PULVERISERS

Pulverisers are employed to pulverise

the pre-crushed raw coal to the
required fineness before it is admitted
into the boiler/ furnace for combustion
in Coal-fired Thermal Power Stations.
 BHEL’s JOURNEY 1960’s TO 2010
FOR PULVERISERS
• IN THE 60’s BHEL DESIGNED, MANUFACTURED AND SUPPLIED BALL MILLS WITH
INDIRECT FIRING SYSTEM.

• IN THE 70’s BHEL ENTERED INTO COLLABORATION WITH M/s COMBUSTION

ENGINEERING-USA FOR BOWL MILLS WITH DIRECT FIRING SYSTEM.

• IN THE 80’s BHEL ENTERED INTO COLLABORATION WITH M/s STEIN INDUSTRIE-
FRANCE FOR BALL TUBE MILLS.

• IN EARLY 2000s, BHEL ADOPTED THE MILLS TO SUIT INDIAN COAL CONDITION
AND DEVELOPED BHEL 280 BOWL MILLS AND INTRODUCED PLANETARY
GEARBOX IN PLACE OF MILL BASES WITH WORM GEAR DRIVE.

• IN THE YEAR 2005 BHEL ENTERED INTO COLLABORATION WITH M/s ALSTOM
USA FOR HIGHER CAPACITY BOWL MILLS SUITABLE FOR 660/ 800/ 1000 MW
SUPER-CRITICAL UNITS.
 RANGE OF PULVERISERS

• MEDIUM SPEED – BOWL MILLS.

XRP 623 (18 TPH) TO BHEL280 MILL (91 TPH)

HP 1103 (87.1 TPH) AND HP 1203 (121 TPH)

• LOW SPEED – BALL TUBE MILLS.

BBD 3448 (35 TPH), BBD 4760 (90 TPH),

BBD 4772 (110 TPH)
 PRESENT MANUFACTURING
RANGE OF PULVERISERS
I. BOWL MILL
MILL SIZE BASE CAPACITY
•XRP – 623 18.4 TPH
•XRP – 703 26.4 TPH
•XRP – 803 39.8 TPH
•XRP – 883 51.1 TPH
•XRP – 903 54.1 TPH
•XRP - 1003 68.1 TPH
•XRP - 1043 72.0 TPH
•HP - 1103 87.1 TPH
•BHEL – 280 91.0 TPH
•HP - 1203 121 TPH
 CLASSIFIER
RAW COAL CHUTE
ASSY.

MILL BODY
GIRTH GEAR
LINERS

GRINDING MEDIA SCREW

CONVEYOR

MAIN REDUCER

AUXILLARY
REDUCER
 PRESENT MANUFACTURING
RANGE OF PULVERISERS
II. BALL TUBE MILL

MILL SIZE BASE CAPACITY

•BBD 3448 30.5 TPH
•BBD 4760 79.0 TPH
•BBD 4772 110.0 TPH
 GRINDING PROCESS IN THE BOWL MILL

P.F. TO BOILER
RAW COAL

HEAVY
PARTICLES CLASSIFIER

P.F.+AIR
HOT AIR GRINDING ZONE
DRYING & GRINDING

REJECTS
MOISTURE DRYING REQUIREMENTS

MILL OUTLET
DETERMINE
VOLATILES TEMP
MILL INLET

ASH GRINDING ELEMENTS

HGI GRINDABILITY

CALORIFIC VALUE MILL SIZING

 MODIFICATIONS

IN THE
EXISTING
MILLS
 BOWL MILL
• Provision of Mechanical face seal in worm gear boxes.

• Fabricated Mill bottom and thicker insulation cover

plates.

• Modified scrapper assembly.

• Thicker main vertical shaft design.

• External lube oil system.

• Ceramic tiled inner cone

 BOWL MILL

• Liners for Sep.body, Jrl. Frame

• Ceramic lined mill discharge valve.

• Flap type mill discharge valve in place of butterfly type.

• Insert type Grinding rolls.

