010 3 Design RawMill QMR - TUBAFA

Roller mill QUADROPOL
Mech. design
Training TUBAFA at Polysius in Germany

November 20th to 30th 2012
Thys s enKrupp Polys ius

QUADROPOL²- Mill
Full damping of roller unit by foundation

Mill housing free of grinding forces
Equal hot gas and material distribution
Low vibration
Good accessibility to main components
Easy maintenance
Four or two roller operation
Designed for 500 to 12.000kW
Roller Mill QUADROPOL
Design
2 Thys s enKrupp Polys ius
QUADROPOL²- Mill – QMR² - Main components
Separator
Feed Chute
Grit Cone
Mill Housing
Roller Unit
Hot Gas Inlet Grinding Table
Gear Box
Main Motor
Foundation

Design
QUADROPOL²- Mill – QMR²

Design
QUADROPOL²- Mill -Transmission of Grinding Forces – Normal operation
•• Full Roller Unit

Fulldamping
damping of
ofroller
roller
units
unitsby
byfoundation
foundation
•• Mill
Millhousing
housingcompletely
completely Grinding Table
free
freeof
offorces
forces
Foundation
•• smooth
smoothand
andlow-
low-
vibration Gear Box
vibrationoperation
operation
•• low
lowintake
intakeofoffalse
falseair
airin
in
entire
entireroller
rollermill
mill
Design
QUADROPOL²- Mill -Transmission of Grinding Forces – Rough Running
•• Full Roller Unit

Fulldamping
damping of
ofroller
roller Zero Gap
units
unitsby
byfoundation
foundation ~10mm
•• Mill
Millhousing
housingcompletely
completely Grinding Table
free
freeof
offorces
forces
Foundation
•• No
Nocontact
contactto
tothe
the
grinding Gear Box
grindingtable
table
•• Gear
Gearbox
boxprotection
protection

Design
QUADROPOL²- Roller Unit
Less moving masses

Only two roller bearings
Only one roller sealing, positioned outside the mill
Easy changing of bearing seal
Only one hydraulic Cylinder for mill operation
Only one piston accumulator for mill operation
Low vibration during operation
Easy maintenance
Design
QUADROPOL²- Roller Unit - QM² 45/23
1,7m

Design
QUADROPOL²- Roller Unit – Main components
Pressure Bearing Hydraulic Cylinder
Roller Bearing
Tension Frame (tapered)
Piston Accumulator
Roller Tyre
Fixed Bearing
(maintenance-free)
Roller Axle
Lifting Cylinder Zero Gap Adjusting
Design
QUADROPOL²- Roller Unit – Bearings
Two!! Roller Bearings

Paired Tapered
Roller Bearing
Fixed Bearing
(maintenance-free)

Design
QUADROPOL²- Roller Unit – Dismounting
Standard “LUKAS” Cylinder

Dismounting Cylinder
Shifting Skates
Travel-out Cylinder

Design
QUADROPOL²- Roller Unit - Dismantling

Design

Design

Design

Design
QUADROPOL²- Roller Unit - Roller Sealing Outside Mill
Mill outside Mill inside

Design
QUADROPOL²- Roller Unit - Roller Sealing Outside Mill
Mill outside Mill inside
One!! Rotating Sealing Outside Mill

Design
QUADROPOL²- Lubrication
All sensors outside the mill

No piping inside the roller
One lubrication unit for each roller unit
Good accessibility to lubrication components
Easy maintenance

Design
QUADROPOL²- Lubrication units
Oil supply line Double change over filter
Temperature gauge Pressure gauge
Flow meter
Pump
Return flow
Thermostat valve
Water – Oil cooler
Heaters
Oil tank
Temperature measurement

Design
QUADROPOL²- Lubrication - Roller Bearings

Design
QUADROPOL²- Hydraulic
Only one hydraulic cylinder for mill operation

Only one piston accumulator for mill operation
Flow optimised hydraulic pipe
Good accessibility to hydraulic components
Easy changing of cylinder
Easy maintenance

Design
QUADROPOL²- Hydraulic
One !! Piston Accumulator
Flow Optimised Pipe

One!! Hydraulic Cylinder
Oil
Nitrogen

Design
QUADROPOL²- Hydraulic – Connection Pipe between Cylinder and Accumulator
Flow Optimised Hydraulic Pipe
Not Flow Optimised Hydraulic Pipe

Design
QUADROPOL²- Hydraulic – Cylinder and Pressure Bearing
Hydraulic Cylinder
Piston
Pressure Bearing
(hydrostatic)

Design
Hydraulic Cylinder
Piston
Hydraulic Oil
Pressure Bearing
(hydrostatic)

Design
Hydraulic Cylinder
Hydraulic Oil
Piston
Pressure Bearing
(hydrostatic)

Design
Hydraulic Cylinder
Hydraulic Oil
Piston
Pressure Bearing
(hydrostatic)
Oil Pressure Metal Contact

Design
QUADROPOL²- Hydraulic – Start-up Cylinder and Bladder Accumulator

Design
QUADROPOL²- Grinding Table
Table segments optimised for casting

Table isolation reduces thermal deformation
and stresses
Easy changing of the table segments
Dam ring bolted for quick adjustment

Design
Table Liner
Dam Ring
Grinding Table
Insulation
Table Liner Fastening
Grinding Table

