With the rapid development of material science and technology, the demand for fine materials in various industries is increasing day by day. As one of the key equipment for the preparation of fine materials, the sand mill belongs to the wet ultra-fine grinding equipment. It is a grinding equipment with wide material adaptability and high efficiency developed from the ball mill, and is widely used in the fields of metallurgy, mining, non-metallic mineral materials, chemical industry, ceramics and new materials.
The sand mill is mainly divided into two types: the vertical sand mill and the horizontal sand mill. The horizontal sand mill is a fully enclosed wet grinding and dispersing machine that can be operated continuously. The feed pump sends the liquid-solid mixture that has undergone pre-dispersion treatment into the cylinder from the feed end of the cylinder. Together with the evenly distributed zirconia beads pre-loaded in the cylinder, they are cut by the high-speed rotating dispersing blades, causing the solid particles and aggregates in the material to have violent collisions and shearing with the grinding medium, quickly grinding the material particles into fine ones and dispersing the aggregates, achieving extremely small fineness and a narrow particle size distribution range in a short time.
Nano-powders are widely used in high-tech ceramic materials. However, the agglomeration phenomenon of nano-powders is serious, which affects their application effects. To solve the problem of powder agglomeration, mechanical methods are usually adopted in industry. Commonly used grinding equipment mainly includes horizontal sand mills, vertical bead mills and ball mills. The horizontal sand mill has the widest adaptability to materials and is one of the most advanced and efficient grinding equipment. With a high-performance cooling system and an automatic control system, it can realize continuous processing and continuous discharge of materials, greatly improving production efficiency.
To study the depolymerization effects of different grinding equipment and grinding process parameters on powder agglomerates, engineers from many enterprises such as Lomon Billions have taken zirconia powder with a d50 of 1.355μm as the research object. First, they carried out grinding tests under the same grinding conditions using a vertical ball mill, a vertical bead mill and a horizontal sand mill respectively to determine the best grinding equipment. Then, using the optimal grinding equipment, they selected the ratio of medium to material, the solid content of the slurry, the linear velocity and the grinding time as test factors and carried out a four-factor and three-level orthogonal test to determine the best grinding process parameters.
The conclusions drawn from the above tests are as follows:
(1) The grinding effect of the horizontal sand mill is the best, and the d50 of the zirconia slurry after grinding is 0.303μm.
(2) When the horizontal sand mill is used as the grinding equipment, under the conditions of a medium-to-material ratio (m_medium:m_material) of 4:1, a slurry solid content (w) of 45%, a linear velocity of 10m·s⁻¹ and a grinding time of 25h, the grinding effect is the best, and the d50 of the zirconia slurry after grinding is about 0.3μm.
The performance of ZnO varistors mainly depends on their material composition and microstructure, and their microstructure is largely determined by the characteristics of the powder. The smaller the particle size of the raw materials in ZnO varistors, the more conducive it is to the uniformity of their mixing. Uniform composition is the basis for the uniform reaction among various components during the sintering process of varistors. Among the raw materials currently used in the production of ZnO varistors, the main raw material ZnO is an ultra-fine powder, while the particle sizes of the additive oxides are relatively coarse and their respective particle size differences are large, which is not conducive to the uniform distribution of various raw materials during the preparation process.
Researchers from Shanghai University used a horizontal sand mill to micronize and nanonize the mixed additive oxides to explore the impact of the additive particle size on the performance of ZnO varistors. They conducted a comprehensive analysis of the prepared ZnO varistors by means of analysis methods such as viscosity, Zeta potential, SEM, XRD and electrical measurement equipment.
The results showed that by using yttria-stabilized zirconia beads for grinding in a horizontal sand mill, the refined additive particle size reached the micro-nano level, the ZnO grain size of the prepared varistors decreased, and the microstructure became more uniform. Compared with other mechanical grinding equipment, the horizontal sand mill is not only more efficient, but also has a narrower particle size distribution range for refined materials, which can reach the micro-nano level. After the additives are refined by the horizontal sand mill, their particle sizes decrease, they mix more evenly with ZnO, more spinel phases are formed during the sintering process into ceramics, the growth of ZnO grains is inhibited, the number of grain boundary layers per unit thickness is increased, the uniformity of the microstructure is improved, and the comprehensive electrical performance of the varistors is enhanced.
The manufacturing process technology of multilayer ceramic capacitors (MLCC) has developed very rapidly. Among them, the preparation technology and methods of ceramic slurries are of great significance for manufacturing products with excellent performance. Good ceramic slurry dispersion technology can avoid the agglomeration of ceramic powder particles, reduce the porosity of the diaphragm, improve the compactness of the capacitor ceramic body, and ultimately achieve the purpose of improving the electrical performance and reliability of the capacitor.
In the development process of ceramic slurry dispersion, some mechanical grinding equipment such as ball milling tanks and basket sand mills have been widely used in the dispersion of MLCC ceramic slurries. In recent years, large MLCC manufacturers in Japan and South Korea have gradually used horizontal sand mills. Due to the advantages of high efficiency, the ability to use 0.1mm zirconia microbeads, suitability for slurries with small particle sizes, concentrated slurry particle size distribution, good reproducibility and simple operation, more and more MLCC manufacturers have begun to use horizontal sand mills.
As a key process for the initial crushing of titanium dioxide in titanium dioxide enterprises, only after the crushing process can the initial titanium dioxide be within a certain particle size range, so that inorganic and organic coating treatments can be carried out to reflect its good pigment properties.
Researchers from Pangang Group took wet ball-milled initial titanium dioxide as raw materials and used a horizontal sand mill to study the impact of different sand milling processes on the particle size of the slurry. They also investigated the impact of different particle sizes of the slurry on its whiteness and water dispersibility.
