Structural Optimization of Horizontal Sand Mills

Horizontal sand mills are critical equipment in various industries, particularly the chemical sector, for fine material preparation. This study delves into the composition and operation of horizontal sand mills, identifying structural issues that hinder their efficiency and quality. Four key components are analyzed: the grinding device, cooling system, spindle, and machine base, and structural enhancements are proposed for each. These optimizations boost material flow, grinding efficiency, quality, and cooling performance, ensuring that horizontal sand mills perform at their best.

1. Introduction

China's chemical industry is rapidly expanding, placing significant demands on chemical machinery. In this landscape, horizontal sand mills are essential for fine material preparation. They find applications not only in the chemical industry but also in ceramics, metallurgy, and other sectors. This study concentrates on horizontal sand mills, aiming to optimize their four critical components to improve performance and meet the high standards of the chemical industry.

1.1 Structure of Horizontal Sand Mills

Horizontal sand mills consist of six primary components: the grinding device, spindle components, cooling system, machine base, device, and control system. Each plays a crucial role in the functioning of the sand mill.

• Grinding Device: This core component comprises grinding discs, steel sleeves, filters, spindles, and ceramic barrels. It's responsible for material grinding and processing.

• Spindle Components: These components facilitate power transmission from the electric motor to the spindle and, in turn, to the grinding device.

• Cooling System: Given that sand mills generate heat, an efficient cooling system is essential. It includes water pipes, water tanks, water pumps, and a chiller.

• Device: Components like diaphragm pumps, material inlet/outlet systems, and air pumps are also part of the system.

• Machine Base: The machine base doesn't directly affect grinding quality but secures and protects various components. It's composed of a shell, angle iron, and steel plates.

• Control System: This system governs the entire operation of the horizontal sand mill.

1.2 Working Principles of Horizontal Sand Mills

The basic working principle of horizontal sand mills involves loading the grinding barrel with the material to be ground. The electric motor drives the spindle, which stirs the material within the barrel. Material and grinding media undergo grinding under the action of the grinding disc. The combination of the impeller's speed and the added weight of the grinding media generates significant shear and impact forces, leading to efficient grinding and even particle size distribution.

2. Structural Optimization Analysis

2.1 Structural Optimization of the Grinding Device

2.1.1 Issues with the Grinding Device

Common problems with the grinding device include:

• Inefficient material flow in the grinding chamber, hindering grinding efficiency.

• Excessive wear of grinding media during operation.

• Limitations on spindle length, restricting the number of grinding discs.

• High noise and vibration levels, especially at high spindle speeds.

2.1.2 Optimization Analysis of the Grinding Device

The study suggests optimizing the grinding device to address these issues. The proposed changes include:

Redesigning grinding discs to improve grinding efficiency. The optimization involves increasing the disc radius to enhance the kinetic energy of the grinding media, thereby improving grinding. The design also includes wheel spokes to accelerate material flow and increase mixing force.

Variable distance discs allow for more grinding discs within the same spindle length, resulting in higher grinding speeds.

Shifting to silicon nitride material for the grinding disc, known for its wear resistance and thermal conductivity. Modifications such as using an arc shape help prevent stress concentration and reduce wear on grinding media.

2.2 Structural Optimization of the Cooling System

2.2.1 Issues with the Cooling System

Traditional cooling systems face problems like:

Inadequate cooling capacity, leading to elevated temperatures within the sand mill.

High energy consumption and increased wear on cooling system components.

Poor cooling efficiency due to the complex structure of the cooling channel.

2.2.2 Optimization Analysis of the Cooling System

To improve the cooling system, the study suggests several changes:

Redesign the cooling channel in the spindle for better maintenance and reduced risk of water leakage.

Adjust the cooling channel direction and diameter in the spindle for even cooling.

Replace frictional seals with non-contact seals like magnetic seals to prevent water leakage and reduce friction.

Implement flow channel design changes to enhance cooling efficiency.

Optimizing the cooling system not only reduces heat generation but also increases cooling efficiency, maintaining stable operating temperatures, and preserving material quality.

3. Structural Optimization of the Spindle

3.1 Issues with the Spindle

The spindle plays a vital role in transmitting power from the electric motor to the grinding device. It faces challenges such as:

• Length limitations, leading to vibration and deflection.

• Complex cooling channel structure.

• Limited adaptability to different machine bases.

• High maintenance requirements and operational costs.

3.2 Optimization Analysis of the Spindle

Structural optimization of the spindle involves the following enhancements:

• Extending spindle length to enhance adaptability and reduce vibration.

• Simplifying the cooling channel design for easier maintenance and improved cooling efficiency.

• Optimizing the spindle connection structure to enhance stability.

• Employing non-contact magnetic seals to reduce maintenance and operational costs.

4. Structural Optimization of the Machine Base

4.1 Issues with the Machine Base

The machine base, responsible for securing and protecting components, faces issues like:

• Limited adaptability to different components and structures.

• Inadequate mechanical performance.

• Complex structure.

• High production costs.

• Maintenance difficulties.

4.2 Optimization Analysis of the Machine Base

Optimizing the machine base can address these problems. Suggested changes include:

• Enhancing adaptability to various components and structures.

• Improving mechanical performance through advanced materials and structural design.

• Simplifying the machine base's structure to reduce costs and facilitate maintenance.

5. Conclusions

Implementing the structural optimizations discussed yields several advantages:

Improved material flow, enhancing grinding efficiency.

Reduced wear on grinding media, saving energy and improving grinding quality.

Higher cooling efficiency and less heat generation.

Extended spindle length for better adaptability.

Easier maintenance and reduced operational costs.

These optimizations ensure that horizontal sand mills perform at peak efficiency with minimal energy consumption, meeting the demands of industries like the rapidly growing chemical sector in China. In turn, this enhances the production of high-quality materials."

This shortened version provides a concise overview of the structural optimization of horizontal sand mills while retaining the key information and recommendations for improvement.