Professional Documents
Culture Documents
EDM
Ball Mill
Ball Mill
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HGRS Tikaria_Mill Workshop SEPT-07
What is a End Discharge Mill (EDM)?
Air outlet
2st Compartment
I t
Intermediate
di t diaphragm
di h (Fine Grinding)
1st Compartment
(Coarse Grinding)
Mill discharge
Drive
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HGRS Tikaria_Mill Workshop SEPT-07
EDM
EDM =
E d Discharge
End Di h Mill
Product discharge
at mill end
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HGRS Tikaria_Mill Workshop SEPT-07
Elements of Ball Mill - Overview
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HGRS Tikaria_Mill Workshop SEPT-07
Mill Drive Concepts
Drive Concepts for
Ball mills
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HGRS Tikaria_Mill Workshop SEPT-07
Example Planetary Gear Drive
Planetary gear reducer concept MAAG
Two gear stages with three planets
All shafts with friction bearings
Annulus
Pinions, planets surface-hardened
Annulus through-hardened Planets
Gear coupling
Key point::
Face load distribution of the
LS-gear stage
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HGRS Tikaria_Mill Workshop SEPT-07
Potential Technical Problems Drive
4 Dynamic behaviour
A lot of individual rotating masses
risk of resonance vicinities
5 6 7
Torsional/structural vibrations
Pinion shaft bending vibrations
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HGRS Tikaria_Mill Workshop SEPT-07
Gearboxes
Gear reducer
Polysius Combiflex
Planetary Gear
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HGRS Tikaria_Mill Workshop SEPT-07
Potential Damages Drives
Breakage damage (pinions)
Cause: Inadequate transverse
load distribution, brittle material
Fatigue breakage
I iti l d
Initial damage:
Pitting on the pitch line
Secondary damage:
Tooth breakage
g
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HGRS Tikaria_Mill Workshop SEPT-07
Potential Problems Drive
Single pinion drive (2’300 kW)
Breakage failure of the pinion in the
gear reducer
Heavy (active) pitting on the drive
pinion
Possible Cause: 1
- Inadequate load distribution (1)
- Overload of the tooth flanks (2)
2 1
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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
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Feed Arrangements for Ball Mills
(Slurry mill)
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HGRS Tikaria_Mill Workshop SEPT-07
Feed Arrangement (Example Step Feeder)
Material feed
Ventilation air
Advantages
Good mill ventilation
Easy
y to maintain
Simple design
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HGRS Tikaria_Mill Workshop SEPT-07
Elements of Ball Mill – Overview (Internals)
External
elements
Mill ffeed
d Mill Mill di
discharge
h Mill
arrangement Mill head Mill shell bearing arrangement drive
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HGRS Tikaria_Mill Workshop SEPT-07
Overview Internal Elements
A Coarse grinding
compartment
B Intermediate
diaphragm
C Fine grinding
compartment
D Discharge
diaphragm
E Grinding media
F Retention ring
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HGRS Tikaria_Mill Workshop SEPT-07
Liners for Coarse Grinding
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HGRS Tikaria_Mill Workshop SEPT-07
Lifting Height Requirements (1st Chamber)
This criteria has to be
confirmed case by case h0
through evaluation of the
coarse grinding.
Rule of thumb: h must be
greater than 50 [mm]
Rotation sense
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Head Liners
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Open Diaphragm (Drying Chamber Diaphragm)
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Intermediate Diaphragm
2nd Compartment
Fine Grinding
Intermediate diaphragm
1st Compartment
Coarse Grinding
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HGRS Tikaria_Mill Workshop SEPT-07
Function of Intermediate Diaphragm
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HGRS Tikaria_Mill Workshop SEPT-07
Intermediate diaphragm
Discharge diaphragm
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Discharge Diaphragm
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HGRS Tikaria_Mill Workshop SEPT-07
Material Quality and Application of Shell Liners
High
g chromium Most used material. Suitable
alloy cast 12 – 15% Cr 50 - 55 for big and small mills (Notch
impact strength 4 – 10 J/cm2)
liners
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HGRS Tikaria_Mill Workshop SEPT-07
Life Time of Shell Liners
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HGRS Tikaria_Mill Workshop SEPT-07
Grinding Media
Coarse grinding Ø 90 – 50 [mm]
A
A
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HGRS Tikaria_Mill Workshop SEPT-07
Ball filling degree (f)
98
93
Power [%]
85
Typical range
75
20 25 30 35 40 - 45 f [%]
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HGRS Tikaria_Mill Workshop SEPT-07
Steps of Grinding
Coarse
C Medium
M di Fine
Fi
Grinding Grinding Grinding
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HGRS Tikaria_Mill Workshop SEPT-07
Coarse Grinding: Parameters for Optimising
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HGRS Tikaria_Mill Workshop SEPT-07
Grinding Media
1.Compartment
Ø Ball [mm] Weight [ t ] Percent [%]
90 25.0 25.0
80 35 0
35.0 35 0
35.0
70 25.0 25.0
60 15.0 15.0
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HGRS Tikaria_Mill Workshop SEPT-07
Grinding Media (2nd Compartment)
Holcim Standard for OPC > 3’200 [cm2/g], closed circuit
system
2.Compartment
Ø 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
15
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HGRS Tikaria_Mill Workshop SEPT-07
Material Quality of Grinding Media
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HGRS Tikaria_Mill Workshop SEPT-07
Specific Wear Rates of Grinding Media
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HGRS Tikaria_Mill Workshop SEPT-07
Mill Efficiency
[%R] [cm2/g]
acc
acc. Chamber 1 Blaine
(coarse grinding) Blaine Value
Chamber 2
(fine grinding)
Sieve Residues
Li
Liner-Lifting
Lifti : l
low hi h
high
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HGRS Tikaria_Mill Workshop SEPT-07
Optimum Material Level 1st Chamber
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HGRS Tikaria_Mill Workshop SEPT-07
Optimum Material level 2nd chamber
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HGRS Tikaria_Mill Workshop SEPT-07
Mill Ventilation
H 2O
Hot gases
H 2O H2O
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HGRS Tikaria_Mill Workshop SEPT-07
Fine Grinding and Mill Cooling
PROBLEM SOLUTION
Insufficient
su c e t mill coo
cooling
g Adapted
p mill cooling,
g,
lead to material playing with:
agglomeration on balls Clinker temperature
and liners Mill ventilation
il i
The grinding is not any Water injection
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HGRS Tikaria_Mill Workshop SEPT-07
Water Injection Systems
130
counter
120
current
110
Air from
Air from co-current
blower 100
H2O blower H2O
co-current 90
(Double)
Rotary union 80
1st 2nd Comp.
Mill length
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HGRS Tikaria_Mill Workshop SEPT-07