A) MILL COMPONENTS

Foundation
Mill support assembly
Grinding bowl assembly
Air Guide housing
Mill housing assembly
Dynamic classifier
Mill ring pipes
Grinding journal assembly.

Mill foundation, foundation parts and base frame

Drawing-Nor.: Description
ECM-0157-1010 Mill Foundation

Foundation
The mill foundation is a block designed out of reinforced concrete.
Forces, produced during the grinding process, are induced via the base frame and
the foundation parts in the mill foundation..

Foundation parts

The foundation parts are divided in anchor boxes for the mill and the gear and
the anchor plates. The anchor boxes consists of special designed ducts,
integrated in the rebar / reinforced concrete and are cast-in with the mill
foundation. T-head bolts, are installed in the anchor boxes.
The anchor plates serve for fixation of the hydraulic cylinder for the grinding
journal demounting. The anchor plates are set into the rebar / reinforce concrete
of the base level (0m level) or the mill foundation. A bracket is welded on the
anchor plates for the mounting and demounting cylinder of the grinding journal.

Base frame

The mill motor, the coupling guard, the mill gear and the mill support are screwed
on the base frame. The frame consists of the welded structures and is cast with
the mill foundation with non-shrinking concrete. This grouting ensures a good
connection between mill and foundation. The wholes in the base frame profiles
serve a better distribution of the grouting. This ensures that the concrete fills all
areas of the base frame and guarantees a frictional correction. Bores on the
upper side of the base frame provide ventilation during the grouting of the base
frame. The base frame is not coated to provide a better connection between the
base frame and the concrete.

Mill drive components

The mill drive components are the mill motor, the coupling and the mill gear.

Mill drive motor

An induction motor drives the mill. Heat capacity during the operation is
dissipated via water- or air -cooling. In special cases, the motor can be quipped
with a rest heating to avoid condensation. Please refer the Vendor manual for
more information.

Coupling

Warning!
Do not touch the operating coupling!
Risk of injury!

The flexible coupling connects the mill drive motor and the mill gear. It consists of
two coupling parts with installed flexible packets, screwed together. This screw
connection allows a separation of the mill and the gear without an axial
adjustment of one of the aggregate. Please find more details about the coupling
in Appendix 1 Main mill gear and Coupling.

Mill gear

The mill gear is a 3x power-split pinion-planetary gear. Very high axial forces,
occurring during the grinding process, are gathered by the in the housing upper
part installed segment thrust bearings and induced via the gear housing into the
mill foundation. The compact design and the ribbing of the whole housing provide
a high stiffness for better operation security and increase the durability of the
axial bearing Oil (DIN 51517-3 VG 320) is injected for cooling and lubrication. A
spill on the upper side of the segment thrust bearing allows the lubrication of
lower located gear areas. Labyrinth gaskets are sealing the driving shaft and the
driving flange. Breathers installed on the housing provide pressure compensation.
Please refer vendor manual for more information.

Gear lubrication supply

The planetary-gear is lubricated via a compact lubrication aggregate and a

connecting tube system (pressure- and suction tubes). The lubricant, pumped
from the lower gear area is injected via a double filter unit, water or air cooler, at
the segment thrust bearing in the upper area gear area. Pressure switches and
flow monitors in the in feed system supervise the oil circulation. In the gear, the
oil temperature and level is used as protection criterion and switch-on release for
the oil pump. Please refer vendor manual for more information.

Mill support

The mill support forms the socket between mill housing and base frame. The gear
is installed in the tunnel of the mill support.

The mill support is screwed on the base frame. The support design as a tunnel
allows an installation of the mill gear and the mill motor from two sides. The large
hollow spaces in the mill support serve as seal air distributor. The Sealing of the
grinding bowl against the atmosphere is fixed on the mill support. The bottom
armor is located on the upper side of the mill support. The armor protects the
support against wear, produced by foreign matters. The gear is protected against
the heat of the drying gases by special concrete under the bottom armor.
Moreover, the reject box is installed in the mill support. Via the reject box foreign
matters, carried by the scraper, are transported in the reject box.

Drawing code Description

SM29-395-0001 Mill Support assembly
Housing

The housing is divided in the air guide housing and the mill housing.

