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CEMTEC – Cement and Mining Technology GmbH, A-4470 Enns S. Pellissetti

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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CEMTEC – Cement and Mining Technology GmbH, A-4470 Enns S. Pellissetti

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  1. CEMTEC – Cementand Mining Technology GmbH, A-4470 Enns S. Pellissetti www.cemtec.at, s.pellissetti@cemtec.at

  2. 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

  3. 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

  4. 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

  5. Core Business Turnkey projects Tube mill / Vertical mill / AG & SAG mill wet & dry applications Separators Dryers Pelletizing Spare parts

  6. Global Customers

  7. Diversified Industries Cement Mining Building Materials Waste / Recycling Filling (paper, glas, paint, plastic, etc. ) Energy FGD / Desulfurisation

  8. 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

  9. 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

  10. 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

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

  12. 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

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

  14. 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

  15. Overviewofvariousmilltypes • Ball millsforCementindustry • RawmealmillØ 4.2 x 10m , 170 tphCementizillo / Italy

  16. 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

  17. Overviewofvariousmilltypes • Rod mill • ROD millforwet AlO2-grinding Ø 4.2 x 6m, 270 tph Aluminium Stade/Germany

  18. 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

  19. 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

  20. Layout - AG-Mill 22´ x 10,2´forinformationonly

  21. 3D Views - AG-Mill 22´ x 10,2´forinformationonly

  22. 3D Views - AG-Mill 22´ x 10,2´forinformationonly

  23. 3D Views - AG-Mill 22´ x 10,2´forinformationonly

  24. Top View - AG-Mill 22´ x 10,2´forinformationonly

  25. Side View - AG-Mill 22´ x 10,2´forinformationonly

  26. Drive Station - AG-Mill 22´ x 10,2´forinformationonly GearRim Main Gear Box Coupling Main Motor Pinion Station Elastic Coupling Inching Drive

  27. Inching Drive - AG-Mill 22´ x 10,2´forinformationonly Elastic Couplings Auxilary Gear Box Motor withbrake Fluid Coupling Double Brake

  28. PID´s - AG-Mill 22´ x 10,2´forinformationonly

  29. PID - AG-Mill 22´ x 10,2´forinformationonly

  30. PID - AG-Mill 22´ x 10,2´forinformationonly

  31. AlrosaUdachnyAG-Mill 30´ / 10´

  32. 3D-Views AlrosaUdachnyAG-Mill 30´ / 10´

  33. Mill Shell AssemblyAG-Mill 30´ / 10´

  34. Main BearingAG-Mill 30´ / 10´

  35. Mill Lining AG-Mill 30´ / 10´

  36. FeedandDischargeTrunnionAG-Mill 30´ / 10´

  37. PinionShaft/GearRimAG-Mill 30´ / 10´

  38. GearRim / PinionLubrication SystemAG-Mill 30´ / 10´

  39. Main BearingLub UnitAG-Mill 30´ / 10´

  40. 3D-Views SAG-Mill 22´ / 6´

  41. Main BearingSAG-Mill 22´ / 6´

  42. SAG-Mill 22´ / 10´

  43. 3D-ViewsAG-Mill 32´ / 14´

  44. AG-Mill 32´ / 14´

  45. AG-Mill 32´ / 14´

  46. Mill Lining AG-Mill 32´ / 14´

  47. 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

  48. Layout PTD-850-80 Preliminary

  49. 3D-views PTD-850-80

  50. Typicaldriveconcept 4 1 2 5 5 3 1……….Main motor 2……….Gear box 3……….V-belts 4……….Main coupling 5……….Belt pulley´s

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