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General Advantages:
High Utilisation factor. Low susceptibility to wear. Low cost for core parts as well as replacement of worn out parts compared to other grinding units. Long residence time to ensure thorough grinding even for harder particles. Unaffected by any kind of foreign bodies that may enter. Minimum downtime for grinding media renewal.
TUBE MILL
GOVERNING FACTORS:
1 Grindability:
Grindability - normally varies in the range of +/- 4 %. Clinker and cement raw materials are heterogeneous in structure, their work index values are always higher, but below their natural grain size than above it. The Grindability index is based on the following; Moisture content high means low performance Hardness & Brittleness relates to fineness Porosity more means high performance Physical & Chemical properties - Free Mgo is found to have negative effect whereas high free lime indicates positive influence. - Increase in SR (Silica ratio) decreases the grindability & vice versa in the case of specific gravity. - Increase in C3S & Decrease in C2S increase the overall grindability. - Effect may arise, not only on the raw materials but also due to the burning & cooling methods.
Mill L / D ratio:
The ratio, however varies with the circuit used, material type, feed Size and grinding requirements. Generally there is no fixed rule; however tube mills have the ratio of 3 to 6: 1 and ball mills are of 2: 1. Residence time depends on mill size, grindability of feed and conditions of grinding. Power input >>> Fraction of mill volume occupied by the grinding charge. >>> 1/ critical speed >>> Interior diameter etc., .i.e .., I = k D2.5 L Where k is a constant The above relation indicates that increasing dia gives higher power than increasing length.
Mill Speed:
If the mill is allowed to run at low speed it results into rolls back down of grinding media, known as cascading. In contrast if it runs at high speed, the grinding media will be thrown and results in to an effect known as cataracting.
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TUBE MILL
Hence the optimum speed must be less than the critical speed. Critical speed occurs when the centrifugal force is equal to the weight of the grinding body at the highest point on the lining. Ie ..By formula, C = 42.3 / D Where D is internal diameter in M. Increased speed increases the mill capacity & power consumption. It also increases the metal wear as well as the maintenance cost per ton of ground.
Mill Loading :
In any Tube mill, the grinding action is determined by the charge volume. The power input for moving the mill charge at a given speed is directly proportional to the charge weight (Grinding media charge plus weight of material) and the distance between the centres of gravity to the charge. If the quantity and / or grading of the media are changed and the power consumption does not change proportionately, it indicates that the centre of gravity has shifted.
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TUBE MILL
In general, the lower and upper values of Loading are as Charge volume < 25 % Sliding of the media results and Charge volume > 45 % Indicates disturbances along the Trajectories of the grinding Media. Therefore, for balls the charge volume will be in the range of 26 to 45 % and for cylpebs it is of the order of 25 to 33 %.
Mill Liners:
Mill liners have the direct roll on the power efficiency and increased reliability. It has two direct functions, viz. a) To increase the strength of mill shell b) To lower the maintenance cost Mill linings are subjected to severe abrasive action by the feed material and the grinding media due to continuous operation under excessive heat. Therefore the following important parameters are to be considered before selection:
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TUBE MILL
1) Shape or profile - Square lifter - Bevelled - Single or double wave - Corrugated - Shiplap - Wedgebar - Blocktype 2) Material of construction - Chromium - Nickel - Molybedenum - Copper - Alloys of above 3) Method of fixing - With bolts of less numbers ( Just to increase the strength of mill shell and simultaneously to reduce the maintenance cost ) - Without bolts for mill diameter of 4M and above 4) Metal wear - Wear could be due to Sliding & Impact - Factors such as size & shape of grinding media, liners physical & metallurgical properties, pattern of motion or speed, operating temperature & the abrasiveness of the material to be ground are responsible for wear. - By using chrome alloys of chromium content from 12 to 25 %, Wear rate can be reduced to an optimum value of 25% less than the conventional liners.
TUBE MILL
Ie., to say that even small changes in limiting the size of product can cause considerable influence on the mill capacity. Mill capacity decreases as the demand in fineness increases.
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CONCLUSION:
The above points give us a clear picture about the basics of a tube mill in respect to the grinding operation of a cement plant. These tools will help in identifying the nature of a problem if a nonperformance of a mill is reported. However solving the real problem is the expertise of the individual in consultation with the designers. THE END
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