wet ball mill/wet type ball mill/wet ball milling machine--zhengzhou bobang heavy industry machinery co.,ltd
Wet type ball mill are mostly used in the industry production. It is to increase the high grinding efficiency under the ball mill grinding and striking, from which the granularity is even and no flying dust with little noise, being the most universal powder machine in the benefication as powder grinding the ferrous metal like gold, silver, plumbum, zinc,copper,molybdenum,manganese,tungsten etc, as the nonmetal powder grinding like graphite,feldspar, potash feldspar, phosphorus ore, fluorite, clay, and swell soil etc. The wet type ball mill need to add the liquid into the grinding ball media auxiliary (water or ethanol). The material output gate is trumpet shape, with screw device inside, easy to discharging the material.
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high energy ball milling process for nanomaterial synthesis
It is a ball milling process where a powder mixture placed
in the ball mill is subjected to high-energy collision from
the balls. This process was developed by Benjamin and
his coworkers at the International Nickel Company in the
late of 1960. It was found that this method, termed
mechanical alloying, could successfully produce fine, uniform
dispersions of oxide particles (Al2O3, Y2O3, ThO2) in
nickel-base superalloys that could not be made by more
conventional powder metallurgy methods. Their
innovation has changed the traditional method in which production
of materials is carried out by high temperature synthesis.
Besides materials synthesis, high-energy ball milling
is a way of modifying the conditions in which chemical
reactions usually take place either by changing the reactivity
of as-milled solids (mechanical activation
increasing reaction rates, lowering reaction temperature of
the ground powders)or by inducing chemical reactions
during milling (mechanochemistry). It is, furthermore,
a way of inducing phase transformations in starting
powders whose particles have all the same chemical composition: amorphization or polymorphic transformations of
compounds, disordering of ordered alloys, etc.
The alloying process can be carried out using different
apparatus, namely, attritor, planetary mill or a horizontal
ball mill. However, the principles of these operations are
same for all the techniques. Since the powders are cold
welded and fractured during mechanical alloying, it is critical
to establish a balance between the two processes in order
to alloy successfully. Planetary ball mill is a most frequently
used system for mechanical alloying since only a very small
amount of powder is required. Therefore, the system is particularly
suitable for research purpose in the laboratory. The
ball mill system consists of one turn disc (turn table) and two
or four bowls. The turn disc rotates in one direction while
the bowls rotate in the opposite direction. The centrifugal
forces, created by the rotation of the bowl around its own
axis together with the rotation of the turn disc, are applied
to the powder mixture and milling balls in the bowl. The
powder mixture is fractured and cold welded under high energy
The figure below shows the motions of the balls and the powder.
Since the rotation directions of the bowl and turn disc are opposite, the centrifugal forces are alternately synchronized.
Thus friction resulted from the hardened milling balls and
the powder mixture being ground alternately rolling on the
inner wall of the bowl and striking the opposite wall. The
impact energy of the milling balls in the normal direction
attains a value of up to 40 times higher than that due to
gravitational acceleration. Hence, the planetary ball mill can
be used for high-speed milling.
During the high-energy ball milling process, the powder
particles are subjected to high energetic impact. Microstructurally, the
mechanical alloying process can be divided into four stages: (a) initial
stage, (b) intermediate stage, (c) final stage, and (d) completion
(a) At the initial stage of ball milling, the powder particles
are flattened by the compressive forces due to the collision of the balls. Micro-forging leads to changes
in the shapes of individual particles, or cluster of particles
being impacted repeatedly by the milling balls
with high kinetic energy. However, such deformation
of the powders shows no net change in mass.
(b) At the intermediate stage of the mechanical alloying
process, significant changes occur in comparison with
those in the initial stage. Cold welding is now significant.
The intimate mixture of the powder constituents
decreases the diffusion distance to the micrometer
range. Fracturing and cold welding are the dominant
milling processes at this stage. Although some dissolution
may take place, the chemical composition of
the alloyed powder is still not homogeneous.
