Primarily focusing on ceramic factories, data shows that using cobblestones (natural round pebbles) plus 10% high-alumina balls (φ35MM) to grind slurry can reduce the grinding time by 15% compared to using cobblestones alone. Using medium-alumina balls mixed with 30% high-alumina balls (φ35MM) for grinding slurry can cut the grinding time by approximately 30% compared to using medium-alumina balls. Just by saving on electricity costs, the additional cost of using high-alumina balls can be recouped in about 2 years. Some manufacturers' reports indicate that replacing medium-alumina balls with high-alumina balls and bricks in ball mills for grinding ceramic raw materials results in less than one-third of the wear on cobblestones, a 20% reduction in grinding time, more stable product quality, and longer use of high-alumina products without frequent replacement of ball liners, making it a more cost-effective solution overall. Grinding raw materials with high-alumina balls not only saves electricity and increases production but also enhances the efficiency of machinery and provides significant protection for mechanical equipment.
In addition to the ceramic industry, quartz, chemical industry, and other sectors are progressively experimenting and employing high-alumina balls in production. Quartz factories primarily use them to produce silicon micro-powders. Practice has shown that replacing quartz balls with high-alumina balls for producing 325 mesh silicon micro-powder can significantly enhance yield and product quality, such as brightness and uniformity. Moreover, as the wear rate is not as fast as that of quartz balls, it saves labor and time costs associated with adding ballstone. The main issue with using high-alumina balls is that their high hardness and brittleness can lead to cracking and uneven surfaces on the ballstone during dry grinding, resulting in excessive wear. The only solution is to polish the ballstone before shipment, select out cracked or highly worn balls, and minimize customer losses as much as possible.