Design
Dam Ring Clamping Plate

Retaining Plate
Table Liner
Grinding Table
Grinding Table Expansion Bolt

Insulation
Design
Table Liner
Dam Ring
Grinding Table
Insulation

Design
Table Liner
Wedge Element
Grinding Table
Lug
Table Liner Fastening

Design
QUADROPOL²- Mill Housing
Mill housing free of grinding forces

Optimised gas flow profile from inlet to separator
Optimised material carrying capacity from
nozzle ring to separator
Feed chute integrated into grit cone
Perfect material mix to centre of grinding table
Stable mill performance
Less wear
Design
Feed chute integrated into grit cone
Perfect material mix to centre of

grinding table
Optimised gas flow profile

and material carrying capacity from
nozzle ring to separator

Design
QUADROPOL²- Mill Housing - Circumferential Nozzle Ring

Design

Design
Deflector Plates
Guide Plates
Gas Duct

Design
- optimised flow profile by CFD-calculation

- optimised strength of the housing by FE-calculation

Design
QUADROPOL²- Mill Housing – CFD Calculation
QM²

Design
QM²

Design
High gas speed

Low gas speed to catch the material
wear protection

Design
QUADROPOL²- Foundation

Low movement of Roller unit during
rough running
Damping of roller unit by concrete
Less total cost

Design
QUADROPOL²- Mill Foundation – QMR²

Design
QUADROPOL²- Mill Foundation – Pretension of Concrete
Base Plate
Grouting
Fixation of Roller Unit
Pretension of Concrete

Design

Design

Design
QUADROPOL²- Wear Protection
Quality for roller tyre and table liner

Ceramic
Portable wear plates for the mill housing
Quality of the wear plates according to

the wear rate
Bolted wear plates

Design
QUADROPOL²- Wear Protection - Roller Axle, Roller Body and Mill Housing
Wear protection Mill Housing

Wear Plate
Roller Tyre
Ceramic inserts
Wear protection Roller body

Compound Plate
Spherical disc with hard facing
Wear protection Roller axle

Compound Plate
Wear Plate
Design
QUADROPOL²- Wear Protection - Mill
Rotor Blades
Compound Plate
Feed Chute
Compound Plate Guide Vanes
Compound Plate
Grit Cone
Mill Housing Compound Plate
Wear Plate
Roller Tyre
Ceramic inserts
Table Insulation Table Liners

Compound Plate Ceramic inserts
Discharge Ring
Driver Plate: Compound Plate
Scraper: Cast Iron 60 HRC

Design
QUADROPOL²- Wear Protection - Mill Housing
Mill Housing
Wear Plate
Deflector Plates
Compound Plate
Guide Plates
Wear Plate
Gas Duct
Wear plate
Discharge Ring
Driver Plate: Compound Plate
Scraper: Cast Iron 60 HRC

Design
QUADROPOL²- Sepol Separator

Design
Upper bearing
arrangement
Discharge bend Rotor
Guide vane ring

Housing
Grit cone

Design
QUADROPOL²- Sepol Separator - Rotor
Upper bearing
arrangement
Rotor blades
Lower bearing
arrangement

Design
QUADROPOL²- Sepol Separator – Upper bearing arrangement
Axial spherical roller bearing
Lube nipple
Radial shaft seal

Design
QUADROPOL²- Sepol Separator – Lower bearing arrangement
Labyrinth ring
Axial spherical roller bearing
Lube pipe

Design

Design

Design
QUADROPOL²- Plant Layout
If Quadropol is located outside of a building no stationary crane
is needed for maintenance. All 4 roller units can be pulled into
a position that provides accessibility by a mobile crane.
• Position of cyclones at 45 °
to main mill axis
• Services rails prolonged

where necessary
• Prolonged service rails

mounted on steel or concrete
structure designed to carry
only weight of roller unit

Design

Design

Design
Design

010 3 Design RawMill QMR - TUBAFA

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Roller mill QUADROPOL

Training TUBAFA at Polysius in Germany

Thys s enKrupp Polys ius

Full damping of roller unit by foundation

Hot Gas Inlet Grinding Table

Roller Mill QUADROPOL

Roller Mill QUADROPOL

•• Full Roller Unit

•• Full Roller Unit

Roller Mill QUADROPOL

Less moving masses

Roller Mill QUADROPOL

Two!! Roller Bearings

Roller Mill QUADROPOL

Standard “LUKAS” Cylinder

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Mill outside Mill inside

Roller Mill QUADROPOL

Mill outside Mill inside

One!! Rotating Sealing Outside Mill

Roller Mill QUADROPOL

All sensors outside the mill

Roller Mill QUADROPOL

Temperature gauge Pressure gauge

Water – Oil cooler

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Only one hydraulic cylinder for mill operation

Roller Mill QUADROPOL

Flow Optimised Pipe

Roller Mill QUADROPOL

Flow Optimised Hydraulic Pipe

Not Flow Optimised Hydraulic Pipe

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Oil Pressure Metal Contact

Roller Mill QUADROPOL

Table segments optimised for casting

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Dam Ring Clamping Plate

Grinding Table Expansion Bolt

Roller Mill QUADROPOL

Table Liner Fastening

Roller Mill QUADROPOL

Mill housing free of grinding forces

Feed chute integrated into grit cone

Perfect material mix to centre of

Optimised gas flow profile

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Roller Mill QUADROPOL

- optimised flow profile by CFD-calculation

Roller Mill QUADROPOL

Roller Mill QUADROPOL

Roller Mill QUADROPOL