A Presentation on

MILLS

By
B.Govind Rajulu
ADE /Mills, Stage II,
Dr.NTTPS.
 PULVERISERS OR MILLS
 The most efficient way of utilising coal for steam
generation is to burn it in pulverised form
 The purpose of mills is to pulverise crushed coal
and facilitate supply to boiler in powder form at
required fineness and temperature
 ADVANTAGES OF
PULVERISATION
 Efficient utilisation of cheaper low grade coals
 Flexibility in firing with ability to meet
fluctuating loads
 Ability to design and build high unit capacity
steam generators
 Better reaction to automatic controls
 Ability to use high combustion air temps and
increasing the overall efficiency of Blr.
 High availability
 FACTORS THAT AFFECT THE
PERFORMANCE OF MILLS
 Grindability of coal
 Moisture content
 Fineness of output required
 Size of coal input
 Mill wear
CALORIFIC VALUE OF COAL
 CV of coal does not affect the performance of
mills
 Variation of CV decides the no of mills
required to be kept in service
 The CV decides the no of mills required per
Boiler and also the size of Boiler
 There are two heating values .They are HHV
or GCV and LHV or NCV.
 TYPES OF FIRING SYSTEMS
TWO TYPES OF SYSTEMS ARE
ADOPTED
 Indirect firing system(intermediate storage
bins are used)
 Direct firing system
 In direct firing system,the Primary air lifts the
pc after drying it to the required level and
transports to the Boiler through coal pipes
where it is burnt in suspension.
 TYPES OF MILLS
 The mills are classified based upon their speeds
 Slow speed mills: The mills usually rotating between
15 to 25 rpm are called slow speed mills. Eg. Ball
tube mills. These are also called Horizontal mills (at
V TPS STG II ,III)
 Medium speed mills: These will be operating at 50 to
100 rpm. Eg. Bowl mills and Ball and Race mills ( at
VTPS STAGE I,IV)
 High speed mills: These are directly coupled to the
driving motor and run at 750 to 1000 rpm . Eg
.Beater wheel mills ( at Neyveli)
 BALL MILL WORKING
PRINCIPLE

 The ball charge and coal fed into mill are

carried to a certain height and allowed to fall
 The coal is crushed due to (i)impact of the
balls on coal particles,(ii)attrition as the
particles slide over each other and also over
liners
 BALL TUBE MILL
 Ball tube mills are represented by BBD
 BBD : Boyer Ball Direct
 Types :-
 BBD 4760
 BBD 4772
 I. BBD 4760 Mill :-
 Shell dia : 4.7m
 Shell length : 6.0m
 Motor Speed : 989 Rpm
 Mill Speed : 15 Rpm
 A.E Consumption : 1 to 1.10MWH
 Mill output : 105 TPH
 Mill current : 135 to 140 Amps
 Air through mill : 120 TPH
PARTS OF BALL TUBE MILLS
 Mill Body with liners and main bearings
 Drive group consisting of main motor,aux motor,gear boxes
etc
 Conveyor body and Screw conveyor system
 Classifier system
 Mill lubricating oil system
 Girth gear lubrication system
 Girth gear seal air system
 Mill seal air system
 Mill level control system
 Ball feeding/charging system
 MILL BODY
 Mill body is fabricated with thick alloy steel plates of
thickness of 32mm
 The entire internal surface is covered with liners to
avoid erosion of body
 Grinding media of about 60 to 90 MT of sizes
30,40,50mm dia will be loaded
 The entire mill is supported on specially desighed anti
friction bearings.
 One of the bearing is free and the other is fixed.The
free bearing is designed to take care of axial and
angular displacement occurring during operation .
 HICHROME LINERS

