FINE ROLLER MILL

ALPHA II
WFZH Type ALPHA II : The standard of hydraulic
high-performance roller mills, for roller
PRODUCT INFORMATION gaps ≤ 0,5 mm.
 ALPHA II at Nibra in
Groß Ammensleben

Maximum fineness of grind

at minimum roller gap
The new «Alpha II» represents the latest product of continuing, systematic evolution in
the fine grinding of plastic and semi-plastic ceramic materials in roller mills set to
effective gap widths of < 0.5mm. The «Alpha II» is designed for use as a second or
third roller mill in series with appropriate primary and/or fine roller mills. It comes with
roller widths of 1,000, 1,200 and 1,500 mm and diameters of 800 and 1,000 mm for
milling capacities up to 100 t/h at a roller-gap setting of 1 mm.

The main merits of «Alpha II» at a glance

Minimized grinding tolerances thanks to the mor- Longer-lasting wear parts and less maintenance
phomechanical principle "disk beats rocker". effort thanks to newly reengineered and opti-mized
roll scrapers.

Precise retention of roller-gap settings enabled by Highly reproducible grinding thanks to high-resolu-

low-play bearings. tion electronic roller-gap setting action.

Minimized deformation and stress spikes in all

components thanks to systematic application of
the FE method.

Longer-lasting roller shells and greater reliability

thanks to optimized design and attachment.

2 P R O D U C T I N F O R M AT I O N W F Z H
Throughput of «Alpha II»

140
b = 1500 mm
130
Q[t/h] = b * s * v * f1 * f2 * sg * 3600 s = 1 mm
120 b = Roller width [m]
s = Roller gap [mm]
110
v = Circumferential speed [m/s]
100 f1 = Efficiency b = 1200 mm
f2 = Wear of roller s = 1 mm
90
sg = Weight of bulk meterial [t/m3]
80
Vulometric throughput [t/h]

70 b = 1500 mm
s = 0,5 mm
60

50 b = 1200 mm
s = 0,5 mm
40

30

20

10

0
0 2 4 6 8 10 12 14 16 18 20 22
Circumferential speed of coller [m/s]

Morphomechanical design objectives

of the «Alpha II»

< 0.5-mm roller gap and < 0.1 mm max. gap-width deviation

Roller D Minimal deformation D High flexibility in case of overload

Shaft D Little bend and tension

Bearing D Min. deformation of bearing seat D Reduced bearing tolerance

Adjustment (rocker arm) D Little deformation and elasticity D Constant change of gap

Pretension D Short way to power an hacks D High stiffness and damping

Roller frame D Hight stiffness D Natural stability

Scraper D High proper frequency at max. D Best possible scraper function

heat dissip.

3
 The design

Getting a roller gap of less than 0.5 mm to stay within

a deviation tolerance of less than 0.1 mm re-quires
that all morphomechanical elements as well as the
hydraulic and electronic systems be fully up to the
task. Considering the strict criteria to be met and the
complexities of the operating environment, the use of
modern design methods - FEM in particular - is indi-
spensable. For example, all of the «Alpha II's» essenti-
al elements have been systematically analyzed and
engineered in terms of deformation, stress and vibra-
tion behavior, and any element that failed to meet the
stringent requirements was replaced, e.g., the "rocker"
concept was retired in favor of the "disk" concept.

New structure-mechanical principle

"disk" instead of "rocker arm"

The deformation behavior

… of the geometrically optimized rollers was simulated

for various dynamic load cases, and the results sho-
wed that conventional notions about roller deformation
and stress do not conform to reality. The new insights
were incorporated into the mill's design and are now
being implemented in cooperation with our partners in
the materials technology sector

The hydraulic system

… for generating the preload comprises a pump &

motor, a pair of hydraulic cylinders and a symmetrically
arranged pressure accumulator. Lines of equal length
between the accumulator and the hydraulic cylinders
guarantee that the rollers remain parallel, even under
Deformation of roller shell
extreme loads.

