Disc & Rotor Mills
Laboratory Disc Mill Medium Hard Material Grinding Coal Coke Ore Pulverizer
Item Number: PP-GE20
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Product Overview
This disc mill is a heavy-duty laboratory pulverizer designed for efficient size reduction of medium-hard materials such as coal, coke, ore, and similar substances. Its robust construction and precision engineering make it an indispensable tool for sample preparation in demanding industrial and research settings. The mill employs a dual-disc grinding mechanism that combines compressive and shearing forces to achieve rapid and uniform comminution.
Targeted at metallurgy, geology, building materials, and chemical laboratories, this equipment consistently delivers a final particle size of 0.2 mm or less, critical for accurate analytical testing. The adjustable disc gap ensures that operators can fine-tune the output to meet specific requirements, whether for XRF analysis, chemical assays, or physical property testing. Easy cleanup and low maintenance further enhance laboratory productivity by minimizing cross-contamination between samples.
Built around a rigid frame and high-quality components, the system is engineered for long-term reliability. The high-manganese steel grinding discs offer exceptional durability, resisting the abrasive wear that comes from continual processing of hard particles. A belt-driven power train minimizes abrupt load shocks, protecting the motor and bearings while ensuring smooth operation. This mill is a premium investment for labs that demand precision, consistency, and endurance.
Key Features
- Robust High-Manganese Steel Grinding Discs: Both the fixed and rotating discs are manufactured from high-manganese steel, a material renowned for its superior wear resistance and work-hardening properties. This ensures an extended service life even when processing abrasive materials like ore or clinker. The discs maintain their grinding profile over time, contributing to consistent output quality.
- Precision Disc Gap Adjustment: The clearance between the discs is easily adjusted using a dual-handwheel system. A large handwheel locks the position, while a small handwheel turns a threaded spindle to move the rotating disc forward or backward with micrometer precision. This allows the operator to control the final particle size down to ≤0.2 mm without tools, adapting quickly to different material characteristics.
- Stable and Low-Noise Operation: A well-balanced rotor and flexible V-belt drive combine to minimize vibration and operational noise. The belt transmission absorbs startup shocks and motor torque fluctuations, resulting in smooth acceleration and quiet running. This makes the mill suitable for noise-sensitive laboratory environments.
- Easy Cleaning and Maintenance: The grinding chamber is designed for straightforward access: the end cover and hopper can be removed quickly to expose the discs for cleaning. The simple layout eliminates concealed areas where sample residue might accumulate. Fast cleaning procedures reduce turnaround time between different sample batches and prevent cross-contamination.
- Efficient High-Throughput Grinding: Capable of processing up to 100 kg of material per hour, this system meets the needs of high-volume labs without compromising fineness. Its continuous feeding capability enables integration into automated sample preparation lines. The combination of speed and capacity makes it a cost-effective solution for busy industrial laboratories.
- Sealed Grinding Chamber: The fully enclosed grinding house prevents the escape of fine dust during operation. This not only keeps the laboratory environment clean but also protects operators from inhaling potentially hazardous particulates. Integrated seals around the feed opening and discharge chute enhance containment.
- Reliable Belt Drive System: The motor transmits power to the spindle via heavy-duty V-belts that provide inherent overload protection. In the event of a jam, the belts slip, preventing damage to the motor and grinding components. This design enhances safety and reduces unplanned maintenance.
- Versatile Feed Size Handling: With a maximum feed size of 10 mm, the mill can accept a wide range of input materials directly, often eliminating the need for a pre-crusher. This reduces sample preparation time and simplifies workflow, especially for heterogeneous batches.
- Compact and Space-Saving Design: Dimensions of 1030 x 550 x 770 mm mean the unit occupies minimal bench or floor space. It can be installed on a sturdy workbench without special foundations, saving valuable lab real estate.
- Consistent Particle Size Output: The parallel disc surfaces and precise gap adjustment yield a narrow particle size distribution, producing homogeneous samples essential for reproducibility in analytical methods. This uniformity is maintained over long production runs, ensuring stable process outcomes.
