Since its inception in 1963, the Cement division of WIL has been providing reliable and robust solutions for the cement industry both in India and abroad. We undertake complete responsibility for the design, engineering, manufacture, supply, project management and supervision of erection & commissioning of all mechanical, electrical, instrumentation, control and automation of complete cement plant equipment and clinker grinding units on EP basis.
Based on past collaborations with various reputed and proven technology providers overseas WIL offers you a single source solution for everything needed to set up a new modern, power and fuel efficient cement plant and clinker grinding units. WIL also offers custom made solutions for modernization/retrofitting of existing plant on EP basis, with in-house engineering capabilities and modern technologies.
Article published in International Cement Review Magazine February-2014, on Grinding on Time with WIL on 0.6 mtpa Clinker Grinding Unit Supplied to M/s. Reliance Cement Company Pvt. Ltd. in Butibori, Maharashtra (India)
Article published in International Cement Review Magazine August-2016, on Coal to pet Coke Grinding on 20 tph Pet Coke Grinding Vertical Roller Mill System Supplied to M/s. ACC Ltd. in Himachal Pradesh (India)
Mahesh Shinde Head(Cement) Walchandnagar Industries Ltd. Walchand House, 15/1/B-2 G.A. Kulkarni Path, Kothrud, Pune 411 038, Maharashtra, India. E-mail :[email protected] Phone : +91 (020) 30252432 Mobile: 093721 57341
Years of cement production practice shows that cement particle gradation should be distributed continuously within a certain size range. Generally speaking, the cement particles smaller than 32 m are beneficial to reduce bleeding and early strength, but as the size of particles gets smaller, although the hydration activity increases, the voidage of particles will also increase when they accumulate, the coagulation time will become longer, and the compatibility with admixture will become worse. Therefore, the proportion of cement particles smaller than 3 m is better less than 10%. Due to the particles of 10 to 24m have a significant effect on early strength, accounting for 55% to 65% of the best. As to particles larger than 64 m which only play a filling role, the smaller the number, the better. All in all, the optimal cement particle size distribution should match the particles bulk density with its hydration activity. Only when these conditions are met can we produce high-quality cement.
At present, there are a lot of enterprises whose cement production can meet the above requirements, and the quality, output, efficiency and other indicators are at the leading level in the cement industry. Customers generally highly approve of the cement they produce. After some investigations, it is found that these enterprises all adopt the ball mill of closed-circuit grinding system as cement grinding equipment. Why they choose the ball mill closed-circuit grinding system? And what are its advantages?
The open-circuit grinding system of the ball mill is shown as follows: materials (including clinker, gypsum, mixed materials, etc.) mixed according to a certain proportion will be directly stored in the steel silo as finished cement products after being ground by the ball mill.
The open-circuit grinding system has the characteristics of simple production process, less equipment, simple maintenance, small investment, etc., but it still has many insuperable shortcomings. For example, we usually choose to extend the grinding time to ensure the ground cement reaches a higher fineness, which may reduce the output and increase electricity consumption, abrasion and the temperature of cement after grinding. Whats more, it prolongs the staying time of a lot of fine powders in the ball mill, resulting in the excessive content of materials under 3m, greatly decreasing the crushing efficiency. In addition, too much fine powder will increase the amount of water needed for cement. And high cement temperature will cause gypsum dehydration, affect the comprehensive performance of cement, easily lead to the process admixture volatilization in concrete mixing.
If we properly reduce the cement fineness requirements, shorten the material grinding time is the most direct way. Then there will be an increase in production, a decrease in power consumption and abrasion, while the content of particles larger than 64 m will also increase significantly. These cement particles in concrete are very difficult to hydration, only filling role, augment the amount of clinker in cement and seriously affect the economic benefits of enterprises. Of course, even if we set a more appropriate cement fineness, it is difficult to change the current situation that the flow velocity in the open-circuit ball mill is only 1/2-1/3 of that in the closed-circuit ball mill with the same specification, which will lead to poor comprehensive performance of finished cement, low system output and unsatisfactory enterprise benefits.
The closed-circuit grinding system of the ball mill is shown as follows: materials mixed in a certain proportion will firstly enter the cement ball mill for grinding and then be sent to the powder concentrator by bucket elevator. The powder concentrator divides the materials into coarse and fine materials. Fine material is the material that reaches the fineness requirement of the finished product. They will be collected by bag filter and sent directly into the cement silo. The coarse materials should be sent back to the ball mill for regrinding.
The technological process of closed-circuit grinding system is complex and the cost of equipment, investment and maintenance are relatively high, but the distribution of cement particles which are processed by this system is reasonable so that they can prepare high-performance concrete. In addition, the closed-circuit grinding system has the characteristic of high efficiency, high output, low cement temperature, and good comprehensive benefit. Generally, the output of the closed-circuit ball mill is 15% ~ 25% higher than that of the open-circuit ball mill with the same size. However, the superiority of the closed-circuit grinding system is closely related to the comprehensive performance of the powder concentrator, the selection of ball mills technological parameters, the arrangement method of pipeline and the level of production management. As long as we carry out the project according to the law of the closed-circuit grinding process, operate carefully and strengthen management, we can ensure the production of this system to run smoothly and efficiently.
