INTRODUCTION

• Material grinding in cement mills is carried out in two different stages. During the first stage,
coarse lumps of materials being fed into the mill and crushed down to a more manageable
size by the action of the grinding media (ball charge).

• In a two chamber mill, this stage is carried out in the first chamber which generally occupies
about 27% of the effective length of the mill. The first chamber shell lining must be designed
to ensure an efficient lifting effect of the grinding media so that it can crush the material by
an impact action, this being essential as coarse material can only be reduced under this
condition. However, the lining must not lift the charge too high as this would result in some
of the media falling directly onto the shell liners, resulting in increased wear.

• The first chamber media charge must ensure a maximum number of impacts on the
material to be ground and the forces generated must be strong enough to quickly reduce
the material size. The choice of grinding media in the first chamber will be depended on the
size and type of material being ground, but in most cases the media ranges in size from 90
mm to 60 mm diameter.
• Once the material has been reduced in size in the first chamber, it is discharged by means
of a diaphragm into the second chamber of the mill where the next stage of grinding will
take place.

• During the second stage of material grinding, it is necessary that an attrition action takes
place rather than an impact action, because the material entering the second chamber has
already been reduced to more manageable size.

• Second chamber linings are designed firstly to enable an attrition grinding action to take
place and secondly to produce an automatic segregation of the grinding media,
• Automatic segregating (classifying) liners are designed to direct the large media to the inlet
end of the second chamber, with a gradual reduction of ball size along the length of the
chamber.

• There is a ratio that exists between the product size and the media size which varies at every
point along the second chamber as the product becomes finer, Generally the optimum ratio is
reached with 50 mm diameter at the inlet end, with gradually decreasing diameter of media
along the rest of the chamber.

• When a material has reached the finished size, it is discharged from the outlet end of the
second chamber by means of a diaphragm and is then lifted out of the mill by a series of
fabricated steel lifters and guides.
• Figure below shows a schematic arrangement of a two chamber tube mill fitted with step and
classifying liners.
FIRST CHAMBER SHELL LINERS
 STEP LINERS (1.5M TO 5.0M DIAMETER MILL)

• These are widely accepted as the most efficient type of lining that can be used in the first
chamber, although it is only with the introduction of hard chromium iron alloys that these
liners have been used. The development of harder materials arose due to the inability of the
original manganese steel liners to retain their shape, with the ‘step’ quickly wearing down
thereby becoming ineffective. Step liners produced in hard alloy materials retain their shape
extremely well and, therefore, have the great advantage of being able to provide an efficient
lifting action of the grinding media throughout their life.
• The most important characteristic of first chamber liners is that they are able to lift the
grinding media high enough in the mill to ensure that an impact action takes place between
the media and the material being ground. Step liners are able to perform this lifting action
more efficiently than any other type of liners (e.g. Single hump liner) in mills ranging in sizes
from 1.5M to 5.0M diameters, this is because of the shape of the step liners provides for a
maximum retention of media in a stable state until the point of cascade.
• Below is a typical step liner for a 2.8M diameter tube mill. Although the dimensions of the liner
is based on standard mill bolt hole drillings at 250 mm horizontal separation and by 100π mm
around the circumference of the mill shell, the sizes and the shape of the liners can be
modified to suit any other bolt hole configurations, as well as boltless or semi-boltless linings
if required.
STEP LINER FOR2.8M DIAMETER MILL
 SINGLE HUMP LINER (BELOW 1.5M DIAMETER MILL)
• For tubular mills of less than 1.5M diameter, the advantages of step liners
are out-weighted by two important factors.

• Firstly, the increased height of step liners over that of the equivalent hump
design can reduce the effective volume of the mill to such a level that the
throughput of materials is actually reduced.

• Secondly, the slight increase weight of a step liner may, in small mills,
increase the initial power consumption of the drive motor quite
considerably.

• The overall effect of these two factors combined, could therefore, outweigh
any increase in design efficiency resulting from the application of a step
liner.

• Therefore, for most small diameter mills, a single hump liner is

recommended. This design of liner will not lift the media as efficiently as a
step liner but benefits from its light weight and profile.
SINGLE HUMP LINER FOR 1.5M DIAMETER MILL
SECOND CHAMBER SHELL LINERS
 CLASSIFYING LINERS (1.5M TO 5.0M DIAMETER MILL)

• Classifying liners produce a segregation of the grinding media, the large balls being
directed toward the inlet of the chamber, with the media size decreasing gradually from the
inlet end towards the outlet where the smallest media is located.

