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various grinding mill liner wave pattern

mining industry shell liners

mining industry shell liners

Collapse All | Expand All Cement Tube Mill Internals Introduction Grinding Media Shell Liners Diaphragm Vertical Mill Parts HRCS Casting Crusher Parts Mining Introduction Tube Mill Internals Grinding Media Inlet/Outlet Head Liners Shell Liners Diaphragms Rod Mill Internals Inlet / Outlet Head Liners Shell Liners Power Introduction Tube Mill Internals Introduction Grinding media Shell liners Vertical mill parts HPMS Services Aggregate Introduction

optimising ball mill liners to maximise tonnage

optimising ball mill liners to maximise tonnage

Mill liner design is an important factor in grinding. Testing and selection of the optimum liner profile for a given set of mill operating conditions can improve mill capacity, liner life, and liner wear rate.

In testing four mill liner profiles for 13 x 12 overflow ball mills. Climax found that an improved design increased mill tonnage by 3 tons per hour while reducing finish grind by 1.7% + 100 mesh, reduced liner wear rate, and almost doubled liner life.

The shiplap design is actually an interrupted single wave with the trailing half-wave eliminated. This allows radii of valley and peak to double within a given liner width. Such designs are noted for low lift and the spinning and rolling effect they produce in grinding balls.

The excellent performance of the Climax Triple Wave liner in 9 x 8 and 9 x 9 grate discharge ball mills operating at 76% of critical speed suggested that a scaled-up version of that design might do well in 13 x 12 overflow mills too.

The new Climax Double Wave Design became standard in our 13 x 12 mills in 1967 after initial trials showed it to outgrind and out-last the old shiplap liner. Liner life increased by about 500 hours and metal wear rate was 18% less for the new Double Wave Liner.

The S-100 single wave liner produced better tonnage than previous designs, with reduced grind size, during the first third of its life. But as wave tops wore down, a profile similar to the shiplap contour developed and grinding ability diminished. Over their 18-month life, the S-100 liners produced average tonnage at required grind about equal to that produced by Climax Double Wave liners. Because of greater thickness and harder alloy they lasted longer with lower metal wear rate.

Tonnage and grind were very good during the first 8 months of operation because of the higher, more abrupt profile which gave improved ball lift. During the next 12 months, profile was nearly identical to that of the Climax Double Wave design and the liners produced comparable tonnage. During the last 3 months, this design, worn thinner than Climax liners, extended the large-volume, high-capacity period of especially improved grinding we experience when Climax Double Wave Liners are worn thin, mill volume is maximum, and the mill turns at the highest per cent of critical speed.

grinding cylpebs

grinding cylpebs

Our automatic production line for the grinding cylpebs is the unique. With stable quality, high production efficiency, high hardness, wear-resistant, the volumetric hardness of the grinding cylpebs is between 60-63HRC,the breakage is less than 0.5%. The organization of the grinding cylpebs is compact, the hardness is constant from the inner to the surface. Now has extensively used in the cement industry, the wear rate is about 30g-60g per Ton cement.

Grinding Cylpebs are made from low-alloy chilled cast iron. The molten metal leaves the furnace at approximately 1500 C and is transferred to a continuous casting machine where the selected size Cylpebs are created; by changing the moulds the full range of cylindrical media can be manufactured via one simple process. The Cylpebs are demoulded while still red hot and placed in a cooling section for several hours to relieve internal stress. Solidification takes place in seconds and is formed from the external surface inward to the centre of the media. It has been claimed that this manufacturing process contributes to the cost effectiveness of the media, by being more efficient and requiring less energy than the conventional forging method.

Because of their cylindrical geometry, Cylpebs have greater surface area and higher bulk density compared with balls of similar mass and size. Cylpebs of equal diameter and length have 14.5% greater surface area than balls of the same mass, and 9% higher bulk density than steel balls, or 12% higher than cast balls. As a result, for a given charge volume, about 25% more grinding media surface area is available for size reduction when charged with Cylpebs, but the mill would also draw more power.

grinding rolls/ table liners | shri balaji

grinding rolls/ table liners | shri balaji

SBIPL manufactures and supplies Ni-Hard grinding rollers and Bull ring segments in the below specification. The combination of Ni-Hard rolls and High Chrome table liners is still holding a significant market share as the cheaper cast iron core is easier to machine. BIPL manufactures the same through the bi-metallic technology in the below grade.

Over the years, we have studied the pattern of changing coal quality in thermal plants in India, and with it, the reducing life of mill internals, and associated difficulties. In order to overcome the same, we have after continuous R&D, developed the 3rd generation of High Performance Grinding Rolls and High Performance Bull Ring Segments. Please see below the salient features of this latest, High Performance Grinding Rolls and High Performance Bull Ring Segments HIGH PERFORMANCE GRINDING ROLLS The High Performance Grinding Rolls have hard carbide tips which are mechanically fixed to roll mould, with more than adequate strength in such a fashion that these remain in location, through out its life cycle. The Carbide tips are first separately cast with an alumina grain cake inside the tip body. These tips are then arranged in a suitable pattern to the roll mould (metallic or sand) and further bound by a parent body of SG Iron metal. The intermittent gap maintained between adjacent tips, ensure gripping of coal particles and avoid material slippage. This ensures excellent grinding efficiency throughout the life cycle of the rolls. Mechanical Properties:- They are suitably heat treated to achieve high hardness (in the range of 59-66 HRc) and offer excellent wear resistance. Photo and sketch of above HIGH PERFORMANCE BULL RING SEGMENTS The bull Ring Segment metallurgy is specially developed to give excellent physical, mechanical and metallurgical properties. It is formed by casting a similar alumina grains cake in a high chromium material. Heat treatment is done to achieve microstructure of chromium carbides in matrix of tempered martensite. Special heat treatment controls Retained Austenite below 5%, giving hardness in the range of 59-66 HRc. This allows Bull Ring Segments to be used even up to 45 mm wear without losing of grinding efficiency, maintaining consistently high mill out put and coal fineness. Salient Advantages of High Performance Grinding Rolls and High Performance Bull Ring Segments

remaining useful life prediction of grinding mill liners using an artificial neural network - sciencedirect

remaining useful life prediction of grinding mill liners using an artificial neural network - sciencedirect

Liner wear influences the grinding performance in the context of metal recovery.We estimate remaining height and life of the liners with artificial neural network.Proposed model reduce downtime so is cost effective decision making on maintenance.With applying PCA the numbers of influencing factors for wear reduce from 9 to 5.Performance of the neural network model is consistent for both seen and unseen data.

Knowing the remaining useful life of grinding mill liners would greatly facilitate maintenance decisions. Now, a mill must be stopped periodically so that the maintenance engineer can enter, measure the liners wear, and make the appropriate maintenance decision. As mill stoppage leads to heavy production losses, the main aim of this study is to develop a method which predicts the remaining useful life of the liners, without needing to stop the mill. Because of the proven ability of artificial neural networks (ANNs) to recognize complex relationships between input and output variables, as well as its adaptive and parallel information-processing structure, an ANN has been designed based on the various process parameters which influence wear of the liners. The process parameters were considered as inputs while remaining height and remaining life of the liners were outputs. The results show remarkably high degree of correlation between the input and output variables. The performance of the neural network model is very consistent for data used for training (seen) and testing (unseen).

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