Grindingpartswear, material s, l ifetimeandcosts

LOESCHE Technical Seminar Miami, June 2019

Esteban Perez-Bernal, LOESCHE America
 Agenda
Grinding Parts Wear, Materials, Lifetime and Costs

01 Basics of Wear and Grinding Parts

02 Materials of Grinding Parts and Typical Wear

03 Lifetime and Costs

04 Grinding Part Monitoring and Wear Management

05 Summary

LOESCHE Technical Seminar June 2019

Basics of Wear and Grinding Parts
OVERVIEW
M Tire Grinding Plate Drawing

3 LOESCHE Technical Seminar June 2019

Basics of Wear and Grinding Parts
TYPICAL WEAR PATTERN

 Red = Wear on Tire

 Blue = Wear on Grinding Plate

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Basics of Wear and Grinding Parts
CONSIDERATIONS WHEN MAKING A DECISION

01 At First Sight 02 Don’t lose sight of

 Metal Price  Decline of Mill Performance

 Lead Time  Increase Specific Power
 Wear Rate  Change in Product Quality
 Lifetime  Water / Grinding Aid Usage
 Time Available for
Replace/Rebuild

5 LOESCHE Technical Seminar June 2019

 Agenda
Grinding Parts Wear, Materials, Lifetime and Costs

01 Basics of Wear and Grinding Parts

02 Materials of Grinding Parts and Typical Wear

03 Lifetime and Costs

04 Grinding Part Monitoring and Wear Management

05 Summary

LOESCHE Technical Seminar June 2019

Materials of Grinding Parts
Various Materials Available
NiHardiv
 %Cr <10%
 Fabricated by casting
hardfaced
 Base metal fabricated by casting
 Hardfacing applied in workshop by Automatic
Machines
 Longer lifetime and High Chrome
7 LOESCHE Technical Seminar
High chrome alloys
 %Cr <17%
 Fabricated by casting
Metal matrix composite (MMC)
 High chromium alloy and granularized ceramic
manufactured by casting.
 High Wear Resistance
 No Maintenance – can not hardface
June 2019
Wear of Grinding Parts
Grinding components and wear morphology – uniform wear

Uniform wear

CONICALTIRE wornCONICALTIREANDTABLEPLATE

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Wear of Grinding Parts
Edge fracture

in March in July

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Wear of Grinding Parts
Localized wear

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Wear of Grinding Parts
Variation in wear between castings

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 Agenda
Grinding Parts Wear, Materials, Lifetime and Costs

01 Basics of Wear and Grinding Parts

02 Materials of Grinding Parts and Typical Wear

03 Lifetime and Costs

04 Grinding Part Monitoring and Wear Management

05 Summary

LOESCHE Technical Seminar June 2019

Lifetime and Costs
What variables affect Wear Lifetime

Lifetimes
 Wear life of the grinding parts depends primarily on:
– Hardness of wear material
– Quantity and type of armoring particles
– Fineness and homogeneity of the wear material structure

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Lifetime and Costs
Expected Lifetimes and Costs

Lifetimes
 We can compare the lifetimes of the Material NiHard Chromium Hardfacing MMC
different materials available considering IV Alloy (Ceramic)
operating under the same conditions.
 Lifetimes are based on NiHard Lifetime 1 1.2 1.5 2
 Costs are generalized and vary by market.
Cost $ $ $$ $$$

14 LOESCHE Technical Seminar June 2019

 Agenda
Grinding Parts Wear, Materials, Lifetime and Costs

01 Basics of Wear and Grinding Parts

02 Materials of Grinding Parts and Typical Wear

03 Lifetime and Costs

04 Grinding Part Monitoring and Wear Management

05 Summary

LOESCHE Technical Seminar June 2019

Grinding Part Monitoring
Wear Measurement Table

Ideal Not Ideal

LOESCHE Technical Seminar June 2019

Grinding Part Monitoring
Wear Measurement Tire

Ideal Not Ideal

LOESCHE Technical Seminar June 2019

Grinding Part Monitoring
Example of Measuring

LOESCHE Technical Seminar June 2019

Grinding Part Monitoring
Wear Data from Loesche – Results after Measuring Wear

LOESCHE Technical Seminar June 2019

Grinding Part Monitoring
Wear Data from Loesche – Results after Measuring Wear (Continued)

