Ballm Sepol Mechanics

Page 1 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\bmill_sepol_mechanics.
ppt
150 WEI, 140 CD
Mechanical Training
Ball Mill + SEPOL
Krupp Polysius Corp.

Page 2 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\bmill_sepol_mechanics.ppt
150 WEI, 140 CD
• General Overview
Content:
• Mill Inlet
• Mill Discharge
• Mill Liners
• Ball Charge
• Intermediate Diaphragm
• Discharge Diaphragm
• Slide Shoe Bearings
• COMBIFLEX Drive
• Oil Supply System
• Water Spray System
• Grinding Aid System
• Inspections and Maintenance
150 WEI, 140 CD
General Overview

150 WEI, 140 CD
General overview
1 Mill cylinder
1.5 Man-hole
2 Mill head
3 Mill head liners
4.1 Mill liners chamber 1
4.2 Mill liners chamber 2
2 9 3 5 Intermediate diaphragm
6 Discharge diaphragm
7 Mill inlet
8 Mill discharge
9 Mill bearing
10 Mill drive
11 Water injection

150 WEI, 140 CD
Mill cylinder of a one-compartment tube mill

150 WEI, 140 CD
Mill Inlet

150 WEI, 140 CD
Mill inlet
7.1 Mill inlet

7.2 Inlet cone
7.3 Air socket
7.4 Guard grille
7.5 Sliding plates
7.6 Wear plates

150 WEI, 140 CD
Mill inlet

150 WEI, 140 CD
Mill inlet-chute lining

150 WEI, 140 CD
Mill Discharge

150 WEI, 140 CD
Mill discharge
8.1 Discharge housing

8.2 Outlet cone
8.3 supporting structure
8.4 Inspection door
8.5 Seal
8.6 Connecting flange for exhaust air
8.7 Product discharge

150 WEI, 140 CD
Discharge of a cement mill ( 3,6 x 11 m)

150 WEI, 140 CD
Mill Liners

150 WEI, 140 CD
Mill liners
chamber 1: chamber 2:
lifting liners classifying (segregation) liners

150 WEI, 140 CD
Classifying liners in chamber 2

150 WEI, 140 CD
Mill shell without liners

150 WEI, 140 CD
Ball Charge

150 WEI, 140 CD
Example for ball size distribution for Ball Mills in

closed circuit with a High Efficiency Separator
separator (without pregrinding)
D Ball 100 90 80 70 60 50 average ball-weight

(mm) (g/pc)
% --- 25 30 25 20 --- 1590
Chamber 2 (with SEPOL-separator)
D Ball 50 40 30 25 20 17 average ball-weight
(mm) (g/pc)
% 8 10 20 24 23 15 49

150 WEI, 140 CD
Ball charge
1. Compartment:
coarse balls
2. Compartment:
ball filling classified
because of liners

150 WEI, 140 CD
Intermediate Diaphragm

150 WEI, 140 CD
Intermediate diaphragm for tube mills

150 WEI, 140 CD
Intermediate diaphragm
5.1 Intermediate diaphragm

framework
5.2 lifter
5.3 Support
5.4 Slotted plate
5.9 Segments of filler ring

150 WEI, 140 CD
Intermediate diaphragm
5.1 Intermediate diaphragm

framework
5.2 lifter
5.3 Support
5.4 Slotted plate
5.5 Backwall plate
5.6 Cone
5.7 Clamping ring
5.8 Grid

150 WEI, 140 CD
Adjustable diaphragm for tube mills grinding dry materials
slotted plates
adjustable lifters
cone
diaphragm segment

150 WEI, 140 CD
Segments of adjustable diaphragms with lifters in different

positions

150 WEI, 140 CD
Shifting the lifter

150 WEI, 140 CD
Discharge Diaphragm

150 WEI, 140 CD
Discharge diaphragm
6.1 Discharge diaphragm

framework
6.2 Lifter
6.3 Support
6.5 Slotted plate
6.10 segments of filler ring
6.11 Insulation

