Dimensioning Of Tube Mills Internet: Complete Guide & Downlo

Dimensioning of tube mills 2 is the second volume of the grinding dimensioning series: the advanced workbook: where the first file built the mill from the Bond power, this second file takes the dimensioning further: the internals, the media systems, the ventilation, the drive trains, the process integration and the troubleshooting: the dimensioning of the “whole machine”: the shell thickness, the trunnion bearings, the gear drive, the lubrication, the foundations, and the auxiliary systems: the file is the second module of the grinding design: the engineer of the cement office finishes the two files and owns the complete tube mill design procedure.

The Complete Cement Technical Package (931 files including the books, the courses, the Excel tools and the presentations: $249.99 one-time: instant download via the PayPal payment) includes this volume 2 with its strength calculations, the drive selection tables, the ventilation workbook and the complete worked example: the two dimensioning files belong together: the package keeps them both: the one-time price buys the whole library.

This article presents the file in its order: the mechanical dimensioning of the shell, the bearings and the drives, the ventilation, the coupling to the process, the maintenance dimensioning and the example sheets: the reader uses it together with the first volume of the series.

1. The Scope of the Second Dimensioning Volume

The first volume dimensioned the process: the power, the D and the L: the second volume dimensions the machine and its systems:

• The mechanical: the shell thickness, the heads, the trunnions, the bearings, the drive: the steel of the mill: the strength of the components under the load of the 300 tons of the charge and the rotation:
• The electrical: the motor type, the gearbox, the VSD, the auxiliary power: the kW from the first volume to the components: the starting torque, the power factor, the energy bill:
• The ventilation: the mill gas flow, the temperature, the drying, the dust collection: the air of the mill: the flow that carries the product and the heat:
• The auxiliary: the lubrication, the cooling, the hydraulic lifting, the hoisting of the media: the systems that keep the mill alive:

THE TWO-VOLUME STRUCTURE: the process dimensioning (volume 1) and the machine dimensioning (volume 2): the two must match: the process power determines the drive: the drive and the load determine the shell: the chain of the numbers continues to the foundation bolts: the file organizes the sequence so the engineer never skips a step: the “complete” dimensioning of the tube mill in the two files: this volume alone, with its tables, takes the numbers of volume 1 and renders them mechanical.

2. The Shell and the Heads: The Strength of the Drum

The tube of the mill: the steel cylinder that carries the charge and the rotation:

• The shell plates: the rolled steel: the typical 35-60 mm (the 4-5 m mills), the high quality structural: the welding of the longitudinal and the circumferential seams: the geometry: the “the drum” 2: the bend:
• The loads: the shell carries the weight of the shell, the liners and the charge (the ~300 t): the bending, the torsion, the pressure (the lifting: the gas): the dynamic (the ball impacts): the fatigue: the design stress: the factor of the safety:
• The heads and the trunnions: the end closures: the cast steel heads: the trunnions (the hollow journals) support the mill in the bearings and admit the feed and the discharge: the trunnion diameter = the feed opening: the reinforcement: the stress concentration:
• The tyres and the supports: the classical cement mills on the trunnion bearings: the modern the slide-shoe (the hydrostatic pads): the supports at the L/4 — the L/3 (the bending minimized): the design: the trunnion: the flat: the sliding: the base frames:

THE SHELL CALCULATION in the file: the bending moment of the beam on the two supports with the distributed load, the torsion of the drive, the stress check with the fatigue factors: the worksheet: the plate thickness: the standard: the 4.6 x 16 m: the shell: the 60 mm: the steel: the flanges: The mill manufacturers: the fabrication: the stress relief: the dimensional: The file: the tables of the standard shells: the “the closed”: the heads: the reinforcing rings: the roller: the lubrication: the elements: the drawing: the dimension: the complete: the engineer: the “the drum”: the supplier: the quality: the ISO: the fabrication: The documents.

