The cement ball mill is a kind of cement grinding mill. It is mainly used for grinding the clinker and raw materials of the cement plant, and also for grinding various ores in metallurgical, chemical and electric power enterprises. It has the characteristics of strong adaptability to materials, continuous production, large crushing ratio and easy to adjust the fineness of grinding products. The cement ball mill can be used not only in dry method cement production line but also in wet method cement production line. In addition, it can realize the simultaneous grinding and drying, which is the important equipment for cement grinding. AGICO is one of the leading cement ball mill manufacturers in China. We supply the high quality equipment. If you are interested, please feel free to contact us.
The materials are uniformly fed into the first chamber of the mill by the feeding device through the feeding hollow shaft. There is a stepped or corrugated liner plate and some steel balls of different specifications in the chamber. The cylinder rotates approximately once every couple of seconds, and the centrifugal force produced when the cylinder rotates brings the steel ball to a certain height and then falls down. This kind of impact force will have a grinding effect on the material. After the kibbling in the first chamber, the materials will enter the second chamber through the monolayer partition board, which is inlaid with a flat liner plate and contains steel balls to further grind the materials. After that, the powder will be discharged through the discharge device.
AGICO Group is an integrative enterprise group. It is a Chinese company that specialized in manufacturing and exporting cement plants and cement equipment, providing the turnkey project from project design, equipment installation and equipment commissioning to equipment maintenance.
1. Product Name Forged ball Grinding ball Forging ball Forged steel ball Forged grinding steel ball Cast iron ball Casting ball High chrome balls Ball mill balls Grinding balls for mining Cement grinding balls 2. Application Grinding media balls are used in ball mill for mining,cement plant ,power plant. 3. Classification Forged ball Cast iron ball Cylpebs Hot rolling ball Ceramic grinding ball Grinding rods 4. Forged balls, hot rolling balls specification Forged ball, hot ...
1. Product Name Forged ball Grinding ball Forging ball Forged steel ball Forged grinding steel ball Cast iron ball Casting ball High chrome balls Ball mill balls Grinding balls for mining Cement grinding balls
So when buy high chrome steel balls for cement plant use, or buy other specifications of Grinding Steel Balls, please focus on good quality over price. In the long run, ALLSTAR Good quality grinding steel balls can help you save much more costs.
Wear resistant high chromium Cast Iron Balls for Cement building materials High chromium cast ironballIntroduction: High chromium cast iron ball also known as wear-resistant steel ball ,are widely used in the ball mill grinding process. Application : Cement building materials, metal mining, coal thermal power, chemical engineering, light industrial papermaking,magnetic materials, ceramic coatings Case :Cement building materials, metal mining, coal paste thermal power Key words: High Chromium ball ,High chrome grinding ball, high chrome ball, high chrome cast steel ball, High Chrome Casting Grinding Balls,High Chrome grinding media ball,High Chrome mill ball Wear-resistant high Chromium cast iron ball technology parameters name brand Chemical composition C Si Mn Cr P S Mo AI high chromium ball ZQCr10 1.8-3.2 0.3-1.2 0.3-1.0 10.0-10.5 0.1 0.1 trace trace Cu Ni Nb Ti Zr V B Mg trace trace trace trace trace trace trace trace Wear-resistant steel ball mechanical properties and microstructure analysis name brand surface hardness (HRC) Impact value Ak(J/cm2) microstructure Falling ball impact fatigue life high chromium ball ZQCr10 58-66 2.5 M+C 80 15000 80 10000 Ccarbide Mmartensite Wear-resistant high chromium cast iron ball products specifications Specifications(mm) Each weight(Kg) Quantity(pcs) per ton 30 0.11 9091 40 0.257 3891 50 0.50 2000 60 0.867 1153 70 1.37 729 80 2.05 487 90 2.90 345 100 4.00 250 110 5.30 188 120 6.80 147 125 7.75 129 130 8.74 114 The process line of production of cast iron balls RAW MATERIALS CUTTING STOVE AUTOMATIC PRODUCTION-LINE TRANSFER MACHINE QUENCHING HEAT TREATMENT DIMENSION TEST PACKING TRANSPORTATION OR SEA FREIGHT Packing:Container bags or steel drums or others. For Container Bag, Net weight 1000Kgs ,Gross Weight 1002KGS ,Measurement 0.4CBM For Steel Drums ,Net weight 850-950Kgs ,Gross Weight 865-965KGS ,Measurement 0.3CBM . Shipping and delivery Port of loading:Qingdao Port,China Delivery time : Normally 2-3 weeks after down payment received. Partial shippment allowed FAQ Payment terms :T/T (30% DP,balance against copy of B/L.; L/C Samples : Free samples are provided for test before trial order MOQ :1 Ton For more information about our products ,Pls feel free to contact us Wejinanzhongweiwillcontinuetopromotethebenefitsandapplicationsofourgrinding mediatoan ever-wideningindustrialmarketplace. Wearereadytocontributeourshareinadvancingmutualbenefitandwin-wincooperation.
The process line of production of cast iron balls RAW MATERIALS CUTTING STOVE AUTOMATIC PRODUCTION-LINE TRANSFER MACHINE QUENCHING HEAT TREATMENT DIMENSION TEST PACKING TRANSPORTATION OR SEA FREIGHT
Can also called grinding media steel ball, grinding ball, its a common type of grinding media. The physical media to crush materials (metal ores, cement, coal powder, silicon sand) by self-weight impact force and grinding force, always was called grinding media. The normal grinding media are steel ball, steel cylpebs and steel bar, particularly processed cast alloy, alloy round steel bars are as raw materials to produce those grinding media. It can be divided into cast iron balls and forged steel balls according to the production technics.
Shougang Steel Ball can provide: Cr 1%-28%, hardness: HRC40-66, Dia.10mm-150mm alloy cast steel balls. The balls have a lot of excellent properties, such as higher hardness, good abrasive resistance, together with a good surface finish and small dimensional allowance after scientific heating treatment, as one type of grinding media, it can be widely used in ball mill grinding systems of mines, cement, building materials and chemical industries,etc.