(c) At the final stage of the mechanical alloying process,
considerable refinement and reduction in particle size
is evident. The microstructure of the particle also
appears to be more homogenous in microscopic scale
than those at the initial and intermediate stages. True
alloys may have already been formed.
(d) At the completion stage of the mechanical alloying
process, the powder particles possess an
extremely deformed metastable structure. At this
stage, the lamellae are no longer resolvable by optical
microscopy. Further mechanical alloying beyond this
stage cannot physically improve the dispersoid distribution.
Real alloy with composition similar to the
starting constituents is thus formed.
Theoretical considerations and explorations of planetary
milling process have been broadly studied in order to better
understand and inteprate the concept. Joisels work is
the first report to study the shock kinematics of a satellite
milling machine. This work focused on the determination
of the milling parameters that were optimized for
shock energy. The various parameters were determined geometrically
and the theoretical predictions were examined
experimentally using a specifically designed planetary mill. Schilz et al. reported that from a macroscopical
point of view, the geometry of the mill and the ratio
of angular velocities of the planetary to the system wheel
played crucial roles in the milling performance. For a particular
ductile-brittle MgSi system, the milling efficiency of
the planetary ball was found to be heavily influenced by the ratio of the
angular velocity of the planetary wheel to that of the system wheel as
well as the amount of sample load. Mio et al. studied the effect of rotational direction
and rotation-to-revolution speed ratio in planetary ball
milling. Some more theoretical issues and kinematic modeling
of the planetary ball mill were reported later in related
references. Because mechanical alloying of materials
are complex processes which depend on many factors,
for instance on physical and chemical parameters such as
the precise dynamical conditions, temperature, nature of the
grinding atmosphere, chemical composition of the powder
mixtures, chemical nature of the grinding tools, etc., some
theoretical problems, like predicting nonequilibrium phase transitions under
milling, are still in debate.
For all nanocrystalline materials prepared by high-energy
ball milling synthesis route, surface and interface contamination
is a major concern. In particular, mechanical attributed
contamination by the milling tools (Fe or WC) as well as
ambient gas (trace impurities such as O2, N2 in rare gases)
can be problems for high-energy ball milling. However,
using optimized milling speed and milling time may effectively
reduce the contamination. Moreover, ductile materials
can form a thin coating layer on the milling tools that
reduces contamination tremendously. Atmospheric contamination
can be minimized or eliminated by sealing the vial
with a flexible O ring after the powder has been loaded
in an inert gas glove box. Small experimental ball mills can
also be completely enclosed in an inert gas glove box. As a
consequence, the contamination with Fe-based wear debris
can be reduced to less than 12 at.% and oxygen and nitrogen
contamination to less than 300 ppm. Besides the
contamination, long processing time, no control on particle
morphology, agglomerates, and residual strain in the crystallized
phase are the other disadvantages of high-energy ball
Notwithstanding the drawbacks, high-energy ball milling
process has attracted much attention and inspired numerous
research interests because of its promising results,
various applications and potential scientific values. The synthesis
of nanostructured metal oxides for gas detection is
one of the most promising applications of high-energy ball
milling. Some significant works have been reported in recent
years. Jiang et al.
a-Fe2O3MO2 (M: Ti and Sn) solid
solutions by high-energy milling for C2H5OH detection.
The 85 mol%
a-Fe2O3SnO2 sample milled for 110 hours
showed the highest sensitivity among all the samples studied.
The best sensitivity to 1000 ppm C2H5OH in air at an
operating temperature of 250 C was about 20. Zhang et al. synthesized FeSbO4 for LPG detection. They found
that there were two-step solid-state reactions occurring in
the raw powders during the ball milling:
The response and recovery times of their sensor were less
than one second. The sensitivity to 1000 ppm C2H5OH at
an operating temperature of 375 C was about 45. Diguez et al. employed precipitation method
to prepare nanocrystalline SnO2 and planetary milling to
grind the obtained powder for NO2 detection. They found
that the grinding procedure of the precursor and/or of the
oxide had critical effect on the resistance in air. As a result,
the gas sensing properties to NO2 had been considerably
improved. Cukrov et al. and Kersen et al. synthesized
SnO2 powders by mechanochemical processing for
O2 and H2S sensing applications, respectively. The O2 sensor
exhibited stable, repeatable and reproducible electrical
response to O2. More recently, Yamazoes group
reported the sensing properties of SnO2Co3O4 composites
to CO and H2. A series of SnO2Co3O4 thick films
containing 0100% Co3O4 in mass were prepared from the
component oxides through mixing by ball-milling for 24 h,
screen-printing and sintering at 700 C for 3 h. The composite
films were found to exhibit n- or p-type response to CO
and H2 depending on the Co3O4 contents in the composites.
