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Mill shell lining



Headquarters/Germany            Foundry/Austria
Christian Pfeiffer              Christian Pfeiffer
Maschinenfabrik GmbH            Maschinenfabrik GmbH
Sudhoferweg 110-112             Werkstraße 5
59269 Beckum                    8940 Liezen
Germany                         Austria
Tel. +49 (0) 25 21/8 49-00      Tel. +43 (0)3612/270-0
Fax +49 (0) 25 21/8 49-123      Fax +43 (0)3612/270-589
office@christianpfeiffer.de     office@cpb.at
www.christianpfeiffer.de        www.christianpfeiffer.de

Italy                           South America
Christian Pfeiffer              Christian Pfeiffer
Mezzomerico SpA                 Latinoamericana S.A.
Via Marano Ticino 7             Parque Industrial Liviano
28040 Mezzomerico (NO)          Av. Brasil Calle # 1
Italy                           Santa Cruz, Bolivia
Tel. +39 (03 21) 92 3010        Tel. +591 (3) 34 81768
Fax +39 (03 21) 92 3141         Fax +591 (3) 34 92 597
info@christianpfeiffer.it       christianpfeiffer@unete.com
www.christianpfeiffer.it        www.christianpfeiffer.de

USA                                                           Konzept und Gestaltung Kulms & Halbur/CPR Lippstadt · D-Vo. / 2,1-00-engl. / 2.04


American Pfeiffer Corporation
3407 West Chester Pike
Newtown Square, PA 19073-4227
USA
Tel. +1 (610) 35 66 995
Fax +1 (610) 35 68 987
cpb@americanpfeiffer.com
www.americanpfeiffer.com
principle
Principle of the mill
                        High energy input for the
                        comminution process
                          Cement, which is used as     The grinding process
                        a basis for numerous con-     usually takes place in ball
                        struction activities, is an   or tube mills which, due
                        attractive raw material       to their simple principle,
                        that can be manufac-          are widespread through-
                        tured almost uniformly        out the world and require
                        through-out the world.        only low maintenance
                                                      efforts.
                          Although the extraction
                        of raw materials – lime-      The rotary movement of
                        stone, clay and aggrega-      the mill shell causes the
                        tes – is still relatively     grinding media (cast steel
                        simple and inexpensive,       balls) to rise, fall or roll
                        the various stages of pro-    onto the material to be
                        duction in the cement         ground with high impact
                        works require a high-         or pressure energy and
                        energy input. Particularly    thus performs the com-
                        in the various grinding       minution.
                        processes – the genera-
                        tion of raw meal prior to
                        the burning process and
                        grinding of the cement
                        clinker - requires around
                        20 million kWh power
                        consumption per year for
                        a medium-sized pro-
                        duction line. This amounts
                        to around 60 % of the
                        energy input of a pro-
                        duction line.




                        Mill
Safe and simple:
                                                                                                                                                                                        Ball mills
                                                                                                                                                                         Conventional
                                                                                                                                                                         design           Every year around 1.4
Mill shell lining
                                                                                                                                                                                        billion tons of cement
                                                                                                                                                                                        clinker are ground, 90 %
                    Lining systems                                                                                                                                                      of which is ground in ball
                    for tube mills                                                                                                                                                      mills. This size reduction
                                                                                                                                     Direction of rotation                              process requires approx.
                      Tube or ball mills are                                                                                                                             Wave profile   8 % of the entire world’s
                    horizontal shells in which                                                                                                                                          energy requirement.
                    charged balls of varying
                    sizes “smash“ the material                                                                                                                                          The principle of the ball
                    passing through by im-               Modified shape                                                                                                                 mill is simple; reliability
                    pact energy.                         improves the effi-                                                                                                             and availability of the
                                                         ciency of the mill                                                                                                             systems guarantee high
                    The mill shell is fitted                                                                                                                                            operating reliability. Ball
                    with an inner lining to                Christian Pfeiffer is not                                                                                     Progressive    mills have proven their
                                                                                                                                                                         lifter
                    protect the mill cylinder:           only the manufacturer of                                                                                                       worth in nearly all cement
                    A lining consisting of               the lining systems, but                                                                                                        production lines of the
                    highly wear resistant sec-           also applies to the pro-                                                                                                       world.
                    tional plates serves as              cedural flows in the grind-
                    protection against wear.             ing unit. Our know-how        Lifting effect and
                                                         puts us in a position to      slippage of the ball charge

