There are two ways to make fine and ultra fine ground calcium carbonate powder. One is dry grinding of calcium carbonate and the other is wet grinding. For commercial manufacturing, dry grinding of calcium carbonate involves crushing and grinding basic materials such as limestone or marble. And there are several kinds of calcium carbonate grinding mill for dry grinding, such as ball mill, Raymond mill, vibrating mill, roller mill, vertical mill, jet mill, and so on. As for wet grinding of calcium carbonate, it obtains fine and ultra fine calcium carbonate powder by grinding slurry form of limestone or marble. And there is mainly wet grinding mill with different capacities. To choose a suitable calcium carbonate grinding mill, we first have to have a general understanding of these grinders for calcium carbonate.
Calcium Carbonate Dry Grinding Mill
Raymond mill is widely used in manufacturing of calcium carbonate powder. For its working principle, Raymond mill can roll and crush the feed limestone or marble to powder. Under the impact of rollers, feed material itself will be squeezed, rubbed, cut and ground. And Raymond mill has competitive advantages in investment and energy consumption when it is used for making calcium carbonate powder under 400 mesh. However, the working principle of the Raymond mill determines the lower proportion of produced fine powder. For example, among 400 mesh calcium carbonate powder, fine powder under 10μm is about 35% and under 5μm is only 5%, which is far lower than that of other calcium carbonate grinding mill. Advanced Raymond mill or paired with classifier, can also make 600-1250 mesh calcium carbonate powder. However, as mentioned above, the low proportion of fine powder means low production capacity and high energy consumption. So it is not advisable and economical to make calcium carbonate powder above 600 mesh.
Due to low investment and low energy consumption, roller mill is widely used in small and medium corporate. For working principle, it is the advanced version of Raymond mill. So it has the same working principle with Raymond mill. And the differences are that the diameters of rollers in roller mill are smaller than those of Raymond mill, and there are many rollers in roller mill. What’s more, there are three to four tiers of rolling. As a result, roller mill for calcium carbonate can produce 600-1500 mesh ground calcium carbonate powder with low energy consumption. However, for above 1000 mesh calcium carbonate powder, a roller mill alone can produce small capacity, and different roller mill can produce different calcium carbonate powder, which makes the final product quality unstable.
Vertical mill technology is initially designed by Germany and it has the same working principle with both Raymond mill and roller mill. As a result, vertical mill also produce low capacity of fine powder at one unit time. Nonetheless, the rollers in vertical mill work with hydraulic system which makes the roller can pose higher impact on feed material. So the grinding efficiency of vertical mill is higher than that of Raymond mill. Nowadays, the vertical mill for calcium carbonate is equipped with three rollers, improving fine powder production efficiency, and it mainly produces calcium carbonate powder under 1000 mesh. Then the installed classifier is upgraded and the vertical mill can now produce ground calcium carbonate powder under 1250 mesh. In fact, combined with extra classifier doing secondary classifying, vertical mill can also produce calcium carbonate under 1250 mesh.
Ball Mill with Classifying System
Ball mill is also known as rotary ball mill. Inside the ball mill, there are many different sizes of balls, which is called ball media. And when the ball mill rotates, the ball media and feed limestone inside the ball mill will collide and crush so as to make fine and ultra fine calcium carbonate powder. After interior redesign, the grinding impact of ball mill is improved and thus become the ultra fine ball mill. Ball mill is widely used in processing ground calcium carbonate, Kaolin, talc and other non-metallic minerals. Take making calcium carbonate for example. The ball mill can make calcium carbonate powder with 600-6000 mesh(paired with ultra fine secondary air classifier). Ball mill is especially suitable for making calcium carbonate powder with 800-2500 mesh. And a ball mill alone can produce 1 million ton/year to 10 million ton/year.
With the high speed rotating of hammers inside, hammer mill can smash limestone to powder. And it makes little fine and ultra fine powder in one unit time. As a result, hammer mill is of high energy consumption and low capacity for making calcium carbonate powder.
Drying Agitator Mill
It has high grinding efficiency and paired with air classifier, it can make fine calcium carbonate powder, especially ultra fine calcium carbonate above 1250 mesh. And the disadvantage is that an agitator mill alone has small capacity.
Comparison between these Dry Grinding Mill
Suppose you want produce calcium carbonate with 1250 mesh, and here we will outline the feed material sizes, optimum production fineness, energy consumption, capacity one machine alone.
|Equipment type||Feed material size(D90 mm)||Product optimum fineness (D97 mesh)||1250 mesh
|4R Raymond mill (installed with classifier)||≤20||100-400||/||/|
|Hammer mill(paired with classifier)||≤8||600-1000||260||0.2-0.6|
|Roller mill(paired with classifier)||≤30||200-1000||140||0.5-1.6|
|Vertical mill(installed with classifier)||≤30||200-1000||/||/|
|Ball mill(paired with classifier)||≤6||600-6000||170||1.0-8.0|
Detailed Comparison between Ball Mill and Vertical Mill
Compared with other calcium carbonate grinding mills, ball mill and vertical mill are more widely used in manufacturing of calcium carbonate powder. In following chart, we will outline the pros and cons of both ball mill and vertical mill for calcium carbonate plant.
|Ball mill||Vertical mill|
|Desired size ≤325 mesh||Not suitable||Very suitable|
|325-600 mesh||Suitable||Very suitable|
|Product with larger surface||Low energy consumption|
|600-1000 mesh||Suitable||Very suitable|
|Product with larger surface||Low energy consumption|
|≥1000mesh||Very suitable||Need secondary classifying|
|Stable quality with larger surface||Unstable product quality|
|Energy consumption||Higher for ≤1250 mesh||Lower for ≤1250 mesh|
|Same ≥1250||Same ≥1250|
|Preferred Application||Paper and paint||Plastic|
|Operation and maintenance||Simple||More complicate|
Wet Grinding Mill for Calcium Carbonate
Wet grinding of calcium carbonate obtains calcium carbonate powder by grinding the slurry form of raw material. And it mainly uses wet batching mill. Wet grinding mill produces calcium carbonate powder with D60=2μm and D90=2μm as paper filler and paint product.
In all, to choose the best suited calcium carbonate grinding mill, you need to understand the working principle of these mills, its production capacity, energy consumption and so on. Besides, there are other factors to be considered: property of raw material, applications of final products, desired fineness and so on.
Daswell machinery is a professional manufacturer of calcium carbonate plant and we have delivered several successful calcium carbonate grinding plant projects around the world. We provides complete set of equipment for calcium carbonate grinding plant. According to your specific requirements, we can offer you tailored turnkey solutions for your calcium carbonate manufacturing plant and provide best suited equipment.