150 WEI, 140 CD
Discharge diaphragm
6.1 Discharge diaphragm framework

6.3 Support
6.4 Support
6.6 End disc
6.7 Cone
6.8 Clamping ring
6.9 Grid
6.11 Insulation

150 WEI, 140 CD
POLYSIUS discharge diaphragm for ball mills

150 WEI, 140 CD
Slide Shoe Bearing

150 WEI, 140 CD
Slide shoe bearing
low pressure
lubrication

150 WEI, 140 CD
Slide shoe profile
1 Lower housing segment

6 Bearing shoe
7 Axial pivoting bearing
8 Adjusting device of the bearing shoe
9 Temperature sensor
10 Bearing seat
150 WEI, 140 CD
Slide shoe bearing
1 Lower housing segment

2 Dismounting flap
3 Oil return socket
4 Upper housing segment
5 Y-seal
6 Bearing shoe
7 Axial pivoting bearing
8 Adjusting device of the
bearing shoe
9 Temperature sensor
10 Bearing seat

150 WEI, 140 CD
Slide shoe bearing arrangement

150 WEI, 140 CD
Slide shoe bearing

17
17 Dismounting
device

150 WEI, 140 CD
Thrust (fixed) bearing for axial guide

150 WEI, 140 CD
Actual sealing design for bearing cover
• riding ring (mill shell)

• oil spray ring
• V- seal (open in 6 o´clock pos. for
discharge of oil and dust
• Y- seal with discharge holes in 6
o´clock position
• bearing cover
• additional cover with discharge
hole
• plate which prevents oil inside
contamination of concrete of
foundation cover
• concrete foundation

150 WEI, 140 CD
COMBIFLEX Drive

150 WEI, 140 CD
COMBIFLEX Drive
Finish grinding Ball mill

150 WEI, 140 CD
Structure of the Ball mill, drive side end
• bearing cover (drive end)

• slide ring
• mill inlet chute
• girth gear
• COMBIFLEX- gearbox
• slide shoe bearings
• additional cover
• additional plate

150 WEI, 140 CD
POLYSIUS Ball Mill; drive end

150 WEI, 140 CD
COMBIFLEX design (drawing)
• input shaft
• intermediate shaft (movable in

axial direction)
• output shaft
• self- aligning pinion

150 WEI, 140 CD
Self-aligning pinion
Permitted tilting: ± 10 mm

150 WEI, 140 CD
COMBIFLEX 2000
X
Krupp Polysius Corp. Z
150 WEI, 140 CD
COMBIFLEX internal gears
Input shaft
Self-aligning
pinion
Direct contact with spur gear

150 WEI, 140 CD
COMBIFLEX, view from mill side
• second stage: upper pinion
• intermediate shaft
• input shaft

150 WEI, 140 CD
COMBIFLEX; arrangement of sole plates

150 WEI, 140 CD
Oil Supply System

150 WEI, 140 CD
Oil supply system: flow sheet for fixed bearing
31 Oil reservoir
32 Level switch
33 Heating system
35 Low-pressure pump
36 Non-return valve
37 Pressure limiting valve
38 Oil filter
39 Pressure switch
40 High-pressure pump
41 Non-return valve
42 Pressure-relief valve
43 Pressure switch
50 Low-pressure pump
51 Non-return valve
52 Pressure relief valve
53 Oil filter
54 Oil cooler
55 Flow monitor
56 Pressure switch
150 WEI, 140 CD
Oil supply system: flow sheet for floating bearing
40 High pressure pump

41 Non-return valve
42 Pressure relief valve
43 Pressure switch
61 Oil reservoir
62 Level switch
70 Low pressure pump

71 Non-return valve
72 pressure relief valve
73 Oil filter
74 Oil cooler
75 Flow monitor

150 WEI, 140 CD
Water Spray System

150 WEI, 140 CD
Water spray system 1.0; 2.0 Injection lances

1.1 Protective air fan
1.2 Suction filter
1.3 Motor
1.4 Piping
1.5 Injection nozzle
2.5 Rotary connecting element
3.0 Feed-water regulator
3.1 Shut-off valve (water inlet)
3.2 Drain valve
3.3 Float switch
4 Change-over filter
5.0 Motor-pump unit
5.2 Coupling
5.3 Overflow valve
6 Contact pressure gauge
7 Drain and vent valves
8 Solenoid valve
9;12 Motorized valve for injection
lances 1.0; 2.0
10;13 Flowmeter for injection
lances 1.0; 2.0
11;14 Pressure gauge for injection
lances 1.0; 2.0
150 WEI, 140 CD
Water spray system
3.0 Feed-water regulator