It can be divided into medium carbon, high carbon steel ball based on Carbon percentage, it related to 5 products, Carbon percentage is from 0.38% to 1.05%, Hardness is from HRC 48-65. The products property will be high in hardness, good in wear-resistance, low in breakage rate after isothermal quenching treatment. As one kind of grinding media, forged steel ball was widely used in ball mill and semi-auto grinding mill system of mines, building materials and chemical industries.
Summing up the year 2020, we can very calmly state that Energosteels grinding balls compete with similar products of world producers. Thus, we have significantly increased sales in the foreign market. At the beginning of 2021, we received several requests to calculate the grinding balls assortment for the loading into ball mill. In this article, we will consider the one of the requests from a company based in Yemen that specializes in cement production.
Inside diameter: 4.2 meters Total inside length: 13 meters Production capacity: 7510t/h (Closed circuit, ordinary carbonate cement, specific surface area: 320m2/Kg) feeding size5mm, moisture0.5%, air speed in mill 0.5m/s. Mill rotary speed: 15.80.1r/min Charging capacity of grinding medium: 230 ton.
The raw material for cement production has a high abrasion rate. Consequently, when calculating the assortment the balls with increased volumetric hardness have been taken into account. Into the first chamber of two-chamber mill is loaded with balls from 80 to 40 mm in diameter. The second chamber is loaded with balls from 40 to 25 mm in diameter.
Into the first chamber: 80mm 53 tons, 70mm 33 tons, 60mm 10 tons, 50mm 10 tons, 40mm 3 tons. The average diameter of this assortment is 71mm. The current loading shall be carried out with a steel ball of 80 mm;
Lets remind that to receive free advice on calculating the assortment of grinding ball, you may visit our website and fill in the necessary fields. The specialists of our company will make the necessary calculations and will contact you in the shortest possible time.
Am sure your BallMill is considered the finest possible grinding mill available. As such you will find it is designed and constructed according to heavy duty specifications. It is designed along sound engineering principles with quality workmanship and materials used in the construction of the component parts. YourBallMill reflects years of advancement in grinding principles, materials, and manufacturing techniques. It has been designed with both the operators and the erectors viewpoints in mind. Long uninterrupted performance can be expected from it if the instructions covering installation and maintenance of the mill are carried out. You may be familiar with installing mills of other designs and manufacture much lighter in construction. YourBallis heavy and rugged. It should, therefore, be treated accordingly with due respect for its heavier construction.
The purpose of this manual is to assist you in the proper installation and to acquaint you a bit further with the assembly and care of this equipment. We suggest that these instructions be read carefully and reviewed by everyone whenever involved in the actual installation and operation of the mill. In reading these general instructions, you may at times feel that they cover items which are elementary and perhaps not worthy of mention; however in studying hundreds of installations, it has been found that very often minor points are overlooked due to pressure being exerted by outside influences to get the job done in a hurry. The erection phase of this mill is actually no place to attempt cost savings by taking short cuts, or by-passing some of the work. A good installation will pay dividends for many years to come by reduced maintenance cost.With the modern practice of specialized skills and trades, there is often a line drawn between responsibilities of one crew of erectors and another. Actually the responsibility of installation does not cease with the completion of one phase nor does it begin with the starting of another. Perhaps a simple rule to adopt would be DO NOT TAKE ANYTHING FOR GRANTED. This policy of rechecking previously done work will help guarantee each step of the erection and it will carefully coordinate and tie it into subsequent erection work. To clarify or illustrate this point, take the example of concrete workers completing their job and turning it over to the machinist or millwright. The latter group should carefully check the foundation for soundness and correctness prior to starting their work.
Sound planning and good judgement will, to a great extent, be instrumental in avoiding many of the troublesome occurrences especially at the beginning of operations. While it is virtually impossible to anticipate every eventuality, nevertheless it is the intention of this manual to outline a general procedure to follow in erecting the mill, and at the same time, point out some of the pitfalls which should be avoided.
Before starting the erection of the mill, adequate handling facilities should be provided or made available, bearing in mind the weights and proportions of the various parts and sub-assemblies. This information can be ascertained from the drawings and shipping papers.
The gearing, bearings, and other machined surfaces have been coated with a protective compound, and should be cleaned thoroughly with a solvent, such as Chlorothene, (made by Dow Chemical). Judgement should be exercised as to the correct time and place for cleaning the various parts. Do not permit solvents, oil or grease to come in contact with the roughened top surfaces of the concrete foundation where grouting is to be applied; otherwise proper bonding will not result.
After cleaning the various parts, the gear and pinion teeth, trunnion journals and bearings, shafting and such, should be protected against rusting or pitting as well as against damage from falling objects or weld splatter. All burrs should be carefully removed by filing or honing.
Unless otherwise arranged for, the mill has been completely assembled in our shop. Before dismantling, the closely fitted parts were match marked, and it will greatly facilitate field assembly to adhere to these match marks.
The surfaces of all connecting joints or fits, such as shell and head flanges, trunnion flanges, trunnion liner and feeder connecting joints, should be coated with a NON-SETTING elastic compound, such as Quigley O-Seal, or Permatex to insure against leakage and to assist in drawing them up tight. DO NOT USE WHITE LEAD OR GREASE.
Parts which are affected by the hand of the mill are easily identified by referring to the parts list. In general they include the feeder, feed trunnion liner, discharge trunnion liner if it is equipped with a spiral, spiral type helical splitter, and in some cases the pan liners when they are of the spiral type. When both right and left hand mills are being assembled, it is imperative that these parts which involve hand be assembled in the correct mill.
Adequate foundations for any heavy equipment, and in particular grinding mills, are extremely important to assure proper operation. The foundation should preferably be in one piece, that is, with a reinforced slab footing (so called mat) extending under both trunnion bearing foundations as well as the pinion bearing foundation. If possible or practical, it should be extended to include also the motor and drive. With this design, in the event of some movement, the mill and foundation will tend to move as a unit. ANY SLIGHT SETTLING OF FOUNDATIONS WILL CAUSE BEARING AND GEAR MISALIGNMENT, resulting in excessive wear and higher maintenance costs. It has been found that concrete foundations on a weight basis should be at least 1 times the total weight of the grinding mill with its grinding media.
Allowable bearing pressure between concrete footings and the soil upon which the foundation rests should first be considered. The center of pressure must always pass through the center of the footing. Foundations subject to shock should be designed with less unit pressure than foundations for stationary loads. High moisture content in soils reduces the amount of allowable specific pressure that the ground can support. The following figures may be used for preliminary foundation calculations.