• By achieving this segregation an optimum balance between media/material size is achieved

and hence the most efficient grinding action results, leading to increased yield compared to
other types of liners.
• In a mill equipped with standard multi-wave liners, classification is not normally achieved and
perhaps worse still, in certain cases a reverse segregation of the grinding media occurs, with
small media being directed towards the inlet end and large media towards the outlet end of
the chamber. It is clear that such a situation will lower the efficiency of the mill, as small
media, e.g. 16mm diameter ball, is completely inefficient in reducing particles entering the
second chamber of a grinding mill. Similarly, large media, e.g. 50mm diameter ball, would be
inefficient in reducing particles located at the outlet end of the mill due to its lower surface
area to volume characteristic.
• The design and dimensions of classifying liners alter as mill diameter increases. In small
diameter mills, e.g. less than 2.4M diameter, classifying liners of 250mm pitch length
provide an efficient segregation of the grinding media throughout the chamber. In mills of
larger diameter, it has been established that classifying liners spread over 500mm pitch
lengths give the most efficient segregation. In such cases, two liners of 250mm pitch
length are combined to make one classifying pitch.

• All classifying liners are flared towards the outlet end of the second chamber, the angle
of flare bring depended on the mill diameter, 50 to 200 being more efficient in small
diameter mills and 200 to 250 being more efficient for large diameter mills. Whatever may
be the angle of flare, the maximum height of the classifying liners should never exceed a
value (0.05 x mill diameter) in order to avoid an excessive decrease in the effective
volume of the mill.
• Immediately preceding each flared section is a horizontal zone which help to govern the
maximum height of the classifying liner, without having to reduce the fare angle. This
zone also acts to direct large media towards the inlet end of the chamber whilst
gradually pushing the small media to the highest part of the flare angle and thus towards
the outlet end. The length of this zone will vary with the maximum height, angle of flare
and diameter of the mill but it is generally between one to two times the maximum height
of the classifying liner.

• Classifying liners are designed with a series of corrugations along the flare angle, which
aids in the lifting of the media and enables a efficient grinding action and grading action
to take place with minimum slippage.

• The radius of corrugation will vary along the entire length of the flare angle due to the
circumferential length of the liner altering at every point along the angle of the flare. It will
also depend on the number of corrugation that can be fitted into the circumferential pitch
of the liner. However, as a general guide the radius should be approximately 50 mm.
 CLASSIFYING LINER FOR 2.8M DIAMETER MILL
• The dimensions shown in this figure are based on standard mill bolt-hole drilling of 250mm
horizontal separation and by 100л mm around the circumference. However the sizes and
shapes of the liners can be modified to suit any bolt drilling in addition to semi-boltless or
completely boltless mill situation.
• Some designs of classifying liners eliminate the horizontal portion of the liner and instead
use two or three different flair angle and 250mm pitch depending on the diameter of the
mill. An example of such liner for a 2.8M diameter Mill shown below.
• Similar to this concept a design of classifying liners for 5M diameter mill is shown below:
 MULTIWAVE LINER FOR MILLS WITH DIAMETER OF 1.5M & BELOW

• For mills of very small diameter a classifying liner is not recommended for two major reasons.

• Firstly, the relative higher weight of the classifying lining over that of a standard multi-wave
lining may impose too great a load on the motor, taking into consideration the relative low
power motors normally installed in small mills.

• Secondly, in order for an effective angle of flare to be achieved, the maximum height of the
classifying liner necessary would reduce the effective volume of the mill by an excessive
amount, resulting in a possible loss of efficiency and lower material throughput.
• For these reasons it is recommended that a non-classifying lining to be used in small
diameter tube mills.

