Superior Performance Through Innovative Technology

IhrAnsprechpartner in sterreich:

Cement Products
Tube Mill Parts:
Grinding Media Ball Mill Liners Partition Diaphragm Discharge Diaphragm

Vertical Mill Parts:

Grinding Elements incl. Monometal/Inserted/Sintercast-11

Crusher Parts
Blow Bars Hammers

Preheater Parts
Dipping Tubes

Introduction

PRODUCTS FOR CEMENT INDUSTRY RANGE & CAPACITIES

Products High chrome grinding media Mill liners VSM parts static casting Centrifugally cast rolls Blow bars & hammers Heat resistant castings Diaphragms Annual cap. M.T. 40000* 5500 1800 3000 700 300 50 Nos. Range 12 mm to 110 mm dia, 1.8 to 5.8 M dia.mills Up to 16.5 MT single piece Raymond/CE mills Up to 1 MT single piece Dipping tubes 1.8 to 5.8 M dia.mills
10

*GM ca pa city pro posed to go upto 55000 MT PA in I ndia a nd 45000 MT PA in Ca nada

29

Grinding Media
First Chamber
Vegatough 18 - Standard Grade
Hardness >60 RC, RC Range <1%, RA <6% Outperforms Competition by Ave 10% Batch Check of Quenched Properties Allows Fine Tuning of Tempering All Media is Batch Tempered with 18000mt Capacity/Annum

VegaPlus - High Performance Grade

Hardness >63.5 RC, RC Range <1%, RA <5% 40-70% Improvement in Wear Rates High Carbide Content Multiple Tempering Cycles to Achieve Optimum RC & RA

Product Grinding media

VEGA PLUS

C Cr. Other alloying elements Hardness RA

Vegatough-18 2.3% Avg. 17% Avg. 2.0% Max > 59.5 RC < 6%

Vegaplus 2.9% Avg 21% Avg 4.0% Max > 63.5 RC < 5%

47

Pro duct Grind ing m edia

VEGAPLUS MANUFACTURING SPECIALISATION

Manufacturing of Vegaplus requires special facilities. This grade has very high carbide content and hence special precautions are required during cooling of poured moulds. In order to get optimum combination of hardness and RA, this grade requires multiple stress relieving/tempering cycles which drastically reduces production capacity. Thanks to special slow mould cooling techniques and large tempering capacity available at AIAE - it is possible to produce this material commercially.
48

Product Grinding media

VEGAPLUS COMPARISON WITH VEGATOUGH 18

Plant (India) Mill diameter Liner profile Produc t Blaine Vega tough 18 consumption rate Materia l ground Vega plus consumption rate

GACL Kodinar J P Re wa Durgapur Cement

4.4 m 4.8 m 3.4 m

DWL Step liner DWL

OPC PPC ( 20% fly ash) PSC (50% slag)

3340 3200 3500

27.48gms/t 92.76gms/t 105.00gms/t

699396 655748 49257

5.97gms/t 44.48gms/t 52.33gms/t

Additional feature of Vegaplus is that at the end of the trial there was no deshaping/ tear which is observed in norm al grind ing media. This m eans that there is no need of regrading every year and mill can perf orm consistently for long duration.
46

Grinding Media
Second Chamber
Vegahard 12 Standard Grade
High level of Physical Integrity Through Rigorous Process Control Non-Automated Quality Inspections No Breakages or Mismatch Higher Hardness and Cr Content Excellent Wear & Good Corrosion Resistance Highly corrosion resistant grade

Vegahard 15 High Performance Grade

Vegahard 18

Product Grinding media

GRINDING MEDIA FOR SECOND CHAMBER

Vega alloy Hardness (HRC) Cr% Wear resistance Vegahard-12 64-68 10-13 Good Vegahard-15 66-69 14-16 Excellent Vegahard-19 62-66 17-20 Moderate