3. The Bearings: The Trunnion and the Slide-Shoe Systems

The support of the mill: the bearings take the vertical load and the thrust:

• The trunnion bearings: the classic: the journal of the trunnion in the white-metal lined bearing: the oil bath/splash: the hydrostatic: the jacking: the temperature watch (the max 55-70°C): the clearance: the self-alignment:
• The slide shoes: the modern: the mill shell carries the tyres at the ends: the shoes (the hydrostatic oil pads) under the tyres: the pressure of the 300 t on the pads: the pump, the valve, the oil film: the shoe: the start/stop the low-speed:
• The thrust: the axial: the helical drive forces: the axial bearing: the thrust ring: the adjustment: the wear of the “the thrust pads”:
• The design numbers: the bearing pressure: the oil: the pump capacity: the cooling: The file: the calculations: the specific pressure (the N/mm²) and the pV: the maximum: the temp: the alarms: the lubrication: the viscosity: the selection: the filter: the tank: the safety of the bearing: the “white metal” the damage: the file: the sensor: the “start from the cold”: the jamming:

THE BEARING DESIGN: the load split (the 4 points): the total: the pressure: the oil film: the jacking: The “the mill no”: the start: The hydraulic: The “the pre”: the start: the film: the reduction: The mill: the trunnion: the pad: The modern: the shoes: the lubricant: the temperature: the “the air the filter”: The file: the lubrication systems: the diagrams: the pressure: the flow: the 3-5 bars: the high: The dimension: the bearing: the complete: the oil: the file: the annex: the tables: The “thousands”: the “the friction”: the kWh: the bearing: the file:

4. The Drive Train: The Motor, the Gearbox, the Pinion

The power of the first volume arrives at the mill through the drive chain:

• The ring gear and the pinion: the big gear (the ring) bolted at the mill shell: the pinion on the output shaft of the reducer: the gear ratio: the 4.6 m mill: the ~150 teeth vs the 20: the module: the speed: the forces: the backlash: the alignment (the critical: the gear life): the measurement: the spray lubricant:
• The gearbox: the helical/bevel reducer: the ratio: the input motor speed (the 1500/1000 rpm) to the mill (the 15-26 rpm): the center distance: the torque: the selection from the catalog of the vendors: the “the size”: the duty: the power:
• The motor: the synchronous or the asynchronous: the kW: the starting torque: the pinion: the breakaway: the 200% starting: the cycloconverter/VSD: the modern: the synchronous: the efficiency 95+: the power factor correction:
• The clutch and the coupling: the air clutch (the soft start: the inching), the torque limiting: the inching drive (the maintenance: the ball changing): The file: the train: the selection: the table: the standard: the 5,600 kW: the pinion: the 2.5 m: the gear: the 8 m: the train: the anchor: the alignment: the vibration: The drive dimensioning the design: the gear: the fatigue: the file: the formulas: the tooth: the 25 teeth: the durability: the load: the factor: the vendor: the “the standard”: the deliver: the complete:

THE DRIVE CHAIN: the selection of the components: the input: the torque, the speed, the duty: the outputs: the motor, the reducer, the pinion, the ring gear: the file: the three tables: the catalog the approach: the “the train” the quotation: the mechanical: The pinion: the hardening: the gear: the case: the file: the maintenance: the alignment: the spray: the pinion “the face”: The “the centre” the calculation: the backlash: the file: the “the pinion: the drive” the final: the torque: the file: the complete: the dimension: the module: the numbers:

5. The Ventilation of the Mill: The Air, the Heat and the Drying

The mill breathes: the gas flow through the drum: the ventilation serves the transport, the drying and the temperature:

• The air flow: the 1.0-1.5 m/s in the mill (the velocity of the gas): the volume flow: the fan: the filter: the vent flow: The flow carries the fines: the product: the “the vent” the residue: the mill dust: the blowing of the cement: The gas flow: the process:
• The drying duty: the raw mill: the hot gas (from the kiln/ the hot gas generator) dries the feed: the moisture 4-8% to the <1%: the heat balance: the required: the m³: the temperature: the file: the psychrometric: the heat: the mass: The moisture: the process:
• The temperature control: the cement mill: the gypsum dehydration: the 100-120°C limit: the ventilation takes the heat: the water injection (the atomized) cools: the temperature: the feed: the water: The clinker: the temperature: The mill: the residue: the temperature the balance:
• The collection: the mill vent to the bag filter: the dust: the vent gas: the fan: the filter: the product: the return: The air: the “the mill dust”: the cement: the returns: The bag: The “the vent” the system: the filter: the sizing: the file: the “the mill fan” the selection: the volume: the pressure: the kWh: the “the system” the curve: the operating: the file:

THE VENTILATION DIMENSIONING: the balance of the heat and the mass: the inputs: the feed, the moisture, the hot gas temperature, the heat losses: the outputs: the air volume, the fan power, the filter size, the dew point: the worksheet of the file: The example: the raw mill: the 4.6×13: the gas: the 700°C: the 12% moisture: the mix: the 320°C: the volume: the 200,000 m³/h: the fan: the filter: the dew point: the file: the tables: the humidity: The vent: the practical: the water injection: the “the calcination”: The “the drying” the raw: the file: the complete: the “the mill: the air”: the dimension: the “the cooling” the cement: the water: the inject: The file: the two cases: the raw and the cement: the air: the volume: the power: the flow: the “the discharge”:

6. The Grinding Media Systems: The Charging and the Handling

Beyond the first charge, the media life is a dimensioned system:

• The first charge: the volume of the media (volume 1), the tonnes, the delivery, the charging opening: the “the charge”: the ramps: The crane: the ball feeder: the chute: the mill rotation: the distribution:
• The make-up (the top-up): the daily/weekly additions: the measured power or the level: the ball: the size: the 90 mm: the top-up: the balls: the wear: the file: the formula: the ball consumption: the kg per ton: the schedule: The “the make-up”: the quality: the mill: the “the level”: the ball: The addition: The formula: the “the total”: the additions: the file: the “the media management” the Excel: the charge, the wear, the top-up:
• The sorting (the re-screening): the periodic: the mill emptied: the balls sorted: the worn below the limit: the fresh: the sorting interval: the 6-12 months: the cleaning: the “the media”: the mesh: the separators: The sorting: the classification:
• The media and the wear: the ball quality: the hardness: the breakage: The rejects: the broken: the removal: the “the cleaning”: the magnet: The iron: the media: The file: the tables: the ball life: the t: The “the steel” the cost: the media the process: The “the charge” the dimension:

THE MEDIA MANAGEMENT: the “the balls” the dimension: the top-up: The file: the dedicated: the Excel: the media: the inventory: the consumption: The “the ball mill”: the media: the “the level”: the power: The charge: the first: The “the dimension” of the media: The “the sorting”: the plant: The mill: the media: the cost: the kWh: The file: the “the ball” the numbers: The total: the balance: The “the media” the maintenance: the file: the “the charge” the complete: The media: the system: the file: The media: the dimension: the total: the tonnage: the ball: the “the entire”:

7. The Lubrication Systems: The Oil of the Giant

The lubrication of the mill: the oil films that carry the loads:

• The types: the gear lubrication (the spray: the viscosity the gear: the EP), the bearing oil (the hydrodynamic: the ISO VG 220-460), the pinion: the oil: The viscosity: the selection:
• The systems: the oil tank, the pumps (the main and the standby), the filters (the duplex: the change), the coolers (the water/oil: the plate), the heaters (the cold start), the return: the instrumentation: the pressure, the temperature, the level, the flow: The alarms: the trips:
• The spray gear lubrication: the ring gear: the spray nozzles: the air/oil: the intermittent: The consumption: the lubrication: the gear: the wear: The file: the “the spray” the adjustment: The gear: the flank: the spray: the pattern:
• The hydrostatic: the slide shoe: the pumps: the pressure: the film: the jacks: The “the lift”: the start: the rotation: The low speed: The file: the complete: the lube: the schematics: the P&ID: The sensors: the “the mill safe”: The “the oil” the cleanliness: the ISO codes: The filtration: the water: the emulsions: The file: the “the lube”: the dimension: the tank: the pumps: the coolers: The selection: the vendors: The file: the table: the “the duty” the load:

THE LUBRICATION DIMENSIONING: the flows: the tank: the heat: The load: The bearing: the heat: the cooler: The “the oil” the temperature: The file: the heat balance of the lube: the selection of the cooler: The “the gear” the spray: the consumption: The file: the maintenance: the filters: the analysis: The oil: the sample: the analysis: the wear: The file: the “the lubrication” the chapter: The complete: the “the mill” the oil: The “the system” the design: The file: the engineer: the P&ID: The “the lube” the components: The dimension: The file: the diagrams: The complete: the mill: the lubrication: the “the file” the answers: The bearings: the gears: The “the oil” the load: The file: the tables: the oil: the selection:

8. The Foundation and the Base Frame: The Mill Meets the Ground

The mill rests on the concrete: the foundation dimensioning:

• The loads: the static (the mill, the charge, the bearings), the dynamic (the media impacts, the gear forces, the imbalances), the seismic: The combined: the design: The foundation: The “the block”: the concrete: the rebar: The base:
• The base frames: the steel frames: the bearing pedestals: the anchor bolts: the grouting: The level: the alignment: The tolerance: The “the mill”: the torque reaction: The drive: The base: The “the fixed” the end: The expansion: The thermal: The alignment: The file:
• The vibration: the isolation: the springs: the dampers: The vibration measurements: The limits: The “the mill”: the vibration: The monitoring: The file: the alarm: the trips: The “the foundation”: the resonance: The design: the frequency: The “the mass”: The file: the calculation: the natural frequency: The avoidance: The resonance:
• The civil works: the excavation, the pile caps, the mass concrete, the cracks control: The file: the drawings: the details: The “the foundation” the dimension: The “the pit”: The lubrication: The drains: The “the construction”: The file: the “the foundation” the complete:

THE FOUNDATION DESIGN: the soil: the bearing: The settlement: The file: the “the foundation” the chapter: The “the mill” the load: The “the dimensions”: The base: the block: The “the soil”: the report: The design: The file: the “the mill” the ground: The vibration: The concrete: The file: the drawings: The “the foundation”: the calculation: The “the anchor”: the bolts: The file: the complete: The engineer: the “the civil” the interface: The file: the “the foundation” the numbers: The mill: the ground: The “the total”: the dimension: The file: the “the foundation” the chapter: The complete: the dimension: the mill:

9. The Process Integration: The Mill in the Flowsheet

The mill dimensioning ends in the flowsheet: the interfaces:

• The feed system: the bin, the feeder, the chute, the inlet trunnion: the “the feed” the dimension: the belt: The “the mill feed”: the moisture: The “the inlet”: the spiral: The feed: The “the chute”: the hopper: The “the feed”: the speed:
• The discharge: the outlet trunnion: the “the discharge”: the chute: the elevator: the air slide: The “the discharge”: the temperature: The “the product”: the conveying: The “the outlet”: the dust: The “the discharge” the dimension: The “the elevator”: the bucket: The “the air slide”: the aeration: The “the discharge”: the “the return”: the classifier:
• The classifier (the separator): the closed circuit: the dimensioning of the separator: the air: The “the wheel”: The “the fines”: The “the oversize”: the return: The “the mill”: the “the loop”: The “the product”: the residue: The “the separator”: the “the mill”: the balance: The “the circuit”: the file: the “the tromp”: the curve: The “the efficiency”: The “the classification”: the dimension: The file: the “the separator” the table:
• The sampling and the control: the “the mill”: the sampler: the “the residue”: the “the power”: The control: The “the loop”: the “the feed”: The “the fineness”: the “the separator”: The “the control”: the “the plant”: The “the integration”: The file: the “the P&ID”: The “the flow”: the complete: The “the mill”: the “the flowsheet”: The “the dimension”: the file: the “the integration” the chapter: The complete: the “the cement”: the “the circuit”:

THE INTEGRATION: the mill is one machine among the many: The “the feed”: the “the product”: the “the return”: The “the loop”: The dimension: The “the elevator”: the “the separator”: The file: the “the flowsheet”: The “the balance”: The “the material”: the “the flow”: The “the dimension”: The “the complete”: the “the mill” the “the plant”: The “the integration”: The file: the “the process”: the chapter: The “the balance”: the “the heat”: The “the mass”: The file: the “the complete”: the “the mill”: the “the circuit”: The “the integration”: the file: the “the dimension”: the “the balance”: the “the flow”: The “the mill”: the “the plant”: the “the integration”: The file: the “the mass balance”: The “the flowsheet”: The “the complete”: the “the integration”:

10. The Dimensioning Example of Volume 2: The Complete Machine

The full worked example: the 4.6 x 16 m cement mill from volume 1 receives its machine design:

• The shell: the 60 mm: the heads: the trunnion: The bearing: the “the load”: the “the hydrostatic”: the shoes: The “the lube”: the pump: the filter: the cooler: The “the dimension”:
• The drive: the 5,600 kW: the motor: the reducer: the pinion: the ring gear: the clutch: the inching: The “the torque”: the “the selection”: The “the gear”: the module: The “the teeth”: The “the alignment”: The “the spray”: The “the dimension”:
• The ventilation: the 220,000 m³/h: the 1.2 m/s: the fan: the filter: the temperature: The “the dew point”: The “the water”: the injection: The “the dimension”: the “the fan”: the “the power”:
• The auxiliaries: the media: the charging: the make-up: The “the lubrication”: the oil: The “the foundation”: the concrete: The “the anchors”: The “the base”: The “the complete”: the “the machine”: The “the file”: the “the drawing”: the “the spec”: The “the dimension”:

THE COMPLETE EXAMPLE: the numbers flow from the top to the bottom: The “the power”: the “the shell”: The “the drive”: The “the bearing”: The “the ventilation”: The “the foundation”: The “the auxiliaries”: The “the total”: The “the spec”: The “the tender”: The “the file”: the “the worksheet”: The “the complete”: The “the machine”: The “the dimension”: the “the numbers”: The “the engineer”: The “the dimension”: The “the example”: The “the file”: the “the complete”: The “the example” the “the appendix”: The “the tables”: The “the result”: The “the tender”: The “the complete”: The “the dimension”: The “the machine”:

11. Frequently Asked Questions on the Tube Mill Dimensioning, Volume 2

Do I need both dimensioning volumes?