 COMPOSITION & HARONESS

 Carbon ---------------- 2.4 --------2.8%
 Silicon ----------------- 1.0% max
 Chromium --------------- 22.0 -------- 28.0%
 Phosphorous ------------ 0.6% max
 Sulphur ----------------- 0.06% max
 Manganese -------------- 0.5 -------- 1.5%
 Nickel --------------------- 0.5% max
 Molybdenum ------------ 0.6% max
 Copper ------------------- 1.0% max
 Guaranteed Running hours : 30,000 ---------35,000 Running hours
 (Including reversal of liners)
 Liners will be reversed at half of the total guaranteed life.
 Total liners per mill : 520 no’s
 Cylindrical liners -------------------------------------------320no’s
 Cylindrical liners with Oblique wave (DE) ---------------40no’s
 Cylindrical liners with oblique wave (NDE) --------------40no’s
 Short conical liners -----------------------------------------40no’s
 Long conical liners ------------------------------------------40no’s
 Inlet side liners with boss --------------------------------- 08no’s
 without boss --------------------------------------32no’s
BALL MILL WORN OUT LINERS
BALL MILL WORNOUT LINERS
 MILL DRIVE SYSTEM
 The drive system consists of a HT Motor
(6.6kv,2100kw,980rpm) and reduction gear box,
Pinion and a Girth Gear mounted on mill body
 The mill speed with main motor is 15rpm
 The mill speed with aux motor is 0.2rpm ie. at barring
 The main reducer is provided with a separate lub.
System consisting of pump, cooler etc.
 Aux.reducer is provided to keep mill on barring,and
to rotate the mill to required position for maitenance
works
GIRTH GREASE SYSTEM
 MILL SEAL AIR SYSTEM
 The seal air system ensures tightness
between the rotating part of the mill and
the fixed part.
 The seal air is also given to
 PF shut-off gates
 Gravimetric Feeders

 Screw conveyor bearings

 MILL SEAL AIR SYSTEM AND
GIRTH GEAR SEAL AIR SYSTEM
 Mill seal air system ensures tightness between
the rotating part of the mill and the fixed part.
 This is composed of a filter, Trunnion seal air
fans ( 2 nos),seal air box etc.
 The Girth gear seal air system ensures
tightness of the protection box of the girth gear
wheel and consists of a girthgear seal air fan,
filter and girthgear housing.
 BALL FEEDING SYSTEM
 This facilitates feeding of Grinding media ie
50 mm dia. Balls into the mill online to
maintain the capacity of the mill normal by
compensating the worn out grinding media.
 HICHROME GRINDING MEDIA

 CHEMICAL COMPOSITION
 Chromium --------------- 12 To 17.5%
 Carbon ---------------- 2 To 3.5%
 Molybdenum ------------ 0.8% max
 Silicon ----------------- 0.8% max
 Manganese -------------- 0.7 To 2%
 Phosphorous ------------ 0.05% max
 Sulphur ----------------- 0.05% max
 Nickel --------------------- 1.0% max
 HARDNESS : 600 ------------- 650 BHN
 DIAMETER : 50mm,
 SHAPE : Spherical
 Wear rate formula : Net grinding media consumed for a period
 ------------------------------------------------------
 Total coal crushed during the same period
 Wear rate depends upon the quality of coal
PARAMETERS TO BE MONITORED
FOR BALL CHARGING
 i) Average energy consumption of mill should be 1.00MWH if it falls below
 1.00MWH, then ball charging is required.
 ii) Mill main motor current should be maintained between 135 to 140 amps. If
 the current falls below 135 amps, then ball charging is required.
 iii) Mill noise level should be 8-10% of its maximum noise level.
 iv) Sieve analysis of a pulverized fuel
 The sieve analysis is the measurement of finness of the pulverized fuel .
 Sieve analysis will be done under 03 different types of meshes ViZ : 52,100 &
200 mash
 Passage through 52 mesh should be > 95%
 Passage through 100 mesh should be > 85%
 Passage through 200 mesh should be > 65%
 If the sieve analysis values fall below the above said values, then ball charging
is required.


