Two-compartment, single-compartment, air-swept and shell-supported designs, with liners, diaphragms, slide rings, slide shoes, geared drives and on-site maintenance support.
Polysius ball mills are configured by project for material, feed, grinding circuit, support and drive. Current website and manufacturer brochures do not publish a uniform model-size table. This page lists traceable designs and performance without inventing models or diameters.
The current website confirms continued product supply; structural and drive data come from the 2018 manufacturer brochure. Where no uniform model code is published, only configurations and traceable parameters are listed.
| Published type / configuration | Structure and application | الأبعاد الرئيسية / parameters | System interfaces | Product status |
|---|---|---|---|---|
| Two-compartment closed-circuit ball mill | Coarse grinding in the first compartment, fine grinding in the second; the intermediate diaphragm regulates material flow | Published maximum first-compartment ball diameter 100 mm | Can form a closed circuit with a sepol® high-efficiency separator | Current website and 2018 manufacturer brochure |
| Single-compartment ball mill | For finer feed; may serve as the second grinding stage after pregrinding | Mechanical discharge through the discharge diaphragm | Can form a combined grinding system with a polycom® high-pressure grinding roll | 2018 manufacturer brochure |
| Air-swept mill | Single-compartment design for moist materials requiring drying with low-temperature gas | Pneumatic discharge directly to an air-swept separator | For coal or petroleum coke when fitted with the appropriate explosion-protection system | 2018 manufacturer brochure |
| Shell-supported ball mill | Shell supported by slide rings, slide-shoe bearings and hydraulic lifting | Each bearing group uses 2, 4 or 6 slide shoes according to mill size | Hydrostatic or hydrodynamic shoe lubrication according to load | 2018 manufacturer brochure |
| COMBIFLEX® drive | High-power mill drive with floating shafts and hardened gears | Published maximum 8,000 kW single drive; 16,000 kW dual drive | Girth gear and slide ring/shoes occupy one compact housing area | 2018 manufacturer brochure |
| Direct geared drive | Girth-gear/pinion drive for lower-power mills | No uniform power or diameter model table in the public brochure | Check girth gear, pinion, bearings, couplings and alignment as a set | 2018 manufacturer brochure |
Before manufacture, confirm full nameplate, serial number, shell diameter and length, compartments, support, drive power, gear data, liner layout, diaphragms, drawing numbers and revisions.
First-compartment impact, second-compartment fine grinding, diaphragm flow and feed/discharge erosion produce different failures. Confirm materials, profiles, slots and manufacture separately by position.
First-Compartment Lifting / Activator Liner
Works with large balls to provide lift and impact. Confirm profile, lifting angle, segments, thickness, holes, bolts and rotation against the shell liner layout.
Material selection: Faces impact, abrasion and cyclic loads. Candidate alloy steel, chromium-molybdenum wear steel or composite liners require checks against ball size, speed, material and current-part failures.
View the common part page →Second-Compartment Classifying Liner
Classifies smaller grinding media along the mill for fine grinding. Confirm profile, classification direction, holes, segments, wear allowance and diaphragm interfaces against installation drawings.
Material selection: Continuous abrasion, fatigue and stable classification govern selection. First-compartment high-lift profiles and materials cannot simply be transferred here.
Submit second-compartment liner drawings →
Intermediate Diaphragm & Wear Plate
Separates coarse and fine grinding compartments and regulates throughput. Confirm frame, slots, centre opening, wear plates, scoops, fastening and media filling against the diaphragm assembly drawing.
Material selection: According to diapol 2.0 information, slotted and backwall plates may use through-hardened rolled steel plate or high-chromium iron where service requires. Check frames and fasteners separately.
Submit diaphragm assembly drawings →
Discharge Diaphragm / Central Grate
Provides mechanical discharge and controls outlet passages. Confirm slots, free area, centre opening, thickness, sectors, flow and discharge-device interfaces against installation drawings.
Material selection: Balance slot stability, blockage resistance, media impact and wear. Confirm plate material, hardness and toughness together with slot geometry.
View the common part page →
polalloy Slotted & Backwall Plate
Diaphragm slotted and backwall plates. Published manufacturer data specify 50 mm thickness and 58 HRC hardness, with slot shape adapted to service. Schedule replacement at 8–10 mm remaining thickness.
Material selection: A through-hardened plate route emphasizing hardness through thickness, wear resistance and fracture resistance. Published properties cannot be assigned directly to plates from other sources or grades.
Submit slotted-plate dimensions and conditions →
Diaphragm Lifter Scoop & Head
Transfer material through the diaphragm to the next compartment and regulate flow. Confirm fixed/adjustable design, orientation, count, opening, connections and media clearance against diapol or installation drawings.
Material selection: Abrasion, media impact and repeated loads act together. Determine scoop, head and fastening materials and replacement intervals separately.
Submit scoop and diaphragm records →
Feed-End & End-Wall Liner
Protect the straight inlet end wall, inlet cone and adjacent shell. Confirm contours, holes, segments, overlaps, feed-chute clearance and left/right position against end-assembly drawings.
Material selection: Impact, abrasion and local flow differ from the middle of the shell. Confirm material, thickness and fastening-zone toughness by position.
