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CEMTEC – Cement and Mining Technology GmbH, A-4470 Enns S. Pellissetti www.cemtec.at , s.pellissetti@cemtec.at. Mechanical aspects of grinding mills CIM Exhibition 2011, May 22 to 24, Montreal. Introduction Company figures Overview about various mill types

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slide1

CEMTEC – Cementand Mining Technology GmbH, A-4470 Enns

S. Pellissetti

www.cemtec.at, s.pellissetti@cemtec.at

mechanical aspects of grinding mills cim exhibition 2011 may 22 to 24 montreal
MechanicalaspectsofgrindingmillsCIM Exhibition 2011, May 22 to 24, Montreal
  • Introduction
  • Company figures
  • Overviewaboutvariousmilltypes
  • Mechanicalaspectsof modern grinding ball millsandpelletizingdiscs
  • Mill design / FE-Simulations
  • Electric & Automation
  • Highlights 2009 / 2010
  • R&D activities
company structure
Company Structure

Order intake

2008: 56 Mio €

2009: 47 Mio €

Turnover

2008: 56 Mio €

2009: 49 Mio €

Staff

2008: 75

2009: 80

R&D Invest

2008: 1,05 Mio €

2009: 1,27 Mio €

Austria -Europe

CPI

Shanghai Machinery Co., Ltd.

Puerto Ordaz - Venezuela

Madrid - Spain

cemtec s value chain
Cemtec‘s Value Chain

Engineering

Manu-facture

Inst. Comm.

After Sales

PM

R&D

  • Coordination
  • Controlling
  • Purchasing
  • Product

to be processed

  • Process
  • Equipment
  • Design
  • Process
  • Equipment
  • HW / SW
  • Manufacture
  • Assembly
  • Transport
  • On Site
  • Installation
  • Supervision
  • Commissioning
  • Ramp-up / Prod. Supp.
  • Spare Parts Man.
  • Maintenance

Turnkey Plants

Equipment

core business
Core Business

Turnkey projects

Tube mill / Vertical mill / AG & SAG mill

wet & dry applications

Separators

Dryers

Pelletizing

Spare parts

diversified industries
Diversified Industries

Cement

Mining

Building Materials

Waste / Recycling

Filling

(paper, glas, paint, plastic, etc. )

Energy

FGD / Desulfurisation

references market position
References / marketposition
  • References (tubegrindingmills)
  • NUMBER OF SOLD MILLS
    • Total 263 pcs.
    • Cementindustry 65 pcs.
  • TOTAL INSTALLED GRINDING POWER
    • Total 382 MW
    • Cementindustry 256 MW
  • TOP MILL SIZE
    • Total  9,75 x 4,27 m
    • Cementindustry 5,2 x 16,75 m
slide9

Mechanical aspects of grinding millsCIM Exhibition 2011, May 22 to 24, Montreal

  • Introduction
  • Company figures
  • Overviewaboutvariousmilltypes
  • Mechanicalaspectsof modern grinding ball millsandpelletizingdiscs
  • Mill design / FE-Simulations
  • Electric & Automation
  • Highlights 2009 / 2010
  • R&D activities
slide10

Overviewofvariousmilltypes

  • Semi-Autogenousmill(SAG)
  • Autogenousmill (AG)
  • Low L/D proportion
  • Grinding material grinds itself
  • Pre-Grinding applications
  • High capacity / productivity
  • Process senitive against feed input variations
  • L/D proportion is small( up to 7m)
  • Wet or dry grinding
  • Pre-grinding
  • Grinding media: mill feed + 12-14% balls
  • Feeding grain size up to 400mm
  • Higher productivity than AG-Mills
  • Less sensitive concerning fluctuations of feeding material than AG-Mills
slide11

Overviewofvariousmilltypes

  • AG and SAG millsfor Mining industry
  • Limestone semi- autogeneosmillØ 6.7 x 3m100 tph
  • OMYA / Austria
slide12

Overviewofvariousmilltypes

  • Ball millwith 1 chamber (wetgrinding)
  • Semi-Autogenmühlen
  • Overflow-discharge
  • L/D-proportionishigh
  • Wetgrinding (pulp)
  • simple design andhandling
  • Openedandclosed (common) circuit
  • Fine grinding (dangerofovergrinding)
  • Fillingdegreeofgrindingmedia: 30 - 45%
  • Mill lining: rubber
  • Grindingmedia: steek(ball fill = 4.5-4.85 t/m³)
  • L/D-proportion is high
  • Wet or dry grinding
  • More complicated discharge (selection of slot width !)
  • Open & closed (common) circuit
  • Danger of over grinding, lower grinding media filling degree: approx. 30%
  • Mill lining: mostly steel
  • Dischargediaphragm
slide13