• A standard multi-wave liner as shown in the next slide will provide the necessary lifting action
required by the media to achieve a grinding action. It will not however provide segregation of
the grinding media, therefore, the mill will never work with optimum efficiency.
MULTI-WAVE LINER FOR A 1.5M DIAMETER MILL
FEED END WALL LINERS
• Feed end liners are designed to provide a smooth entry of material into the mill and
to offer necessary protection to the mill shell at this point.
• To achieve this, the most efficient design has been shown to have smooth inlet
liners, completely free from any ribs, radiating down the length as occasionally found
in certain alternative approaches. Increased wear is common on all vertical lining
parts particularly in the first mill compartment. The position of the greatest wear can
be calculated from the following formulae and illustration given below:

MILL CENTRE LINE

R A B

WEARING ZONE

MILL SHELL

• A = R x 0.48, B= R x 0.78 where R is the radius of the mill measured from its centre
line to the inside surface of the shell.
• To accommodate for the increased wear at the feed end, the thickness of the inlet
liners which are situated high wear zone are normally increased by approximately
20mm over the reminder of the liners.
• Inlet liners are generally segmented to facilitate ease of both manufacture and
handling.
• The overall size of each segment will be depended on the number and spacing of bolt
drillings in the inlet shell, with a minimum of two bolt holes being required in each segment. It
should also be noted that segments must be small enough to be taken through the man hole
for fitting.

• As stated earlier, the feed end liners must of necessity be of substantial thickness to endure
the tremendous impact and increased wear during operation. However, the thickness must
not be so great as to adversely effect the efficiency of the mill due to either their increased
weight or excessive reduction of the effective mill volume. For most application, a thickness of
30mm to 40mm is recommended depending on the diameter of the mill with an increase to
50mm to 60mm respectively at the wearing zone.

• A design of a inlet head liner for a 2.8M diameter mill is shown in the next slide.
 INLET END LINER FOR 2.8M DIAMETER MILL

1135dia
22.50°
R643.5
X
R40.0 40.0

157.0

476.2
2790dia

54.0 Ø100.0
6.0 450.9
511.3

45.0
B

R15.0 50.3 11.25°

442.3
SECTION XX
45.0
3.0 3.0

R1594.3
VIEW B X R1581.8
DIAPHRAGMS
 INTERMIDIATE DIAPHRAGMS

• These items which are effectively slotted plates are positioned between the first and second
chamber of the mill, their application being to hold back the first chamber ball charge while at
the same time allowing the partially ground material to pass through into the second chamber
for further grinding. There are basically two types of intermediate diaphragm, a single plate
and foot design, and a double plate with lifters. Both type perform the same function, namely
that of ensuring a smooth and efficient transfer of material of the correct size from the first
chamber to the second chamber.
• The factors that govern which type of diaphragm to use are the size of the mill, and in case of
small mills, its weight and cost. For small diameter mills of less than about 2.8M diameter,
with a relatively low throughput of material, it is cheaper and just as efficient to use a single
plate diaphragm and foot. It is also a lighter weight design than the double plate type, which
in small size mills can be a significant factor.

• Whenever possible, slots should always be laid out circumferentially rather than radially as
this helps to reduce “peening over” of the slots by the media during service and its adverse
affect of restricting throughput.
 SINGLE PLATE DIAPHRAGM
• The single plate design consists of a series of segments, each with a pattern of slots, through
which the finished ground material from the first chamber passes through to the second
chamber for further grinding.

• The segments are held in position in the mill by bolting to a circumferential row of foot liners
which are themselves bolted to the mill shell, and which whenever possible are of the same
width as the standard shell liners, to prevent the necessity for the provision of any special
liners for fitting purpose. For small mills, more often than not, the foot liner is an integral part
of diaphragm itself.

• Two clamping rings are bolted on either side of the segments at the inside diameter. These
are used to keep the diaphragm segments vertically in line for rigidity.

• Such an arrangement for a 2.4M diameter mill is shown in next slide.

 DOUBLE PLATE DIAPHRAGM

• Double plate diaphragms with centre lifters are used generally for mills of diameter greater
than 2.8M. They offer a more rigid design than the single plate type and also permit a more
efficient flow of material ( an important factor in the larger mills with the increased quantity of
material passing through them) due to the action of the centre lifters.

• The assembly consists of series of ring segments, each with a series of slots on the first
chamber side and bolted on to a steel framework. On the second chamber side is a series of
liners of similar size but without slots, these also being bolted on to a steel framework.
• In between the two steel frameworks mentioned above are a set of curved steel lifters which
radiate from a cone in the centre of the mill, to the mill shell.