They complement each other: volume 1: the process power, D, L, the media, the compartments: volume 2: the shell, the bearings, the drive, the ventilation, the foundation: the design of the new mill needs both: the upgrade study often only volume 1: the file: the two volumes: the “the complete”: the cement: the “the dimensioning”: The package contains both: the one-time: the 249: the “the volumes”: the “the complete”: The answer: yes, for the full design.

Which components of the drive wear out first?

The ring gear and the pinion (the alignment: the spray: the load), the bearings (the oil: the contamination), the clutch (the starts), the gearbox: The “the maintenance”: the alignment checks: the oil analysis: The “the wear”: the monitoring: The file: the “the maintenance”: the “the schedule”: The “the parts”: the stock: The “the critical”: the “the spare”: The “the gear”: The answer: the gear first, if the alignment is not controlled.

How do I know the ventilation of my mill is right?

From the product: the residue, the temperature, the moisture: from the measurements: the gas velocity, the fan power, the dew point: The “the symptoms”: the mill hot: the residue high: the blinding: The “the vent”: the “the check”: The file: the “the vent”: the “the checklist”: The “the temperature”: the “the flow”: The “the answer”: the measured: the “the target”: the “the file”: the “the tables”: The “the vent”: the “the right”: the “the check”: The “the mill”: the “the gas”: the “the air”: The “the flow”: the “the velocity”: The answer: from the balance of the heat and the mass, checked by the measurements.

What is the importance of the inching drive?

It rotates the mill at the low speed for the maintenance: the ball changing, the inspection, the positioning: The “the inching”: the “the gear”: The “the maintenance”: the “the time”: The “the hydraulic”: the “the motor”: The “the design”: the “the standard”: The “the mill”: The answer: the hours saved in the maintenance and the safety of the personnel.

Can the existing mill be upgraded using these files?

Yes: the retrofit studies: the ventilation increase, the media optimization, the drive upgrade, the separator replacement: The “the study”: the “the balance”: The “the file”: the “the tools”: The “the kWh”: the “the tph”: The “the upgrade”: The “the plant”: the “the economics”: The “the answer”: the files give the method and the numbers: the payback: the “the decision”: The “the engineering”: the “the upgrade”: The “the complete”: the “the file”: the “the method”: The answer: yes, with the measured data.

12. Conclusion: The Second Volume Completes the Machine

The dimensioning of the tube mills, volume 2: the machine dimensioning: the shell, the bearings, the drive, the ventilation, the foundation, the auxiliaries: The “the complete”: the “the mill”: The “the numbers”: the “the engineer”: The “the dimension”: the “the whole”: The “the volume”: the “the first”: The “the package”: the “the complete”: The “the grinding”: the “the design”: The “the file”: the “the workbook”: The “the cement”: the “the industry”: The “the dimension”: the “the future”: The “the complete”: the “the machine”: The “the mill”: The “the end”: the “the file”: The “the knowledge”: the “the library”: The “the complete”: the “the cement”: The “the engineer”: the “the numbers”: The “the dimension”: the “the tube mill”:

The Complete Cement Technical Package (931 files: $249.99 one-time: the PayPal: the instant download) includes both the dimensioning volumes with the complete worksheets, the Excel calculators, the tables and the drawings: plus the Bond, the separators, the ventilation, the drive chapters: the whole grinding library: the one-time price: the instant access: the lifetime: the cement professional: the design office: the university: the knowledge: the “the package”: the “the click”: the “the PayPal”: the “the button”: the “the library”: the “the complete”: the “the cement”: the “the industry”: the “the dimensioning”: the “the tube mill”: the “the second”: the “the volume”: the “the file”: the “the knowledge”: the “the package”:

This file is part of the Complete Cement Technical Package (931 files) available from cementequipment.org. Respective rights holders; library copy for the licensed single user.