Mill Shell Lining

1. Mill shell lining
Headquarters/Germany Foundry/Austria
Christian Pfeiffer Christian Pfeiffer
Maschinenfabrik GmbH Maschinenfabrik GmbH
Sudhoferweg 110-112 Werkstraße 5
59269 Beckum 8940 Liezen
Germany Austria
Tel. +49 (0) 25 21/8 49-00 Tel. +43 (0)3612/270-0
Fax +49 (0) 25 21/8 49-123 Fax +43 (0)3612/270-589
office@christianpfeiffer.de office@cpb.at
www.christianpfeiffer.de www.christianpfeiffer.de
Italy South America
Christian Pfeiffer Christian Pfeiffer
Mezzomerico SpA Latinoamericana S.A.
Via Marano Ticino 7 Parque Industrial Liviano
28040 Mezzomerico (NO) Av. Brasil Calle # 1
Italy Santa Cruz, Bolivia
Tel. +39 (03 21) 92 3010 Tel. +591 (3) 34 81768
Fax +39 (03 21) 92 3141 Fax +591 (3) 34 92 597
info@christianpfeiffer.it christianpfeiffer@unete.com
www.christianpfeiffer.it www.christianpfeiffer.de
USA Konzept und Gestaltung Kulms & Halbur/CPR Lippstadt · D-Vo. / 2,1-00-engl. / 2.04
American Pfeiffer Corporation
3407 West Chester Pike
Newtown Square, PA 19073-4227
USA
Tel. +1 (610) 35 66 995
Fax +1 (610) 35 68 987
cpb@americanpfeiffer.com
www.americanpfeiffer.com

2. principle
Principle of the mill
High energy input for the
comminution process
Cement, which is used as The grinding process
a basis for numerous con- usually takes place in ball
struction activities, is an or tube mills which, due
attractive raw material to their simple principle,
that can be manufac- are widespread through-
tured almost uniformly out the world and require
through-out the world. only low maintenance
efforts.
Although the extraction
of raw materials – lime- The rotary movement of
stone, clay and aggrega- the mill shell causes the
tes – is still relatively grinding media (cast steel
simple and inexpensive, balls) to rise, fall or roll
the various stages of pro- onto the material to be
duction in the cement ground with high impact
works require a high- or pressure energy and
energy input. Particularly thus performs the com-
in the various grinding minution.
processes – the genera-
tion of raw meal prior to
the burning process and
grinding of the cement
clinker - requires around
20 million kWh power
consumption per year for
a medium-sized pro-
duction line. This amounts
to around 60 % of the
energy input of a pro-
duction line.
Mill

3. Safe and simple:
Ball mills
Conventional
design Every year around 1.4
Mill shell lining
billion tons of cement
clinker are ground, 90 %
Lining systems of which is ground in ball
for tube mills mills. This size reduction
Direction of rotation process requires approx.
Tube or ball mills are Wave profile 8 % of the entire world’s
horizontal shells in which energy requirement.
charged balls of varying
sizes “smash“ the material The principle of the ball
passing through by im- Modified shape mill is simple; reliability
pact energy. improves the effi- and availability of the
ciency of the mill systems guarantee high
The mill shell is fitted operating reliability. Ball
with an inner lining to Christian Pfeiffer is not Progressive mills have proven their
lifter
protect the mill cylinder: only the manufacturer of worth in nearly all cement
A lining consisting of the lining systems, but production lines of the
highly wear resistant sec- also applies to the pro- world.
tional plates serves as cedural flows in the grind-
protection against wear. ing unit. Our know-how Lifting effect and
puts us in a position to slippage of the ball charge
Besides the protection of positively influence the
the mill diaphragm, the grinding process due to
lining also has the task of the modified shape of the Consistent grinding efficiency
improving the lifting and segments and thus im- throughout the operation
flow of the balls due to prove the efficiency of a
the particular shape of grinding system while In comprehensive test material to be ground.
the individual plates. minimising wear. series, CPB has optimised The shape of the lifter is
the shaping of the pro- retained through-out its
Different heights and the gressive lifter to such service life; therefore the
layout of the individual an extent that the ball grinding efficiency
wear plates ensure the charge ensures optimum remains consistent during
correct distribution of the comminution of the the entire service life.
trail of balls and reduce
the relative movement
between the balls and the
lining. CPB-Design: Constant height of lifter
through-out the entire service life
Conventional design: Decreasing hub height
from the first operating hour onwards
Mill shell lining