• As the mill rotates, ground material from the first chamber of the mill passes through the slots
in the plates on to the steel lifters at the centre of the framework. The lifters carry the material
to the centre of the mill where a cone discharges the material into the second chamber. The
plates on the second chamber side are designed to provide a barrier between the lifters and
the second compartment.
• The total width of the diaphragm arrangement usually corresponds to the width of a standard
shell liner, to prevent the need for special shell liners. The diaphragm framework is bolted to
the shell of the mill by a series of bolts at the same circumferential pitch as for the shell liners.

• This style of diaphragm is well suited to large mills where a strong construction is needed to
take the tremendous battering from the media and where the built-in lifters can cope with the
high throughput of material efficiently.

• A double plate diaphragm arrangement with lifters for a 4M diameter mill is shown in the next
slide.
 1st CHAMBER

LIFTER PLATE LIFTER PLATE

2nd CHAMBER
• Both type of diaphragm plates need to be of sufficient thickness to withstand the high rate of
wear caused by the action of the grinding process, especially in the first chamber size. In
practice the thickness is limited by the weight of the plates and by the reduction of the
effective volume that can be withstood. Generally the thickness will range between 40 to 50
mm depending on the mill diameter for double plate diaphragms and 50 to 55 mm for single
plate diaphragms.

• The overall dimensions of individual plates are determined by both their ease o
manufacturing and handling and also the dimensions of the man-hole.
 FLOW CONTROL DIAPHRAGM

• This type of diaphragm arrangement helps in improving the working condition of the mills and
increase the production or reduce the power consumption, grinding media and liner wear.
This type of diaphragm enables adjustment of the material level in the grinding chamber.

• The basic principle of this type of diaphragms is to control the flow of material from first
chamber to second chamber to suit the product fineness and particle size distribution.
• In standard double diaphragm with plain lifters, the flow of material from first chamber to the
next is not controlled by the diaphragms. Desired particle size distribution have to be
achieved by limiting the circulating load or by a very highly selective separator. This causes
lack of material in first chamber and in turn increases wear and reduces energy efficiency.

• In flow control diaphragms, instead of lifter plates, there are number of scooping devices
whose lifting capacity can be controlled by changing the angle of their openings, thereby,
controlling the movement of material. As a result high circulating load in conjunction with finer
ball charge can be used and as the material level is always high in first chamber, less wear
and high energy efficiency can be achieved.
• A schematic arrangement of a Flow Control Diaphragm is shown below:
 OUTLET DIAPHRAGM

• Outlet diaphragms are situated at the outlet end of the second chamber of a tube mill.
Generally they are of similar construction to a two plate intermediate diaphragm, with a series
of segmented plates containing a pattern of slots bolted to a steel framework. The framework
is adjacent to a series of steel lifters which radiate from a cone in the center of the shell. The
outlet diaphragm differs from the intermediate diaphragms as it does not have a set of blank
liners on the other side of the lifters. In this instance, the lifters back on the mill shell or on to a
series of mild steel plates attached to the shell. As the mill rotates the finished material from
the second chamber passes through the slots in the plates and on to the steel lifters. The
material then slides along the lifters to a cone at the centre of the mill where it is directed out
of the mill via the trunion.
• Outlet diaphragm plates are usually of the same overall size as those in intermediate
diaphragms, the only difference being the size of slots. In most cases, the bolts holding the
plates will pass straight through the framework arrangement and are bolted on the outside of
the shell. Each plate needs a minimum of two bolts for adequate support.

• An outlet diaphragm arrangement for a 4M diameter mill is shown in the next slide.
 LIFTER
PLATES

DISCHARGE CONE
• In some cases the design differs from the above by combining the plates and lifters into one
casting. Although this increases the cost of the castings, economies may be gained as there
is no need to have a steel framework. However, this is not a practical proposition in most mills
as the overall size of the liners would prevent them passing through the manhole for fitting.

• As with intermediate diaphragm, the slots should always be laid out circumferentially rather
than radially.
DIAPHRAGM SLOT DESIGN
 INTERMEDIATE DIAPHRAGM SLOTS
• The size and number of slots in a diaphragm plate will depend on several factors, such as the
type and size of material being ground and the throughput required. Experience has shown
that the ideal slot size for an intermediate diaphragm to be one of 6mm wide, with a design
similar to that shown below:

• This design allows maximum throughput of material and the flared angle on the inlet side
helps to prevent the slots from blocking during service.