50

Product Grinding media

WEAR RATE OF GRINDING MEDIA

Wear rate figures given below are expected wear rate for Vegatough-18 & Vegahard-12, for both the chambers taken together. Normally, both the chambers contribute equally to the wear rate
Material OPC OPC PPC (25% fly ash) PSC (55% slag) PPC (25% fly ash) PSC (55% slag) PSC (70% slag) Limestone (<1% SiO2) Limestone (6% SiO2) Limestone (10% SiO2) Coal (15% ash) Coal (>25% ash) Fineness (Bl) 3000 4500 3800 3800 4500 4500 4500 17% R/90 Microns 17%R/90 Microns Range of wear rate gm/T 30-50 60-100 80-160 120-160 160-190 160-190 120-210 20-25 75-100 190-220 60-100 120-150
58

PROBLEMS ENCOUNTERED WITH GRINDING MEDIA DURING SERVICE

Product Grinding media

Selecting the correct grinding media for a particular application is important to avoid potential problems, such as: High wear rate Deshaping Spalling Breakage

These problems can usually be traced to either quality of balls or peculiar working conditions.

53

59

Design conc ept

THE GOLDEN TRIANGLE

There has to be total compatibility between application, metallurgy and design.

24

Product Ball mill liners

71

Products Ball mill liners

ALLOYS FOR FEED HEAD LINERS AND FIRST CHAMBER SHELL LINERS
Vega Alloy Hardness (HRC) C% Cr % Wear resistance Impact resistance Vegaline-107 49-52 0.2-0.5 6-9 Moderate Excellent Vegaline-112 48-52 1.0-1.5 11-14 Good Good Vegaline-125 54-56 2.2-2.6 22-26 Excellent Moderate

75

Products Ball mill liners

FIRST CHAMBER LINER FEATURES

Choice of design of liners depends on mill operating parameters such as : Mill Dia Speed Of Rotation Material To be Ground Volume Load Max. Ball Dia The Length Of The Chamber Hardness Feed Size Composition

77

FIRST CHAMBER LINER VARIOUS PROFILES

Profile Step linersDifferent profiles like smooth or wavy working face and high lift depending on the operating conditions Feature and Application Continuous and sufficient lifting action. -Standard application where some amount of fine generation is expected in the crushing zone also. -For hard feed materials -For mills showing high wear of internals due to slippage phenomenon.

Products Ball mill liners

Sketch

Double wave Crushing efficiency remains constant Linerthroughout its working life. The dead zone is minimum. When the material to crush is extremely hard and high lifting action is required
78

FIRST CHAMBER LINER VARIOUS PROFILES

Profile Feature and Application

Products Ball mill liners

Sketch

Doublestep Liner

Crushing efficiency remains constant almost throughout its working life. When high lifting action is required but the mill has high speed of rotation

79

Products Ball mill liners

VEGALITE LINERS
Unit weight of individual liner is restricted to 25 kgs. Ease of handling Modular design for fitment in wide range of mill sizes Supply of liners at reduced delivery time

82

Products Ball mill liners

VEGALITE LINERS FOR MILL DIA. 4.0 TO 4.4 M

84

Products Ball mill liners

FIRST CHAMBER LINERS BENEFITS OF DOUBLE WAVE LINERS

Reduces the slippage of balls Reduction in the SPC of the first chamber. The grooving phenomenon is much less More lift results in better crushing efficiency. The dead zone is reduced. Due to uniform wear, the lifting action is consistent throughout the life time Boltless design benefits in elimination of breakage, falling of liners, more uniform metallurgy etc.
86

Products Ball mill liners

ADVANTAGE OF DOUBLE WAVE LINERS

Mill equipped with DWL Liner Dead zone Mill equipped with S&W Liner

Dead zone is minimized

87

WEAR PROFILE OF DOUBLE WAVE LINER - LAKSHMI CEMENT

CM#1: 4000 dia. X 15050 L Date of Installation : 26.05.1996 Date of Removal : 19.07.2001 Running hours : 31,000 hrs. Material ground : 2,945,000 Mt
Weight (KG.)
Worn-out liner

