Using an inferior grade of grinding media can result in poor grinding, clogged screens, damaged separator rings, excessive mill and component wear, and mechanical seal failure. Additionally, many of today's newer high-energy grinding mill configurations demand a better grade of grinding media. However, the ceramic manufacturer must be aware of what qualities comprise this new generation of ceramic grinding beads. Surface condition Size range or gradation With inferior media, fractured hollow beads, irregular shapes and satellite pieces that have broken during processing can often clog screens and damage mill components. Additionally, such media can contain rough or pitted ceramic bead surfaces, or fractured pieces of ceramic that become mixed with the media charge and create excessive wear on the grinding chamber and components.
Size is also important.
A media charge with a wide size range is very inefficient because it causes a disruption of the desired flow pattern inside the mill. They also feature a consistent microstructure, which provides improved hardness and toughness for long media life, resulting in less downtime. And they are much higher in density than other beads, generally carrying a specific gravity of 4.0 or higher. This increased density provides greater grinding efficiency in discrete pass or recirculation grinding, reduced processing times, higher throughputs and the ability to process higher viscosity formulations. These new beads also feature excellent roundness, which increases efficiency and maximizes shear inside the milling device, and smooth bead surfaces, which reduce mill component wear and are more easily washed between formulations.