Applications
| Application | Description | Key Benefit |
|---|---|---|
| Coal Sample Preparation | Grinding raw coal to analytical fineness for proximate analysis, calorific value determination, and ash fusion tests. The mill homogenizes heterogeneous coal samples quickly, ensuring that test portions are truly representative of the bulk. | Achieves ≤0.2 mm final size with minimal loss of volatiles and no binder deformation, crucial for accurate thermal and chemical characterization. |
| Coke Crushing for Metallurgical Testing | Pulverizing coke samples for CRI (Coke Reactivity Index) and CSR (Coke Strength after Reaction) tests, which are essential for blast furnace operation optimization. The mill handles hard, abrasive coke particles with ease. | Uniform particle size improves the precision of reactivity measurements, leading to more reliable coke quality assessments. |
| Ore Pulverization for Geochemical Analysis | Reducing ore samples for X-ray fluorescence (XRF), inductively coupled plasma (ICP) analysis, and traditional wet chemistry. The mill processes diverse ore types including sulfides, oxides, and silicates. | Homogeneous grinding minimizes the nugget effect and ensures representative subsampling, enhancing detection limits and accuracy. |
| Geological Sample Processing | Crushing rocks, minerals, and drill core fragments for petrography, mineral liberation analysis, and grade evaluation. The adjustable disc gap allows gentle size reduction to avoid destroying structural features when needed. | Preserves mineral grain integrity while achieving desired fineness, aiding in accurate phase identification. |
| Building Material Quality Control | Grinding cement raw meal, clinker, limestone, and gypsum for fineness control and quality compliance testing. The mill's consistent performance supports statistical process control in production. | Delivers repeatable Blaine and sieve residue results, enabling tight adherence to product specifications. |
| Chemical Industry Sample Prep | Milling catalyst precursors, pigments, and specialty chemicals to fine powders for surface area analysis, particle sizing, or reactivity tests. The low-heat grinding action protects thermally sensitive materials. | Sealed operation prevents cross-contamination and exposure to reactive or toxic compounds, maintaining safety and sample purity. |
| Environmental Sample Analysis | Preparing soil, sediment, and solid waste samples for heavy metal analysis, pesticide residue testing, and bioavailability studies. The robust discs handle gritty, heterogeneous matrices without excessive wear. | Achieves thorough homogenization, reducing analytical error from widely varying particle compositions. |
| Laboratory R&D Material Development | Prototyping new ceramic, composite, or metallurgical powders by milling experimental formulations. The rapid cycle time and easy cleanability support iterative development. | Fine control over particle size accelerates process optimization and helps identify optimal milling conditions. |
Technical Specifications
| Parameter | Specification |
|---|---|
| Model | PP-GE20 |
| Disc Diameter | 350 mm |
| Maximum Feed Size | ≤10 mm |
| Final Discharge Size | ≤0.2 mm |
| Productivity | 100 kg/h |
| Motor Power | 4 kW |
| Disc Material | High-manganese steel |
| Dimensions (L x W x H) | 1030 x 550 x 770 mm |
The grinding gap is adjustable via a dual-handwheel mechanism; the large handwheel locks the setting, while the small handwheel provides fine feed control. This ensures reproducible particle size outputs across different materials.
Why Choose This Product
- Proven Long-Term Reliability: Thousands of units operating worldwide in rigorous industrial labs testify to the durability of this design. The cast-iron frame and heavy-duty spindle ensure stability under load, while the simple belt drive minimizes potential failure points. Users report years of trouble-free service with only routine maintenance.
- Superior Build Quality: The use of high-manganese steel for the grinding discs sets this mill apart from competitors using standard tool steels. This material work-hardens under repeated impact, actually becoming tougher over time. Combined with precision machining of the disc surfaces, it delivers exceptional grinding efficiency and longevity.
- Precision Particle Control: The fine-adjustment screw mechanism enables repeatable gap settings accurate to micrometers. Once set, the large handwheel securely locks the position, eliminating drift during extended runs. This level of control is essential for achieving consistent analytical results in accredited laboratories.
- Versatile Material Handling: From soft coal to hard ore, this mill adapts to a wide hardness range without tooling changes. This versatility reduces the need for multiple mills, freeing up capital and lab space. Operators can switch between materials in minutes thanks to rapid cleaning features.
- Responsive Support and Customization: Our dedicated support team provides on-site commissioning, training, and ongoing technical advice. We stock critical spares for express delivery anywhere. For unique applications, we can customize disc materials, feed configurations, or integrate the mill into automated systems. Contact us today to explore a solution tailored to your laboratory's exact needs.
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