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    17 views36 pages

    030 Wear Parts and Wear Resistant Material in Mills

    Uploaded by

    kING
    cement

    Copyright:

    © All Rights Reserved
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    of 36
    The International Maintenance Seminar 2002 MIDTH Institute™ Wear Parts and Wear Resistant Materials in Ball Mills Lecture 05-03 MIDTH The International Maintenance Seminar - 2002 Institute” TABLE OF CONTENTS NATURE OF WEAR IN GRINDING INSTALLATIONS .... 3. INFLUENCE ON LIFE TIME FOR WEAR PARTS. Bal MATERIAL TOBE GROUND. .esssestssesinsnlstntetnsnseesen cece 3.2 LINING THICKNESS: 3.3. SHAPES AND SURFACE: 1 3.4. Mitt DIAMETER 7 BS BALL SIZE ecco 28 4, MAINTENANCE OF GRINDING MEDIA CHARGE .... 4.1 BQUILIBRIUM CHARGE 4.2. CALCULATION OF CHARGH AND POWER UPTAKE jocccocotesscotmeneneiinsntenenes LO 5, GRINDING MEDIA QUALITY 12 6, MILL LINING MATERIALS, 13 TeTHNING TYPES ccsasssiscusnsi TAL SHELL LINING IN BALL MILES ae 7.2 VERTICAL LINING PARTS IN BALL MILLS... 8. SERVICE LIFETIME OF MILL LININGS... 9. MILL INSPECTION / SPARE PARTS. 10, HANDLING / ERECTION OF LINING PARTS... 10.1 HANDLING AND ADAPTING... 10.2. Fixation of Lining Parts 12. CONCLUSION... Wear Parts 1 The International Maintenance Seminar - 2002 my By i" Institute’ 5 INTRODUCTION This lecture comments on the main features concerning operating conditions, mill lining parts and grinding media charge in respect to influence from wear on mill performance and maintenance of grinding installations A cement plant handles large quantities of many different materials, which to a large extent, are hard and abrasive. Consequently, wear may be a very serious problem, This is even more the case for the grinding installations where the materials are exposed to heavy forces and movements. The equipment in the grinding installations therefore have to be protected with sufficient wear resistant materials for two different reasons: 1, To protect the equipment from damage and decay 2. To maintain maximum output at optimum operating conditions Sufficient control of the wear parts has to be done to prevent inconvenient siop of production In the worst case, missing or poor maintenance of the wear parts may result in damage of the main components of the machine. The consequence of this may be an expensive repair and stop of the production line for maybe half a year or more. 2. NATURE OF WEAR IN GRI ING INSTALLATIONS As shown in Figure 1, grinding in ball mills takes place by lifting the grinding media charge and the material to be ground followed by a retum to the bottom part of the mill tube. In this continuous cascading movement, two different types AcTRUTON of grinding take place. Attrition grinding is defined by reduction of the grain sizes by different velocity between the grinding pants, Aurition grinding Wear Parts 3 miDTH Institute” The International Maintenance Seminar where maximum difference in velocity occurs. This type of grinding will give wear on the grinding media and on the vertical parts of the lining. Acceleration of the gr ding balls in the lower part of the charge will also cause some wear on the horizontal lining parts. Impact grinding is defined as high velocity crushing of the material between the grinding elements, partly between grinding balls, and partly between grinding balls and the horizontal lining parts. Impact grinding takes place especially at the lower part of the ball charge and causes wear on the horizontal lining parts and on the grinding media To handle the mentioned types of grinding in respect to wear, the material quality of the wear parts in a grinding mill must therefore partly be resistant to over-hammering without cracking, and partly withstand abrasive wear. For material qualities, see section 6. 