MAJOR MECHANICAL MODIFICATIONS

DONE IN RAW MATERIAL AREA-SP3

A PRESENTATION BY:

TEAM MECHANICAL-
RMA(SP-3)
 CONTENTS
1. RE-USE:
Rubber window modification – Rod Mill section

2. RE-THINK:
Linking process water and fire fighting pipelines –Lubrication Section

3. RE-ENGINEER:
Belt feeder 41 – Hammer Crusher Section
RE-USE
 Rod Mill Window
Modification

ROD MILL SECTION – RAW MATERIAL AREA, SP-3

Rod Mills
 Rod Mill: Specifications
Mill Size - 2700 (diameter) x 3800 mm (length)
Crushing capacity - 30 tph (rated) , 36 tph (designed)
Feed size - -10mm
Product size - -3mm
Material to be crushed - Coke
Bulk Density - 0.6 T/M3
Moisture Content - 5 – 12%
Mill Speed - 15.3 rpm
Rod Loading - 34% of the shell volume
Cooling requirement - 160 lph @ 2.5 kg/cm2
 Rod Mill Window Modification
The Problem:
Non Availability Of Rubber Window
Shell Plates

Rods
 Rod Mill Window Modification
The Rubber Window:
• Fixed inside the shell cavity at the discharge end of the
Rod Mill along the periphery

• Number Of Rubber Windows used : 14nos.

• Function : It cushions the impact action of the rods

against the Shell during operation

• Average Life : 8 to 12 months

 Rod Mill Window Modification
Impact On Rod Mill
Crack development and propagation in Rod
Mill Shell
 Rod Mill Window Modification

Reasons For Crack Development:

• Thinning of Shell due to wearing out action of Coke on

Shell over a long period of time

• Impact of the rods on the Shell directly due to damaged

rubber windows
 Rod Mill Window Modification
Implications :
• Close to 90 hours of maintenance for repairing shell cracks
between May and September 2014

• Close to 540 man hours worth of labour spent on repairs

• 72 packets of welding electrodes used

• Decrease in reliability of equipment

Modified Rubber Window
 Raw Material Used:
Raw Material Used:

Used Shell Plates

 Rod Mill Window Modification
The Process:
1.Drilling the Shell Plate to accommodate Counter – sunk
holes:
 Rod Mill Window Modification
2. Marking dimensions for cutting
 Rod Mill Window Modification
2. Marking dimensions for cutting
 Rod Mill Window Modification
3.Cutting the liners with the help of knife :
 Rod Mill Window Modification
4.The Finished Product
 Rod Mill Window Modification
5.Fixing the liner inside the Rod Mill
ROD MILL SHELL

COUNTER-SUNK
BOLTS
MODIFIED
RUBBER
WINDOW

REINFORCING
PLATE
DISCHARGE
WINDOW CAVITY
 Rod Mill Window Modification

Rubber Window After fixing

 Rod Mill Window Modification

Advantages
• Control over Crack development
• Control over Discharge Window Strip breakage
• Time saving in Maintenance

Shortcomings
• Limited life span
• High manpower consumption
• Limited stock of worn out Shell plates
RE-THINK
Linking fire fighting pipeline
with process water pipeline

LUBRICATION SECTION – raw material area

 Linking Pipelines..

Background

• The Hammer Crushers' Oil coolers and Rod Mills’ bearings need
process water for cooling

• This requirement is met by the Process water pumps of

Machine-1
 Linking Pipelines..

The Problem
• Repair in Process water pumps/pipeline of Pump house of Machine-
1 results in stoppage of process water to Package-2 and hence
equipment cannot function

• Resulting in shortage of crushed Coke and Flux

 Linking Pipelines….

Solution
To link the firefighting pipeline and
process water pipeline at site
 Linking Pipelines….
Pipeline Modification At Rod Mills : Overview
 Linking Pipelines….
Work done
1. Arresting water leakage in the firefighting pipeline/process
water pipeline

2. Checking /Changing of de-functional Valves in both

Firefighting and Process water pipelines in the route

3. Flushing out the rust/trash etc. of firefighting pipeline

4. Laying of Pipeline in Rod Mill and Hammer Crusher area with

the appropriate fittings
 Linking Pipelines….
Pipeline Modification at Hammer Crushers : Overview
 Linking Pipelines....
A Problem faced:

• During change-overs, process pipeline frequently got clogged

 Linking Pipelines..
In-House Fabricated Water Filter
 Linking Pipelines….

In-House Fabricated Water Filter

 Linking Pipelines..

Outcome:

• Uninterrupted supply of process water to Rod Mills and

Hammer Crushers

• Repair of process water pipelines can be carried out

without affecting operations
RE-ENGINEER
Bunker -41 belt feeder

HAMMER CRUSHER SECTION –SP-3

Hammer Crushers
Parts of a Hammer Crusher
Point Of Comparison Primary Hammer Crusher Secondary Hammer
Crusher
Equipment name Reversible Hammer Mill
Quantity 3
Capacity Rated - 250 tph , Designed - 300tph
Material to be crushed Limestone
Rotor size 1500*2300 mm
Rotor speed 700 rpm
Product size 15 mm -3 mm (90% )
Drive system Variable Speed Fluid Constant Speed Fluid
Coupling Coupling
Material of construction:

Body as per IS : 2062

Shaft EN 8/C45
Liners Mn Steel , IS : 276 Gr.4 (D)
Hammers GS 42 Cr Mn Mo V 12
 Bunker -41 belt feeder
The Problem

Frequent jamming of the vibro-feeder during monsoon

leading to :

• Frequent stoppage of flux crushing

• Wastage of manpower and effort

 Bunker -41 belt feeder
The solution
• Replacement of vibro-feeder-41 with belt feeder

• Increasing the slope of vibro-feeder body

 Bunker -41 belt feeder

Work done

• The slope of the vibro-feeder body was increased by

providing packing so that the height increased by 36mm.
 Bunker -41 belt feeder
Belt feeder 41 :work done

• It was designed to run a 1200mm belt with the capacity

of feeding 400 tons/Hr of flux material

• The belt feeder structure was pre-fabricated near the site

• The existing vibro-feeder was dismantled.

 Bunker -41 belt feeder

Belt feeder :work done

• The pre-fabricated belt feeder structure was erected.

• The gear box and motor were fitted with the belt feeder
structure

• Conveyor belt was mounted

 Bunker -41 belt feeder

Belt feeder :work done

• The mouth of the bunker-41 and The feed chute of the

Hammer Crusher were modified

• Trials were taken with load

 Bunker -41 belt feeder
Before modification
 Bunker -41 belt feeder
After modification
 Bunker -41 belt feeder

Result
• Jamming problem solved

• The modification has helped in smooth running of

Hammer crusher
 Bunker -41 belt feeder

Upcoming Project:

• Erection of Belt Feeder to remove stones seperated from

stone thrower in R-110 belt conveyor
Thank You!!