• The total number of slots in the diaphragm and hence the effective area will again depend on
the factors such as throughput required. However in most applications it has been shown that
the area should be the maximum that can be practically achieved, as this will compensate for
any slots which do get blocked and will allow sufficient cooling air to pass through the mill.
The effective slot area of an intermediate diaphragm in relation to the mill area will usually be
between 4% and 14%.
 OUTLET DIAPHRAGM SLOTS
• Similar factors govern the size of the outlet diaphragm slots as those in intermediate
diaphragms.
• Generally, it has been shown that the optimum slot size for an outlet diaphragm liner to be
one of 8mm wide, with a design shown below:

• This design is identical to the intermediate diaphragm slot and has all the same advantages.
• The effective area and number of slots will, as before, be dependent on a number of factors
such as the throughput required. The effective area of an outlet diaphragm in relation to mill
area will usually be between 6% and 15%. It is important that that the slot size be reasonably
small, particularly in open circuit mills to avoid either blocking or the loss of small worn media.
• Blanking plates (solid plate without slots) can be provided to help to regulate or reduce flow of
material to a required level, which is especially useful in open circuit mills in order to retain
material for a longer period in the grinding chamber.
BOLT SPACINGS
• The spacing or pitch of the bolt holes in the shell of a mill available for holding liner plates is
extremely important, as the distance between each bolt hole will govern the following:-
1. The size and shape of the liner plates.
2. The number of different size of liners required and therefore, the number
of patterns required.
3. The total number of liners (all sizes) required.
4. The individual weights of the liners (important from the handling and fitting
aspects)

• The majority of the tube mills of metric dimensions built nowadays are supplied with bolt
holes drilled to the German DIN standard spacing of 250mm along the length oh the shell,
and 100л mm (314.2mm) around the circumference. This is the most suitable spacing
because of following reasons:-

a) The total number of different patterns needed to line the entire shell can be reduced to a
minimum, in many cases as little as 3 or 4 patterns being required.
b) If the plant has more than one mill of the same diameter with standard bolt spacing, the
same liners can be used in each mill, as they are fully interchangeable. This will mean the
total number patterns for all the mills will be 3 or 4 as against the usual 14+ patterns needed
in each mill of non standard drillings. The spares for each mill and also the storage costs will
be considerably reduced. Lower production costs are frequently achieved
as mechanized molding method for bulk production may be used.

c) The liner plates are usually smaller in size and are much easier to handle, both during
manufacturing and during fitting in the mill.

d) Inspection will be easier and cheaper due to the standardization of liner plate design.

e) The design of the liners will quicker and cheaper to detail and the arrangement will appear
more presentable to the customer.
• Virtually all the older tubular mills and even some newer ones have non standard drillings. In
addition, some individual manufacturer adopt their won standard for use in their range of
mills. If bolt spacing required a single bolt liner having a overall size greater than
400x400mm, then serious thought should be given to adopting a semi-boltless lining design.
SEMI-BOLTLESS LININGS
• For tube mills with bolt spacing of more than 400mm either circumferentially or longitudinally,
it may advantageous and, in some cases, essential that a semi-boltless design is utilized.

• Some of the criteria which help to determine whether a bolted or semi-bolted lining should be
used are as follows:-

1. Would a single bolt liner be too big to go through the manholes in the mill?
2. Will the single bolt liner be so heavy to make manufacture and fitting difficult?
3. Can the shape of the step or classifying liner still be effective over a long pitch?
4. Would the pattern quantity required for a semi-boltless lining be too great (in some cases, it
can be double the quantity required for a single bolt liner arrangement)?
5. Is the mill shell accurate enough or in good enough condition to accept the close tolerances
required of a semi-boltless lining?
6. Does the customer have the skilled labor and the necessary equipments should the semi-
boltless liner require any on-site dressing for accurate fitting?
7. Production and inspection costs will be greater due to more dressing being required and a
jig being required to establish the accuracy of dimensions.
• There are basically three different designs of semi-boltless linings used in tube mills:-

• Bolted Wedge –
This design can be used in tube mills with bolt spacing of between 400mm to 800mm in both
first chamber and second chamber. The design consist of a bolted liner at every bolt pitch
with one un-bolted liner in between i.e. a bolted, un-bolted, bolted, un-bolted liner
arrangement through rings and rows of liners in the mill. The bolted liners are shaped
sufficiently to act as a “wedge” against a suitably shaped un-bolted liner to be held firmly in
position.

