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EDM
Ball Mill
Ball Mill
HGRS
Tikaria_Mill Workshop
SEPT-07
(Fine Grinding)
1st Compartment
(Coarse Grinding)
Mill feed arrangement
Mill discharge
Drive
HGRS
Tikaria_Mill Workshop
SEPT-07
EDM
EDM =
End Discharge Mill
Product discharge
at mill end
HGRS
Tikaria_Mill Workshop
SEPT-07
HGRS
Tikaria_Mill Workshop
SEPT-07
G i r t h g e a r u n i ts
C e n tr a l d r iv e s
S in g le p in io n c o n c e p t
( < 2 '5 0 0 k W )
S in g le d r iv e w ith
tw o p in io n s
( < 5 '0 0 0 k W )
T w o -w a y p o w e r s p littin g
re d u c er
( < 6 '0 0 0 k W )
D o u b l e - p i n io n c o n c e p t
( < 5 '0 0 0 k W )
D o u b le d r iv e w ith
fo u r p in io n s
(< 1 0 '0 0 0 k W )
P la n e ta r y g e a r r e d u c e r
(< 1 2 '0 0 0 k W )
HGRS
Tikaria_Mill Workshop
SEPT-07
Gear coupling
Drive arrangement
HGRS
Sun pinions
Tikaria_Mill Workshop
7
SEPT-07
HGRS
Tikaria_Mill Workshop
SEPT-07
1.
Axial/radial runout
2.
3.
4.
5.
6.
7.
Dynamic behaviour
Torsional/structural vibrations
HGRS
Tikaria_Mill Workshop
SEPT-07
Gearboxes
Gear reducer
Polysius Combiflex
Planetary Gear
HGRS
Tikaria_Mill Workshop
10
SEPT-07
Initial damage:
Pitting on the pitch line
Secondary damage:
Tooth breakage
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HGRS
Tikaria_Mill Workshop
SEPT-07
reducer
Heavy (active) pitting on the drive pinion
Possible Cause:
1
2
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HGRS
Tikaria_Mill Workshop
SEPT-07
Mill Bearing
Advantages slide shoe bearings:
No size and capacity limitation of the
mill
Simple design of wear plates
Far higher limit of gas temperature at
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HGRS
Tikaria_Mill Workshop
SEPT-07
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HGRS
Tikaria_Mill Workshop
SEPT-07
Ventilation air
Advantages
15
HGRS
Tikaria_Mill Workshop
SEPT-07
Head
liners
Mill head
Grinding Shell
liners
media
Mill shell
Intermediate
diaphragm
Mill
bearing
Retention
ring
Mill discharge
arrangement
Mill
drive
Discharge
diaphragm
Internal
elements
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HGRS
Tikaria_Mill Workshop
SEPT-07
Coarse grinding
compartment
Intermediate
diaphragm
Fine grinding
compartment
Discharge
diaphragm
Grinding media
Retention ring
17
HGRS
Tikaria_Mill Workshop
SEPT-07
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HGRS
Tikaria_Mill Workshop
SEPT-07
h0
h > 0.5 ho
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HGRS
Tikaria_Mill Workshop
SEPT-07
Rotation sense
20
HGRS
Tikaria_Mill Workshop
SEPT-07
Head Liners
21
HGRS
Tikaria_Mill Workshop
SEPT-07
22
HGRS
Tikaria_Mill Workshop
SEPT-07
Intermediate Diaphragm
2nd Compartment
Fine Grinding
Intermediate diaphragm
1st Compartment
Coarse Grinding
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HGRS
Tikaria_Mill Workshop
SEPT-07
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HGRS
Tikaria_Mill Workshop
SEPT-07
Intermediate diaphragm
HGRS
Tikaria_Mill Workshop
SEPT-07
Discharge diaphragm
Discharge diaphragm
26
HGRS
Tikaria_Mill Workshop
SEPT-07
Discharge Diaphragm
27
HGRS
Tikaria_Mill Workshop
SEPT-07
Chemical
Composition
12 14% Mn
2 3% Cr
12 15% Cr
Hardness Remarks
(HRC)
40
40 - 42
50 - 55
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HGRS
Tikaria_Mill Workshop
SEPT-07
29
HGRS
Tikaria_Mill Workshop
SEPT-07
Grinding Media
Coarse grinding 90 50 [mm]
HGRS
Tikaria_Mill Workshop
SEPT-07
HGRS
Tikaria_Mill Workshop
SEPT-07
Power [%]
98
93
85
Typical range
75
20
25
30
35
40 - 45
f [%]
32
HGRS
Tikaria_Mill Workshop
SEPT-07
Steps of Grinding
Coarse
Grinding
Medium
Grinding
Fine
Grinding
33
HGRS
Tikaria_Mill Workshop
SEPT-07
Efficiency parameters
Power parameters
Filling degree
Chamber length
Mill diameter
Liner design and condition
Mill speed
HGRS
Tikaria_Mill Workshop
SEPT-07
Grinding Media
4,4 [t/m3]
4,6 [t/m3]
4,7 [t/m3]
HGRS
Tikaria_Mill Workshop
SEPT-07
Weight [ t ]
Percent [%]
90
25.0
25.0
80
35.0
35.0
70
25.0
25.0
60
15.0
15.0
Total
100.0
100
[g]
1667
[m2 / t ]
10.2
HGRS
Tikaria_Mill Workshop
SEPT-07
system
2.Compartment
Ball [mm]
Weight [ t ]
Percent [%]
50
20.0
10.0
40
20.0
10.0
30
32.0
16.0
25
32.0
16.0
20
42.0
21.0
17
54.0
27.0
200.0
100
15
Total
Average ball weight
[g]
41
[m2 / t]
32.8
37
HGRS
Tikaria_Mill Workshop
SEPT-07
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HGRS
Tikaria_Mill Workshop
SEPT-07
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HGRS
Tikaria_Mill Workshop
SEPT-07
Mill Efficiency
[%R]
acc.
[cm2/g]
Blaine
Chamber 1
(coarse grinding)
Blaine Value
Chamber 2
(fine grinding)
Sieve Residues
[m]
HGRS
Tikaria_Mill Workshop
SEPT-07
Liner-Lifting :
low
high
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HGRS
Tikaria_Mill Workshop
SEPT-07
42
HGRS
Tikaria_Mill Workshop
SEPT-07
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HGRS
Tikaria_Mill Workshop
SEPT-07
Mill Ventilation
Material transport
Cooling
Removal of fines
Fluidisation of material
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HGRS
Tikaria_Mill Workshop
SEPT-07
Moist additive
Hot clinker
Cooling air
H 2O
Cooling air
Hot gases
Product
H 2O
H 2O
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HGRS
Tikaria_Mill Workshop
SEPT-07
SOLUTION
lead to material
agglomeration on balls
and liners
The grinding is not any
playing with:
Clinker temperature
Mill ventilation
Water injection
Use of grinding aid
(temporary solution
because expensive)
46
HGRS
Tikaria_Mill Workshop
SEPT-07
Product
temp. [C]
2nd Comp.
no water
injection
130
120
Air from
blower
Air from
blower
H2O
(Double)
Rotary union
110
H2O
co-current
1st
counter
current
100
co-current
90
80
2nd Comp.
Mill length
47
HGRS
Tikaria_Mill Workshop
SEPT-07