Superior Performance

Through
Innovative Technology

IhrAnsprechpartner in Österreich:
 Cement Products
• Tube Mill Parts:
• Grinding Media
• Ball Mill Liners
• Partition Diaphragm
• Discharge Diaphragm

• Vertical Mill Parts:

• Grinding Elements incl. Monometal/Inserted/Sintercast-11

• Crusher Parts
• Blow Bars
• Hammers

• Preheater Parts
• Dipping Tubes
 Introduction

PRODUCTS FOR CEMENT INDUSTRY

RANGE & CAPACITIES
Annual cap. Range
Products
M.T.
High chrome grinding
40000* 12 mm to 110 mm dia,
media
Mill liners 5500 1.8 to 5.8 M dia.mills

VSM parts static casting 1800 Up to 16.5 MT single piece

Centrifugally cast rolls 3000 Raymond/CE mills

Up to 1 MT single piece
Blow bars & hammers 700

Heat resistant castings 300 Dipping tubes

Diaphragms 50 Nos. 1.8 to 5.8 M dia.mills

*GM ca pa city pro posed to go upto 55000 MT PA in I ndia a nd 45000 MT PA in Ca nada 10
29
 Grinding Media
• First Chamber
• Vegatough 18 - Standard Grade
• Hardness >60 RC, RC Range <1%, RA <6%
• Outperforms Competition by Ave 10%
• Batch Check of Quenched Properties Allows Fine Tuning of Tempering
• All Media is Batch Tempered with 18000mt Capacity/Annum

• VegaPlus - High Performance Grade

• Hardness >63.5 RC, RC Range <1%, RA <5%
• 40-70% Improvement in Wear Rates
• High Carbide Content
• Multiple Tempering Cycles to Achieve Optimum RC & RA
 Product
Grinding media

VEGA PLUS

Vegatough-18 Vegaplus
C 2.3% Avg. 2.9% Avg
Cr. 17% Avg. 21% Avg
Other alloying 2.0% Max 4.0% Max
elements
Hardness > 59.5 RC > 63.5 RC
RA < 6% < 5%

47
 Pro duct
Grind ing m edia

VEGAPLUS
MANUFACTURING SPECIALISATION

Manufacturing of Vegaplus requires special facilities.

 This grade has very high carbide content and hence

special precautions are required during cooling of poured
moulds.

 In order to get optimum combination of hardness and RA,

this grade requires multiple stress relieving/tempering
cycles which drastically reduces production capacity.

 Thanks to special slow mould cooling techniques and large

tempering capacity available at AIAE - it is possible to
produce this material commercially.

48
 Product
Grinding media

VEGAPLUS COMPARISON WITH

VEGATOUGH 18
Plant (India) Mill Liner Produc t Blaine Vega tough 18 Materia l Vega plus
diameter profile consumption rate ground consumption rate

GACL Kodinar 4.4 m DWL OPC 3340 27.48gms/t 699396 5.97gms/t

PPC
J P Re wa 4.8 m Step liner ( 20% fly ash) 3200 92.76gms/t 655748 44.48gms/t
Durgapur PSC
Cement 3.4 m DWL (50% slag) 3500 105.00gms/t 49257 52.33gms/t

Additional feature of Vegaplus is that at the end of the trial

there was no deshaping/ tear which is observed in norm al
grind ing media. This m eans that there is no need of regrading
every year and mill can perf orm consistently for long duration.

46
 Grinding Media
• Second Chamber
• Vegahard 12 Standard Grade
• High level of Physical Integrity Through Rigorous Process Control
• Non-Automated Quality Inspections
• No Breakages or Mismatch
• Vegahard 15 High Performance Grade
• Higher Hardness and Cr Content
• Excellent Wear & Good Corrosion Resistance
• Vegahard 18
• Highly corrosion resistant grade
 Product
Grinding media

