BALL TUBE MILL BBD 4772

INTRODUCTION

The pulverizer is a machine, designed and built for continuous operation over an extended period,
with minimal wear on the working parts. Wear of pulverizer parts depends on many factors that
vary from one installation to another.

Characteristics of the fuel, operating hours of individual pulverisers, availability of pulveriser due to
unit load demands, and maintenance force availability are all factors that determine the frequency
and scheduling of pulveriser inspection and maintenance.

The factor influencing the type of firing to be adopted on a boiler is basically the evaporation
capacity which depends on pulverizer ultimately.

The basic advantage of pulverized coal fire is a higher thermal efficiency, lower labour cost and
flexibility in operation.

Beside this availability of mills for operation is the main deciding factor for the plant load factor. It’s
possible to generate full capacity from thermal units if the required mills are operated at near full
capacity.

TYPE OF MILLS

1) Low speed Mill These mills operate at 17 to 20 rpm. Tube ball mill is low speed mill.
The advantage of this mill is low maintenance and operational cost. Disadvantage is more
power consumption.
2) Medium Speed Mill These mills operate between 30-100 rpm. Combustion
engineering’s bowl mill and Babcock and Wilcox ball mill are medium speed mill.
3) High speed Mill This mill is directly coupled to the motor and is run at 500 to 1000 rpm.
Hammer mills are of this design. Disadvantage of these mills are higher maintenance cost
and power consumption.

MILL DETAILS

S.N. MILLS NORMAL SIZE NORMAL BALL RANGE CHARGE

DESIGNATION CAPACITY (METRES) (TONS) (TONS / HR)
1 BBD 3448 3.4 X 4.8 L 30 – 40 30.5
2 BBD 4760 4.7 X 6.0 L 70 – 90 79.0
3 BBD 4772 4.7 X 7.2 L 80-110 99

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Silent features of Milling Plant- BBD 4772

Type Pressurized
Size BBD 4772
BBD- Broyeur Boulets Direct
47- 4.7 Meter diameter of tube/shell
72-7.2 Mmeter length of tube /shell
Number of Pulverisers Per Unit 5
Number of Pulverisers in service for design coal 100% BMCR 4
Number of Pulverisers in service for Worst coal 100% BMCR 4
Capacity of each mill Design coal -90 T/Hr
Worst Coal - 103 T/Hr
Ball load 85 Tons
Design coal grindability 55 HGI Scale
Maximum moisture content 12%
Fineness through 200 mesh screen 70%
MAIN Motor 2400KW;1500rpm,11KV
Main reducer Reduction 1500-120rpm
Girth gear Reduction 15.3 rpm

CONSTRUCTION

The mill drum is fabricated from thick steel plates provided with fabricated dished ends and flanges
for bolting the gear rim. The dished ends are provided with machined flanges for accommodating
mill journals which are precisely machined from steel casting and are supported on antifriction
bearing. The entire internal surface of the mill shell is covered with cast amour plates bolted to the
shell with a 10 mm thick asbestos board placed between the shell and the amour plates.

The internal surface of the journals are provided with steel liners consisting of helix which could
prevent the coal or ball getting entrenched inside the journal and facilitates automatic return of the
ball to the mill drum.

The entire drum with mill journals supported on specially designed antifriction bearings. One of the
bearing is fixed and other is free. The fixed bearing is provided on the gear rim side. The free
bearing is designed to take the axial and angular displacements occurring during the operation

The lubricating unit for the bearing consists of an oil tank; gear pump and heat exchanger. The
bearing are cooled and lubricated by maintaining the flow of the required oil inside the housing.
The temperature of oil is indicated by thermometer provided. The leakage of the oil from the
bearing is prevented by provision of sufficient Labyrinth with seals.

The drive mechanism consist of a high tension motor and a reduction gear box; the driving shaft
carrying the pinion which is supported on antifriction bearings and gear rim bolted to the drive
flange of the mill drum. Resilient grid type couplings connect the motor with gear box with the
pinion shaft. The pinion and gear unit are enclosed in a sheet casing which serves as oil tank for
lubricating the gear drive.

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The gear box has inbuilt oil cooler for cooling the oil inside. The inlet and discharge elbows of the
mill are provided with replaceable liners fabricated from steel sheets. Sealing glands provided
between rotating parts of the mill and elbows prevents any leakage from the circuit.

The foundation frames are fabricated from thick steel sections consisting of three parts with
precisely machined mating surfaces bolted together .The entire frame is leveled on the pedestal
bolted to the foundation and grouted. Forged steel balls of three different sizes -40mm, 50 mm and
6o mm are used as the charge. The quantity of the ball charge will be around 25% of the volume
of the mill. While operating the mill, only 60 mm balls are added depending upon the requirements.
The designation of mill denotes drum shell diameter and length.

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DESCRIPTION

The mill consists basically of rotating cylindrical body resting on two bearings (One at each end) by
means of trunions.

