Tube Mills

TUBE MLLS
IMPORTANT DATA TO DESIGN A TUBE MILL

Feed material: Environment:

Temperature [C]: Altitude [m a.s.l.]
Grain size [80% < x m]: Ambient temperature [C]
Work Index acc. Bond [kWh/t]: Tension [V]
Feed quantity [kg/h]: Design

Process: Product:
Dry / wet grinding max. temperature [C]:
Open / closed circuit Grain size [80% < x m]:
Grinding media (Al2O3, St, Cylpebs,..) Blaine valuet [cm/g]
AUTOGENE (AG) MILLS
Wet or dry grinding
Pre-grindign (coarse grinding)
Grinding media = feed material
Feed size up to approx. 400 mm
High throughputs
Sensible to feed composition

SEMI- AUTOGENE (SAG) MILLS

Wet or dry grinding
Pre-grinding (coarse grinding)
Grinding media = feed material + 4-12%
balls (ball sizes 100 - 140 mm)
Feed size up to approx. 400 mm
Higher throughputs than AG mills
Less sensible to feed composition than
AG mills
ROD TUBE MILLS

PERIPHERAL PERIPHERAL
DISCHARGE CENTRE
OVERFLOW AT THE END DISCHARGE
Wet grinding Mostly drying grinding
Pre-grinding up to 200 t/h Pre-grinding and high capacity
For coarse product with Top size in For special applications
open circuit With end discharge finer product
Regular grain distribution With central discharge coarser product
Regular grain distribution
BALL MILLS

OVERFLOW DISCHARGE DIAPHRAGM

Wet grinding
Robust and simple
In open or closed (mostly) circuit
Fine grinding (danger of over-grinding)
Filling ratio 30 - 45%
Dry or wet grinding
Discharge side more complicated than
with overflow principle
In open or closed (mostly) circuit
Danger of over-grinding not such big
Filling ratio approx. 30%
PEBBLE MILL

Dry or wet grinding

Mostly with discharge diaphragm
Fine grinding
Grinding media: - A screened fraction of mill feed
- Flint
- Porcelain balls
- Al2O3 balls
Bigger than for ball mills at same absorbed power
2- CHAMBER-BALL MILLS

Mainly to produce cement

Dry process grinding
Costly mill internals
In closed circuit
Fine grinding
Filling ratio 28 - 33%
 CONCICAL BALL MILLS

Ceramic industry
Dry or wet grinding
Overflow or discharge diaphragm
Classification of grinding media by conical mill shell
Very efficient, large comminution step possible
Only available in small up to medium sizes
CONSTRUCTION OF A MILL
1 2
1 BEARING
2 MILL SHELL 5
4
3 DRIVE
4 INLET
5 OUTLET
6 GEAR RIM LUBRICATION 7
8
7 WATER INJECTION
8 MOTORS
9 LINING
3 6 9
 1 - BEARING OF A MILL

HLG TRUNNION BEARING AS PLAIN BEARING

Hydrostatic / Hydrodynamic

HLP TRUNNION BEARING AS

SELF-ALIGNING ROLLER BEARING
Grease lubrication / Oil lubrication

GSL SLIDE SHOE BEARING

Hydrostatic / Hydrodynamic
 HLG HLP GSL
Cement mills up to Mining up to 2.000 kW Cement mills from 3,6
1.800 kW m (> 2000 kW)
Application
Mining Standard for Var. smaller mills up Sometimes also for
larger mills to approx. 800 kW mining industry

Small bearing sealings Reasonable price No cast parts

Shorter erection times No outside oil Mill is shorter

+ Better maintenance industry Simple connection PDC

accessibility Simple erection Straight diaphragms
Advantages
Maintenance-friendly (wear)
Inlet opening (air)

Cast parts Limitation of For bigger diameters

-
Mill builds longer at diameter division of tyres
same EGL Limited stability Lining beneath the
Disadvantages Drying chamber to tyres
connect
HLG HLP GSL
2 - MILL SHELL

FLANGE
with bolted mill heads for HLG or HLP

WITH WELDED MILL HEADS

with bolted bearing journal for HLG

WITH TYRES
for slide shoe bearing
 FLANGE WELDED TYRE

HLP
Application HLG GSL
HLG

Mill head can be Cheaper, as less Lower total weight of

+
dismantled mechanical mill
Light (transport) machining required Mill cheaper
Advantages Mill heads can be
produced in GGG

Erection costly Cast alloy required Limited

-
Machining High weight to manufacturing
transport possiblities
Disadvantages Mill shells not Transport weights
exchangeable
FLANGE WELDED TYRE
3 - DRIVE

CENTRAL DRIVE
via planetary gear or bevel spur gear

GEAR RIM / PINION

with one pinion or double pinion

DMGH - DRIVE
compact mill drive for high capacities
 GEAR RIM /
CENTRAL DMGH
PINION
Cement industry and Most frequently used. For big cement mills
for smaller mills > 2.200 kW
Application