The n-type response was exhibited at 200 C or above
by SnO2-rich composites (Co3O4 content up to 5 mass%).
The sensor response to both CO and H2 was significantly
enhanced by the addition of small amounts of Co3O4 to
SnO2, and the response at 250 C achieved a sharp maximum
at 1 mass% Co3O4. The p-type response was obtained at
200 C or below by the composites containing 25100 mass%
Co3O4. The sensitivity as well as selectivity to CO over H2
could thus be increased by the addition of SnO2 to Co3O4.
Besides the above mentioned researches, significant
efforts on the synthesis of nanostructured metal oxide with
high-energy ball milling method for gas sensing have been
actively pursued by the authors of this chapter. In our research, we use the
high-energy ball milling technique to synthesize various nanometer
powders with an average particle size down to several nm, including nano-sized
a-Fe2O3 based solid
solutions mixed with varied mole percentages of SnO2, ZrO2
and TiO2 separately for ethanol gas sensing application,
stabilized ZrO2 based and TiO2 based solid solutions mixed
with different mole percentages of
a-Fe2O3 and synthesized
SrTiO3 for oxygen gas sensing. The synthesized powders
were characterized with XRD, TEM, SEM, XPS, and DTA.
Their sensing properties were systematically investigated and
sensing mechanisms were explored and discussed as well.
ball milling - an overview | sciencedirect topics
Ball milling is often used not only for grinding powders but also for oxides or nanocomposite synthesis and/or structure/phase composition optimization [14,41]. Mechanical activation by ball milling is known to increase the material reactivity and uniformity of spatial distribution of elements . Thus, postsynthesis processing of the materials by ball milling can help with the problem of minor admixture forming during cooling under air after high-temperature sintering due to phase instability.
Ball milling technique, using mechanical alloying and mechanical milling approaches were proposed to the word wide in the 8th decade of the last century for preparing a wide spectrum of powder materials and their alloys. In fact, ball milling process is not new and dates back to more than 150 years. It has been used in size comminutions of ore, mineral dressing, preparing talc powders and many other applications. It might be interesting for us to have a look at the history and development of ball milling and the corresponding products. The photo shows the STEM-BF image of a Cu-based alloy nanoparticle prepared by mechanical alloying (After El-Eskandarany, unpublished work, 2014).
Ball milling, a shear-force dominant process where the particle size goes on reducing by impact and attrition mainly consists of metallic balls (generally Zirconia (ZrO2) or steel balls), acting as grinding media and rotating shell to create centrifugal force. In this process, graphite (precursor) was breakdown by randomly striking with grinding media in the rotating shell to create shear and compression force which helps to overcome the weak Vander Waal's interaction between the graphite layers and results in their splintering. Fig. 4A schematic illustrates ball milling process for graphene preparation. Initially, because of large size of graphite, compressive force dominates and as the graphite gets fragmented, shear force cleaves graphite to produce graphene. However, excessive compression force may damage the crystalline properties of graphene and hence needs to be minimized by controlling the milling parameters e.g. milling duration, milling revolution per minute (rpm), ball-to-graphite/powder ratio (B/P), initial graphite weight, ball diameter. High quality graphene can be achieved under low milling speed; though it will increase the processing time which is highly undesirable for large scale production.
Fig. 4. (A) Schematic illustration of graphene preparation via ball milling. SEM images of bulk graphite (B), GSs/E-H (C) GSs/K (D); (E) and (F) are the respective TEM images; (G) Raman spectra of bulk graphite versus GSs exfoliated via wet milling in E-H and K.
