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Technical Seminar Miami 2013
Miami, September 17 - 19, 2013
Proceedings Convening Networking Sharing knowledge
Page 2
© by LOESCHE
Final programme September 16, 2013 19:00 - 22:00
Social activity, Location TBD - meet in hotel lobby
September 17, 2013
Technical Seminar at DoubleTree by Hilton Grand Hotel Biscayne Bay
08:30 - 09:00
Registration open: Coffee and networking
09:00 - 09.15
Welcome address / opening remarks / Agenda overview - Perla Ruiz, LOESCHE America, Inc.
09:15 - 09:30
Meet the delegates - Introduce yourself to the audience
09:30 - 10:30
Introduction LOESCHE vertical roller mills - Desi Delgado, LOESCHE America, Inc.
10:30 - 10:45
Coffee and networking
10:45 - 12:00
Process, operation & evaluation of LOESCHE mills - Christian-Martin Ruthenberg, LOESCHE GmbH
12:00 - 13:00
Lunch and networking
13:00 - 14:30
Main assembly groups - Peter Lolschou, LOESCHE America, Inc.
14:30 - 14:45
Coffee and networking
14:45 - 15.45
Open discussion
© by LOESCHE
September 18, 2013 08:30 - 09:00
Coffee and networking
09:00 - 09:15
Agenda overview - Perla Ruiz, LOESCHE America, Inc.
09:15 - 10:30
Maintenance & procedures - Peter Lolschou, LOESCHE America, Inc.
10:30 - 10:45
Coffee and networking
Page 3
Final programme 10:45 - 11:45
Main mill gearbox - Desi Delgado, LOESCHE America, Inc.
11:45 - 13:00
Hydraulic Systems: Function & design Part 1- Dirk Grube, LOESCHE GmbH
13:00 - 14:00
Lunch and networking
14:00 - 14.45
Hydraulic Systems: Function & design Part 2- Dirk Grube, LOESCHE GmbH
14:45 - 15:00
Coffee and networking
15:00 - 16:30
Process parameters - Christian-Martin Ruthenberg, LOESCHE GmbH
September 19, 2013 Coffee and networking
09:00 - 09:15
Agenda overview - Perla Ruiz, LOESCHE America, Inc.
09:15 - 10:45
Stabilization of mill in upset conditions - Christian-Martin Ruthenberg, LOESCHE GmbH
10:45 - 11:00
Coffee and networking
11:00 - 12:30
Optimization of grinding plants: Upgrades, modifications - Desi Delgado, LOESCHE America, Inc.
12:30 - 13:30
Lunch and networking
13:30 - 14:45
World Café - hosted workshops
14:45 - 15:00
Coffee and networking
15:00 - 15:30
World Café summary
15:30 - 15:45
Closing remarks - end of seminar - Perla Ruiz, LOESCHE America, Inc.
© by LOESCHE
08:30 - 09:00
Page 4
Organisers Perla Ruiz Project engineer, LOESCHE America, inc.
Desi Delgado Customer Service Manager, LOESCHE America. Inc.
Main activities: • Technical Support for existing plants in the Americas • Office coordinator for new project installation & commissioning supervisors • Inspections and investigations at plant sites
Main activities: • Onsite and remote technical support to customers in the Americas • Training on mechanical design and maintenance • Customer service
email: [email protected]
email: [email protected]
In cooperation with LOESCHE Training Center, Germany: Theodora Bruns Head of Training Center, LOESCHE GmbH
Dr Regina Krammer Deputy Head Training Center, LOESCHE GmbH, Germany
Main activities: • Development of blended learning concepts for internal and external use • Business development • Customer service
Main activities: • Development of blended learning concepts for internal and external use • Design of eLearning courses • Knowledge management and communication
email: [email protected]
email: [email protected]
© by LOESCHE
Christian-Martin Ruthenberg Technical trainer, LOESCHE GmbH, Germany Main activities: • Development of training concepts for customers • Process auditing • Training on process and operation of LOESCHE grinding plants email: [email protected] Page 5
Lecturers Desi Delgado
Christian-Martin Ruthenberg
Customer Service Manager, LOESCHE America. Inc.
Technical trainer, LOESCHE GmbH
Main activities: • Onsite and remote technical support to customers in the Americas • Training on mechanical design and maintenance • Customer service
Main activities: • Development of training concepts for customers • Process auditing • Training on process and operation of LOESCHE grinding plants
email: [email protected]
email: [email protected]
Peter Lolschou
Dirk Grube
Field Service Manager, LOESCHE America, inc.
Deputy director Design, LOESCHE GmbH
Main activities: • Technical field services • Customer support • Inspections and investigations at plant sites
Main activities: • Design of hydraulic applications at LOESCHE mills • Coordination of design draftsmen email: [email protected]
© by LOESCHE
email: [email protected]
Page 6
About LOESCHE Since 1906, LOESCHE GmbH has been constructing vertical roller grinding mills. Patented in 1928, our roller grinding mill technology has been continually advanced and in the meantime is synonymous with LOESCHE GmbH. The key competence of the company is the design and development of individual concepts for grinding and drying plants for the cement, steel and iron, power, ores and minerals industry. The service portfolio ranges from first concept to commissioning augmented by maintenance, repair, training as well as modernization of grinding plants and spare parts activities. In April 2012, LOESCHE GmbH, Germany, has entered into a close cooperation agreement with pyroprocess specialist A TEC Holding GmbH, Austria. LOESCHE and A TEC will be partners for the realisation of plant improvement projects, environmental projects and will be in the position to offer complete process solutions. Having taken over the specialised department “Combustion Technology” of UCON AG Containersysteme KG, Gelsenkirchen, in April 2012, LOESCHE offers thermal process technological solutions, thus covering another field of activities with related products e.g. industrial burners and hot gas generators.
When communicating learning content about all matters pertaining to LOESCHE technology the Training Center uses the the principle of ‚integrated learning‘ (Blended Learning Concept) with the aid of the latest learning methods and media. It combines online courses which are not tied to a specific time and place with traditional attending teaching and seminars in order to consolidtate the knowledge so imparted in the best manner possible and with lasting effect.
For more information please refer to: www.loesche.com LOESCHE GmbH Hansaallee 243 D-40549 Duesseldorf Tel.: +49-211-5353-0 Fax: +49-211-5353-500
© by LOESCHE
LOESCHE is a privately owned company with its headquarter located in Dusseldorf, Germany and is represented worldwide with more than 850 employees, subsidiaries in the USA, Brazil, Spain, Great Britain, South Africa, India, United Arab Emirates, Russia and P.R. China as well as agents in more than 20 countries. The LOESCHE Training Center was founded in 2008. A young, innovative team of editors, eLearning authors and technical trainers drafts and creates trainings and eLearning courses, documents and manuals in accordance with the latest media-didactic principles, tailored to the needs and requirements of the customers.
Page 7
Introduction LOESCHE vertical roller mills by Desi Delgado, LOESCHE America, Inc.
Introduction LOESCHE vertical roller mills
© by LOESCHE
Desi Delgado, Technical Instructor Miami, September 2013
Page 8
Table of contents
Technical Seminar for:
General LOESCHE in brief LOESCHE worldwide History Range of application Special features Fundamentals of vertical roller mills Principles of design Mill / classifier structure
Welcome!
Pictures
2
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
3
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 9
General
General
LOESCHE in brief
LOESCHE worldwide
LOESCHE GmbH is a privately owned company founded 1906 in Berlin, Germany Certified according to DIN EN ISO 9001 Main shareholder: Dr. Thomas Loesche Management: Dr. Thomas Loesche, Dr. Joachim Kirchmann Employees in Düsseldorf: 400 Employees worldwide: 850 Turnover 2012: Euro 290 millions worldwide
4
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
5
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 10
General
General
History
History
1906 - Foundation in Berlin 1927 - Invention of the ‚LOESCHE mill‘
2012 – Loesche purchases majority share in ATEC / Greco – Wolrd leader in cement pyro process technology
1961 - Introduction of the hydropneumatic spring system 1970 - Patented 4-roller mill for raw material grinding 1980 - Patented modular coal mill 2003 - Largest cement mill in the world (capacity 300 t/h), type 3+3 2005 - LOESCHE s latest invention – 6-roller mill for raw material grinding 2006 - 100 years LOESCHE 2008 - Since 1906, LOESCHE has supplied worldwide over 2740 VRMs 2008 - LOESCHE achieved 7442 Blaine in grinding slag 2010 - LOESCHE achieved 6067 Blaine in grinding clinker 2010 - Operation of VRM PPC and OPC without water for grinding bed preparation 6
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 11
General
8
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
9
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
General
Page 12
General History
Historical VRM design
History LM-1928
10
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
11
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
General
Page 13
General
General
History
History
1970 - Introduction of the Hydropneumatic Spring System
1970 - Patented 4-Roller Mill
12
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
13
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 14
Fields of Application
General History
Loesche Grinding Plants are mainly used in the following industries
1980 – Patented modular coal mill
Cement Industry
14
Cement raw material grinding plants 2, 3, 4 and 6 grinding roller mills Capacity up to 1,200 t/h of cement raw material Drive motors up to 7,000 kW
Dry grinding plants for capacity up to 200 t/h Grinding of a wide range of coals varying from steam coal, bituminous, anthracite, lignite to predried lignite coal
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Industrial Minerals Industry
Iron and non-ferrous Ores
Grinding plants for Dry-grinding plants the processing of for baryte, betonite, minerals quick lime, colemanite, dolomite, gypsum, graphite, feldspar, limestone, kaoline, magnesite, manganese ore, phosphate, titanium slag and titanium dioxide etc.
Hot Gas Generator
Hot Gas Generators for all industries Gas, Oil and Coal fired
15
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Power, Iron, Steel and Cement Industry
Page 15
Cement Industry
Power, Iron, Steel Industry
Cement raw material grinding plants 2, 3, 4 and 6 grinding roller mills Capacity up to 1,200 t/h of cement raw material Drive motors up to 7,000 kW
16
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Dry grinding plants for capacity up to 200 t/h Grinding of a wide range of coals varying from steam coal, bituminous, anthracite, lignite to predried lignite coal
Page 16
Industrial Minerals Industry
Iron and non-ferrous Ores
Grinding plants for the processing of minerals and ores
Dry-grinding plants for baryte, betonite, quick lime, colemanite, dolomite, gypsum, graphite, feldspar, limestone, kaoline, magnesite, manganese ore, phosphate, titanium slag and titanium dioxide etc.
18
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
19
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 17
Hot Gas Generator
Mill in Operation
Hot Gas Generators for all industries Gas, Oil and Coal fired
20
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
21
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 18
General
General
Mill structure: LM xx.x+x CS with LSKS xx CS r
Mill structure: LM xx.x RM with LSKS xx
56
2
2
81
22
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 19
General
General
Mill structure: LMxx.x D with LSKS xx D
Special features of LOESCHE VRMs
24
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Grinding Drying all in one machine Transportation Classifying High flexibility in terms of Products Recipes Product properties Product qualities Combination of compressive and shear forces for a highly efficient grinding process Rollers fixed individually in rocker arms without intermediate frame Hydropneumatic loading of rollers Possibility of swinging-out grinding elements for easy maintenance and replacement
Page 20
General
General
Loesche VRM – Special Features
Fundamentals of Vertical Roller Mills LOESCHE Vertical Roller Mills
Grinding velocity
centrifugal force
Flat grinding table Large tapered rollers Combination of compressive and shear forces for comminution Rollers fixed individually in rocker arms without intermediate frame Low masses, low vibration level Hydro-pneumatic loading of rollers Hydraulic swing-out-device for easy replacement of grinding elements
table diameter
table diameter table rpm
table diameter 26
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
27
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 21
General
General
Fundamentals of Vertical Roller Mills
Special features of LOESCHE VRMs
28
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 22
General
General
Principle of design: Modular design
Principle of design: Modular design Raw material/coal/petcoke mills
A high interchangeability of parts is gained by modules: A module consists of:
Roller Rocker arm Pedestal Hydraulic cylinder (inside the pedestal)
2- roller- mill
30
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
3- roller- mill
Page 23
General
General
RM
Coal
32
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 24
General
General
Coal
Comparison grinding technologies Advantages / disadvantages Ball mill
34
High pressure roller press
+
-
-
Investment costs (building)
-
+
+/-
Operation costs
-
+ +
+ +
Capacity
-
+
+/-
Change of wear parts
+
+/-
+/-
Noise emission
-
+
+
Flexibility
-
+
+
Fineness
+
+
-
Cement quality 1 day strength
+
-
-
28 day strength
-
+
+
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
35
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Vertical roller mill
Investment costs (machinery)
Page 25
General
General
Mill structure
Mill structure: Main assembly groups
Sogamoso RM
Illustration of a LOESCHE Mill LM 3+3 C/S
The LOESCHE VRM for grinding cement/slag consists primarily of Raw material feed
Classifier LSKS
Mill
M-roller
Mill body incl. lining
Classifier
M-rocker arm
S-spring assembly S-rocker arm
Mill gearbox
Table
Hydraulic system S-roller
M-spring assembly
Mill gearbox Illustration
36
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Mill stand Illustration
37
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Mill drive
Page 26
General
General
Mill structure: Main assembly groups Rocker arm M-roller
M-roller
S-roller
Classifier structure: Main assembly groups Lining
Classifier drive
Mill body
Outlet duct Upper housing
Grinding plate
Rocker arm S-roller
Intermediate frame
Dam ring
Guide vane Louvre / armour ring
Ring duct
Lower housing Scraper
Table
Pedestal
Classifier rotor Hot gas inlet
Mill gearbox
Classifier grit cone Concrete foundation
Foundation frame
Reject flap
Feed chute Illustration
38
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
39
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 27
Table of contents
Pictures
General
VRM for cement / slag with product separation in bag house.
LOESCHE in brief LOESCHE worldwide History Range of application Special features Fundamentals of vertical roller mills Principles of design Mill / classifier structure
Pictures
40
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
41
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 28
Pictures
Pictures
10 units of LM 28.2 D Taiwan Power Co. Taichung , Taiwan, 2000
42
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
43
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Ras al Khaimah Arab Emirates LM 60.4 RM
Page 29
Pictures
Pictures
Mill body / scraper / ring duct Mill motor
44
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
45
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Lubrication line and mill gearbox
Page 30
Pictures
Pictures Roller of LM 28.2 D
Louvre ring from above
46
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
47
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Louvre ring from below
Page 31
Pictures
Pictures Buffer
S-roller: rocker arm in working position
48
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
49
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
M-roller: rocker arm in working position
Page 32
Pictures High pressure hydraulic hoses
Hydraulic cylinder
Piston (left) and bladder (right) accumulator
50
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
51
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Pictures
Page 33
Pictures
Rotor (without bearing cartridge)
Static flap /guide vane assembly
Thank you for your attention
52
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
53
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 34
Process, operation, and evaluation of LOESCHE mills by Christian-Martin Ruthenberg, LOESCHE GmbH
Process, operation & evaluation of LOESCHE vertical roller mills
© by LOESCHE
Ch.-M. Ruthenberg, Technical Trainer Loesche GmbH Technical Seminar Miami, 2013-09-17
Page 35
Agenda
Different LOESCHE mill types Range of application
Different LOESCHE mill types
LOESCHE VRMs are mainly used in: Cement industry Coal fired power plants Iron making plants with blast furnace injection/ PCI (pulverised coal injection) Minerals and ore industry
Processes inside a mill Different process circuits Control values
Raw material mill
Evaluation of performance
2
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Coal/petcoke mill
Mineral mill
3
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Clinker & slag mill
Page 36
Different LOESCHE mill types
Different LOESCHE mill types
Mill structure: LM 56.4 RM with LSKS 88
Differences
56
Feed material Moisture content Grain size distribution Flow characteristics Grindability
.4
88
Illustration extract out of DWG 935021-00-3 LM 69.6 RM 4
Process, operation & evaluation of Loesche vertical roller mills Rev.A
5
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 37
Different LOESCHE mill types
Agenda
Differences
Different LOESCHE mill types Processes inside a mill
Machine Grinding force (according to grindability) Table speed (centrifugal force) Dam ring (grinding bed) S-rollers (deaeration) Louvre and armour ring (drying)
Different process circuits Control values Evaluation of performance
Illustration extract out of DWG 935021-00-3 LM 69.6 RM 6
Process, operation & evaluation of Loesche vertical roller mills Rev.A
7
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 38
Processes inside a mill
Agenda
The LOESCHE VRM combines
Different LOESCHE mill types Processes inside a mill
Grinding
Different process circuits
mill drive, gearbox, table and rollers Hot gas source: HGG, cooler, gas pre-heater
Classifying
Evaluation of performance
Transportation
Transportation Gas flow introduced by fan
Control values
Classifying
Drying
Drying Grinding
LDC / LSKS
in one machine. Clinker/slag mill 8
Process, operation & evaluation of Loesche vertical roller mills Rev.A
9
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 39
Process circuits
Process circuits
Raw meal grinding plant
Coal grinding plant with external inert gas source
10
Process, operation & evaluation of Loesche vertical roller mills Rev.A
11
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 40
Process circuits
Agenda
Clinker/slag grinding plant
Different LOESCHE mill types
Damper S (Stack)
Processes inside a mill Different process circuits
Damper R (Recirculation)
Control values Evaluation of performance
Damper Z1 (Fresh air)
Hot gas generator
12
Process, operation & evaluation of Loesche vertical roller mills Rev.A
13
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 41
Mill inlet pressure
Mill differential pressure
Clinker/slag grinding plant
Clinker/slag grinding plant
Damper S (Stack)
Damper S (Stack)
Damper R (Recirculation)
Damper R (Recirculation)
Damper Z1 (Fresh air)
Damper Z1 (Fresh air)
Hot gas generator
14
Process, operation & evaluation of Loesche vertical roller mills Rev.A
15
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Hot gas generator
Page 42
Mill outlet temperature
Process gas flow
Clinker/slag grinding plant
Clinker/slag grinding plant
Damper S (Stack)
Damper S (Stack)
Damper R (Recirculation)
Damper R (Recirculation)
Damper Z1 (Fresh air)
Damper Z1 (Fresh air)
Hot gas generator
16
Process, operation & evaluation of Loesche vertical roller mills Rev.A
17
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Hot gas generator
Page 43
Control Values
Agenda Different LOESCHE mill types Raw material
Coal
Clinker
Inlet pressure
Differential pressure
-
Outlet temperature
Gas flow
Different process circuits Control values Evaluation of performance
18
Process, operation & evaluation of Loesche vertical roller mills Rev.A
19
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Processes inside a mill
Page 44
Evaluation of performance
Process evaluation Clinker/slag grinding plant
Damper S (Stack)
Improvements (according to requirements)
Damper R (Recirculation)
Audit Assessment Operation
Damper Z1 (Fresh air)
Construction
Commissioning
Optimisation
Performance Run Hot gas generator
20
Process, operation & evaluation of Loesche vertical roller mills Rev.A
21
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 45
Summary Different LOESCHE mill types
Raw material, coal and clinker/slag mill
Processes inside a mill
Grinding, drying, transport and classifying
Different process circuits
Raw material, coal and clinker/slag mill
Control values
Thank you for your attention
Inlet pressure, differential pressure, outlet temperature and gas volume
Evaluation of performance
Operation, audits and required improvements
Essential knowledge of system, process and relations 22
Process, operation & evaluation of Loesche vertical roller mills Rev.A
23
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 46
Main assembly groups by Peter Lolschou, LOESCHE America, Inc.
Main Assembly Groups LOESCHE vertical roller mills
© by LOESCHE
Peter K. Lolschou, Technical Instructor Miami, September 2013
Page 47
Table of contents
Overview CS
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration 2
Q….00-4 en_TM_Maintenance Part 1_Rev.E
3
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Example: Bilbao LM 46.2+2 CS
Page 48
Overview
Overview
RM
D
Example: Lengerich LM 46.4 RM
Example: Nasice LM 20.2 D Illustration
Illustration 4
Q….00-4 en_TM_Maintenance Part 1_Rev.E
5
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Page 49
Table of contents
Main assembly groups CS
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Mill body Lining
M-lever sealing
M-roller tire
Table
M-roller
M-rocker arm
Grinding plate
HSLM: Hydraulic system M-roller
Mill stand
HSMS M-roller lubrication* Swinging device*
Grinding bed sprinkler* M-rocker arm bearing lubrication*
* These items are not shown in this illustration 6
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Illustration 7
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Page 50
Main assembly groups
Main assembly groups
RM
D Mill body Mill body
Lining Roller tire Roller
Lever sealing
Table
Roller tire
Rocker arm
Grinding plate
Lever sealing
Lining
Roller
Table
Rocker arm Grinding plate
HSLM: Hydraulic system roller
HSLM: Hydraulic system roller
Mill stand
Mill stand HSMS roller lubrication* Grinding bed sprinkler* Swinging device* Water injection* Rocker arm bearing lubrication* * These items are not shown in this illustration
* These items are not shown in this illustration
Illustration 8
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Reject box Illustration 9
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Water Injection* Swinging device* Rocker arm bearing lubrication*
Slide with pneumatic interlock
Page 51
Table of contents Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
CS 2+2
X
X
7
1 2 6 5 4
3
1 Ring duct 2 Gas duct 3 Foundation frame 4 Gearbox baseplate
5 Pedestal (S) 6 Pedestal cpl. 7 Bridge
000605
Mill stand - structure
Illustration 10
Q….00-4 en_TM_Maintenance Part 1_Rev.E
11
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Page 52
Mill stand - structure
Mill stand - structure
CS 3+3
RM X-X
1
X
6
X
1
6
7
5 2 3
X
2 4
X
4
000596
5
000503
3
1 Bridge with railing 2 Ring duct 3 Gas duct 4 Foundation frame
1 Ring duct 2 Gasduct 3 Foundation frame
Illustration 12
4 Gearbox baseplate 5 Pedestal cpl. 6 Bridge Illustration
Q….00-4 en_TM_Maintenance Part 1_Rev.E
13
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
5 Pedestal cpl. 6 Block (for S roller: take-up for swinging device) 7 Gearbox baseplate
Page 53
Mill stand - structure
Mill stand - function
Foundation frame LM x.3+3 CS
Ring duct – CS, RM, D The ring duct surrounds the table. Ring duct
The ring duct channels the hot gas into the louvre / armour ring. The ring duct is air-tight by welding.
Access door
The walls are partly hard surfaced to control wear. The floor of the ring duct is doublewalled to stiffen the design and provide thermal insulation towards the gearbox below.
