AIA ENGINEERING LIMITED

VEGA INDUSTRIES LIMITED

A Company & Product Presentation
2019
INDUSTRIES LINKED WITH US:
CORPORATE PROFILE
COMPANY TURNOVER OUR EXPERIENCE
(2018-2019) 2.4 Million Tons of High chrome grinding media in operation
426 Million USD 367,000 MT of High chromium linersinstalled
950 ball mills retrofitted with improved performance
CAPITAL 1,360 diaphragms installed
506 Million USD 261,000 tons of High chromium and Composite Vertical Mill parts
Includes assets, reserves
2,000 CE/ Alstom Mills retrofitted with improved performance
and surplus
7,000 mills studied and audited
CURRENT MARKET 90 service and installation engineers
CAPITALIZATION Global rate contracts with leading Cement, Mining and Thermal Groups
2.45 Billion USD Association with OEM for optimum wear solution and technology
up gradation
VEGA SERVICE ADVANTAGE
KEY DIFFERENTIATORS
Operational Excellence & Quality
• State of the art manufacturing plants
• High Process Automation
• Uncompromising thrust on total quality

Continuous R&D & Product Innovations

• Large team of design and process engineers
• Exclusive R&D foundry and HT facility
• Strategic tie up with University of Queensland and ALS Lab Australia

Core Industry Focus & Domain Knowledge

• One of its kind Technical Services Function
• TCO Capabilities
Global Logistics
• Contracts with major shipping lines covering 125 countries and 150 ports
• Warehousing & Distribution facility in USA, Canada, UK, South Africa, Australia
and Chile
• Timely door delivery at various domestic and international destinations
COMPANY MISSION
OUR PROMISE TO OUR CUSTOMERS
Reduction in Wear Cost
• Widest range of alloys and heat treatment cycles
• Application based customized solutions
• Optimized and enhanced wear life

Reduction in Energy Cost

• Process Optimization
• Mill Audits - Diagnostic Studies & Solutions
Benefits in down stream efficiency in mining
• Circuit & reagent study and research for optimum savings and recovery
Strong after-sales support
• Largest team of Technical Service Engineers
• Global Sales & Service Network
• Manufacturing Plants - with large available capacity
VERTICAL ROLLER
MILL PARTS

Rollers
Tyres
Rings
Segments
FACTORS INFLUENCING
GRINDING ELEMENTS DESIGN

• Design Characteristics of Grinding Elements • Feed Characteristics

– Hub & Clamping Ring Dimensional
Accuracy
– Critical Dimensions & Tolerances
– Roller working face profile
– Moisture contents
– Abrasive contents like Pyrites, Quarts,Fe,
Alumina
– Hardness; Particle size distribution

• Mill Operational Aspect • Performance

Parameters
– Dam ring Height; Nozzle Ring
Velocity – Residue, Blaine
– Table RPM; Specific Grinding Force – SPC
– Inter-grinding – Mill throughput
EFFECT OF NON - UNIFORM WEAR
ON OPERATION OF VRM

High wear on inner Non-uniform Excessive High

track Polysius Table wear Polysius Wear Pffier
RM57/28 Roller RM60/29 MPS 89G

Wave Collar Edge Wave

formation formation Chipping Formation
Pfeiffer MPS Losche LM Losche LM ATOX 50
2800 35.3 56.2+2
HARDFACING OLD SOLUTION

• It has short delivery time as compared to new set .

• Possibility of re-use of base material more number of times.

• In situ hard facing helps in keeping original profile.

• Availability of many suppliers and variety of electrodes in the

market.

• No specific technique is required. Cheap labor available in the

market.
DISADVANTAGES OF
HARDFACING

• Repeated hard facings causes cracks and breakage Stress Cracks

during operation
Overlay

• Difficult to maintain same performance

Steel
over successive rewelds Substrate

• Welding fumes - a health hazard

• In Situ hard facing

- Increased down time and reduced mill

availability

- Enhanced risk of bearing failures

- Capacity drop
EFFECT OF NON - UNIFORM WEAR
ON OPERATION OF VRM
The uneven wear on the Grinding Elements in a VRM can have severe drawbacks
on the operation

• Loss of production

• Increase of specific electric energy consumption

• Poor Fineness and burn ability of the coal

• Higher Energy Consumption in the boiler

MAJOR TYPES OF WEAR
& THEIR IMPLICATIONS
Wear Type Factors Possible Solution

ABRASION Presence of • Improve the Hardness

(A) • Quartz • Best Solution in casting made of Ceramic
• Pyrites
• Stone

CORROSION Presence of • Any alloy with the Cr contents of >25 %

(C) • Water contents

IMPACT • Due to Mill design • Provide Cushioning effect with the design
(I) • Solution with Soft Core and Very Hard
• Metal to Metal contact
• Hard foreign • Grinding face. AIAE Inserted Solution is the one
particles in the feed
CONVENTIONAL WEAR
RESISTANT ALLOYS – VEGA OFFERINGS
Alloy Carbon Chromium Hardness R.A Carbides
Cr Mo (V01) 0.5 - 0.8 % 1.5 - 2.5 % 30 - 40 Rc