Milling of graphite layers can be instigated in two states: (i) dry ball milling (DBM) and (ii) wet ball milling (WBM). WBM process requires surfactant/solvent such as N,N Dimethylformamide (DMF) , N-methylpyrrolidone (NMP) , deionized (DI) water , potassium acetate , 2-ethylhexanol (E-H)  and kerosene (K)  etc. and is comparatively simpler as compared with DBM. Fig. 4BD show the scanning electron microscopy (SEM) images of bulk graphite, graphene sheets (GSs) prepared in E-H (GSs/E-H) and K (GSs/K), respectively; the corresponding transmission electron microscopy (TEM) images and the Raman spectra are shown in Fig. 4EG, respectively .
Compared to this, DBM requires several milling agents e.g. sodium chloride (NaCl) , Melamine (Na2SO4) [31,32] etc., along with the metal balls to reduce the stress induced in graphite microstructures, and hence require additional purification for exfoliant's removal. Na2SO4 can be easily washed away by hot water  while ammonia-borane (NH3BH3), another exfoliant used to weaken the Vander Waal's bonding between graphite layers can be using ethanol . Table 1 list few ball milling processes carried out using various milling agent (in case of DBM) and solvents (WBM) under different milling conditions.
Ball milling of graphite with appropriate stabilizers is another mode of exfoliation in liquid phase.21 Graphite is ground under high sheer rates with millimeter-sized metal balls causing exfoliation to graphene (Fig. 2.5), under wet or dry conditions. For instance, this method can be employed to produce nearly 50g of graphene in the absence of any oxidant.22 Graphite (50g) was ground in the ball mill with oxalic acid (20g) in this method for 20 hours, but, the separation of unexfoliated fraction was not discussed.22 Similarly, solvent-free graphite exfoliations were carried out under dry milling conditions using KOH,23 ammonia borane,24 and so on. The list of graphite exfoliations performed using ball milling is given in Table 2.2. However, the metallic impurities from the machinery used for ball milling are a major disadvantage of this method for certain applications.25
Reactive ball-milling (RBM) technique has been considered as a powerful tool for fabrication of metallic nitrides and hydrides via room temperature ball milling. The flowchart shows the mechanism of gas-solid reaction through RBM that was proposed by El-Eskandarany. In his model, the starting metallic powders are subjected to dramatic shear and impact forces that are generated by the ball-milling media. The powders are, therefore, disintegrated into smaller particles, and very clean or fresh oxygen-free active surfaces of the powders are created. The reactive milling atmosphere (nitrogen or hydrogen gases) was gettered and absorbed completely by the first atomically clean surfaces of the metallic ball-milled powders to react in a same manner as a gas-solid reaction owing to the mechanically induced reactive milling.
Ball milling is a grinding method that grinds nanotubes into extremely fine powders. During the ball milling process, the collision between the tiny rigid balls in a concealed container will generate localized high pressure. Usually, ceramic, flint pebbles and stainless steel are used.25 In order to further improve the quality of dispersion and introduce functional groups onto the nanotube surface, selected chemicals can be included in the container during the process. The factors that affect the quality of dispersion include the milling time, rotational speed, size of balls and balls/ nanotube amount ratio. Under certain processing conditions, the particles can be ground to as small as 100nm. This process has been employed to transform carbon nanotubes into smaller nanoparticles, to generate highly curved or closed shell carbon nanostructures from graphite, to enhance the saturation of lithium composition in SWCNTs, to modify the morphologies of cup-stacked carbon nanotubes and to generate different carbon nanoparticles from graphitic carbon for hydrogen storage application.25 Even though ball milling is easy to operate and suitable for powder polymers or monomers, process-induced damage on the nanotubes can occur.
Ball milling is a way to exfoliate graphite using lateral force, as opposed to the Scotch Tape or sonication that mainly use normal force. Ball mills, like the three roll machine, are a common occurrence in industry, for the production of fine particles. During the ball milling process, there are two factors that contribute to the exfoliation. The main factor contributing is the shear force applied by the balls. Using only shear force, one can produce large graphene flakes. The secondary factor is the collisions that occur during milling. Harsh collisions can break these large flakes and can potentially disrupt the crystal structure resulting in a more amorphous mass. So in order to create good-quality, high-area graphene, the collisions have to be minimized.