Foundation frame
Hot gas inlet Ring duct Illustration 14
Illustration CS Q….00-4 en_TM_Maintenance Part 1_Rev.E
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Table of contents
Table - structure
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
CS, RM, D The table consists of Table casting Clamping ring Dam ring Scatter ring (if fitted) Louvre ring Armour ring Scraper
Illustration 16
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Table - structure
Table - structure
CS
RM 13
9
1
14
8
1 2
8
10 3
4 5
6
1 Table casting 2 Armour ring 3 Louvre ring 4 Insulating material 5 Bore for discharging foreign bodies 6 Dam ring 7 Scatter ring
8 Table bolts 9 Auxiliary equipment 10 Drive pin 11 Scraper 12 Ring duct 13 Cover 14 Clamping ring
Illustration
1 Roller 2 Armour ring 3 Louvre ring 4 Table casting 5 Ring duct 18
Q….00-4 en_TM_Maintenance Part 1_Rev.E
6 Scraper 7 Grinding plate 8 Clamping ring 9 Dam ring 10 Scatter ring
Illustration 19
© by LOESCHE
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6
4 5
000583
10
000607
11
3
9
2 7
12
7
Page 56
Table - structure
Table - structure
D
1
2
CS
3
Armour ring
Clamping ring
Table without dam ring
4
5
10
12
6
8
1 Clamping ring 2 Cover plate 3 Table casting 4 Armour ring 5 Louvre ring 6 Scraper
7 Drive pin 8 Gearbox output flange 9 Sealing air chamber 10 Wear rings 11 Dam ring 12 Scatter ring
Table guard preassembled Casted table
Louvre ring Illustration
Illustration 20
Dam ring
Q….00-4 en_TM_Maintenance Part 1_Rev.E
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000653
9
11
Page 57
Table - structure
Table - function
Dam ring – CS, RM, D
Louvre ring - CS, RM, D Generates the initial airlift
Louvre ring
The dam ring consists of ring segments stacked / bolted on top of each other and can be adjusted by adding or removing segments.
Important factors are:
To have sufficient velocity to avoid excessive reject To have sufficient amount to lift the finer material to the classifier Too high velocity will lift coarse material and create wear on mill lining and classifier Too low velocity will result in excessive reject and a table overload Gas flow ideally is evenly distributed Cover plates fine-tune gas velocity and gas distribution Louvre ring is subject to high wear and needs frequent inspections
Typical heights are
200 - 350 mm for slag / clinker 60 - 70 mm for limestone (RM) 60 – 100 mm for raw meal / coal
Dam ring
Inclination of louvres creates defined vortex and supports material drying
Grinding plates
Different mill sizes have different angles for the louvres Illustration 22
Armour ring Illustration D
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Louvre ring
Page 58
Table - function
Table of contents
Armour ring - CS, RM, D
Louvre ring
Acts as protection for mill body For clinker / slag and raw meal: The hollow area between the inclined plates and the mill housing will fill up with material and act as autogenous wear protection The armour ring is subject to heavy wear and needs frequent inspections Armour ring
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration CS 24
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M-roller - structure
M-roller - structure
CS, RM, D
CS
12
The M-roller consists of Roller axle Tire Clamping ring Hub Hub cover Taper roller bearing Guard Cylindrical roller bearing Sealing sleeve Cover disc Slip ring sealing
13
2
3
4 5 6
7
10
9
8
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Illustration 27
© by LOESCHE
26
8 Guard 9 Cylindrical roller bearing 10 Sealing sleeve 11 Rocker arm 12 Cover disc 13 Sealing air inlet 14 Slip-ring seal
000506
11
1 Roller axle 2 Tire 3 Clamping ring 4 Hub 5 Hub cover 6 Cover disc 7 Taper roller bearing Q….00-4 en_TM_Maintenance Part 1_Rev.E
1
14
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Roller - structure 9
10
11
D
1
12
10
9
2
2
3
11
3 4
4
8 7
8
5
7 000584
6
1 Tire 2 Clamping ring 3 Hub cover 4 Cover disc 5 Taper roller bearing 6 Guard ("bell housing")
6
Illustration 28
1 Clamping ring 2 Hub 3 Hub cover 4 Cover disc 5 Spherical roller bearing 6 Bell housing Q….00-4 en_TM_Maintenance Part 1_Rev.E
5
7 Sealing sleeve 8 Slip-ring seal cpl. 9 Cylindrical roller bearing 10 Roller axle 11 Oil dipstick Illustration 29
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7 Cylindrical roller bearing 8 Slip-ring sealing 9 Cover disc 10 Roller axle 11 Sealing sleeve 12 Hub
1
000651
RM
Roller - structure
Page 61
Roller - structure RM, CS, D Seal sizes and gaps
M-roller - structure CS
3
Number and location Depending on design: 2 or 3 M-rollers Each clamped on a rocker arm Spaced equidistant from each other Axial inclination to the horizontal grinding track (in zero setting) The position of the M-roller on the table which means the distance to the dam ring can be changed by using the distance ring inserted between the conical sleeve on the rocker arm and the corresponding axle shoulder.
are project dependent!
2 4,5
1 Fixing ring 2 Sealing ring 3 O-ring 4 Sealing set 5 Spiral spring ring
Illustration 30
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Roller - structure
Roller - structure
RM
D
Number and location
Number and location
Depending on design: 2 , 4 or 6 rollers Each clamped on a rocker arm Spaced equidistant from each other Axial inclination to the horizontal grinding track (in zero setting)
Depending on design: 2 , 3, 4 rollers Each clamped on a rocker arm Spaced equidistant from each other Axial inclination to the horizontal grinding track (in zero setting)
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Table of contents
CS
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
2
9
X 3 10 4
X
11
8
12
5
6
13 14
7
1 Rocker arm 2 Clamping sleeves 3 Roller axle 4 Cylindrical roller bearing (locating bearing) 5 Ring 6 Pedestal 7 Pivot point of spring-assembly cylinder 34
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8 Clamping sleeves 9 Fork 10 Central lever 11 Bearing block on pedestal 12 Cylindrical roller bearing (floating bearing) 13 Flange centring sleeve Illustration 14 Rocker-arm axle 35
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000508
M-rocker arm – structure
Page 64
Rocker arm – structure 11
RM
Rocker arm – structure
X-X
X
D
1
10
12 13
2
14
4
1
3
2
15 4
3
5
6
6
7 8 9
5
13
6
8
10 12 14
11 10
7
Illustration
1 Clamp with taper sleeve 9 Sealing air connection 2 Hood 10 Fork 3 Clamping sleeve connection 11 Journal 4 Rocker arm clamp 12 Bearing block 5 Seal 13 Fixed bearing 6 Rocker arm 14 Mounting for hydropneumatic spring assembly 7 Hub 15 Cover Illustration 8 Floating bearing
001023
X
1 transport lug 8 Fixed bearing 2 Taper pin connection 9 Pivot point of spring assembly cylinder 3 Lever 10 Clamping sleeve connection 4 Flange sleeve connection with oil connection 11 Sealing air connection 5 Axle 12 Taper sleeve 6 Floating bearing 13 Roller shaft 7 Fork 14 Clamping sleeve connection 36
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000652
9
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Table of contents
Grinding parts – function CS
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Depending on the material the grinding plate can be hard-faced by expert companies 8 to12 times Wear reference measurements are needed Replacement / re-welding frequency is predicted by wear measurements Recommended max. wear before welding is app. 35 mm Typical wear rate for clinker / slag is 6 – 8 g/t product; about 2 to 3 g/t for limestone Rollers run on outside of the grinding path
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Grinding plate:
Page 66
Table of contents
RM
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
X 3
3
11
X
A
A
10
4 9 8 7
6
Q….00-4 en_TM_Maintenance Part 1_Rev.E
A-A 12
2
13
1 Sealing bar (secured to the mill body) 2 Mill body 3 Sealing cap 4 Wear ring 5 Armour ring 6 Lining plate 7 Sealing bar (secured to the mill body) 40
5
8 Seal 9 Sealing bar (secured to the rocker arm) 10 Rocker arm 11 Seal 12 Sealing bar (secured to the mill body) 13 Seal Illustration 41
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2
1
000853
M-lever sealing - structure
Page 67
Lever sealing - structure
M-lever sealing - structure
D
CS, RM Flange for cover door
Seals: Cover door Sealing flanges around box mounted on shaft (moving with roller)
Shaft mounted box Illustration 42
Illustration CS Q….00-4 en_TM_Maintenance Part 1_Rev.E
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Lever sealing - structure
Table of contents
D
Lever sealing
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration 44
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HSLM: hydraulic system M-roller - structure
HSLM: hydraulic system M-roller - structure
CS, RM, D
CS M-spring assembly
The hydraulic system M-roller consists of:
Hydraulic cabinet HSLM
M-spring assembly Hydraulic cabinet HSLM Ring pipeline with pressure transmitter Connecting pipeline Bladder accumulator For systems with counter pressure: Piston accumulator Hydraulic cylinder For CS, D: Buffer
Illustration 46
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HSLM: hydraulic system M-roller - structure
HSLM: hydraulic system M-roller - structure
RM
CS HSLM power unit M-spring assembly
Buffer
Hydraulic cabinet HSLM
Illustration 48
Illustration Q….00-4 en_TM_Maintenance Part 1_Rev.E
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HSLM: hydraulic system M-roller - structure CS, RM, D Bladder accumulator
HSLM: hydraulic system M-roller - structure Piston accumulator for systems with counter pressure
N2
Oil
Illustration 50
Illustration Q….00-4 en_TM_Maintenance Part 1_Rev.E
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Table of contents
HSMS: roller lubrication - structure CS, RM
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
The HSMS roller lubrication consists of Hydraulic cabinet HSMS Connecting pipeline LM lubrication line Seal air inlet Oil level
Vent line
Inlet line / Outlet line
Illustration 52
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HSMS: roller lubrication - structure
HSMS: roller lubrication - function
CS, RM
CS, RM M-roller Tank
Pipelines are connected to rollers by hoses (roller movement) If oil is too cold, the pressure pump is outrunning the suction pump and the roller will be overfilled If the oil is too hot, the internal sealings of the roller may be damaged In normal operation the suction pump capacity is higher = always some oil runs from tank Suction pump is started first, several minutes later the pressure pump The circulation starts / stops with app. 30 minutes delay to the feed to allow the rollers to heat up and cool down
Heater
Cooler
Suction pump Oil filter Pressure pump
Pressure line Suction line Illustration 54
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HSMS: roller lubrication - data
Table of contents
CS, RM
Example
Oil type is project dependent
Oil Type and Quantity ISO VG 320 (see lubrication list) Pump capacity Suction pump 30% higher capacity than pressure pump Interlocked oil temperature limits in return / suction line T > 70 C - - - Alarm 1; oil too hot T > 80 C - - - Alarm 2; if oil > 80 C for > 30 minutes = stop pumps Interlocked tank oil temperature limits T < 15 C - - - no start of pumps T < 55 C - - - start heater in tank T > 60 C - - - stop heater in tank T > 70 C - - - Alarm 1; oil too hot T > 80 C - - - Alarm 2; if oil > 80 C for > 30 minutes = stop pumps
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Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Page 75
M-rocker arm bearing lubrication - structure
M-rocker arm bearing lubrication - function
CS, RM, D
CS, RM, D (depending on size)
The M-rocker arm bearing lubrication consists of (depending on mill size)
grease pump lubrication lines grease distributors leading to the rocker arm floating and locating bearings
Rocker arm bearings
The connections from rocker arm to hydraulic cylinders are manually greased The connection on top and bottom of hydraulic cylinders are manually greased Rocker arm pivot point
Hydraulic cylinder pivot point
M-rocker arm bearing lubrication ensures maximum bearing service life.
Grease pump pumps grease from reservoir into outlets
Each outlet is connected to a distribution unit that has equal outlets
The outlets of each distributor are connected to pipelines to greasing points
All pipelines are mounted in protected corners and therefore difficult to reach
Illustration CS 58
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M-rocker arm bearing lubrication - function
Table of contents
CS
The control system will start the pump when the mill feed is started The pump will run for 5 minutes, time is adjusted during commissioning Then the pump shuts down for 55 minutes, time is adjusted during commissioning As long as the mill is running the pump starts every runtime-hour Commissioning will ensure that the pump / distributors convey the proper amount of grease into the proper grease point The system will alarm if there is a problem with the grease flow, level or pump 8 hours after the initial alarm, the mill will shut down if the system is not corrected
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration CS 60
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Slide – structure
Slide – function
D
D Slide with pneumatic interlock
The slide cpl. ensures that the mill is shut off in a dust- and gastight state within tenable limits when foreign bodies are removed and in the event of reject material. It is usually located between the outlet hopper of the mill ring duct and the reject box.
Reject box
Illustration 62
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Table of contents
Pneumatic interlock – structure D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
1 2 15
3
4
9
11 13
12
5
6
14 10
8
7
Illustration 64
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Table of contents
Reject box – function D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
The end face of the reject box incorporates a large door with a seal and several quick-release locks. Foreign bodies and reject material from the mill is collected in the reject box. When the door is opened, the reject box can be emptied with a shovel
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The reject box is a welded round container with a torispherical head which is anchored on the mill floor. The reject box is erected underneath the mill ring duct and connected to this duct via an inlet hopper. A shut-off device (slide) is inserted between the box inlet funnel and connecting flange.
Page 80
Table of contents Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
RM X 1
2
X
3
4 000597
Mill body - structure
1 Cover 2 Mill body 3 Pointer 4 Mill door Illustration 68
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Mill body - structure
Mill body – structure Mill door – CS, RM, D
M-roller cover
Doors with quick-release covers are provided for inspection of the mill interior.
S-roller cover
It is not allowed to access the mill without following all safety procedures.
Mill door
Lining plates Central air flap (project specific) Illustration CS 70
Illustration Q….00-4 en_TM_Maintenance Part 1_Rev.E
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Page 82
Table of contents Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
CS 1
X 2
3
4
X
5
1 Mill body (top view) 2 S-cover lining 3 Lining plates
000638
Lining - structure
4 M-cover lining 5 Mill door lining
Illustration 72
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Lining - structure
Table of contents
RM
3 2
1
2
2
2
000599
2
1 Cast lining plates 2 Wear-resistant steel plates 3 Mill body
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration 74
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Sealing air – structure
Sealing air – structure
RM
RM
Illustration 76
Illustration Q….00-4 en_TM_Maintenance Part 1_Rev.E
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Sealing air and cleaning air – structure
Sealing air and cleaning air – structure
D
D
Illustration 78
Illustration Q….00-4 en_TM_Maintenance Part 1_Rev.E
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Page 86
Table of contents
Water injection - structure RM, D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration D 80
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© by LOESCHE
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Water injection - structure
Water injection - function
RM, D
RM, D The water piping connected to the pump aggregate is split into several feed pipes. The feed pipes end at the distribution pipes at the mill upper housing flange. Each distribution pipe is connected to spray nozzles via flexible hoses. The spray nozzles are screwed into the pipes which are flanged to the upper housing. The nozzles are arranged so they spray water between the rollers. The nozzle switchover point is at the lower characteristic curve range so that large pressure surges can be avoided (see also "Characteristic curve sheet: pumps + nozzle").
Illustration D 82
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© by LOESCHE
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Table of contents
Grinding bed sprinkler - structure CS, RM
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Plant water system supplies water to the pump Pump pumps water into pipeline to mill, excess water returns to plant system Water is split into pipelines, one injection per M-roller Injection lances distribute water across grinding path Compressed air supplied to purge lances (avoids dribbling into stopped mill)
Illustration 84
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© by LOESCHE
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Grinding bed sprinkler - structure
Grinding bed sprinkler - structure
CS, RM
CS, RM 2
1
8
9
10
7
5
4
1 Grinding roller
6 Orifice plate
2 Tire
7 Compressed-air line
3 Grinding plate
8 Grinding chamber
4 Table casting
9 Pipe holder
5 Water line
10 Sprinkler pipe
Illustration CS 86
Illustration CS Q….00-4 en_TM_Maintenance Part 1_Rev.E
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© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
3 000518
6
Page 90
Table of contents
Swinging device – structure CS, RM, D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
HSAV Pump unit
Illustration 88
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© by LOESCHE
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Swinging device – function
Table of contents
CS, RM, D
The swinging device serves to swing out/in the rollers
A
B 1 6
2
3
5
4
4 Hydraulic pump unit, HSAV
2 Hydraulic cylinder
5 Pedestal
3 Joint seating
6 Grinding roller, swung in
Illustration 90
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© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
1 Grinding roller, swung out
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Page 92
Classifier - structure
Classifier - structure LSKS Classifier drive Outlet duct
The classifier consists of
Upper housing
Classifier drive* Intermediate frame
Classifier lubrication line*
Guide vane
Upper housing with outlet duct and support for classifier drive* Lower housing with static guide vane*, lining* and feed chute
Lower housing
Rotor* with rotor blades* and bearing cartridge* Grit cone*
Classifier rotor
Classifier grit cone * These items are not shown in this illustration
Illustration
Illustration 92
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© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Feed chute
Page 93
Classifier - structure
Classifier - structure
LSKS ZD
LDC
Upper bearing
Classifier drive
Classifier Drive Outlet duct
Upper housing
Lower bearing Feed chute
Rotor shaft Rotor with removable rotor blades
Intermedi ate shaft Classifier grit cone
Lower housing
Intermediate frame
Guide vane
Stiff support pipes towards lower housing hold lower end of bearing cartridge in position (no swinging)
Classifier grit cone Illustration
Illustration 94
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© by LOESCHE
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Rotor
Page 94
Classifier - structure LSKS ZD power plant
Classifier drive - structure LSKS for CS, RM
Feed chute
Classifier drive consists of Classifier motor Classifier gearbox (speed monitor, temperature probes) Classifier lubrication with instrumentation (temperature, oil flow, speed monitor, …) Coupling, coupling guard, supports, hoses, etc.
Outlet duct
Upper housing Classifier drive
Classifier motor
Classifier lubrication
Rotor Coupling guard
Lower housing
Reservoir
Coupling Classifier gearbox
Classifier grit cone
Guide vane
Bell housing
Illustration
Illustration 96
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© by LOESCHE
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Classifier drive - structure
Classifier drive - structure Classifier gearbox lubrication system
D
Classifier drive consists of Classifier motor Grease pump
is a circular or splash lubrication that needs a certain rpm of the rotor to supply sufficient lubrication (never idle rotor) Temperature (PT100): Oil temperature < 0 C classifier drive stop Oil temperature > 85 C warning signal to control station Oil temperature > 90 C classifier drive stop
4 7
6
5
1 2 3
14 8
Resistance thermometer
13
1 Sealing air connection 2 Cover 3 Castellated disc 4 Multi-V pulley, bearing cartridge 5 Labyrinth ring 6 Proximity switch 7 Power belts
10
RM/CS Not existing for coal
Illustration 98
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Illustration 99
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Pump
9
11
8 Multi-V pulley, motor 9 Guard 10 Motor 11 Console 12 Classifier upper housing 13 Inspection cover
Cooling water inlet
001059
12
Oil reservoir
Page 96
Lining – structure LSKS Lining
Thank you for your attention
Lining in the classifer upper housing 100
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© by LOESCHE
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Maintenance & procedures by Peter Lolschou, LOESCHE America, Inc.
Maintenance & Procedures LOESCHE vertical roller mills
© by LOESCHE
Peter K. Lolschou, Technical Instructor Miami, September 2013
Page 98
Table of Contents
M-Roller – Maintenance Work
M-Roller - CS, RM, D
CS
Swinging Device - CS, RM, D
Visual check: Tightness / attachment of all bolts at roller covers and tires Wear of shaft protection Oil leaks / oil level / slip ring sealing Seal air labyrinth seal by hand Roller tire coating / wear
Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D
Intervals: Visual check weekly Check slip ring sealing and seal air labyrinth,and dismount yearly Rebuild / exchange seals as needed Detailed wear measurement Change / re-weld roller tires as needed Take oil samples as specified Exchange oil as necessary determined by sample quality
M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier
Illustration CS 2
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© by LOESCHE
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Roller – Maintenance Work
Roller – Maintenance Work
RM
D
Visual check: Tightness / attachment of all bolts at roller covers and tires Wear of shaft protection Oil leaks / oil level / slip ring sealing Seal air labyrinth seal by hand Roller tire coating / wear
Visual check: Tightness / attachment of all bolts at roller covers and tires Wear of shaft protection Oil leaks / oil level / slip ring sealing Seal air labyrinth seal by hand Roller tire coating / wear
Intervals: Visual check weekly Check slip ring sealing and seal air labyrinth,and dismount yearly Rebuild / exchange seals as needed Detailed wear measurement Change / re-weld roller tires as needed Take oil samples as specified Exchange oil as necessary determined by sample quality
Intervals: Visual check weekly Check slip ring sealing and seal air labyrinth,and dismount yearly Rebuild / exchange seals as needed Detailed wear measurement Change / re-weld roller tires as needed Take oil samples as specified Exchange oil as necessary determined by sample quality Illustration RM
Illustration D 4
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© by LOESCHE
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M-Roller – Maintenance Work
Roller – Maintenance Work
CS
RM
Minimum gap between M-roller and table
Roller tires are highly chrome-alloyed, wear resistant but brittle To avoid tire damage no tramp metal must invade the mill (external reject handling system in feed 10 mm transport), also metal to metal contact between rollers and table must be avoided A minimum gap of 10 mm is adjusted for monitoring The adjustment has to be checked weekly: Lift rollers – thread buffer out 3 revolutions – set minimum 10 mm plate under roller – lower rollers – adjust buffers until they touch the rocker arm – lift rollers – extract 10 mm plates The gap will increase with wear. The grinding efficiency will deteriorate over time.
Minimum gap between M-roller and table
Buffer
Roller tires are highly chrome-alloyed, wear resistant but brittle To avoid tire damage no tramp metal must invade the mill (external reject handling system in feed 10 mm transport), also metal to metal contact between rollers and table must be avoided A minimum gap of 10 mm is adjusted for monitoring The monitoring has to be checked weekly: Lift rollers – set minimum 10 mm plate under roller – lower rollers – calibrate the monitoring – lift rollers – extract 10 mm plates – repeat the procedure with different plates. The monitoring will drift with wear. The grinding efficiency will deteriorate over time.
Illustration
Illustration 6
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© by LOESCHE
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Roller – Maintenance Work
M-Roller – Maintenance Work
Coal
CS
Minimum gap between Roller and table
Bearing Replacement
Roller tires are highly chrome-alloyed, wear resistant but brittle Metal to metal contact between rollers and table 5 mm must be avoided A minimum gap of 5 mm is adjusted for monitoring The adjustment has to be checked weekly: Lift rollers – thread buffer out 3 revolutions – set 5 mm plate under roller – lower rollers – adjust buffers until they touch the rocker arm – lift rollers – extract 5 mm plates The gap will increase with wear. The grinding efficiency will deteriorate over time.
