FTA

PRSENTATION
ON

BALL AND TUBE

MILL
RHITESH KUMAR

Presentation Outline
1. COAL TYPES OF COAL
2. WHY PULVERISATION OF COAL?
3. FIRING DIRECT FIRING, INDIRECT FIRING
4. PULVERISERS TYPES, CLASSIFICATION
5. BALL & TUBE MILLS CONSTRUCTIONAL

FEATURES
6. GRINDING PRINCIPLE IN TUBE MILLS

COAL
MOST EASILY AVAILABLE
ABUNDANTLY AVAILABLE
CHEAP FUEL SOURCE
EASILY TRANSPORTABLE

GRADE OF COAL
BASED ON CALORIFIC VALUE, GRADING OF COALGRADE
KCAL/KG
A
>6200
B
5600-6200
C
4490-5600
D
4200-4490
E
3360-4200
F
2400-3360
G
1300-2400

WHY PULVERISED FORM OF COAL

IT HAS MADE MODERN STEAM GENERATING UNITS

HIGHLY THERMAL EFFICIENT, RELIABLE AND SAFE.

IT HAS MADE EFFICIENT USE OF LOW GRADE COALS.

IT PROVIDES GOOD CONTROL OVER COAL AIR

MIXTURE PROPORTION, FLAME STABILITY WITH

MINIMUM LEVEL OF UNBURNT CARBON.

FIRING

DIRECT FIRING
Coal is ground and is directly carried from the
Pulverizer to the Furnace by use of Pressurized air.
Pressurized Air from Primary Air Fans goes to the
Pulverizers.
Sufficient temperature is maintained for drying of coal
and moving the Pulverised Coal to the furnace without
settling.

FIRING

INDIRECT FIRING
Here coal is ground and is carried from Pulveriser to
an Intermediate Bunker. Based on the Unit load
demand pulverised coal moves from the Intermediate
Bunker to the Furnace.
A suction fan helps in sucking the pulverized fuel to
the furnace.
This system is suitable, where the boiler load varies
and the mills consume huge power. But, the
disadvantage is that the capital cost is high due to extra
bunkers and fans. Also, there is danger of Fire in the
Intermediate Bunkers

FUNCTIONAL REQUIREMENTS OF
PULVERISER
DRYING OF COAL
GRINDING OF COAL
TRANSPORTATION OF PULVERIZED COAL

MECHANISM OF PULVERISATION
BASED ON PRINCIPLES OF PARTICLE SIZE

REDUCTION

IMPACT
ATTRITION
CRUSHING

PULVERISERS USE ONE, TWO OR ALL THE

THREE PRINCIPLES.

TYPES OF PULVERISERS
Speed

Type

Low
10 to 20 RPM
Ball tube mills
(16 rpm in
Vindhyachal)

Medium
High
40 to 70 RPM 900 to 1000
RPM
Bowl Mill,
MPS Mill,
Ball and Race
mill

Impact or
Hammer
Mill.
Beater Mill
or Fan Mill.

TYPES OF MILL

Tube or ball mills: These are low-speed

machines that grind the coal with steel balls in
a rotating horizontal cylinder.

Vertical spindle mill: These are mediumspeed machines that include bowl mills, ring roll
mills, and ring and ball mills. The bowl mills are
further divided into deep bowl or shallow bowl
mills.
Impact mill: These are high-speed impact
machines that use beater wheels to crush the
coal.

Ball & Tube Mills

Tube mills: The tube mills are low-speed machines that

grind the coal with steel balls in a rotating horizontal
cylinder. Due to its shape only, people call it as Tube Mill
and due to use of Grinding Balls for crushing, it is called
Ball Mill. Hence, is the name Ball Tube Mill

TUBE MILL
These are slow speed Mills. The Mills are
designated as BBD-4772
Where,
B Broyer (Name of inventor).
B Boulet (French word for Balls).
D Direct firing.
47 Diameter of shell (in Decimeters) i.e. 4.7m dia.
72 Length of shell (in Decimeters) i.e. 7.2 m length.

BALL & TUBE MILL

Tube mills are employed to pulverize the precrushed raw coal to the required fineness before it
is admitted into the boiler furnace for combustion.
The operating characteristics i.e. Faster
response to Load variation of tube mills make it
the best mill available for the direct firing system
of the coal.

CONSTRUCTION OF TUBE
MILL
CYLINDRICAL SHELL
LINER
SHORT CONICAL LINER
LONG CONICAL LINER
INLET LINER
SCREW CONVEYOR
RIBBON
HOT AIR TUBE
CONNECTING ROD

The Shells which contain ball and liner are of 7.2 mtr. length.
The Shells are of three pieces. The Intermediate shell connects to
the end shells by flange joints.
60 Nos. Bolts in each
flange
CHEEK

TRUNION
40 Nos. Trunion to
Cheek Joint Bolts in
each end

SHELL FLANGE
GIRTH GEAR

DETAILS FOR SCREW CONVEYOR ASSEMBLY

RIBBON

SHAFT
ANGLE

CHAIN
&
CHAIN LINK

MILL DETAILS

Design coal capacity- 83.15 Tons/Hr

Ball charged- 90 Tons (50 mm, 40 mm, 30 mm)
Speed 15 to 16 rpm
Screw assembly- Right hand helix(DE side)
Left hand helix (NDE side)
Direction of rotation of Shell from NDE end-AntiClockwise.
Shell door opening- two numbers.
Shell liners- 600 nos.
weight of liners- 60.26 MT

MILL LUBRICATION
SYSTEM
TRUNION
SUPPORT BEARING

H
P

OIL
TANK

BS
LP
FILTER

COOLER

Pum
p

MILL LUBRICATION
DETAILS

LP PUMP FLOW 137 Ltrs/min.

