Superior Performance Through Innovative Technology- VEGA Industries
description
Transcript of Superior Performance Through Innovative Technology- VEGA Industries
Superior Performance
Through
Innovative Technology
IhrAnsprechpartner in Österreich:
Cement Products
• Tube Mill Parts:• Grinding Media
• Ball Mill Liners
• Partition Diaphragm
• Discharge Diaphragm
• Vertical Mill Parts:• Grinding Elements incl. Monometal/Inserted/Sintercast-11
• Crusher Parts• Blow Bars
• Hammers
• Preheater Parts• Dipping Tubes
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PRODUCTS FOR CEMENT INDUSTRY
RANGE & CAPACITIES
ProductsAnnual cap.
M.T.Range
High chrome grinding
media40000* 12 mm to 110 mm dia,
Diaphragms 50 Nos.
Heat resistant castings 300Dipping tubes
VSM parts static casting 1800 Up to 16.5 MT single piece
Blow bars & hammers 700Up to 1 MT single piece
Mill liners 5500 1.8 to 5.8 M dia.mills
Introduction
1.8 to 5.8 M dia.mills
*GM capacity proposed to go upto 55000 MTPA in India and 45000 MTPA in Canada
Centrifugally cast rolls 3000 Raymond/CE mills
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Grinding Media
• First Chamber• Vegatough 18 - Standard Grade• Hardness >60 RC, RC Range <1%, RA <6%
• Outperforms Competition by Ave 10%
• Batch Check of Quenched Properties Allows Fine Tuning of Tempering
• All Media is Batch Tempered with 18000mt Capacity/Annum
• VegaPlus - High Performance Grade• Hardness >63.5 RC, RC Range <1%, RA <5%
• 40-70% Improvement in Wear Rates
• High Carbide Content
• Multiple Tempering Cycles to Achieve Optimum RC & RA
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> 63.5 RC> 59.5 RCHardness
< 5%
4.0% Max
21% Avg
2.9% Avg
Vegaplus
< 6%RA
2.0% MaxOther alloying
elements
17% Avg.Cr.
2.3% Avg.C
Vegatough-18
Product
Grinding media
VEGA PLUS
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VEGAPLUS
MANUFACTURING SPECIALISATION
Product
Grind ing media
Manufacturing of Vegaplus requires special facilities.
This grade has very high carbide content and hencespecial precautions are required during cooling of poured
moulds.
In order to get optimum combination of hardness and RA,
this grade requires multiple stress relieving/temperingcycles which drastically reduces production capacity.
Thanks to special slow mould cooling techniques and largetempering capacity available at AIAE - it is possible toproduce this material commercially.
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VEGAPLUS COMPARISON WITH
VEGATOUGH 18
Product
Grinding media
3500
3200
3340
Blaine
49257
655748
699396
Materia l
ground
DWL
Step liner
DWL
Liner
profile
3.4 m
4.8 m
4.4 m
Mill
diameter
52.33gms/t105.00gms/t
PSC
(50% slag)
Durgapur
Cement
44.48gms/t92.76gms/t
PPC
( 20% fly ash)J P Rewa
5.97gms/t27.48gms/tOPCGACL Kodinar
Vegaplus
consumption rate
Vega tough 18
consumption rate
Produc tPlant (India)
Additional feature of Vegaplus is that at the end of the trial
there was no deshaping/ tear which is observed in normal
grinding media. This means that there is no need of regrading
every year and mill can perform consistently for long duration.
