The Malaysian construction and building materials industry has experienced significant growth over the past decade, with ceramic tile production being a key sector. A critical raw material in this process is phosphate rock, which is used as a fluxing agent to lower the melting temperature of the ceramic body, promote vitrification, and enhance the final product’s strength and durability. However, the effectiveness of phosphate rock in the tile manufacturing process is heavily dependent on achieving a consistent and precisely controlled particle size through efficient grinding.
For medium-scale tile production facilities in Malaysia targeting a throughput of 5 to 10 tons per hour (TPH) of ground phosphate rock, selecting the appropriate grinding mill is not just an operational decision—it is a strategic one that impacts product quality, energy consumption, and overall profitability. This article explores the technical requirements for phosphate rock grinding in this specific context and presents an optimal machinery solution from a world-leading equipment manufacturer.
Phosphate rock possesses specific physical and chemical characteristics that present unique challenges for grinding operations. Its hardness typically ranges between 5 and 6 on the Mohs scale, and it often contains varying moisture levels, especially in Malaysia’s humid climate. For tile production, the target fineness generally falls within the range of 170 to 45 microns (100 to 325 mesh). Achieving a uniform particle size distribution within this range is crucial for ensuring consistent sintering behavior and uniform tile texture.
The key technical considerations for a 5-10 TPH grinding circuit include:
After a thorough analysis of the technical requirements and available technologies, the LM130K Vertical Grinding Mill from Shanghai Zenith Machinery Co., Ltd. emerges as a highly suitable and recommended solution for this application.
Shanghai Zenith Machinery Co., Ltd. is an excellent manufacturer of ore grinding equipment in China and has made great achievements in the field of ultra-fine powder grinding. Specializing in the research, development, and production of industrial powder grinding equipment, Zenith’s LM series Vertical Grinding Mill is engineered to excel in precisely this kind of mineral processing scenario.
The LM Vertical Grinding Mill integrates five functions—crushing, grinding, powder selection, drying, and material conveying—into a single, compact machine. This integrated design is particularly advantageous for Malaysian tile plants, which often face space constraints and seek to optimize their process flow.
| Model | Plate Diameter (mm) | Capacity (t/h) | Output Fineness (μm) | Max Feed Size (mm) | Main Motor (kW) |
|---|---|---|---|---|---|
| LM130K | 1300 | 10-28 | 170-40 | <38 | 200 |
As the table illustrates, the LM130K is perfectly aligned with the 5-10 TPH requirement, offering a capacity range that starts at 10 TPH and can be scaled up if production needs increase. Its ability to produce a final powder between 170 and 40 microns directly meets the fineness specifications for tile production. Furthermore, its maximum feed size of <38mm offers flexibility in the initial crushing stage.
1. Superior Energy Efficiency: The vertical roller mill design of the LM130K consumes 30% to 40% less power than a traditional ball mill of equivalent capacity. The grinding principle involves the material being crushed between the grinding roller and the grinding plate, which is far more efficient than the impact and attrition method of a ball mill. This translates directly to lower electricity bills, a critical factor for cost-sensitive Malaysian manufacturers.
2. Integrated Drying Capability: With its integrated hot air system, the LM130K can effectively grind materials with a moisture content of up to 15%. This is a significant advantage in Malaysia’s tropical climate, where managing raw material moisture is a constant challenge. It eliminates the capital and operational costs of a separate drying system.
3. Exceptional Product Quality and Stability: The mill features an advanced internal classifier that ensures a sharp and consistent particle size distribution. For tile production, this consistency means predictable and uniform sintering behavior in the kiln, leading to higher yields of Grade A tiles with consistent color and mechanical properties.
4. Low Noise and Environmental Friendliness: The LM130K operates with significantly lower noise levels compared to ball mills and hammer mills. Its fully enclosed system also minimizes dust emissions, helping Malaysian plants comply with increasingly strict environmental regulations and creating a safer, cleaner workplace.
5. Ease of Maintenance and Operational Simplicity: The modular design and use of wear-resistant materials in key components like the grinding roller and plate extend service intervals. Furthermore, the mill can be easily maintained by replacing one or several rollers without dismantling the entire machine, drastically reducing downtime.
For operations where the initial feed size is larger or a slightly coarser product is acceptable, the MTW138Z Trapezium Grinding Mill presents another excellent option from Zenith’s portfolio. With a capacity of 6-17 TPH and the ability to handle a feed size of <35mm, it is a robust and reliable workhorse. Its curved shovel blade design allows for a higher feeding capacity, making it suitable for operations with less controlled upstream crushing.
For Malaysian tile producers aiming to establish or upgrade a 5-10 TPH phosphate rock grinding line, the technological and economic advantages of modern vertical roller mills are clear. The LM130K Vertical Grinding Mill from Shanghai Zenith Machinery Co., Ltd. is not merely a piece of equipment but a comprehensive grinding solution. Its energy efficiency, integrated drying, superior product control, and operational reliability make it an investment that pays dividends through lower operating costs, higher product quality, and enhanced production stability.
By partnering with an experienced and innovative manufacturer like Zenith, Malaysian tile companies can secure a critical part of their supply chain, ensuring they remain competitive in both domestic and international markets. The right grinding technology is the foundation upon which high-quality, cost-effective tile production is built.