GRINDING MEDIA FOR

SECOND CHAMBER
Vega alloy Vegahard-12 Vegahard-15 Vegahard-19

Hardness (HRC) 64-68 66-69 62-66

Cr% 10-13 14-16 17-20

Wear resistance Good Excellent Moderate

50
 Product
Grinding media

WEAR RATE OF GRINDING MEDIA

Wear rate figures given below are expected wear rate for Vegatough-18 &
Vegahard-12, for both the chambers taken together. Normally, both the
chambers contribute equally to the wear rate
Material Fineness (Bl) Range of wear rate gm/T
OPC 3000 30-50
OPC 4500 60-100
PPC (25% fly ash) 3800 80-160
PSC (55% slag) 3800 120-160
PPC (25% fly ash) 4500 160-190
PSC (55% slag) 4500 160-190
PSC (70% slag) 4500 120-210
Limestone (<1% SiO2) - 20-25
Limestone (6% SiO2) - 75-100
Limestone (10% SiO2) - 190-220
Coal (15% ash) 17% R/90 Microns 60-100
Coal (>25% ash) 17%R/90 Microns 120-150 58
 Product
PROBLEMS ENCOUNTERED WITH Grinding media

GRINDING MEDIA
DURING SERVICE

Selecting the correct grinding media for a particular application

is important to avoid potential problems, such as:

 High wear rate

 Deshaping
 Spalling
 Breakage

These problems can usually be traced to either quality of balls

or peculiar working conditions.

53
59
 Design conc ept

THE GOLDEN TRIANGLE

There has to be total compatibility between application,
metallurgy and design.

24
Product
Ball mill liners

71
 Products
Ball mill liners

ALLOYS FOR FEED HEAD LINERS AND

FIRST CHAMBER SHELL LINERS

Vega Alloy Vegaline-107 Vegaline-112 Vegaline-125

Hardness (HRC) 49-52 48-52 54-56
C% 0.2-0.5 1.0-1.5 2.2-2.6
Cr % 6-9 11-14 22-26

Wear resistance Moderate Good Excellent

Impact resistance Excellent Good Moderate

75
 Products
Ball mill liners

FIRST CHAMBER LINER -

FEATURES
Choice of design of liners depends on mill operating
parameters such as :

- Mill Dia
- Speed Of Rotation Hardness
- Material To be Ground Feed Size
- Volume Load Composition
- Max. Ball Dia
- The Length Of The Chamber

77
 Products

FIRST CHAMBER LINER –

Ball mill liners

VARIOUS PROFILES
Profile Feature and Application Sketch
Step liners- Continuous and sufficient lifting action.
Different
profiles like -Standard application where some amount of
smooth or fine generation is expected in the crushing
wavy zone also.
working face
and high lift -For hard feed materials
depending on
the operating -For mills showing high wear of internals due
conditions to slippage phenomenon.

Double wave Crushing efficiency remains constant

Liner- throughout its working life. The dead zone
is minimum.

When the material to crush is extremely hard

and high lifting action is required

78
 Products

FIRST CHAMBER LINER –

Ball mill liners

VARIOUS PROFILES

Profile Feature and Application Sketch

Doublestep Crushing efficiency remains constant

Liner almost throughout its working life.

When high lifting action is required but

the mill has high speed of rotation

79
 Products
Ball mill liners

VEGALITE LINERS

 Unit weight of individual liner is restricted to 25 kgs.

 Ease of handling

 Modular design for fitment in wide range of mill sizes

 Supply of liners at reduced delivery time

82
 Products
Ball mill liners
VEGALITE LINERS FOR
MILL DIA. 4.0 TO 4.4 M

84
 Products
Ball mill liners
FIRST CHAMBER LINERS -
BENEFITS OF DOUBLE WAVE LINERS

 Reduces the slippage of balls

 Reduction in the SPC of the first chamber.
 The grooving phenomenon is much less
 More lift results in better crushing efficiency.
 The dead zone is reduced.
 Due to uniform wear, the lifting action is consistent
throughout the life time
 Boltless design benefits in elimination of breakage,
falling of liners, more uniform metallurgy etc.