Grinding Media
• Second Chamber• Vegahard 12 Standard Grade• High level of Physical Integrity Through Rigorous Process Control
• Non-Automated Quality Inspections
• No Breakages or Mismatch
• Vegahard 15 High Performance Grade• Higher Hardness and Cr Content
• Excellent Wear & Good Corrosion Resistance
• Vegahard 18
• Highly corrosion resistant grade
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GRINDING MEDIA FOR
SECOND CHAMBER
Product
Grinding media
ModerateExcellentGoodWear resistance
17-2014-1610-13Cr%
62-6666-6964-68Hardness (HRC)
Vegahard-19Vegahard-15Vegahard-12Vega alloy
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WEAR RATE OF GRINDING MEDIA
Product
Grinding media
Wear rate figures given below are expected wear rate for Vegatough-18 &
Vegahard-12, for both the chambers taken together. Normally, both the
chambers contribute equally to the wear rate
120-15017%R/90 MicronsCoal (>25% ash)
60-10017% R/90 MicronsCoal (15% ash)
190-220-Limestone (10% SiO2)
75-100-Limestone (6% SiO2)
20-25-Limestone (<1% SiO2)
120-2104500PSC (70% slag)
160-1904500PSC (55% slag)
160-1904500PPC (25% fly ash)
120-1603800PSC (55% slag)
80-1603800PPC (25% fly ash)
60-1004500OPC
30-503000OPC
Range of wear rate gm/TFineness (Bl)Material
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Product
Grinding mediaPROBLEMS ENCOUNTERED WITH
GRINDING MEDIA
DURING SERVICE
Selecting the correct grinding media for a particular applicationis important to avoid potential problems, such as:
High wear rate Deshaping
Spalling
Breakage
These problems can usually be traced to either quality of ballsor peculiar working conditions.
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THE GOLDEN TRIANGLE
Design concept
There has to be total compatibility between application,
metallurgy and design.
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Product
Ball mill liners
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ALLOYS FOR FEED HEAD LINERS AND
FIRST CHAMBER SHELL LINERS
Vega Alloy Vegaline-107 Vegaline-125Vegaline-112
Hardness (HRC) 49-52 54-5648-52
C % 0.2-0.5 2.2-2.61.0-1.5
Cr % 6-9 22-2611-14
Wear resistance Moderate ExcellentGood
Impact resistance Excellent ModerateGood
Products
Ball mill liners
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Choice of design of liners depends on mill operating
parameters such as :
- Mill Dia
- Speed Of Rotation Hardness - Material To be Ground Feed Size
- Volume Load Composition - Max. Ball Dia
- The Length Of The Chamber
FIRST CHAMBER LINER -
FEATURES
Products
Ball mill liners
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Sketch Feature and ApplicationProfile
Step liners-
Differentprofiles like
smooth or
wavy
working face
and high lift
depending onthe operating
conditions
Continuous and sufficient lifting action.
-Standard application where some amount of
fine generation is expected in the crushing
zone also.
-For hard feed materials
-For mills showing high wear of internals due
to slippage phenomenon.
Double wave
Liner-Crushing efficiency remains constant
throughout its working life. The dead zone
is minimum.
When the material to crush is extremely hard
and high lifting action is required
FIRST CHAMBER LINER –
VARIOUS PROFILES
Products
Ball mill liners
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Doublestep
Liner
Crushing efficiency remains constant
almost throughout its working life.
When high lifting action is required but
the mill has high speed of rotation
Sketch Feature and ApplicationProfile
Products
Ball mill linersFIRST CHAMBER LINER –
VARIOUS PROFILES
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Unit weight of individual liner is restricted to 25 kgs.
Ease of handling
Modular design for fitment in wide range of mill sizes
Supply of liners at reduced delivery time
VEGALITE LINERS
Products
Ball mill liners
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VEGALITE LINERS FOR
MILL DIA. 4.0 TO 4.4 M
Products
Ball mill liners
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FIRST CHAMBER LINERS -
BENEFITS OF DOUBLE WAVE LINERS
Reduces the slippage of balls
Reduction in the SPC of the first chamber.
The grooving phenomenon is much less
More lift results in better crushing efficiency.
The dead zone is reduced.
Due to uniform wear, the lifting action is consistent
throughout the life time
Boltless design benefits in elimination of breakage,
falling of liners, more uniform metallurgy etc.
Products
Ball mill liners
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ADVANTAGE OF DOUBLE
WAVE LINERS
Dead zone
Mill equipped with S&W Liner
Dead zone is
minimized
Mill equipped with DWL Liner
Products
Ball mill liners
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WEAR PROFILE OF DOUBLE WAVE
LINER - LAKSHMI CEMENT
CM#1: 4000 dia. X 15050 L
Date of Installation : 26.05.1996
Date of Removal : 19.07.2001Running hours : 31,000 hrs.
