Can the 5R4119 Raymond Mill Produce 2-0mm Aggregate?
I. Demand Analysis
1. Equipment and Scenario: A 5R4119 Raymond mill is used. This is a large, traditional pendulum mill, typically used for grinding non-metallic minerals (such as limestone, barite, gypsum, talc, etc.). The finished product fineness ranges from 80 mesh (0.18mm) to 400 mesh (0.038mm), with a large production capacity.
2. Target Product: Particles ranging from 2mm to 0mm. This is a very broad particle size requirement, describing the category of crushed material or manufactured sand, rather than fine powder.
3. Core Constraints: A constraint is placed on the particle size range of 0.613mm - 0.044mm in the tabula value.
◦ Terminology Clarification: tabula value likely refers to screen residue (or particle size distribution). In the mining and building materials industries, percentage oversize or pass rate are commonly used to express particle size distribution.
◦ Particle Size Interpretation:
▪ 0.613mm (approx. 30 mesh)
▪ 0.044mm (approx. 325 mesh)
◦ Meaning of Limitation: The customer wants to control the particle content in the final product within the range of 0.613mm (coarse/fine sand) to 0.044mm (extremely fine powder). This could mean a requirement that there shouldn't be too much (e.g., to avoid excessive powder affecting product performance or generating dust), or a requirement that there shouldn't be too little (requiring a certain amount of filler). Often, in context, the upper limit is more commonly considered (i.e., not containing too much fine powder).
5R4119 Raymond mill
II. Core Contradiction and Problem Analysis
The contradiction lies in the mismatch between the inherent characteristics of the equipment and the product objectives.
1. The equipment is a grinding mill, while the requirement is crushing/screening:
◦ The 5R4119 Raymond mill is a grinding equipment whose working principle is to grind materials into fine powder through grinding rollers. Its advantage is the production of fine powder (such as powder below 200 mesh).
◦ To produce 2-0mm granular material, the most economical and efficient equipment is a crushing and screening production line consisting of a crusher (such as an impact crusher or cone crusher) and a vibrating screen. Using a Raymond mill for this purpose is like using a cannon to kill a mosquito—high energy consumption, significant wear, mismatched output, and a high risk of producing excessive powder.
2. Limitations directly address equipment shortcomings:
◦ 0.044mm (325 mesh) is precisely the particle size that the Raymond mill produces most easily and best. Limiting the content of this particle size is equivalent to requiring a high-output fine powder machine to reduce the production of so much fine powder, which is technologically difficult and uneconomical.
◦ 0.613mm (30 mesh) is considered relatively coarse for a Raymond mill and is difficult to retain within the grinding chamber. It must either be further ground or separated by an air classification system. To stably retain this portion of particles requires adjusting parameters such as the classifier's (analyzer's) speed and airflow to unconventional settings, which may affect the normal operation of the equipment and output.
III. Speculation of the Customer's True Intent
Based on the above analysis, the customer's true need may not be the literal producing 2-0mm material using a 5R4119 mill, but rather:
1. Requirement Scenario: The customer may need a granular material for roadbed filling, concrete aggregate, or building materials with specific requirements. These materials typically require a certain gradation (i.e., a proportional mix of particles of different sizes) and strict control over the content of fine powder (especially below 0.075mm), as excessive fine powder can affect compaction, strength, or cause dust.
2. Existing Limitations: The customer may already have a 5R4119 Raymond mill on-site and wants to utilize existing equipment to produce this product, saving on the investment of a new crushing and screening production line.
3. Misconceptions about the Equipment: The customer may believe that a Raymond mill can adjust the fineness and therefore can also produce coarser granules, lacking sufficient understanding of its working principle, energy consumption, and wear costs.
IV. Recommendations for Construction Companies/Solution Providers
Conduct in-depth communication with clients to clarify and guide their needs, and provide professional solutions:
1. Key Communication Points (Clarifying True Needs):
◦ “What is the main purpose of your final product? Is it for building aggregate, backfill, or something else?
◦ “Regarding the 0.613mm-0.044mm particle size limit, what are the specific numerical requirements? Is it a requirement that the throughput be below a certain value (e.g., <15%)?
◦ “For the overall particle size of 2-0mm, are there specific gradation curve requirements? (For example, a gradation zone similar to that of construction sand)
2. Provide Professional Solutions (Two Approaches):
◦ Solution A (Recommended Solution): Establish a Dedicated Production Line
▪ Frankly speaking: Directly using 5R4119 to produce the target product is neither technically feasible nor economically viable.
▪ Recommendation: Design a simple “crushing-screening-dust removal short-process production line for the client. For example: Feeder + Fine jaw crusher/cone crusher + Vibrating screen (multi-layer screen, separating 2-5mm, 5-10mm, etc., and removing some fine powder) + Dust collector (controlling dust below 0.044mm).
▪ Advantages: High output, low energy consumption, easy control of product gradation, fully meets the requirements.
◦ Option B (Compromise/Modification Option): Major modification and process adjustment of the existing mill system.
▪ Only considered if the customer insists on using the existing 5R4119 and investing in a new production line is extremely difficult.
▪ Modification measures may include:
▪ Significantly reducing the classifier speed to allow coarse particles to pass through.
▪ Adjusting the fan airflow to reduce fine powder collection.
▪ Adding a high-efficiency vibrating screen after milling to remove excessively fine powder (<0.3mm or <0.044mm) and process it as another product.
▪ It may be necessary to replace the grinding rollers and rings with those more suitable for coarse grinding.
▪ The risks must be clearly stated: a significant decrease in output, a significant increase in power consumption, a drastically accelerated rate of equipment wear (due to the high wear from coarse grinding), unstable product particle size, and operating costs far exceeding those of a new production line.
The customer's intentions involve a fundamental contradiction between equipment functionality and product objectives. The core issue is not how to use a Raymond mill to meet this contradictory requirement, but rather helping the customer recognize their true need: to produce granular materials that meet specific gradations (including fine powder limitations), and providing the most economical and reliable technical approach.
About of Baichy Heavy Industry
Baichy Heavy Industry is a high-tech mining equipment company integrating R&D, manufacturing, sales, and after-sales service. Focusing on crushing, grinding, and mineral processing equipment, we provide professional solutions to our customers. We are ISO9001:2015 、certified, and our products include mobile crushing palnts, crawler crushing plant, construction waste crushing plants, jaw crushers, sand making machines, cone crushers, fine crushers, grinding mills, ball mills, etc., all with reliable performance to meet diverse project needs.
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