Products Ball mill liners

Lifting height (MM ) 51.7

% of Weight 53%

% of Lifting height 72.8%

37.63

Worn-out portion

32.55

19.3

47%

27.2%

Original liner

70.18

71

100%

100% 91

Products Ball mill liners

QUICK RESPONSE : AN EXAMPLE

Customer Product Date of receipt of enquiry Date of submission of techno commercial offer Date of receipt of order Committed delivery Kryvy Rih Cement (Heidelburger Zement), Ukraine Complete mill internals (AIAE design) with grinding media and water spray system. 27th August 2003 15th September 2003

16th October 2003 6 th February 2004 unloaded at port Odessa for mill 1. 23rd February 2004 unloaded at port Odessa for mill 2.
70

99

LEVEL CONTROL DIAPHRAGM FUNCTION

Product Partition diaphragm

To keep the material level in the 1st chamber at an optimum level. The material entering the diaphragm chamber through the slotted grates exits into the second chamber only through the rotating cylindrical lifters.

100

LEVEL CONTROL DIAPHRAGM CYLINDRICAL LIFTERS

Product Partition diaphragm

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) 101 = constant

Product Partition diaphragm

ALLOYS FOR WEARING PARTS OF LEVELCONTROL DIAPHRGM

Vega Alloy Hardness (HRC) C% Cr % Wear resistance Impact resistance Vegaline-107 49-52 0.2-0.5 6-9 Moderate Excellent Vegaline-112 48-52 1.0-1.5 11-14 Good Good Vegaline-125 54-56 2.2-2.6 22-26 Excellent Moderate

109

Product Ball mill liners

71

SECOND CHAMBER LINER VARIOUS PROFILES

Profile Standard Classifying Liner Feature and Application A very high level of attrition leading to maximum grinding efficiency. Standard application for 2nd chamber of ball mills where highest level of grinding efficiency is required. Deep Wave Classifying Liner Improved wear resistance by reducing the ball slippage. When a coarse final product is desired and some amount of crushing is also needed in the 2nd chamber. Sketch

Products Ball mill liners

111

SECOND CHAMBER LINER VARIOUS PROFILES

Feature and Application Conveying Improved material transport in the alongwith the normal Classifying mill classification function. Liner When a high volume loading is required which in turn leads to problem of material flowability due to higher level of restriction by the balls. Lifting Classifying Liner
High air volumes can be utilized in the circuit since possibility of changing to mono chamber configuration. Usually for applications where it becomes necessary to have both crushing and grinding in the same chamber.

Products Ball mill liners

Profile

Sketch

Thin Classifying Liners

For mills requiring a very high volume loading to absorb maximum available power.

112

Products Ball mill liners

ALLOYS FOR SECOND CHAMBER SHELL LINERS

Vega alloy. Hardness (HRC) C% Cr % Wear resistance Vegaline-212 55-57 1.5-2.0 11-14 Good Vegaline-225 59-61 2.2-2.6 22-26 Excellent

Both the grades are suitable only for non-lifting liners and ball charge with <60 mm dia balls.

113

115

Product Discharge diaphragm

OUTLET DIAPHRAGM - FUNCTION

Free passage of material from chamber to the mill outlet Ensure maximum opening area for optimum ventilation Prevent escape of small size grinding media from the mill

116

OUTLET DIAPHRAGM FEATURES

Product Discharge diaphragm

AIAE outlet diaphragm has important features like peripheral ring bolted to the shell ensuring perfect sitting of the frame and overlapping grate plates to prevent leakage of materials. The design is adapted for any type of shell drilling pattern and sizing of parts is such that they can be easily carried inside the mill through manhole also.