Overviewofvariousmilltypes

  • Wetgrinding ball millforlimestonegrindingwithin FGD plants (FGD – Fluent Gas Desulfurization)
  • Limestonewetgrindingmill (FGD)Ø 2.4 x 4.5m11 tph
  • SCBMC / Shanghai
slide14

Overviewofvariousmilltypes

  • Ball millwith 2 chambers (Cementgrinding)
  • L/D-proportionishigher
  • Common in cementindustry
  • Drygrinding
  • Process in closedcircuit
  • Big crushingrange: outletgrainsize P80:  40mm => 25-40µm
  • Fine grinding
  • Grinding media fillingdegree: between 28 and 30%
  • Complexmillinternals
  • Milllining: steel
  • Typical ball composition: chamber I: 100 – 60 mm; chamberII: 60 – 12 mm
slide15

Overviewofvariousmilltypes

  • Ball millsforCementindustry
  • RawmealmillØ 4.2 x 10m , 170 tphCementizillo / Italy
slide16

Overviewofvariousmilltypes

  • Rod mill (Mining)
  • PeripheryDischarge at mill end
  • Peripherydischarge at middle of mill
  • Overflow-discharge
  • Wet grinding
  • Pre-grinding up to 200 t/h
  • For very fine grinding material
  • For very raw grinding material in opened circuit
  • smooth particle size distribution
  • usuallydrygrinding
  • Pre-grindingwith high productivity
  • For specialapplications
  • Discharge on end => fine product
  • Centre discharge =>coarseproduct
  • Smoothparticlesizedistribution
slide17

Overviewofvariousmilltypes

  • Rod mill
  • ROD millforwet AlO2-grinding Ø 4.2 x 6m, 270 tph

Aluminium Stade/Germany

slide18

MechanicalaspectsofgrindingmillsCIM Exhibition 2011, May 22 to 24, Montreal

  • Introduction
  • Company figures
  • Overviewaboutvariousmilltypes
  • Mechanicalaspects of modern grinding ball millsandpelletizingdiscs
  • Mill design / FE-Simulations
  • Electric & Automation
  • Highlights 2009 / 2010
  • R&D activities
slide19

Mechanicalfeaturesof modern grindingmills

  • Components of a grindingmill (Overview)

2

1

  • Main bearing
  • Millshell
  • Main drive
  • Girthgearlubrication
  • Main motor
  • Millinlet(feed material)
  • Milloutlet(discharge box)
  • Millinternals
  • Waterinjection

7

6

9

5

3

8

4

drive station ag mill 22 x 10 2 for information only
Drive Station - AG-Mill 22´ x 10,2´forinformationonly

GearRim

Main Gear Box

Coupling

Main Motor

Pinion Station

Elastic Coupling

Inching Drive

inching drive ag mill 22 x 10 2 for information only
Inching Drive - AG-Mill 22´ x 10,2´forinformationonly

Elastic Couplings

Auxilary Gear Box

Motor withbrake

Fluid Coupling

Double Brake

slide47

PelletizingdiscsTechnical data

  • Disc type PTD-750-80
  • Nominal design capacity 185 t/ph
  • Max. feeding material 20 mm
  • Moisturecontent 8-9 %
  • Adjustablediscspeed 5-11 rpm
  • Disc diameter 7.500 mm
  • Disc depth (adjustablemanual) 700-900 mm
  • Disc slope (adjustable) 45-53 °
  • Directionofroationboth
  • Lubricationsystemcentralized / spraying
  • Main drivespeednom. 1500 rpm
  • Installedmaindrive power 230 kw
  • Lining material UHMW-PE
  • Total weightofdiscapp. 48 to
slide50

Typicaldriveconcept

4

1

2

5

5

3

1……….Main motor

2……….Gear box

3……….V-belts

4……….Main coupling

5……….Belt pulley´s

slide51

Typicalscheme – lub. system

Preliminary

Preliminary

slide53

Slope / inclinationdrive

-level switch

-screw jack

-slope motor

-connection point

-spindle

-level switch

slide54

Scraperunit

rim scraper

bottom scraper

side scraper

lead plate

slide55

Watersprayingsystem

Tangential-flow hollow

cone nozzles

-Uniform hollow cone

spray pattern

-Flow rate adjustable

slide60

Mechanical aspects of grinding millsCIM Exhibition 2011, May 22 to 24, Montreal

  • Introduction
  • Company figures
  • Overviewaboutvariousmilltypes
  • Mechanicalaspectsof modern grinding ball millsandpelletizingdiscs
  • Mill design / FE-Simulations
  • Electric & Automation
  • Highlights 2009 / 2010
  • R&D activities
slide62