Material ground : 2,945,000 Mt
Weight
(KG.)
Lifting
height
(MM)
% of
Weight
% of
Lifting
height
Worn-out
liner37.63 51.7 53% 72.8%
Worn-outportion
32.55 19.3 47% 27.2%
Original
liner70.18 71 100% 100%
Products
Ball mill liners
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QUICK RESPONSE : AN EXAMPLE
Products
Ball mill liners
6th February 2004 unloaded at port Odessa for mill 1.
23rd February 2004 unloaded at port Odessa for mill 2.
Committed delivery
16th October 2003Date of receipt of
order
15th September 2003Date of submission of
techno – commercial
offer
27th August 2003Date of receipt of
enquiry
Complete mill internals (AIAE design) with grinding
media and water spray system.
Product
Kryvy Rih Cement (Heidelburger Zement), UkraineCustomer
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100
LEVEL CONTROL DIAPHRAGM -FUNCTION
To keep the material level in the 1st
chamber at an optimum level.
The material entering the diaphragm
chamber through the slotted grates
exits into the second chamber only
through the rotating cylindrical lifters.
Product
Partition diaphragm
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LEVEL CONTROL DIAPHRAGM –
CYLINDRICAL LIFTERS
These lifters can be easily adjusted by turning them on their axis.
Q (Lifter output/mill through put) = S (Effective c/s area) x h (Effective
material height in the lifter)
= constant
Product
Partition diaphragm
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ALLOYS FOR WEARING PARTS OF
LEVELCONTROL DIAPHRGM
Vega Alloy Vegaline-107 Vegaline-125Vegaline-112
Hardness (HRC) 49-52 54-5648-52
C % 0.2-0.5 2.2-2.61.0-1.5
Cr % 6-9 22-2611-14
Wear resistance Moderate ExcellentGood
Impact resistance Excellent ModerateGood
Product
Partition diaphragm
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Product
Ball mill liners
111
Sketch Feature and ApplicationProfile
Standard
Classifying
Liner
A very high level of attrition
leading to maximum
grinding efficiency.
Standard application for 2nd
chamber of ball mills where
highest level of grinding
efficiency is required.
Deep Wave
Classifying
Liner
Improved wear resistance by
reducing the ball slippage.
When a coarse final product is
desired and some amount of
crushing is also needed in the
2nd chamber.
Products
Ball mill linersSECOND CHAMBER LINER -
VARIOUS PROFILES
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Conveying
Classifying
Liner
Improved material transport in the
mill alongwith the normal
classification function.
When a high volume loading is required
which in turn leads to problem of
material flowability due to higher level
of restriction by the balls.
Lifting
Classifying
Liner
High air volumes can be utilized in the
circuit since possibility of changing to
mono chamber configuration.
Usually for applications where it
becomes necessary to have both crushing
and grinding in the same chamber.
Thin
Classifying
Liners
For mills requiring a very high
volume loading to absorb maximum
available power.
Sketch Feature and ApplicationProfile
SECOND CHAMBER LINER -
VARIOUS PROFILES
Products
Ball mill liners
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Vega alloy. Vegaline-212
1.5-2.0 2.2-2.6
ALLOYS FOR SECOND CHAMBER
SHELL LINERS
C %
11-14 22-26Cr %
Good ExcellentWear resistance
55-57 59-61Hardness (HRC)
Vegaline-225
Products
Ball mill liners
Both the grades are suitable only for non-lifting liners and ball charge with
<60 mm dia balls.
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Free passage of material from
chamber to the mill outlet
Ensure maximum opening
area for optimum ventilation
Prevent escape of small size
grinding media from the mill
Product
Discharge diaphragm
OUTLET DIAPHRAGM - FUNCTION
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AIAE outlet diaphragm has important features like peripheral
ring bolted to the shell ensuring perfect sitting of the frame
and overlapping grate plates to prevent leakage of materials.