MILL DRIVE & BOWL ASSEMBLY
• BOWL MILLS:

• CERAMIC LINED INNER CONES

(TILES FITTED ON BOTH THE SIDES)
AND
VENTURI OUTLETS PROVIDED
FOR LONGER LIFE.
 MODIFICATIONS DONE AT
DESIGN STAGE
• BOWL MILLS:

• Ni-HARD LINERS ARE PROVIDED ON WEAR PRONE

PART LIKE JOURNAL HEAD, JOURNAL OPENING
FRAMES, SEPARATOR TOP TO PROTECT THESE
CRITICAL COMPONENTS & TO HAVE LONGER
WEAR LIFE.

• BUTTERFLY TYPE MILL DISCHARGE VALVE

REPLACED WITH FLAP TYPE.

• MDV CASTINGS REPLACED WITH CERAMIC LINED

FABRICATED BODY FOR LONGER LIFE.
CERAMIC TILE LINED MDV BODY

THE BODY IS FABRICATED

INSTEAD OF CASTING
MILL DISCHARGE VALVE
ASSEMBLY
Journal
Assembly
with Ni-hard
Grinding roll
SECTIONAL VIEW OF CARBIDE INSERTS

S G IRON

INSERTS
Made of
Hi-Cr / Sintered
carbide
Hi-Cr INSERTS ROLL
Grinding rolls in initial wear condition
 Worn out grinding roll
after 6500 running hours
 Worn out grinding roll
after 6800 running hours
 PRESSURE SPRING DESIGN
• SITE STUDY HAS PROVED THAT PRESSURE SPRINGS WITH LESS
SPRING STIFFNESS & MORE COMPRESSION GIVES BETTER ROLL
WEAR LIFE AND LESS POWER CONSUMPTION THAN SPRINGS
WITH HIGHER STIFFNESS AND LESS COMPRESSION VALUE.

• HENCE, NOW PROCURING SPRINGS WITH 20,000 LBS/INCH

SPRINGS INSTREAD OF 30,000 LBS/IN.

• THERE IS LESS VIBRATION DUE TO HIGHER LIFT OF THE SPRING

UNDER FOREIGN MATERIAL.

• THIS ALSO RESULTED IN LESS COST OF THE SPRINGS DUE TO

SMALLER ROD DIAMETER.
THE STIFFNESS OF THE SPRING REDUCED TO HAVE
LESS POWER CONSUMPTION AND LONGER ROLL LIEF
 .

PLANETARY GEARBOX

Vs

CONVENTIONAL GEARBOX
WITH WORM & WORM GEAR
 PLANETARY GEAR BOX
• Compact design and is placed independent of mill
foundation.

• Gears are made of hardened special steel material. Hence

give long trouble free operation.

• Easy to replace. Hence, the gear box can be taken out to

work shop for any maintenance (clean area).

• Less down time of the mill for maintenance of Gearbox.

• Less Lube oil requirement (from 3000 ltr to 1100 lr/Mill-

65% saving)

• Weight Reduced from 60 Tons to 33 Tons

MILL DRIVE ASSEMBLY (WORM
& WORM GEAR TYPE).
• The gear box is very bulky and the grey iron casting
is complicated and heavy.
• Maintenance of Internals has to be carried out in
situ, thus resulting in long shut down of mill and to
be carried out in dusty atmosphere.
• Gearbox oil quantity requirement is high.
• The efficiency is low.
• Mill drive assembly with worm gear set has
efficiency of 90%. While planetary gear box has
efficiency of 95%.
MILL DRIVE & BOWL ASSEMBLY
WORM GEAR BOX
PLANETARY GEARBOX
Low speed table
Tilting pads

Housing
Planetary Stage

Bevel gear stage

Gear coupling

PLANETARY GEAR BOX

PLANETARY GEAR BOX
Planetary Gear Box Assembly Animation
SPRING COUPLING
COUPLING BETWEEN DRIVE MOTOR
AND PLANETARY GEAR BOX
DRIVE COUPLING WITH SPRING GRID ON ONE SIDE
AND DISC COUPLING ON OTHER SIDE
 BHEL 280 MILL
• DEVELOPED BHEL280 MILL. NOW SUCCESSFULLY
RUNNING AT CHANDRAPUR STPS UNIT-6.

- BASE CAPACITY 91.0 TPH. SUITABLE FOR 500 & 660 MW

SIZE UNITS.