86
 Products
Ball mill liners

ADVANTAGE OF DOUBLE
WAVE LINERS

Mill equipped with DWL Liner

Dead zone

Mill equipped with S&W Liner

Dead zone is
minimized
87
 Products
WEAR PROFILE OF DOUBLE WAVE Ball mill liners

LINER - LAKSHMI CEMENT

CM#1: 4000 dia. X 15050 L

Date of Installation : 26.05.1996

Date of Removal : 19.07.2001
Running hours : 31,000 hrs.
Material ground : 2,945,000 Mt

Weight Lifting % of % of
(KG.) height Weight Lifting
(MM ) height
Worn-out 37.63 51.7 53% 72.8%
liner

Worn-out 32.55 19.3 47% 27.2%

portion

Original 70.18 71 100% 100%

liner
91
 Products
Ball mill liners

QUICK RESPONSE : AN EXAMPLE

Customer Kryvy Rih Cement (Heidelburger Zement), Ukraine

Product Complete mill internals (AIAE design) with grinding

media and water spray system.
Date of receipt of 27th August 2003
enquiry
Date of submission of 15th September 2003
techno – commercial
offer
Date of receipt of 16th October 2003
order
Committed delivery 6 th February 2004 unloaded at port Odessa for mill 1.
23rd February 2004 unloaded at port Odessa for mill 2.
70
99
 Product
Partition diaphragm
LEVEL CONTROL DIAPHRAGM -
FUNCTION

 To keep the material level in the 1st

chamber at an optimum level.

 The material entering the diaphragm

chamber through the slotted grates
exits into the second chamber only
through the rotating cylindrical lifters.

100
 Product
Partition diaphragm
LEVEL CONTROL DIAPHRAGM –
CYLINDRICAL LIFTERS

These lifters can be easily adjusted by turning them on their axis.

Q (Lifter output/mill through put) = S (Effective c/s area) x h (Effective
material height in the lifter) 101
= constant
 Product
Partition diaphragm

ALLOYS FOR WEARING PARTS OF

LEVELCONTROL DIAPHRGM

Vega Alloy Vegaline-107 Vegaline-112 Vegaline-125

Hardness (HRC) 49-52 48-52 54-56
C% 0.2-0.5 1.0-1.5 2.2-2.6
Cr % 6-9 11-14 22-26

Wear resistance Moderate Good Excellent

Impact resistance Excellent Good Moderate

109
Product
Ball mill liners

71
 Products
SECOND CHAMBER LINER - Ball mill liners

VARIOUS PROFILES

Profile Feature and Application Sketch

A very high level of attrition
Standard leading to maximum
Classifying
grinding efficiency.
Liner
Standard application for 2nd
chamber of ball mills where
highest level of grinding
efficiency is required.

Deep Wave Improved wear resistance by

Classifying reducing the ball slippage.
Liner
When a coarse final product is
desired and some amount of
crushing is also needed in the
2nd chamber.
111
 Products
SECOND CHAMBER LINER - Ball mill liners

VARIOUS PROFILES
Profile Feature and Application Sketch
Conveying Improved material transport in the
Classifying mill alongwith the normal
Liner classification function.
When a high volume loading is required
which in turn leads to problem of
material flowability due to higher level
of restriction by the balls.
Lifting High air volumes can be utilized in the
Classifying circuit since possibility of changing to
Liner mono chamber configuration.
Usually for applications where it
becomes necessary to have both crushing
and grinding in the same chamber.
Thin For mills requiring a very high
Classifying volume loading to absorb maximum
Liners available power. 112
 Products
Ball mill liners

ALLOYS FOR SECOND CHAMBER

SHELL LINERS

Vega alloy. Vegaline-212 Vegaline-225

Hardness (HRC) 55-57 59-61

C% 1.5-2.0 2.2-2.6

Cr % 11-14 22-26
Wear resistance Good Excellent

Both the grades are suitable only for non-lifting liners and ball charge with
<60 mm dia balls.

113
115
 Product
Discharge diaphragm

OUTLET DIAPHRAGM - FUNCTION

 Free passage of material from

chamber to the mill outlet

 Ensure maximum opening

area for optimum ventilation

 Prevent escape of small size

grinding media from the mill

116
 Product
Discharge diaphragm
OUTLET DIAPHRAGM -
FEATURES

AIAE outlet diaphragm has important features like peripheral

ring bolted to the shell ensuring perfect sitting of the frame
and overlapping grate plates to prevent leakage of materials.

