ballmill egypt

ball mill grinding drives

ball mill grinding drives

Designed to deliver exceptional levels of performance and value, David Brown Santasalo ball mill drives are optimised for primary and secondary grinding applications. Extensively field tested and proven in harsh cement applications, our mill drive gearboxes cover all grinding applications up to 10 MW per drive and we have single, double and triple reduction gearing available depending on the required ratio and motor speed.

condition monitoring of ball mill with hd technologies - cbm connect

condition monitoring of ball mill with hd technologies - cbm connect

Orcem in the Netherlands manufactures a special concrete called ECO2cem. One of the advantages of ECO2cem is that during the production process less CO2 is produced, making ECO2cem a very environment-friendly product. Orcem has two production plants, one in the Netherlands and one in Ireland (Ecocem). Both plants have used the VCM system from SPM Instrument for years with the LR/HR and dBm/dBc techniques; however, Orcem and Ecocem were both very interested in the new SPM HD technology. After long discussions, both plants decided to switch from the VCM system to the newer Intellinova system and with fabulous results, which are highlighted in chapter 2. To produce ECO2cem, Orcem uses furnace slag. This slag is a waste product of a steel mill. Iron ore, calcium, and cokes are melted in a blast furnace at 1500C, producing a liquid cast iron. Due to the low density of the non-iron parts, called furnace slag, the slag floats to the surface and is used for the production of the ECO2cem consisting of mainly calcium, aluminum and silicon.

During the period from May 2014 until September 2014, a serious problem was detected well before any serious consequences occurred. Readings from the input shaft of the gearbox showed a clear bearing damage. Approximately three months before the alarm, SPM HD measurements indicated this bearing failure. After this initial bearing problem, another problem evolved on the output shaft and the decision was made to replace the complete gearbox with a renovated one. The gearbox was replaced on the 5th of June, resulting in green condition evaluation for all measuring points again. Yet another problem caught was a fan bearing that needed to be replaced because it had been damaged during installation. Since the previous online system (VCM) was replaced with the Intellinova series of online systems, the SPM HD measuring technique has proven able to measure bearing damages with exceptional prewarning times, giving the customer the opportunity to plan for repair/exchange of the defective machinery and the ability to check the quality of maintenance work done by contractors. For more information about the different cases, please refer to chapter 5.

There are many different types of mills; ball mills, rod mills, SAG (Semi-Autogenous Grinding) and autogenous mills. In a ball mill, steel or stone balls are mixed with the ore and during rotation of the drum the ore is ground, by friction and compression, into a suitable fineness for the next step in the process. The main component of all mills is a rotating drum, turning with a suitable speed, gearbox, and motor. The mill is a very important part of the milling process in the cement industry. In many cases, the entire process can be severely limited or completely stopped if the mill ceases to operate and close observation of mill equipment condition is therefore essential. An unplanned stop must be avoided at almost any cost. Many years ago, SPM Instrument installed a VCM system on the mill gearbox and motor.

Besides the gearbox, the electric motor and the support bearings of the girth wheel are equipped with shock pulse and vibration transducers. Other applications monitored are a fan and a wind sifter. In total, sixteen shock pulse transducers and eight vibration transducers are connected to an Intellinova standard system. Shock pulse transducers are installed on all bearing positions. Vibration transducers are installed on the input shaft DE (V) and output shaft NDE (H/A). RPM is measured using a proximity switch facing the motor shaft.

The first signs of bearing damage were visible around May 5th, 2014, using only the SPM HD measuring technique. The SPM HDm value was fluctuating, and when looking at the spectra, the first signs of BPFO harmonics could be seen. Later the HDm and HDc values were both increasing and a significant increase was seen from the 29th of July. The decision was made to plan for a replacement. Around September 2014, the spectrum was full of BPFO harmonics.

The decision was made to implement the newly introduced HD ENV technique. Because there was no vibration transducer on the input shaft NDE, the decision was made to install a transducer with a magnet base at that point in order to acquire extra data on the developing bearing damage. Two bands were used; Filter 3 (500Hz -10KHz) and Filter 4 (5KHz 40KHz). The transducer was installed on the 25th of September. When analyzing the spectra and time signal, there were clear signs of an inner race damage. The time signal showed a clear BPFIM signal. Below is the trend graph from the same measuring point, using the HD ENV technology.

The pictures show damage on the inner and outer raceway; however, the inner raceway is the most damaged. The outer race was not visible in the HD ENV measurements. On the other hand, the inner race damage was not visible on the SPM HD measurements. This demonstrates the added value of using complementary measuring technologies like SPM HD and HD ENV.

The first signs of bearing damage were visible around the end of June 2014, using the SPM HD measuring technique. From that date on, the BPFI trend was increasing and fluctuating. From the end of March 2015, the values elevated even further. The gearbox was replaced on June 5th and this resulted in a green evaluation for all measuring points again. The bearing was examined and the inner race damage was confirmed by the gearbox supplier.

