Professional Documents
Culture Documents
on Mill Diaphragms
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TABLE OF CONTENT:
- Introduction
- Conclusion
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Latest Technology on Mill Diaphragms
INTRODUCTION
Grinding of raw materials to produce clinker and the finish grinding of clinker
with additives to produce cement is still one of the main energy consuming
steps in the production process of the cement plants. About 65 % of the total
energy used by a cement plant is consumed by the different grinding
facilities. Hence, the optimisation of grinding plants related to their
performance and specific energy consumption is very important for the end-
user.
With the optimisation of ball mills, the valuation and regulation of the material
transport through the mill is of great importance. On the one hand, the
material-to-be-ground shall remain long enough in the grinding compartment
to achieve the specified product fineness at the mill discharge and on the
other hand, over-grinding is not wanted, i.e. increased retention time.
For this purpose, the intermediate diaphragm of the ball mill has to fulfil a
central task:
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Latest Technology on Mill Diaphragms
For more than 75 years Christian Pfeiffer is now producing diaphragms and
the company has gained comprehensive experiences with their production
and utilisation. Totally more than 5,000 diaphragms have been sold mainly
for applications in the cement industry.
The present paper gives an overview about the most modern innovations for
intermediate diaphragms.
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Latest Technology on Mill Diaphragms
- width of diaphragm
- slot width and slot shape
- adaptation to specific filling degree
- adaptation of open surface area for optimising mill ventilation
- flow control for optimised material transport
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Latest Technology on Mill Diaphragms
The slotted plates on the side facing the 1st grinding compartment must
therefore be wear resistant and breakage-proof, and the slots should remain
free from clogging by material and grinding media even after long mill
operating periods.
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Latest Technology on Mill Diaphragms
The diaphragm support structure on the side facing 1st grinding compartment
consists of the plate cross. Seated inside the diaphragm is equipped with
curved lifters inclined in the direction of material transport.
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Latest Technology on Mill Diaphragms
The outer fastening ring which forms the contact with the mill tube takes the
thermal stresses and those caused by ovality and movement of the mill tube
as well as the forces exerted by the
grinding media charge. This fastening
ring is turned to produce a smooth
seating surface against the mill tube. At
the bolted connections to the mill tube
the ring has rectangular openings which
take the holding plates which make up
the actual connection to the mill tube,
the so-called “floating fixation”.
The holding plates are bolted to the mill tube and have a certain amount of
clearance in relation to the corresponding openings in the retaining ring. This
means that the intermediate diaphragm can move easily in relation to the mill
tube, which compensates the coming-up forces. In contrast to diaphragms
which are fixed rigidly to the mill tube by bolted connections this type of
fixation allows a reliable movement between the diaphragm and the mill tube
itself. Flexing as well as thermal and mechanical stress which have their
source in the mill tube, are not transferred to the diaphragm. Thus, fixation of
the diaphragm plates on the support structure is risk less, bolt and plate
breakage does not occur.
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Latest Technology on Mill Diaphragms
At the centre opening of the diaphragm, a larger or smaller angle ring is used
depending on the filling ratio of the corresponding grinding compartment. In
this way it is possible, in combination with the inner wear plates, to adapt the
intermediate diaphragm to suit a wide range of filling ratios for different
grinding applications. The maximum central opening can be set in each case.
Classical material flow control systems collect the ground cement from the
first compartment through the slots of
the diaphragm plates and discharge
them by different technical solutions into
the centre of the diaphragm. The
disadvantage of all solutions known so
far is the fact that the material is directly
affected by the air flow through the
centre screen. As a result, the material
is usually “blown” too far into the 2nd
grinding compartment so that a
significant part of the effective grinding length is lost.
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Latest Technology on Mill Diaphragms
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Latest Technology on Mill Diaphragms
Diaphragm plates
The plates over an intermediate diaphragm
are subdivided into different plate rings
which are dimensioned to suit the filling ratio
and the position of the main wear zone. The
diaphragm support structure has additional
holes for the diaphragm plates so that the
plate distribution can be altered at any time
if there is a change in operating conditions.
In this way the main wear zone can be
limited to only one, or at maximum two,
plate rings. The sizes of the individual
diaphragm
backside plates
and slotted plates are selected so that they are
still easy to handle during installation and
dismantling.
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Latest Technology on Mill Diaphragms
It is clear that the retaining system using a conical bolt swage offers great
advantages. With cylindrical bolt swages the plates
must be changed at a residual thickness of 15 mm,
but with a retaining system using conical bolt
swages the plate can be used down to a residual
thickness of 8 mm or less.
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Latest Technology on Mill Diaphragms
The CPB diaphragm plates are made of highly wear and breakage resistant
rolled steel material which is solely manufactured by well-known steel
producers acc. to the specification given by Christian Pfeiffer.
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Latest Technology on Mill Diaphragms
MILL VENTILATION
In cement grinding the mill ventilation system fulfils two important functions:
- Cooling the cement and removing the heat generated during the
grinding process.
- Carrying part of the finished product out of the grinding area.
It is well known that the energy used during the grinding process in ball mills
is almost entirely converted into heat.
Adequate mill ventilation occurs at air velocities between 1.2 and 1.5 m/s in
the free cross-section of the mill. Typical ventilation data for the intermediate
diaphragms are given in the schematic sketch.
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Latest Technology on Mill Diaphragms
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Latest Technology on Mill Diaphragms
The main purpose of such a mill tube inspection is the elimination of obvious
bottle necks which may hinder a proper performance of the mill.
- mill main fan and filter have to be checked and, if necessary, adapted
to the new conditions
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Latest Technology on Mill Diaphragms
CONCLUSION
Modern grinding technology with tube mills requires new and tailor-made
diaphragms. According to the specific process requirements of the grinding
plant each diaphragm is especially designed for the particular tube mill:
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