The design is adapted for any type of shell drilling pattern and
sizing of parts is such that they can be easily carried inside
the mill through manhole also.

117
 Product
Discharge diaphragm

ANTI-CHOKING GRATES

118
 Designing &
retrofitting
ACC TIKARIA – CM#1
Breakage observed in CM# 3 internals supplied by competition.
No breakage in CM#1 internals designed and supplied by AIAE in suitable
metallurgy.

125
Competition internals AIAE internals
 Designing &
retrofitting
LAFARGE SEATTLE FM#2,USA
After AIAE designed internals were installed, significant
reduction in power was noticed.
Mill no. Before After
Diameter 4.0 m
2nd chamber liner Dragpeb Classifying
Absorb power 1613 KW 1497 KW
Output 40 tph 40 tph

Specific Power consumption 40.75 KWh/T 37.45 KWh/T

Saving in Specific power 10.4 %

128
 Designing &
retrofitting
LAFARGE ARASMETA CM#1, INDIA
Initial design was by FLS. After detailed study,we decided to change
chamber lengths, partition wall diaphragm and second chamber liners.
These steps resulted in significent improvement in performance.
Mill no. Before After
Diameter 4.0m
Length 10.93m
RPM 16.54
1st chamber liner Block type Block type
Intermediate dph. Combidan LCD
2nd chamber liner Dragpeb Classifying
Absorb power 2756 KW 2644 KW
Blaine (OPC) 3000 3200
Output 65 tph 76 tph
Superiority in Production 16.9%
Saving in Specific power 21.8% 127
 Products
Ball mill liners

LIFE GUARANTEES
The table below gives guarantees for OPC grinding at 3600 Blaine.
Description of parts and a lloys Gua rantee Expected
life

Head liner Vegaline125 20,000 h 25,000 h

Head liner Vegaline112 15,000 h 20,000 h
Grates for LCD – Vegaline 107 12,000 h 18,000 h
Bac k plate for LCD – Vegaline 112 25,000 h 30,000 h
Discharge grates – Vegaline 112 30,000 h 35,000 h
1 st Ch. lifting liner Vega line 112 25,000 h 30,000 h
1 st Ch. lifting liner Vegaline 125 30,000 h 40,000 h
1 st Ch. Double wave line r- Vegaline 107 25,000 h 30,000 h
2 nd Ch. Classifying liner - Ve galine 212 50,000 h 60,000 h

OPC at 4500 Blaine, less 15%.

PSC with 3600 Blaine less 25%.
PSC with 4500 Blaine less 40%
Dry lime stone with <1% SiO2 add 30%
Dry lime stone with 6% SiO2, less 40% as per above.
The above figures of guarantees of liners are for guidance only. 97
 Products
Ball mill liners

LIFE GUARANTEES

The actual wear rates are governed by various factors such as :

 Hardness of clinker and its grindability.

 Moisture in the additives.
 Type of circuit (Roller press/ Separator/Pregrinder/Precrusher)
 Maximum ball size.
 Volume loading.
 Material level.
 Condition of liners.
 Type of diaphragm etc.

98
 Products
Vertical mill parts

AIA/VEGA TODAY

 30000 tons of wear parts for vertical mills used.