3. INFLUENCE ON LIFE TIME FOR WEAR PARTS Aside from the material quality for the lining parts, several other circumstances result in different wear rates in a grinding mill 3.1 Material to be Ground An essential factor in respect to the wear rate is the chemical composition of the material to be ground, A high content of silicon oxides as free quartz will often give a high wear rate, and so will different aggregates such as purzolane, slag and fly ash. The wear rate due 10 chemical composition of the grinding material differs from plant to plant, and in general, the wear rate has to be determined individually. Fundamentally, the grain size of the material only influences the wear when the material: ~ is exposed to grinding, - isunder pressure = ormoves ata high velocity. Tn a two compartment dry grinding ball mill, the highest wear occurs in the coarse grinding compartment due to coarser maierial, but of course also due to the larger grinding media than Wear Pants 4 > a - MIDTH The International Maintenance Seminar - 2002 Institute” in the fine grinding compartment. If the material is not under stress from the ball charge as for instance, inside the diaphragm, the wear is so low that no special wear protcetion in needed. Wet grinding poses a special problem because sliding slurry ofien is very abrasive. The risk of corrosion should also be taken into account For grinding in ball mills, special attention must be given to the amount of material in the mill, Running the mill with a feed rate which is too low or no feed at all, for any length of time, can be extremely dangerous for the lining parts, especially in the coarse grinding compartment. Therefore, the operator should always run the mill with a certain amount of material in the mill monitored by the noise level from the coarse grinding compartment. The mill should only be emptied for grinding material in very special situations, i.e, for main service inside the mill, At normal stop situations, the mill must be stopped at the same time as jortly after the the material feeders and at normal start situations. The feeders m: mill is started. 3.2 Lining Thickness Itis obvious that a thicker lining will have a longer ————— wear lifetime than a thin one. But in this connection, \ itis important to Keep in mind that an increase ofthe °° [—~) lining thickness in a ball mill will give a decreasein 3 oD Ne power consumption. Figure 2 shows that an increase of the shell lining thickness from 35 mm to 95 mm ail i equal to only 3% diameter reduction in a 4.2 m mill, «will result ina drop in power uptake to 90% for the. “4 same specific ball charge. To compensate for this drop in power uptake, it is of eo 2 nt ea ameter eduction course obvious to iry to compensate by a higher Figure 2 ball charge, But often this is not possible bec: the specific charge will become too high. As it Wear Parts 5 MIDTH Institute” The International Maintenance Seminar can be seen in Figure 3, the ball charge must be increased from about 30% to about 38% for the above mentioned change of lining to keep the power upiake, i.e, the mill capacity. This may be impossible due to the center openings in the mill. Furthermore, the extra grinding media charge to obtain the original power consumption is ‘fic ball charge related to linin; tant power uptal 50% 45 40 y 35 30 = 3 9 60 100 140 160mm igure 3 equal to about 15% and therefore represents an additional investment, Toad on mill shell and bearings, example Chamber 2 i a 4.6 mM. at constant power uptake 1) 40mm lining thickness SHELL LINING = 44.6 KN/m GRINDING MEDIA CHARG! = 205.5 kN/m GRINDING MATERTALS a 34.2 Kn/m TOTAL 283.4 KN/m 2) 100 mm lining thickness SHELL L: NG =I GRINDING MEDIA CHARGE = GRINDING MATERIALS = ab =! Figure 4 By selecting a thicker shell lining to obtain a longer lining lifetime. the load on mill shell and, Wear Parts 6 o @ : The International Maintenance Seminar - 2002 MIDTH € Institute ‘on mill bearings will increase, due to a higher weight of the thicker lining and due to the bigger ball charge. Also, the bigger ball charge will contain a higher amount of material to be ground. As shown in an example in Figure 4, the load is increased with 24%. Fora 8 m long mill chamber, this is equal to 56 tons higher mill weight. The mill shell and the bearings must be dimensioned for this extra load before changing to a thicker lining 3.3. Shapes and Surfaces tee foaso Many different types of linings in ball mills have been used to optimize mill performance and grinding efficiency. Basically, the shape and surface have an effect on the grinding efficiency. 