LOESCHE Technical Seminar June 2019

Wear management
Effect of wear over grinding efficiency - throughput
A B

240
220
200
Mill throughput, t/h

180
160
140
120
100
80
60
40
20
Stage 1 Stage 2 Stage 3
0
Thisisa29/12
Pl acehol der17/02
text 08/04 28/05 17/07 05/09 25/10 14/12 02/02
Running time

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Wear management
Throughput model

PN

P0
Optimum
Mill throughput, t/h

P1

Actual

Stage 1 Stage 2 Stage 3

0 T0 T1 T2 T3
Running time

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Wear management
Throughput model – financial analyses

Stage Y X (Excel date) Date No. days

0 198.3211788 38396.2265 13/02/2005 0
1 220 38434.5162 23/03/2005 38.2897
2 220 38489.6774 17/05/2005 93.4509
3 195.65 38717.6965 31/12/2005 321.47

Stage Ave. t Max t Diff. t No days Ave. h/day Total h Loss, t

1 209.16059 220 10.8 38.2897 17.46682 668.7995 7,249
3 207.82500 220 12.2 228.0191 17.46682 3982.77 48,490
55,740

Loss limestone-> clinker 0.6

Sale price clinker, €/t € 50.00 Gross margin 30%
Loss value € 1,672,188.40 Contribution loss, € € 501,656.52

If running at maximum efficiency

t/h 220
h/day 17.4668
t/day 3843
Idle days 15

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Wear management
Effect of wear over grinding efficiency – specific electric consumption

E1 Actual
E0
EN

Optimum
consumption, kwh/t
Specific electric

Stage 1 Stage 2 Stage 3

0 T1 T2
Running time

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 Wear management
Effect of life extension over efficiency losses

Set 1 Set 2

Optimum Optimum
Mill Throughput, t/h

Mill Throughput, t/h

PN PN

P0 P0

P1 Actual P1 Actual
Stage 1

Stage 2

Stage 3

Stage 1

Stage 2

Stage 3
0 T1 T2 T3 T1 T2 T3 0 T’1 T’2 T’3

Time, h Time, h

POSSIBLEALTERNATIVES: REPLACECOMPONENTSORTOP-UPBYWELDHARDFACING

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 Agenda
Grinding Parts Wear, Materials, Lifetime and Costs

01 Basics of Wear and Grinding Parts

02 Materials of Grinding Parts and Typical Wear

03 Lifetime and Costs

04 Grinding Part Monitoring and Wear Management

05 Summary

LOESCHE Technical Seminar June 2019

Review and closure
Wear processes

 Result of a complex process

– Stresses
– Geometry
– Materials
– Abrasive media

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Review and closure
Wear – cement production and grinding mills

 In vertical mills the wear of the grinding components can have different aspects:
– Uniform wear
– Edge fractures
– Localised wear
– Variation between castings

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Review and closure
Wear management

 The milling efficiency normally changes with the state of wear of the grinding components
– Stage 1: bedding-in period prior to efficient milling
– Stage 2: optimum efficiency
– Stage 3: degrading efficiency with progress of wear.

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Review and closure
Decision modelling

 The life of components can be extended through metallurgy or use of metal-matrix composites.
 Nevertheless, lifetime extensions do not improve efficiency over long periods of time.
– This is because stages 1 and 3 are implicitly wasteful.
– The proportion between the inefficiency zones in stages 1 and 3 and the total lifetime does not change with
abrasion resistance.
– The only alternatives to eliminate stage 3 is to replace the component or build up by weld hardfacing.

30 LOESCHE Technical Seminar June 2019

 Esteban Perez Bernal
LOESCHE America

THANKYOU 20170 Pines Blvd, Suite 302

Pembroke Pines, FL USA
for your attention

Email: eperez@loescheamerica.com