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We have a 4x16 ceramic lined ball mill and we are milling precipitated calcium carbonate. We are trying to to get to a gradation of D50: 3 micron and D90: 8 micron, however we are having trouble getting the gradation down. Currently we are at a D50 of 5.5 micron and D90 of ~15 micron. We are using grinding aid and running the mill at 28 rpm. Our air classifier's rotor is running at 2200 rpm. We are also only getting approximately 100 lbs an hour, when our mill manufacturer said our mill has the capability of 3,000 lbs per hour.
The two main issues we are struggling with are getting the gradation down in size AND the amount of output we are getting. Does anyone have any suggestions for us on these issues?
We also believe we have an issue with static causing our air classifier to miss the smaller particles since they are clumping. We are going to try pumping ionized air into our mill to help with this issue, does anyone have any experience with this?