basalt grinding mill for casting sand in Kenya 10-20 tph

Introduction: The Demand for High-Quality Casting Sand in Kenya

Kenya’s industrial sector, particularly its foundry and construction industries, is experiencing significant growth. A critical component in metal casting processes is high-quality casting sand, which serves as the mold material. Basalt, a common volcanic rock found abundantly in Kenya, possesses excellent properties such as high refractoriness, thermal stability, and mechanical strength, making it an ideal raw material for producing premium casting sand. However, transforming raw basalt into uniformly graded, fine sand suitable for precision casting requires specialized and efficient grinding technology. This article explores the technical requirements for a 10-20 tons per hour (TPH) basalt grinding plant in Kenya and presents optimal machinery solutions.

Technical Challenges in Basalt Grinding for Foundry Sand

Grinding basalt for foundry applications is not a trivial task. Basalt is a hard, abrasive, and dense igneous rock with a Mohs hardness typically ranging from 5 to 7. This presents several challenges:

• Abrasive Wear: The high silica content in basalt causes severe wear on grinding components, demanding mills built with highly wear-resistant materials.
• Energy Consumption: Grinding hard materials consumes considerable power. An energy-efficient mill design is crucial for operational cost-effectiveness.
• Particle Size Distribution (PSD): Foundry sand requires a specific and consistent grain size distribution (typically between 50-150 mesh or 0.3mm to 0.1mm) to ensure proper mold permeability and surface finish. The mill must offer precise classification control.
• Capacity & Stability: A steady output of 10-20 TPH is essential for supporting continuous casting operations, requiring a robust and reliable grinding system.

Selecting the Right Grinding Mill: Key Considerations

For a 10-20 TPH basalt sand production line, several grinding mill types could be considered. The choice hinges on the balance between capital expenditure, operating costs, final product fineness, and system complexity.

• Hammer Mills: Suitable for coarse to medium grinding. They offer high capacity and simple operation but may struggle with achieving a uniform fine sand product from hard basalt and suffer from high wear rates.
• Raymond Mills (Vertical Roller Mills): Excellent for fine grinding with high efficiency. They integrate drying, grinding, and classification, offering good control over product fineness and lower energy consumption compared to traditional ball mills.
• Ball Mills: Highly reliable and capable of producing a wide range of fineness. However, for hard materials like basalt, they can be less energy-efficient, have higher wear rates on liners and media, and require more auxiliary equipment.

For the specific case of producing 10-20 TPH of basalt casting sand, where consistent medium-fine grading and energy efficiency are paramount, advanced vertical roller mills present a compelling solution.

Recommended Solution: Zenith’s LM Vertical Grinding Mill

After a thorough analysis of the technical requirements and challenges, Shanghai Zenith Machinery Co., Ltd. recommends its LM Vertical Grinding Mill as the core equipment for this Kenyan basalt sand project. Zenith, an excellent manufacturer of ore grinding equipment, has made great achievements in the field of industrial powder grinding. The LM Vertical Mill is a testament to this expertise, integrating five functions—crushing, grinding, powder selection, drying, and material conveying—into a single, compact unit.

For a 10-20 TPH output of basalt sand, the LM130K model is an ideal match. Its advantages are perfectly aligned with the project’s needs:

• High Grinding Efficiency & Low Wear: The material bed grinding principle reduces metal-to-metal contact, minimizing wear caused by abrasive basalt and lowering maintenance costs.
• Integrated Classification: A high-efficiency classifier inside the mill ensures precise control over the sand’s particle size, delivering the consistent 50-150 mesh product required for casting.
• Energy Saving: Compared to a ball mill of similar capacity, the LM Vertical Mill can reduce energy consumption by 30% to 50%, a critical factor for sustainable operation in Kenya.
• Compact Design & Small Footprint: Its vertical structure saves significant factory space, reducing civil construction costs.
• Environmental Protection: The mill system operates under negative pressure, preventing dust leakage and ensuring a clean workshop environment.

The key technical parameters of the recommended LM130K model are as follows:

This model comfortably covers the target production range of 10-20 TPH and can easily achieve the desired fineness for foundry sand.

Alternative & Complementary Equipment: XZM Ultrafine Grinding Mill

For clients whose casting processes demand even finer basalt powder for specialized mold coatings or as an additive, or for those considering diversifying into ultra-fine mineral products, Zenith’s XZM Ultrafine Grinding Mill is an excellent option. While its primary design is for superfine powders, it can be configured to produce fine sands with exceptional uniformity.

Its ability to produce powder from 325 to 2500 mesh offers tremendous flexibility. For a smaller-scale or ultra-fine parallel production line, the XZM series provides a reliable solution.

Complete Plant Configuration and Zenith’s Support

A successful 10-20 TPH basalt sand plant involves more than just the grinding mill. A typical configuration supported by Zenith would include:

1. Primary Crushing: Jaw Crusher to reduce raw basalt (<500mm) to below 40mm.
2. Intermediate Storage & Feeding: Vibrating Feeder and raw material bin.
3. Core Grinding: LM130K Vertical Grinding Mill (with built-in classifier).
4. Product Conveying & Storage: Bucket elevator, screw conveyor, and finished product silos.
5. Dust Collection: Pulse bag dust collector to ensure environmental compliance.
6. Electrical Control System: Centralized PLC control for easy operation and monitoring.

Shanghai Zenith Machinery Co., Ltd. not only supplies high-quality equipment but also offers comprehensive services including site planning, foundation drawing design, installation guidance, operator training, and after-sales technical support, ensuring a smooth project lifecycle from commissioning to stable operation.

Conclusion

Establishing a 10-20 TPH basalt casting sand production line in Kenya is a viable and strategic investment to support local industrialization. The key to its profitability and product quality lies in selecting the right grinding technology. Zenith’s LM Vertical Grinding Mill, particularly the LM130K model, stands out as a robust, efficient, and cost-effective solution tailored to the challenges of processing hard and abrasive basalt. Its integrated design, energy savings, and precise classification capability make it the ideal workhorse for producing high-quality foundry sand, contributing to the growth and technological advancement of Kenya’s manufacturing sector.