Ball Mill

Molycop’s MillSlicer uses advanced digital signal processing techniques to provide an accurate view of the change in mill fill level (vectors) and improve milling throughput and efficiency in ball mills.

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Features

  • High-frequency indication of mill fill level vectors to improve mill operation
  • Zero crosstalk from adjacent (nearby) mills
  • All-digital system, no component drift, not affected by temperature, dust or dirt, unlike typical microphone systems
  • 4–20mA output
  • 3 x resolution when compared to microphone-based systems
  • Fast and easy installation that can typically be performed in less than two hours
  • Quick calibration procedure that can be performed in less than five minutes per sensor when the mill is operating under normal conditions – i.e. the mill is filled to a level that is used in normal ‘day-to-day’ production
  • Signal sensitivity changes can be made very quickly without re-calibrating the unit

Overview

Molycop’s MillSlicer can be used specifically for ball mills, featuring a wireless shell sensor and two wired inlet/outlet sensors. The signals can be integrated into an automated control loop or used to enhance manual control, providing valuable real-time insights for optimising mill performance through Molycop’s Data Platform integration.

The vibration sensors are magnetically mounted to the metal bearing structure and to the mill shell. One vibration sensor cable is 10m (~30ft) long and the other is 30m (~100ft) long. All cables are shielded. 

The main unit requires AC power (100–220V AC, 50/60Hz) and has a 4–20mA output that corresponds to each of the fill vectors for each of the sensors (shell, inlet and outlet).

Typical Uses

Molycop's MillSlicer is used by ball mill operations to accurately monitor mill fill levels, enabling them to optimise milling throughput and enhance power utilisation. Data captured enables operators to improve mill operation and efficiency.

Benefits

  • Optimise milling throughput: Controlling the mill fill level rather than bearing pressure increases milling capacity
  • Increase mill efficiency: Improve mill power utilisation with optimised grinding
  • Reduce OpEx: Reduce ball consumption/ton milled and reduce liner wear by operating the mill at an optimal fill level
  • Seamless integration: Molycop's MillSlicer for ball mills seamlessly integrates with various systems, including process control, AI and consulting platforms, ensuring a comprehensive and connected optimisation solution.
  • Expert support: Access support and technical assistance to implement and utilise Ball MillScan.
  • Long-term value: Investment in MillSlicer for ball mills offers additional data and insights for ongoing mill optimisation and continuous improvement.

Downloads

Milling / Metallurgist / Process engineer / Products / Download / Tech Sheets & Brochures Ball MillSlicer

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