DUMPED GRINDING MEDIA
FOR SEGREGATION
DUMPED GRINDING MEDIA
FOR SEGREGATION
 BARRING IS NECESSORY
 When the mill is stopped with coal inside in
order to prevent coal gasification , burning
or formation of a thick and strong layer on
the surface.
 When mill is stopped for a very long time
(more than one month ) in order to make
sure that all the lubricated parts are covered
by oil to prevent oxidation.
 When the mill is going to be taken into
service the mill has to be kept in on barring
to ensure that it is ready for service in all
respects.
 BOWL MILL WORKING
 The Bowl mill consists of revolving Bowl and
Grinding Rolls (3 nos) and the bowl will be
rotating at 55 rpm
 The coal fed to the centre of revolving bowl is
forced between the grinding rolls and the bowl
for getting pulverised
 The coal is crushed by the impact against the
liners and by attrition
 DETAILS OF VTPS STAGE-I BOWL
MILLS
 Bowl mill XRP 783

 Bowl mills are indicated by XRP

 X : Represents for frequency
 R : Raymond’s
 P : Pressurised
 Type –I
 XRP – 783
 78 Represents dia of the Bowl i.e, 78”
 3 Represents no. of grinding rolls i.e, 3no’s
 Motor Details
 Rating : 335 KW
 Voltage : 6.6KV
 Speed : 988 RPM

Gear Ration : 1 : 18 4/5 A.E ----- 0.26 MWH
 Air Through mill : 36.0TPH Current ------- 36 Amps
 Mill out put : 55 TPH (35 TPH)
 Mill Speed : 52 RPM
 1set of bull ring segments consists of 45 pcs G. Rollers : NI- I
 ½ pc BRS : NI- IV
 ¼ pc Hardness : 550 BHN
 Life : 6months
High performance milling system

 Centrifugally casted inserted rollers -3no’s

 Life : 10,000 – 12,000Rmtrs
 Classifier vanes : 24 no’s
 Gear Bow Oil :
 Capacity : 1050 litres Temperature : 50ºC
 Type : 5 Mesh SP 320
 Life : 3 Years
 Worm wheel : 94 teeths 10 years + 10 years
 Work shaft : 5 teeths - Do -
 Roller Journal assembly :
 Oil - SP 680 - 27 litres
 Two no’s Journal bearings.
 Details of Dr.NTTPS Stage IV mills
 Bowl mill XRP – 1003
 100” is the dia of the Bowl
 3 Represents the no. of grinding rolls
 Total mills: 7no’s, In service : 5 no’s
 Motor Details;
 Ratings : 525KWH
 Voltage : 3.3KV
 Speed : 1000RPM
 Mill speed : 42RPM
 Mill output : 65TPH
 Air through mill : 1.5 to 2 times of mill output
 Gear box type : Planetary gear box
 A.E : 0.65 MWH
 Motor current : 130amps.
Bull Ring Segment Arrangement
 ADVANTAGES OF BOWL MILLS
OVER BALL MILLS
 Low power consumption  High power consumption
 Minimum maintenance  More maintenance
 Wide capacity (1.7 to 100  Wide capacity
TPH)  No rejects
 Quiet ,vibrationless  Better reaction to auto
operation controls
 Ability to handle wide range  Faster loading of boiler
of coals(HGI 35 to 100 and  More fineness and less
moisture 2 to 26%) Boiler erosion
 Coal rejects are to be  Low unburnt carbon
handled
 OPERATION AND
MAINTENANCE
 The output of pc from mills is governed by the
boiler requirements
 The mill outlet temp is to be maintained as per
design to ensure proper combustion of coal
 The airflow through the mill is to be
maintained at required to ensure proper drying
and transportation of pc to Boiler
 CONCLUSION
 The milling plant is to be kept always in trim
condition to get the full output of the Boiler
 They need careful operation, periodic
inspection, maintenance to get the full benefits.