                    Besides the protection of            positively influence the
                    the mill diaphragm, the              grinding process due to
                    lining also has the task of          the modified shape of the     Consistent grinding efficiency
                    improving the lifting and            segments and thus im-         throughout the operation
                    flow of the balls due to             prove the efficiency of a
                    the particular shape of              grinding system while          In comprehensive test             material to be ground.
                    the individual plates.               minimising wear.              series, CPB has optimised          The shape of the lifter is
                                                                                       the shaping of the pro-            retained through-out its
                    Different heights and the                                          gressive lifter to such            service life; therefore the
                    layout of the individual                                           an extent that the ball            grinding         efficiency
                    wear plates ensure the                                             charge ensures optimum             remains consistent during
                    correct distribution of the                                        comminution of the                 the entire service life.
                    trail of balls and reduce
                    the relative movement
                    between the balls and the
                    lining.                                                                                                           CPB-Design: Constant height of lifter
                                                                                                                                      through-out the entire service life




                                                                                       Conventional design: Decreasing hub height
                                                                                       from the first operating hour onwards




                                                  Mill shell lining
Fastening systems                                                                 Compact                                                  Lining plates for
                                                                                                                                           all mill systems
                                                                                                                                             The lining of the mill
                                                                                                                                           cylinder is subject to a
                                                                                                                                           high level of abrasion
                                                                                                                                           under the harsh condi-
                                                                                                                                           tions of everyday opera-
                                                                                                                                           tion.
                      As a specialist in linings
                     for ball mills, CPB can
                     offer any fastening
                     system required. All li-
                     nings are tailor made to
                     the requirements of your
                     mill.


                      The fastening systems
                     described below are stan-
                     dard:
                                                     A bolted fastening
                                                   requires a drill hole in the
                                                   mill cylinder for each
                                                   plate. The system is easy
                                                   to operate and can
                                                   be installed without the         Boltless fastening sys-    lining plates. It enables
                                                   assistance of CPB spe-         tems also include the        standard format plates      We have developed a
                                                   cialists.                      system developed by CPB      (DIN dimension) to be       number of proprietary
                                                                                  that is known as Compact     used and thus increases     enhancements, in parti-
                                                                                  Lining. The lining plates    the cost-effectiveness of   cular for semi-bolted
                                                   With a semi-bolted             are held on a guide rail     the mill.                   fastening, as it unites
                                                                                                                                           the most advantages in
                    Systems


                                                   fastening option, at least     that is bolted to the mill     Compact lining has pro-
                                                   two rows of plates are         cylinder.                    ven its worth in practice   everyday operation:
                                                   bolted. Special tools are        Particularly where the     and is being used in an     - high degree of
                                                   needed for installation; in    position of the drilled      increasing number of          installation safety,
                                                   this case it is recommend-     holes of the mill cylinder   mills.                      - quick replacement
                                                                                                                                             of plates,
                                                   ed to have CPB staff to        are inconsistent, Compact
                                                                                                                                           - short down-time during
                                                   supervise the installation     Lining is an alternative                                   overhaul.
                                                   of the system.                 option for fastening the



                                                    With the boltless option,
                                                   lining plates are forced-
                                                   fitted with positive
                                                   locking without any bolts.
                                                   Installation calls for pre-
                                                   cise preparation and
                                                   should only be carried out
                                                   with assistance from CPB
                                                   specialists.
Stages of production
                                                      Stages of                                                                                                               Secure data
                                                                                                                                                                              for investment
                                                                                                                                                                              decisions

                       CPB linings are
                       used successfully
                       through-out the
                       world