117

Product Discharge diaphragm

ANTI-CHOKING GRATES

118

ACC TIKARIA CM#1

Designing & retrofitting

Breakage observed in CM# 3 internals supplied by competition. No breakage in CM#1 internals designed and supplied by AIAE in suitable metallurgy.

Competition internals

125

AIAE internals

LAFARGE SEATTLE FM#2,USA

Designing & retrofitting

After AIAE designed internals were installed, significant reduction in power was noticed.
Mill no. Diameter 2nd chamber liner Absorb power Output Specific Power consumption Saving in Specific power Before 4.0 m Dragpeb 1613 KW 40 tph 40.75 KWh/T Classifying 1497 KW 40 tph 37.45 KWh/T 10.4 % After

128

LAFARGE ARASMETA CM#1, INDIA

Designing & retrofitting

Initial design was by FLS. After detailed study,we decided to change chamber lengths, partition wall diaphragm and second chamber liners. These steps resulted in significent improvement in performance. Mill no. Diameter Length RPM 1st chamber liner Intermediate dph. 2nd chamber liner Absorb power Blaine (OPC) Output Superiority in Production Saving in Specific power Before 4.0m 10.93m 16.54 Block type Combidan Dragpeb 2756 KW 3000 65 tph Block type LCD Classifying 2644 KW 3200 76 tph 16.9% 21.8%
127

After

Products Ball mill liners

LIFE GUARANTEES
The table below gives guarantees for OPC grinding at 3600 Blaine.
Description of parts and a lloys Gua rantee Expected life

Head liner Vegaline125 Head liner Vegaline112 Grates for LCD Vegaline 107 Bac k plate for LCD Vegaline 112 Discharge grates Vegaline 112 1 st Ch. lifting liner Vega line 112 1 st Ch. lifting liner Vegaline 125 1 st Ch. Double wave line r- Vegaline 107 2 nd Ch. Classifying liner - Ve galine 212

20,000 h 15,000 h 12,000 h 25,000 h 30,000 h 25,000 h 30,000 h 25,000 h 50,000 h

25,000 h 20,000 h 18,000 h 30,000 h 35,000 h 30,000 h 40,000 h 30,000 h 60,000 h

OPC at 4500 Blaine, less 15%. PSC with 3600 Blaine less 25%. PSC with 4500 Blaine less 40% Dry lime stone with <1% SiO2 add 30% Dry lime stone with 6% SiO2, less 40% as per above. The above figures of guarantees of liners are for guidance only.

97

Products Ball mill liners

LIFE GUARANTEES
The actual wear rates are governed by various factors such as :

Hardness of clinker and its grindability. Moisture in the additives. Type of circuit (Roller press/ Separator/Pregrinder/Precrusher) Maximum ball size. Volume loading. Material level. Condition of liners. Type of diaphragm etc.

98

Products Vertical mill parts

AIA/VEGA TODAY

30000 tons of wear parts for vertical mills used. 400 mills retrofitted with improved performance More than 2000 inserted rolls used

Products Vertical mill parts

MANUFACTURING CAPACITY MAXIMUM WEIGHT PER PIECE

Inserted rollers 12 MT Conventional (monometal) rollers 16.5 MT

Table liners 10 MT

Products Vertical mill parts

ALLOYS FOR TABLE LINERS AND ROLLS

Specification Vegaline V20 C% 2.6 Cr% 20 Hardness 60 RC % carbides 27

Vegaline V16
Vegaline V26 Sintercast-11

3.0
3.2

16
26

64 RC
63 RC

30
35

Composite of high chrome iron and nonmetallic refractory oxides.