It is strongly recommended to have experienced personnel and correct tools. Remove inner cover plate Loosen inner rings Pump high pressure oil into grooves of bearing seats using the delivered handpump Remove taper roller bearing Remove inner and outer rings and distance sleeves Remove cylindrical roller bearing by using a hydraulic jack
Buffer
Illustration 8
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© by LOESCHE
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Roller – Maintenance Work
Roller – Maintenance Work
Coal Bearing Replacement
RM Bearing Replacement
10
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M-Roller – Maintenance Work
Roller – Maintenance Work
CS/RM
Coal
Exchange of M-roller
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Exchange of roller
- It is recommended to have a Loesche expert on site for supervision Remove M-roller covers (seal and cover) Disconnect seal air and (if needed) lubrication hoses Install blind plugs to avoid oil loss into breather (and open bores for hoses) Install swing-out devices (all parts) Remove locking pins Swing roller out of mill Remove roller assembly Lift roller assembly in position and tighten bolts Secure bolts Swing roller back into mill Install locking pins (use swinging device for aligning bores) Uninstall swing out device (all parts) Remove blind plugs from oil lubrication connections Re-install seal air and oil lubrication hoses Re-install M-roller covers (cover door and seals) Clean work area and store hydraulic cart / cylinder / hoses in clean and safe area
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
12
Remove roller covers (seal and cover) Disconnect PT100 (Temperature sensor) Install swing-out devices (all parts) Remove locking pins Swing roller out of mill Remove roller assembly Lift roller assembly in position and tighten bolts Secure bolts Swing roller back into mill Install locking pins (use swinging device for aligning bores) Uninstall swing out device (all parts) Re-install PT100 Re-install M-roller covers (cover door and seals) Clean work area and store hydraulic cart / cylinder / hoses in clean and safe area
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© by LOESCHE
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It is recommended to have a Loesche expert on site for supervision
Page 104
M-Roller – Maintenance Work
M-Roller – Maintenance Work Exchange of M-roller
Exchange of M-roller
4. Install swing-out devices (all parts)
1. Remove roller covers (seal and cover) 2. Disconnect seal air and (if needed) for RM: lubrication hoses 3. Install blind plugs to avoid oil loss into breather (RM: and open bores for hoses)
1
2/3
Illustration CS
Illustration 14
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15
© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
pins to fix transistion to rocker arm Swing-out transition for rocker arm pin to fix transition to cylinder shaft Maintenance cylinder (functional) Pin to fix cylinder to foundation eye-bolt connection hoses: HSAV Pump unit - cylinder HSAV pump unit (functional, filled with oil)
Page 105
M-Roller – Maintenance Work
M-Roller – Maintenance Work Exchange of M-roller tire
Illustration
6. Swing roller out of mill
Locking pin(s) Rocker arm shaft
Exchange of M-roller 5. Remove locking pins 6. Swing roller out of mill To swing-out the M-roller (S-roller similar): Extend the maintenance cylinder shaft fully using the mobile hydraulic cart Attach shaft to swing-out transition part at rocker arm Remove the locking pins (1 per side) Use the hydraulic cart to move the maintenance cylinder shaft back in The roller will then pivot at the common pivot pin as it swings into the vertical / maintenance position
Illustration 16
Illustration Q…-01-4 en_TM_Maintenance Part 2_Rev.B
17
© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 106
Table of Contents
M-Roller – Maintenance Work
M-Roller - CS, RM, D
Exchange of M-roller
Swinging Device - CS, RM, D
7. Roller removal
Grinding Parts: roller tires, grinding plate - CS, RM, D
Open outer shaft cover and loosen / take out bolts of outside clamp ring (at bottom of roller when swung-out) Install lifting eye bolts (original delivered) Install manual hydraulic jack under shaft and press roller shaft out of rocker arm seat Do not use force of crane to loosen roller assembly (either rocker arm or crane could break) Once lose the roller assembly is lifted off using a crane and the lifting eye bolts
Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier Illustration 18
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
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Swinging Device – Film
Swinging Device – Maintenance Work CS, RM, D Flanged sleeve
The hydraulic cylinder has to be stored vertically. Proper dismounting and mounting of taper pin- and flanged sleeve connection of rocker arm - fork connection is important. Intervals:
Taper pin connection
Swinging device
check completeness and function of all auxiliary-parts prior to use of auxiliary parts. Maintenance: change oil vent off air of swing out cylinder clean tank
Illustration 20
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21
© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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Table of Contents
Grinding Parts – Maintenance Work
M-Roller - CS, RM, D
CS, RM, D
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier Illustration 22
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© by LOESCHE
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Page 109
Grinding Parts – Maintenance Work
Grinding Parts – Maintenance Work
CS, RM, D
1
1
CS, RM, D
2
2
Back of roller ca. 10 mm
X
X
Front of roller
000524
3 3
1 Tire profile ruler 2 Tire 3 Hub
Illustration 24
Illustration Q…-01-4 en_TM_Maintenance Part 2_Rev.B
25
© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 110
Grinding Parts – Maintenance Work
Grinding Parts – Maintenance Work
CS, RM, D
CS, RM, D Grinding plate
Roller tire
Wear Measurement
Using a template, wear has to be measured approximately weekly or as needed The measurements have to be recorded and used to predict when welding or exchange of the grinding parts is required Maximum recommended wear before rewelding: 30 mm Maximum recommended wear before exchanging: according to contract For Clinker / slag and coal: Do not forget to re-adjust buffers Roller measurement tool as per drawing Table = “straight edge” with markers
Illustration 26
Illustration Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Tire profile ruler
Page 111
Grinding Parts – Maintenance Work
Grinding Parts – Maintenance Work
Picture1 : new M-roller tire Picture 2: M-Roller tires in the range of re-welding Picture 3: limit of re-weldable wear
1
Pictures 4, 5 and 6 show M-Roller tires beyond rewelding Tire exchange imminent Picture 7 shows a tire at the breaking point
3
4
6
5
7
2
Illustration CS
Illustration CS 28
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© by LOESCHE
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Grinding Parts – Maintenance Work
Grinding Parts – Maintenance Work
CS, RM
CS, RM
Welding procedures for roller tires and grinding plate To be performed by experienced welding company Needs specialised equipment (automatic welding head, large welding gear) Will be done inside the mill with all parts installed The table is turned by means of an auxiliary drive for welding the grinding plate The tires are turned by the table or by separate drives for each roller It is critical for both procedures to set-up the welding ground properly, not to damage bearings and gears. Generally, when welding the grinding plate or tires check for Grinding plate set tight and all clamping bolts torqued Tires set tight and all clamping bolts torqued Tires are not broken or cracked in any spot Tires and grinding plate should be built back up to the original profile App. 8 to 12 re-weldings are possible Welding in an external workshop is also possible after dismounting all grinding parts Illustration 30
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© by LOESCHE
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Table of Contents
Table – Maintenance Work
M-Roller - CS, RM, D
Auxiliaries table – CS, RM, D
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM
Hydraulic jack
M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Table support
Reject Box – D Classifier
Illustration CS 32
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 114
Table – Maintenance Work
Table – Maintenance Work
CS, RM
Effects of dam ring height on production and quality – CS, RM, D
Visual check
The grinding plates wear out which may increase the effective height of the dam ring. It might be necessary to weld on / exchange the grinding plates or adjust the dam ring height to keep a constant mill performance.
Armour ring wear
Dam ring wear
Louvre ring / Cover plates wear Clamping ring wear and tightness of bolts Illustration CS
Changing the dam ring height is used to achieve the following effects: Stabilization of mill operation (vibration control) Optimization of specific power consumption Optimization of product fineness (rough tuning)
Table seal wear and tear
The following results will be achieved: Improved product fineness (dam ring higher) Improved specific power consumption (dam ring lower)
Intervals: Visual check weekly Repair / retighten as needed Change / re-weld grinding plates as needed
The optimum dam ring height will be determined during commissioning.
Change / re-weld louvre / armour ring as needed Roller / table wear measurement every 3 months For clinker / slag: stop buffer adjustment every 3 months Shift intervals according to the specific „wear behavior“ of the mill 34
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© by LOESCHE
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Table of Contents
HSMS: roller lubrication – maintenance work
M-Roller - CS, RM, D
CS, RM
Swinging Device - CS, RM, D
Visual check:
Grinding Parts: roller tires, grinding plate - CS, RM, D
Tank oil levels Tank oil temperatures Flow in suction line sight glasses Indication of pressure / suction gauges Leaks along all pipelines / hoses Temperature of oil from / to rollers Connection at rollers tight Filter dirty indication (if provided)
Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D
Intervals: Visual checks daily Filter clogged weekly, if no indication is provided Oil samples of each tank unit every 3,500 Rth (Runtime-hours) Oil change as needed / per manual (see lubrication list) During oil change open tank units and clean oil sludge thoroughly
Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier
Illustration 36
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 116
HSMS: roller lubrication – maintenance work
Table of Contents
CS, RM
M-Roller - CS, RM, D
Lubrication list
Project dependent
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier 38
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© by LOESCHE
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Page 117
Rocker Arm – Maintenance Work
Table of Contents
CS, RM, D
M-Roller - CS, RM, D
Maintenance / Interval: Visual checks inside / outside (weekly) Check seal air labyrinths (every 6 monthls) Check bearing clearance (annually) Change / re-weld labyrinths as needed Change bearings as needed Re-tighten / re-seal / repair as needed
Swinging Device - CS, RM, D
Axle
Rocker arms - visual check: Grease supply of 3+1 bearings Condition of grease pump Cracks in casted rocker arm Tightness of all bolts Seal air supply Condition / adjustment of buffers Condition of shaft sealing box (inside)
Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D
Rocker arm bearings
Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D
Hydraulic spring assembly
Reject Box – D Classifier Illustration CS 40
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
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M-Rocker Arm Bearing Lubrication – Maintenance Work
M-Rocker Arm Bearing Lubrication – Maintenance Work
CS
CS Visual check: Lid of grease tank tightly closed (auto system) Grease tank full (auto system, lubrication list on next slide) Leaks at pump unit (auto system) Grease pipelines intact (auto & manual systems) Grease leaks at pipelines, distributors or bearings (auto & manual systems)
Project dependant
Intervals: Visual checks daily Supply the 12 manual grease points with grease according to documentation (lubrication list) daily (lubrication list)
Illustration CS 42
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© by LOESCHE
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Table of Contents
M-Lever Sealing – Maintenance Work
M-Roller - CS, RM, D
CS, RM, D
M-lever sealing
Visual check: attachment bolts of lever sealing parts wear of lever sealing parts proper adjustment of gaskets and bellows check flanges between rocker arms and mill body for tightness
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D
Maintenance: change worn parts
M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D
Intervals: visual check weekly change worn parts according to actual wear shift interval according to the specific „wear behaviour“ of the mill
HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier
Illustration CS 44
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© by LOESCHE
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Table of Contents
HSLM: hydraulic system M-roller - function
M-Roller - CS, RM, D
CS, RM, D : With counter pressure The M-rollers crush the grinding material through their own weight and additionally applied hydraulic pressing force. The pressing force of the M-rollers on the grinding material is generated by the hydro-pneumatic spring assembly system. For CS, D: A stop buffer on the rocker arm prevents the tires from coming into direct contact with the grinding plates.
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D
Operating pressure
M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D
Counter pressure
Reject Box – D Classifier
Illustration 46
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HSLM: hydraulic system M-roller - function
HSLM: hydraulic system M-roller - function
D: Without counter pressure
Gas valve
The rollers crush the grinding material through their own weight and additionally applied hydraulic pressing force. The pressing force of the rollers on the grinding material is generated by the hydro-pneumatic spring assembly system. A stop buffer on the rocker arm prevents the tires from coming into direct contact with the grinding plates.
Function of accumulators
The accumulators act as shock absorbers and as a system Shell pressure equalizer Standard charge: 50% of expected operation oil pressure, exact values to be adjusted during commissioning (>30% ; < 70%) Nitrogen pressure can only be measured with oil pressure completely drained Bladder
Oil valve
Oil Illustration 48
Illustration Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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HSLM: hydraulic system M-roller – Maintenance Work
HSLM: hydraulic system M-roller – Maintenance Work
Lubrication instructions
Lubrication instructions
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Table of Contents
HSLM: hydraulic system M-roller – Maintenance Work
M-Roller - CS, RM, D Filtration skid / Filling cart
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D
Loesche delivered a cart with an oil pump and a filter unit to ensure that only properly filtered oil is filled or topped up into the Hydraulic Tank. This cart is to be used during normal maintenance. Typical filter size < 25 micron (e.g. 10)
Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier
Illustration 52
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Lining – Maintenance Work
Table of Contents
CS, RM, D Inspection and replacement The lining has to be checked for wear regularly. Worn plates can be replaced / exchanged with equally shaped less worn plates be replaced by a new plates Severe and premature wear can be adjusted by louvre ring cover placement review of the design of the armour ring inclination (Loesche involvement recommended)
M-Roller - CS, RM, D Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D
CS
Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier Illustration 54
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Water injection – Maintenance Work
Table of Contents
RM, D
M-Roller - CS, RM, D
Visual check: Inspect the nozzles for wear and contamination Protect hoses from physical damage The mountings of the distributor line on the mill body should be checked regularly to make sure that they are tight.
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM
Repair: Replace nozzles if necessary Replace hoses if necessary After repair work screwed fittings should be resealed with hemp or sealing tape The mountings of the distributor line on the mill body should be checked regularly to make sure that they are tight. Intervals: Visual checks every 6 months Repair if necessary
M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier
56
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M-Rocker Arm - CS, RM, D
Page 126
Mill stand - Maintenance Work
Mill stand - Maintenance Work
CS, RM, D
Ring duct – CS, RM, D
Visual check:
Inspections can be carried out through the ring duct access door (confined space)
Condition and tightness of bolts of bearing caps Condition of weldings
Wear at scraper supports should be repaired with hard-faced welding
Oil accumulations or material chunks on concrete foundation Condition of anchor bolts
The scrapers should be checked regularly for wear and secure mounting
Condition of gearbox attachment bolts Interval: weekly
The lower housing is subject to heavy wear and may be hardfaced or lined with Densit
Check torque Interval: yearly
Superbolt system
Illustration 58
Illustration Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Hydraulic tension system
Page 127
Table of Contents
Classifier – Maintenance Work
M-Roller - CS, RM, D
LSKS
Swinging Device - CS, RM, D
Visual check: Oil level / leaks at classifier gearbox Bolts at upper housing, static guide vanes, rotor drive, lower bearing supports still tight Wear and tear on static vanes, rotor blades, upper / lower housing, grit cone (inside) Position / wear of static guide vanes Level in grease container Leaks in grease lines (outside / inside) Lining in upper / lower housing missing
Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D
Water Injection – RM, D
Retighten, repair, refill Replace worn rotor blades / static vanes Repair worn grit cone / housing and replace worn liners Replace missing / broken ceramic liners Exchange bearing cartridge Follow supplier‘s manual for gearbox oil
Mill Stand – CS, RM, D
Intervals:
HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D
Visual checks every week as needed or as in manual
Reject Box – D Classifier
Illustration 60
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Classifier – Maintenance Work LSKS Visual check:
Classifier – Maintenance Work LSKS
Project dependent
Project dependent
Oil level / leaks at classifier gearbox Bolts at upper housing, static guide vanes, rotor drive, lower bearing supports still tight Wear and tear on static vanes, rotor blades, upper / lower housing, grit cone (inside) Position / wear of static guide vanes Level in grease container Leaks in grease lines (outside / inside) Lining in upper / lower housing missing Retighten, repair, refill Replace worn rotor blades / static vanes Repair worn grit cone / housing and replace worn liners Replace missing / broken ceramic liners Exchange bearing cartridge Follow supplier‘s manual for gearbox oil
Intervals:
Visual checks every week as needed or as in manual
Click to open Illustration 62
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Rotor – Maintenance Work
Rotor – Maintenance Work
LSKS
LSKS Guide vanes and rotor blades
Exchange of rotor blades
The guide vanes are not adjustable. The guide vane position has a direct impact on the product quality and classifier efficiency Static guide vanes and rotor blades need to be inspected frequently for wear, tear and position since these parts are directly responsible for product fineness and quality
If visual inspection reveals wear / tear on rotor blades – exchange is necessary 1. Unbolt and extract locking rings (upper/lower end of blades at inside) 2. Pull blades out of guide-slots 3. Insert new blades into guide slots 4. Bolt down locking rings and secure bolts by tack welding
Illustration
Exchange blades in pairs 180 degrees opposite of each other OR re-balance rotor upon first start
Illustration
Illustration 64
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Rotor – Maintenance Work
Rotor – Maintenance Work LSKS
LSKS
Rotor clearance
Static
Exchange of Bearing Cartridge
Project dependent
1. Secure rotor by chain-falls to upper housing (ceiling)
Visual check • wear • imbalance
2. Dismount classifier gearbox (as complete unit using a crane), pulling gearbox vertical upwards off coupling
Interval every 6 months for more details, please see in manual
3. Disconnect automatic grease system and instrumentation from bearing cartridge 4. Unbolt flange cartridge – upper housing 5. Unbolt flange cartridge – rotor 6. Use crane to pull old cartridge out off classifier
Dynamic
7. Use crane to insert new cartridge into classifier 8. Re-assemble in reverse order Illustration
Illustration 66
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Rotor – Maintenance Work LSKS
Grease lubrication of bearing cartridge: Grease reservoir with level sensor Continuous low level alarm will trip the system after X hours (usually 8 hours) Single outlet grease pump Grease splitter (50:50) 2 lines into (upper / lower bearing) Pump runs for 10 minutes, shuts down for 50 minutes and restarts as long as classifier is running The bearing temperature is monitored continually by temperature sensors
Grease type KPF 2 G 20 or comparable Amount: 8 Liter in pump reservoir, 2 kg in bearing cartridge and pipelines
Illustration 68
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Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Thank you for your attention
Page 132
Mechanical design and maintenance: Mill Gearbox by Desi Delgado, LOESCHE America, Inc.
Mechanical Design and Maintenance Mill gearbox
© by LOESCHE
Desi Delgado, Technical Instructor Miami, September 2013
Page 133
Table of contents
Gearboxes
Selection of Gearboxes for LOESCHE Mills
Mill gearbox Gearboxes
Rated Power of Mill Drive
Type of Gearbox
< ~350 kW
Bevel-Helical; 2-/3-Stages
Maintenance
< ~2.000 kW
Bevel-Planetary; 2-Stages
Gearbox internals
> ~2.000 kW
Bevel-Helical-Planetary; Bevel-Planetary-Planetary; 3-Stages
Sub-suppliers Coupling Gearbox lubrication
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Gearbox
Gearbox
Bevel-Helical-Planetary-Gearbox with 3-stage Reduction
Bevel-Planetary-Gearbox with 2-stage Reduction
Output Flange
Thrust Bearing
Planetary Stage
Input Shaft
Gear Coupling Bevel-Gear Stage
Housing
HelicalGear Stage
FLENDER KMP 4
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FLENDER KMPS
Page 135
Gearbox
Gearbox
Loesches Strategy of Mill and Drive Sizes
Bevel-Planetary-Gearbox with 3 stage Reduction
FLENDER KMPP 6
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Table of contents
Gearbox
Unification Concept for CRM and C/S-mills
Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
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Mill gearbox
Mill gearbox
Sub-suppliers
Sub-suppliers
Sub-suppliers approved by LOESCHE
CMD, France rating up to 1.500kW Smaller gearboxes Bevel-Helical, planetary
CMD, France Flender (Siemens), Germany, Bocholt Formosa Heavy Industries (Licence of M/s Renk), Taiwan, Keller, Germany, St. Augustin Maag (FLS), Swiss Moventas, Germany, Wuppertal Renk (MAN) / Renk-Maag, Germany, Augsburg Seisa (SHI), Japan
10
Keller Siegburg, Germany
rating 200 kW up to 1.500 kW
Maag, Winterthur, Swiss (HQ)
rating … up to 5.400 kW
Moventas, Wuppertal Germany
rating 200 kW up to 1.500 kW
Renk, Augsburg, Germany
rating up to 5.400 kW
Seisa, Osaka Japan
rating 450 kW up to 4.500 kW
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Flender, Bocholt(HQ), rating 200 kW up to 7.000 kW Voerde (machining, assembly) Germany
Page 138
Table of contents
Mill gearbox Sub-suppliers
Mill gearbox Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
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Mill gearbox
Gearbox
Coupling
Coupling
Different types High flexible couplings: Flender Flexible couplings: Bolt type: Flender
- ELPEX ENG …
- RUPEX RWN …, RUPEX-APEX
Elastic RUPEX coupling, Type RAK
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Mill gearbox
Mill gearbox
Coupling
Coupling RUPEX
ELPEX
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Table of contents
Mill gearbox - Coupling
Mill gearbox Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
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Mill gearbox
Mill gearbox – Gearbox Lubrication
Gearbox lubrication Always included in the scope of supply of gearbox suppliers Usually consists of: Low pressure pump, Filter, oil cooler (water/air) HP-pumps, Instrumentation pressure transmitter, RTD‘s flow meter, and gauges (temperature, pressure, flow indicator), heating device, oil container
Signals of instruments are interlocked in PLC Certain sequences and paramaters must be adhered to
Project dependent 20
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Table of contents
Mill gearbox – Gearbox Lubrication
Mill gearbox Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
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Mill gearbox
Mill gearbox
Maintenance
Maintenance Gearbox removal procedure overview
On-site check
Please have expert on site
An annual check should be completed by the gearbox supplier
Illustrations
High vibration / severe torque variations to be avoided
Maintenance drive
Check for the mill operation data, maintenance Visual check, oil level, leaks, abnormal noise, oil filter, oil level check and oil analysis, History of oil analysis and oil exchanges
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Mill gearbox
Mill gearbox
Maintenance
Maintenance Condition monitoring
Gearbox handling/lifting
vibrations, temperature, pressure, torque, speed, …
data collection, filtering, storage, analyzing
Signals analog or digital
storage, analysis, trend…
Modem / COM Server/ Internet Router data
computer
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messages
SMS e-mail FAX
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(optional) limit settings, filter settings, trigger settings, …
Page 146
Table of contents
Mill gearbox Maintenance
Mill gearbox
Condition monitoring
Mill gearbox 4xT
a
Sub-suppliers
a a
Coupling Gearbox lubrication
Lubrication oil inlet T
n M
a T
T
p
Δp Main Filter
Δp
Maintenance
Maintenance Filter
Gearbox internals
T T
a
MINI
8Ch.