LP PUMP PR.- 10 Bar.
LP PUMP SPEED 750 rpm.
B&S PUMP FLOW 6 Ltrs/min.
B&S PUMP PR.- 70 Bar.
B&S PUMP SPEED 1450 rpm.
HP PUMP FLOW 40 Ltrs/min.
H PUMP PR.- 80 Bar.
HP PUMP SPEED 965 rpm.
TANK CAPACITY- 1800 Ltrs.

MAIN REDUCER

Output
Shaft

DETAILS OF MAIN REDUCER

LOW SPEED
SHAFT 118.98
rpm

LUB.
OIL
LINES
HIGH SPEED
SHAFT
1487 rpm

MAIN REDUCER
DETAILS

CAPACITY- 300 Ltrs.

OIL- SERVO MESH SP 460.
HIGH SPEED SHAFT- 1487 rpm
LOW SPEED SHAFT- 118.98 rpm.
DE SIDE- RESILIENT (BIBBY) COUPLING
NDE SIDE GEARED COUPLING.

REDUCER LUBRICATION
This is closed cycle lubrication system
This is required for the lubrication of gears and bearings
The oil is pumped to the different points in the reducer by
motorized pumps.
Oil is sprayed to the gears by means of nozzles in the gearbox
at the mating plane.
The bearings get oil through nozzles inside the gearbox
The pumps are screw pump.
Oil coolers are used to cool the lubricant coming out of the
reducer.
After the filter the oil goes to the reducer.

Schematic Diagram of Main Reducer

Lube Oil System
MILL

FILTER

MAIN
REDUCER

COOLING
WATER

OIL
COOLER

PUMP DISCHARGE/ OIL INLET TO REDUCER

PUMP SUCTION/OIL OUTLET TO REDUCER
OIL COOLER ASSEMBLY
OIL FILTER ASSEMBLY
LUB.OIL PUMP

MAIN REDUCER LUB. OIL DETAILS

SCREW PUMP.

SPEED- 1500 rpm

FLOW RATE- 79 Liters/Min.
PRESSURE- 2 Bars.
WATER FLOW THROUGH COOLERS- 60-65 LPM
COOLER WATER I/L & O/L TEMP.- 35 & 45 deg.
FILTER RATING- 160 Microns.

GIRTH GEAR
GREASING
NOZZLE

NOZZLE
GREASE
DISTRIBUTOR
GREAS PUMP
M

GREASE
BARREL

ELECTRICAL
SHUT OFF
VALVE
COMPRESSED AIR
SUPPLY

AIR FILTER

GIRTH GEAR GREASE PUMP

NO.OF DISCHARGE: 06
SPEED- 1400 rpm.
FLOW RATE- 0-18M3 /24 Hrs.
MAX. PRESSURE- 100 Bars.
OIL: Servo Tak-40
SPRAY INTERVAL- 30Sec.

VIEW OF SEAL AIR FAN

MOTOR

GEARED BEARING
COUPLING HOUSING

IMPELLER
HOUSING

TRUNION SEAL AIR FAN

CAPACITY 3.9 m3/sec.
SPEED- 2880 rpm.
HEAD DEVELOPED- 1650 mmWCL.
MEDIUM HANDLING- Atmospheric air.
ORIENTATION- Axial suction & vertical delivery.

VISCOUS FILTER
DRIVING
GEAR

COARSE MAT
FILTER

OIL SUMP

Behind the Coarse mat

filter, the fine mesh filter is
present. It is also called Oil
drop eliminator. This is
present to prevent carry
over of oil drops to the
Impeller.
Both the Coarse mat filter and
the Oil drop eliminator screens
rotate intermittently as per the
Timer settings. Normally, it is
30 sec. rotation after every 20
minutes

MILL CLASSIFIER ARRANGEMENT

MULTIPORT OUTLET
CLASSIFIER CONE
INTERNAL CONE
HEX. CONE
ASSEMBLY

REFUSAL DUCT

P.F. DISCHARGE TO
CLASSIFIER

BALL FEEDING DETAILS

PRINCIPLES OF GRINDING
Raw Coal is fed into the Mill for Grinding.
Grinding takes place by Impact and attrition.

MAINTENANCE
PRACTICES
Ball Charging when

current goes
below 95 Amps. for which current
data is collected from UCB on First
of every week.
day
Monthly Preventive Maintenance of
Mills, R C Feeders and Seal Air fans
Minor Overhaul of Mills in 4-6 months
in which P/M works,
Servicing &
Replacement of CADs, Girth Gear
Grease Pumps servicing is carried
out.

Problems faced in the Mills at

Vindhyachal
Failure of Liners
Explosion in the Mills
Girth Gear Greasing trouble
Frequent Jamming of CADs
Frequent Filter Choking
Firing of Wet coal in the Mills
Non-operation of Viscous filters