7 On the other hand, very fancy designs of the lining are not needed, The lining must be able to lift the ball charge to give appropriate impact grinding without crushing the shell lining. The lining must also minimize sliding movement between the ball charge and shell lining. When using a wide range of grinding media sizes, for instance, in a one compartment raw mill for dry grinding. a lining which is able to classify the ball charge is needed. But this type of lining has only minor effect in a fine grinding compartment in a cement mill, Various suppliers often promise to obtain a higher mill output at lower power consumption by selecting a special lining type. However, when installing this new lining type, the better rill performance, if any, is often reached by nursing the mill and the mill installation, by cleaning, the grates, sorting the grinding media charge and so on, and not because of the new lining type. 3.4 Mill Diameter ‘The diameter of a ball mill can have a detrimental effect on the mill lining, The impact from the grinding media in large diameter mills will be greatly increased by the higher fall of the cascading ball charge ‘Apart from the impact, the wear from proper atirition will also reduce lining life in large diameter mills, For mills with constant length to diameter ratio, the power uptake and therefore also the mill output is proportional to the mill diameter in the power of 3.5. The mill shell area, on the other hand, is only proportional to the mill diameter in the power of 2.0. Consequently. it ean be seen that the lining area per unit power uptake will decrease with the Wear Parts 7 MIDTH Institute” The Intemational Maintenance Seminar mill diameter in the power of -1.5. This fact, together with a higher grinding pressure on the lining in large diameter mills, accounts for shortening of the lifetime of the linings, The effect of the mill diameter on lifetime of the shell lining is shown = relation to mill diameter} in the graph in Figure 5. No units are indicated on the axes, as the service life in hours depends also on material used for the lining pants and for the grinding medi. Furthermore the grinding material to be ground, as well as operation of the mill and the grinding circuit may affect the service life. The graph just illustrate why different wear rates may be seen on plant with different mill sizes, grinding Figure 5 the same product. 3.5 Ball Size Particularly for large diameter ball mills, use of oversized grinding balls will increase the wear rate and the risk of crushing the shell lining, especially in the coarse grinding ‘compartment. Itis very important to determine the largest ball size in such a way that it is just able to crush the coarse part of the grinding material in the mill, Ifthe grain sizes in front of the diaphragm are appropriate when using 90 mm balls as the largest size, then 100 mm balls should not be used. A 100 mm ball has 37% higher energy when it hits the lining than a 90 mm ball, This higher energy level may have a detrimental effect on the lining. ‘Wear Parts 8 ® heavier than on lining plates. 70 2 to | 14.68 | 158.08 | 172 ‘Consequently, the grinding media cha a : ngmedia charge [65 € | ea | 10 | vote | 119007 | 102 has to be adjusted for wear with regular, | $2—g5 ee Ere rea 0 | seen [zat ies ‘rather short, intervals, 4540 of —T 49 © [} 40 | 10 | 2001 | 50265 | 02 nA we 3 ew Total: | 60 [83.315 | 681.372 | 100 ana Arorege i , 4.1 Equilibrium Charge Forthe charge | Avereee [tae 4 i —_ g [mer] ‘Wear on the ball change will reduc (italoondtons 4 989 1022 REN The: zl ill pedis the Equilibrium conditions 1.321 4055, mMIDTH The International Mainte1 Seminar - 4 ions jintenance Seminar - 2002 Institute” MAINTENANCE OF GRINDING MEDIA CHARGE During commissioning of the plant, the necessary fineness of the product is established. The total ball charge in each compartment as well as the size of grinding media to give optimum performance has been found. To substain ~ optimum mill performance. itis $| = S_ |Z important to maintain the grinding media 28/55 48 | #3 charge. 