The design is adapted for any type of shell drilling pattern and
sizing of parts is such that they can be easily carried inside
the mill through manhole also.
Product
Discharge diaphragm
OUTLET DIAPHRAGM -
FEATURES
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ANTI-CHOKING GRATES
Product
Discharge diaphragm
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ACC TIKARIA – CM#1
Breakage observed in CM# 3 internals supplied by competition.
No breakage in CM#1 internals designed and supplied by AIAE in suitable
metallurgy.
Designing &
retrofitting
AIAE internals Competition internals
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LAFARGE SEATTLE FM#2,USADesigning &
retrofitting
After AIAE designed internals were installed, significant
reduction in power was noticed.
37.45 KWh/T40.75 KWh/TSpecific Power consumption
10.4 % Saving in Specific power
40 tph40 tphOutput
1497 KW1613 KWAbsorb power
ClassifyingDragpeb2nd chamber liner
4.0 mDiameter
AfterBeforeMill no.
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LAFARGE ARASMETA CM#1, INDIA
16.9%Superiority in Production
21.8% Saving in Specific power
76 tph65 tphOutput
32003000Blaine (OPC)
2644 KW2756 KWAbsorb power
ClassifyingDragpeb2nd chamber liner
LCDCombidanIntermediate dph.
Block typeBlock type1st chamber liner
16.54RPM
10.93mLength
4.0mDiameter
AfterBeforeMill no.
Designing &
retrofitting
Initial design was by FLS. After detailed study,we decided to change
chamber lengths, partition wall diaphragm and second chamber liners.
These steps resulted in significent improvement in performance.
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LIFE GUARANTEES
Products
Ball mill liners
Description of parts and a lloys Guarantee Expected
life
Head liner Vegaline125
Head liner Vegaline112
Grates for LCD – Vegaline 107
Back plate for LCD – Vegaline 112
Discharge grates – Vegaline 112
1st Ch. lifting liner Vega line 112
1st Ch. lifting liner Vegaline 125
1st Ch. Double wave liner- Vegaline 107
2nd Ch. Classifying liner - Vegaline 212
20,000 h
15,000 h
12,000 h
25,000 h
30,000 h
25,000 h
30,000 h
25,000 h
50,000 h
25,000 h
20,000 h
18,000 h
30,000 h
35,000 h
30,000 h
40,000 h
30,000 h
60,000 h
The table below gives guarantees for OPC grinding at 3600 Blaine.
OPC at 4500 Blaine, less 15%.
PSC with 3600 Blaine less 25%.PSC with 4500 Blaine less 40%
Dry lime stone with <1% SiO2 add 30%
Dry lime stone with 6% SiO2, less 40% as per above.
The above figures of guarantees of liners are for guidance only.
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LIFE GUARANTEES
Products
Ball mill liners
The actual wear rates are governed by various factors such as :
Hardness of clinker and its grindability.
Moisture in the additives.
Type of circuit (Roller press/ Separator/Pregrinder/Precrusher)
Maximum ball size.
Volume loading.
Material level.
Condition of liners.
Type of diaphragm etc.
Products
Vertical mill parts
AIA/VEGA TODAY
30000 tons of wear parts for vertical mills used.
400 mills retrofitted with improved performance
More than 2000 inserted rolls used
Products
Vertical mill parts
MANUFACTURING CAPACITY –
MAXIMUM WEIGHT PER PIECE
Inserted rollers – 12 MT
Conventional (monometal) rollers – 16.5 MT
Table liners – 10 MT
ALLOYS FOR TABLE LINERS AND ROLLS
3563 RC263.2Vegaline V26
Composite of high chrome iron and nonmetallic
refractory oxides.