                       With know-how based on
                       many years of experience
                       in grinding technology,
                       our designers are con-
                       stantly working on the
                                                                                                                                                                                Christian Pfeiffer will
                       further development and
                                                                                                                                                                              always provide you with
                       improvement of mill li-
                                                                                                                                                                              secure output data for
                       nings. To date, more than
                                                                                                                                                                              your investment decisions
                       2000 mills throughout
                                                                                                                                                                              since we determine all
                       the world have been fit-
                                                                                                                                                                              necessary parameters for
                       ted with our lining sys-
                                                                                                                                                                              the successful operation
                       tems.
                                                                                                                                                                              of your grinding system in
                                                                                                                                                                              semi-industrial tests.
                                                            Precise plates thanks
                                                            to a unique casting process                                                                                        In addition, our Rese-
                                                                                                                                                                              arch and Development
                                                             At CPB, the lining          of the plate, different      At CPB, the plates are                                  team applies itself to the
                                                            systems are made from        materials containing up    cast using the shell mould                                new and further improve-
                                                            cast steel. Depending on     to 26 % chrome are used.   casting procedure. This                                   ment of machines, com-
                                                            the particular application                              casting method is ideal                                   ponents and procedures.
                                                                                                                    through-out the world                                     The extent of our experts’
                                                                                                                    for manufacturing wear       Quality as a                 success in this field has
                                                                                                                    resistant systems for tube   requirement                  already often been proven
                                                                                                                    mills. It allows adherence   for international            over the past few dec-
                                                                                                                    to very small manufactur-    success                      ades, and the results of
                                                                                                                    ing tolerances and sup-                                   their efforts have often
                                                                                                                    plies precise, dimension-     To meet the require-        become milestones in the
                                                                                                                    ally stable cast material    ments of our international   development of modern
                                                                                                                    products.                    customers, our quality       grinding systems.
                                                                                                                                                 assurance system has been
                                                                                                                      Qualified toolmakers       certified since 1994.
                                                                                                                    and mould designers pro-
                                                                                                                    duce precise models from      We constantly monitor
                                                                                                                    steel and thus create the    and log all stages of pro-
                                                                                                                    basis for the mass pro-      duction, from the material
                                                                                                                    duction of the castings.     charge through manufac-
                       CNC processing centre for model construction                                                                              ture to dispatch of the
                                                                                                                                                 goods.
We have many


                                                                                                                                                   Replacement                                                           advantages to
                                                                                                                                                                                                                         offer in addition
                                                                                                                                                                                                                         to our products
Replacement and service
                                                                                                                                                                                                                          One advantage is our
                                                                                                                                                                                                                         comprehensive service.



                          Successful start after overhaul of mill                                                                                  Quick availability
                            When the new lining         continually operated with     The mill is then filled with     Systematic evaluations
                                                                                                                                                   in the event of a
                          system has been installed,    material. To examine the      grinding media up to the       and many years of prac-       plate breakage
                          the mill must be opti-        grinding progress, the mill   optimum          operating     tical experience on the         Metal in the feed mate-
                          mised. Optimisation is        is subjected to an emer-      charge for the normal          part of our engineers         rial, operation of the mill
                          carried out step-by-step      gency shutdown and            operation of the mill.         guarantee that every mill     without material feed or
                          in accordance with the        sample of materials are                                      can be adjusted to meet       with insufficient material
                          recommendations of our        taken from along the mill      For optimisation it is        customer requirements.        may result in plate break-
                          specialists.                  axis. A grinding diagram      also necessary to consider                                   age.
                            The mill is first charged   can now be created on         the influencing parame-
                          with 80 % of the calcula-     the basis of the particle     ters of the entire grinding                                  With the semi-bolted or        To avoid long downtimes,
                          ted grinding media and        size distribution analysis.   system.                                                      boltless fastening options,   we have developed a spe-
                                                                                                                                                   breaks may result in fail-    cial repair kit. With the
                                                                                                                                                   ure of the lining system,     use of this kit, individual
                                                                                                                                                                                                                           From individual recom-
                                                                                                                                                   for this reason this dam-     damaged plates can be
                                                                                                                                                                                                                         mendations,       detailed
                                                                                                                                                   age must be repaired          replaced without difficul-
                                                                                                                                                                                                                         planning, up to reliable
                                                                                                                                                   immediately.                  ty.
                                                                                                                                                                                                                         installations. Even after-
                                                                                                                                                                                                                         wards, we are there for
                                                                                                                                                                                   The Christian Pfeiffer
                                                                                                                                                                                                                         you if questions arise, or
                                                                                                                                                                                 installation team or the
                                                                                                                                                                                                                         if you require anything,
                                                                                                                                                                                 company’s own mainte-
                                                                                                                                                                                                                         and naturally for main-
                                                                                                                                                                                 nance engineers can
                                                                                                                                                                                                                         tenance and inspection.
                                                                                                                                                                                 replace the plates.
                                                                                                                                Specific surface
                           Residue mass -%                                                                                acc. to Blaine [cm2/g]                                                                          If you would like to




                                                                                                                                                                                                               service
                                                                                                                                                                                                                         have more information
                                                                                                                                                                                                                         about our products and
                                                                                                                                                                                                                         services. Call us. It will be
                                                                                                                                                                                                                         a pleasure for us to
                                                                                                                                                                                                                         assist you.




