DETAILS OF COAL PULVERISERS FOR POWER PLANTS
Types of Pulverisers
Coal pulverisers may be classified by speed, as follows:
- Low Speed
- Medium Speed
- High Speed
Low Speed
Ball and Tube Mills
A ball mill is a pulveriser that consists of a horizontal rotating cylinder,
up to three diameters in length, containing a charge of tumbling or cascading
steel balls, pebbles, or rods.
A tube mill is a revolving cylinder of up to five diameters in length
used for fine pulverization of ore, rock, and other such materials; the
material, mixed with water, is fed into the chamber from one end, and passes
out the other end as slime (slurry).
Both types of mill include liners that protect the cylindrical structure
of the mill from wear. Thus the main wear parts in these mills are the balls themselves
and the liners. The balls are simply "consumed" by the wear process
and must be re-stocked, whereas the liners must be periodically replaced. The
ball and tube mills are low-speed machines that grind the coal with steel balls
in a rotating horizontal cylinder. Due to its shape only, people call it as
Tube Mill and due to use of Grinding Balls for crushing, it is called Ball
Mill. Hence, is the name Ball Tube Mill. These Mills are also designated as BBD
4772; where, B - Broyer (Name of Inventor). B - Boulet (French word for Balls).
D - Direct firing. 47 - Diameter of shell (in Decimetre) i.e. 4.7 metres is the
shell diameter. 72 - Length of shell (in Decimetre) i.e. 7.2 metres is the length
of shell.
By the name the grinding in the ball and tube mill is produced by
rotating quantity of steel balls by their fall and lift due to rotation of
tube. The ball charge may occupy one third to half of the total internal volume
of the shell. The significant feature incorporated in the BBD mills is its
double end operation, each end catering to one elevation of a boiler. The
system facilitated entry of raw coal and outlet of pulverized fuel from same
end simultaneously. This helps in reducing the number of installations per
unit.
Mill Internals and Other Details
A ball tube mill may be described as a cylinder made of steel plate
having separate heads or trunion attached to the ends with the trunion resting
on suitable bearings for supporting the machine. The trunion are hollow to
allow for the introduction of discharge of the materials undergoing reduction
in size. The mill shell is lined with chilled iron, carbon steel, manganese
steel, high chrome liners attached to shell body with counter sunk bolts. These
liners are made in different shapes so that the counter inside surface of the
mill is suited for requirement of application.
The Shells are of three pieces. The Intermediate shell connects to the
end shells by flange joints and the total length of shell is 7.2 metres. The
liners are fastened to the inner side of mill shell (cylindrical part) to
protect the shell from the impact of steel balls. There are 600 Nos. of liners
of ten variants in each shell weighing around 60.26 MT. The original lift value
of the liners is around 55 mm and the minimum allowable lift is
20 mm.
Working Principles
Primary air in the case of Tube Mill has dual function to perform. It is
used as drying as well as transporting media and by regulating the same, the
Mill output is regulated. Governed by the pulverized fuel outlet temperature
requirement, the combination of cold air and hot air dampers are suitably regulated
to have proper primary air temperature. Apart from raising the coal temperature
inside the Mill for drying and better grinding, the same air works in tandem as
a carrying media for pulverised coal through annular space between fixed
trunion tube and rotating hot air tube on way to classifier. Coal-laden air
passing through double cone static classifiers with adjustable classifier vanes
for segregation into pulverised fuel of desired fineness and coarse particles
continues its journey towards nozzle of coal burners for combustion. Coarse
particles rejected in classifier find their way back to mill for another cycle
of grinding. In order to avoid excess sweeping of coal from Mill only, part of
the primary air, directly proportional to the boiler load demand is passed
through Mill. Further to ensure and maintain sufficient velocity of pulverized
fuel and to avoid settling in pulverised fuel pipes, an additional quantity of
primary air is fed in to mixing box on raw coal circuit. This by-pass air
tapped from the primary air duct going in to Mill makes appreciable
contribution for drying of raw coal by flash drying effect in addition to
picking up the pulverised fuel from Mill outlet for its transportation towards
classifiers. Tube mill output while responding to boiler load demand is
controlled by regulating primary air-flow. Such regulation by sweeping away of
pulverized fuel from Mill being very fast rather well comparable with oil
firing response, needs coal level to be maintained in the Mill. Mill level
control circuit sensing the decreased coal level in Mill automatically increases
the speed of raw coal feeder and vice versa. Maintaining the coal level in Mill
offers built-in-capacity cushion of pulverised fuel to take care of small
interruption in raw coal circuit. The mill is pressurized and the tightness is
ensured by plenum chambers around the rotating trunion filled with pressurized
seal air. Bleeding seal air from plenum chamber to Mill provides air cushion
between pulverized fuel in the Mill and the outside atmosphere. Inadequacy or
absence of seal air will allow escape of pulverized fuel into atmosphere
creating nuisance. On the other hand excess of seal air leaking into Mill will
affect the desired Mill outlet temperature. As such the seal air is controlled
by a local control damper by maintaining just sufficient differential pressure
for sealing of pulverized fuel.