QUALITY PLAN FOR PROCESS CONTROL OF VERTICAL MILL PARTS

Stage of manufacturing Property checked Testing procedure

Products Vertical mill parts

Frequency of check

Melting
Melting Moulding Moulding Moulding Mould knock out Heat treatment Annealing Fettling First machining

LM temperature
LM composition Sand quality Mould hardness Correctness of cores Physical defects Time/Temperature correspondence Hardness Dimensions Dimensions

Immersion pyrometer
Optical spectrometer Transverse strength Mould hardness tester Core setting gauges Visual inspection Data logging on computer Rockwell hardness tester Gauges Measuring instruments

Each heat
Each heat 1 sample per day Random Each mould Each casting Continuous data logging Each batch Each casting Each casting

QUALITY PLAN FOR PROCESS CONTROL OF VERTICAL MILL PARTS

Stage of manufacturing
Quenching Final machining Final inspection Final inspection Final inspection Final inspection Final inspection

Products Vertical mill parts

Property checked
Hardness/RA Dimensions Physical defects Internal soundness Correctness of angle for rolls Fitment for tables Surface protection

Testing procedure
Rockwell hardness tester/Sigmameter Measuring instruments Visual/DP UT Blue matching gauges Assembly Painting

Frequency of check
Each casting Each casting Each casting Each casting Each casting Each set Each casting

Product Polysius mill parts

SUPPLIES OF POLYSIUS COAL MILL PARTS

Mill type Customer

RMK 17
RMK 21/30 RMK 23

Krupp Polysius
Vasavadatta Cement Vasavadatta Cement Gujarat Ambuja Neer Shree Cement JP Rewa Cement Aditya Cement Vikram Cement

RMK 25/12 RMK 2713

Product Polysius mill parts

SUPPLIES OF POLYSIUS RAW MILL PARTS

Mill type RM39 RM41 Customer India Cements Gujarat Ambuja Gajambuja Cement India Cements India Cements Krupp Polysius India Cements Gujarat Ambuja Eastern

RM43 RM43 RM46 RM51

INSPECTION PRACTICE FOR POLYSIUS TABLES

Product Polysius mill parts

After machining, the tables are set on an inspection table. Reference diameters are marked. The gap between two segments is noted. The mating surfaces are numbered.

Product Inserted Grinding roll

POLYSIUS INSERTED ROLLS

AIAE supply inserted rolls for Polysius Coal mills. The rolls have composite construction. Hard high chromium iron inserts are embedded on ductile iron. Such construction provides optimum combination of wear resistance and safety against breakage.

Product Inserted Grinding roll

POLYSIUS COAL MILLS EQUIPPED WITH INSERTED ROLLERS

Sr. No OA No. Plant Location (State)
Rajasthan

Mill ID

Roller

Specification

1 2 3 4 5 6 7

6233 6249 6240 6995 6791 6239 7116

Neer Shree Cement

RMK 23

X X X X X
X

B 17 10 B 17 10 B 17 10 B 17 10 B 17 10 B 17 10 B 27 10

Vikram Super Cement Madhya Pradesh RMK 27/13 Vasavadatta Cement JP Rewa Aditya Cement Vasavadatta Cement Vasavadatta Cement Karnataka RMK 23

Madhya Pradesh RMK 25 Rajasthan Karnataka Karnataka RMK 27/30 RMK 21 RMK 23

Product Atox mill parts

SUPPLIES OF ATOX MILL PARTS

Mill Designation Atox-17.5 Atox-20 Atox-22.5 Atox-27.5 Customers DCC, Shree Cement Madras Cement GARL, Binani,CCGL L & T Awarpur, L & T Hirmi Prism Cement, Siam Cement Shree Cement GARL, Fuller KCP GCCL, Binani Siam City No. of sets supplied (tables) 4 3 5 5 No. of sets supplied (rolls) 7 3 7 7

Atox-37.5 Atox-40 Atox-45

3 2 -

2 3 1
12

20

Product Loe sche mill parts

LIST OF LOESCHE MILL INTERNALS SUPPLIED BY AIAE

Mill designation LM17/20 LM18/20 LM18/20 LM19/20 LM20/15 LM21/20 LM21/20D LM24/20 LM24/23 LM25/20 LM26/30 LM26/30D Customer NCCL, KCP Aso Kanda, Siam Cement Vikram Cement Lafarge Arasmeta Fuller, Negeri Simbilen Alson Cement Rassi Cement Rajashree Cement Siam Cement JP Rewa, JP Bela, GACLD, TISCO Maihar Cement Philippines India India Thailand India India
23