3.1 Shut-off valve (water inlet)
3.2 Drain valve
4 Change-over filter
5.0 Motor-pump unit

5.1 Motor
5.2 Coupling
5.3 Overflow valve
5.4 Drain plug
6 Contact pressure gauge

7 Drain and vent valves
8 Solenoid valve
9;12 Motorized valve for injection
lances 1.0; 2.0
10;13 Flowmeter for injection
lances 1.0; 2.0
11;14 Pressure gauge for injection
lances 1.0; 2.0

150 WEI, 140 CD
Grinding Aid System

150 WEI, 140 CD
Grinding Aid System

150 WEI, 140 CD
Mechanical Training
SEPOL Separator

150 WEI, 140 CD
Content
• Operation Description
• Separator Wear and Wear Protection
• SEPOL Inlet Damper
• SEPOL Internals
• Material Feed
• SEPOL Guide Vanes
• SEPOL Rotor
• Rotor Seal
• SEPOL Supports and Bearings

150 WEI, 140 CD
Operation Description

150 WEI, 140 CD
Operation description of the Polysius separator SEPOL NSV

Motor
Material feed
Material feed housing
Disperion plate
Rotor
Guide vanes
Adjustable air
inlet louvre
Separating room
Coarse material passes

rotor not and drops into
coarse collection cone
Fineproduct passes rotor
and is transported
with the air to the
Coarse Cyclones or baghouse
material
back to mill
Tipping valve

150 WEI, 140 CD
Operation description of SEPOL separator NSV

FEED BOX
DISPERSION PLATE ROTOR BLADES

AIR GUIDE PLATE GUIDE VANE
AIR INLET DUCT
FRESH AIR OR CIRCULATING AIR
SEPARATOR FEED
SEPARATOR REJECTS
VENT AIR WITH FINES
CYCLONE
REJECT CONE

150 WEI, 140 CD
Operation description of SEPOL separator NSV without

cyclones
FEED BOX
DISPERSION PLATE ROTOR BLADES

AIR GUIDE PLATE GUIDE VANE
AIR INLET DUCT
FRESH AIR OR CIRCULATING AIR
SEPARATOR FEED
SEPARATOR REJECTS
VENT AIR WITH FINES
REJECT CONE

150 WEI, 140 CD
Polysius SEPOL separator NSV

Protection tube for drive shaft
Dispersion plate
Baffle ring
Rotor blades
Inlet spiral
Guide vanes
Wear ring for guide vane support
Wear protection for bearing

Air / Product suspension and grease lines
Discharge Bend reject cone

150 WEI, 140 CD
Separator Wear and Wear

Protection

150 WEI, 140 CD
SEPOL NSV standard wear protection

Protection tube for drive shaft: mild steel
Lining of dispersion plate: ceramic mortar
Baffle ring: mild steel
Rotor blades: mild steel

Lining circumference of inlet spiral:
AR plate
Guide vanes: AR plate
Wear ring: compound steel plate
Bearing suspension and grease lines:

Lining of air/product ceramic tube
discharge: ceramic mortar
Reject cone: completely of AR plate

150 WEI, 140 CD
Wear - influencing factors
• Process parameter: - Velocity of particles

- Angle of impact
- Material load / bulk material mass
• Wear medium: - Shape of particles

- Hardness of particles
- Grain size
• Type of wear protection: - Hardness

- Surface

150 WEI, 140 CD
Wear protection materials for SEPOL separator
• Cast basalt
• Ceramic mortar (DENSIT WEARSTOP M40, M60, M80)
• Al2O3 - ceramic (KALOCER or similar)
• Compound steel with hard facing (EURODUR)
• Wear resistant steel (CREUSABRO 4000)

