2 Jens 03-01-TubeMill

Page 1 SilzR 03 Sep 2007 S:\Team\Training\BAZIFA\030-Cementproduction\03-01-TubeMill.
ppt
Page 2 SilzR 03 Sep 2007 S:\Team\Training\BAZIFA\030-Cementproduction\03-01-TubeMill.ppt
Content: • General Overview

• Drive
• Slide Shoe Bearings
• Oil Supply System
• DIAPOL
• Mill Inlet
• Mill Discharge

• Drive
• DIAPOL
• Mill Inlet
• Mill Discharge
Ball mill
Discharge diaphragm
Intermediate diaphragm
Mill inlet
Mill discharge
2. Compartment:
ball filling classified
because of liners
1. Compartment:
lifting liners &
coarse balls
Drive
General overview
1 Mill cylinder
1.5 Man-hole
2 Mill head
3 Mill head liners
4.1 Mill liners chamber 1
4.2 Mill liners chamber 2
2 9 3 5 Intermediate diaphragm
6 Discharge diaphragm
7 Mill inlet
8 Mill discharge
9 Mill bearing
10 Mill drive
11 Water injection

• Drive
• DIAPOL
• Mill Inlet
• Mill Discharge
Drive
Page 8 BlattonG 20 Okt 2005SilzR S:\Dept\A032\032.2\Konstruktionsrichtlinien\Rohrmühlen\15_Präsentationsunterlagen\Vortraege\BallMill Mai.2005.ppt03 Sep 2007 S:\Team\Training\BAZIFA\030-
Cementproduction\03-01-TubeMill.ppt
COMBIFLEX Drive
History of the COMBIFLEX drive

1986 start of joint development Flender - Polysius
1989 start-up of the first COMBIFLEX at Alsen Cement, Lägerdorf
1992 first order of double drives (2 x 4000 kW) for 3 SAG mills in Iran
1997 start-up of the biggest COMBIFLEX- SAG mill with double drive in
Australia (10.4 m inner diameter ; 2 x 5,500 kW)
1998 order of 100th POLYSIUS COMBIFLEX mill
1998 start-up of the world´s biggest cement mill (5.6 m inner diameter;
2 x 4,600 kW)
2001 commissioning of next generation COMBIFLEX 2000 design
Advantages of the COMBIFLEX drive

• Common bearing and girth gear cover
– only two lube oil systems for the mill (one for fixed and floating side)
– 2 instead of 4 sealings for drive side required
• Low space requirements
– allows a more compact civil design
– allows several motor arrangements
• low operating cost
– no grease required
– low maintenance cost
– no necessity for realignment of drive
– only two lube oil systems for the mill
• low investment cost compared to central drives
Advantages of Combiflex drive (2)

• high availability and life time
– bending and thermal expansion do not result in overloading or
misaligning of toothing due to self aligning pinions and load distribution in
2nd gear stage
– no wear of tooth flanks due to oil lubrication
– low risk of pitting formation
– Lower stresses in the head walls compared to trunnion bearings
• bigger mill inlet and outlet cross sections possible
• easy adjustment of the mill shell in case of foundation settlements
• simple design of the water injection system
COMBIFLEX Reducer
Self Aligning Pinions
Spray Nozzles
COMBIFLEX 2000
Z
POLYSIUS COMBIFLEX Drive ISAMUE (Ball Mill)


• Drive
• DIAPOL
• Mill Inlet
• Mill Discharge
Structure of the ball mill drive side

• bearing cover (drive end)
• slide ring
• mill inlet chute
• girth gear
• COMBIFLEX- gearbox
• slide shoe bearings
Advantages of one common bearing cover

• only one oil circuit
– one supply unit instead of three (one for bearings, girth gear and gearbox)
– simple maintenance (one type of oil quality and oil filter)
• simpler design
– only one instead of two housings
– two instead of four sealings
– shorter foundation
• better access to liner bolts
5 4 Slide shoe bearing
1
Lower housing segment
2
Dismounting flap
3
Oil return socket
4
Upper housing segment
6 7 5
Seal with dust cover
9 6
Bearing shoe
7
Axial pivoting bearing
8
Adjusting device of the
bearing shoe
8 9 Temperature sensor
10 Anchorage
11 Piping
2
11
10
1
3
Optimized hydrodynamic Bearing Shoe

Features:
• symmetric shape
• spec. load up to
3 MPa
Central HP Supply • increased central
high pressure supply
• double low pressure
supply on both edges
Double LP Supply for better cooling and
oil distribution
• shoe thickness
Measuring Shoe for Burzem optimized acc. to
load distribution
Slide shoe bearing arrangement

Installation of Mill Shell

Ball Mill (Ø 5.0 m x 15.75 m)

Neuestes Dichtungskonzept - actual sealing design
• big inner roof (for oil)
• dust roof (outside of housing)
• oil spray ring
• inner oil sealing (Y- Seal; two

springs) without grease
• outer dust sealing (V- seal fixed on

housing)

• Drive
• DIAPOL
• Mill Inlet
• Mill Discharge
roof
Pump
Oil water cooler
Double filter
Return line
Oil tank
Cooling water
connection
Oil supply unit
with oil / air cooler