The ball-milling process is common in grinding machines as well as in reactors where various functional materials can be created by mechanochemical synthesis. A simple milling process reduces both CO2 generation and energy consumption during materials production. Herein a novel mechanochemical approach 1-3) to produce sophisticated carbon nanomaterials is reported. It is demonstrated that unique carbon nanostructures including carbon nanotubes and carbon onions are synthesized by high-speed ball-milling of steel balls. It is considered that the gas-phase reaction takes place around the surface of steel balls under local high temperatures induced by the collision-friction energy in ball-milling process, which results in phase separated unique carbon nanomaterials.
Conventional ball milling is a traditional powder-processing technique, which is mainly used for reducing particle sizes and for the mixing of different materials. The technique is widely used in mineral, pharmaceutical, and ceramic industries, as well as scientific laboratories. The HEBM technique discussed in this chapter is a new technique developed initially for producing new metastable materials, which cannot be produced using thermal equilibrium processes, and thus is very different from conventional ball milling technique. HEBM was first reported by Benjamin  in the 1960s. So far, a large range of new materials has been synthesized using HEBM. For example, oxide-dispersion-strengthened alloys are synthesized using a powerful high-energy ball mill (attritor) because conventional ball mills could not provide sufficient grinding energy . Intensive research in the synthesis of new metastable materials by HEBM was stimulated by the pioneering work in the amorphization of the Ni-Nb alloys conducted by Kock et al. in 1983 . Since then, a wide spectrum of metastable materials has been produced, including nanocrystalline , nanocomposite , nanoporous phases , supersaturated solid solutions , and amorphous alloys . These new phase transformations induced by HEBM are generally referred as mechanical alloying (MA). At the same time, it was found that at room temperature, HEBM can activate chemical reactions which are normally only possible at high temperatures . This is called reactive milling or mechano-chemistry. Reactive ball milling has produced a large range of nanosized oxides , nitrides , hydrides , and carbide  particles.
The major differences between conventional ball milling and the HEBM are listed in the Table 1. The impact energy of HEBM is typically 1000 times higher than the conventional ball milling energy. The dominant events in the conventional ball milling are particle fracturing and size reductions, which correspond to, actually, only the first stage of the HEBM. A longer milling time is therefore generally required for HEBM. In addition to milling energy, the controls of milling atmosphere and temperature are crucial in order to create the desired structural changes or chemical reactions. This table shows that HEBM can cover most work normally performed by conventional ball milling, however, conventional ball milling equipment cannot be used to conduct any HEBM work.
Different types of high-energy ball mills have been developed, including the Spex vibrating mill, planetary ball mill, high-energy rotating mill, and attritors . In the nanotube synthesis, two types of HEBM mills have been used: a vibrating ball mill and a rotating ball mill. The vibrating-frame grinder (Pulverisette O, Fritsch) is shown in Fig. 1a. This mill uses only one large ball (diameter of 50 mm) and the media of the ball and vial can be stainless steel or ceramic tungsten carbide (WC). The milling chamber, as illustrated in Fig. 1b, is sealed with an O-ring so that the atmosphere can be changed via a valve. The pressure is monitored with an attached gauge during milling.
where Mb is the mass of the milling ball, Vmax the maximum velocity of the vial,/the impact frequency, and Mp the mass of powder. The milling intensity is a very important parameter to MA and reactive ball milling. For example, a full amorphization of a crystalline NiZr alloy can only be achieved with a milling intensity above an intensity threshold of 510 ms2 . The amorphization process during ball milling can be seen from the images of transmission electron microscopy (TEM) in Fig. 2a, which were taken from samples milled for different lengths of time. The TEM images show that the size and number of NiZr crystals decrease with increasing milling time, and a full amorphization is achieved after milling for 165 h. The corresponding diffraction patterns in Fig. 2b confirm this gradual amorphization process. However, when milling below the intensity threshold, a mixture of nanocrystalline and amorphous phases is produced. This intensity threshold depends on milling temperature and alloy composition .