150 WEI, 140 CD
SEPOL NSV high-quality wear protection type “C”

Protection tube for drive shaft: compound steel plate
Lining of dispersion plate: ceramic mortar
Baffle ring: compound steel plate
Rotor blades: compound steel plate

Lining circumference of inlet spiral:
AR plate
Guide vanes: compound steel plate
Wear ring: compound steel plate
Bearing suspension and grease lines:

Lining of air/product ceramic tube
discharge: ceramic mortar
Reject cone and lower housing:
ceramic mortar

150 WEI, 140 CD
Standard wear protection for SEPOL with cyclones

Duct work - clean gas side:
Wear protection of separator: without waer liners
See separate sheet
Collecting duct - clean gas side:

without wear liners
Cyclone ceiling:
Ceramic mortar
Air fan housing:

Cyclone cone:
AR plate
Ceramic mortar
Rotor air fan:
Hard faced compound steel
Ceramic mortar
AR plate

150 WEI, 140 CD
Precautions to reduce SEPOL wear

• Early detection of wear, repair of damaged points, countermeasures
• Avoid junction points and uneveness in the lining surface (turbulences with
consequential erosion)
• Check the distribution of the material to be separated and improve,

if required and possible
• Check the air distribution (velocities) and adjust, if required
• Measure and reduce the air flow rate to the designed air flow rate,
if required
• Check the guide vane position: the angle of aperture should be between
15 and 30º
• Check the gap of the rotor seal at regular intervals and readjust to approx.
2mm (depending on the operating temperature and the size of the machine)

150 WEI, 140 CD
SEPOL Inlet Damper

150 WEI, 140 CD
SEPOL inlet damper
Air inlet damper:

all six valves can be adjusted individually.
Air though one channel can be throttled
They are normally fully open, but can be adjusted
in case of heavy wear at rotor blades
in case of uneven air distribution
in this area
Two horizontal guide Separating air

plates divide the SEPOL’s (ambient or
upper housing into three recirculated air)
channels
SEPOL air inlet spiral

150 WEI, 140 CD
Material Feed

150 WEI, 140 CD
Material feed
Material inlet
Split feed housing
Inspection door
Conical outlet

150 WEI, 140 CD
SEPOL Internals

150 WEI, 140 CD
SEPOL internals
Rotor blades
Rotor shaft
Lower shaft bearing
Air inlet spiral
Guide vanes

150 WEI, 140 CD
SEPOL Guide Vanes

150 WEI, 140 CD
SEPOL guide vanes
5-15 º
clogging of guide vanes possible
wear at guide vanes possible
15- 30º = normal guide vane position

25º = setting recommended by Polysius
Above 40º
• vibrating of the guide vanes possible
• excessive wear at the rotor blades
• deposits of coarse material in the air inlet spiral
• oversized material might get dragged into finished product

150 WEI, 140 CD
SEPOL Rotor

150 WEI, 140 CD
SEPOL separator rotor
Rotor shaft Material feed
Guide vanes
Dispersion plate
Air inlet spiral
Rotor blades

150 WEI, 140 CD
SEPOL rotor
Parted rotor blades of compound steel plates with screwed support ring
Screwed support ring
Rotor blade fastening

Though base material
Hard facing layer,

approx. 63 HRC

150 WEI, 140 CD
Rotor Seal

150 WEI, 140 CD
Rotor seal
Rotor
Internal seal ring, Rejects

adjustable “apron”
Material discharge bend

(seal area adjusted
during erection) External labyrinth, replaceable
External seal ring, adjustable

150 WEI, 140 CD
Rotor seal with seal air
Rotor blade
Internal seal ring
Rotor seal area
External seal ring

Rejects
“apron”
Separator air and
product discharge
Seal air

150 WEI, 140 CD
Supply of seal air to the rotor seal

Rejects
“apron”
Seal air
Separator
air and
product
discharge

150 WEI, 140 CD
SEPOL Supports and Bearings

150 WEI, 140 CD
Lower SEPOL shaft and rotor bearing

Ceramic wear protection Supporting steel Tube
Spring discs
Grease lines
Notice:
To extend lifetime, rotate the ceramic
tubes early enough when wear occurs!