Oil supply system: flow sheet for fixed bearing
40 Level switch
60-64 Heating system
90 Low-pressure pump
130 Non-return valve
150 Pressure limiting valve
160 Oil filter
230,231 Pressure switch
250 High-pressure pump
300 Pressure-relief valve
320 Pressure switch
330 Low-pressure Filter pump
390 Pressure relief valve
410 Oil filter
170 Oil cooler
240,241 Flow monitor
370 Pressure switch
Tank group
Fliter
oil circuit
High pressure
oil circuit
Low pressure
oil circuit

• Drive
• DIAPOL
• Mill Inlet
• Mill Discharge
Discharge diaphragm
Intermediate diaphragm
Page 34 BlattonG 08 Nov 2004SilzR I:\_Vortag\DIAPOL\am Silz\DIAPOL_BLA_EN_11_04.ppt03 Sep 2007 S:\Team\Training\BAZIFA\030-Cementproduction\03-01-TubeMill.ppt
• Why was the developed?

• Design of the
• The in industrial practice
Page 36 BlattonG 07 Feb 2002SilzR I:\_Vortag\DIAPOL\am Silz\DIAPOL_BLA_EN_11_04.ppt03 Sep 2007 S:\Team\Training\BAZIFA\030-Cementproduction\03-01-TubeMill.ppt
L
P O
I A
D
DIAPOL© identification
segment
support
segment
slotted plate
support
segment
backwall plate
slotted plate
inner plate
support
segment
backwall plate
slotted plate
scoop fixed
innner plate
support slider
segment
scoop
scoop adjustable
scoop head
Page 47 I:\_Vortag\DIAPOL\am Silz\DIAPOL_BLA_EN_11_04.ppt03 Sep 2007 S:\Team\Training\BAZIFA\030-Cementproduction\03-01-TubeMill.ppt
JND DCD DRD

Air speed in the diaphragm
old Polysius diaphragm

DIAPOL©
• Why was the developed?

• Design of the
• The in industrial practice
Properly stressed structure

• Cosideration of the wall in assembled state
• Wall is made up of individual segments
ø 5.4 m x 14.5 m (EGL)

Design also for proper maintenance

• Scoop head removal (three bolts per head)
• Scoop removal (two bolts per scoop)
• Slide gate adjustable
• Slide gate removal (one bolt per slider)
• The bolts are not exposed

to wear and tear due to
material being ground
• Easy access to
chamber 2
through the
diaphragm
Proper wear protection to suit

operational filling level
Filling level at ideal state
Filling level in operation, approx. 5/7 of the

level at idle state
Proper wear protection to suit

operational demands
CREUSABRO 4000
Wear protection
CREUSABRO 4000
optimal material behind the

DIAPOL©
Reduced pressure drop

Ø 3.4 m x 13 m EGL
Before conversion
p = -10.1 mbar
After conversion
p = -8.7 mbar
Pressure drop
reduced by
13.9 %

• Drive
• DIAPOL
• Mill Inlet
• Mill Discharge
Mill inlet
Mill inlet

• Drive
• DIAPOL
• Mill Inlet
• Mill Discharge
Mill discharge
Mill discharge
8.1 Discharge housing
8.2 Outlet cone
8.3 supporting structure
8.4 Inspection door
8.5 Seal
8.6 Connecting flange for
exhaust air
8.7 Product discharge3
Discharge of a cement mill ( 3,6 x 11 m)


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Page 1 SilzR 03 Sep 2007 S:\Team\Training\BAZIFA\030-Cementproduction\03-01-TubeMill.

Content: • General Overview

Content: • General Overview

Content: • General Overview

History of the COMBIFLEX drive

Advantages of the COMBIFLEX drive

Advantages of Combiflex drive (2)

Self Aligning Pinions

POLYSIUS COMBIFLEX Drive ISAMUE (Ball Mill)

Content: • General Overview

Structure of the ball mill drive side

Advantages of one common bearing cover

5 4 Slide shoe bearing

Optimized hydrodynamic Bearing Shoe

Slide shoe bearing arrangement

Installation of Mill Shell

Ball Mill (Ø 5.0 m x 15.75 m)

Neuestes Dichtungskonzept - actual sealing design

• big inner roof (for oil)

• dust roof (outside of housing)

• oil spray ring

• inner oil sealing (Y- Seal; two

• outer dust sealing (V- seal fixed on

Content: • General Overview

Oil water cooler

Oil supply unit

with oil / air cooler

Oil supply system: flow sheet for fixed bearing

Oil supply system: flow sheet for fixed bearing

Oil supply system: flow sheet for fixed bearing

Oil supply system: flow sheet for fixed bearing

Oil supply system: flow sheet for fixed bearing

Content: • General Overview

• Why was the developed?

JND DCD DRD

Air speed in the diaphragm

old Polysius diaphragm

• Why was the developed?

Properly stressed structure

ø 5.4 m x 14.5 m (EGL)

Design also for proper maintenance

• The bolts are not exposed

Proper wear protection to suit

Filling level at ideal state

Filling level in operation, approx. 5/7 of the

Proper wear protection to suit

optimal material behind the

Reduced pressure drop

Content: • General Overview

Content: • General Overview

Discharge of a cement mill ( 3,6 x 11 m)

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