The closed-circuit grinding system is not suitable for any cement plant. On the one hand, its process is relatively complex and the number of equipment is large. On the other hand, it has strict requirements for related equipment and production management. If these basic requirements can not be met, its productive result is not as good as an open-circuit cement grinding system. The rejection of the closed-circuit grinding process by some enterprises is based on the fact that the output and quality of the system are not high due to the insufficient equipment or inadequate management so that they conclude that closed-circuit grinding process is inferior to open-circuit grinding. But the most fundamental reason is that these enterprises did not carry on the project construction according to the law of closed-circuit grinding process. Because, at present, the cement that has the best quality all comes from the closed-circuit grinding system is the best proof.
AGICO Cement is a cement equipment manufacturer with more than 20 years experience. We are the long-term partner of many large and medium-sized cement enterprises in different countries, providing cement equipment and EPC project construction. The closed-circuit grinding system ball mill for cement grinding and the matching powder concentrator and dust collector all have the characteristic of high wear resistance, smooth running and long service life.
In addition, we also provide the EPC cement project construction service. It includes cement plant design, equipment onsite installation, real-time commissioning, spare parts service, equipment maintenance and equipment operation training. High-quality equipment and efficient service make AGICO a trustworthy partner for you!
AGICO Group is an integrative enterprise group. It is a Chinese company that specialized in manufacturing and exporting cement plants and cement equipment, providing the turnkey project from project design, equipment installation and equipment commissioning to equipment maintenance.
Ashoka's cement plant unit has continued focused on objectives of product improvement and quality. In our entire turnkey cement plant equipments and machinery, we supply a complete assembly consisting of different machines and equipment, which facilitate the plant to execute efficiently and manufacture a better-quality completed product as per the international quality standards.
We are fully committed to combine our strengths with the best pricing structures. Cement plant machinery equipments used in cement plants are compact, powerful and reasonably priced that meet all applications, to give trouble free and competent performance. Unit has all the skills to commence all aspects of cement plant construction. Ashoka cement plants India are environmental friendly.
Clinker Grinding Units : - Ashoka Group supplies a cement grinding unit with each of its cement plant. Grinding units can also be supplied separately for other cement plants. We supply grinding units upto 2000 TPD plants, capable of handling all types of cement. We offer to our clients a versatile grinding unit whose heavy and rugged construction is built for continuous trouble free operation everyday. We design and manufacture rust and moisture proof grinding units.
Features: Economical, Less Power consumption, High Performance, Robust Construction and Minimum Maintenance cost. The voltage consumption, weight, model and production capacity of the Clinker Grinding Unit depends on customers specifications.
Kiln and Kiln Shells: - As a Cement kiln manufacturers we manufacture all type of process equipments including Vertical and roller Kiln and Shells - Kiln Shells is involved in the process of burning the raw mixture thereby resulting in the clinker. This clinker is then subjected to grinding to produce cement. In modern cement manufacturing plants, kiln make the most complex and expensive portion of plant as it should be operated round the clock. Hence the duratiion till which kiln is active determines the output of whole plant. Pyroprocessing is the completely unique stage of the cement industry which is dedicated to the much specialized and complex multi-disciplinary technology.
Capacity Size & Application Suitable for production capacity up to 10,000 MT per day. Size: Upto 4.5 m diameter. Application: Sponge Iron Plants, Cement Plants, Chemical & Mineral Plants, Mining Industry
Ball Mill Manufacturers: - As a leading turnkey cement plant manufacturer, we design and supply ball mills for cement industry. We expertise in heavy fabrication with largest workshops in Delhi NCR in India with all latest equipped and technologies required for cement plants for up to 3000 TPD production.
Ball Mill shell is fabricated from high quality tested plates. The mill consists, both side end bottoms (material steel casting) Girth gear, Mg. Steel liners bolted with heavy forged bolts & nuts, man holes, feed & discharge hood, torsion shaft, pinion with shaft, Pinion Bearing housing, cooling system and other machined equipments.
Application Common applications for our ball mills is grinding of clinker for cement manufacturing, mineral ores, calcium bauxites, silicates and other materials that can be ground into fines either by wet process or by dry process.
Mill Headers & Mill Ends: - The mill headers are very useful in increasing the material temperature and that too in a perfectly continuos fashion particularly in heavy duty industry. The overall size of the kiln depends on the condition at which the process is going on. Depending on the specifications of the process, the length and diameter is calculated. Kiln sections will be sized depending on the practicability of the transport and efficiency of industry.
The optimim capacity that will be compatible to ball mills is upto 5.0m diameter in shell. The size will be upto the flange diameter of 6.0 m and height is about 3.0 m. The max weight of single piece will be upto 50MT. These specifications will go well with the rod mills and ball mills.
