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Limestone 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

Limestone

If you are looking for high end-product fineness for suspensions with good flow properties with a steep particle size distribution, a horizontal agitated media mill can be a good solution. Often used for wet materials like chemicals, foodstuffs, metals, pigments, and paints.


<h2>Continuous wet milling of particles down to the submicron range</h2>
The Agitated Media Mill AHM from Hosokawa Alpine is a horizontal, cylindrical milling chamber that is universal in use for the continuous wet milling of particles down to the submicron range. This horizontal milling chamber was especially designed for suspensions with good flow properties where a steep particle size distribution and high end-product fineness are demanded.

Ball mills rotate around a horizontal axis, partially filled with the material to be ground plus the grinding medium. The mill is suitable for both continuous and batch operations, also available in sizes suitable for the laboratory, the testing center or for large-scale production.

Chemicals, minerals, PCC, ceramics, foodstuffs, metals, pigments, paints (mass production), laboratory, nanoparticles, abrasives, pharmaceutics. This mill is suitable for small amounts of product and for development trials, also in the nanotechnology sector. Extremely small grinding beads (&lt; 0.2 mm) can be employed with this mill, and investigations regarding the stabilization of suspensions in the submicron range can be executed.

Horizontal Agitated Media Mill

Agitated media mills are media mills that employ an agitated (or stirred) grinding media action for grinding of the ultrafine particles. In this case, a ceramic grinding media grinds mineral, metal, or chemical powder. The most typical application is the manufacture of GCC slurries used for the production of paper, but also ultrafine limestone slurries, such as calcium carbonate, limestone, and marble.


<h2>Cost-efficient grinding of highly concentrated limestone slurries</h2>
The agitated media mill ANR from Hosokawa Alpine is designed for the cost-efficient ultrafine grinding of highly concentrated limestone slurries. The operating mode and the design permit the production of extremely high qualities with regard to fineness, degree of whiteness, and abrasiveness.

The mill design ensures low-maintenance continuous system operation with no expensive downtime periods. The flow pattern goes from bottom to top, whereby the feed material is ground to the required end fineness with the aid of ceramic grinding beads (zirconium silicate or zirconium oxide).

Efficient cooling of the mill stator removes the heat generated during grinding.

The agitator elements and the grinding chamber wall are made of wear-resistant hardened materials.

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Vertical agitated wet media mill

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

When high cutting forces and high throughput are required, you need a granulator that has proven its reliability under the hardest of tasks.


<h2>High troughput proven economical granulation</h2>
The Ro Rotoplex from Hosokawa Alpine consists in a cross-scissor-cut rotor that offers process technological superiority, saves energy, increases the service life, and improves the material feeding characteristics. These large granulators are capable of extremely high capacities due to our unique design and multiple knife geometry. Besides the classic field of plastics size reduction, Rotoplex large-scale granulators are exemplary for fiber, film, purgings, wire and cable and many more difficult materials.

Characterized by performance capacity, economy, and operating reliability. High-grade spheroidal graphite cast iron ensures that even in continuous heavy-duty operation, the Rotoplex granulators do their job reliably over many years.

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Large granulator

Quality of gypsum and stucco products are highly influenced by the quality of the calcining process employed in production. Consistent grinding, purification, and drying of raw mineral inputs prior to their being entrained in the hot gas flow of the calcining equipment ensures efficient calcining and a resultant high-quality final product.


<h2>Grinding, purifying, drying, and calcining from a single piece of equipment</h2>
Claudius Peters’ EM Mill is a calcining system for gypsum and stucco with an integrated grinding mill. The mill uses free moving steel balls rather than stationary rollers which ensures uniform fine grinding while avoiding the need for any bearings inside the mill. The grinding system employed requires very little maintenance and has been known to achieve a service life of over 40,000 hours. At the base of the grinding system, a scraper acts on the ball track conveying foreign material out of the mill into the reject box.

The efficiency of the grinding system allows low material time inside the mill enhancing the controllability of the process and ensuring uniform product quality. After sufficient grinding material is entrained in a calcining gas flow of unusually high temperature which yields lower gas volumes and optimal energy consumption. The constant randomized motion of the ball grinding system ensures even and constant distribution of raw gypsum for exposure to the calcining flow.

Mill for calcining gypsum

Waste products and rejected materials are inevitably generated from any gypsum products manufacturing process. This efficiency can be greatly reduced however, with the use of a specialized crusher designed for recycling them back into the production process.


<h2>A recycling crusher specifically designed for the gypsum processing industry</h2>
Claudius Peters’ Reclaim Crusher is a milling machine specifically designed for processing wet and dry waste products from the gypsum processing industry into materials that can be blended with raw gypsum and re-introduced into the primary production process. The unit consists of a heavy duty housing and two independently rotating screws. The slow rotation action of the screws breaks the materials into pieces ideally suited for further processing into gypsum products. Each screw’s rotation is reversible and is controlled by a shaft mounted gearbox and variable frequency drive motor.

Reclaim crusher

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

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Limestone milling

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