Country India Thailand India India

Product Loe sche mill parts

LIST OF LOESCHE MILL INTERNALS SUPPLIED BY AIAE

Mill designation LM30/30 LM30/31 LM32/40 LM34/40 LM36/40 LM36/41 LM38/40 LM38/40 LM38/41 Customer APMC Kanthan Orissa, Madras, Dalmia Cements Saurashtra, Vikram Manikgarh Cements Lakshmi Cement DCC Sikka, Narmada Lafarge Arasmeta Padang Cement Maihar Cement Siam City Country Malaysia India India India India India Indonesia India Thailand

24

Products Sintercast-11

SINTERCAST 11 WEAR RESISTANT PARTS

For grinding material with high abrasivity we recommend Sintercast-11 parts.
Sintercast-11 parts are a composite product involving hard refractory oxides mixed with high chrome irons. Sintercast-11 has proved a very effective in extending life of wear parts.

Products Sinterca st-11

SINTERCAST-11 ROLL IN ATOX 27.5 MILL

Photographs after 700 RH. Sintercast parts are expected to to give double the life of conventional high chrome parts. 56

Products Sintercast-11

PERFORMANCE OF SINTERCAST 11 WEAR PARTS IN ATOX 27.5 COAL MILL

Parameters
Running hours Production (tons) Roll average wear (mm) Roll wear rate (g/t) Table average wear (mm) Table wear rate (g/t) Life

AIAE conventional roll

1181 86000* 24.0 * 6.0 * 39 * 13.5 * 2500

AIAE Sintercast-11 roll

1032 76000 8.5 2.5 11 4.3 >6000 (expected)

* Parameters at 1181 running hours

Plant : L & T Hirmi (India)

COMPARISON OF PROPERTIES
SR. NO 1 PROPERTIES NI HARD ROLLS 56 Rc C : 3.2 % , Cr:2.5 % , Ni:4.0 % 2000 - 2500 Hrs 22 - 24 mm per 1000 Hrs HIGH CHROME INSERTED ROLLS 60 64 Rc SINTER CAST GRINDING ROLLS High wear resistant due to hard ceramics C:2.5 - 3.5 % , Cr: 18 - 27 % , & Ceramic Grains impregnated with metal 10000 - 12000 Hrs 5 - 6 mm per 1000 Hrs > Four times than NI Hard rolls consistent and best due to Honey-comb type structure on rolls Negligible Consistent Once in a Month

HARDNESS

CHEMICAL COMPOSITION AVERAGE LIFE

WITH > 35 % ash COAL

C: 3.0 % , Cr:15.25 %

3 4 5 6 7 8 9

5000 - 6000 Hrs 10 - 12 mm per 1000 Hrs > Two times than NI Hard rolls Consistent and better due to serrations on rolls Negligible Consistent Once in a Month

WEAR RATE WITH > 35 % ash COAL GRINDING ELEMENTS LIFE GRINDING ABILITY COLLAR FORMATION MILL THROUGHPUT

Reduced due to slippage of rolls High Reduced with Life

RING ROLLER SETTING Twice in a month WITH > 35 % ash COAL

COMPARISON OF INSERTED ROLL AND SINTER CAST GRINDING ROLLS Plant : GEB WANAKBORI

Measuring point

Roller no: J1

Measuring Point

Roller no: J2

Wear depth in mm

Wear depth in mm Running Hrs: 6627 A B 45 66

Running Hrs: 6627

A B C D E 12 23 21 11 7

C
D E

56
44 12

HAMMERS FOR CRUSHERS

DIPPING TUBES