MIDI 13 Ch. a: M: n: p: T:
acceleration (vibration) torque speed pressure temperature
MAXI 19 Ch.
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Gearbox KMPP
Page 147
Gearbox
Gearbox
Lubrication
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On Stock
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Mill gearbox
Mill gearbox
Gearbox internals
Gearbox internals
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Mill gearbox
Mill gearbox
Gearbox internals
Gearbox internals
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Mill gearbox Gearbox internals
Thank you for your attention
36
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Hydraulic systems: Function & design by Dirk Grube, LOESCHE GmbH
The hydraulic systems at LOESCHE mills Overview
© by LOESCHE
Dirk Grube Technical Seminar Miami, 2013
Page 152
Agenda
Hydraulic systems - overview
1. Hydraulic systems 2. Hydropneumatic spring system - HSLM 3. Roller lubrication unit - HSMS 4. Hydraulic for support roller - HSSW 5. Swinging out device - HSAV 6. Fill unit - HSBF
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Hydraulic application and their power unit nomenclature
Hydraulic systems - different types
Nomenclature for all application are similar!
LM …CS HSLM with counterpressure
HSMS
Roller lubrication system
Hydropneumatic spring system
Hydropneumatic spring system
HSLM is the abbreviation for the German: [Hydraulikschrank LOESCHE Mühle]
LM …D
LM …RM HSLM with counterpressure
Example: HSLM 1000/45/2
HSSW
Hydraulic positioning device for the S-roller
HSMS
Roller lubrication system
HSAV
Swinging out device
Hydropneumatic spring system
HSLM without counterpressure Hydropneumatic spring system
HSMS is the abbreviation for the German: [Hydraulikschrank Mahlwalzen Schmierung] HSSW is the abbreviation for the German: [Hydraulikschrank Support Walzen] HSAV is the abbreviation for the German: [Hydraulikschrank Ausschwenk Vorrichtung] HSBF is the abbreviation for the German: [Hydraulikschrank Befüll Filtriereinheit]
HSBF
Filling and filter unit
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HSLM with counterpressure
Page 154
Hydropneumatic spring system
Hydropneumatic spring system – design & position
Assembly groups
HSLM, ring and connection pipeline: Hydropneumatic spring system
HSLM
Ring pipeline
Spring assembly
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Connecting pipeline
Page 155
Roller lubrication system
HSMS – hydraulic plan roller lubrication system
HSMS
connecting pipe line
roller
8
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lubrication line
Page 156
Mill hydraulic – system for S-roller
HSSW – hydraulic plan
Hydraulic system S - roller
HSSW
S - spring assembly
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connecting pipe line
Page 157
HSAV and swinging cylinder
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HSBF
Page 158
Agenda 1. Hydropneumatic spring system – components – overview 2. Hydraulic cylinder
The hydropneumatic spring ass. group in LOESCHE mills
3. Rod head and clamping nut 4. Piston and bladder accumulator
Components Dirk Grube Technical Seminar Miami, 2013
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Hydraulic system – hydropneumatic spring system
Hydropneumatic spring system – function (1) Damping the system (2) Induce grinding force
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Hydropneumatic spring system
Hydropneumatic spring system – design
Assembly groups
Spring assembly Hydropneumatic spring system
HSLM
Connecting pipeline
Ring pipeline
Hydraulic cylinder Rod head
Spring assembly
Clamping nut Bladder accumulator Piston accumulator
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Hydropneumatic spring system – design
Hydropneumatic spring system – design
Hydraulic cylinder
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Clamping nut and rod head
Page 162
Hydropneumatic spring system – design
Hydropneumatic spring system – design
Piston accumulator
Bladder accumulator
N2
Oil
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Agenda 1. Hydraulic system with counter pressure 2. Function
The hydropneumatic spring system in LOESCHE mills Function (with counter pressure) Dirk Grube Technical Seminar Duesseldorf, 2013-07-25
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Hydraulic system with counter pressure
Hydraulic system with counter pressure LM …CS HSLM with counterpressure
HSMS
Roller lubrication system
Hydropneumatic spring system
HSSW
Hydraulic positioning device for the S-roller
LM …D
LM …RM HSLM with counterpressure Hydropneumatic spring system
HSMS
Roller lubrication system
HSAV
Swinging out device
3
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Hydropneumatic spring system
HSLM without counterpressure Hydropneumatic spring system
HSBF
Filling and filter unit
4
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HSLM with counterpressure
Page 165
Hydropneumatic spring system – working pressure
Hydropneumatic spring system – with counter pressure Operating mode
Movie roller 5
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Movie rod head
Page 166
Hydropneumatic spring system – with counter pressure
Hydropneumatic spring system – design & position HSLM, ring and connection pipeline:
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HSLM hydraulic scheme – with counter pressure
The hydropneumatic spring system in LOESCHE mills Diagram spring stiffness and roller force Dirk Grube Technical Seminar Duesseldorf, 2013-07-26
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Agenda
Hydropneumatic spring system – diagrams Diagram spring stiffness and load per roller
1. Diagram: roller force with counter pressure 2. Diagram: spring stiffness with counter pressure
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Hydropneumatic spring system – load per roller
Hydropneumatic spring system – spring stiffness
Design and life time calculated for 100 % of roller force.
Stiffness with too high counterpressure
~3,8
ca. 55 %
~2,2
Stiffness increased by too high counterpressure of 25 bar (against 15 bar) by + 74 %! 4
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Hydropneumatic spring system – spring stiffness
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Hydropneumatic spring system – load per roller
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Page 172
FW = 30%
FW = 30%
COUNTERPRESSURE
COUNTERPRESSURE
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FW = 60% FW = 55%
LOAD PER ROLLER
WORKING PRESSURE
FW = 60% FW = 55%
Hydropneumatic spring system – load per roller
LOAD PER ROLLER
WORKING PRESSURE
Hydropneumatic spring system – load per roller
Page 173
Hydropneumatic spring system – load per roller
FW = 55%
The hydropneumatic spring system in LOESCHE mills
LOAD PER ROLLER
WORKING PRESSURE
FW = 70%
Coal mills - HSLM with counter pressure and not counter pressure Dirk Grube Duesseldorf, 2013-07-26
COUNTERPRESSURE
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Agenda
Hydropneumatic spring system
1. Hydraulic system HSLM with counter pressure 2. Hydraulic system HSLM without counter pressure
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Hydraulic system HSLM at coal mills - different types
Hydropneumatic spring system – with counter pressure Operating mode
LM …D HSLM with counterpressure Hydropneumatic spring system
HSLM without counterpressure Hydropneumatic spring system
Movie roller 4
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Movie rod head
Page 176
Hydropneumatic spring system – without counter pressure
HSLM with counter OR not counter pressure 1. In coal mills in normal case hydraulic system HSLM with counter pressure is not necessary. But it can be an option. 2. Hydraulic system HSLM with counter pressure is necessary if part load operating at coal mills is a customer‘s requirement. (frequently power plants and steel plants are aware to operate in part load)
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Decrease working pressure for part load
Trend operation trends for counter pressure system
100
90
90
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
10
0
Grinding bed
10
20
30
40
Hydraulic systems in LOESCHE mills: design & function Rev.A
50 60 Mill Load [%]
70
80
90
100 h]
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8
Operating pressure
0 0
Hydraulic systems in LOESCHE mills: design & function Rev.A
Grinding bed [mm]
Working Operating & Conte /Pressure [bar]
100
Page 178
Increase counter pressure additional for part load
Trend operation trends for counter pressure system
100
90
90
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
10
0
Conter pressure Grinding bed
10
20
30
40
Hydraulic systems in LOESCHE mills: design & function Rev.A
50 60 Mill Load [%]
70
80
90
100 h]
11
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10
Operating pressure
0 0
Hydraulic systems in LOESCHE mills: design & function Rev.A
Grinding bed [mm]
Working Operating & Conte /Pressure [bar]
100
Page 179
Comparison of trends
HSLM scheme with counter pressure operation trends for counter pressure system
90
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
Operating pressure
Grinding bed
10
0
0 0
10
20
30
40
50 60 Mill Load [%]
70
80
90
100 h]
operation trends for counter pressure system
100
Working Operating & Conte /Pressure [bar]
Grinding bed [mm]
100
90
100
90
90
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
Grinding bed [mm]
Working Operating & Conte /Pressure [bar]
100
Operating pressure Conter pressure Grinding bed
10
0
0 0
10
30
40
50 60 Mill Load [%]
70
80
90
100 h]
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HSLM scheme without counter pressure
Thank you for your attention
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Page 181
Process parameters by Christian-Martin Ruthenberg, LOESCHE GmbH
Process parameter of LOESCHE vertical roller mills
© by LOESCHE
Ch.-M. Ruthenberg, Technical Trainer Loesche GmbH Technical Seminar Miami, 2013-09-17
Page 182
Agenda
Processes inside a mill
Processes inside a mill Process Parameters Dependencies Examples
Transportation
Classifying
Drying
Grinding
Summary
Clinker/ slag mill 2
Process parameter_Rev.1
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Page 183
Processes inside a mill
Processes inside a mill Flow
Transportation Flow
Drying Temperature
Classifying Speed
Pressure
Constantly controlled & stable
Grinding Pressure
Consistent product
Temperature
Speed
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Page 184
Agenda
Process Parameters
Processes inside a mill
Pressure
Mill inlet vs. Outlet (dp mill) Filter inlet vs. Outlet (dp filter) Working and counter pressure (grinding force) Compressed air
Process Parameters Dependencies Examples Summary
Flow
Material Reject Gas Water (Fuel) Product
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Mill outlet gas Material Water Product
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Process parameter_Rev.1
Temperature
Page 185
Agenda
Dependencies
Processes inside a mill Process Parameters
Temperature
Dependencies Examples Summary
Pressure
Speed
Flow
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Page 186
Examples - Filter
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Process parameter_Rev.1
Examples - Hopper
Page 187
Clinker/slag grinding plant
Examples - Hopper
Damper S (Stack)
Damper R (Recirculation)
Damper Z1 (Fresh air)
Minimum value
Max value
Limestone hopper level
6.85 m
10.23 m
Raw mill body vibration
7.81 mm/s
14.24 mm/s
Raw mill motor power
4536 kW
5490 kW 14
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Process parameter_Rev.1
Hot gas generator
Page 188
Agenda
Summary
Processes inside a mill
Processes inside a mill
Process Parameters
transport, grinding, drying and classifying
Dependencies Process parameters
Examples
flow, pressure, temperature and speed
Summary
Dependencies
flow, pressure, temperature and speed
Examples
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Process parameter_Rev.1
filter and hopper
Page 189
Thank you for your attention
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Stabilization of mill in upset conditions by Christian_Martin Ruthenberg, LOESCHE GmbH
Stabilization in upset condition
© by LOESCHE
Ch.-M. Ruthenberg, Technical Trainer Loesche GmbH Technical Seminar Miami, 2013-09-17
Page 191
Agenda
Upset condition = Vibration
Upset condition = Vibration
Gas volume
Water sprinkling
Unstable grinding bed Immediate measures & root causes Most common causes
Mill body vibration 2
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Page 192
Upset condition = Vibration Unstable grinding bed
Upset condition = Vibration Unstable grinding bed Changes in feed material
Unstable Conditions
Feed material
Process & Operation
Maintenance
Moisture Grain size Grindability Temperature Foreign material …
Process & Operation
Classifier speed Grinding force Gas flow Water sprinkling …
Maintenance
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Stabilization in upset condition _Rev.1
Dam ring, support ring Roller and grinding plates Scrapers Water sprinkling …
Page 193
Upset condition = Vibration Unstable grinding bed
Agenda Upset condition = Vibration
Caused by too coarse or too fine material
Unstable grinding bed Immediate measures & root causes Most common causes
Grain size distribution
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Stabilization in upset condition _Rev.1
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Immediate measures & root causes
Agenda
For fast response: Water sprinkling Working pressure Classifier speed
Upset condition = Vibration Unstable grinding bed Immediate measures & root causes Most common causes
Vibration
Solve root cause
Reverse immediate measure
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Stabilization in upset condition _Rev.1
Apply immediate measure
Page 195
Most common causes
Most common causes - feed
Feed
Operation
Wear
Lumps
Memory
Roller & table
Segregation
Interpretation
Dam ring
Source: Loesche report (KN Swain OCL 2007-03-14)
Lumps > 150 mm = 56 pieces Lumps > 120 mm < 150 mm = 76 pieces Hand gloves = 6 pieces Gunny bags = 4 pieces Cotton waste = 200 gram Number of stoppage due to star feeder = 0 10
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Stabilization in upset condition _Rev.1
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Most common causes - wear
Thank you for your attention
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Optimization of grinding plants: Upgrades, modifications by Desi Delgado, LOESCHE America, Inc.
Optimization of Grinding Plants: Modifications, Upgrades & Audits Type: clinker / slag, raw meal, coal
© by LOESCHE
Desi Delgado, Technical Instructor Miami, September 2013
Page 198
Modifications / Upgrades
Modifications
Upgrades
Audits / Optimization
Modifications / Upgrades
Justification can be quantified
Production increase Energy Savings Achieve optimum product quality Decreased downtime …
Justification not easily quantified Ease of maintenance / Operation Replace obsolete / difficult to source components Provide more control / insight of mill system (instrumentation / sensors / advanced control) …
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Examples - Modification
Examples - Modification
Roller position indicators (Linear Transducers)
Roller position indicators (Linear Transducers) Provide actual roller position information as opposed to simply High, Low, ETC Can be used to see if material is evenly distributed Can see if breakouts or foreign materials are in the mill by observing periodic oscillation Small investment for the amount of insight provided
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Examples - Modification
Examples - Modification
Updated Design (i.e. Rod Head)
Updated Design (Grinding Elements)
Old Design
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Ductile Hardfaced
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
MMC
New Design
Page 201
Examples - Modification
Examples - Modification
G 20Mn5
Facial side protected
Highest Forces
V 100 Mo
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Main wear area
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Examples - Modification
Examples - Modification
• Ductile Iron core accepts welding easier • Less Risk of cracking • Longer Wear life compared to Hi Chrome • Harder Materials can be applied to areas of less wear • Profile tracking and optimal Manufacturing
Ductile Iron w/ Hardfacing
Metal Matrix Composite
Cost
“X”
“X” – “X + 50%”
“X + 100%-150%
Life
1
1.5
2
Re-Weldable
Yes but difficult
Yes
NO
• Hardfacing required • Risk in cracking
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Chromium Alloy
Page 203
Examples - Upgrade
Examples - Upgrade
High Efficiency Classifier Classifier Type LKS
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Classifier Type LSKS
Page 204
Examples - Upgrade
Examples - Upgrade
Improved velocity profile
Enlarged classifying zone
v1 < v2 Vnew = Vold ⋅ 85% v2 new = v2old
(new geometry) v2
Modified shape v1
Reduced pressure drop across the mill Less gas volume Increase of classifying efficiency
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
• Enhanced classifier efficiency and less power consumption of classifier • Less fines in the material rejected by rotor • Better stability of grinding bed leads to better grinding efficiency
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Loesche Classifier
Loesche Classifier
From LKS to LSKS
From LKS to LSKS
LM 30.4 (Quebec)
Achieved Results (Examples): LM 32.4 (Höver) Production Increase
21 %
Power Saving
> 1,5 kWh/t
Fineness
Before
After
% R 0.200
1.48
0.41
% R 0.090
11.04
11.78
Production Increase (Material A)
15,5 %
Production Increase (Material B)
22,5 %
LM 30.4 (Aslan 2) Production Increase
8,5 %
Power Saving
> 1,5 kWh/t
Fineness
Before
After
% R 0.200
2.1
0.7
LM 38.4 (Hereke) Production Increase
16,3 %
Power Saving
0,6 kWh/t
16
18,8 %
Power Saving
1,5 kWh/t
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
LM 27.2 (Isparta) Production Increase
Page 206
Examples - Upgrade
Modifications
Larger Rollers
Increase Roller diameter Can increase the throughput Of the mill.
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Audits / Optimization
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Upgrades
Page 207
Audits & Optimization
Audits & Optimization
Carried out by Internal, OEM or Independent consultant Compare Actual/Measured/Historical/Benchmarks Should be carried out periodically or after major events
Internal Personnel
Detailed Equipment knowledge Industry references and experiences Knowledge of upgrade and improvements available Costs
Ideally audits will help to:
Availability
Maximization of availability and reliability Maximization of the operational and functional safety Minimization of unplanned repairs Increase of the operational lifetime
Product/Project support Range of General Knowledge Bias
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Independent Consultant
Historical Knowledge of installed equipment
Major overhauls / equipment modifications Changes in feed material Changes in product
OEM
Page 208
Audits & Optimization
Audits & Optimization Example
Example visual inspections:
Visual inspections leakages, damages, etc. Check of the filling pressure of the hydraulic accumulator smooth and stable operation
Oil- and grease pipes leakages Expansion joints damages At coal mills level of the rejectbox
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Page 209
Audits & Optimization
Audits & Optimization Alternative:
Sampling for oil analysis
Installation of an Online Condition Monitoring System Oil sensor at the lubrication system continuous monitoring of all relevant parameters
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
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Audits & Optimization
Trouble-free operation
Wear measurement at the grinding parts
Wear measurement at the grinding parts
Measurement at the grinding plate Ideal
Not Ideal
• Fixed reference point
• No Fixed reference point
• Consistent measurements
• Inconsistent measurements
Ideal
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Not Ideal
27
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Measurement at the roller tyres
Page 211
Trouble-free operation
Audits
Wear measurement at the grinding parts
Process Audit
Regularly record of the wear
Process Audit – Field measurements Measurement of pressure temperature O2-content power consumption of the components Volume flow etc. at the different measuring points
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Page 212
Audits
Audits
Process Audit
Process Audit
Comparison of the hand measurement with the values in the CCR
Scope of work Execution of hand measurements at the complete grinding plant
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Page 213
Audits & Optimization
Audits & Optimization
Process Audit
Summary
Results
Mechanical Audit:
Evaluation of the results with regard to stated targets Summary of the findings and a detailed overview of measurements In the event of a deviation necessary actions should be defined and planned
Process Audit:
Information about the mechanical condition of the grinding plant
Information about the process parameters of the grinding plant
Identify wear zones
Identify optimization potentials / Bottle Necks
New adjustment based on current state
New adjustment to the target state
Spare parts / Repair strategy and planning
Results: Written recommendations for operation and maintenance Historical records to benchmarking Reference point for future operation / scenarios Reduce unplanned down time Increase of the plant efficiency
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© by LOESCHE
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Page 214
Audits & Optimization Process Optimization
Audits & Optimization - Plant Optimization Process Optimization
Example: Adjustment of working pressure
At parameter changes one has to:
working pressure = f (output)
Adjust the control loops
working pressure [bar]
Readjustment of alarms/setpoints (if necessary)
High pressure High power consumption Unstable behaviour Low pressure Low capacity
output [%] 34
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Page 215
Audits & Optimization - Plant Optimization
Audits & Optimization - Plant Optimization
Process Optimization
Summary 110%
Example - Adjustment of classifier speed
No Audits
100% 90%
Mech. Failure`
80%
Product fineness is adjusted by classifier speed
70%
Grinding is too fine
60% 50%
Unnecessary increase of wear
1
Decrease of plant performance
Cont. loss of efficiency
Baseline Knowledge Spare Parts Mechanical Condition Plant Efficiency Plant availability 2
3
4
5
6
7
8
9
10
110%
Loss of personnel / Knowledge 11
12
13
14
15
14
15
16
17
18
19
20
21
22
23
24
Audits
100% 90%
Change of the relation between volume flow and classifier speed
80%
Savings at the mill fan
70% 60% 50% 36
Mid Campaign Baseline Optimization Knowledge Spare Parts Mechanical Condition Plant Efficiency Plant availability
1 en_TM_Maintenance 2 3 4 Part5 3_Rev.A 6 Q….-03-4
7
8
Loss of knowledge and training
9
10
11
12
13
16
17
18
19
20
21
22
23
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© by LOESCHE
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Mech. Failure` Identified and corrected
Page 216
Thank you for your attention
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
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Miami, September 17 - 19, 2013
Proceedings Convening Networking Sharing knowledge
Page 2
© by LOESCHE
Final programme September 16, 2013 19:00 - 22:00
Social activity, Location TBD - meet in hotel lobby
September 17, 2013
Technical Seminar at DoubleTree by Hilton Grand Hotel Biscayne Bay
08:30 - 09:00
Registration open: Coffee and networking
09:00 - 09.15
Welcome address / opening remarks / Agenda overview - Perla Ruiz, LOESCHE America, Inc.
09:15 - 09:30
Meet the delegates - Introduce yourself to the audience
09:30 - 10:30
Introduction LOESCHE vertical roller mills - Desi Delgado, LOESCHE America, Inc.
10:30 - 10:45
Coffee and networking
10:45 - 12:00
Process, operation & evaluation of LOESCHE mills - Christian-Martin Ruthenberg, LOESCHE GmbH
12:00 - 13:00
Lunch and networking
13:00 - 14:30
Main assembly groups - Peter Lolschou, LOESCHE America, Inc.
14:30 - 14:45
Coffee and networking
14:45 - 15.45
Open discussion
© by LOESCHE
September 18, 2013 08:30 - 09:00
Coffee and networking
09:00 - 09:15
Agenda overview - Perla Ruiz, LOESCHE America, Inc.
09:15 - 10:30
Maintenance & procedures - Peter Lolschou, LOESCHE America, Inc.
10:30 - 10:45
Coffee and networking
Page 3
Final programme 10:45 - 11:45
Main mill gearbox - Desi Delgado, LOESCHE America, Inc.
11:45 - 13:00
Hydraulic Systems: Function & design Part 1- Dirk Grube, LOESCHE GmbH
13:00 - 14:00
Lunch and networking
14:00 - 14.45
Hydraulic Systems: Function & design Part 2- Dirk Grube, LOESCHE GmbH
14:45 - 15:00
Coffee and networking
15:00 - 16:30
Process parameters - Christian-Martin Ruthenberg, LOESCHE GmbH
September 19, 2013 Coffee and networking
09:00 - 09:15
Agenda overview - Perla Ruiz, LOESCHE America, Inc.
09:15 - 10:45
Stabilization of mill in upset conditions - Christian-Martin Ruthenberg, LOESCHE GmbH
10:45 - 11:00
Coffee and networking
11:00 - 12:30
Optimization of grinding plants: Upgrades, modifications - Desi Delgado, LOESCHE America, Inc.