No gear rim / pinion Cost-effective drive High drive capacities

+
Easy to maintain version for large tube possible
Favourable price for mills Compact construction
Advantages capacities < 90 kW

Big gears and high Maintenance Outside oil industry

-
investment cost for Grease disposal Large sealing
large mills diameter (oiltight)
Disadvantages Installation length
CENTRAL GEAR RIM/PINION DMGH
4 - INLET

INLET TUBE
mostly for wet mills

INLET CHUTE
with fresh air flap for mill ventilation

INLET SCREW
for problematic feed materials
 TUBE CHUTE SCREW
Wet grinding Dry grinding Dry grinding for heavy
for very free-flowing free-flowing products
products
Application

Favourable price Air flap for regulation Dosing

+
Simple construction of mill air supply
possible.
Advantages Access to the
grinding chamber.

Low air supply to the Not suitable for heavy Low air supply to the

-
mill free-flowing products mill
High price
Disadvantages
TUBE CHUTE SCREW
5 - OUTLET

OVERFLOW MILLS WITH/WITHOUT

SCREEN CAGE
for wet mills

DISCHARGE DIAPHRAGM OUTLET CASING

for wet and dry mills

CENTRAL DISCHARGE
for dry mills
 DISCHARGE CENTRAL
OVERFLOW
DIAPHRAGM DISCHARGE
Wet grinding Dry and wet grinding Special applications
Cement industry Double rotator
Application

Simple Higher filling ratio

+
Lifetime of the mill possible
Cost
Advantages

Limited filling ratio Lifetime

-
Lost of grinding More costly
media
Disadvantages
OVERFLOW DISCHARGE DIAP. CENTRAL
6 - GEAR RIM LUBRICATION

GREASE SPRAYING LUBRICATION

for drive systems with gear rim and pinion

OIL LUBRICATION
for drive systems with DMGH
 GREASE OIL

DMGH
Application Gear rim / pinion
Gear rim / pinion

No outside oil industry Heat removal

More simple sealings Better lubricants providing

Advantages + Investment cost

Simple lubrication system
Use of start-up and repair
(distribution)
Nearly every lubricant can be used

lubricants possible
Removal of grease Costly sealings (oiltight)

-
No heat removal Costy lubrication systems
Lubricant suppliers Investment cost
Disadvantages
GREASE OIL
7 - WATER INJECTION

into the FIRST CHAMBER

for drive systems with gear rim and pinion

into the SECOND CHAMBER VIA OUTLET

for drive systems with DMGH

into the SECOND CHAMBER VIA

INTERMEDIATE DIAPHRAGM
for drive systems with gear rim and pinion
 SECOND SECOND via
FIRST
via OUTLET INTERM. DIAP.

For very hot feed

Application material
To reduce the product temperature

Simple With the air flow

+
Favourable price

Advantages

Against the air flow Costly

-
(aggolomeration at
the nozzle)
Disadvantages
FIRST SECOND SECOND
VIA OUTLET VIA INTERM. DIAP.
8 - DRIVE MOTOR

SLIP RING MOTOR WITH STARTER

for drive systems within high power range

SQUIRREL CAGE MOTOR WITH SOFT STARTER

for drive systems within low power range

SQUIRREL CAGE MOTOR WITH FC

for drive systems within low power range incl. speed regulation

HIGH AND LOW VOLTAGE MOTORS

 SLIP RING SQUIRREL CAGE SQUIRREL
with starter with soft starter CAGE with FC
Preferred mill drive Up to 400 kW Mills with speed
in the low voltage area regulation up to 16 MW
(however, only usual
Application
for low power range)

Lower starting current Simple Speed regulation

+
(at high starting Cheap
moment)
Advantages

Wear High starting current Cost

(net requirements)

-
Starter is only protection
for the mechanism
Disadvantages

115% from price 100% price (400kW/400V) 150% from price

9 - MILL INTERNALS

STEEL LINING
for wet and dry mills

RUBBER LINING
for wet mills

CERAMIC LINING
for iron-free grinding
 STEEL RUBBER CERAMIC

Dry grinding (general)

Application Wet grinding (mining) Wet grinding Iron-free grinding
Cement grinding

Easy procurement of Lower weight No impurities by

+
spare parts Simple erection Fe&Cr
Simple erection Low wear Lower wear
Advantages No temperature Noise reduction
limitation

High weight Not applicable for Costly erection

Wear high feed quantities only suitable for

Disadvantages - Fe&Cr impurities

Rust upon standstill
of the mill
temperature
limitation to <80C
only for wet grinding
Al2O3 grinding media
or flint => large mills
with small capacity
Noise emissions
STEEL RUBBER CERAMIC
 ACCESSORIES

SERVICE
 ACCESSORIES FOR GRINDING PLANTS

LAB MILL LM0405 GRINDING MEDIA GRINDING MEDIA DOSING

SORTING MACHINE
For trial grinding For the regulated charging of
available in design Balls from 17 up to 100 mm grinding media (topping up)
C and S7 12 tons/h (depending on ball size) during the grinding proces with
high wear
SERVICE
ON
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