Drawing code Description

SM29-381-0001 Air Guide Housing

The air guide housing is flanged on the mill support. It consists of heat resistant
material, if necessary. One hot air inlet and two access doors and the side armor
are located in the air guide housing. Downward, the air guide housing is locked
up by the bottom armor.

Hot Air Inlet

Warning!
Do not touch hot air inlet in heated state or while operating!
Risk of injury!

The transport gas accesses the air guide housing via the hot air inlet. It circulates
the grinding bowl before is passes via the vane wheel in the grinding chamber.
The hot air inlet is shaped upwards, to prevent deposit. The ribbing of the inlet
provides stiffness.

Side armour

Two up to four scrapers, installed on the mill bowl, are circulating in the air guide
housing to transport foreign matter to the reject box. Side armors protect the air
guide housing against wear. The armor protects the inside of the housing where
the scrapers are located against wear and prevents deposit by material rejected
from the vane wheel.
Access door

Warning!
Do not open access door during operation!
Danger of life!

The access doors give access to the air guide housing or mill housing. Before
opening the access doors, make sure the mill has been shutdown correctly.
Pasted square packing, which is connected to the access door when closing,
guarantees absolute impermeability. The solid doorframe provides an extra
stiffness for the air guide housing and mill housing.

Mill housing

Drawing code Description

SM29-393-0001 Mill Housing assembly

The mill housing is flanged on the air guide housing and encloses the grinding
chamber. It consists of three grinding journal openings, 3 access doors and the
housing armor. The grinding journals are hooked in the grinding journal openings
and closed with the journal cover.

Journal Opening

Three journal openings are located in the mill housing and bordered by the
journal frame, welded on the outside of the mill housing.

The journal covers, shutting off the journal opening, are fixed with hinges, welded
on the mill housing. Before retracting the journal cover the face between journal
cover and journal frame must be sealed. Use a two component sealing, preferably
CHETRA MPG or CHESTERTON 860. The sealing consists of a sealing compound
and a hardener. The sealing compound is applied undulating on the one face. The
hardener is sprayed on the other face. Approximately one hour after the joining of
the two faces, the sealing provides absolute impermeability. The sealing can be
peeled of easily and completely without any problems. Due to this easy removing
process, a extensive cleaning of the flange is not necessary. The hydraulic
cylinders for the grinding pressure are mounted on the journal cover and produce
the forces, which are transferred on the grinding journals. The grinding journals
are fixed via eccentric bushes in the circular cutouts of journal cover and journal
frame.

Grinding journal stopper

The grinding journal stopper is mounted on the journal cover. Via the grinding
journal distance between roller and bowl is adjusted (6.5.2.4 Grinding track
distance). Access door

Warning!
Do not open access doors during operation!
Danger of life!

Before opening the access door, make sure the mill has been shutdown correctly.
Due to identical construction, the access doors of the mill housing are
exchangeable with the access doors of the air guide housing .

Housing armor

The housing armor is located on the inner side, between the journal openings, on
the lower part of the mill housing. The armor protects the housing against wear.
To avoid dust deposit, the housing armor is designed with no horizontal face.

Vane wheel

The vane wheel is located in the grinding chamber. The grinding chamber
separates the air guide housing and the mill housing. The vane wheel is mounted
with screws on the outer diameter of the grinding bowl and leads the transport
gas in the grinding chamber. The vane wheel is equipped with wear-resistant
blades. Due to these plates, the transport gas velocity gets a horizontal direction,
which provides a better distribution of the pulverized material to the classifier. If
the grinding speed needs adjustment, single openings of the vane wheel can be
covered with covering sheets.
Grinding components

SM29-380-0001 Grinding Bowl

Assembly
SM29-382-0001 Grinding Journal
Assembly

The grinding tools consist of the grinding bowl and three grinding journals. The
grinding process takes place between the grinding rollers and the bowl liners. The
grinding journal stopper prevents contact between the grinding roller and the
bowl liners.

Grinding bowl system

The grinding bowl system consists of:

The grinding bowl and the dam ring
The bowl liners
Scrapers
The grinding bowl sealing
The vane wheel

Grinding bowl and dam ring

The grinding bowl, made of ductile iron or cast steals, is rotationally-

symmetrically designed and mounted with screw to the mill gear. The dam ring is
located on the outer diameter of the grinding bowl.

