control over the impact, shear, and attrition parameters allows you to produce the right particle size distribution that matches multiple applications.
<h2>Find the right fineness profile for the job</h2>
Calcium carbonate is ubiquitous in manufacturing but producing it at a suitable grade demands precision and flexibility from the milling technology. Grinding is not simply a race to the finest grain size – equipment has to adapt to the specific use. The requirements change not only by industry but by manufacturer too.

Wood coatings, for example, typically use calcium carbonate as a filler. But manufacturers employ GCC of different grain sizes in their formulas, depending on the product range. Polymers made primarily to enhance the aesthetic effect of wood use GCC with a particle size distribution of around 7 µm. Coating products designed for scratch resistance require finer grains of about 3 µm.

Ground calcium carbonate is a versatile material, but its effectiveness is determined by the precision of particle dimensions.  The power of GCC lies in its broad fineness spectrum, whether it is formulated into an antacid tablet, used to dye a silk shirt, or mixed to increase the adherence of wall paints.

Grinding calcium carbonate down to size

Mineral

The nearly 5,000 known minerals on earth share some characteristics to be classified as minerals – they are inorganic, solid, naturally occurring elements and have a particular chemical formula and an ordered internal geometric structure. However, minerals are not all the same. One way to divide them is based on their physical characteristics such as hardness, luster, color, and shape. For example, the diamonds we use to make jewelry are very hard minerals while talc is a soft mineral; gold is a shiny mineral while others are less so.

Minerals

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