12:30 - 13:30
Lunch and networking
13:30 - 14:45
World Café - hosted workshops
14:45 - 15:00
Coffee and networking
15:00 - 15:30
World Café summary
15:30 - 15:45
Closing remarks - end of seminar - Perla Ruiz, LOESCHE America, Inc.
© by LOESCHE
08:30 - 09:00
Page 4
Organisers Perla Ruiz Project engineer, LOESCHE America, inc.
Desi Delgado Customer Service Manager, LOESCHE America. Inc.
Main activities: • Technical Support for existing plants in the Americas • Office coordinator for new project installation & commissioning supervisors • Inspections and investigations at plant sites
Main activities: • Onsite and remote technical support to customers in the Americas • Training on mechanical design and maintenance • Customer service
email: [email protected]
email: [email protected]
In cooperation with LOESCHE Training Center, Germany: Theodora Bruns Head of Training Center, LOESCHE GmbH
Dr Regina Krammer Deputy Head Training Center, LOESCHE GmbH, Germany
Main activities: • Development of blended learning concepts for internal and external use • Business development • Customer service
Main activities: • Development of blended learning concepts for internal and external use • Design of eLearning courses • Knowledge management and communication
email: [email protected]
email: [email protected]
© by LOESCHE
Christian-Martin Ruthenberg Technical trainer, LOESCHE GmbH, Germany Main activities: • Development of training concepts for customers • Process auditing • Training on process and operation of LOESCHE grinding plants email: [email protected] Page 5
Lecturers Desi Delgado
Christian-Martin Ruthenberg
Customer Service Manager, LOESCHE America. Inc.
Technical trainer, LOESCHE GmbH
Main activities: • Onsite and remote technical support to customers in the Americas • Training on mechanical design and maintenance • Customer service
Main activities: • Development of training concepts for customers • Process auditing • Training on process and operation of LOESCHE grinding plants
email: [email protected]
email: [email protected]
Peter Lolschou
Dirk Grube
Field Service Manager, LOESCHE America, inc.
Deputy director Design, LOESCHE GmbH
Main activities: • Technical field services • Customer support • Inspections and investigations at plant sites
Main activities: • Design of hydraulic applications at LOESCHE mills • Coordination of design draftsmen email: [email protected]
© by LOESCHE
email: [email protected]
Page 6
About LOESCHE Since 1906, LOESCHE GmbH has been constructing vertical roller grinding mills. Patented in 1928, our roller grinding mill technology has been continually advanced and in the meantime is synonymous with LOESCHE GmbH. The key competence of the company is the design and development of individual concepts for grinding and drying plants for the cement, steel and iron, power, ores and minerals industry. The service portfolio ranges from first concept to commissioning augmented by maintenance, repair, training as well as modernization of grinding plants and spare parts activities. In April 2012, LOESCHE GmbH, Germany, has entered into a close cooperation agreement with pyroprocess specialist A TEC Holding GmbH, Austria. LOESCHE and A TEC will be partners for the realisation of plant improvement projects, environmental projects and will be in the position to offer complete process solutions. Having taken over the specialised department “Combustion Technology” of UCON AG Containersysteme KG, Gelsenkirchen, in April 2012, LOESCHE offers thermal process technological solutions, thus covering another field of activities with related products e.g. industrial burners and hot gas generators.
When communicating learning content about all matters pertaining to LOESCHE technology the Training Center uses the the principle of ‚integrated learning‘ (Blended Learning Concept) with the aid of the latest learning methods and media. It combines online courses which are not tied to a specific time and place with traditional attending teaching and seminars in order to consolidtate the knowledge so imparted in the best manner possible and with lasting effect.
For more information please refer to: www.loesche.com LOESCHE GmbH Hansaallee 243 D-40549 Duesseldorf Tel.: +49-211-5353-0 Fax: +49-211-5353-500
© by LOESCHE
LOESCHE is a privately owned company with its headquarter located in Dusseldorf, Germany and is represented worldwide with more than 850 employees, subsidiaries in the USA, Brazil, Spain, Great Britain, South Africa, India, United Arab Emirates, Russia and P.R. China as well as agents in more than 20 countries. The LOESCHE Training Center was founded in 2008. A young, innovative team of editors, eLearning authors and technical trainers drafts and creates trainings and eLearning courses, documents and manuals in accordance with the latest media-didactic principles, tailored to the needs and requirements of the customers.
Page 7
Introduction LOESCHE vertical roller mills by Desi Delgado, LOESCHE America, Inc.
Introduction LOESCHE vertical roller mills
© by LOESCHE
Desi Delgado, Technical Instructor Miami, September 2013
Page 8
Table of contents
Technical Seminar for:
General LOESCHE in brief LOESCHE worldwide History Range of application Special features Fundamentals of vertical roller mills Principles of design Mill / classifier structure
Welcome!
Pictures
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2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 9
General
General
LOESCHE in brief
LOESCHE worldwide
LOESCHE GmbH is a privately owned company founded 1906 in Berlin, Germany Certified according to DIN EN ISO 9001 Main shareholder: Dr. Thomas Loesche Management: Dr. Thomas Loesche, Dr. Joachim Kirchmann Employees in Düsseldorf: 400 Employees worldwide: 850 Turnover 2012: Euro 290 millions worldwide
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2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 10
General
General
History
History
1906 - Foundation in Berlin 1927 - Invention of the ‚LOESCHE mill‘
2012 – Loesche purchases majority share in ATEC / Greco – Wolrd leader in cement pyro process technology
1961 - Introduction of the hydropneumatic spring system 1970 - Patented 4-roller mill for raw material grinding 1980 - Patented modular coal mill 2003 - Largest cement mill in the world (capacity 300 t/h), type 3+3 2005 - LOESCHE s latest invention – 6-roller mill for raw material grinding 2006 - 100 years LOESCHE 2008 - Since 1906, LOESCHE has supplied worldwide over 2740 VRMs 2008 - LOESCHE achieved 7442 Blaine in grinding slag 2010 - LOESCHE achieved 6067 Blaine in grinding clinker 2010 - Operation of VRM PPC and OPC without water for grinding bed preparation 6
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 11
General
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2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
General
Page 12
General History
Historical VRM design
History LM-1928
10
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
11
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
General
Page 13
General
General
History
History
1970 - Introduction of the Hydropneumatic Spring System
1970 - Patented 4-Roller Mill
12
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
13
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 14
Fields of Application
General History
Loesche Grinding Plants are mainly used in the following industries
1980 – Patented modular coal mill
Cement Industry
14
Cement raw material grinding plants 2, 3, 4 and 6 grinding roller mills Capacity up to 1,200 t/h of cement raw material Drive motors up to 7,000 kW
Dry grinding plants for capacity up to 200 t/h Grinding of a wide range of coals varying from steam coal, bituminous, anthracite, lignite to predried lignite coal
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Industrial Minerals Industry
Iron and non-ferrous Ores
Grinding plants for Dry-grinding plants the processing of for baryte, betonite, minerals quick lime, colemanite, dolomite, gypsum, graphite, feldspar, limestone, kaoline, magnesite, manganese ore, phosphate, titanium slag and titanium dioxide etc.
Hot Gas Generator
Hot Gas Generators for all industries Gas, Oil and Coal fired
15
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Power, Iron, Steel and Cement Industry
Page 15
Cement Industry
Power, Iron, Steel Industry
Cement raw material grinding plants 2, 3, 4 and 6 grinding roller mills Capacity up to 1,200 t/h of cement raw material Drive motors up to 7,000 kW
16
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
17
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Dry grinding plants for capacity up to 200 t/h Grinding of a wide range of coals varying from steam coal, bituminous, anthracite, lignite to predried lignite coal
Page 16
Industrial Minerals Industry
Iron and non-ferrous Ores
Grinding plants for the processing of minerals and ores
Dry-grinding plants for baryte, betonite, quick lime, colemanite, dolomite, gypsum, graphite, feldspar, limestone, kaoline, magnesite, manganese ore, phosphate, titanium slag and titanium dioxide etc.
18
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 17
Hot Gas Generator
Mill in Operation
Hot Gas Generators for all industries Gas, Oil and Coal fired
20
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
21
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 18
General
General
Mill structure: LM xx.x+x CS with LSKS xx CS r
Mill structure: LM xx.x RM with LSKS xx
56
2
2
81
22
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
23
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 19
General
General
Mill structure: LMxx.x D with LSKS xx D
Special features of LOESCHE VRMs
24
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
25
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Grinding Drying all in one machine Transportation Classifying High flexibility in terms of Products Recipes Product properties Product qualities Combination of compressive and shear forces for a highly efficient grinding process Rollers fixed individually in rocker arms without intermediate frame Hydropneumatic loading of rollers Possibility of swinging-out grinding elements for easy maintenance and replacement
Page 20
General
General
Loesche VRM – Special Features
Fundamentals of Vertical Roller Mills LOESCHE Vertical Roller Mills
Grinding velocity
centrifugal force
Flat grinding table Large tapered rollers Combination of compressive and shear forces for comminution Rollers fixed individually in rocker arms without intermediate frame Low masses, low vibration level Hydro-pneumatic loading of rollers Hydraulic swing-out-device for easy replacement of grinding elements
table diameter
table diameter table rpm
table diameter 26
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 21
General
General
Fundamentals of Vertical Roller Mills
Special features of LOESCHE VRMs
28
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
29
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 22
General
General
Principle of design: Modular design
Principle of design: Modular design Raw material/coal/petcoke mills
A high interchangeability of parts is gained by modules: A module consists of:
Roller Rocker arm Pedestal Hydraulic cylinder (inside the pedestal)
2- roller- mill
30
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
31
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
3- roller- mill
Page 23
General
General
RM
Coal
32
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
33
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 24
General
General
Coal
Comparison grinding technologies Advantages / disadvantages Ball mill
34
High pressure roller press
+
-
-
Investment costs (building)
-
+
+/-
Operation costs
-
+ +
+ +
Capacity
-
+
+/-
Change of wear parts
+
+/-
+/-
Noise emission
-
+
+
Flexibility
-
+
+
Fineness
+
+
-
Cement quality 1 day strength
+
-
-
28 day strength
-
+
+
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
35
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Vertical roller mill
Investment costs (machinery)
Page 25
General
General
Mill structure
Mill structure: Main assembly groups
Sogamoso RM
Illustration of a LOESCHE Mill LM 3+3 C/S
The LOESCHE VRM for grinding cement/slag consists primarily of Raw material feed
Classifier LSKS
Mill
M-roller
Mill body incl. lining
Classifier
M-rocker arm
S-spring assembly S-rocker arm
Mill gearbox
Table
Hydraulic system S-roller
M-spring assembly
Mill gearbox Illustration
36
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Mill stand Illustration
37
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Mill drive
Page 26
General
General
Mill structure: Main assembly groups Rocker arm M-roller
M-roller
S-roller
Classifier structure: Main assembly groups Lining
Classifier drive
Mill body
Outlet duct Upper housing
Grinding plate
Rocker arm S-roller
Intermediate frame
Dam ring
Guide vane Louvre / armour ring
Ring duct
Lower housing Scraper
Table
Pedestal
Classifier rotor Hot gas inlet
Mill gearbox
Classifier grit cone Concrete foundation
Foundation frame
Reject flap
Feed chute Illustration
38
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
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© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 27
Table of contents
Pictures
General
VRM for cement / slag with product separation in bag house.
LOESCHE in brief LOESCHE worldwide History Range of application Special features Fundamentals of vertical roller mills Principles of design Mill / classifier structure
Pictures
40
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
41
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 28
Pictures
Pictures
10 units of LM 28.2 D Taiwan Power Co. Taichung , Taiwan, 2000
42
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
43
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Ras al Khaimah Arab Emirates LM 60.4 RM
Page 29
Pictures
Pictures
Mill body / scraper / ring duct Mill motor
44
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
45
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Lubrication line and mill gearbox
Page 30
Pictures
Pictures Roller of LM 28.2 D
Louvre ring from above
46
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
47
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Louvre ring from below
Page 31
Pictures
Pictures Buffer
S-roller: rocker arm in working position
48
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
49
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
M-roller: rocker arm in working position
Page 32
Pictures High pressure hydraulic hoses
Hydraulic cylinder
Piston (left) and bladder (right) accumulator
50
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
51
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Pictures
Page 33
Pictures
Rotor (without bearing cartridge)
Static flap /guide vane assembly
Thank you for your attention
52
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
53
© by LOESCHE
2013 Technical Seminar Miami – Introduction to Vertical Roller Mills
Page 34
Process, operation, and evaluation of LOESCHE mills by Christian-Martin Ruthenberg, LOESCHE GmbH
Process, operation & evaluation of LOESCHE vertical roller mills
© by LOESCHE
Ch.-M. Ruthenberg, Technical Trainer Loesche GmbH Technical Seminar Miami, 2013-09-17
Page 35
Agenda
Different LOESCHE mill types Range of application
Different LOESCHE mill types
LOESCHE VRMs are mainly used in: Cement industry Coal fired power plants Iron making plants with blast furnace injection/ PCI (pulverised coal injection) Minerals and ore industry
Processes inside a mill Different process circuits Control values
Raw material mill
Evaluation of performance
2
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Coal/petcoke mill
Mineral mill
3
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Clinker & slag mill
Page 36
Different LOESCHE mill types
Different LOESCHE mill types
Mill structure: LM 56.4 RM with LSKS 88
Differences
56
Feed material Moisture content Grain size distribution Flow characteristics Grindability
.4
88
Illustration extract out of DWG 935021-00-3 LM 69.6 RM 4
Process, operation & evaluation of Loesche vertical roller mills Rev.A
5
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 37
Different LOESCHE mill types
Agenda
Differences
Different LOESCHE mill types Processes inside a mill
Machine Grinding force (according to grindability) Table speed (centrifugal force) Dam ring (grinding bed) S-rollers (deaeration) Louvre and armour ring (drying)
Different process circuits Control values Evaluation of performance
Illustration extract out of DWG 935021-00-3 LM 69.6 RM 6
Process, operation & evaluation of Loesche vertical roller mills Rev.A
7
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 38
Processes inside a mill
Agenda
The LOESCHE VRM combines
Different LOESCHE mill types Processes inside a mill
Grinding
Different process circuits
mill drive, gearbox, table and rollers Hot gas source: HGG, cooler, gas pre-heater
Classifying
Evaluation of performance
Transportation
Transportation Gas flow introduced by fan
Control values
Classifying
Drying
Drying Grinding
LDC / LSKS
in one machine. Clinker/slag mill 8
Process, operation & evaluation of Loesche vertical roller mills Rev.A
9
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 39
Process circuits
Process circuits
Raw meal grinding plant
Coal grinding plant with external inert gas source
10
Process, operation & evaluation of Loesche vertical roller mills Rev.A
11
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 40
Process circuits
Agenda
Clinker/slag grinding plant
Different LOESCHE mill types
Damper S (Stack)
Processes inside a mill Different process circuits
Damper R (Recirculation)
Control values Evaluation of performance
Damper Z1 (Fresh air)
Hot gas generator
12
Process, operation & evaluation of Loesche vertical roller mills Rev.A
13
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 41
Mill inlet pressure
Mill differential pressure
Clinker/slag grinding plant
Clinker/slag grinding plant
Damper S (Stack)
Damper S (Stack)
Damper R (Recirculation)
Damper R (Recirculation)
Damper Z1 (Fresh air)
Damper Z1 (Fresh air)
Hot gas generator
14
Process, operation & evaluation of Loesche vertical roller mills Rev.A
15
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Hot gas generator
Page 42
Mill outlet temperature
Process gas flow
Clinker/slag grinding plant
Clinker/slag grinding plant
Damper S (Stack)
Damper S (Stack)
Damper R (Recirculation)
Damper R (Recirculation)
Damper Z1 (Fresh air)
Damper Z1 (Fresh air)
Hot gas generator
16
Process, operation & evaluation of Loesche vertical roller mills Rev.A
17
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Hot gas generator
Page 43
Control Values
Agenda Different LOESCHE mill types Raw material
Coal
Clinker
Inlet pressure
Differential pressure
-
Outlet temperature
Gas flow
Different process circuits Control values Evaluation of performance
18
Process, operation & evaluation of Loesche vertical roller mills Rev.A
19
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Processes inside a mill
Page 44
Evaluation of performance
Process evaluation Clinker/slag grinding plant
Damper S (Stack)
Improvements (according to requirements)
Damper R (Recirculation)
Audit Assessment Operation
Damper Z1 (Fresh air)
Construction
Commissioning
Optimisation
Performance Run Hot gas generator
20
Process, operation & evaluation of Loesche vertical roller mills Rev.A
21
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 45
Summary Different LOESCHE mill types
Raw material, coal and clinker/slag mill
Processes inside a mill
Grinding, drying, transport and classifying
Different process circuits
Raw material, coal and clinker/slag mill
Control values
Thank you for your attention
Inlet pressure, differential pressure, outlet temperature and gas volume
Evaluation of performance
Operation, audits and required improvements
Essential knowledge of system, process and relations 22
Process, operation & evaluation of Loesche vertical roller mills Rev.A
23
© by LOESCHE
Process, operation & evaluation of Loesche vertical roller mills Rev.A
Page 46
Main assembly groups by Peter Lolschou, LOESCHE America, Inc.
Main Assembly Groups LOESCHE vertical roller mills
© by LOESCHE
Peter K. Lolschou, Technical Instructor Miami, September 2013
Page 47
Table of contents
Overview CS
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration 2
Q….00-4 en_TM_Maintenance Part 1_Rev.E
3
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Example: Bilbao LM 46.2+2 CS
Page 48
Overview
Overview
RM
D
Example: Lengerich LM 46.4 RM
Example: Nasice LM 20.2 D Illustration
Illustration 4
Q….00-4 en_TM_Maintenance Part 1_Rev.E
5
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Page 49
Table of contents
Main assembly groups CS
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Mill body Lining
M-lever sealing
M-roller tire
Table
M-roller
M-rocker arm
Grinding plate
HSLM: Hydraulic system M-roller
Mill stand
HSMS M-roller lubrication* Swinging device*
Grinding bed sprinkler* M-rocker arm bearing lubrication*
* These items are not shown in this illustration 6
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Illustration 7
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Page 50
Main assembly groups
Main assembly groups
RM
D Mill body Mill body
Lining Roller tire Roller
Lever sealing
Table
Roller tire
Rocker arm
Grinding plate
Lever sealing
Lining
Roller
Table
Rocker arm Grinding plate
HSLM: Hydraulic system roller
HSLM: Hydraulic system roller
Mill stand
Mill stand HSMS roller lubrication* Grinding bed sprinkler* Swinging device* Water injection* Rocker arm bearing lubrication* * These items are not shown in this illustration
* These items are not shown in this illustration
Illustration 8
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Reject box Illustration 9
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Water Injection* Swinging device* Rocker arm bearing lubrication*
Slide with pneumatic interlock
Page 51
Table of contents Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
CS 2+2
X
X
7
1 2 6 5 4
3
1 Ring duct 2 Gas duct 3 Foundation frame 4 Gearbox baseplate
5 Pedestal (S) 6 Pedestal cpl. 7 Bridge
000605
Mill stand - structure
Illustration 10
Q….00-4 en_TM_Maintenance Part 1_Rev.E
11
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Page 52
Mill stand - structure
Mill stand - structure
CS 3+3
RM X-X
1
X
6
X
1
6
7
5 2 3
X
2 4
X
4
000596
5
000503
3
1 Bridge with railing 2 Ring duct 3 Gas duct 4 Foundation frame
1 Ring duct 2 Gasduct 3 Foundation frame
Illustration 12
4 Gearbox baseplate 5 Pedestal cpl. 6 Bridge Illustration
Q….00-4 en_TM_Maintenance Part 1_Rev.E
13
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
5 Pedestal cpl. 6 Block (for S roller: take-up for swinging device) 7 Gearbox baseplate
Page 53
Mill stand - structure
Mill stand - function
Foundation frame LM x.3+3 CS
Ring duct – CS, RM, D The ring duct surrounds the table. Ring duct
The ring duct channels the hot gas into the louvre / armour ring. The ring duct is air-tight by welding.
Access door
The walls are partly hard surfaced to control wear. The floor of the ring duct is doublewalled to stiffen the design and provide thermal insulation towards the gearbox below.
Foundation frame
Hot gas inlet Ring duct Illustration 14
Illustration CS Q….00-4 en_TM_Maintenance Part 1_Rev.E
15
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Page 54
Table of contents
Table - structure
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
CS, RM, D The table consists of Table casting Clamping ring Dam ring Scatter ring (if fitted) Louvre ring Armour ring Scraper
Illustration 16
Q….00-4 en_TM_Maintenance Part 1_Rev.E
17
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Page 55
Table - structure
Table - structure
CS
RM 13
9
1
14
8
1 2
8
10 3
4 5
6
1 Table casting 2 Armour ring 3 Louvre ring 4 Insulating material 5 Bore for discharging foreign bodies 6 Dam ring 7 Scatter ring
8 Table bolts 9 Auxiliary equipment 10 Drive pin 11 Scraper 12 Ring duct 13 Cover 14 Clamping ring
Illustration
1 Roller 2 Armour ring 3 Louvre ring 4 Table casting 5 Ring duct 18
Q….00-4 en_TM_Maintenance Part 1_Rev.E
6 Scraper 7 Grinding plate 8 Clamping ring 9 Dam ring 10 Scatter ring
Illustration 19
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
6
4 5
000583
10
000607
11
3
9
2 7
12
7
Page 56
Table - structure
Table - structure
D
1
2
CS
3
Armour ring
Clamping ring
Table without dam ring
4
5
10
12
6
8
1 Clamping ring 2 Cover plate 3 Table casting 4 Armour ring 5 Louvre ring 6 Scraper
7 Drive pin 8 Gearbox output flange 9 Sealing air chamber 10 Wear rings 11 Dam ring 12 Scatter ring
Table guard preassembled Casted table
Louvre ring Illustration
Illustration 20
Dam ring
Q….00-4 en_TM_Maintenance Part 1_Rev.E
21
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
7
000653
9
11
Page 57
Table - structure
Table - function
Dam ring – CS, RM, D
Louvre ring - CS, RM, D Generates the initial airlift
Louvre ring
The dam ring consists of ring segments stacked / bolted on top of each other and can be adjusted by adding or removing segments.