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 Trunion Tube:-It supports whole body on journal bearings

LINERS

On the inner side of the drum, liners are fitted with the help of shell bolts.These liners are 10 type
and 600 in numbers.

MILL LINERS DETAILS

• Inlet liners 16 x 2 = 32 nos.
• Inlet liners with Boss liners 4x2 = 08 nos.
• Wave liners (Type I) 10 x 2 = 20 nos.
• Wave liners (Type II) 10 x 2 = 20 nos.
• Wave liners (Type III) 10 x 2 = 20 nos.
• Wave liners (Type IV) liners 10 x 2 = 20 nos.
• Cylindrical liners (Type I) 20 x 10 = 200 nos.
• Cylindrical liners (Type II) 20 x 10 = 200 nos.
• Short conical liners 20 x 2 = 40 nos.
• Long conical liners 20 x 2 = 40 nos.
• Total 600 nos. of Liners

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Wave Liner
(Type III )

Wave Liner
(Type IV )

INLET
LINER

BOSS

INLET LINER WITH

BOSS

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 Ribbon

Link
s

Bearing Shaft

SCREW CONVEYOR:-Screw conveyor lays major role of coal admission in coal mill. Ribbon is attached to
the tube by means of chain link which carry coal to the drum.

BEARING LINER -
LINER COMPOSITION :-PHOSPHORUS BRONZE, ZINC-0.30 %, TIN-5.00 %, IRON- 0.10 %,
LEAD-0.05 %, Copper 94.35%

SEALING SYSTEM
Mill operates under high pressure .Counter pressure provided by seal air fans prevent any leakage
to the outside.

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Bearing for Trunion

LP Oil 3-4 kg/cm2

HP oil 50-80Kg/cm2 Trunion tube

Bearing Liner
B&S oil 30-40 kg/cm2

Coal Flow in the Mill

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Driving Mechanism

Main Motor1480
RPM
GIRTH GEAR 15 RPM

Gear Coupling

Main Reducer
Gear Box

Counter shaft bearing Pinion 240RPM

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PRINCIPLE OF OPERATION OF BALL & TUBE COAL MILL
The ball tube mill consists of two perfectly symmetrical grinding circuits. It then passes through the
trunnion tube whose screw conveyor conveys the coal into the mills. The mill drum carrying the
ball charge rotates on antifriction bearings. Raw coal is fed to the drum through the inlet elbow and
gets crushed to powder inside the mill drum. The ball charge and the coal are carried to certain
height inside the drum and allowed to fall down. Due to the impact of the balls on coal particles
and due to attrition as the particles slide over each other and also over the liners, the coal gets
crushed. Hot primary air is introduced into the mill through the central tube of the screw conveyor.
It completes the coal drying and carries the pulverized coal out of the mill through trunnion
annuals around the central tube, counter to the raw coal feeding direction. The double cone type
classifier is fitted with adjustable vanes to regulate the pulverized coal particle size. The large
grains of the coal fall back by gravity into the trunnion inlet and are repulverized. The finely ground
coal particle is suspended in air is transported from the classifier outlet to the burners for injection
in to the furnace.
Primary air in case of Tube mill has dual function to perform. It is used as drying as well as
transporting media 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 is regulated to
have proper primary air temperature. In addition to raising the coal temperature inside the mill
for drying & better grinding, the same air works as carrying media for pulverized 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 classifier with adjustable classifier vanes for segregation into
pulverized fuel of desired fineness, and 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 P.F. pipes an additional quantity of
primary air is fed in to mixing box on raw coal circuit. This by-passed air tapped from primary air
duct going into the mill makes appreciable contribution for drying of raw coal by flash drying effect
in addition to picking up the pulverized fuel from mill outlet for its transportation towards classifier.
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 increases the speed of raw coal feeder and vice
versa. Maintaining the coal level in mill offers built in capacity cushion of pulverized fuel to take
care of short interruption in raw coal circuit.

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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 outside atmosphere. Inadequacy or absence of seal
air will allow escape of pulverized fuel into atmosphere.
On the other hand excess of seal air leaking into mill will affect the mill outlet temperature; as such
the seal air is controlled by a local control damper by maintaining just sufficient differential
pressure for sealing.
SALIENT FEATURES
Horizontal type slow speed in the range of 13-20 rpm.
Pulverization of Coal by attrition and by impact of hard balls.
Speed reduction achieved by gear train consisting of reduction gear box and large spur gear.
Coal can be fed and removed from both sides of the mill.
Half mill operation for partial loads allowed.
Input coal size 25 mm while output is 70 to 90 microns
Very high coal fineness achievable.
ADVANTAGES
The above principle of grinding and operation give these mills the following distinct advantages.
Very high availability.
Low maintenance.
Fast response over load range.
Low coal to air flow ratio.
Ability to pulverize wide range of coals.
No mills rejects.
Virtually unaffected by foreign material.
Hard and abrasive fuels ground efficiently
Constant capacity and fineness.
Flexibility of available capacity.
Large reserve capacity.

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