 400 mills retrofitted with improved performance

 More than 2000 inserted rolls used

 Products
Vertical mill parts

MANUFACTURING CAPACITY –
MAXIMUM WEIGHT PER PIECE

 Inserted rollers – 12 MT

 Conventional (monometal) rollers – 16.5 MT

 Table liners – 10 MT
 Products
Vertical mill parts

ALLOYS FOR TABLE LINERS AND ROLLS

Specification C% Cr% Hardness % carbides

Vegaline V20 2.6 20 60 RC 27

Vegaline V16 3.0 16 64 RC 30

Vegaline V26 3.2 26 63 RC 35

Sintercast-11 Composite of high chrome iron and nonmetallic

refractory oxides.
 Products
QUALITY PLAN FOR PROCESS Vertical mill parts

CONTROL OF VERTICAL MILL PARTS

Stage of manufacturing Property checked Testing procedure Frequency of check
Melting LM temperature Immersion pyrometer Each heat
Melting LM composition Optical spectrometer Each heat
Moulding Sand quality Transverse strength 1 sample per day
Moulding Mould hardness Mould hardness tester Random
Moulding Correctness of Core setting gauges Each mould
cores
Mould knock out Physical defects Visual inspection Each casting
Heat treatment Time/Temperature Data logging on Continuous data
correspondence computer logging
Annealing Hardness Rockwell hardness Each batch
tester
Fettling Dimensions Gauges Each casting
First machining Dimensions Measuring Each casting
instruments
 Products
QUALITY PLAN FOR PROCESS Vertical mill parts

CONTROL OF VERTICAL MILL PARTS

Stage of manufacturing Property checked Testing procedure Frequency of check

Quenching Hardness/RA Rockwell hardness Each casting
tester/Sigmameter
Final machining Dimensions Measuring Each casting
instruments
Final inspection Physical defects Visual/DP Each casting
Final inspection Internal soundness UT Each casting
Final inspection Correctness of Blue matching gauges Each casting
angle for rolls
Final inspection Fitment for tables Assembly Each set
Final inspection Surface protection Painting Each casting
 Product
Polysius mill parts
SUPPLIES OF POLYSIUS
COAL MILL PARTS

Mill type Customer

RMK 17 Krupp Polysius

RMK 21/30 Vasavadatta Cement

RMK 23 Vasavadatta Cement

Gujarat Ambuja
Neer Shree Cement
RMK 25/12 JP Rewa Cement
RMK 2713 Aditya Cement
Vikram Cement
 Product
Polysius mill parts
SUPPLIES OF POLYSIUS
RAW MILL PARTS
Mill type Customer

RM39 India Cements

RM41 Gujarat Ambuja

Gajambuja Cement
India Cements

RM43 India Cements

RM43 Krupp Polysius

RM46 India Cements

RM51 Gujarat Ambuja Eastern

 Product
INSPECTION PRACTICE FOR Polysius mill parts

POLYSIUS TABLES

After machining, the tables are set on an inspection table.

Reference diameters are marked. The gap between two
segments is noted. The mating surfaces are numbered.
 Product
Inserted Grinding roll

POLYSIUS INSERTED ROLLS

AIAE supply inserted rolls for Polysius Coal mills. The rolls have
composite construction. Hard high chromium iron inserts are
embedded on ductile iron. Such construction provides optimum
combination of wear resistance and safety against breakage.
 Product
Inserted Grinding roll

POLYSIUS COAL MILLS EQUIPPED

WITH INSERTED ROLLERS

Location
Sr. No OA No. Plant Mill ID Roller Specification
(State)

1 6233 Neer Shree Cement Rajasthan RMK 23 X B 17 10

2 6249 Vikram Super Cement Madhya Pradesh RMK 27/13 X B 17 10

3 6240 Vasavadatta Cement Karnataka RMK 23 X B 17 10

4 6995 JP Rewa Madhya Pradesh RMK 25 X B 17 10

5 6791 Aditya Cement Rajasthan RMK 27/30 X B 17 10

6 6239 Vasavadatta Cement Karnataka RMK 21 X B 17 10

7 7116 Vasavadatta Cement Karnataka RMK 23 X B 27 10

6
 Product
Atox mill parts

SUPPLIES OF ATOX MILL PARTS

Mill Customers No. of sets No. of sets
Designation supplied (tables) supplied (rolls)
Atox-17.5 DCC, Shree Cement 4 7

Atox-20 Madras Cement 3 3

Atox-22.5 GARL, Binani,CCGL 5 7

Atox-27.5 L & T Awarpur, L & T 5 7

Hirmi
Prism Cement, Siam
Cement
Atox-37.5 Shree Cement 3 2

Atox-40 GARL, Fuller KCP 2 3

GCCL, Binani
Atox-45 Siam City - 1
12
20
 Product
Loe sche mill parts

LIST OF LOESCHE MILL INTERNALS

SUPPLIED BY AIAE
Mill designation Customer Country
LM17/20 NCCL, KCP India
LM18/20 Aso Kanda,
LM18/20 Siam Cement Thailand
LM19/20 Vikram Cement India
LM20/15 Lafarge Arasmeta India
LM21/20 Fuller, Negeri
Simbilen
LM21/20D Alson Cement Philippines
LM24/20 Rassi Cement India
LM24/23 Rajashree Cement India
LM25/20 Siam Cement Thailand
LM26/30 JP Rewa, JP Bela, India
GACLD, TISCO
LM26/30D Maihar Cement India 23
 Product
Loe sche mill parts