Bowl liners

Because of the grinding process taking place on the grinding track, the bowl
liners are exposed to wear. For this reason, the bowl liners consist of single cast
segments, fit into the grinding bowl. The bowl liner segments form a track, raked
towards the center and fixed by a retaining ring. The bowl liners are designed
wear-resistant with a wear-resistant base material.

Scrapers

The scraper transports rejects from the air guide housing to an opening in the
bottom armor. Form here; the rejects are transported to the reject box. In case of
transport gas leakage or emergency shutdown, grinding material is also
transported in the reject box. The scrapers are installed in pairs, staggered at 80
degrees on the lower border if the grinding bowl. To prevent damage by rejects,
the scrapers are pivoting. Due to centrifugal forces, the scrapers set up in radial
working position when operating. The working area of the scrapers is equipped
with wear resistant material. If necessary a second pair of scrapers can be
installed staggered at 90 degrees.

Grinding bowl sealing

Warning!
Do not touch the grinding bowl sealing during operation!
Risk of injury!

The grinding bowl sealing separates the rotating bowl from the environment. The
sealing consists of two square gland packing on top of each other, located in the
mill support (6.3 Mill Support) The gland packing is cooled and protected
against the transport gas and grinded material mixture by seal air. See also
chapter maintenance and commissioning.

Vane Wheel

The vane wheel is registered under the subassembly 380 Grinding Bowl
Assembly and described in chapter

Grinding Journal

382 Grinding Journal

Three grinding journals are installed staggered at 120 degree in the grinding
chamber. The eccentric bushes between the journal frame and the journal cover
fix the journal. The design allows the grinding journal to pivot around the journal
shaft. The bearing of the grinding journal in the mill housing is realized with silent
blocs.
The grinding roller rotates the journal axis. The bearing is realized with an x-
shaped taper roller bearing (fixed bearing) and a cylindrical roller bearing (loose
bearing), located in the bearing housing. The bearings are specially designed for
this application and rated for a service life of 100.000 operating hours.

Grinding Roller

382 Grinding Journal

The grinding roller is exposed to wear during the grinding process. For this reason
the roller is designed as an easy exchangeable wear-part. There are different
design options for the grinding roller. Usually the grinding roller consists of a cast
carrier and a wear-resistan.

Grinding Journal Lubrication

382 Grinding Journal

An injection opening for lubrication is located at the upper end of each journal
axis. A wear resistant metal tube mounted on journal cover and grinding journal,
serves for the lubrication of the grinding journal. An oil dipstick, which can be
operated from outside during mill operation, provides the check for oil-quality
and oil-level in the grinding journal. The bearings, located in the grinding journal
are lubricated via dip lubrication. Lubricant-type and lubricant amount are listed
Lubricant list and lubricant intervals. The oil level must be checked regularly
during operation and must not exceed or under-run the min.-and max indication.
The prescribed lubrication intervals must be followed to guarantee a long service
life of the grinding journal. Use only high quality CLP-lubricant (ISO VG 460)
according to DIN 51502 (or ISO 12925-CKC 460). With higher operating
temperatures, it is recommended to use synthetic oil. Please find details about oil
quality and about oil exchange.

Grinding journal sealing

382 Grinding journal

The grinding journal sealing is divided into two systems. Firstly, seal air prevents
grinded material to enter the inside of the grinding journal and to debase the
lubricant, which would diminish the service life of the rolling bearing and other
parts. Secondly, two pressure-proof rotary shaft seals keep the lubricant in the
inside of the grinding journal when it is moving. Grease filling between these
rotary shaft seals provides an additional seal effect and increases the service life
of the rotary shaft seals. The originate grease must not be mixed with other
greases. Please find more information about grease-type and grease amount
Lubricant list and lubricant intervals.

Grinding track distance

The basic concept of the ALSTOM bowl mill is to prevent the metallic contact
between grinding roller and grinding track at any time.

Grinding roller and grinding bowl must not have

Caution! contact at any time to avoid damage of the grinding

components!