Each un-bolted liner is manufactured with small machining pads along the mating faces to
enable accurate seating of the liners by grinding suitable amount of material off the pad
where necessary. An example of wedge type semi-boltless liner is shown below:
• Multi Wedge:

This design can be used in tube mills with bolt spacing so far apart as to require more than
one un-bolted liner between every bolted liner. This would apply to bolt spacing of about
800mm upwards as long as long as there are at least some bolt holes in the ring or row.

Unlike the previous design, the bolted liners cannot hold the unbolted liners in position purely
by the action of a “wedge shape” as this would only be effective on an un-bolted liner
adjacent to a bolted liner.

In this design, each liner, both bolted and un-bolted, fits flush against the next. The bolted
liners therefore act purely as a means for ‘pushing’ and ‘locking’ all the liners against each
other. Each liner is provided with a male and female nib arrangement at the mating surface
for accurate location.

Due to the fact that each liner must seat flush against its adjacent liner, the overall dimensions
between the mating surfaces must be very accurate which will necessitate each liner being
dressed and checked in purpose made jig. An example shown below:
• Shimmed Liners:

An alternative design which eliminates any accurate machining and the need for jigs is
achieved by placing between each liner a mild steel shim.

The shims are supplied in a variety of thicknesses, usually 3mm to 9mm so that any
inaccuracies can be eliminated by selecting a suitable shim thickness.

Each shim is provided with male nib in each mating surface which eliminates accurate
locations to be made with a suitably positioned female slot on the mating faces of the liners.
Each liner is manufactured to give a theoretical 6mm gap between each pair of liners.
Therefore, the range of shims (3mm to 9mm) should be sufficient to take up any discrepancy.

The bolted liners again act as a useful means of pushing all the liners and shims firmly
against each other. An example shown below:
 Advantages & Disadvantages of Semi-Boltless Linings
• The disadvantages are many and include the following:
1. The total number of patterns required in most cases be double that of a single bolt lining.
2. More dressing of the castings will be required.
3. More accurate inspection and usually a jig will be necessary.
4. If the liner cracks or breaks, there is a serious danger of any unbolted liners adjacent to it
breaking loose in the mill, leaving the shell exposed.
5. At least 3 liners must be lifted each time a liner is to be replaced.
6. Sufficient skilled labor will be required on site to enable accurate fitting of the liners.
7. On site dressing may be required on some liners if bolt-hole centers are not drilled
accurately in the mill shell.

• The advantages are as follows:

1. Eliminates the need for a customer to re-drill the mill shell to enable a single bolt lining to be
installed.
2. Less bolt holes will result in reduced spillage.
3. The mill shell may possibly be produced with a thinner section.
BOLTLESS LININGS
• Tubular mills manufactured with no bolt holes drilled in the shell can obviously only be lined
using a lining that is not depended on bolts. Such a lining would either have to be capable of
holding itself in position or rely on a material such as cement to hold in position.

• Whatever lining is employed, it will still be necessary to have at least some bolted liners in the
mill. Those would be required for the man-hole and surround liners and for the first and last
row of each chamber. This is essential both for the initial fitting of a lining and for replacement
or lifting of an worn out or broken liner. It may be also necessary to remove the first or last
row to replace the end liners or the diaphragms liners.
• The disadvantages of boltless linings compares to a bolted lining are far greater and much
more serious than its advantages:-

1. Fitting the liners in the mill is much more difficult, as once one half of a ring of liners are
fitted, it is necessary to hold the liners in position while the mill is rotated and the other half of
the ring is fitted. To achieve this, it is necessary to use a hydraulic jack to hold the first half of
the ring in place as the mill is turned through 900 and 1800. This is obviously a time
consuming and costly operation, as every ring of liners in the mill has to be fitted in this
manner.