The experimental results showed that when the rotational speed of the sand mill was 3000r/min, 1.8mm zirconia beads, the feed concentration was 410 g/L, the rotational speed of the feed pump was 1, and the filling rate was 80%. Under the optimal conditions, the median particle size of the slurry after the first-stage sand milling in the laboratory was reduced by 36nm compared with that of the two-stage sand milling slurry. The smaller the particle size, the better the water dispersibility of the slurry. When the median particle size of the slurry was 231nm, the water dispersibility reached 99.3%. Different particle sizes of the slurry basically had no impact on the whiteness.
Professor Zheng Shuilin from China University of Mining and Technology (Beijing) and others took the horizontal sand mill as the ultra-fine grinding equipment to study the impact of the filling rate of the grinding medium, the rotational speed of the mill, the powder content in the slurry, the addition amount of the grinding aid and the grinding time on the ultra-fine grinding effect of rutile titanium dioxide. The results showed that under the conditions of a medium filling rate of 70%, a mill rotational speed of 2250r/min, a powder mass fraction of 50% in the slurry and an addition mass fraction of 0.4% of the grinding aid, the particle sizes d50 and d97 of the titanium dioxide obtained by ultra-fine grinding of rutile titanium dioxide for 20min could reach 0.48μm and 1.07μm respectively.
In addition to being related to the types and proportions of constituent materials, the performance of coatings is also closely related to the preparation methods. During the production process of coatings, the dispersion of pigments is very important. A good dispersion process can make pigment particles fully dispersed and give play to their characteristics. The pigment particle size has a great impact on the gloss, colorability and transparency of the coating film. The horizontal sand mill is a key equipment for realizing the dispersion of aggregates in coating production and significantly improves the ultra-fine dispersion effect. Moreover, for the grinding of high-end nano-color pastes, a horizontal sand mill with axial discharge should be used, and 0.1mm zirconia beads should be used for grinding.
For lithium iron phosphate and other lithium-ion battery cathode materials, due to the differences in formulation processes and characteristic requirements in the early powder preparation process, different types of equipment are selected. According to the physical characteristics of the ingredients in lithium iron phosphate, accurate weighing and mixing equipment are selected. Currently, this process is feasible in terms of actual requirements and equipment maturity. However, in the processes of grinding and homogenization, corresponding influencing factors will appear. Generally speaking, the horizontal sand mill combined with yttrium-zirconium beads is more suitable for this process. For rough grinding, 0.6 - 0.8mm zirconia beads are used, and for fine grinding, 0.3 - 0.4mm zirconia beads are used.
In addition, among the methods for preparing solid electrolyte Ta-LLZO powders, the solid-phase reaction method is the most practical method for large-scale production of presintered powders. Before pressing and sintering, the presintered powders are generally ground to the sub-micron level to improve their sintering activity. The preparation process of solid electrolytes is more refined, and the requirements for powder particle size are higher. Traditional ball milling equipment is no longer sufficient to meet its requirements, and its production relies on horizontal sand mills.
The processing price of industrial mineral powders is relatively low, so processing equipment with a large processing capacity is required. The development of large ultra-fine stirred mills with fine product particle size, uniform distribution and large processing capacity is an urgent task for the deep processing of industrial mineral powders. Super-large horizontal sand mills (such as IsaMill) are fine grinding equipment with promising prospects, high energy utilization rate and fine product particle size for the regrinding or fine grinding of gold and silver mines, molybdenum mines, copper mines, nickel mines, lead-zinc mines and iron mines. In addition, due to its simple structure, convenient operation and maintenance, it is widely used in industrial production such as gold mines, non-ferrous metal mines, metal mines and magnetic materials. The SG4.5 zirconia composite balls perform excellently in the grinding of non-ferrous metal mines.
There are many problems in the production of suspension systems, such as uneven dispersion, fast sedimentation and poor suspension performance. In addition to the influence of factors such as dispersants and other auxiliaries, the particle fineness and particle size distribution are the main factors affecting the physical stability of the suspension system and are also the key issues in the research of the suspension system. The main means to solve the fineness problem is to improve the grinding efficiency in the processing process and select appropriate grinding media, such as using yttria-stabilized zirconia beads, which have high hardness, low wear and do not cause pollution to materials.
In the preparation process of water suspension systems, vertical sand mills and horizontal sand mills are currently commonly used key equipment, and their processing processes have a great impact on the physical stability of the product during storage. To study the impact of these two types of sand mills and grinding time on the grinding efficiency and storage physical stability of the suspension system, a biotechnology company in Guangdong carried out a series of experimental comparisons. The results showed that by extending the grinding time, the average particle size and particle size distribution (the percentage of particle size < 3μm) of the particles in the suspension system can be reduced, the viscosity of the suspension system can be increased, and thus the physical stability of the suspension system can be improved. Under the same conditions, the grinding efficiency of the horizontal sand mill is higher than that of the vertical sand mill.
Suspension seed coating agents, as one of the most widely used types of pesticides at present, play roles in killing insects, sterilizing and providing plant nutrition in crops. However, there is a phenomenon of poor suspension stability in the production of suspension seed coating agents, such as uneven dispersion and fast sedimentation. Among them, the particle fineness and particle size distribution are the main factors affecting the physical stability of the suspension system and are also the key issues in the research of suspension seed coating agents.
Through years of mechanized production practice of suspension seed coating agents, scientific researchers from the Xinjiang Academy of Agricultural Sciences have carried out multiple screening tests, studies and analyses. The results showed that from the current development trend, the horizontal sand mill is an indispensable means and approach to solve the mechanized production process of suspension seed coating agents and is an indispensable production equipment in the mechanized operation of pesticides. Usually, low-density zirconium silicate beads can be used as the grinding medium.
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