Portland cement mixed with sand and aggregate in the proper proportions has come to be standard practice in making concrete. For general reference cement is usually shipped in sacks containing one cubic foot of material. A barrel usually holds 4 cubic feet. Cement will deteriorate with age and will quickly absorb moisture so it should be stored in a dry place. For best results the sand and gravel used should be carefully cleaned free of humus, clay, vegetal matter, etc.
Concrete may be made up in different mixtures having different proportions of sand and aggregate. These are expressed in parts for example a 1:2:4 mixture indicates one bag of cement, 2 cubic feet of sand, and 4 cubic feet of gravel. We recommend a mixture of 1:2:3 for ball mill and rod mill foundations. The proper water to sand ratio should be carefully regulated since excess water increases the shrinkage in the concrete and lends to weaken it even more than a corresponding increase in the aggregate. Between 5 to 8 gallons of water to a sack of cement is usually recommended, the lower amount to be used where higher strength is required or where the concrete will be subject to severe weathering conditions.
Detailed dimensions for the concrete foundation are covered by the foundation plan drawing submitted separately. The drawing also carries special instructions as to the allowance for grouting, steel reinforcements, pier batter, foundation bolts and pipes. During concrete work, care should be taken to prevent concrete entering the pipes, surrounding the foundations bolts, which would limit the positioning of the bolts when erecting the various assemblies. Forms should be adequately constructed and reinforced to prevent swell, particularly where clearance is critical such as at the drive end where the gear should clear the trunnion bearing and pinion bearing piers.
For convenience in maintenance, the mill foundations should be equipped with jacking piers. These will allow the lifting of one end of the mill by use of jacks in the event maintenance must be carried out under these conditions.
Adequate foundations for any heavy equipment, and in particular Marcy grinding mills, are extremely important to assure proper operation of that equipment. Any slight settling of foundations will cause bearing and gear misalignment, resulting in excessive wear and higher maintenance costs. It has been found that concrete foundations on a weight basis should be approximately 1 times the total weight of the grinding mill with its grinding media.
Allowable bearing pressure between concrete footings and the soil upon which the foundation rests should first be considered. The center of pressure must always pass through the center of the footing. Foundations subject to shock should be designed with less unit pressures than foundations for stationary loads. High moisture content in soils reduces the amount of allowable pressure that that material can support. The following figures may be used for quick foundation calculations:
Portland cement mixed with sand and aggregate in the proper proportions has come to be standard practice in making concrete. For general reference cement is usually shipped in sacks containing one cubic foot of material. A barrel usually consists of 4 cubic feet. Cement will deteriorate with age and will quickly absorb moisture so it should be stored in a cool, dry place. The sand and gravel used should be carefully cleaned for best results to be sure of minimizing the amount of sedimentation in that material.
Concrete may be made up in different mixtures having different proportions of sand and aggregate. These are expressed in parts for example a 1:2:4 mixture indicates one bag of cement, 2 cubic feet of sand, and 4 cubic feet of gravel. We recommend a mixture of 1:2:3 for ball mill and rod mill foundations. The proper water to sand ratio should be carefully regulated since excess water will tend to weaken the concrete even more than corresponding variations in other material ratios. Between 5 to 8 gallons of water to a sack of cement is usually recommended, the lower amount to be used where higher strength is required or where the concrete will be subject to severe weathering conditions.
We recommend the use of a non-shrinking grout, and preferably of the pre-mixed type, such as Embeco, made by the Master Builders Company of Cleveland, Ohio. Thoroughly clean the top surfaces of the concrete piers, and comply with the instructions of the grouting supplier.
1. Establish vertical and horizontal centerline of mill and pinion shaftagainst the effects of this, we recommend that the trunnion bearing sole plate be crowned so as to be higher at the center line of the mill. This is done by using a higher shim at the center than at the endsand tightening the foundation bolts of both ends.
After all shimming is completed, the sole plate and bases should be grouted in position. Grouting should be well tamped and should completely fill the underside of the sole plate and bases. DO NOT REMOVE THE SHIMS AFTER OR DURING GROUTING. When the grout has hardened sufficiently it is advisable to paint the top surfaces of the concrete so as to protect it against disintegration due to the absorption of oil or grease.
If it is felt that sufficient accuracy in level between trunnion bearing piers cannot be maintained, we recommend that the grouting of the sole plate under the trunnion bearing opposite the gear end be delayed until after the mill is in place. In this way, the adjustment by shimming at this end can be made later to correct for any errors in elevation. Depending on local climatic conditions, two to seven days should he allowed for the grouting to dry and set, before painting or applying further loads to the piers.
Pinion bearings are provided of either the sleeve type or anti-friction type. Twin bearing construction may use either individual sole plates or a cast common sole plate. The unit with a common sole plate is completely assembled in our shop and is ready for installation. Normal inspection and cleaning procedure should be followed. Refer to the parts list for general assembly. These units are to be permanently grouted in position and, therefore, care should be taken to assure correct alignment.
The trunnion bearing assemblies can now be mounted on their sole plates. If the bearings are of the swivel type, a heavy industrial water-proof grease should be applied to the spherical surfaces of both the swivels and the bases. Move the trunnion bearings to their approximate position by adjustment of the set screws provided for this purpose.
In the case of ball mills, all internal wearing parts will pass through the manhole, whereas in the case of open end rod mills they will pass through the discharge trunnion opening. When lining the shell, start with the odd shaped pieces around the manhole opening if manholes are furnished. Rubber shell liner backing should be used with all cast type rod mills shell liners. If the shell liners are of the step type, they should be assembled with the thin portion, or toe, as the leading edge with respect to rotation of the mill.
Lorain liners for the shell are provided with special round head bolts, with a waterproof washer and nut. All other cast type liners for the head and shell are provided with oval head bolts with a cut washer and nuts. Except when water proof washers are used, it is advisable to wrap four or five turns of candle wicking around the shank of the bolt under the cut washer. Dip the candle wicking in white lead. All liner bolt threads should be dipped in graphite and oil before assembly. All liner bolt cuts should be firmly tightened by use of a pipe extension on a wrench, or better yet, by use of a torque wrench. The bolt heads should be driven firmly into the bolt holes with a hammer.