4. Fastening systems Compact Lining plates for
all mill systems
The lining of the mill
cylinder is subject to a
high level of abrasion
under the harsh condi-
tions of everyday opera-
tion.
As a specialist in linings
for ball mills, CPB can
offer any fastening
system required. All li-
nings are tailor made to
the requirements of your
mill.
The fastening systems
described below are stan-
dard:
A bolted fastening
requires a drill hole in the
mill cylinder for each
plate. The system is easy
to operate and can
be installed without the Boltless fastening sys- lining plates. It enables
assistance of CPB spe- tems also include the standard format plates We have developed a
cialists. system developed by CPB (DIN dimension) to be number of proprietary
that is known as Compact used and thus increases enhancements, in parti-
Lining. The lining plates the cost-effectiveness of cular for semi-bolted
With a semi-bolted are held on a guide rail the mill. fastening, as it unites
the most advantages in
Systems
fastening option, at least that is bolted to the mill Compact lining has pro-
two rows of plates are cylinder. ven its worth in practice everyday operation:
bolted. Special tools are Particularly where the and is being used in an - high degree of
needed for installation; in position of the drilled increasing number of installation safety,
this case it is recommend- holes of the mill cylinder mills. - quick replacement
of plates,
ed to have CPB staff to are inconsistent, Compact
- short down-time during
supervise the installation Lining is an alternative overhaul.
of the system. option for fastening the
With the boltless option,
lining plates are forced-
fitted with positive
locking without any bolts.
Installation calls for pre-
cise preparation and
should only be carried out
with assistance from CPB
specialists.

5. Stages of production
Stages of Secure data
for investment
decisions
CPB linings are
used successfully
through-out the
world
With know-how based on
many years of experience
in grinding technology,
our designers are con-
stantly working on the
Christian Pfeiffer will
further development and
always provide you with
improvement of mill li-
secure output data for
nings. To date, more than
your investment decisions
2000 mills throughout
since we determine all
the world have been fit-
necessary parameters for
ted with our lining sys-
the successful operation
tems.
of your grinding system in
semi-industrial tests.
Precise plates thanks
to a unique casting process In addition, our Rese-
arch and Development
At CPB, the lining of the plate, different At CPB, the plates are team applies itself to the
systems are made from materials containing up cast using the shell mould new and further improve-
cast steel. Depending on to 26 % chrome are used. casting procedure. This ment of machines, com-
the particular application casting method is ideal ponents and procedures.
through-out the world The extent of our experts’
for manufacturing wear Quality as a success in this field has
resistant systems for tube requirement already often been proven
mills. It allows adherence for international over the past few dec-
to very small manufactur- success ades, and the results of
ing tolerances and sup- their efforts have often
plies precise, dimension- To meet the require- become milestones in the
ally stable cast material ments of our international development of modern
products. customers, our quality grinding systems.
assurance system has been
Qualified toolmakers certified since 1994.
and mould designers pro-
duce precise models from We constantly monitor
steel and thus create the and log all stages of pro-
basis for the mass pro- duction, from the material
duction of the castings. charge through manufac-
CNC processing centre for model construction ture to dispatch of the
goods.

6. We have many
Replacement advantages to
offer in addition
to our products
Replacement and service
One advantage is our
comprehensive service.
Successful start after overhaul of mill Quick availability
When the new lining continually operated with The mill is then filled with Systematic evaluations
in the event of a
system has been installed, material. To examine the grinding media up to the and many years of prac- plate breakage
the mill must be opti- grinding progress, the mill optimum operating tical experience on the Metal in the feed mate-
mised. Optimisation is is subjected to an emer- charge for the normal part of our engineers rial, operation of the mill
carried out step-by-step gency shutdown and operation of the mill. guarantee that every mill without material feed or
in accordance with the sample of materials are can be adjusted to meet with insufficient material
recommendations of our taken from along the mill For optimisation it is customer requirements. may result in plate break-
specialists. axis. A grinding diagram also necessary to consider age.
The mill is first charged can now be created on the influencing parame-
with 80 % of the calcula- the basis of the particle ters of the entire grinding With the semi-bolted or To avoid long downtimes,
ted grinding media and size distribution analysis. system. boltless fastening options, we have developed a spe-
breaks may result in fail- cial repair kit. With the
ure of the lining system, use of this kit, individual
From individual recom-
for this reason this dam- damaged plates can be
mendations, detailed
age must be repaired replaced without difficul-
planning, up to reliable
immediately. ty.
installations. Even after-
wards, we are there for
The Christian Pfeiffer
you if questions arise, or
installation team or the
if you require anything,
company’s own mainte-
and naturally for main-
nance engineers can
tenance and inspection.
replace the plates.
Specific surface
Residue mass -% acc. to Blaine [cm2/g] If you would like to
service
have more information
about our products and
services. Call us. It will be
a pleasure for us to
assist you.
Distributionparticle size by fractions fractions
Distribution of of particle size by