150 WEI, 140 CD
Lower support of guide vanes
Guide vane bearing pin Lower guide vane bearing,

segmented, adjustable
Segmented protective ring,

made of compound steel
Guide vanes tilted by 15º

150 WEI, 140 CD
Bearing and drive traverse
Drive support
Material feed
Guide vanes pins for

bearing and adjustment

150 WEI, 140 CD
Question: SEPOL internals

150 WEI, 140 CD
Maintenance and
Servicing Requirements
SEPOL Separator

150 WEI, 140 CD
Necessary regular Frequency Irregularities and Measures,

checks their causes Remarks
1. Abnormal noises and Daily (local Imbalance - Clean
vibrations checking, - due to formation - Avoid static
vibration of coating electric charge
monitoring) (by earthing)
2. Functioning of flap valves weekly - Incorrectly set - Readjust
weights
- Jamming flaps
- Defective
bearing
3. Drive unit *)
- gear unit
- oil cooler
- motor
- shrunk on disk
- coupling
*) acc. to separate machine manual or manufacturer’s instructions

150 WEI, 140 CD
Necessary regular Frequency Irregularities and Measures,

checks their causes Remarks
4. Circulating air fan *) Vibrations See Point 1
- rotor (Vibration - due to formation
monitoring) of coating
- Improper - balance the rotor
balancing
- inlet nozzle if necessary - Wear; setting - Replace wearing
not concentric part, adjust the
nozzle
5. Checking the lubrication Every 2 weeks
pipes for leakage (visual check)
6. Checking antifriction Every 2 weeks
bearings including (visual check;
labyrinth seals for temperature
sufficient supply of monitoring)
lubricants
7. Central lubrication system *)
(if existent)
8. Cracks and leaks Every 4 weeks Repair

(visual check)
*) acc. to separate machine manual or manufacturer’s instructions

150 WEI, 140 CD
Necessary regular checks Frequency Irregularities Measures,

and their causes Remarks
9. Wear Every 4 weeks Repair or refurbish
- Lining of the upper (depends on the as necessary.
section of the housing wear attrition)
- Lining of the dispersion Checking and
plate working inside the
- Lining of the rejects cone separator must only
- Lining of the feed box be done after the
- Lining of the turning unit has been
fixture on the rotor shaft disconnected from
- Lining of the cyclone the electricity
cover supply.
- Lining of the cyclones
- Lining of the distributor
housing and the piping
- Wear protection of
lubrication pipe
- Wear protection of
tension rods
- Rotor blades
- Guide vane ring and
guide vanes
- Access ring
150 WEI, 140 CD
Necessary regular checks Frequency Irregularities Measures,

and their causes Remarks
10. Bolted connections for Every 6 month
prescribed tightening torque (for the 1st
commissioning
after 100
operating hours)

150 WEI, 140 CD
Troubleshooting
SEPOL Separator

150 WEI, 140 CD
Nr. Problem Cause Measures Note
1. Finished material Feed material - Feed in fresh air before Sufficient

temperature too high too hot separator (possibly dedusting is
(danger of install fresh-air-pipe- necessary
hemihydrate formation) sockets) (system fan and
- Try increasing the mill’s system filter must
aeration be sufficiently big)
- Inject water into the mill
2. Granulometric Guide vane - set guide vanes more In steps of 5,
distribution is too flat ring is opened tangentially max 10
too far
3. Granulometric Excessive - set guide vanes more In steps of 5,
distribution is too steep tangential radial max 10
(water demand of setting of the - Throttle the circulating
cement possibly too guide vanes air fan or system fan
high) (lower the separator
efficiency)

150 WEI, 140 CD
4. Oversize grains in Ineffective - Re-adjust sealing ring

finished material sealing
between rotor
and fines
discharge
Leaky - Seal the door Suction due to
inspection door pressure
in finished difference
product outlet between finished
material pipe and
tailings cone
5. Coatings on the rotor High material - Reduce moisture
blades moisture content of material
content (e.g.
gypsum, - Additional heating
admixtures)
Static electric - Earth the separator
charge
6. High water demand of Granulometric - Adjust guide vanes Flatter curve in
the product distribution too RRS diagram
steep (see Point 3)