- WITH THIS NUMBER OF MILLS IN 500 MW WOULD BE

ONLY 8, THERE BY REDUCING NUMBER OF
AUXILIARIES, BOILER ELEVATIONS

SPECIAL FEATURES OF BHEL280 MILL:

-- STATE OF THE ART PLANETARY GEARBOX.
-- SPLIT TYPE MILLSIDE AIR INLET HOUSING.
-- SINTERED CARBIDE GRINDING ELEMENTS.
Bowl Mill
BHEL 280 MILL UNDER ERECTION AT
CHANDRAPUR STPS UNIT-6C.
 MODIFICATIONS DONE AT
DESIGN STAGE
• BOWL MILLS:

• MILLS ARE LOCATED BETWEEN BOILER AND ESP

INSTEAD OF BOILER AND TURBINE BAY FOR
BETTER MAINTENANCE.

• PNEUMATIC REJECT HANDLING SYSTEM PROVIDED

IN PLACE OF BELT CONVEYOR.

• ELECTRICALLY OPERATED MILL HANDLING

SYSTEMS PROVIDED INSTEAD OF MANUAL
SYSTEMS. WITH TWO CRANE ARRANGEMENT.
 THE SECOND SERVICE CRANE CAN ELIMINATE ALL THE MILL CRANES
•Existing Arrangement » New Arrangement

•Service Crane
•Service Crane

• Mill cranes

•Service Crane
IN THE OLD ARRANGEMENT THERE WAS ONE
SERVICE CRANE AND NUMBER OF MILL
CRANES. IN THE NEW ARRANGEMENT
THERE ARE ONLY TWO SERVICE CRANES
AND INDIVIDUAL MILL CRANES ARE
ELIMINATED.

THIS RESULTED IN MATERIAL COST SAVING,

SAVING IN ERECTION TIME AND EASE OF
OPERATION.
A SECOND SERVICE CRANE

– Service Crane
 PULVERISERS
for

SUPER CRITICAL BOILERS

HP 1103- FOR 660 MW

HP 1203 – FOR 800 MW
HP 1303 – FOR 1000 MW
 HP Pulverizer Key Features

• Removable planetary gearbox

• External journal loading springs

• Robust journal design

• Horizontal pivot scrapers

• Aerodynamic vane wheel

• Extended life of all wearing parts

• Optimized classifier

• Knife gate valves

• Simplified design

• Ease of maint. and construction

Coal Mills Windsor Unit

• Low operating and maint. cost
Review 10A-100112
 HP Pulverizer Arrangement

Adjustable Classifier Knife Gate

Blades Discharge Valve
Return Cone
Vane Wheel
External Springs
Deflectors
Vane Wheel
Journal Scrapers
Removable
Gearbox
 HP Pulverizer Arrangement

Classifier Drive Knife Gate

Assembly Discharge Valve
Classifier Rotor
Vane Wheel
External Springs
Deflectors
Vane Wheel

Journal Scrapers
Removable
Seal Air Header Gearbox
Lube Oil
System
Planetary Gearbox
 Journal Spring Assembly

SPRING
FLOATING AIR SEAL
ORIFICE PLATE
ADJUSTING STUD

SPRING STUD

ADJUSTING NUT GRAPHITE IMPREGNATED

BRONZE BUSHING
GRAPHITE IMPREGNATED
BRONZE BUSHING
 HP Journal Design

ONE PIECE BEARING

STEM CONNECTION HOUSING

TRIPPLE OIL SEALS

& WEAR RING

TWO IDENTICAL TAPERED INSERT TYPE ROLL

ROLLER BEARINGS WITH
100,000 HOURS B-10 LIFE
Tilt Out Journal Maintenance

•Roll removal
•Bearing and shaft stem assembly
removal
•Check bearing end play
•Change oil
•Replace seals
 Scraper Design

Horizontal pivot shaft

Replaceable, Torsion Spring

Adjustable wear plate
HP Pulverizer Wear Protection
HP Bowl Mill
Dynamic Classifier
 *

BY IMPLEMENTING ABOVE MODIFICATIONS,

AND
WITH PROPER O&M PRACTICES
(PREVENTIVE MAINTENANCE AND
PREDICTED MAINTENANCE)
MILLING SYSTEM
CAN BE MADE
MOST FRIENDLY
EQUIPMENT IN THE
POWER STATION.