Sintercast-11
3064 RC163.0Vegaline V16
2760 RC202.6Vegaline V20
% carbidesHardnessCr%C%Specification
Products
Vertical mill parts
QUALITY PLAN FOR PROCESS
CONTROL OF VERTICAL MILL PARTS
Products
Vertical mill parts
Each castingGaugesDimensionsFettling
Each batchRockwell hardness
tester
HardnessAnnealing
RandomMould hardness testerMould hardnessMoulding
Each castingMeasuring
instruments
DimensionsFirst machining
Continuous data
logging
Data logging on
computer
Time/Temperature
correspondence
Heat treatment
Each castingVisual inspectionPhysical defectsMould knock out
Each mouldCore setting gaugesCorrectness of
cores
Moulding
1 sample per dayTransverse strengthSand qualityMoulding
Each heatOptical spectrometerLM compositionMelting
Each heatImmersion pyrometerLM temperatureMelting
Frequency of checkTesting procedureProperty checkedStage of manufacturing
Products
Vertical mill parts
Each setAssemblyFitment for tablesFinal inspection
Each castingUTInternal soundnessFinal inspection
Each castingBlue matching gaugesCorrectness of
angle for rolls
Final inspection
Each castingVisual/DPPhysical defectsFinal inspection
Each castingPaintingSurface protectionFinal inspection
Each casting Measuring
instruments
DimensionsFinal machining
Each castingRockwell hardness
tester/Sigmameter
Hardness/RAQuenching
Frequency of checkTesting procedureProperty checkedStage of manufacturing
QUALITY PLAN FOR PROCESS
CONTROL OF VERTICAL MILL PARTS
Vasavadatta Cement
Gujarat Ambuja
Neer Shree Cement
RMK 23
Vasavadatta CementRMK 21/30
Krupp PolysiusRMK 17
CustomerMill type
SUPPLIES OF POLYSIUS
COAL MILL PARTS
JP Rewa CementRMK 25/12
Aditya Cement
Vikram Cement
RMK 2713
Product
Polysius mill parts
Krupp PolysiusRM43
India CementsRM43
India CementsRM39
Gujarat Ambuja EasternRM51
India CementsRM46
Gujarat Ambuja
Gajambuja Cement
India Cements
RM41
CustomerMill type
SUPPLIES OF POLYSIUS
RAW MILL PARTS
Product
Polysius mill parts
INSPECTION PRACTICE FOR
POLYSIUS TABLES
Product
Polysius mill parts
After machining, the tables are set on an inspection table.
Reference diameters are marked. The gap between two
segments is noted. The mating surfaces are numbered.
AIAE supply inserted rolls for Polysius Coal mills. The rolls have
composite construction. Hard high chromium iron inserts are
embedded on ductile iron. Such construction provides optimum
combination of wear resistance and safety against breakage.
POLYSIUS INSERTED ROLLS
Product
Inserted Grinding roll
Sr. No OA No. PlantLocation
(State)Mill ID Roller Specification
1 6233 Neer Shree Cement Rajasthan RMK 23 X B 17 10
2 6249 Vikram Super Cement Madhya Pradesh RMK 27/13 X B 17 10
3 6240 Vasavadatta Cement Karnataka RMK 23 X B 17 10
4 6995 JP Rewa Madhya Pradesh RMK 25 X B 17 10
5 6791 Aditya Cement Rajasthan RMK 27/30 X B 17 10
6 6239 Vasavadatta Cement Karnataka RMK 21 X B 17 10
7 7116 Vasavadatta Cement Karnataka RMK 23 X B 27 10
POLYSIUS COAL MILLS EQUIPPED
WITH INSERTED ROLLERS
Product
Inserted Grinding roll
6
12-
2
3
5
5
3
4
No. of sets
supplied (tables)
1Siam CityAtox-45
3GARL, Fuller KCP
GCCL, Binani
Atox-40
2Shree CementAtox-37.5
7L & T Awarpur, L & T
Hirmi
Prism Cement, Siam
Cement
Atox-27.5
7GARL, Binani,CCGLAtox-22.5
3Madras CementAtox-20
7DCC, Shree CementAtox-17.5
No. of sets
supplied (rolls)
CustomersMill
Designation
Product
Atox mill parts
SUPPLIES OF ATOX MILL PARTS
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LIST OF LOESCHE MILL INTERNALS
SUPPLIED BY AIAE
Product
Loesche mill parts
Aso Kanda,LM18/20
India
India
Thailand
India
India
Philippines
India
India
Thailand
India
Country
Maihar CementLM26/30D
JP Rewa, JP Bela,GACLD, TISCO
LM26/30
Siam CementLM25/20
Rajashree CementLM24/23
Rassi CementLM24/20
Alson CementLM21/20D
Fuller, Negeri
Simbilen
LM21/20
Lafarge ArasmetaLM20/15
Vikram CementLM19/20
Siam CementLM18/20
NCCL, KCPLM17/20
CustomerMill designation
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LIST OF LOESCHE MILL INTERNALS
SUPPLIED BY AIAE
Product
Loesche mill parts
IndonesiaPadang CementLM38/40
Thailand
India
India
India
India
India
India
Malaysia
Country
Siam CityLM38/41
Maihar CementLM38/40
Lafarge ArasmetaLM36/41
DCC Sikka, NarmadaLM36/40
Lakshmi CementLM34/40
Saurashtra, Vikram
Manikgarh Cements
LM32/40
Orissa, Madras,
Dalmia Cements
LM30/31
APMC KanthanLM30/30
CustomerMill designation
SINTERCAST 11 WEAR RESISTANT PARTS
For grinding material with high abrasivity we recommend
Sintercast-11 parts.