22/22 | Gf | as [mm] fromm] |) Sg} [rend] _| [9] Benj 20 | 10 one eseasd| 7 ‘The wear on grinding media is much as 60 } ] 1 80 | 10 [2467 | z0r062 size of each and every grinding ball with Figure 6 the same rate measured as diameter reduction per hour. Based on this and based on the fact that a composition of different sizes of grinding media gives the best grinding economy, FLS ecommends use of so called equilib where size distribution of the balls is kept constant when compensation for wear is being um charges ineach compartment, An equilibrium grindiag media charge is a charge, made continuously with only one or two sizes, Use of such a charge means that grinding capacity is maintained through a very long time of operation. The theory for equilibrium charges, illustrated in Figure 6, is based on the same number of grinding media in each fraction or range of ball size. In the shown charge for a coarse grinding compartment, the average piece weight and specific surface are kept constant by adding only 100 mm balls as, compensation for wear. Wear Parts 9 MIDTH Institute” The International Maintenance Seminar 4.2 Calculation of Charge and Power uptake As the wear of grinding media proceeds, the power uptake on the mill decreases. Therefore, the charge has to be loaded up with regular intervals. In order not 10 overload gear or motor, it should be established how many kW are drawn extra when adding one ton of grinding media, The power uptake, the size of the ball charge, the wear rate and the distribution of grinding media between the individual compartments should be recorded from the very start of the installation. Basis for this should be regular measurements of the power consumption, measurements of the size of the charge and samples of grinding media, How to calculate the size of a grinding media charge in a grinding compartment, based on measurements inside the mill is Calculation of Grinding Media Charge| 1 Chaser agi fh Ta Chumber Dialer, fh [a Centre diswnce {n] Relative hight of change | ‘Volume of Chamber Lin lk weight 3 Was) Specie Charge far Prac bs wing media cha F__ [homes] [k= 00neqey | Frcicigh aborechags |H [jmj | H=h+D2. Example ‘Measured in acoasse grinding chamber in a 40 m diameter ball mil D=3.85 mS mm Kning) 300m h=0600.m Detcemin the grinding aia chavge in % and in tonnes Relative hight ofehange hvd = 0.6002.85 = 0.155 VolumeotCaamber— V = n/4x3.53%0,00= M9? Specific Charge 4g. =305%. From able bs Bulk weight 8 =43.Fromtable bt Grinding megiachuge F = OD a 30549 =458 omnes Examnle2: tcrmin th esate distance and the giindng meia charge for 33.5% ‘harge ia te eater fom example Relative hight oFehage Av Cente distance 4 Grinding mediacharge F From tables 1314.35 = 504m Died 3033.531.5 = 50.3 tonnes given in Figure 7. Needed values for specific charge and bulk weigth are given in table b3 and b4, enclosure 1. ‘Wear Parts 10 i i MIDTH @ tenance Seminar - 2002 reps For measurement of the ball charge to calculate the power [Caleulation of Powor cuneumption b2 uptake, it is important that the mill is not overloaded with grinding materials. To ensure this, a short nun with stopped feeders for new material to the mill may be allowed. The € mill must be ina steady = juation before the feeders The power consumption ofa grinding compartment in a mill ie given by he formele are stopped, and the mill must Power ~ Charge Amof gravity: Velocity Ne (Fg): (sin): (4"2- D/60) be stopped as soonasadrop | rom whic Nia) =[€- 981 /60]-Fin “u-D-t [kW in noise level is registered on ‘Them speeda {rpm are normal between 70 and 80% of the eiteal speed. The eracal speed is eal eulated by following fornmala a(srit)= (60: v @81/2-D))/*]=423 vo) [pm the noise level monitor. ‘Taetoraue factor u= sin’ depends on the type of lining, the size ofthe trinding media and wetherthe grinding is wet or dy. For values of[u, see table bd Calculation of power consumption is given in Figures and values forthe [Bessie i to teemte ot yeviy ita. Porvoo relative distance to the centre Ir 45; m bearings and gene are sufcieny all tobe disregarded, so thatthe accumalated Net) from the griding compartments represen's @ of gravity is given in table b3, [pe put afte mtr ke. the val on mator pate by asimar load enclosure 1, Also'same’ /Taeloserin the motor is normally ceckoned to be $9, 50 that he input approximate values for the Ieaphe sisritece Nien sues 1) /095 [kW torque factor wis given in en) 10.95 Te] table b4, enclosure |. Figure 8 However, for actual mills in operation, the torque factor for the grinding compartments have to be determined individually by comparison of readed and calculated power uptake just before and just after reloading the mill compartments to compensate for wear. At regular intervals, the ball charge, especially in the coarse grinding compartment, should be emptied out for classification. In multi-compartment mill grinding balls less than about half the diameter of the biggest grinding ball in the compartment are normally not useful and have Wear Parts ul MIDTH Institute™ The International Maintenance Seminar to be scrapped, In one-compartment mills with classifying lining, the ball charge often is a combination between a coarse and a fine grinding charge. For a 50/50 ratio between the wo ball charges, the scrapping size is normally about half the diameter of the largest ball size in the fine grinding charge. Too many undersized grinding media in a ball mill result in a poor grinding efficiency, reduction in the transport capacity in the compartment and blockage of the slots in the diaphragm and in the outlet grate. When recharging the mill, is important to protect the mill shell lining by placing sufficient material in the mill to prevent the heavy balls from hitting the shell lining direetly. 5. GRINDING MEDIA QUALITY Forged steel balls exist today in normal and hardened qualities. They are available at low cost in most countries. When they are used against low abrasive materials, the total operation cost may be lower than for the more expensive cast Cr-alloyed grinding media. Grinding media made from white cast iron are wear resistant, but the quality varies from one supplier to another. The risk of brittleness breakage in mills larger than 3 meters is rather high for this material. Cast grinding media made of Cr-alloyed Steel is extremely FORGED cast ‘ NORMAL | HARDENED| WHITE Cl, | CR-ALLOY Harness HB | 350-625 | 600-700 | 400 | 600-700 SLURRY Large Balls | 2-50 | 15-40 0-20 Small Balls | 40-80 | 20-50 | 30-60 | 15-30 wear resistant and can be supplied from several suppliers. For dry grinding, the wear rate may be RAW MEAL reduced as much as 6 (0 8 Large Balis 8-30 10-20 25 alls | 3 28 26 | 13 times compared with the Siiall_ Bal 2d ind CEMENT alii Lorge Batls | 20-40 10-20 25 ‘Small Balls 5-15 210 5-6 1-3 Expected wear rates in /grams per kWh) for the different types of grinding media are given in Figure 9. As for the Figure 9 MIDTH he hh i i nar - : The International Maintenance Seminar - 2002 Institute” shell lining, wear on grinding media increases drastically if the mill operates with levels of grinding material which are too low. Ifa poor quality of grinding media is being used, a high quantity of small worn out or broken gtinding media will be formed. An excessive amount of small picees from grinding media will reduce the grinding efficiency and reduce the transport capacity in the mill, Furthermore, they may gradually block the grates, causing a reduction in the free flow of material and air through the grates. In this situation, the grate will often have to be cleaned by hand. Using low quality grinding media, it may be neces 3 intervals of several years. ‘ary to empty the mill for classification say rinding media, this is only needed with nes a year, With highly wear r When making comparisons between cheap, low quality and expensive, high quality grinding media, the mentioned points should be taken into consideration 6. MILL LINING MATERIALS In Figure 10 is shown an overview of typical figures for different types of lining materials FYPE OF MILL LINING | RESISTANT AGAINST MECHANICAL PROPERTIES MATERIALS: ABRASION | IMPACT ne | ny | em Steel plate: NO NO. = = = Flint / SILEX NO, NO. = os = [White east iron YES. NO, 350 — 400 Manganese steel NO YES. 5225 2590 NICROMAX (NIHARD 2) YES. TES) 2550 E320 (Shramium Melysdenum NO. YES 3802 90 [High Chromium alloys YES. Yes ‘SEVERAL DIFFERENT TYPES ‘CHEMICAL COMPOSITION c% | _Cr% | _Mo% __| _Mn% | __Ni% Steel plate. = = eae Se = Fllnt/ SILEX = = = = = [White cast iren 74-34 [520 = (ECE = Manganese steel 41-13 [205 = 15 = 13.5 = NIGROMAX(NIHARD 2) | 26-29 | 44-24 |

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