Medium Speed
Ring and Ball Mill/Ball and Race Mill
This type of mill consists of two rings separated by a series of large
balls, like a thrust bearing.
The lower ring rotates, while the upper ring presses down on the balls via a
set of spring and adjuster assemblies, or nitrogen gas pressurised rams/loading
cylinders. The material to be pulverized is introduced into the centre or side
of the pulveriser (depending on the design). As the lower ring rotates, the
balls to orbit between the upper and lower rings, and balls roll over the bed
of coal on the lower ring. The pulverized material is carried out of the mill
by the flow of air moving through it. The size of the pulverized particles
released from the grinding section of the mill is determined by a classifier
separator - if the coal is fine enough to be picked up by the air, it is
carried through the classifier. Coarser particles return to the grinding zone
for further pulverization.
Vertical Spindle Roller Mill
Similar to the ring and ball mill, this mill uses large "tyres"
to crush the coal. These are usually found in utility plants.
Raw coal is gravity-fed through a central feed pipe to the grinding
table where it flows outwardly by centrifugal action and is ground between the
rollers and table. Hot primary air for drying and coal transport enters the wind
box plenum underneath the grinding table and flows upward through a swirl ring
having multiple sloped nozzles surrounding the grinding table. The air mixes
with and dries coal in the grinding zone and carries pulverized coal particles
upward into a classifier.
Fine pulverized coal exits the outlet section through multiple discharge
coal pipes leading to the burners, while oversized coal particles are rejected
and returned to the grinding zone for further grinding. Pyrites and extraneous
dense impurity material fall through the nozzle ring and are ploughed, by
scraper blades attached to the grinding table, into the pyrites chamber to be
removed. Mechanically, the vertical roller mill is categorized as an applied
force mill. There are three grinding roller wheel assemblies in the mill
grinding section, which are mounted on a loading frame via pivot point. The
fixed-axis roller in each roller wheel assembly rotates on a segmentally-lined
grinding table that is supported and driven by a planetary gear reducer
directly coupled to a motor. The grinding force for coal pulverization is
applied by a loading frame. This frame is connected by vertical tension rods to
three hydraulic cylinders secured to the mill foundation. All forces used in
the pulverizing process are transmitted to the foundation via the gear reducer
and loading elements. The pendulum movement of the roller wheels provides a
freedom for wheels to move in a radial direction, which results in no radial
loading against the mill housing during the pulverizing process.
Depending on the required coal fineness, there are two types of
classifier that may be selected for a vertical roller mill. The dynamic
classifier, which consists of a stationary angled inlet vane assembly
surrounding a rotating vane assembly or cage, is capable of producing micron
fine pulverized coal with a narrow particle size distribution. In addition,
adjusting the speed of the rotating cage can easily change the intensity of the
centrifugal force field in the classification zone to achieve coal fineness
control real-time to make immediate accommodation for a change in fuel or
boiler load conditions. For the applications where a micron fine pulverized coal
is not necessary, the static classifier, which consists of a cone equipped with
adjustable vanes, is an option at a lower cost since it contains no moving
parts. With adequate mill grinding capacity, a vertical mill equipped with a
static classifier is capable of producing a coal fineness less than 50 mesh up
to 99.5 percent or more and less than 200 mesh up to 80 percent or more, while
one equipped with a dynamic classifier produces coal fineness less than 100
mesh up to 100 percent and less than 200 mesh up to 95 percent or more.
In 1954, a Jet Pulveriser
was developed which operates like a Vertical Pulverizer; the coal is pulverized
by the high speed air action only; forcing/pressurizing coal against coal.
Bowl Mill
Similar to the vertical roller mill, it also uses “tyres” to crush coal.
There are two types, a deep bowl mill, and a shallow bowl mill.
High Speed
Attrition Mill
Rotor, Stationary Pegs
Beater Wheel Mill
Hammer Mill
It is used in farms for grinding grain and chaff for feed.
Demolition Pulveriser
An attachment fitted to an excavator. Commonly used in demolition work
to break up large pieces of concrete.
Posted in Blog on 22 January, 2013