                          Distributionparticle size by fractions fractions
                           Distribution of of particle size by

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Mill Shell Lining

  • 1. Mill shell lining Headquarters/Germany Foundry/Austria Christian Pfeiffer Christian Pfeiffer Maschinenfabrik GmbH Maschinenfabrik GmbH Sudhoferweg 110-112 Werkstraße 5 59269 Beckum 8940 Liezen Germany Austria Tel. +49 (0) 25 21/8 49-00 Tel. +43 (0)3612/270-0 Fax +49 (0) 25 21/8 49-123 Fax +43 (0)3612/270-589 office@christianpfeiffer.de office@cpb.at www.christianpfeiffer.de www.christianpfeiffer.de Italy South America Christian Pfeiffer Christian Pfeiffer Mezzomerico SpA Latinoamericana S.A. Via Marano Ticino 7 Parque Industrial Liviano 28040 Mezzomerico (NO) Av. Brasil Calle # 1 Italy Santa Cruz, Bolivia Tel. +39 (03 21) 92 3010 Tel. +591 (3) 34 81768 Fax +39 (03 21) 92 3141 Fax +591 (3) 34 92 597 info@christianpfeiffer.it christianpfeiffer@unete.com www.christianpfeiffer.it www.christianpfeiffer.de USA Konzept und Gestaltung Kulms & Halbur/CPR Lippstadt · D-Vo. / 2,1-00-engl. / 2.04 American Pfeiffer Corporation 3407 West Chester Pike Newtown Square, PA 19073-4227 USA Tel. +1 (610) 35 66 995 Fax +1 (610) 35 68 987 cpb@americanpfeiffer.com www.americanpfeiffer.com
  • 2. principle Principle of the mill High energy input for the comminution process Cement, which is used as The grinding process a basis for numerous con- usually takes place in ball struction activities, is an or tube mills which, due attractive raw material to their simple principle, that can be manufac- are widespread through- tured almost uniformly out the world and require through-out the world. only low maintenance efforts. Although the extraction of raw materials – lime- The rotary movement of stone, clay and aggrega- the mill shell causes the tes – is still relatively grinding media (cast steel simple and inexpensive, balls) to rise, fall or roll the various stages of pro- onto the material to be duction in the cement ground with high impact works require a high- or pressure energy and energy input. Particularly thus performs the com- in the various grinding minution. processes – the genera- tion of raw meal prior to the burning process and grinding of the cement clinker - requires around 20 million kWh power consumption per year for a medium-sized pro- duction line. This amounts to around 60 % of the energy input of a pro- duction line. Mill
  • 3. Safe and simple: Ball mills Conventional design Every year around 1.4 Mill shell lining billion tons of cement clinker are ground, 90 % Lining systems of which is ground in ball for tube mills mills. This size reduction Direction of rotation process requires approx. Tube or ball mills are Wave profile 8 % of the entire world’s horizontal shells in which energy requirement. charged balls of varying sizes “smash“ the material The principle of the ball passing through by im- Modified shape mill is simple; reliability pact energy. improves the effi- and availability of the ciency of the mill systems guarantee high The mill shell is fitted operating reliability. Ball with an inner lining to Christian Pfeiffer is not Progressive mills have proven their lifter protect the mill cylinder: only the manufacturer of worth in nearly all cement A lining consisting of the lining systems, but production lines of the highly wear resistant sec- also applies to the pro- world. tional plates serves as cedural flows in the grind- protection against wear. ing unit. Our know-how Lifting effect and puts us in a position to slippage of the ball charge Besides the protection of positively influence the the mill diaphragm, the grinding process due to lining also has the task of the modified shape of the Consistent grinding efficiency improving the lifting and segments and thus im- throughout the operation flow of the balls due to prove the efficiency of a the particular shape of grinding system while In comprehensive test material to be ground. the individual plates. minimising wear. series, CPB has optimised The shape of the lifter is the shaping of the pro- retained through-out its Different heights and the gressive lifter to such service life; therefore the layout of the individual an extent that the ball grinding efficiency wear plates ensure the charge ensures optimum remains consistent during correct distribution of the comminution of the the entire service life. trail of balls and reduce the relative movement between the balls and the lining. CPB-Design: Constant height of lifter through-out the entire service life Conventional design: Decreasing hub height from the first operating hour onwards Mill shell lining