The drive end shock pulse measuring point has been elevated since measurement started; the alarm and alert levels were already adjusted in the past. The bearings for the exhaust fan were replaced because the shock pulse spectra started showing the BS and BSFM defect frequencies from the 2nd half of 2014.

When the new bearing was installed, the HDc readings increased further, meaning lack of lubrication and therefore high load on the bearing. This normally indicates the bearing mounted incorrectly. When the spectrum was investigated, the FTF and BS frequencies were visible. The service provider who replaced the bearing was called and the decision was made to change the bearing once more. After this 2nd exchange, the overall value and the cage rate (FTF) evaluation dropped to normal values again.

The combination of vibration and SPM HD shock pulse measurement is ideal for this type of application. The shock pulse technology is very suitable for the detection of bearing damages in noisy environments like the gearbox in this case study. Vibration technology is optimal for low frequency related fault conditions like unbalance, loose gears and misalignment. Thanks to the sensitivity of the SPM system and the long pre-warning times, maintenance actions could be planned well in advance. The contribution of the condition monitoring system is evident as it was able to detect two bearing damages during the warranty period. As a result of this, the gearbox was replaced without any cost for Orcem.

7.1 Customer references Jeroen Bmer, Plant Manager at Orcem Moerdijk says: Without any doubt, SPM HD is the preferred method for condition monitoring of our rotating equipment. Mills, fans etc. are subject to demanding operating conditions and over the years we have been able to avoid countless component failures thanks to the sensitivity of the SPM HD measuring technique, which we use to monitor all our auxiliary equipment. For the extension of our production facility, to become in operation in 2017, we will use the SPM Technology.

Robbert has a mechanical engineering background. Involved in condition monitoring since 2012, Robbert holds an ISO 18436-2 CAT III certification. Robbert is mainly involved in vibration analysis reporting, customer training and support.

ball mill system with classifier for producing calcium carbonate - professional manufacturer of mineral processing plants

ball mill system with classifier for producing calcium carbonate - professional manufacturer of mineral processing plants

When it comes to grinding calcium carbonate, there are many ways with different grinding mills. However, of all these ways, ball mill combined with classifier is one of the most used way for manufacturing ground calcium carbonate powder. For paired with classifier, calcium carbonate ball mill can produce high quality ultra fine ground calcium carbonate powder with 600-2500 mesh. Ball mill for grinding calcium carbonate is well known for great production capacity. Whats more, the ball mill and classifier system for calcium carbonate can operate continuously. As for energy consumption, Daswell ball mill and classifier system has been greatly improved so that they consume less energy in operation. Ball Mill for Grinding Calcium Carbonate Ball mill grinder is usually used to grind crushed materials, such as ores, chemicals, ceramic raw material and others. This article mainly talks about ball mill for grinding calcium carbonate. Ground calcium carbonate powder is in greater demand worldwide in ...Get Free Solutions Air Classifier for Calcium Carbonate Air classifier is an industrial machine to separate materials by a combination of size, shape and density. And of course air classifier can be used to separate different materials. Usually, an air classifier can work alone, or work with grinding ...Get Free Solutions

As a grinding mill, ball mill has been used for more than a century. Currently, the ball mill technology with diameter below 5 meters has met international standard. However, when it comes to grinding calcium carbonate or quartz, there are still many misunderstandings. For example, ball mill for calcium carbonate is not suitable for making ultra fine calcium carbonate powder, and there can be great iron contamination which lower the whiteness degree, also it can be high energy consumption. In fact, with the constant effort and innovation, Daswell has solved these questions and developed cost efficiency ball mill for calcium carbonate.

Air classifier can further cut the calcium carbonate powder from ball mill to fine and ultra fine fineness. And sometimes, according to customers needs in powder fineness, there can be also more than one classifiers needed. Daswell air classifiers have different numbers of classifier wheels. And combined with calcium carbonate ball mill, air classifier for calcium carbonate is core equipment for grinding calcium carbonate plant. After grinding in the calcium carbonate ball mill, the ground calcium carbonate will be directed to classifier or more than one classifiers. In the classifier, the ground calcium carbonate will be cut into fine and ultra-fine powder, which be blown into product silo through bucket elevator. For the coarse ground calcium carbonate powder, they will be rejected and transported to ball mill for second time grinding.

If you want to produce high capacity of ultra fine ground calcium carbonate, the best suited way of producing fine calcium carbonate is to use ball mill with ultra-fine classifying system. To get desired fineness ground calcium carbonate, both the turning speed of ball mill and classifier can be adjusted. Quality equipment for calcium carbonate plant can be operated in time and guarantee the contractual capacity. The ball mill and classifier system for grinding calcium carbonate is an investment for 20 and 30 years rather than several years. Daswell will offer turnkey solutions for calcium carbonate plant according to customersrequirements. Daswell ball mill and classifier is of high quality so that they can work for a long service time. Please fill the form below to get free quotes. We will reply in 24 hours. Product Model: Your Name(required): Your Email(required): Your Tel: Your country: Your Company: Your Message(required):

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