Figure 2. (a) Dark-field TEM image of Ni10Zr7 alloy milled for 0.5, 23, 73, and 165 h in the vibrating ball mill with a milling intensity of 940 ms2. (b) Corresponding electron diffraction patterns .
Fig. 3 shows a rotating steel mill and a schematic representation of milling action inside the milling chamber. The mill has a rotating horizontal cell loaded with several hardened steel balls. As the cell rotates, the balls drop onto the powder that is being ground. An external magnet is placed close to the cell to increase milling energy . Different milling actions and intensities can be realized by adjusting the cell rotation rate and magnet position.
The atmosphere inside the chamber can be controlled, and adequate gas has to be selected for different milling experiments. For example, during the ball milling of pure Zr powder in the atmosphere of ammonia (NH3), a series of chemical reactions occur between Zr and NH3 [54,55]. The X-ray diffraction (XRD) patterns in Fig. 4 show the following reaction sequence as a function of milling time:
The mechanism of a HEBM process is quite complicated. During the HEBM, material particles are repeatedly flattened, fractured, and welded. Every time two steel balls collide or one ball hits the chamber wall, they trap some particles between their surfaces. Such high-energy impacts severely deform the particles and create atomically fresh, new surfaces, as well as a high density of dislocations and other structural defects . A high defect density induced by HEBM can accelerate the diffusion process . Alternatively, the deformation and fracturing of particles causes continuous size reduction and can lead to reduction in diffusion distances. This can at least reduce the reaction temperatures significantly, even if the reactions do not occur at room temperature [57,58]. Since newly created surfaces are most often very reactive and readily oxidize in air, the HEBM has to be conducted in an inert atmosphere. It is now recognized that the HEBM, along with other non-equilibrium techniques such as rapid quenching, irradiation/ion-implantation, plasma processing, and gas deposition, can produce a series of metastable and nanostructured materials, which are usually difficult to prepare using melting or conventional powder metallurgy methods [59,60]. In the next section, detailed structural and morphological changes of graphite during HEBM will be presented.
Ball milling and ultrasonication were used to reduce the particle size and distribution. During ball milling the weight (grams) ratio of balls-to-clay particles was 100:2.5 and the milling operation was run for 24 hours. The effect of different types of balls on particle size reduction and narrowing particle size distribution was studied. The milled particles were dispersed in xylene to disaggregate the clumps. Again, ultrasonication was done on milled samples in xylene. An investigation on the amplitude (80% and 90%), pulsation rate (5 s on and 5 s off, 8 s on and 4 s off) and time (15 min, 1 h and 4 h) of the ultrasonication process was done with respect to particle size distribution and the optimum conditions in our laboratory were determined. A particle size analyzer was used to characterize the nanoparticles based on the principles of laser diffraction and morphological studies.
ball mill - retsch - powerful grinding and homogenization
Ball mills are among the most variable and effective tools when it comes to size reduction of hard, brittle or fibrous materials. The variety of grinding modes, usable volumes and available grinding tool materials make ball mills the perfect match for a vast range of applications.
RETSCH is the world leading manufacturer of laboratory ball mills and offers the perfect product for each application. The High Energy Ball Mill Emax and MM 500 were developed for grinding with the highest energy input. The innovative design of both, the mills and the grinding jars, allows for continuous grinding down to the nano range in the shortest amount of time - with only minor warming effects. These ball mills are also suitable for mechano chemistry. Mixer Mills grind and homogenize small sample volumes quickly and efficiently by impact and friction. These ball mills are suitable for dry, wet and cryogenic grinding as well as for cell disruption for DNA/RNA recovery. Planetary Ball Mills meet and exceed all requirements for fast and reproducible grinding to analytical fineness. They are used for the most demanding tasks in the laboratory, from routine sample processing to colloidal grinding and advanced materials development. The drum mill is a type of ball mill suitable for the fine grinding of large feed sizes and large sample volumes.