In order to minimise the effect of pulp race, we recommend that the spaces between the ends of the shell liners and the head liners or grates be filled with suitable packing. This packing may be in the form of rubber belting, hose, rope or wood.
If adequate overhead crane facilities are available, the heads can be assembled to the shell with the flange connecting bolts drawn tightly. Furthermore, the liners can be in place, as stated above, and the gear can be mounted, as covered by separate instructions. Then the mill can be taken to its location and set in place in the trunnion bearings.
If on the other hand the handling facilities are limited it is recommended that the bare shell and heads be assembled together in a slightly higher position than normal. After the flange bolts are tightened, the mill proper should be lowered into position. Other intermediate methods may be used, depending on local conditions.
In any event, just prior to the lowering of the mill into the bearings the trunnion journal and bushing and bases should be thoroughly cleaned and greased. Care should be taken not to foul the teeth in the gear or pinion. Trunnion bearing caps should be immediately installed, although not necessarily tightened, to prevent dirt settling on the trunnions. The gear should be at least tentatively covered for protection.
IMPORTANT. Unless the millwright or operator is familiar with this type of seal, there is a tendency to assume that the oil seal is too long because of its appearance when held firmly around the trunnion. It is not the function of the brass oil seal band to provide tension for effective sealing. This is accomplished by the garter spring which is provided with the oil seal.
Assemble the oil seal with the spring in place, and with the split at the top. Encircle the oil seal with the band, keeping the blocks on the side of the bearing at or near the horizontal center line so that when in place they will fit between the two dowel pins on the bearing, which are used to prevent rotation of the seal.
Moderately tighten up the cap screws at the blocks, pulling them together to thus hold the seal with its spring in place. If the blocks cannot be pulled snuggly together, then the oil seal may be cut accordingly. Oil the trunnion surface and slide the entire seal assembly back into place against the shoulder of the bearing and finish tightening. Install the retainer ring and splash ring as shown.
In most cases the trunnion liners are already mounted in the trunnions of the mills. If not, they should be assembled with attention being given to match marks or in some cases to dowel pins which are used to locate the trunnion liners in their proper relation to other parts.
If a scoop feeder, combination drum scoop feeder or drum feeder is supplied with the mill, it should be mounted on the extended flange of the feed trunnion liner, matching the dowel pin with its respective hole. The dowel pin arrangement is provided only where there is a spiral in the feed trunnion liner. This matching is important as it fixes the relationship between the discharge from the scoop and the internal spiral of the trunnion liner. Tighten the bolts attaching the feeder to the trunnion liner evenly, all around the circle, seating the feeder tightly and squarely on its bevelled seat. Check the bolts holding the lips and other bolts that may require tightening. The beveled seat design is used primarily where a feeder is provided for the trunnion to trunnion liner connection, and the trunnion liner to feeder connection. When a feeder is not used these connecting joints are usually provided by a simple cylindrical or male and female joint.
If a spout feeder is to be used, it is generally supplied by the user, and should be mounted independently of the mill. The spout should project inside the feed trunnion liner, but must not touch the liner or spiral.
Ordinarily the feed box for a scoop tender is designed and supplied by the user. The feed box should be so constructed that it has at least 6 clearance on both sides and at the bottom of the scoop. This clearance is measured from the outside of the feed scoop.
The feed box may be constructed of 2 wood, but more often is made of 3/16 or plate steel reinforced with angles. In the larger size mills, the lower portion is sometimes made of concrete. Necessary openings should be provided for the original feed and the sand returns from the classifiers when in closed circuit.
A plate steel gear guard is furnished with the mill for safety in operation and to protect the gear and pinion from dirt or grit. As soon as the gear and pinion have been cleaned and coated with the proper lubricant, the gear guard should be assembled and set on its foundation.
Most Rod Mills are provided with a discharge housing mechanism mounted independently of the mill. This unit consists of the housing proper, plug door, plug shaft, arm, and various hinge pins and pivot and lock pins. The door mechanism is extra heavy throughout and is subject to adjustment as regard location. Place the housing proper on the foundation, level with steel shims and tighten the foundation bolts. The various parts may now be assembled to the housing proper and the door plug can be swung into place, securing it with the necessary lock pins.
After the mill has been completely assembled and aligned, the door mechanism centered and adjusted, and all clearances checked, the housing base can be grouted. The unit should be so located both vertically and horizontally so as to provide a uniform annular opening between the discharge plug door and the head liners.
In some cases because of space limitation, economy reasons, etc., the mill is not equipped with separate discharge housing. In such a case, the open end low discharge principal is accomplished by means of the same size opening through the discharge trunnion but with the plug door attached to lugs on the head liner segments or lugs on the discharge trunnion liner proper. In still other cases, it is sometimes effected by means of an arm holding the plug and mounted on a cross member which is attached to the bell of the discharge trunnion liner. In such cases as those, a light weight sheet steel discharge housing is supplied by the user to accommodate the local plant layout in conjunction with the discharge launder.
TRUNNION BEARING LUBRICATION. For the larger mills with trunnion bearings provided with oil seals, we recommend flood oil lubrication. This can be accomplished by a centralized system for two or more mills, or by an individual system for each mill. We recommend the individual system for each mill, except where six or more mills are involved, or when economy reasons may dictate otherwise.
In any event oil flow to each trunnion bearing should be between 3 to 5 gallons per minute. The oil should be adequately filtered and heaters may be used to maintain a temperature which will provide proper filtration and maintain the necessary viscosity for adequate flow. The lines leading from the filter to the bearing should be of copper tubing or pickled piping. The drain line leading from the bearings to the storage or sump tank should be of adequate size for proper flow, and they should be set at a minimum slope of per foot, perferably per foot. Avoid unnecessary elbows and fittings wherever possible. Avoid bends which create traps and which might accumulate impurities. All lines should be thoroughly cleaned and flushed with a solvent, and then blown free with air, before oil is added.
It is advisable to interlock the oil pump motor with the mill motor in such a way that the mill cannot be started until after the oil pump is operating. We recommend the use of a non-adjuslable valve at each bearing to prevent tampering.
