Cemex Guadalajara

Report on existing diaprhagm & Presentation of Vega LCD

-Inspection date : 26/10/2011

Following pages will have a comparison between existing and Vega diaphragm. The template of comparison is given here Comparison

Existing diaphragm photo

Vega diaphragm photo

Text present diaphragm

Text Vega diaprhagm

Comparison 1 Material transport from 1st chamber

In present diaphragm, material transport from the gaps between wear plates which is quit often blocked by grinding media as shown in the picture.

In Vega diaphragm Proper placing of lifters and grooving on the outer grate plates make sure that there is minimum blockage and flarring.

Comparison 2 False transport from diaphragm

In present diaphragm the wear plates have flat fitting edge which can be opened in operation and act as fault transport point

In Vega diaphragm wear plates are assembled with overlapping. With this arrangement, fault transport is totally avoided.

Comparison 3 Flexibility of structure

Rigid structure Flexible structure

In present diaphragm two plates are assembled together with common structure segment. This drastically reduce the flexibility of structure which results in frequent breakage on structure and also damage the screen and hardware as well as wear plate itself.

In Vega diaphragm each wear plates is assembled on separate structure segment which does not have any physical connection with adjacent structure. This ensure sufficient flexibility on whole assembly.

Comparison 4 material transport from diaphragm

There is no control over the flow of material from first chamber to second chamber in present diaphragm. Wide opening on structure for material transport makes this diaphragm totally useless.

Vega diaphragm is supplied with unique installation of cylindrical lifter which regulates flow from first chamber to second chamber by very simple mechanism.

Comparison 5 Central screen

In present diaphragm, the central screen is with smaller opening which increases resistance of air transport. This diaphragm is not suitable for higher air velocity in the mill. For high temperature feed, part of cooling is generally done with higher air speed in the mill.

Vega diaphragm is supplied with wide central screen opening which allow efficient air flow through diaphragm. It is proven that the pressure loss with Vega diaphragm is minimum.

Comparison 6 Self cleaning of slots

In present diaphragm, the big gaps between wear plates are normally chocked with balls which further deteriorate the material transport from first chamber and also damage the structure and screen.

Vega diaphragm is supplied with grooves to continuously clean the slots while in working. This provides un-interrupted passage from first chamber to diaphragm strucutre.

Is your diaphragm made for your specific requirement ?

Think Again.

Vega Design Level Control Diaphragm

Function of diaphragm. Process advantage. Maintenance advantage. Grate plate advantage

LEVEL CONTROL DIAPHRAGM

FUNCTION

To keep the material level in the 1st chamber at an optimum level.

The material entering diaphragm chamber through slotted grates exits into second chamber only through rotating cylindrical lifters.

the the the the

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

LEVEL CONTROL DIAPHRAGM PROCESS ADVANTAGES

Optimum leading retention time of the material to optimum crushing efficiency

in 1st chamber

Possibility of using a coarse ball charge in chamber without risk of resultant lack of material

the

1st

Reduced pressure drop due to large and circular central screen Central screen design empowers it to self clean during mill operation Correct material level also conditions for the grinding media ensures ideal working

Slot size is designed as per the feed material characteristics and to ensure optimum air flow through the diaphragm

LEVEL CONTROL DIAPHRAGM MAINTENANCE ADVANTAGES

Flexible mill structure absorbs dynamic deformation of the

Ability of the frame structure pressures of the ball charge

to

withstand

axial

No leakage of material & grinding media from one chamber to another due to overlapping design No cutting/welding of he frame structure segments at the site The frame structure segments, grate plates and back plates are designed for easy handling and for minimise installation time The central screen has a door, which facilitates movement of any person from 1st chamber to the 2nd chamber. Down time is reduced for routine mill inspection as the manhole of the 2nd chamber is not required to be opened.

LEVEL CONTROL DIAPHRAGM GRATE PLATE ADVANTAGES

Best possible material flow through the diaphragm as the slots are circumferentially arranged

The original slot openings are maintained for a longer period of time as flaring of slots is avoided
No leakage of material or grinding media from one chamber to another due to overlapping design The bolt heads are protected, thus avoiding falling down of grate or back plates due to bolt failure. Moreover the number of bolts is reduced to minimum The replacement of any grate or back plate is independent of other plates or adjacent shell liners The wear pattern is considered while designing the plates

Thank you