Important factors are:
To have sufficient velocity to avoid excessive reject To have sufficient amount to lift the finer material to the classifier Too high velocity will lift coarse material and create wear on mill lining and classifier Too low velocity will result in excessive reject and a table overload Gas flow ideally is evenly distributed Cover plates fine-tune gas velocity and gas distribution Louvre ring is subject to high wear and needs frequent inspections
Typical heights are
200 - 350 mm for slag / clinker 60 - 70 mm for limestone (RM) 60 – 100 mm for raw meal / coal
Dam ring
Inclination of louvres creates defined vortex and supports material drying
Grinding plates
Different mill sizes have different angles for the louvres Illustration 22
Armour ring Illustration D
Q….00-4 en_TM_Maintenance Part 1_Rev.E
23
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Louvre ring
Page 58
Table - function
Table of contents
Armour ring - CS, RM, D
Louvre ring
Acts as protection for mill body For clinker / slag and raw meal: The hollow area between the inclined plates and the mill housing will fill up with material and act as autogenous wear protection The armour ring is subject to heavy wear and needs frequent inspections Armour ring
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration CS 24
Q….00-4 en_TM_Maintenance Part 1_Rev.E
25
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Page 59
M-roller - structure
M-roller - structure
CS, RM, D
CS
12
The M-roller consists of Roller axle Tire Clamping ring Hub Hub cover Taper roller bearing Guard Cylindrical roller bearing Sealing sleeve Cover disc Slip ring sealing
13
2
3
4 5 6
7
10
9
8
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Illustration 27
© by LOESCHE
26
8 Guard 9 Cylindrical roller bearing 10 Sealing sleeve 11 Rocker arm 12 Cover disc 13 Sealing air inlet 14 Slip-ring seal
000506
11
1 Roller axle 2 Tire 3 Clamping ring 4 Hub 5 Hub cover 6 Cover disc 7 Taper roller bearing Q….00-4 en_TM_Maintenance Part 1_Rev.E
1
14
Page 60
Roller - structure 9
10
11
D
1
12
10
9
2
2
3
11
3 4
4
8 7
8
5
7 000584
6
1 Tire 2 Clamping ring 3 Hub cover 4 Cover disc 5 Taper roller bearing 6 Guard ("bell housing")
6
Illustration 28
1 Clamping ring 2 Hub 3 Hub cover 4 Cover disc 5 Spherical roller bearing 6 Bell housing Q….00-4 en_TM_Maintenance Part 1_Rev.E
5
7 Sealing sleeve 8 Slip-ring seal cpl. 9 Cylindrical roller bearing 10 Roller axle 11 Oil dipstick Illustration 29
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
7 Cylindrical roller bearing 8 Slip-ring sealing 9 Cover disc 10 Roller axle 11 Sealing sleeve 12 Hub
1
000651
RM
Roller - structure
Page 61
Roller - structure RM, CS, D Seal sizes and gaps
M-roller - structure CS
3
Number and location Depending on design: 2 or 3 M-rollers Each clamped on a rocker arm Spaced equidistant from each other Axial inclination to the horizontal grinding track (in zero setting) The position of the M-roller on the table which means the distance to the dam ring can be changed by using the distance ring inserted between the conical sleeve on the rocker arm and the corresponding axle shoulder.
are project dependent!
2 4,5
1 Fixing ring 2 Sealing ring 3 O-ring 4 Sealing set 5 Spiral spring ring
Illustration 30
Q….00-4 en_TM_Maintenance Part 1_Rev.E
31
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Page 62
Roller - structure
Roller - structure
RM
D
Number and location
Number and location
Depending on design: 2 , 4 or 6 rollers Each clamped on a rocker arm Spaced equidistant from each other Axial inclination to the horizontal grinding track (in zero setting)
Depending on design: 2 , 3, 4 rollers Each clamped on a rocker arm Spaced equidistant from each other Axial inclination to the horizontal grinding track (in zero setting)
32
Q….00-4 en_TM_Maintenance Part 1_Rev.E
33
© by LOESCHE
Q….00-4 en_TM_Maintenance Part 1_Rev.E
Page 63
Table of contents
CS
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
2
9
X 3 10 4
X
11
8
12
5
6
13 14
7
1 Rocker arm 2 Clamping sleeves 3 Roller axle 4 Cylindrical roller bearing (locating bearing) 5 Ring 6 Pedestal 7 Pivot point of spring-assembly cylinder 34
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8 Clamping sleeves 9 Fork 10 Central lever 11 Bearing block on pedestal 12 Cylindrical roller bearing (floating bearing) 13 Flange centring sleeve Illustration 14 Rocker-arm axle 35
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000508
M-rocker arm – structure
Page 64
Rocker arm – structure 11
RM
Rocker arm – structure
X-X
X
D
1
10
12 13
2
14
4
1
3
2
15 4
3
5
6
6
7 8 9
5
13
6
8
10 12 14
11 10
7
Illustration
1 Clamp with taper sleeve 9 Sealing air connection 2 Hood 10 Fork 3 Clamping sleeve connection 11 Journal 4 Rocker arm clamp 12 Bearing block 5 Seal 13 Fixed bearing 6 Rocker arm 14 Mounting for hydropneumatic spring assembly 7 Hub 15 Cover Illustration 8 Floating bearing
001023
X
1 transport lug 8 Fixed bearing 2 Taper pin connection 9 Pivot point of spring assembly cylinder 3 Lever 10 Clamping sleeve connection 4 Flange sleeve connection with oil connection 11 Sealing air connection 5 Axle 12 Taper sleeve 6 Floating bearing 13 Roller shaft 7 Fork 14 Clamping sleeve connection 36
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9
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Table of contents
Grinding parts – function CS
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Depending on the material the grinding plate can be hard-faced by expert companies 8 to12 times Wear reference measurements are needed Replacement / re-welding frequency is predicted by wear measurements Recommended max. wear before welding is app. 35 mm Typical wear rate for clinker / slag is 6 – 8 g/t product; about 2 to 3 g/t for limestone Rollers run on outside of the grinding path
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Grinding plate:
Page 66
Table of contents
RM
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
X 3
3
11
X
A
A
10
4 9 8 7
6
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A-A 12
2
13
1 Sealing bar (secured to the mill body) 2 Mill body 3 Sealing cap 4 Wear ring 5 Armour ring 6 Lining plate 7 Sealing bar (secured to the mill body) 40
5
8 Seal 9 Sealing bar (secured to the rocker arm) 10 Rocker arm 11 Seal 12 Sealing bar (secured to the mill body) 13 Seal Illustration 41
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1
000853
M-lever sealing - structure
Page 67
Lever sealing - structure
M-lever sealing - structure
D
CS, RM Flange for cover door
Seals: Cover door Sealing flanges around box mounted on shaft (moving with roller)
Shaft mounted box Illustration 42
Illustration CS Q….00-4 en_TM_Maintenance Part 1_Rev.E
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Lever sealing - structure
Table of contents
D
Lever sealing
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration 44
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HSLM: hydraulic system M-roller - structure
HSLM: hydraulic system M-roller - structure
CS, RM, D
CS M-spring assembly
The hydraulic system M-roller consists of:
Hydraulic cabinet HSLM
M-spring assembly Hydraulic cabinet HSLM Ring pipeline with pressure transmitter Connecting pipeline Bladder accumulator For systems with counter pressure: Piston accumulator Hydraulic cylinder For CS, D: Buffer
Illustration 46
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HSLM: hydraulic system M-roller - structure
HSLM: hydraulic system M-roller - structure
RM
CS HSLM power unit M-spring assembly
Buffer
Hydraulic cabinet HSLM
Illustration 48
Illustration Q….00-4 en_TM_Maintenance Part 1_Rev.E
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HSLM: hydraulic system M-roller - structure CS, RM, D Bladder accumulator
HSLM: hydraulic system M-roller - structure Piston accumulator for systems with counter pressure
N2
Oil
Illustration 50
Illustration Q….00-4 en_TM_Maintenance Part 1_Rev.E
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Table of contents
HSMS: roller lubrication - structure CS, RM
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
The HSMS roller lubrication consists of Hydraulic cabinet HSMS Connecting pipeline LM lubrication line Seal air inlet Oil level
Vent line
Inlet line / Outlet line
Illustration 52
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HSMS: roller lubrication - structure
HSMS: roller lubrication - function
CS, RM
CS, RM M-roller Tank
Pipelines are connected to rollers by hoses (roller movement) If oil is too cold, the pressure pump is outrunning the suction pump and the roller will be overfilled If the oil is too hot, the internal sealings of the roller may be damaged In normal operation the suction pump capacity is higher = always some oil runs from tank Suction pump is started first, several minutes later the pressure pump The circulation starts / stops with app. 30 minutes delay to the feed to allow the rollers to heat up and cool down
Heater
Cooler
Suction pump Oil filter Pressure pump
Pressure line Suction line Illustration 54
Illustration Q….00-4 en_TM_Maintenance Part 1_Rev.E
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HSMS: roller lubrication - data
Table of contents
CS, RM
Example
Oil type is project dependent
Oil Type and Quantity ISO VG 320 (see lubrication list) Pump capacity Suction pump 30% higher capacity than pressure pump Interlocked oil temperature limits in return / suction line T > 70 C - - - Alarm 1; oil too hot T > 80 C - - - Alarm 2; if oil > 80 C for > 30 minutes = stop pumps Interlocked tank oil temperature limits T < 15 C - - - no start of pumps T < 55 C - - - start heater in tank T > 60 C - - - stop heater in tank T > 70 C - - - Alarm 1; oil too hot T > 80 C - - - Alarm 2; if oil > 80 C for > 30 minutes = stop pumps
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Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Page 75
M-rocker arm bearing lubrication - structure
M-rocker arm bearing lubrication - function
CS, RM, D
CS, RM, D (depending on size)
The M-rocker arm bearing lubrication consists of (depending on mill size)
grease pump lubrication lines grease distributors leading to the rocker arm floating and locating bearings
Rocker arm bearings
The connections from rocker arm to hydraulic cylinders are manually greased The connection on top and bottom of hydraulic cylinders are manually greased Rocker arm pivot point
Hydraulic cylinder pivot point
M-rocker arm bearing lubrication ensures maximum bearing service life.
Grease pump pumps grease from reservoir into outlets
Each outlet is connected to a distribution unit that has equal outlets
The outlets of each distributor are connected to pipelines to greasing points
All pipelines are mounted in protected corners and therefore difficult to reach
Illustration CS 58
Illustration CS Q….00-4 en_TM_Maintenance Part 1_Rev.E
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M-rocker arm bearing lubrication - function
Table of contents
CS
The control system will start the pump when the mill feed is started The pump will run for 5 minutes, time is adjusted during commissioning Then the pump shuts down for 55 minutes, time is adjusted during commissioning As long as the mill is running the pump starts every runtime-hour Commissioning will ensure that the pump / distributors convey the proper amount of grease into the proper grease point The system will alarm if there is a problem with the grease flow, level or pump 8 hours after the initial alarm, the mill will shut down if the system is not corrected
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration CS 60
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Slide – structure
Slide – function
D
D Slide with pneumatic interlock
The slide cpl. ensures that the mill is shut off in a dust- and gastight state within tenable limits when foreign bodies are removed and in the event of reject material. It is usually located between the outlet hopper of the mill ring duct and the reject box.
Reject box
Illustration 62
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Table of contents
Pneumatic interlock – structure D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
1 2 15
3
4
9
11 13
12
5
6
14 10
8
7
Illustration 64
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Table of contents
Reject box – function D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
The end face of the reject box incorporates a large door with a seal and several quick-release locks. Foreign bodies and reject material from the mill is collected in the reject box. When the door is opened, the reject box can be emptied with a shovel
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The reject box is a welded round container with a torispherical head which is anchored on the mill floor. The reject box is erected underneath the mill ring duct and connected to this duct via an inlet hopper. A shut-off device (slide) is inserted between the box inlet funnel and connecting flange.
Page 80
Table of contents Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
RM X 1
2
X
3
4 000597
Mill body - structure
1 Cover 2 Mill body 3 Pointer 4 Mill door Illustration 68
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Mill body - structure
Mill body – structure Mill door – CS, RM, D
M-roller cover
Doors with quick-release covers are provided for inspection of the mill interior.
S-roller cover
It is not allowed to access the mill without following all safety procedures.
Mill door
Lining plates Central air flap (project specific) Illustration CS 70
Illustration Q….00-4 en_TM_Maintenance Part 1_Rev.E
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Page 82
Table of contents Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
CS 1
X 2
3
4
X
5
1 Mill body (top view) 2 S-cover lining 3 Lining plates
000638
Lining - structure
4 M-cover lining 5 Mill door lining
Illustration 72
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Lining - structure
Table of contents
RM
3 2
1
2
2
2
000599
2
1 Cast lining plates 2 Wear-resistant steel plates 3 Mill body
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration 74
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Sealing air – structure
Sealing air – structure
RM
RM
Illustration 76
Illustration Q….00-4 en_TM_Maintenance Part 1_Rev.E
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Sealing air and cleaning air – structure
Sealing air and cleaning air – structure
D
D
Illustration 78
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Table of contents
Water injection - structure RM, D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Illustration D 80
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Water injection - structure
Water injection - function
RM, D
RM, D The water piping connected to the pump aggregate is split into several feed pipes. The feed pipes end at the distribution pipes at the mill upper housing flange. Each distribution pipe is connected to spray nozzles via flexible hoses. The spray nozzles are screwed into the pipes which are flanged to the upper housing. The nozzles are arranged so they spray water between the rollers. The nozzle switchover point is at the lower characteristic curve range so that large pressure surges can be avoided (see also "Characteristic curve sheet: pumps + nozzle").
Illustration D 82
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Table of contents
Grinding bed sprinkler - structure CS, RM
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Plant water system supplies water to the pump Pump pumps water into pipeline to mill, excess water returns to plant system Water is split into pipelines, one injection per M-roller Injection lances distribute water across grinding path Compressed air supplied to purge lances (avoids dribbling into stopped mill)
Illustration 84
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Grinding bed sprinkler - structure
Grinding bed sprinkler - structure
CS, RM
CS, RM 2
1
8
9
10
7
5
4
1 Grinding roller
6 Orifice plate
2 Tire
7 Compressed-air line
3 Grinding plate
8 Grinding chamber
4 Table casting
9 Pipe holder
5 Water line
10 Sprinkler pipe
Illustration CS 86
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3 000518
6
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Table of contents
Swinging device – structure CS, RM, D
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
HSAV Pump unit
Illustration 88
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Swinging device – function
Table of contents
CS, RM, D
The swinging device serves to swing out/in the rollers
A
B 1 6
2
3
5
4
4 Hydraulic pump unit, HSAV
2 Hydraulic cylinder
5 Pedestal
3 Joint seating
6 Grinding roller, swung in
Illustration 90
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© by LOESCHE
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1 Grinding roller, swung out
Overview - CS, RM, D Main assembly groups – CS, RM, D Mill stand - CS, RM, D Table - CS, RM, D Roller – CS, RM, D Rocker Arm – CS, RM, D Grinding Parts – CS, RM, D Lever Sealing – CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D HSMS: roller lubrication – CS, RM Rocker Arm Bearing Lubrication – CS, RM, D Slide – D Pneumatic interlock – D Reject box – D Mill body - CS, RM, D Lining - CS, RM, D Seal Air – CS, RM, D Water injection - RM, D Grinding bed sprinkler - CS, RM Swinging Device – CS, RM, D Classifier
Page 92
Classifier - structure
Classifier - structure LSKS Classifier drive Outlet duct
The classifier consists of
Upper housing
Classifier drive* Intermediate frame
Classifier lubrication line*
Guide vane
Upper housing with outlet duct and support for classifier drive* Lower housing with static guide vane*, lining* and feed chute
Lower housing
Rotor* with rotor blades* and bearing cartridge* Grit cone*
Classifier rotor
Classifier grit cone * These items are not shown in this illustration
Illustration
Illustration 92
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Feed chute
Page 93
Classifier - structure
Classifier - structure
LSKS ZD
LDC
Upper bearing
Classifier drive
Classifier Drive Outlet duct
Upper housing
Lower bearing Feed chute
Rotor shaft Rotor with removable rotor blades
Intermedi ate shaft Classifier grit cone
Lower housing
Intermediate frame
Guide vane
Stiff support pipes towards lower housing hold lower end of bearing cartridge in position (no swinging)
Classifier grit cone Illustration
Illustration 94
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Rotor
Page 94
Classifier - structure LSKS ZD power plant
Classifier drive - structure LSKS for CS, RM
Feed chute
Classifier drive consists of Classifier motor Classifier gearbox (speed monitor, temperature probes) Classifier lubrication with instrumentation (temperature, oil flow, speed monitor, …) Coupling, coupling guard, supports, hoses, etc.
Outlet duct
Upper housing Classifier drive
Classifier motor
Classifier lubrication
Rotor Coupling guard
Lower housing
Reservoir
Coupling Classifier gearbox
Classifier grit cone
Guide vane
Bell housing
Illustration
Illustration 96
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Classifier drive - structure
Classifier drive - structure Classifier gearbox lubrication system
D
Classifier drive consists of Classifier motor Grease pump
is a circular or splash lubrication that needs a certain rpm of the rotor to supply sufficient lubrication (never idle rotor) Temperature (PT100): Oil temperature < 0 C classifier drive stop Oil temperature > 85 C warning signal to control station Oil temperature > 90 C classifier drive stop
4 7
6
5
1 2 3
14 8
Resistance thermometer
13
1 Sealing air connection 2 Cover 3 Castellated disc 4 Multi-V pulley, bearing cartridge 5 Labyrinth ring 6 Proximity switch 7 Power belts
10
RM/CS Not existing for coal
Illustration 98
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Illustration 99
© by LOESCHE
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Pump
9
11
8 Multi-V pulley, motor 9 Guard 10 Motor 11 Console 12 Classifier upper housing 13 Inspection cover
Cooling water inlet
001059
12
Oil reservoir
Page 96
Lining – structure LSKS Lining
Thank you for your attention
Lining in the classifer upper housing 100
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Maintenance & procedures by Peter Lolschou, LOESCHE America, Inc.
Maintenance & Procedures LOESCHE vertical roller mills
© by LOESCHE
Peter K. Lolschou, Technical Instructor Miami, September 2013
Page 98
Table of Contents
M-Roller – Maintenance Work
M-Roller - CS, RM, D
CS
Swinging Device - CS, RM, D
Visual check: Tightness / attachment of all bolts at roller covers and tires Wear of shaft protection Oil leaks / oil level / slip ring sealing Seal air labyrinth seal by hand Roller tire coating / wear
Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D
Intervals: Visual check weekly Check slip ring sealing and seal air labyrinth,and dismount yearly Rebuild / exchange seals as needed Detailed wear measurement Change / re-weld roller tires as needed Take oil samples as specified Exchange oil as necessary determined by sample quality
M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier
Illustration CS 2
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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Roller – Maintenance Work
Roller – Maintenance Work
RM
D
Visual check: Tightness / attachment of all bolts at roller covers and tires Wear of shaft protection Oil leaks / oil level / slip ring sealing Seal air labyrinth seal by hand Roller tire coating / wear
Visual check: Tightness / attachment of all bolts at roller covers and tires Wear of shaft protection Oil leaks / oil level / slip ring sealing Seal air labyrinth seal by hand Roller tire coating / wear
Intervals: Visual check weekly Check slip ring sealing and seal air labyrinth,and dismount yearly Rebuild / exchange seals as needed Detailed wear measurement Change / re-weld roller tires as needed Take oil samples as specified Exchange oil as necessary determined by sample quality
Intervals: Visual check weekly Check slip ring sealing and seal air labyrinth,and dismount yearly Rebuild / exchange seals as needed Detailed wear measurement Change / re-weld roller tires as needed Take oil samples as specified Exchange oil as necessary determined by sample quality Illustration RM
Illustration D 4
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© by LOESCHE
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M-Roller – Maintenance Work
Roller – Maintenance Work
CS
RM
Minimum gap between M-roller and table
Roller tires are highly chrome-alloyed, wear resistant but brittle To avoid tire damage no tramp metal must invade the mill (external reject handling system in feed 10 mm transport), also metal to metal contact between rollers and table must be avoided A minimum gap of 10 mm is adjusted for monitoring The adjustment has to be checked weekly: Lift rollers – thread buffer out 3 revolutions – set minimum 10 mm plate under roller – lower rollers – adjust buffers until they touch the rocker arm – lift rollers – extract 10 mm plates The gap will increase with wear. The grinding efficiency will deteriorate over time.
Minimum gap between M-roller and table
Buffer
Roller tires are highly chrome-alloyed, wear resistant but brittle To avoid tire damage no tramp metal must invade the mill (external reject handling system in feed 10 mm transport), also metal to metal contact between rollers and table must be avoided A minimum gap of 10 mm is adjusted for monitoring The monitoring has to be checked weekly: Lift rollers – set minimum 10 mm plate under roller – lower rollers – calibrate the monitoring – lift rollers – extract 10 mm plates – repeat the procedure with different plates. The monitoring will drift with wear. The grinding efficiency will deteriorate over time.
Illustration
Illustration 6
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Roller – Maintenance Work
M-Roller – Maintenance Work
Coal
CS
Minimum gap between Roller and table
Bearing Replacement
Roller tires are highly chrome-alloyed, wear resistant but brittle Metal to metal contact between rollers and table 5 mm must be avoided A minimum gap of 5 mm is adjusted for monitoring The adjustment has to be checked weekly: Lift rollers – thread buffer out 3 revolutions – set 5 mm plate under roller – lower rollers – adjust buffers until they touch the rocker arm – lift rollers – extract 5 mm plates The gap will increase with wear. The grinding efficiency will deteriorate over time.