When using the drip oil system it is advisable to place wool yarn or waste inside a canvas porous bag to prevent small pieces of the wool being drawn down into the trunnion journal. If brick grease is used, care should be taken in its selection with regard to the range of its effective temperature. In other words, it should be pointed out that brick grease is generally designed for a specific temperature range. Where the bearing temperature does not come up to the minimum temperature rating of the brick grease, the oil will not flow from it, and on the other hand if the temperature of the bearing exceeds the maximum temperature rating of the brick grease, the brick is subject to glazing; therefore, blinding off of the oil. This brick should be trimmed so that it rests freely on the trunnion journal, and does not hang up, or bind on the sides of the grease box.
When replacing the brick grease, remove the old grease completely. Due to the extended running time of brick grease, there is usually an accumulation of impurities and foreign matter on the top surface, which is detrimental to the bearing.
Where anti-friction bearings are supplied, they are adequately sealed for either grease or oil lubrication. If a flood system is used for the trunnion bearings and it is adequately filtered, it can then be used for pinion bearings with the same precautions taken as mentioned above, with a flow of to 1 gallons per minute to each bearing.
These lubricants can be applied by hand, but we highly recommend some type of spray system, whether it be automatic, semi-automatic or manually operated. It has been found that it is best to lubricate gears frequently with small quantities.
Start the lubrication system and run it for about ten minutes, adjusting the oil flow at each bearing. Check all of the bolts and nuts on the mill for tightness and remove all ladders, tools and other obstructions prior to starting the mill.
Before starting the mill, even though it is empty, we recommend that it be jogged one or two revolutions for a check as to clearance of the gear and its guard, splash rings, etc. The trunnion journal should also be checked for uniform oil film and for any evidence of foreign material which might manifest itself through the appearance of scratches on the journal. If there are any scratches, it is very possible that some foreign material such as weld splatter may have been drawn down into the bushing, and can be found imbedded there. These particles should be removed before proceeding further.
If everything is found to be satisfactory, then the mill should be run for ten to fifteen minutes, and stopped. The trunnion bearings should be checked for any undue temperature and the gear grease pattern can be observed for uniformity which would indicate correct alignment.
It should be noted that with an empty mill the reactions and operating characteristics of the bearings and gearing at this point are somewhat different than when operating with a ball or rod charge. Gear noises will be prominent and some vibration will occur due to no load and normal back-lash. Furthermore, it will be found that the mill will continue to rotate for some time after the power is shut off. Safety precautions should therefore he observed, and no work should be done on the mill until it has come to a complete stop.
We have now reached the point where a half ball or rod charge can be added, and the mill run for another six to eight hours, feeding approximately half the anticipated tonnage. The mill should now be stopped, end the gear grease pattern checked, and gear and pinion mesh corrected, if necessary, according to separate instructions.
The full charge of balls or rods can now be added, as well as the full amount of feed, and after a run of about four to six days, ALL BOLTS SHOULD AGAIN BE RETIGHTENED, and the gear and pinion checked again, and adjusted if necessary.
Where starting jacks are provided for the trunnion bearings of the larger sized mills, they should be filled with the same oil that is used for the lubrication of the trunnion bearings. Before starting the mill they should be pumped so as to insure having an oil film between the journal and the bushing.
When relining any part of the mill, clean away all sand from the parts to be relined before putting in the new liners. For the head liners and shell liners you may then proceed in the same manner used at the time of the initial assembly.
Before relining the grate type discharge head, it is advisable to refer to the assembly drawings and the parts list.Because of such limitations as the size of the manhole opening, and for various other reasons, it will be found that the center discharge liner and cone designs vary. The cone may be a separate piece or integral with either the trunnion liner, or the router discharge liner. Furthermore, it will be found in some mills that the center discharge liner is held by bolts through the discharge head, whereas in other cases it depends upon the clamping effect of grates to hold it in position. In any event, the primary thing to remember in assembling the discharge grate head parts is the fact that the grate should be first drawn up tightly towards the center discharge liner by adjusting the grate set screws located at the periphery of the discharge head. This adjustment should be carried out in progressive steps, alternating at about 180 if possible and in such a manner that, the center discharge liner does not become dislodged from its proper position at the center of the mill. These grate set screws should be adjusted with the side clamp bar bolts loosened. After the grates have been completely tightened with the set screws, check for correct and uniform position of each grate section. The side clamp bar bolts may now be lightened, again using an alternate process. This should result in the side clamp bars firmly bearing against the beveled sides of the grates. The side clamp bars should not hear against the lifter liners.
When new pan liners are installed, they should be grouted in position so as to prevent pulp race in the void space between the discharge head and the pan liner. Another good method of preventing this pulp race is the use of the sponge rubber which can be cemented in place.
After the mill is erected, in order to avoid overlooking both obvious and obscure installation details, we recommend the use of a check list. This is particularly recommended for multiple mill installations where it is difficult to control the different phases of installation for each and every mill. Such a check list can be modeled after the following:
No. 1 Connecting Bolts drawn tight. A. Head and Shell flange bolts. B. Gear Connecting, bolts. No. 2 Trunnion studs or bolts drawn up tight. No. 3 Trunnion liner and feeder connecting bolts or studs drawn up tight. No. 4 Feeder lip bolts tightened. No. 5 Liner bolts drawn up tight. No. 6 Gear. A. Concentric B. Backlash C. Runout D. Joint bolts drawn up tight. No. 7 Coupling and Drive alignment and lubrication. No. 8 Bearings and Gearing cleaned and lubricated. No. 9 Lubrication system in working order with automatic devices including alarms and interlocking systems.
We further recommend that during the first thirty to sixty days of operation, particular attention be given to bolt tightness, foundation settlement and condition of the grouting. We suggest any unusual occurrence be recorded so that should trouble develop later there may be a clue which would simplify diagnosing and rectifying the situation.
As a safety precaution, and in many cases in order to comply with local safety regulations, guards should be used to protect the operators and mechanics from contact with moving parts. However, these guards should not be of such a design that will prevent or hinder the close inspection of the vital parts. Frequent inspection should be made at regular intervals with particular attention being given to the condition of the wearing parts in the mill. In this way, you will be better able to anticipate your needs for liners and other parts in time to comply with the current delivery schedules.
When ordering repair or replacement parts for your mill, be sure to identify the parts with the number and description as shown on the repair parts list, and specify the hand and serial number of the mill.