Mill Bearings Manufacturers: - A bearing can be described as a machine element to check relative motion permitting desired motion and also reduces the friction between mobile parts. A bearing is designed to permit free linear form of movement or to execture free rotation in fixed axis.
manufacturing process of these bearings requires the usage of high-end current technology. The common form of motions that are acknowledged by the bearings are hinge motion (e.g. knee, elbow and door), spherical rotation (e.g. socket joint and ball), linear motion (e.g. drawer) and axial motion (e.g. shaft rotation).
Separators in Cement Industry: - basic function of this separators is to separate very fine sized particles from the coarse particles. During the seperation process, the seperated fine particles are collected at one end in the name of finished product whereas the coarse sized particles are further sent back to undergo the grinding process once again.
A well efficient seperator will always prevent the particles from overgrinding which on the other hand leads to wastage of energy. The separators can be classified into two types: the dynamic separators and the static separators.
Anyang General International Co., Ltd. (AGICO Group) is a ball mills supplier. Our company is mainly engaged in the development, design, manufacture, installation and commissioning of various mining and cement milling equipment and a complete set of the industrial grinding line. AGICO Group was founded in 1997, registered capital 81.34 million yuan, covers an area of 66,000 square meters, has nearly 30,000 square meters of factory buildings and more than 150 sets of various production and processing equipment.
With more than 20 years of experience in the manufacturing and research of mineral and cement milling equipment, AGICO has more than 50 technical patents. All of our ball mills, vertical roller mill, rod mill and AG/SAG mill have passed the ISO9001 international quality system certification.
The ball mill has a vital role in the cement manufacturing process. The mixed raw materials (cement raw meal) before cement production and the finished products (cement clinker) after cement manufacture need to be ground by cement ball mill. The grinding media balls in the ball mill are used in cement plant to help grind blocky or granular grindable materials produced in the cement manufacturing process, so as to achieve the effect of grinding. Vertical roller mill(VRM) and clinker grinding mill and other cement grinding mill are also very common in cement plant.
Various ball mill machines, vertical roller mills and sag mills are widely used in the mining industry. Grate ball mills and raw mills are mostly used for mineral processing in some enterprises of mining industries. Wet ball mill and rod mill are commonly used in mineral processing production line, to grind various hardness ore materials. Customers who need to grind iron ore, siderite, marble, kaolin, mica, feldspar and other ores have chosen our mineral grinding machine.
AGICO uses the latest clean coal technology to create a professional pulverized coal ball mill. Coal mill can grind pulverized coal with different fineness requirements, with high fineness and large output, which can meet the needs of large pulverized coal projects. Coal mill is often used in thermal power plant, cement plant, coal fire power plants, etc. We grind large pieces of coal into pulverized coal, which produces more energy when burned. Therefore, the rotary kilns, boilers and other kiln equipment in these large factories usually use pulverized coal as fuel.
Efficient and energy-saving ball mill, intermittent ball mill, ceramic ball mill, rod ball mill. These types of ball mills can crush materials with different attributes. It is widely used in silicate products, new building materials, refractories, fertilizers, ferrous and non-ferrous metal smelting, glass ceramics and other production industries. Vertical mill, Raymond mill, ring roller mill which divided by different grinding methods can also be used for the production of phosphor powder, nano materials, zinc oxide powder, catalyst, rare earth polishing powder and other materials.
Production capacity: 300t/d Processed material: Silver ore Input size: 25mm Equipment: Wet grate type silver ore ball mill, wet overflow type silver ore ball mill, jaw crusher, cone crusher, flotation machine, concentrator, filter press. Auxiliary equipment: Linear vibration screen, cyclone. Request A Quote Right Now Free Solution Design: [email protected] Project Description Equipment Features Beneficiation Process
Production capacity: 1500t/d Processed material: Copper ore Input size: 25mm Equipment: 98-386t/h copper ball mill, jaw crusher, cone crusher, flotation machine, concentrator, filter press. Auxiliary equipment: Linear vibration screen, cyclone. Request A Quote Right Now Free Solution Design: [email protected] Project Description Equipment Features Beneficiation Process Project Description The 1500t/d Pakistan copper mine project uses a
Production capacity: Annual output of 300,000 tons Processed material: Soft coal Input size: 25mm Equipment: 5 sets of 20tph coal ball mill Auxiliary equipment: Desulfurization, denitrification, dust removal and other devices. Request A Quote Right Now Free Solution Design: [email protected] Project Description Equipment Features Solution Advantages Project Description The project is to build a high-efficiency
Influencing Factors of Tumbling Mill Working Capacity Tumbling mill is also known as a ball mill or rod mill. They are all composed of a cylindrical cylinder lying horizontally on the bearing, and the material is ground into powder by rotating the cylinder. When we want to discuss the factors that affect the tumbling mill
The grinding mill liners are the main wearing part of the ball mill equipment. The ball mill liner replacement should in time when the lining plate is excessively worn. Therefore, the selection and design of mill liners have always been of great concern to users. Function Design of Ball Mill Liners As one of professional
As a ball mills supplier with 22 years of experience in the grinding industry, we can provide customers with types of ball mill, vertical mill, rod mill and AG/SAG mill for grinding in a variety of industries and materials.