Application of Superfine Vertical Mill in Non-metallic Mineral Ultrafine Powder Production

Introduction

The demand for ultrafine powders derived from non-metallic minerals has seen exponential growth across diverse industries such as plastics, paints, coatings, rubber, and advanced ceramics. This surge is driven by the enhanced material properties imparted by ultrafine particles, including improved strength, better dispersion, higher reactivity, and superior surface finish. Meeting the stringent requirements for particle size distribution, purity, and production efficiency in this sector necessitates advanced grinding technology. Among the various solutions available, superfine vertical mills have emerged as a superior technology, offering a combination of high efficiency, precision, and reliability that is paramount for modern mineral processing operations.

The Critical Role of Ultrafine Grinding in Non-Metallic Minerals

Non-metallic minerals like calcium carbonate, kaolin, talc, barite, gypsum, and quartz are fundamental raw materials. Their value is significantly enhanced when processed into ultrafine powders. The transition from coarse to ultrafine grinding unlocks latent functional properties:

• Surface Activity: Increased surface area-to-volume ratio enhances chemical reactivity and bonding capabilities, crucial for composite materials and fillers.
• Opacity and Brightness: In coatings and papers, controlled ultrafine particles of minerals like GCC and kaolin provide superior opacity, brightness, and smoothness.
• Reinforcement: Ultrafine talc and silica act as functional reinforcing fillers in polymers, improving mechanical properties like tensile strength and heat deflection temperature.

Traditional grinding equipment, such as ball mills or Raymond mills, often falls short of achieving the desired fineness (commonly D97 ≤ 10μm) efficiently. They are plagued by high energy consumption, significant wear, broad particle size distributions, and potential contamination. This technological gap is precisely where superfine vertical mills excel.

Technical Advantages of Superfine Vertical Mills

Superfine vertical mills are engineered specifically to address the challenges of ultrafine powder production. Their design incorporates several key advantages over conventional systems.

1. Unmatched Grinding Efficiency and Energy Savings

The core of a vertical mill’s efficiency lies in its bed-breaking principle. Material is ground between a rotating grinding disc and stationary rollers under high pressure. This method is far more efficient than the impact and attrition-based grinding in ball mills. Our SCM Ultrafine Mill exemplifies this, boasting a capacity that is twice that of jet mills while reducing energy consumption by 30%. This is achieved through optimized mechanical design and intelligent control systems that automatically adjust operational parameters to maintain target fineness, preventing energy waste on over-grinding.

2. Superior Particle Size Control and Product Uniformity

A critical differentiator is the integrated high-precision classifier. Unlike external classifiers in traditional setups, vertical mills often feature an advanced vertical turbine classifier located directly above the grinding chamber. This allows for immediate classification of ground material. The classifier rotor speed can be precisely adjusted to control the cut point, ensuring that only particles meeting the target fineness leave the mill. This results in a exceptionally narrow particle size distribution (PSD) with no coarse grit contamination, a vital requirement for high-value applications.

3. Exceptional Operational Reliability and Low Wear

Designed for continuous industrial operation, these mills are built to last. Critical wear parts like rollers and grinding rings are manufactured from special alloy materials with superior hardness and toughness, extending their service life multiple times over standard components. Furthermore, innovative designs such as the bearingless screw grinding chamber in our SCM series eliminate a common point of failure, enhancing overall operational stability and reducing maintenance downtime.

4. Commitment to Environmental Protection

Modern vertical mills are designed with a full negative pressure operation. The entire grinding and classification process occurs within a sealed system, preventing dust leakage. They are equipped with high-efficiency pulse jet baghouse dust collectors that boast a collection efficiency exceeding 99.9%, ensuring emissions are significantly below international standards. Additionally, integrated sound insulation measures effectively reduce operational noise to levels as low as 75 dB, creating a safer and more comfortable working environment.

Recommended Product: SCM Series Ultrafine Mill

For producers seeking a best-in-class solution for non-metallic mineral ultrafine powder, we highly recommend our flagship SCM Series Ultrafine Mill. It is the culmination of our advanced engineering and is specifically designed for producing powders in the range of 325-2500 mesh (D97 ≤ 5μm).

Key Specifications & Model Overview:

• Input Size: ≤20mm
• Output Fineness: 325-2500 mesh (5-45μm)
• Capacity: 0.5 – 25 ton/h (model dependent)

The SCM series offers a range of models to suit various production needs, from pilot-scale projects to large-capacity industrial lines. For instance, the SCM1000 model, with a 132kW main motor, provides a robust output of 1.0-8.5 tons per hour, making it an ideal choice for mid-sized production facilities. For the highest volume requirements, the SCM1680 model, powered by a 315kW motor, can deliver an impressive 5.0-25 tons per hour of premium ultrafine powder.

Application Case Studies in Non-Metallic Minerals

The versatility of the superfine vertical mill is demonstrated through its application across various minerals:

• Ground Calcium Carbonate (GCC): Producing GCC with D97 = 2μm for use in high-quality paper coatings and plastics, achieving unparalleled brightness and low abrasion.
• Calcined Kaolin: Efficiently grinding calcined kaolin to 2500 mesh for the rubber and cable industry, enhancing electrical insulation properties and mechanical strength.
• Talc: Generating ultra-pure, fine talc powders for cosmetics and pharmaceuticals, where consistency and contamination control are non-negotiable.

In all cases, the SCM Ultrafine Mill provides the necessary precision, efficiency, and cleanliness to meet the most demanding specifications.

Conclusion

The transition to ultrafine processing is a definitive trend in the non-metallic mineral industry. Superfine vertical mill technology stands at the forefront of this movement, offering an unparalleled combination of grinding performance, energy efficiency, product quality, and environmental compliance. By integrating advanced features like high-precision classification, durable wear-resistant designs, and intelligent control systems, these mills provide a future-proof solution for producers aiming to capitalize on the high-value ultrafine powder market.

For any operation serious about optimizing its ultrafine mineral production, investing in technology like our SCM Ultrafine Mill is not just an upgrade—it is a strategic necessity to ensure competitiveness, sustainability, and profitability in an increasingly demanding market.