It is strongly recommended to have experienced personnel and correct tools. Remove inner cover plate Loosen inner rings Pump high pressure oil into grooves of bearing seats using the delivered handpump Remove taper roller bearing Remove inner and outer rings and distance sleeves Remove cylindrical roller bearing by using a hydraulic jack
Buffer
Illustration 8
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© by LOESCHE
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Roller – Maintenance Work
Roller – Maintenance Work
Coal Bearing Replacement
RM Bearing Replacement
10
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M-Roller – Maintenance Work
Roller – Maintenance Work
CS/RM
Coal
Exchange of M-roller
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Exchange of roller
- It is recommended to have a Loesche expert on site for supervision Remove M-roller covers (seal and cover) Disconnect seal air and (if needed) lubrication hoses Install blind plugs to avoid oil loss into breather (and open bores for hoses) Install swing-out devices (all parts) Remove locking pins Swing roller out of mill Remove roller assembly Lift roller assembly in position and tighten bolts Secure bolts Swing roller back into mill Install locking pins (use swinging device for aligning bores) Uninstall swing out device (all parts) Remove blind plugs from oil lubrication connections Re-install seal air and oil lubrication hoses Re-install M-roller covers (cover door and seals) Clean work area and store hydraulic cart / cylinder / hoses in clean and safe area
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
12
Remove roller covers (seal and cover) Disconnect PT100 (Temperature sensor) Install swing-out devices (all parts) Remove locking pins Swing roller out of mill Remove roller assembly Lift roller assembly in position and tighten bolts Secure bolts Swing roller back into mill Install locking pins (use swinging device for aligning bores) Uninstall swing out device (all parts) Re-install PT100 Re-install M-roller covers (cover door and seals) Clean work area and store hydraulic cart / cylinder / hoses in clean and safe area
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
It is recommended to have a Loesche expert on site for supervision
Page 104
M-Roller – Maintenance Work
M-Roller – Maintenance Work Exchange of M-roller
Exchange of M-roller
4. Install swing-out devices (all parts)
1. Remove roller covers (seal and cover) 2. Disconnect seal air and (if needed) for RM: lubrication hoses 3. Install blind plugs to avoid oil loss into breather (RM: and open bores for hoses)
1
2/3
Illustration CS
Illustration 14
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
pins to fix transistion to rocker arm Swing-out transition for rocker arm pin to fix transition to cylinder shaft Maintenance cylinder (functional) Pin to fix cylinder to foundation eye-bolt connection hoses: HSAV Pump unit - cylinder HSAV pump unit (functional, filled with oil)
Page 105
M-Roller – Maintenance Work
M-Roller – Maintenance Work Exchange of M-roller tire
Illustration
6. Swing roller out of mill
Locking pin(s) Rocker arm shaft
Exchange of M-roller 5. Remove locking pins 6. Swing roller out of mill To swing-out the M-roller (S-roller similar): Extend the maintenance cylinder shaft fully using the mobile hydraulic cart Attach shaft to swing-out transition part at rocker arm Remove the locking pins (1 per side) Use the hydraulic cart to move the maintenance cylinder shaft back in The roller will then pivot at the common pivot pin as it swings into the vertical / maintenance position
Illustration 16
Illustration Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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Table of Contents
M-Roller – Maintenance Work
M-Roller - CS, RM, D
Exchange of M-roller
Swinging Device - CS, RM, D
7. Roller removal
Grinding Parts: roller tires, grinding plate - CS, RM, D
Open outer shaft cover and loosen / take out bolts of outside clamp ring (at bottom of roller when swung-out) Install lifting eye bolts (original delivered) Install manual hydraulic jack under shaft and press roller shaft out of rocker arm seat Do not use force of crane to loosen roller assembly (either rocker arm or crane could break) Once lose the roller assembly is lifted off using a crane and the lifting eye bolts
Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier Illustration 18
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© by LOESCHE
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Swinging Device – Film
Swinging Device – Maintenance Work CS, RM, D Flanged sleeve
The hydraulic cylinder has to be stored vertically. Proper dismounting and mounting of taper pin- and flanged sleeve connection of rocker arm - fork connection is important. Intervals:
Taper pin connection
Swinging device
check completeness and function of all auxiliary-parts prior to use of auxiliary parts. Maintenance: change oil vent off air of swing out cylinder clean tank
Illustration 20
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 108
Table of Contents
Grinding Parts – Maintenance Work
M-Roller - CS, RM, D
CS, RM, D
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier Illustration 22
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Grinding Parts – Maintenance Work
Grinding Parts – Maintenance Work
CS, RM, D
1
1
CS, RM, D
2
2
Back of roller ca. 10 mm
X
X
Front of roller
000524
3 3
1 Tire profile ruler 2 Tire 3 Hub
Illustration 24
Illustration Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 110
Grinding Parts – Maintenance Work
Grinding Parts – Maintenance Work
CS, RM, D
CS, RM, D Grinding plate
Roller tire
Wear Measurement
Using a template, wear has to be measured approximately weekly or as needed The measurements have to be recorded and used to predict when welding or exchange of the grinding parts is required Maximum recommended wear before rewelding: 30 mm Maximum recommended wear before exchanging: according to contract For Clinker / slag and coal: Do not forget to re-adjust buffers Roller measurement tool as per drawing Table = “straight edge” with markers
Illustration 26
Illustration Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Tire profile ruler
Page 111
Grinding Parts – Maintenance Work
Grinding Parts – Maintenance Work
Picture1 : new M-roller tire Picture 2: M-Roller tires in the range of re-welding Picture 3: limit of re-weldable wear
1
Pictures 4, 5 and 6 show M-Roller tires beyond rewelding Tire exchange imminent Picture 7 shows a tire at the breaking point
3
4
6
5
7
2
Illustration CS
Illustration CS 28
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Grinding Parts – Maintenance Work
Grinding Parts – Maintenance Work
CS, RM
CS, RM
Welding procedures for roller tires and grinding plate To be performed by experienced welding company Needs specialised equipment (automatic welding head, large welding gear) Will be done inside the mill with all parts installed The table is turned by means of an auxiliary drive for welding the grinding plate The tires are turned by the table or by separate drives for each roller It is critical for both procedures to set-up the welding ground properly, not to damage bearings and gears. Generally, when welding the grinding plate or tires check for Grinding plate set tight and all clamping bolts torqued Tires set tight and all clamping bolts torqued Tires are not broken or cracked in any spot Tires and grinding plate should be built back up to the original profile App. 8 to 12 re-weldings are possible Welding in an external workshop is also possible after dismounting all grinding parts Illustration 30
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© by LOESCHE
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Table of Contents
Table – Maintenance Work
M-Roller - CS, RM, D
Auxiliaries table – CS, RM, D
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM
Hydraulic jack
M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Table support
Reject Box – D Classifier
Illustration CS 32
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© by LOESCHE
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Page 114
Table – Maintenance Work
Table – Maintenance Work
CS, RM
Effects of dam ring height on production and quality – CS, RM, D
Visual check
The grinding plates wear out which may increase the effective height of the dam ring. It might be necessary to weld on / exchange the grinding plates or adjust the dam ring height to keep a constant mill performance.
Armour ring wear
Dam ring wear
Louvre ring / Cover plates wear Clamping ring wear and tightness of bolts Illustration CS
Changing the dam ring height is used to achieve the following effects: Stabilization of mill operation (vibration control) Optimization of specific power consumption Optimization of product fineness (rough tuning)
Table seal wear and tear
The following results will be achieved: Improved product fineness (dam ring higher) Improved specific power consumption (dam ring lower)
Intervals: Visual check weekly Repair / retighten as needed Change / re-weld grinding plates as needed
The optimum dam ring height will be determined during commissioning.
Change / re-weld louvre / armour ring as needed Roller / table wear measurement every 3 months For clinker / slag: stop buffer adjustment every 3 months Shift intervals according to the specific „wear behavior“ of the mill 34
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Table of Contents
HSMS: roller lubrication – maintenance work
M-Roller - CS, RM, D
CS, RM
Swinging Device - CS, RM, D
Visual check:
Grinding Parts: roller tires, grinding plate - CS, RM, D
Tank oil levels Tank oil temperatures Flow in suction line sight glasses Indication of pressure / suction gauges Leaks along all pipelines / hoses Temperature of oil from / to rollers Connection at rollers tight Filter dirty indication (if provided)
Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D
Intervals: Visual checks daily Filter clogged weekly, if no indication is provided Oil samples of each tank unit every 3,500 Rth (Runtime-hours) Oil change as needed / per manual (see lubrication list) During oil change open tank units and clean oil sludge thoroughly
Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier
Illustration 36
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 116
HSMS: roller lubrication – maintenance work
Table of Contents
CS, RM
M-Roller - CS, RM, D
Lubrication list
Project dependent
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier 38
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Page 117
Rocker Arm – Maintenance Work
Table of Contents
CS, RM, D
M-Roller - CS, RM, D
Maintenance / Interval: Visual checks inside / outside (weekly) Check seal air labyrinths (every 6 monthls) Check bearing clearance (annually) Change / re-weld labyrinths as needed Change bearings as needed Re-tighten / re-seal / repair as needed
Swinging Device - CS, RM, D
Axle
Rocker arms - visual check: Grease supply of 3+1 bearings Condition of grease pump Cracks in casted rocker arm Tightness of all bolts Seal air supply Condition / adjustment of buffers Condition of shaft sealing box (inside)
Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D
Rocker arm bearings
Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D
Hydraulic spring assembly
Reject Box – D Classifier Illustration CS 40
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 118
M-Rocker Arm Bearing Lubrication – Maintenance Work
M-Rocker Arm Bearing Lubrication – Maintenance Work
CS
CS Visual check: Lid of grease tank tightly closed (auto system) Grease tank full (auto system, lubrication list on next slide) Leaks at pump unit (auto system) Grease pipelines intact (auto & manual systems) Grease leaks at pipelines, distributors or bearings (auto & manual systems)
Project dependant
Intervals: Visual checks daily Supply the 12 manual grease points with grease according to documentation (lubrication list) daily (lubrication list)
Illustration CS 42
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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Table of Contents
M-Lever Sealing – Maintenance Work
M-Roller - CS, RM, D
CS, RM, D
M-lever sealing
Visual check: attachment bolts of lever sealing parts wear of lever sealing parts proper adjustment of gaskets and bellows check flanges between rocker arms and mill body for tightness
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D
Maintenance: change worn parts
M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D
Intervals: visual check weekly change worn parts according to actual wear shift interval according to the specific „wear behaviour“ of the mill
HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier
Illustration CS 44
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 120
Table of Contents
HSLM: hydraulic system M-roller - function
M-Roller - CS, RM, D
CS, RM, D : With counter pressure The M-rollers crush the grinding material through their own weight and additionally applied hydraulic pressing force. The pressing force of the M-rollers on the grinding material is generated by the hydro-pneumatic spring assembly system. For CS, D: A stop buffer on the rocker arm prevents the tires from coming into direct contact with the grinding plates.
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D
Operating pressure
M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D
Counter pressure
Reject Box – D Classifier
Illustration 46
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 121
HSLM: hydraulic system M-roller - function
HSLM: hydraulic system M-roller - function
D: Without counter pressure
Gas valve
The rollers crush the grinding material through their own weight and additionally applied hydraulic pressing force. The pressing force of the rollers on the grinding material is generated by the hydro-pneumatic spring assembly system. A stop buffer on the rocker arm prevents the tires from coming into direct contact with the grinding plates.
Function of accumulators
The accumulators act as shock absorbers and as a system Shell pressure equalizer Standard charge: 50% of expected operation oil pressure, exact values to be adjusted during commissioning (>30% ; < 70%) Nitrogen pressure can only be measured with oil pressure completely drained Bladder
Oil valve
Oil Illustration 48
Illustration Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 122
HSLM: hydraulic system M-roller – Maintenance Work
HSLM: hydraulic system M-roller – Maintenance Work
Lubrication instructions
Lubrication instructions
50
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© by LOESCHE
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Page 123
Table of Contents
HSLM: hydraulic system M-roller – Maintenance Work
M-Roller - CS, RM, D Filtration skid / Filling cart
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D
Loesche delivered a cart with an oil pump and a filter unit to ensure that only properly filtered oil is filled or topped up into the Hydraulic Tank. This cart is to be used during normal maintenance. Typical filter size < 25 micron (e.g. 10)
Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier
Illustration 52
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Page 124
Lining – Maintenance Work
Table of Contents
CS, RM, D Inspection and replacement The lining has to be checked for wear regularly. Worn plates can be replaced / exchanged with equally shaped less worn plates be replaced by a new plates Severe and premature wear can be adjusted by louvre ring cover placement review of the design of the armour ring inclination (Loesche involvement recommended)
M-Roller - CS, RM, D Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D
CS
Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier Illustration 54
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
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Page 125
Water injection – Maintenance Work
Table of Contents
RM, D
M-Roller - CS, RM, D
Visual check: Inspect the nozzles for wear and contamination Protect hoses from physical damage The mountings of the distributor line on the mill body should be checked regularly to make sure that they are tight.
Swinging Device - CS, RM, D Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM
Repair: Replace nozzles if necessary Replace hoses if necessary After repair work screwed fittings should be resealed with hemp or sealing tape The mountings of the distributor line on the mill body should be checked regularly to make sure that they are tight. Intervals: Visual checks every 6 months Repair if necessary
M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D Water Injection – RM, D Mill Stand – CS, RM, D Reject Box – D Classifier
56
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© by LOESCHE
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M-Rocker Arm - CS, RM, D
Page 126
Mill stand - Maintenance Work
Mill stand - Maintenance Work
CS, RM, D
Ring duct – CS, RM, D
Visual check:
Inspections can be carried out through the ring duct access door (confined space)
Condition and tightness of bolts of bearing caps Condition of weldings
Wear at scraper supports should be repaired with hard-faced welding
Oil accumulations or material chunks on concrete foundation Condition of anchor bolts
The scrapers should be checked regularly for wear and secure mounting
Condition of gearbox attachment bolts Interval: weekly
The lower housing is subject to heavy wear and may be hardfaced or lined with Densit
Check torque Interval: yearly
Superbolt system
Illustration 58
Illustration Q…-01-4 en_TM_Maintenance Part 2_Rev.B
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© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Hydraulic tension system
Page 127
Table of Contents
Classifier – Maintenance Work
M-Roller - CS, RM, D
LSKS
Swinging Device - CS, RM, D
Visual check: Oil level / leaks at classifier gearbox Bolts at upper housing, static guide vanes, rotor drive, lower bearing supports still tight Wear and tear on static vanes, rotor blades, upper / lower housing, grit cone (inside) Position / wear of static guide vanes Level in grease container Leaks in grease lines (outside / inside) Lining in upper / lower housing missing
Grinding Parts: roller tires, grinding plate - CS, RM, D Table – CS, RM, D HSMS: roller lubrication - CS, RM M-Rocker Arm - CS, RM, D M-Rocker Arm Bearing Lubrication - CS, RM, D M-Lever sealing - CS, RM, D
Water Injection – RM, D
Retighten, repair, refill Replace worn rotor blades / static vanes Repair worn grit cone / housing and replace worn liners Replace missing / broken ceramic liners Exchange bearing cartridge Follow supplier‘s manual for gearbox oil
Mill Stand – CS, RM, D
Intervals:
HSLM: hydraulic system M-roller - CS, RM, D Lining – CS, RM, D
Visual checks every week as needed or as in manual
Reject Box – D Classifier
Illustration 60
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© by LOESCHE
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Page 128
Classifier – Maintenance Work LSKS Visual check:
Classifier – Maintenance Work LSKS
Project dependent
Project dependent
Oil level / leaks at classifier gearbox Bolts at upper housing, static guide vanes, rotor drive, lower bearing supports still tight Wear and tear on static vanes, rotor blades, upper / lower housing, grit cone (inside) Position / wear of static guide vanes Level in grease container Leaks in grease lines (outside / inside) Lining in upper / lower housing missing Retighten, repair, refill Replace worn rotor blades / static vanes Repair worn grit cone / housing and replace worn liners Replace missing / broken ceramic liners Exchange bearing cartridge Follow supplier‘s manual for gearbox oil
Intervals:
Visual checks every week as needed or as in manual
Click to open Illustration 62
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© by LOESCHE
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Page 129
Rotor – Maintenance Work
Rotor – Maintenance Work
LSKS
LSKS Guide vanes and rotor blades
Exchange of rotor blades
The guide vanes are not adjustable. The guide vane position has a direct impact on the product quality and classifier efficiency Static guide vanes and rotor blades need to be inspected frequently for wear, tear and position since these parts are directly responsible for product fineness and quality
If visual inspection reveals wear / tear on rotor blades – exchange is necessary 1. Unbolt and extract locking rings (upper/lower end of blades at inside) 2. Pull blades out of guide-slots 3. Insert new blades into guide slots 4. Bolt down locking rings and secure bolts by tack welding
Illustration
Exchange blades in pairs 180 degrees opposite of each other OR re-balance rotor upon first start
Illustration
Illustration 64
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Rotor – Maintenance Work
Rotor – Maintenance Work LSKS
LSKS
Rotor clearance
Static
Exchange of Bearing Cartridge
Project dependent
1. Secure rotor by chain-falls to upper housing (ceiling)
Visual check • wear • imbalance
2. Dismount classifier gearbox (as complete unit using a crane), pulling gearbox vertical upwards off coupling
Interval every 6 months for more details, please see in manual
3. Disconnect automatic grease system and instrumentation from bearing cartridge 4. Unbolt flange cartridge – upper housing 5. Unbolt flange cartridge – rotor 6. Use crane to pull old cartridge out off classifier
Dynamic
7. Use crane to insert new cartridge into classifier 8. Re-assemble in reverse order Illustration
Illustration 66
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© by LOESCHE
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Rotor – Maintenance Work LSKS
Grease lubrication of bearing cartridge: Grease reservoir with level sensor Continuous low level alarm will trip the system after X hours (usually 8 hours) Single outlet grease pump Grease splitter (50:50) 2 lines into (upper / lower bearing) Pump runs for 10 minutes, shuts down for 50 minutes and restarts as long as classifier is running The bearing temperature is monitored continually by temperature sensors
Grease type KPF 2 G 20 or comparable Amount: 8 Liter in pump reservoir, 2 kg in bearing cartridge and pipelines
Illustration 68
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
69
© by LOESCHE
Q…-01-4 en_TM_Maintenance Part 2_Rev.B
Thank you for your attention
Page 132
Mechanical design and maintenance: Mill Gearbox by Desi Delgado, LOESCHE America, Inc.
Mechanical Design and Maintenance Mill gearbox
© by LOESCHE
Desi Delgado, Technical Instructor Miami, September 2013
Page 133
Table of contents
Gearboxes
Selection of Gearboxes for LOESCHE Mills
Mill gearbox Gearboxes
Rated Power of Mill Drive
Type of Gearbox
< ~350 kW
Bevel-Helical; 2-/3-Stages
Maintenance
< ~2.000 kW
Bevel-Planetary; 2-Stages
Gearbox internals
> ~2.000 kW
Bevel-Helical-Planetary; Bevel-Planetary-Planetary; 3-Stages
Sub-suppliers Coupling Gearbox lubrication
2
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Gearbox
Gearbox
Bevel-Helical-Planetary-Gearbox with 3-stage Reduction
Bevel-Planetary-Gearbox with 2-stage Reduction
Output Flange
Thrust Bearing
Planetary Stage
Input Shaft
Gear Coupling Bevel-Gear Stage
Housing
HelicalGear Stage
FLENDER KMP 4
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
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FLENDER KMPS
Page 135
Gearbox
Gearbox
Loesches Strategy of Mill and Drive Sizes
Bevel-Planetary-Gearbox with 3 stage Reduction
FLENDER KMPP 6
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Table of contents
Gearbox
Unification Concept for CRM and C/S-mills
Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
8
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Mill gearbox
Mill gearbox
Sub-suppliers
Sub-suppliers
Sub-suppliers approved by LOESCHE
CMD, France rating up to 1.500kW Smaller gearboxes Bevel-Helical, planetary
CMD, France Flender (Siemens), Germany, Bocholt Formosa Heavy Industries (Licence of M/s Renk), Taiwan, Keller, Germany, St. Augustin Maag (FLS), Swiss Moventas, Germany, Wuppertal Renk (MAN) / Renk-Maag, Germany, Augsburg Seisa (SHI), Japan
10
Keller Siegburg, Germany
rating 200 kW up to 1.500 kW
Maag, Winterthur, Swiss (HQ)
rating … up to 5.400 kW
Moventas, Wuppertal Germany
rating 200 kW up to 1.500 kW
Renk, Augsburg, Germany
rating up to 5.400 kW
Seisa, Osaka Japan
rating 450 kW up to 4.500 kW
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
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Flender, Bocholt(HQ), rating 200 kW up to 7.000 kW Voerde (machining, assembly) Germany
Page 138
Table of contents
Mill gearbox Sub-suppliers
Mill gearbox Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
12
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Mill gearbox
Gearbox
Coupling
Coupling
Different types High flexible couplings: Flender Flexible couplings: Bolt type: Flender
- ELPEX ENG …
- RUPEX RWN …, RUPEX-APEX
Elastic RUPEX coupling, Type RAK
14
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Mill gearbox
Mill gearbox
Coupling
Coupling RUPEX
ELPEX
16
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Table of contents
Mill gearbox - Coupling
Mill gearbox Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
18
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Page 142
Mill gearbox
Mill gearbox – Gearbox Lubrication
Gearbox lubrication Always included in the scope of supply of gearbox suppliers Usually consists of: Low pressure pump, Filter, oil cooler (water/air) HP-pumps, Instrumentation pressure transmitter, RTD‘s flow meter, and gauges (temperature, pressure, flow indicator), heating device, oil container
Signals of instruments are interlocked in PLC Certain sequences and paramaters must be adhered to
Project dependent 20
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Table of contents
Mill gearbox – Gearbox Lubrication
Mill gearbox Mill gearbox Sub-suppliers Coupling Gearbox lubrication Maintenance Gearbox internals
Project dependent 22
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Mill gearbox
Mill gearbox
Maintenance
Maintenance Gearbox removal procedure overview
On-site check
Please have expert on site
An annual check should be completed by the gearbox supplier
Illustrations
High vibration / severe torque variations to be avoided
Maintenance drive
Check for the mill operation data, maintenance Visual check, oil level, leaks, abnormal noise, oil filter, oil level check and oil analysis, History of oil analysis and oil exchanges
24
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Page 145
Mill gearbox
Mill gearbox
Maintenance
Maintenance Condition monitoring
Gearbox handling/lifting
vibrations, temperature, pressure, torque, speed, …
data collection, filtering, storage, analyzing
Signals analog or digital
storage, analysis, trend…
Modem / COM Server/ Internet Router data
computer
26
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
messages
SMS e-mail FAX
27
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
(optional) limit settings, filter settings, trigger settings, …
Page 146
Table of contents
Mill gearbox Maintenance
Mill gearbox
Condition monitoring
Mill gearbox 4xT
a
Sub-suppliers
a a
Coupling Gearbox lubrication
Lubrication oil inlet T
n M
a T
T
p
Δp Main Filter
Δp
Maintenance
Maintenance Filter
Gearbox internals
T T
a
MINI
8Ch.
MIDI 13 Ch. a: M: n: p: T:
acceleration (vibration) torque speed pressure temperature
MAXI 19 Ch.