By following the instructions outlined in this manual, mechanical malfunctions will be eliminated. However, inadvertent errors may occur even under, the most careful supervision. With this in mind, it is possible that some difficulties may arise. Whenever any abnormal mechanical reactions are found, invariably they can be attributed to causes which though sometimes obvious are often hidden. We sight herewith the most common problems, with their solutions.
Cause A GROUT DISINTEGRATION. Very often when the grouting is not up to specification the vibration from the mill tends to disintegrate the grouting. In most instances the disintegration starts between the sole plate and the top surface of the grouting near or at the vertical centerline of the mill. As this continues, the weight of the mill causes the sole plate and trunnion bearing base to bend with a resultant pinching action at the side of the bearing near the horizontal center line of the mill. This pinching will cut off and wipe the oil film from the journal and will manifest itself in the same manner as if the lubrication supply had been cut off. If the grout disintegration is limited to about . 050 and does not appear to be progressing further, the situation can be corrected by applying a corresponding amount of shimming between the trunnion bearing base and the sole plate near the centerline of the mill in such a fashion that the trunnion bearing base has been returned to its normal dimensional position. If, on the other hand, the grouting is in excess of . 050 and appears to be progressing further, it is advisable to shut down operations until the sole plate has been re grouted.
Cause B HIGH SPOT ON THE BUSHING. While all BallMill bushings are scraped in the shop to fit either a jig mandrel or the head proper to which it is to be fitted, nevertheless there is a certain amount of seasoning and dimensional change which goes on in the type of metals used. Therefore if high spots are found, the mill should be raised, the bushings removed and rescraped. Bluing may be used to assist in detecting high spots.
Cause C INSUFFICIENT OIL FLOW. Increase the oil supply if it is a flood oil system. If brick grease is used, it is possible that the particular grade of brick may not be applicable to the actual bearing temperature. Refer to the remarks in this manual under the paragraph entitled Lubrication.
Cause E EXCESSIVE RUBBING ON THE SIDE OF THE BUSHING. This comes about due to the improper setting of the bearings in the longitudinal plane. In some cases, particularly on dry grinding or hot clinker grinding mills, the expansion of the mills proper may account for this condition. In any event, it can be remedied by re-adjusting the bearing base on the sole plate longitudinally at the end opposite the drive.
There are many more lubricant suppliers, such as E. F. Houghton and Co. , or Lubriplate Division of Fiske Bros. Refining Co. In making your final selection of lubricants, you should consider the actual plant conditions as well as the standardization of lubricants. New and improved lubricants are being marketed, and we, therefore, suggest that you consult your local suppliers.
As the developer and manufacturer of industry-leading particle size reduction equipment, including Attritors (internally agitated ball mills) and DMQX horizontal media mills, Union Process is uniquely positioned to help you identify and source the correct grinding media for your application.
Union Process customers know they can rely on our extensive technical expertise and years of experience to ensure they get the right grinding media at the right time and the right price for their specific needs. Working in close consultation with our customers, our skilled technical service representatives reviewcustomer requirements like final particle size, physical compatibility and contamination concernsand then recommend media with the right characteristics, including:
metallic grinding medialike carbon steel, forged steel, stainless steel or chrome steel grinding balls are best for some applications, while others requirenon-metallic mediamade of alumina, ceramics, glass, silicon carbide, zirconium oxide or other specialized materials
Union Process is the source for the most up-to-date information on grinding balls and other media. Download our Grinding Media Literature (PDF) to view a detailed sheet, outlining factors to consider when selecting grinding media, along with specifications on the most common types of media.
Offering the optimal combination of grinding media knowledge and manufacturing expertise, Union Process takes your entire operation into account to identify the best grinding media to consistently generate the final particle size and shape required by your application, optimizing the cost effectiveness of your process and extending the life of your mills.
Backed by our long-standing commitment to customer satisfaction, we ensure quality manufacturing and reliable supply of grinding balls and media specifically engineered to meet the requirements of your most demanding milling applications.
Through-Hardened Carbon Steel Balls are magnetic and can be used in the food industry along with 440C stainless steel media. They are a low-cost media that are superior and recommended over case-hardened carbon steel media which have a soft core. They are packaged with no oil finishalways dry packedas they will rust in water.
Chrome Balls (steel type 52100) are through-hardened and tempered steel balls designed to achieve maximum strength and quality. Ball hardness is in the 6067 HRC range. They wear better than 440C stainless steel and through-hardened carbon steel. They are also recommended for applications where a through-hardened steel ball is needed in larger sizes ( and larger). They are sometimes packaged with a very light oil finish to reduce rust due to humidity.
440C Stainless Steel Balls are through-hardened and tempered throughout for maximum strength and quality. They are magnetic, and corrosion-resistant (generally rust-resistant). They are recommended for food applications and lighter colored slurries.
Forged Steel Balls are used for gold mining, cement factories, oil processing and large scale industrial applications. They are made by machine (standard) sizes 20mm75mm. They are manually made (hit by air hammer) sizes 75mm125mm. They have hardness 5563 HRC. All forged balls are through-hardened, and shipped in 55-gallon steel drums. They range in sizes from 20mm125mm. Standard lead time is 68 weeks FOB Akron, Ohio USA.
High Chrome Steel Balls can be used for many different applications. They are available in two grades1013% chrome (surface hardness 60 HRC, core hardness 58 HRC), and 1418% chrome (surface hardness 62 HRC, core hardness 60 HRC). They have a very rough black finish which quickly wears off during initial milling. After that, they have an excellent wear rate. They are available in sizes 6mm120mm. They are shipped in 55-gallon steel drums with standard lead time of 68 weeks FOB Akron, Ohio USA.
Union Process is the one source for 90%, 94%, 99.5% and 99.9% alumina media. 90% alumina is available in satellites and rod/cylinders. 94% alumina balls have excellent wear resistance with higher impact strength to save running costs with less contamination. They have great wear rate generally better than 90% or 99.5%. 99.5% alumina balls have the highest alumina content for a moderate price. The .5% impurity is MgO that is added to inhibit grain growth during sintering in the kiln. There is less than 0.1% silica in the media. 99.9% alumina balls are made of very pure and reactive (expensive) raw materials. They are for high purity alumina applications where contamination is a factor.