View the common part page →
Feed & بطانة قناة التفريغ
Protect chutes, drop points and turns in dusty material flow. Confirm curvature, segments, holes, overlaps, flow, maintenance space and mill-end clearance against chute drawings.
Material selection: Select wear plate, wear alloys or composite linings against size, speed, impact angle, temperature and sticking. Hardness alone is insufficient for substitution.
View the common part page →Check structural and drive spares individually by support type, power, interfaces, loads, material, heat treatment, flaw detection, accuracy, lubrication and alignment.
Mill Shell & Connection Flange
Carry liners, media and material while transmitting torque. Confirm diameter, length, thickness, welds, flanges, holes, roundness, runout and installation datums against general arrangements.
Material selection: A large load-bearing welded structure. Plate, consumables, heat treatment, weld examination, dimensions and residual-stress control must follow original drawings and manufacturing specifications.
View the common part page →
Mill Head, End Wall & Inlet Cone
Connect shell, feed/discharge and support areas. Shell-supported designs use straight end walls and short inlet cones. Confirm contours, holes, flanges, welds and rotating/stationary seal interfaces against installation drawings.
Material selection: Select steel and manufacture against structural loads, weldability, fatigue and dimensional stability; apply nondestructive examination to highly stressed transitions, flanges and welds.
View the common part page →Slide Ring, Sliding Shoe & Bearing Assembly
Shell-supported mills carry loads through slide rings and 2, 4 or 6 shoes per group. Confirm ring diameter, width, roundness, shoe count, oil clearance, load and hot alignment against bearing assembly drawings.
Material selection: Check ring working surfaces, shoe lining and lubrication as one friction pair. Base, surface condition, bearing alloy, oil film and cooling cannot be substituted independently.
Open the shared bearing and bushing page →Bearing-Shoe Hydraulic Lifting Cylinder
Below the shoes, lift and position the shell and provide controlled support during individual-shoe replacement. Confirm bore, stroke, pressure, mounting distance, synchronization and safety locking against hydraulic drawings.
Material selection: Confirm cylinder barrels, rods, pins and seals separately against static load, synchronized lifting, side load, surface treatment, pressure and oil.
Submit hydraulic lifting-system records →
Girth Gear, ترس صغير & Direct Drive
Lower-power mills transmit torque through girth gear and pinion. Check module, tooth count, pressure angle, face width, helix, sectors, centre distance, bearings, couplings and contact pattern as a pair.
Material selection: Select girth-gear and pinion materials separately for bending/contact fatigue, core toughness, surface hardening, dimensions and nondestructive examination. Do not copy an isolated part.
Open the shared gear and pinion page →COMBIFLEX® Gear Unit & Floating Shaft
For high-power mills, with published maximum 8,000 kW single-drive and 16,000 kW dual-drive ratings. Confirm input/output shafts, floating shafts, hardened gears, couplings and lubrication against nameplate and general arrangement.
Material selection: Check heavy-duty gears, shafts and couplings as a set for torque, speed, load spectrum, surface/core properties, accuracy, dynamic balance, nondestructive examination and oil.
Open the shared heavy-duty drive page →
Bearing Lubrication, الموانع & Oil-System Parts
Provide hydrostatic/hydrodynamic films, filtration, cooling and sealing for shoes or trunnion bearings. Confirm pumps, valves, lines, nozzles, seals, pressure, flow, temperature and interlocks against lubrication diagrams.
Material selection: Bearing material, seals, filtration and oil jointly determine film reliability. Elastomer or engineering-plastic seals must match temperature, oil, journal and shaft movement.
Open the shared bearing and bushing page →Only the polgrind® mobile grinding and measuring system specifically documented by Polysius for shell-supported ball mill slide rings is shown.
polgrind® Mobile Slide-Ring Grinding Tool
Manufacturer mobile tools for shell-supported mill slide rings use abrasive belts of different grit sizes to repair uneven, damaged or rough surfaces, limiting disassembly and restoring smooth operation.
Material selection: A dedicated on-site machining system for mill slide rings. Confirm mounting, stock removal, abrasive-belt path, drive, guarding and working space against ring dimensions, damage and shutdown plan.
Submit slide-ring dimensions and damage records →
Slide-Ring Roundness Measurement & Documentation
Before and after polgrind® work, record ring roundness, lifting values and oil temperature to confirm machining datums, grinding results and bearing condition.
Material selection: This is supporting inspection for on-site maintenance, not a generic gauge offering. Measurement points, datums, limits and report format must follow the specific mill and maintenance plan.
Submit slide-ring inspection and repair scope →The current website and brochure configure mills by project, material, compartments, support and drive without a uniform model-size table. Manufacture requires nameplate, serial number, general arrangement and part drawings.
Not by default. The first compartment emphasizes large-ball impact and lift, the second fine grinding and classification, while diaphragms control slots, flow and pressure drop. Confirm profiles, materials and fastening separately.
No. Check the mating gear, module, tooth count, pressure angle, helix, centre distance, sectors, bearings, couplings, lubrication, alignment, material and heat treatment together.
Provide nameplate, serial number, shell dimensions, compartments, supports, drive power, drawing numbers, liner layout, diaphragms, used-part photos, material and conditions for identification, material assessment, manufacture, quality control and delivery.
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