2. Once the mill is in operation, should any liner break it is quite possible that the entire ring of
liners would collapse causing possible damage to the mill and the exposed mill shell. If this
went un-noticed for any length of time, it is also possible that adjacent rings of liners could
slide free and also come down with catastrophic result.
3. Should liners break or even just crack and need replacing, there enormous problem. To
replace the individual liner, the liner adjacent to it must be removed to enable the liner or shim
to slide into position. If the liner to be replaced is located towards the centre of a chamber,
then one adjacent liner in every ring up to and including the bolted inlet or outlet rings need
removing to enable a replacement liner to be slide into position. This means that each ring
from which a liner is removed must be jacked up to prevent all other liners falling out, this
operation being extremely lengthy and of course costly.

4. The mill shell must be accurate and free from any residue material to enable the liners to
seat accurately, otherwise excessive dressing or a sloppy fit may result.

5. Manufacturing cost will be higher due to more accurate castings, increased dressing and
inspection jigs being required.
• Boltless linings do have some advantages over a bolted lining, the more common ones are
listed below:

1. The initial cost of the mill shell is cheaper, due to its savings time and expense of setting
out and drilling the shell.

2. No problem of leakage of ground products from bolt holes.

3. A reduced number of bolts becoming loose and requiring re-tightening.

4.Cost of bolts reduced or eliminated.

• When all the pros and cons are examined and drilling of mill shell is not preferred, there are
three types of boltless linings that can be used.
• There are basically three types of boltless linings that can be employed successfully in
tube mills. All of the used boltless lining plates throughout the entire length of the mill apart
from one ring of bolted liners at each end of a chamber and one set of bolted manhole and
surround liners at each manhole.

1. This design is same as that of semi-boltless liners, except that there are no bolted liners in
the rings or rows, the liners relying purely on the tight fit of the adjacent liners to hold them
against the mill shell.

Due to there being no bolted liners in any rows or rings to help push the liners together, it
is essential that the overall dimensions of every liner as accurate as possible. This can
only be achieved by accurate dressing and checking in a jig and occasionally by using a
final shim.
2. Shimmed Liners:

This design is based on the same principle of semi-boltless shimmed liners but as before,
there are no bolted liners in any of the rows and rings of liners throughout the mill.

The liners rely on the tight fitting of the shims to keep them pressed against the mill shell.
Care must be taken when fitting a ring or row of liners in the mill to ensure the optimum
size shims are used to achieve the tightest practical fit.

A great advantage of this design over the previous design is that no accurate dressing or
expensive jigs are required. This is made possible by using various sizes of shims to take
up any discrepancies present in the lining or mill shell.
3. Slotted liners:

The third design is a modification to the successful slotted flat wave liners. Shell liners are
produced to the same tolerances and shape as a single bolted liner, except a series of
wedge shape slots are provided in the wearing surface of the liners. The liners are bedded
into concrete which is laid on inside the mill shell. Excess concrete is forced through the
slots and between the liners as the liners are pushed into the concrete. When the concrete
sets, the liners are held firmly against the mill shell.

This method is only suitable for second chambers as there are less impact and wear and the
concrete do not wear down to a low level.
SHIMMED BOLTLESS LINER ARRANGEMENT

MILD STEEL SHIM

SINGLE CHAMBER RAW MILL
• Many mill designers favor the use of a single chamber raw mill. In such cases any of the
following ways can be adopted.

1. This design is principally similar to a classifying cement mill (i.e. 1/3rd stepped liners and
2/3rd classifying liners) but without an intermediate diaphragm. Providing the ball charge
calculation is carried out carefully then this concept has been proved successful in many
instances.

1. The other method is having the same liner throughout the mill which will the both the
functions of a stepped liner as well as a classifying liner. Because of the combined
functions they are called combination liners.

These liners have a step circumferentially and a flare angle longitudinally. As such they can
lift the ball sufficiently as well as classify the balls effectively.

A combination liner is shown in the next slide.

COMBINATION LINER
• In addition to what discussed so far a lot of information are necessary for designing a lining
system for a tube mill. Accurate dimension of the mill including shell thickness, bolt hole
details, mill r.p.m., drive system, characteristics of material being ground are some of the
important information which are to be collected before designing.

• A thorough inspection of the mill is also recommended.

• Selection of material composition of the liners is also important as some designs may not be
compatible for a particular material composition.

• Strict process control and inspection during manufacturing the liners are necessary for
trouble free fitting and satisfactory performance.