Alumina Beads are specially formulated to be used in high-energy mills in which a high degree of fineness is required. They are used in various industrial fields such as inks, paints, advanced ceramics, mining, cosmetics and pharmaceutical industries. They are a perfectly spherical shape with high mechanical properties and high wear resistance at a moderate price.
Silicon Carbide Balls are very high-cost grinding media that are used for milling same materials (silicon carbide ball to mill silicon carbide materials) to avoid contamination. They are only available in 5mm,10mm, 15mm and 20mm sizes. They are a special order item.
Silicon Nitride Balls are very high-cost grinding media that are used for milling same materials (silicon nitride ball to mill silicon nitride materials) to avoid contamination. They are now available in 2mm and 3mm and sizes up to 25mm. They are a special order item.
Tungsten Carbide media is the hardest and densest (highest specific gravity) media and is available in both satellites and balls upon request. They are available in sizes ranging from 3/32 to 1 in diameter. They are a high-cost media and are a special order item.
Zirconium Oxide Balls (95% ZrO2) are the strongest, best wearing ceramic media for metal-free, pharmaceutical and food processing grinding. These balls have a white, shiny appearance. They are also available in 38 and cylinders. This 95% grade is high-cost.
Zirconium Oxide SatellitesCeria stabilized (rare earth)are a cheaper zirconium oxide alternative for metal-free applications. They are a brown, shiny ball media that come in size ranges in the smallest sizes (ex: 0.4 0.6mm), then at 6mm come in uniform sizes (6mm, 8mm, etc.) up to 31mm.
Zirconium Silicate Beads are available in fused 68% ZrO2 beads which are a standard reliable media at low cost, and sintered 58% ZrO2 beads which have high breakage resistance, are durable and cost effective. They are used to microgrind paints, inks, dyes, magnetic coatings, minerals, agrochemicals and ceramics.
NOTE: Grinding balls and media are sold on a per pound basis, but ATTRITORS and DMQX-Mills are loaded by volume. Therefore, the more dense the media, the more pounds of media required. For instance, a machine requiring only 40 lbs. of stainless steel may require up to 80 lbs. of tungsten carbide. Information contained herein is accurate and reliable to the best of our knowledge, but our suggestions and recommendations cannot be guaranteed because the conditions of use are beyond our control.
Our skilled technical service representatives also are available for consultation and are always ready to assist you with the selection of grinding media that best answer your particular needs. For assistance, contact Media Sales by calling (330) 929-3333 x228 or byemailing us.
Cement plant motor manufacturing is one of our main product focuses. Cement mills, fans, shredders - in the production of cement, particularly large and efficient motors are required for the most diverse processes. MENZEL offers individual motor solutions for all applications in the cement industry up to 13.8 kV and 25 MW.
Thanks to our many years of experience in the manufacturing of cement plant motors, we are the partner of choice for many cement mills operators all over the world. We offer large low-, medium- and high-voltage motors for various industrial sectors. Cement plants represent a particularly exciting challenge here: continuous use, highest performance requirements, high levels of dust, extreme ambient temperatures or installation altitudes. Where heavy masses of raw material are being transported, crushed, grinded and burned, the highest demands are placed on our cement plant motors.
MENZEL cement plant motors guarantee a trouble-free and high-performance operation of your plant. We offer very robust slip ring and squirrel cage motors that are also suited to difficult start-up conditions. Menzel Elektromotoren not only provides electric motors to end users directly, but is also a supplier and partner of drive manufacturers, distributors, and maintenance companies. As a motor manufacturer, we carry a large stock including many unusual motor versions and is highly experienced in customized motor adaptations.Many repeated orders are proof of highest quality and reliability.
Our electric motors delivery program for the cement industry includes three-phase motors with slip ring rotor or squirrel cage rotor up to 13.8kV. Various designs as well as all types of protection and cooling are possible.
Our electric motors for cement mills and other all are manufactured in compliance with the currently valid EN60034 and IEC60034, VDE, DIN and ISO standards and meet all international standards. Menzel Elektromotoren Berlin is TV certified according to DIN EN ISO 9001.
A costly industrial plant such as a cement mill must produce flawlessly at all times. In the event of a plant shutdown, with MENZEL you can count on a manufacturer who can provide you with electric motors at short notice from stock - worldwide. MENZEL keeps one of the largest stocks of major motors for the cement industry across Europe.
We can provide you with large brand new medium and high voltage motors with squirrel cage or slip ring rotor up to 15000 kW directly from stock. We keep motors of our own MENZEL series, but also of other brands in stock and can provide them within a very few days. Special constructions and individual adjustments of our electric motors are possible at any time.
You have an emergency and plant shut down? The best way to make your inquiryis to use our contact form, specifying how fast you need the electric motor you're looking for.One of our engineers will get in touch with you quickly.
Menzel was to supply a spare slip ring motor for a cement plant in Canada and had to meet very exacting requirements. This was the third order of motors that this Canadian system integrator has recently placed at MENZEL. The new slip ring motor must be able to replace three existing crusher motors in case of a failure. To ensure smooth commissioning at the installation site, which is characterized by very tight space restrictions, Menzel's project manager took the measurements in Canada himself.
Menzel chose a 4.5 MW slip ring motor from stock and built an extended shaft. Furthermore we fitted special adapter plates with mounting holes for all three locations as well as brackets for plug and play mounting of vibration sensors for condition monitoring. The custom-made adapter plates were made in our in-house welding shop, which allows flexible production of special components and custom-made welded designs at all times. In addition, the terminal box of this spare slip ring motor was fitted with long feeder cables to facilitate the third-party connecting-up.
Through our many years of experience in the manufacturing of cement mill motors, we are familiar with a wide variety of requirements and can advise customers from the industrial cement sector around the world. MENZEL electric motors are being operated in numerous industrial plants, not only cement plants. Further reference projects from the industrial cement sector and others can be found here.