  • 4. Fastening systems Compact Lining plates for all mill systems The lining of the mill cylinder is subject to a high level of abrasion under the harsh condi- tions of everyday opera- tion. As a specialist in linings for ball mills, CPB can offer any fastening system required. All li- nings are tailor made to the requirements of your mill. The fastening systems described below are stan- dard: A bolted fastening requires a drill hole in the mill cylinder for each plate. The system is easy to operate and can be installed without the Boltless fastening sys- lining plates. It enables assistance of CPB spe- tems also include the standard format plates We have developed a cialists. system developed by CPB (DIN dimension) to be number of proprietary that is known as Compact used and thus increases enhancements, in parti- Lining. The lining plates the cost-effectiveness of cular for semi-bolted With a semi-bolted are held on a guide rail the mill. fastening, as it unites the most advantages in Systems fastening option, at least that is bolted to the mill Compact lining has pro- two rows of plates are cylinder. ven its worth in practice everyday operation: bolted. Special tools are Particularly where the and is being used in an - high degree of needed for installation; in position of the drilled increasing number of installation safety, this case it is recommend- holes of the mill cylinder mills. - quick replacement of plates, ed to have CPB staff to are inconsistent, Compact - short down-time during supervise the installation Lining is an alternative overhaul. of the system. option for fastening the With the boltless option, lining plates are forced- fitted with positive locking without any bolts. Installation calls for pre- cise preparation and should only be carried out with assistance from CPB specialists.
  • 5. Stages of production Stages of Secure data for investment decisions CPB linings are used successfully through-out the world With know-how based on many years of experience in grinding technology, our designers are con- stantly working on the Christian Pfeiffer will further development and always provide you with improvement of mill li- secure output data for nings. To date, more than your investment decisions 2000 mills throughout since we determine all the world have been fit- necessary parameters for ted with our lining sys- the successful operation tems. of your grinding system in semi-industrial tests. Precise plates thanks to a unique casting process In addition, our Rese- arch and Development At CPB, the lining of the plate, different At CPB, the plates are team applies itself to the systems are made from materials containing up cast using the shell mould new and further improve- cast steel. Depending on to 26 % chrome are used. casting procedure. This ment of machines, com- the particular application casting method is ideal ponents and procedures. through-out the world The extent of our experts’ for manufacturing wear Quality as a success in this field has resistant systems for tube requirement already often been proven mills. It allows adherence for international over the past few dec- to very small manufactur- success ades, and the results of ing tolerances and sup- their efforts have often plies precise, dimension- To meet the require- become milestones in the ally stable cast material ments of our international development of modern products. customers, our quality grinding systems. assurance system has been Qualified toolmakers certified since 1994. and mould designers pro- duce precise models from We constantly monitor steel and thus create the and log all stages of pro- basis for the mass pro- duction, from the material duction of the castings. charge through manufac- CNC processing centre for model construction ture to dispatch of the goods.
  • 6. We have many Replacement advantages to offer in addition to our products Replacement and service One advantage is our comprehensive service. Successful start after overhaul of mill Quick availability When the new lining continually operated with The mill is then filled with Systematic evaluations in the event of a system has been installed, material. To examine the grinding media up to the and many years of prac- plate breakage the mill must be opti- grinding progress, the mill optimum operating tical experience on the Metal in the feed mate- mised. Optimisation is is subjected to an emer- charge for the normal part of our engineers rial, operation of the mill carried out step-by-step gency shutdown and operation of the mill. guarantee that every mill without material feed or in accordance with the sample of materials are can be adjusted to meet with insufficient material recommendations of our taken from along the mill For optimisation it is customer requirements. may result in plate break- specialists. axis. A grinding diagram also necessary to consider age. The mill is first charged can now be created on the influencing parame- with 80 % of the calcula- the basis of the particle ters of the entire grinding With the semi-bolted or To avoid long downtimes, ted grinding media and size distribution analysis. system. boltless fastening options, we have developed a spe- breaks may result in fail- cial repair kit. With the ure of the lining system, use of this kit, individual From individual recom- for this reason this dam- damaged plates can be mendations, detailed age must be repaired replaced without difficul- planning, up to reliable immediately. ty. installations. Even after- wards, we are there for The Christian Pfeiffer you if questions arise, or installation team or the if you require anything, company’s own mainte- and naturally for main- nance engineers can tenance and inspection. replace the plates. Specific surface Residue mass -% acc. to Blaine [cm2/g] If you would like to service have more information about our products and services. Call us. It will be a pleasure for us to assist you. Distributionparticle size by fractions fractions Distribution of of particle size by