Sintercast-11 parts are a composite product involving hard
refractory oxides mixed with high chrome irons.
Sintercast-11 has proved a very effective in extending life of
wear parts.
Products
Sintercast-11
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SINTERCAST-11 ROLL IN ATOX 27.5 MILL
Products
Sintercast-11
Photographs after 700 RH. Sintercast parts are expected to to give
double the life of conventional high chrome parts.
PERFORMANCE OF SINTERCAST 11
WEAR PARTS IN ATOX 27.5 COAL MILL
Products
Sintercast-11
>6000 (expected)2500Life
4.313.5 *Table wear rate (g/t)
1139 *Table average wear (mm)
2.56.0 *Roll wear rate (g/t)
8.524.0 *Roll average wear (mm)
7600086000*Production (tons)
10321181Running hours
AIAE Sintercast-11 rollAIAE conventional rollParameters
Plant : L & T Hirmi (India)
* Parameters at 1181 running hours
SR.
NOPROPERTIES
NI HARD
ROLLS
HIGH CHROME
INSERTED
ROLLS
SINTER CAST
GRINDING ROLLS
1 HARDNESS 56 Rc 60 – 64 RcHigh wear resistant due
to hard ceramics
2CHEMICAL
COMPOSITION
C : 3.2 % ,
Cr:2.5 % ,
Ni:4.0 %
C: 3.0 % ,
Cr:15.25 %
C:2.5 - 3.5 % ,
Cr: 18 - 27 % ,
& Ceramic Grains
impregnated with metal
3AVERAGE LIFE WITH > 35 % ash COAL
2000 - 2500 Hrs 5000 - 6000 Hrs 10000 - 12000 Hrs
4WEAR RATE
WITH > 35 % ash COAL
22 - 24 mm
per 1000 Hrs
10 - 12 mm
per 1000 Hrs
5 - 6 mm
per 1000 Hrs
5GRINDING ELEMENTS
LIFE
> Two times than
NI Hard rolls
> Four times than NI
Hard rolls
6 GRINDING ABILITYReduced due to
slippage of rolls
Consistent and
better due to
serrations on rolls
consistent and best due
to Honey-comb type
structure on rolls
7 COLLAR FORMATION High Negligible Negligible
8 MILL THROUGHPUT Reduced with Life Consistent Consistent
9RING ROLLER SETTING
WITH > 35 % ash COAL Twice in a month Once in a Month Once in a Month
COMPARISON OF PROPERTIES
COMPARISON OF INSERTED ROLL AND SINTER
CAST GRINDING ROLLS
12E
44D
56C
66B
45A
Running Hrs: 6627
Wear depth in mm
Roller
no: J2
Measuring Point
7E
11D
21C
23B
12A
Running Hrs: 6627
Wear depth in mm
Roller
no: J1
Measuring
point
Plant : GEB WANAKBORI
HAMMERS FOR CRUSHERS
DIPPING TUBES