Menzel offers a comprehensive range of larger electric motors for the industrial cement sector. As a manufacturer of electric motors, we place our customers and their individual requirements at the heart of the focus of our engineering work. Our service packages covers far more than just delivering the correct drive. We also offer a wide range of services including support, maintenance, commissioning, consultancy, and logistics. We follow a clear objective, which is to be available to our clients at all times:
Throughout history, cementing materials have played a vital role and were used widely in the ancient world. The Egyptians used calcined gypsum as a cement and the Greeks and Romans used lime made by heating limestone and added sand to make mortar, with coarser stones for concrete.The Romans found that a cement could be made which set under water and this was used for the construction of harbours. This cement was made by adding crushed volcanic ash to lime and was later called a "pozzolanic" cement, named after the village of Pozzuoli near Vesuvius.In places where volcanic ash was scarce, such as Britain, crushed brick or tile was used instead. The Romans were therefore probably the first to manipulate systematically the properties of cementitious materials for specific applications and situations.
Marcus Vitruvius Pollio, a Roman architect and engineer in the 1st century BCE wrote his "Ten books of Architecture" - a revealing historical insight into ancient technology. Writing about concrete floors, for example:"First I shall begin with the concrete flooring, which is the most important of the polished finishings, observing that great pains and the utmost precaution must be taken to ensure its durability"."On this, lay the nucleus, consisting of pounded tile mixed with lime in the proportions of three parts to one, and forming a layer not less than six digits thick."And on pozzolana:"There is also a kind of powder from which natural causes produces astonishing results. This substance, when mixed with lime and rubble, not only lends strength to buildings of other kinds, but even when piers are constructed of it in the sea, they set hard under water."(Vitruvius, "The Ten Books of Architecture," Dover Publications, 1960.)His "Ten books of Architecture" are a real historical gem bringing together history and technology. Anyone wishing to follow his instructions might first need to find a thousand or so slaves to dig, saw, pound and polish...After the Romans, there was a general loss in building skills in Europe, particularly with regard to cement. Mortars hardened mainly by carbonation of lime, a slow process. The use of pozzolana was rediscovered in the late Middle Ages.The great mediaeval cathedrals, such as Durham, Lincoln and Rochester in England and Chartres and Rheims in France, were clearly built by highly skilled masons. Despite this, it would probably be fair to say they did not have the technology to manipulate the properties of cementitious materials in the way the Romans had done a thousand years earlier.
The Renaissance and Age of Enlightenment brought new ways of thinking which led to the industrial revolution. In eighteenth century Britain, the interests of industry and empire coincided, with the need to build lighthouses on exposed rocks to prevent shipping losses. The constant loss of merchant ships and warships drove cement technology forwards.
Smeaton, building the third Eddystone lighthouse (1759) off the coast of Cornwall in Southwestern England, found that a mix of lime, clay and crushed slag from iron-making produced a mortar which hardened under water. Joseph Aspdin took out a patent in 1824 for "Portland Cement," a material he produced by firing finely-ground clay and limestone until the limestone was calcined. He called it Portland Cement because the concrete made from it looked like Portland stone, a widely-used building stone in England.While history usually regards Aspdin as the inventor of Portland cement, Aspdin's cement was not produced at a high-enough temperature to be the real forerunner of modern Portland cement. Nevertheless, his was a major innovation and subsequent progress could be viewed as mere development.A ship carrying barrels of Aspdin's cement sank off the Isle of Sheppey in Kent, England, and the barrels of set cement, minus the wooden staves, were later incorporated into a pub in Sheerness and are still there now. Those who wish can sup a pint and contemplate cement history.A few years later, in 1845, Isaac Johnson made the first modern Portland Cement by firing a mixture of chalk and clay at much higher temperatures, similar to those used today. At these temperatures (1400C-1500C), clinkering occurs and minerals form which are very reactive and more strongly cementitious.While Johnson used the same materials to make Portland cement as we use now, three important developments in the manufacturing process lead to modern Portland cement:
From the turn of the 20th century, rotary cement kilns gradually replaced the original vertical shaft kilns, used originally for making lime. Rotary kilns heat the clinker mainly by radiative heat transfer and this is more efficient at higher temperatures, enabling higher burning temperatures to be achieved. Also, because the clinker is constantly moving within the kiln, a fairly uniform clinkering temperature is achieved in the hottest part of the kiln, the burning zone.The two other principal technical developments, gypsum addition to control setting and the use of ball mills to grind the clinker, were also introduced at around the start of the 20th century.
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Articles like this one can provide a lot of useful material. However, reading an article or two is not really the best way to get a clear picture of a complex material like cement. To get a more complete and integrated understanding of cement and concrete, do have a look at the Understanding Cement book or ebook.
For example, it has about two-and-a-half times as much on ASR, one-and-a-half times as much on sulfate attack and nearly three times as much on carbonation. It has sections on alkali-carbonate reaction, frost (freeze-thaw) damage, steel corrosion, leaching and efflorescence on masonry. It also has about four-and-a-half times as much on cement hydration (comparisons based on word count).
Almost everyone interested in cement is also concerned to at least some degree with concrete strength. This ebook describes ten cement-related characteristics of concrete that can potentially cause strengths to be lower than expected. Get the ebook FREE when you sign up to CEMBYTES, our Understanding Cement Newsletter - just click on the ebook image above.
Ball mills are among the most variable and effective tools when it comes to size reduction of hard, brittle or fibrous materials. The variety of grinding modes, usable volumes and available grinding tool materials make ball mills the perfect match for a vast range of applications.
RETSCH is the world leading manufacturer of laboratory ball mills and offers the perfect product for each application. The High Energy Ball Mill Emax and MM 500 were developed for grinding with the highest energy input. The innovative design of both, the mills and the grinding jars, allows for continuous grinding down to the nano range in the shortest amount of time - with only minor warming effects. These ball mills are also suitable for mechano chemistry. Mixer Mills grind and homogenize small sample volumes quickly and efficiently by impact and friction. These ball mills are suitable for dry, wet and cryogenic grinding as well as for cell disruption for DNA/RNA recovery. Planetary Ball Mills meet and exceed all requirements for fast and reproducible grinding to analytical fineness. They are used for the most demanding tasks in the laboratory, from routine sample processing to colloidal grinding and advanced materials development. The drum mill is a type of ball mill suitable for the fine grinding of large feed sizes and large sample volumes.
We produce a variety of types and sizes of grinding steel ball products. This product has undergone strict quality inspection and testing, and is especially suitable for ball mills in mining, power stations, cement, sand and gravel fields, chemical industries and other industries.Get in Touch with Mechanic