Mill design enhancedby CEA(FEM - Nastran)

  • Results => Deformations / deflections
slide63

Mill design enhancedby CEA(FEM - Nastran)

  • Results => Deformations / deflections
  • Max. displacement in themillcenter
  • Max. angulardeformation at mainmillbearingsurfaces
slide64

MechanicalaspectsofgrindingmillsCIM Exhibition 2011, May 22 to 24, Montreal

  • Introduction
  • Company figures
  • Overviewaboutvariousmilltypes
  • Product line
  • Mechanicalaspectsof modern grinding ball millsandpelletizingdiscs
  • Mill design / FE-Simulations
  • Electric & Automation
  • Highlights 2009 / 2010
  • R&D activities
slide65

Electricsandautomation

(example: fuzzyapplication in cementindustry)

  • Startingsituation

Fuzzy-Logic

controllerapplication

Applicationofconventionalcontrollerare not sufficient

Anychanginghere…

May take a long time until a reactionhere !

Grindingcircuit … controllloopwithhugedead time !

slide66

Electricsandautomation

(example: fuzzyapplication in cementindustry)

Startingsituation

Fuzzy-Logic

controllerapplication

Applicationofconventionalcontrollerare not sufficient

Problem: t1, t3, …. t6

lenght / velocity

=> constant

T2 = Tmill

=> NOT constant,NOT linear

slide67

Electricsandautomation

(example: fuzzyapplication in cementindustry)

  • Startingsituation
  • Problem forclosedloopcontrolof ball mills:
    • Not linear residence time ofclinkerparticle in themill
    • Example:Mill  3,6 x 12 m
  • Additional complication:
    • Fillingandemptyinghave different time constants
slide68

Electricsandautomation

(example: fuzzyapplication in cementindustry)

  • Solution

FuzzyLogiccontrol

The direct, precisemeasurementoflevelinsidethemillenablesthe fastest responsetoanychanges in thegrindingcircuitandthe fastest closedloopcontrol.

=> ElectronicalEar

  • Fillinglevelchamber 1 detectedbyelectronicalear
  • Fillinglevelchamber 2 detectedbyelectronicalear
  • Temperaturemilldischarge
  • Power millmaindrive
  • Power bucketelevator
  • Amountofreject
  • Blaine-value

Setpointmillfeed

Setpoint

separatorspeed

slide69

Electricsandautomation

(example: fuzzyapplication in cementindustry)

  • Operating profit
  • Manual operation
    • Unsatisfyingproduction
  • FuzzyLogiccontroller
    • Fast stabilization
    • Fast reactionofinterruption

Mill feedbyFuzzycontroller

Constant feed

slide70

MechanicalaspectsofgrindingmillsCIM Exhibition 2011, May 22 to 24, Montreal

  • Introduction
  • Company figures
  • Overviewaboutvariousmilltypes
  • Mechanicalaspectsof modern grinding ball millsandpelletizingdiscs
  • Mill design / FE-Simulations
  • Electric & Automation
  • Highlights 2009 / 2010
  • R&D activities
highlights 2008 2009
Highlights 2008/2009

Cementmill in Antwerp(Turn-keycementgrinding plant with 3 x  5,0x16,75m in co-operationwith Christian Pfeiffer Beckum)

highlights 2008 20091
Highlights 2008/2009

Erectionof FGD-Grinding plant, ENEL, Italy

highlights 2008 20092
Highlights 2008/2009

ErectionofCementmill UAE (Turn-keycementgrinding plant)

highlights 2009 2010
Highlights 2009/2010
  • ZEMENT WERK BERLIN
    • Fortheincreaseofcementcapacity in Berlin, CEMTEC hasbeenawardedwiththe order forthedeliveryof a turn-keygrinding plant
    • Delivery: September 2009
    • Erectionstart: December 2009; start-up: October / November 2010
highlights 2009 20101
Highlights 2009/2010
  • VALE
    • Deliveryof 14 pelletizingdiscswith 7,5 m diameterfor a pelletizing plant with 9,5 miotpycapacityfor Oman
    • Delivery: October/November 2009
    • Erectionstart: January 2010; start-up: February 2011
highlights 2011
Highlights 2011
  • VALE
    • Start-upof 7 of 14 pelletizingdiscswith 7,5 m diameter
highlights 20111
Highlights 2011
  • VALE
    • Start-upof 7 of 14 pelletizingdiscswith 7,5 m diameter
highlights 2009 20102
Highlights 2009/2010
  • SANGAN: Order für AG / SAG mill
    • Processing ofironore in Iran
    • Deliveryof a AG/SAG millwithdimensionsof 9,75 x 4,27 m
    • Currentlyundercoldcommisioning
    • Start-up: 1st Q. 2011
highlights 2009 20103
Highlights 2009/2010