150 WEI, 140 CD
7. Poor distribution of the Unfavorable - Alter the inlet cone

separator feed material design of the (possibly correct the
inlet cone cone collar to suit the
flow of material)
Excessive flow - Throttle conveying air

speed of the in the feed through
separator feed
material in the
feed through
Wear on - Repair distribution plate
distribution
plate
8. Overpressure in Insufficient - Open damper before Deduster and fan
separator (dust dedusting dedusting fan wider must be adequate
formation)
Fresh air flap - Throttle fresh-air flap Deduster and fan
opened too must be adequate
wide

150 WEI, 140 CD
9. Excessive negative Damper before - Throttle dedusting air Set negative

pressure in separator dedusting fan pressure before
open too wide separator to the
point where dust
is just prevented
from emerging at
the separator
feed (1-2 mbar)
10. Unfavorable course of - Improve the process
Tromp curve (high technological
material bypass) environment (sufficient
aeration of mill etc)
Separator feed - Add grinding aid at the
material mill
contains
agglomerated
constituents
Insufficient - Install fresh air flap Take the fan
volume of capacity into
separating air account
150 WEI, 140 CD
1. Finished material Feed material - Feed in fresh air before Sufficient

temperature too high too hot separator (possibly dedusting is
(danger of install fresh-air-pipe- necessary
hemihydrate formation) sockets) (system fan and
- Try increasing the mill’s system filter must
aeration be sufficiently big)
- Inject water into the mill
2. Granulometric Guide vane - set guide vanes more In steps of 5,
distribution is too flat ring is opened tangentially max 10
too far
3. Granulometric Excessive - set guide vanes more In steps of 5,
distribution is too steep tangential radial max 10
(water demand of setting of the - Throttle the circulating
cement possibly too guide vanes air fan or system fan
high) (lower the separator
efficiency)

Ballm Sepol Mechanics

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Page 1 L:\DATA\Dept150\Polysius Presentation and Training\Polysius Training\Grinding\Ball Mill\bmill_sepol_mechanics.

Ball Mill + SEPOL

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Mill cylinder of a one-compartment tube mill

Krupp Polysius Corp.

Krupp Polysius Corp.

7.1 Mill inlet

Krupp Polysius Corp.

Krupp Polysius Corp.

Mill inlet-chute lining

Krupp Polysius Corp.

Krupp Polysius Corp.

8.1 Discharge housing

Krupp Polysius Corp.

Discharge of a cement mill ( 3,6 x 11 m)

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Classifying liners in chamber 2

Krupp Polysius Corp.

Mill shell without liners

Krupp Polysius Corp.

Krupp Polysius Corp.

Example for ball size distribution for Ball Mills in

D Ball 100 90 80 70 60 50 average ball-weight

Krupp Polysius Corp.

Krupp Polysius Corp.

Krupp Polysius Corp.

Intermediate diaphragm for tube mills

Krupp Polysius Corp.

5.1 Intermediate diaphragm

Krupp Polysius Corp.

5.1 Intermediate diaphragm

Krupp Polysius Corp.

Adjustable diaphragm for tube mills grinding dry materials

Krupp Polysius Corp.

Segments of adjustable diaphragms with lifters in different

Krupp Polysius Corp.

Shifting the lifter

Krupp Polysius Corp.

Krupp Polysius Corp.

6.1 Discharge diaphragm

Krupp Polysius Corp.

6.1 Discharge diaphragm framework

Krupp Polysius Corp.

POLYSIUS discharge diaphragm for ball mills

Krupp Polysius Corp.

Slide Shoe Bearing

Krupp Polysius Corp.

Slide shoe bearing

Krupp Polysius Corp.

Slide shoe profile

1 Lower housing segment

Slide shoe bearing

1 Lower housing segment

Krupp Polysius Corp.

Slide shoe bearing arrangement

Krupp Polysius Corp.

Slide shoe bearing

Krupp Polysius Corp.

Thrust (fixed) bearing for axial guide

Krupp Polysius Corp.