4 P R O D U C T I N F O R M AT I O N W F Z H
The roller-gap adjustment device

… is in the form of either a convenient single-rocker assembly or, alternatively, a paral-

lel adjuster. The single-rocker version adjusts the roller gap by way of 2 threaded
spindles, or lead screws, and a synchronized pair of high-resolution servomotors. This
guarantees accurate adjustment and equally accurate monitoring of the roller gap. The
servomotors, in turn, are controlled by way of either an electronic operator's panel on
the control console or an optional mechanical synchronizer with a digital roller-gap
display. This is where the roller gap, the roller-gap correction factor and other requisite
parameters are entered. The servomotors and the hydraulic system automatically keep
the roller gap properly adjusted, though it is in principle also possible to adjust the
gap by hand.

Single-rocker assembly

Roller gap adjustment

by hand

Discharger

Since normal operation can involve vibrations as high as

1,000 Hz in close-set rollers, the new discharger assem-
bly offers definite advantages over the conventional type
with respect to accessibility and deformation behavior.
Of decisive importance for any roller mill, the new
discharger also works much better in terms of heat dis-
sipation and insensitivity to vibrations.

Easy assembly and disassembly of discharger

Options

The design of the turning apparatus is constantly

being fine-tuned to ever more stringent stan-dards. In
order to keep the rollers' vibrations away from the rol-
ler turning machine, we offer a choice of systems: eit-
her the turning apparatus can be lifted off with the unit
in operation, or vibration dampers can be installed.

Roller turning machine with vibration dampers

5
 The «Alpha II» in practice

The «Alpha II» passed its acid test at the Pfleiderer roof tile plant in Högeda, where
raw materials are tough and quality standards high.
The «Alpha II», which Pfleiderer uses as a third roller mill, not only achieves a remark-
ably high fine-ness of grind there, but also and in particular very consistent results
over time. Another astounding fact is that the stability of the entire rig and the great
performance of the new discharger made it possible to substantially reduce the roller-
turning intervals.
As of this writing, some twenty-five type-WFZH 8120d and five type-WFZH 8150d
«Alpha II's» were already at work out there fine-grinding plastic and semi-plastic cera-
mic materials in diverse corners of the world.

ALPHA II at Pfleiderer in Höngeda

6 P R O D U C T I N F O R M AT I O N W F Z H
Grinding fineness attained in operation

14

12,84
Measuring terms Labor Pfleiderer/ Höngeda of
performance test WFZH 8120d
12

0,60
10
0,50

0,40

8 0,30

0,20
Screening reject > o,5 mm

6 0,10

0,00
Measuring period 09. - 17. 03 1999
4,08
4

0,81
0,35

0
After pan mill After primary roller mill After 1st fine roller mill After 2nd fine roller mill
Alpha II

FINE ROLLER MILL ALPHA II WFZH

TYPE Roller ø/ width Barrel Max. roller Max. volumetric Power requirement
thickness turning speed throughput (approx.)* (approx.)
mm mm 1/min 1/min kW

WFZH 8100d 800/1000 120 460/460 51 2x 75 - 90

WFZH 8120d 800/1200 120 460/460 62 2x 90 - 110

WFZH 8150d 800/1500 120 460/460 81 2x 110 - 132

WFZH 10120d 1000/1200 140 380/380 67 2x 110 - 132

WFZH 10150d 1000/1500 140 380/380 84 2x 132 - 160

* volumetric throughput for rough-milled material and a roller-gap setting of approx. 1 mm

All illustrations and technical data are non-binding and subject to technical modification due to ongoing development.

7
 Laboratory Performance as you need

Conveying and storing The throughput stated for the machines is in

m3/h. For the extruders it refers to the compact,

Screening wet pressed body, while for the box feeders

and handling equipment it refers to the loose
bulk.
Feeding and propotioning
Please note the following rule of thumb:

Crushing
1 m3 wet pressed body = 1,2 – 1,35 m3
loose bulk
Mixing and homogenizing
1 m3 wet pressed body = 1,36 t fired clay

1 t fired clay = 0,735 m3

Shaping – extruding
wet pressed body

Shaping – molding

Service

HÄNDLE GMBH Maschinen und Anlagenbau

Industriestraße 47
Netzwerk Mensch Werbeagentur 09/2003

75417 Mühlacker (Germany)

Phone + 49 7041 891-1

Fax + 49 7041 891-232

24-Hours-Hotline + 49 171 7323636

info@haendle.com
www.haendle.com