The Grinding track distance is the smallest distance between the bowl liners and
each grinding roller. The grinding track distance of all three grinding journals
should be equal and measure between 5 mm and 8 mm at the closest point
between grinding roller and bowl liner. Different grinding track distances in the
mill may cause irregularities in the grinding process. The accurate adjustment of
the grinding track is described in chapter Adjustment grinding track
distance.

Eccentric bushes

382 Grinding journal

Due to the eccentric adjustment, the grinding roller can be adjusted parallel to
the bowl liner. The grinding track distance must be checked after every eccentric
adjustment. The accurate eccentric adjustment is described in chapter 9.7
Eccentric adjustment.

Classifier

The Classifier is arranged above the grinding chamber and flanged on the mill
housing. The classifier separates the coarse material from the fine material. If the
material is fine enough it is transported via the classifier to the pipes. Grained
material that is not fine enough is reintegrated in the grinding process. There are
two types of classifiers: the dynamic classifier and the static classifier.

Dynamic Classifier

Drawing code Description

SM29-391-0001 Classifier assembly

The dynamic classifier consists of four components:

classifier housing (with dust outlet),
classifier rotor (with exchangeable blades),
classifier drive with tank and gear group,
coal inlet pipe.
The classifier housing is mounted on the mill housing. The classifier drive is
mounted on top of the classifier housing. The classifier rotor is flanged on the
lower part of the classifier drive and is activated by the motor. The dynamic
classifier is equipped with a motor (foreseen for speed controlled operation by
frequency converter). The classifier rotor speed affects the fineness of the
grinded product. High classifier speed produces a high fineness of the grinded
product. Lower classifier speed produces a coarse grinded product.

Classifier Drive

Caution! Do not operate without Seal Air and Lubrication!

The main components of the Classifier Drive are:

Classifier Drive Housing = Oil tank
Classifier Drive Motor,
Gear Group
Axial Bearing
Lubrication with Motor Pump-Group.
The Classifier Rotor is radial and axial installed in a special for this case designed
Axial Bearing. The tightness of the drive housing is layouted by shaft seal ring
systems and seal air system.
The components of lubrication system (Oil pump/motor, oil flow divider,
instrumentation to system control are installed to be accessible from outside at the
Classifier Drive Housing.
An Air Breather Filter is responsible to clear inner humidity.
See also chapter:Maintenance.

Reject System

Warning!
Do not open damper and closure at the same time!
Danger of life!

The reject box is directly connected to the mill support. Rejects and, as the case
may be, grinded material are transported by the scrapers to the opening in the
bottom armor, where the material falls via a chute into the reject box. The reject
box consists of
Housing with supports
Reject chute
Slide Gate (pneumatic)
Lower closure

The Slide Gate separates the mill from the reject box. The lower closure serves
for the emptying of the reject box.
Drawing code Description
SM29-317-0001 Pyrite Box assembly

Grinding Journal Hydraulic System

Drawing code Description

SM29-392-0001 Mill Hydraulic pipes
 Refer Vendor manual for more information

The grinding force is provided by a hydro-pneumatic hydraulic system. The

system provides equal grinding forces on each grinding journal for a smooth
grinding process.

The hydraulic system is structured in 4 parts:

Hydraulic station with tank, pump, filter, magnetic valves, monitoring
devices and accumulator units.
Connection pipes between the hydraulic station and the mill
Ring pipes (A, B- und C pipes) with safety blocs and bladder accumulators
Hydraulic cylinders.

1.1. Seal Air System

Caution! The lack of seal air damages the components!

The seal air quantity and pressure for the mill will be provided by a separate Seal Air
Fan. A pipe will forward the seal air to Mill Support seal air inlet opening
(respectively, will be after fan distributed also to others users)
Mill seal air is supplied to:
Grinding bowl sealing
Grinding journal bearing
Grinding pressure hydraulic cylinder
Classifier drive

The internal distribution of the seal air for each applicant will occur in Mill Support
by special dimensioned pipework. .
The pressure difference between seal air and transport gas is supervised by
the main control system. With the under-run of the differential pressure
between primary air and seal air of 15mbar, the mill must be shutdown.
 The internal distribution of the seal air for each applicant is checked during
commissioning and, if necessary, adjusted via orifice plates.
Seal air on the three journal covers is requested to protect the hydraulic cylinder
plungers.
Drawing code Description
SM29-319-0001 Seal Air System