SANGAN ball mill & AG/SAG mill (Iran)

slide80

Highlights 2010

Start-up of FGD limestonegrinding plant for ENEL(3x660MW thermoelectricpower plant located at Torrevaldaliga Nord / Italy)

slide81

Highlights 2010

  • MARGOON CEMENT IRAN
    • Air separatorforcement
    • Technical dataairseparator(Rotor  2,8m, 200kW,1400-2380 rpm, 185.000 Bm³/h)
    • Delivery: March 2010
    • Start-up: January 2012
slide82

Highlights 2010

  • ALROSA
    • Processing of Kimberlite forprocessingofdiamant in Russia
    • Deliveryof a AG-millwiththedimensions 9,15 m x 3,3 m
    • Delivery: September 2010
    • Start-up: March 2011
slide83

Highlights 2010

  • ALROSA: AG-millwiththedimensions 9,15 m x 3,3 m
  • Finished Layout
  • Engineering
  • Manufacturing
  • Erection
slide84

Highlights 2010

  • ALROSA
    • Processing of Kimberlite forprocessingofdiamant in Russia
    • Deliveryof a AG-millwiththedimensions 9,15 m x 3,3 m
    • Delivery: September 2010
    • Start-up: March 2011
highlights 20112
Highlights 2011
  • VIDEO
    • Start-upof 7 of 14 pelletizingdiscswith 7,5 m diameter
slide86

Highlights 2011

  • Start-up 9,75 x 4,27m SAG mill in Russia
slide87

Highlights 2011

  • Video of 6,1 x 12,4 m ball mill in Iran
slide88

Highlights 2011

  • Video of 6,1 x 12,4 m ball mill in Iran
slide89

Highlights 2011

  • Video of 9,75 x 4,27 m AG mill in Iran
slide90

Highlights 2011

  • Video of 9,75 x 4,27 m AG mill in Iran
slide91

MechanicalaspectsofgrindingmillsCIM Exhibition 2011, May 22 to 24, Montreal

  • Introduction
  • Company figures
  • Overviewaboutvariousmilltypes
  • Mechanicalaspectsof modern grinding ball millsandpelletizingdiscs
  • Mill design / FE-Simulations
  • Electric & Automation
  • Highlights 2009 / 2011
  • R&D activities
cemtec product process development
CemtecProduct & processdevelopment
  • Separator / classifiers
    • „Stand-alone“ classifierCTC
    • outlookforfollowingcombination
    • Combinedwith VRM CTC-B(bottomfeed /airsweptfeed) => Bottomfeed
    • Combinedforoperationwith double rotator- top (Freshfeed)+bottomfeedCTC-D
    • Solid fuelgrindingShock pressureresistant, e.g. coalgrindingCTC-S
cemtec vertical roller mill
Cemtec Vertical roller Mill

Longitudinalsection

Variable rotation speed seperator

Inserted wear segments

3 grinding roller with circulating oil lubrication and sealing air (movable via rotation of C-frame)

Grinding disc in welded design with drive shaft

Radial bearing of drive shaft

C-frame with closed force flow

Hot gas duct for rotating flow generation

Common gear unit (bevel-helical gear unit)

Slide bearing supported grinding disc

Main motor

2-way hydraulic jack with limit stop

Base frame

cemtec vertical roller mill1

Competition

Cemtec

Cemtec Vertical roller Mill

Force flowcoursecomparedtocompetition(e.g. LOESCHE)

  • Open forceflowcoursewithforceflow in thefoundation / baseframewithvibrationdanger
  • Closed force flow course with bounded area in the machine(closed force system)
cemtec vertical roller mill2
CemtecVertical roller Mill
  • Low Budget solution
  • withswivellingframe
  • (higherfoundationcosts)
cemtec r d facilities
Cemtec R&D facilities

Single chambertubemill1,2 x 3m (55 kW)

cemtec r d facilities1
Cemtec R&D facilities
  • Pilot vertical roller mill ( 0,6 m, 45 kW)
cemtec r d facilities2
Cemtec R&D facilities
  • VIDEO: Pilot vertical roller mill ( 0,6 m, 45 kW)
slide100

THANK YOU

S. Pellissetti

CIM Exhibition MontrealMay 22 to 24, 2011