LIST OF LOESCHE MILL INTERNALS

SUPPLIED BY AIAE
Mill designation Customer Country
LM30/30 APMC Kanthan Malaysia
LM30/31 Orissa, Madras, India
Dalmia Cements
LM32/40 Saurashtra, Vikram India
Manikgarh Cements
LM34/40 Lakshmi Cement India
LM36/40 DCC Sikka, Narmada India
LM36/41 Lafarge Arasmeta India
LM38/40 Padang Cement Indonesia
LM38/40 Maihar Cement India
LM38/41 Siam City Thailand

24
 Products
Sintercast-11

SINTERCAST 11 WEAR RESISTANT PARTS

For grinding material with high abrasivity we recommend
Sintercast-11 parts.

Sintercast-11 parts are a composite product involving hard

refractory oxides mixed with high chrome irons.

Sintercast-11 has proved a very effective in extending life of

wear parts.
 Products
Sinterca st-11

SINTERCAST-11 ROLL IN ATOX 27.5 MILL

Photographs after 700 RH. Sintercast parts are expected to to give

double the life of conventional high chrome parts. 56
 Products
Sintercast-11

PERFORMANCE OF SINTERCAST 11
WEAR PARTS IN ATOX 27.5 COAL MILL
Parameters AIAE conventional roll AIAE Sintercast-11 roll

Running hours 1181 1032

Production (tons) 86000* 76000

Roll average wear (mm) 24.0 * 8.5

Roll wear rate (g/t) 6.0 * 2.5

Table average wear (mm) 39 * 11

Table wear rate (g/t) 13.5 * 4.3

Life 2500 >6000 (expected)

* Parameters at 1181 running hours

Plant : L & T Hirmi (India)

 COMPARISON OF PROPERTIES
HIGH CHROME
SR. NI HARD SINTER CAST
PROPERTIES INSERTED
NO ROLLS GRINDING ROLLS
ROLLS
High wear resistant due
1 HARDNESS 56 Rc 60 – 64 Rc
to hard ceramics
C:2.5 - 3.5 % ,
C : 3.2 % ,
CHEMICAL C: 3.0 % , Cr: 18 - 27 % ,
2 Cr:2.5 % ,
COMPOSITION Cr:15.25 % & Ceramic Grains
Ni:4.0 %
impregnated with metal

3 AVERAGE LIFE 2000 - 2500 Hrs 5000 - 6000 Hrs 10000 - 12000 Hrs
WITH > 35 % ash COAL
WEAR RATE 22 - 24 mm 10 - 12 mm 5 - 6 mm
4
WITH > 35 % ash COAL per 1000 Hrs per 1000 Hrs per 1000 Hrs
GRINDING ELEMENTS > Two times than > Four times than NI
5
LIFE NI Hard rolls Hard rolls
Consistent and consistent and best due
Reduced due to
6 GRINDING ABILITY better due to to Honey-comb type
slippage of rolls
serrations on rolls structure on rolls
7 COLLAR FORMATION High Negligible Negligible

8 MILL THROUGHPUT Reduced with Life Consistent Consistent

RING ROLLER SETTING
9 Twice in a month Once in a Month Once in a Month
WITH > 35 % ash COAL
COMPARISON OF INSERTED ROLL AND SINTER
CAST GRINDING ROLLS

Plant : GEB WANAKBORI

Measuring Roller Measuring Point Roller

point no: J1 no: J2
Wear depth in mm Wear depth in mm
Running Hrs: 6627 Running Hrs: 6627
A 12 A 45
B 23 B 66
C 21 C 56
D 11 D 44
E 7 E 12
HAMMERS FOR CRUSHERS
DIPPING TUBES