Process Features of Shanghai ZENITH's 100-Ton-Per-Hour Vertical Grinding Mill

In industries such as non-metallic mineral powder processing, metallurgy, building materials, power generation, and environmental protection, large vertical grinding mills have become core equipment in the grinding field due to their outstanding efficiency and energy-saving advantages. As a renowned domestic grinding machinery manufacturer, Shanghai ZENITH Mining Machinery Co., Ltd. has introduced a 100-ton-per-hour vertical grinding mill. Integrating modern grinding technology, mechanical manufacturing processes, and intelligent control, it demonstrates distinctive technical features, providing a robust solution for large-scale, high-efficiency powder production.

I. Integrated Design Significantly Streamlines Process Flow

Traditional grinding systems typically require multiple devices (such as jaw crushers, conveyors, dryers, ball mills, and classifiers) operating in series, resulting in lengthy processes, large footprints, and high infrastructure investments. ZENITH's 100-ton-per-hour vertical mill adopts a highly integrated vertical structure, successfully consolidating five major processes—crushing, grinding, drying, classification, and collection—into a single unit. This integrated design delivers revolutionary advantages: the entire production flow is completed continuously within one machine, drastically simplifying process layout, reducing inter-equipment connections and civil engineering requirements. This not only lowers initial investment costs but also facilitates centralized management and control of the production line.

II. High-Efficiency Grinding Principle: Low Energy Consumption with High Output

The core advantage lies in its highly efficient grinding principle. During operation, the motor drives the grinding disc rotation via a reducer. Material is fed into the disc's center through the feeding device, where centrifugal force propels it to the disc's periphery. It then enters the working zone between the grinding rollers and the disc. The hydraulic system applies immense crushing pressure to the rollers, pulverizing the material through compression. This “bed grinding” technology pulverizes materials as aggregate particles, achieving far higher energy efficiency than the traditional random collision method of steel balls against materials in ball mills. Consequently, under identical fineness and output requirements, the ZENITH Vertical Mill reduces power consumption by 30% to 50% compared to conventional ball mill systems. For large-scale production at 100 tons per hour, the long-term energy savings are exceptionally substantial.

III. Integrated Drying Capability for High-Moisture Feedstock

Addressing the practical challenge of moisture-containing feedstock, the ZENITH vertical mill incorporates a built-in drying function. Hot air generated by the hot blast furnace enters the mill through the bottom inlet, thoroughly contacting the dispersed material. During grinding, the high-velocity ascending hot air stream promptly carries away the finely ground particles while effectively drying the material. This process feature enables direct processing of raw materials with moisture content as high as 15% or more, eliminating the need for separate drying equipment and processes. This not only further simplifies the system but also enhances adaptability to diverse materials, demonstrating particular advantages when handling moist materials such as slag, water slag, and coal.

IV. High Classification Precision and Adjustable Product Fineness

The ground material rises with the airflow to the top-mounted classifier. The ZENITH vertical mill employs a high-efficiency dynamic turbine classifier. By adjusting the speed of the classifier impeller, the fineness of the desired finished product can be precisely controlled. Particles meeting the fineness specifications are carried by the airflow into the dust collector for collection, while oversized particles are returned to the grinding disc for re-grinding. This internal circulation closed-circuit grinding system ensures a narrow particle size distribution, uniform particle morphology, and a wide fineness adjustment range (typically between 80-600 mesh). It meets the precise fineness requirements of various application fields, achieving a product sieve pass rate exceeding 99%.

V. Stable Operation, Environmental Protection, and High Automation

The equipment also excels in stability and environmental performance. Core wear-resistant components like grinding rollers and discs utilize premium materials such as high-chromium alloys, ensuring extended service life and significantly reduced maintenance intervals. The fully sealed structure, combined with an efficient pulse dust collection system, virtually eliminates dust leakage. This maintains a clean working environment with well-controlled noise levels, fully complying with modern industrial environmental standards. Additionally, the equipment incorporates an advanced automated control system enabling one-button start/stop, remote monitoring, fault diagnosis, and automatic adjustment of parameters such as feed rate, airflow, and grinding pressure. This significantly reduces operator workload while ensuring long-term, stable, and efficient operation of the entire grinding system.