28
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© by LOESCHE
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Gearbox KMPP
Page 147
Gearbox
Gearbox
Lubrication
30
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31
© by LOESCHE
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
On Stock
Page 148
Mill gearbox
Mill gearbox
Gearbox internals
Gearbox internals
32
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33
© by LOESCHE
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Mill gearbox
Mill gearbox
Gearbox internals
Gearbox internals
34
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35
© by LOESCHE
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Mill gearbox Gearbox internals
Thank you for your attention
36
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37
© by LOESCHE
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Page 151
Hydraulic systems: Function & design by Dirk Grube, LOESCHE GmbH
The hydraulic systems at LOESCHE mills Overview
© by LOESCHE
Dirk Grube Technical Seminar Miami, 2013
Page 152
Agenda
Hydraulic systems - overview
1. Hydraulic systems 2. Hydropneumatic spring system - HSLM 3. Roller lubrication unit - HSMS 4. Hydraulic for support roller - HSSW 5. Swinging out device - HSAV 6. Fill unit - HSBF
2
Hydraulic systems in LOESCHE mills: design & function Rev.A
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Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 153
Hydraulic application and their power unit nomenclature
Hydraulic systems - different types
Nomenclature for all application are similar!
LM …CS HSLM with counterpressure
HSMS
Roller lubrication system
Hydropneumatic spring system
Hydropneumatic spring system
HSLM is the abbreviation for the German: [Hydraulikschrank LOESCHE Mühle]
LM …D
LM …RM HSLM with counterpressure
Example: HSLM 1000/45/2
HSSW
Hydraulic positioning device for the S-roller
HSMS
Roller lubrication system
HSAV
Swinging out device
Hydropneumatic spring system
HSLM without counterpressure Hydropneumatic spring system
HSMS is the abbreviation for the German: [Hydraulikschrank Mahlwalzen Schmierung] HSSW is the abbreviation for the German: [Hydraulikschrank Support Walzen] HSAV is the abbreviation for the German: [Hydraulikschrank Ausschwenk Vorrichtung] HSBF is the abbreviation for the German: [Hydraulikschrank Befüll Filtriereinheit]
HSBF
Filling and filter unit
4
Hydraulic systems in LOESCHE mills: design & function Rev.A
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Hydraulic systems in LOESCHE mills: design & function Rev.A
HSLM with counterpressure
Page 154
Hydropneumatic spring system
Hydropneumatic spring system – design & position
Assembly groups
HSLM, ring and connection pipeline: Hydropneumatic spring system
HSLM
Ring pipeline
Spring assembly
6
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7
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Hydraulic systems in LOESCHE mills: design & function Rev.A
Connecting pipeline
Page 155
Roller lubrication system
HSMS – hydraulic plan roller lubrication system
HSMS
connecting pipe line
roller
8
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9
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
lubrication line
Page 156
Mill hydraulic – system for S-roller
HSSW – hydraulic plan
Hydraulic system S - roller
HSSW
S - spring assembly
10
Hydraulic systems in LOESCHE mills: design & function Rev.A
11
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
connecting pipe line
Page 157
HSAV and swinging cylinder
12
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13
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Hydraulic systems in LOESCHE mills: design & function Rev.A
HSBF
Page 158
Agenda 1. Hydropneumatic spring system – components – overview 2. Hydraulic cylinder
The hydropneumatic spring ass. group in LOESCHE mills
3. Rod head and clamping nut 4. Piston and bladder accumulator
Components Dirk Grube Technical Seminar Miami, 2013
2
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 159
Hydraulic system – hydropneumatic spring system
Hydropneumatic spring system – function (1) Damping the system (2) Induce grinding force
3
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4
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Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 160
Hydropneumatic spring system
Hydropneumatic spring system – design
Assembly groups
Spring assembly Hydropneumatic spring system
HSLM
Connecting pipeline
Ring pipeline
Hydraulic cylinder Rod head
Spring assembly
Clamping nut Bladder accumulator Piston accumulator
5
Hydraulic systems in LOESCHE mills: design & function Rev.A
6
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 161
Hydropneumatic spring system – design
Hydropneumatic spring system – design
Hydraulic cylinder
7
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8
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
Clamping nut and rod head
Page 162
Hydropneumatic spring system – design
Hydropneumatic spring system – design
Piston accumulator
Bladder accumulator
N2
Oil
9
Hydraulic systems in LOESCHE mills: design & function Rev.A
10
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 163
Agenda 1. Hydraulic system with counter pressure 2. Function
The hydropneumatic spring system in LOESCHE mills Function (with counter pressure) Dirk Grube Technical Seminar Duesseldorf, 2013-07-25
2
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 164
Hydraulic system with counter pressure
Hydraulic system with counter pressure LM …CS HSLM with counterpressure
HSMS
Roller lubrication system
Hydropneumatic spring system
HSSW
Hydraulic positioning device for the S-roller
LM …D
LM …RM HSLM with counterpressure Hydropneumatic spring system
HSMS
Roller lubrication system
HSAV
Swinging out device
3
Hydraulic systems in LOESCHE mills: design & function Rev.A
Hydropneumatic spring system
HSLM without counterpressure Hydropneumatic spring system
HSBF
Filling and filter unit
4
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
HSLM with counterpressure
Page 165
Hydropneumatic spring system – working pressure
Hydropneumatic spring system – with counter pressure Operating mode
Movie roller 5
Hydraulic systems in LOESCHE mills: design & function Rev.A
6
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
Movie rod head
Page 166
Hydropneumatic spring system – with counter pressure
Hydropneumatic spring system – design & position HSLM, ring and connection pipeline:
7
Hydraulic systems in LOESCHE mills: design & function Rev.A
8
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 167
HSLM hydraulic scheme – with counter pressure
The hydropneumatic spring system in LOESCHE mills Diagram spring stiffness and roller force Dirk Grube Technical Seminar Duesseldorf, 2013-07-26
9
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 168
Agenda
Hydropneumatic spring system – diagrams Diagram spring stiffness and load per roller
1. Diagram: roller force with counter pressure 2. Diagram: spring stiffness with counter pressure
2
Hydraulic systems in LOESCHE mills: design & function Rev.A
3
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Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 169
Hydropneumatic spring system – load per roller
Hydropneumatic spring system – spring stiffness
Design and life time calculated for 100 % of roller force.
Stiffness with too high counterpressure
~3,8
ca. 55 %
~2,2
Stiffness increased by too high counterpressure of 25 bar (against 15 bar) by + 74 %! 4
Hydraulic systems in LOESCHE mills: design & function Rev.A
5
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Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 170
Hydropneumatic spring system – spring stiffness
6
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7
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Hydraulic systems in LOESCHE mills: design & function Rev.A
Hydropneumatic spring system – spring stiffness
Page 171
Hydropneumatic spring system – load per roller
8
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Hydraulic systems in LOESCHE mills: design & function Rev.A
Hydropneumatic spring system – load per roller
Page 172
FW = 30%
FW = 30%
COUNTERPRESSURE
COUNTERPRESSURE
10
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Hydraulic systems in LOESCHE mills: design & function Rev.A
FW = 60% FW = 55%
LOAD PER ROLLER
WORKING PRESSURE
FW = 60% FW = 55%
Hydropneumatic spring system – load per roller
LOAD PER ROLLER
WORKING PRESSURE
Hydropneumatic spring system – load per roller
Page 173
Hydropneumatic spring system – load per roller
FW = 55%
The hydropneumatic spring system in LOESCHE mills
LOAD PER ROLLER
WORKING PRESSURE
FW = 70%
Coal mills - HSLM with counter pressure and not counter pressure Dirk Grube Duesseldorf, 2013-07-26
COUNTERPRESSURE
12
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 174
Agenda
Hydropneumatic spring system
1. Hydraulic system HSLM with counter pressure 2. Hydraulic system HSLM without counter pressure
2
Hydraulic systems in LOESCHE mills: design & function Rev.A
3
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 175
Hydraulic system HSLM at coal mills - different types
Hydropneumatic spring system – with counter pressure Operating mode
LM …D HSLM with counterpressure Hydropneumatic spring system
HSLM without counterpressure Hydropneumatic spring system
Movie roller 4
Hydraulic systems in LOESCHE mills: design & function Rev.A
5
© by LOESCHE
Hydraulic systems in LOESCHE mills: design & function Rev.A
Movie rod head
Page 176
Hydropneumatic spring system – without counter pressure
HSLM with counter OR not counter pressure 1. In coal mills in normal case hydraulic system HSLM with counter pressure is not necessary. But it can be an option. 2. Hydraulic system HSLM with counter pressure is necessary if part load operating at coal mills is a customer‘s requirement. (frequently power plants and steel plants are aware to operate in part load)
6
Hydraulic systems in LOESCHE mills: design & function Rev.A
7
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Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 177
Decrease working pressure for part load
Trend operation trends for counter pressure system
100
90
90
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
10
0
Grinding bed
10
20
30
40
Hydraulic systems in LOESCHE mills: design & function Rev.A
50 60 Mill Load [%]
70
80
90
100 h]
9
© by LOESCHE
8
Operating pressure
0 0
Hydraulic systems in LOESCHE mills: design & function Rev.A
Grinding bed [mm]
Working Operating & Conte /Pressure [bar]
100
Page 178
Increase counter pressure additional for part load
Trend operation trends for counter pressure system
100
90
90
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
10
0
Conter pressure Grinding bed
10
20
30
40
Hydraulic systems in LOESCHE mills: design & function Rev.A
50 60 Mill Load [%]
70
80
90
100 h]
11
© by LOESCHE
10
Operating pressure
0 0
Hydraulic systems in LOESCHE mills: design & function Rev.A
Grinding bed [mm]
Working Operating & Conte /Pressure [bar]
100
Page 179
Comparison of trends
HSLM scheme with counter pressure operation trends for counter pressure system
90
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
Operating pressure
Grinding bed
10
0
0 0
10
20
30
40
50 60 Mill Load [%]
70
80
90
100 h]
operation trends for counter pressure system
100
Working Operating & Conte /Pressure [bar]
Grinding bed [mm]
100
90
100
90
90
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
Grinding bed [mm]
Working Operating & Conte /Pressure [bar]
100
Operating pressure Conter pressure Grinding bed
10
0
0 0
10
30
40
50 60 Mill Load [%]
70
80
90
100 h]
12
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13
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Hydraulic systems in LOESCHE mills: design & function Rev.A
20
Page 180
HSLM scheme without counter pressure
Thank you for your attention
14
Hydraulic systems in LOESCHE mills: design & function Rev.A
15
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Hydraulic systems in LOESCHE mills: design & function Rev.A
Page 181
Process parameters by Christian-Martin Ruthenberg, LOESCHE GmbH
Process parameter of LOESCHE vertical roller mills
© by LOESCHE
Ch.-M. Ruthenberg, Technical Trainer Loesche GmbH Technical Seminar Miami, 2013-09-17
Page 182
Agenda
Processes inside a mill
Processes inside a mill Process Parameters Dependencies Examples
Transportation
Classifying
Drying
Grinding
Summary
Clinker/ slag mill 2
Process parameter_Rev.1
3
© by LOESCHE
Process parameter_Rev.1
Page 183
Processes inside a mill
Processes inside a mill Flow
Transportation Flow
Drying Temperature
Classifying Speed
Pressure
Constantly controlled & stable
Grinding Pressure
Consistent product
Temperature
Speed
4
Process parameter_Rev.1
5
© by LOESCHE
Process parameter_Rev.1
Page 184
Agenda
Process Parameters
Processes inside a mill
Pressure
Mill inlet vs. Outlet (dp mill) Filter inlet vs. Outlet (dp filter) Working and counter pressure (grinding force) Compressed air
Process Parameters Dependencies Examples Summary
Flow
Material Reject Gas Water (Fuel) Product
6
Process parameter_Rev.1
Mill outlet gas Material Water Product
7
© by LOESCHE
Process parameter_Rev.1
Temperature
Page 185
Agenda
Dependencies
Processes inside a mill Process Parameters
Temperature
Dependencies Examples Summary
Pressure
Speed
Flow
10
Process parameter_Rev.1
11
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Process parameter_Rev.1
Page 186
Examples - Filter
12
Process parameter_Rev.1
13
© by LOESCHE
Process parameter_Rev.1
Examples - Hopper
Page 187
Clinker/slag grinding plant
Examples - Hopper
Damper S (Stack)
Damper R (Recirculation)
Damper Z1 (Fresh air)
Minimum value
Max value
Limestone hopper level
6.85 m
10.23 m
Raw mill body vibration
7.81 mm/s
14.24 mm/s
Raw mill motor power
4536 kW
5490 kW 14
Process parameter_Rev.1
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© by LOESCHE
Process parameter_Rev.1
Hot gas generator
Page 188
Agenda
Summary
Processes inside a mill
Processes inside a mill
Process Parameters
transport, grinding, drying and classifying
Dependencies Process parameters
Examples
flow, pressure, temperature and speed
Summary
Dependencies
flow, pressure, temperature and speed
Examples
16
Process parameter_Rev.1
17
© by LOESCHE
Process parameter_Rev.1
filter and hopper
Page 189
Thank you for your attention
18
© by LOESCHE
Process parameter_Rev.1
Page 190
Stabilization of mill in upset conditions by Christian_Martin Ruthenberg, LOESCHE GmbH
Stabilization in upset condition
© by LOESCHE
Ch.-M. Ruthenberg, Technical Trainer Loesche GmbH Technical Seminar Miami, 2013-09-17
Page 191
Agenda
Upset condition = Vibration
Upset condition = Vibration
Gas volume
Water sprinkling
Unstable grinding bed Immediate measures & root causes Most common causes
Mill body vibration 2
Stabilization in upset condition _Rev.1
3
© by LOESCHE
Stabilization in upset condition _Rev.1
Page 192
Upset condition = Vibration Unstable grinding bed
Upset condition = Vibration Unstable grinding bed Changes in feed material
Unstable Conditions
Feed material
Process & Operation
Maintenance
Moisture Grain size Grindability Temperature Foreign material …
Process & Operation
Classifier speed Grinding force Gas flow Water sprinkling …
Maintenance
4
Stabilization in upset condition _Rev.1
5
© by LOESCHE
Stabilization in upset condition _Rev.1
Dam ring, support ring Roller and grinding plates Scrapers Water sprinkling …
Page 193
Upset condition = Vibration Unstable grinding bed
Agenda Upset condition = Vibration
Caused by too coarse or too fine material
Unstable grinding bed Immediate measures & root causes Most common causes
Grain size distribution
6
Stabilization in upset condition _Rev.1
7
© by LOESCHE
Stabilization in upset condition _Rev.1
Page 194
Immediate measures & root causes
Agenda
For fast response: Water sprinkling Working pressure Classifier speed
Upset condition = Vibration Unstable grinding bed Immediate measures & root causes Most common causes
Vibration
Solve root cause
Reverse immediate measure
8
Stabilization in upset condition _Rev.1
9
© by LOESCHE
Stabilization in upset condition _Rev.1
Apply immediate measure
Page 195
Most common causes
Most common causes - feed
Feed
Operation
Wear
Lumps
Memory
Roller & table
Segregation
Interpretation
Dam ring
Source: Loesche report (KN Swain OCL 2007-03-14)
Lumps > 150 mm = 56 pieces Lumps > 120 mm < 150 mm = 76 pieces Hand gloves = 6 pieces Gunny bags = 4 pieces Cotton waste = 200 gram Number of stoppage due to star feeder = 0 10
Stabilization in upset condition _Rev.1
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© by LOESCHE
Stabilization in upset condition _Rev.1
Page 196
Most common causes - wear
Thank you for your attention
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Stabilization in upset condition _Rev.1
Page 197
Optimization of grinding plants: Upgrades, modifications by Desi Delgado, LOESCHE America, Inc.
Optimization of Grinding Plants: Modifications, Upgrades & Audits Type: clinker / slag, raw meal, coal
© by LOESCHE
Desi Delgado, Technical Instructor Miami, September 2013
Page 198
Modifications / Upgrades
Modifications
Upgrades
Audits / Optimization
Modifications / Upgrades
Justification can be quantified
Production increase Energy Savings Achieve optimum product quality Decreased downtime …
Justification not easily quantified Ease of maintenance / Operation Replace obsolete / difficult to source components Provide more control / insight of mill system (instrumentation / sensors / advanced control) …
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Examples - Modification
Examples - Modification
Roller position indicators (Linear Transducers)
Roller position indicators (Linear Transducers) Provide actual roller position information as opposed to simply High, Low, ETC Can be used to see if material is evenly distributed Can see if breakouts or foreign materials are in the mill by observing periodic oscillation Small investment for the amount of insight provided
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Examples - Modification
Examples - Modification
Updated Design (i.e. Rod Head)
Updated Design (Grinding Elements)
Old Design
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Ductile Hardfaced
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
MMC
New Design
Page 201
Examples - Modification
Examples - Modification
G 20Mn5
Facial side protected
Highest Forces
V 100 Mo
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Main wear area
Page 202
Examples - Modification
Examples - Modification
• Ductile Iron core accepts welding easier • Less Risk of cracking • Longer Wear life compared to Hi Chrome • Harder Materials can be applied to areas of less wear • Profile tracking and optimal Manufacturing
Ductile Iron w/ Hardfacing
Metal Matrix Composite
Cost
“X”
“X” – “X + 50%”
“X + 100%-150%
Life
1
1.5
2
Re-Weldable
Yes but difficult
Yes
NO
• Hardfacing required • Risk in cracking
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Chromium Alloy
Page 203
Examples - Upgrade
Examples - Upgrade
High Efficiency Classifier Classifier Type LKS
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Classifier Type LSKS
Page 204
Examples - Upgrade
Examples - Upgrade
Improved velocity profile
Enlarged classifying zone
v1 < v2 Vnew = Vold ⋅ 85% v2 new = v2old
(new geometry) v2
Modified shape v1
Reduced pressure drop across the mill Less gas volume Increase of classifying efficiency
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
• Enhanced classifier efficiency and less power consumption of classifier • Less fines in the material rejected by rotor • Better stability of grinding bed leads to better grinding efficiency
Page 205
Loesche Classifier
Loesche Classifier
From LKS to LSKS
From LKS to LSKS
LM 30.4 (Quebec)
Achieved Results (Examples): LM 32.4 (Höver) Production Increase
21 %
Power Saving
> 1,5 kWh/t
Fineness
Before
After
% R 0.200
1.48
0.41
% R 0.090
11.04
11.78
Production Increase (Material A)
15,5 %
Production Increase (Material B)
22,5 %
LM 30.4 (Aslan 2) Production Increase
8,5 %
Power Saving
> 1,5 kWh/t
Fineness
Before
After
% R 0.200
2.1
0.7
LM 38.4 (Hereke) Production Increase
16,3 %
Power Saving
0,6 kWh/t
16
18,8 %
Power Saving
1,5 kWh/t
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
LM 27.2 (Isparta) Production Increase
Page 206
Examples - Upgrade
Modifications
Larger Rollers
Increase Roller diameter Can increase the throughput Of the mill.
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Audits / Optimization
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Upgrades
Page 207
Audits & Optimization
Audits & Optimization
Carried out by Internal, OEM or Independent consultant Compare Actual/Measured/Historical/Benchmarks Should be carried out periodically or after major events
Internal Personnel
Detailed Equipment knowledge Industry references and experiences Knowledge of upgrade and improvements available Costs
Ideally audits will help to:
Availability
Maximization of availability and reliability Maximization of the operational and functional safety Minimization of unplanned repairs Increase of the operational lifetime
Product/Project support Range of General Knowledge Bias
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© by LOESCHE
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Independent Consultant
Historical Knowledge of installed equipment
Major overhauls / equipment modifications Changes in feed material Changes in product
OEM
Page 208
Audits & Optimization
Audits & Optimization Example
Example visual inspections:
Visual inspections leakages, damages, etc. Check of the filling pressure of the hydraulic accumulator smooth and stable operation
Oil- and grease pipes leakages Expansion joints damages At coal mills level of the rejectbox
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Page 209
Audits & Optimization
Audits & Optimization Alternative:
Sampling for oil analysis
Installation of an Online Condition Monitoring System Oil sensor at the lubrication system continuous monitoring of all relevant parameters
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Page 210
Audits & Optimization
Trouble-free operation
Wear measurement at the grinding parts
Wear measurement at the grinding parts
Measurement at the grinding plate Ideal
Not Ideal
• Fixed reference point
• No Fixed reference point
• Consistent measurements
• Inconsistent measurements
Ideal
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Not Ideal
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© by LOESCHE
Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Measurement at the roller tyres
Page 211
Trouble-free operation
Audits
Wear measurement at the grinding parts
Process Audit
Regularly record of the wear
Process Audit – Field measurements Measurement of pressure temperature O2-content power consumption of the components Volume flow etc. at the different measuring points
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Audits
Audits
Process Audit
Process Audit
Comparison of the hand measurement with the values in the CCR
Scope of work Execution of hand measurements at the complete grinding plant
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Page 213
Audits & Optimization
Audits & Optimization
Process Audit
Summary
Results
Mechanical Audit:
Evaluation of the results with regard to stated targets Summary of the findings and a detailed overview of measurements In the event of a deviation necessary actions should be defined and planned
Process Audit:
Information about the mechanical condition of the grinding plant
Information about the process parameters of the grinding plant
Identify wear zones
Identify optimization potentials / Bottle Necks
New adjustment based on current state
New adjustment to the target state
Spare parts / Repair strategy and planning
Results: Written recommendations for operation and maintenance Historical records to benchmarking Reference point for future operation / scenarios Reduce unplanned down time Increase of the plant efficiency
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Page 214
Audits & Optimization Process Optimization
Audits & Optimization - Plant Optimization Process Optimization
Example: Adjustment of working pressure
At parameter changes one has to:
working pressure = f (output)
Adjust the control loops
working pressure [bar]
Readjustment of alarms/setpoints (if necessary)
High pressure High power consumption Unstable behaviour Low pressure Low capacity
output [%] 34
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Page 215
Audits & Optimization - Plant Optimization
Audits & Optimization - Plant Optimization
Process Optimization
Summary 110%
Example - Adjustment of classifier speed
No Audits
100% 90%
Mech. Failure`
80%
Product fineness is adjusted by classifier speed
70%
Grinding is too fine
60% 50%
Unnecessary increase of wear
1
Decrease of plant performance
Cont. loss of efficiency
Baseline Knowledge Spare Parts Mechanical Condition Plant Efficiency Plant availability 2
3
4
5
6
7
8
9
10
110%
Loss of personnel / Knowledge 11
12
13
14
15
14
15
16
17
18
19
20
21
22
23
24
Audits
100% 90%
Change of the relation between volume flow and classifier speed
80%
Savings at the mill fan
70% 60% 50% 36
Mid Campaign Baseline Optimization Knowledge Spare Parts Mechanical Condition Plant Efficiency Plant availability
1 en_TM_Maintenance 2 3 4 Part5 3_Rev.A 6 Q….-03-4
7
8
Loss of knowledge and training
9
10
11
12
13
16
17
18
19
20
21
22
23
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Q….-03-4 en_TM_Maintenance Part 3_Rev.A
Mech. Failure` Identified and corrected
Page 216
Thank you for your attention
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