Martensitic Steel (C 01) 0.2 - 0.5 % 3-7% 50 - 58 Rc

V - 08 (NI - Hard IV) En

Standard: 12513 - 2.7 - 3.3 % 8.0 - 10.0 % 57 - 62 Rc Ni:4.5 - 6.5 % 40 %
Sub Standard: En-
GJN - HV600

Ni - Hard II 2.7 - 3.1 % 2.0 - 4.0 % > 57 Rc Ni:4.0 - 6.0 % 40 %

V - 20 2.4 - 2.8 % 20 % 58 - 62 Rc 15 - 25 27 %

V - 16 2.8 - 3.2 % 16 % 62 - 65 Rc 15 - 25 32 %

V - 26 3.0 - 3.4 % 26 % > 63 Rc 15 - 25 40 %

V - 25 2.7 - 3.2 % 25 - 27 % > 59 Rc 35 %

SINTERCAST SOLUTION – ITS
VARIANTS & ADVANTAGES
SINTERCAST – For Normal Working Conditions

SINTERCAST SS- For Severe Working Condition

Advantages of Sintercast
• Tailor made solution based on present operating conditions
• Improvement in wear life by 2-3 times
• Total safety against breakage
• Sinter layer will be more harder than hard facing layer and create uniform wear on the
casting so original profile can maintained for longer time
• Consistency in mill output
• Reduced specific power consumption
• Mills can operate at higher operating pressure
 THE NEWEST WEAR
RESISTANT SOLUTIONS
• Inserted Solutions
- Inserted High Chrome

- Inserted Sintercast®

• Mono casting
- High Chrome

- Composite ( Sintercast®)
• Hard Hi Cr inserts embedded in nodular iron
• Hardness of the Inserts: 60-64 Rc.
• Property of Sg Iron: Elongation close to 5%and
Tensile Strength 500 MPS
• Hardness of high chrome on Inserts: 62-64Rc.
• End Hardness of Composite Part: 2100 Hv
• Property of Sg Iron: Elongation close to 5%and
Tensile Strength 500 MPS
SINTERCAST SEGMENTS
TABLE SEGMENTS

Old : Lesser ceramic and

Conventional Grains

New : Higher concentration

of ceramic and Improved
Grains
SHMP MILLS
MPS/ZGM
MILLS
ZGM 123G Sintercast Set金属陶瓷辊套和衬板

Total Set to be supplied 7 sets of roller tire and

Table Segments.
已供应7套
ZGM133G , Performance
after 6500 Hrs.
operation. Life achieved
about 21000 hrs.
LOESCHE MILLS
LOESCHE MILL LM20.2
LAFARGE ARASMETA, INDIA
Indian Coal with 30% Ash & 28%
VM
Other’s Supply Vega's Sintercast

Roller Tires & Table Liner Roller Tires & Table Liner

Installation Date 20-Oct-12 07 -Feb-14

Total Running Hours 7,892 10,116

Total Production 213,000 MT 255,000 MT

Customer has now fully shifted to Vega; and the sets delivering a life of 10000 hrs+ consistently

Xwin after 7892 hrs Sintercast after 8500 hrs

LOESCHE MILL LM28.2 , Coal with Ash contents 40 %. Life achieved about 11000 Hrs
LM35.3D GMR RAIPUR. Maximum wear of 30 mm at 7000 hrs operation for 40 % ash
coal.
MHI MILLS
MVM 28RL, Coal with Ash contents 38 %. Life achieved about 13000 Hrs
MVM 32RL, Coal with Ash contents 43 %. Life achieved about 13500 Hrs
TECHNICAL
SERVICES
TECHNICAL SERVICES APPROACH
AIA Engineering offers various Technical Services in addition to supplying and installing wear parts for
crushing and grinding applications.

Our services includes the following:

• Mill inspection & Performance Audits for optimization

• Submission of Comprehensive reports
• Ball charge recommendations – Expected benefit in operation up to 5%.
• Measurement of mill shell for drawing development assistance
• Mark Ball Test for unknown operating conditions
• Installation supervision and commissioning
• Ball Sorting Machine service
• Stock assessment and management

We have team of over 100 experts traveling all over the world for Technical Service requirements.
TECHNICAL SERVICES APPROACH RELATED
TO DRAWINGS AND INSTALLATION

• We have a full fledged drawing and design department with technically competent staff at
our works in Ahmedabad.

• All the latest accessories and latest software for the computers such as AutoCAD, Pro - E
are available.

• The service of our drawing office is available for our customers for developing the
drawings for different parts.

• Team of well trained and Experienced Installation Engineers.

• Supervision services for Domestic & International customers.

• Completion of Installation in minimum possible mill down time.

• Mill shell dimension measurement services for customer support.