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Capital cost lower Raw coal is directly feed into revolving bowl. Due to centrifugal forces it is directed to the small gap between the bowl and springloaded rollers, causing the rolls to turn and the raw coal
2 to ground. Then the pulverized coal is dried by heated air entering below the bowl and carried up through the classifier and out through the multiple vane outlet assembly to the fuel piping system. Mill Reject system is required (manual or sluice type). Periodically the PA inlet ducts need inspection and removal of accumulated reject and raw coal. It is susceptible to damage from tramp iron and other Extraneous material entering with raw coal, calls for mill shutdown to cool and then remove the extraneous material. pulverized by the impact of the falling balls & the abrasion between them. Air through mills is the carrying media for pulverized coal, through annular space between fixed trunion tube and rotating hot air tube on way to classifier. Reject removal system is not required. However periodically the hot air box/mixing box needs inspection and removal of accumulated balls and raw coal. It is generally insensitive to tramp iron, except in case of large piece. Large piece of tramp iron causes damage to screw conveyor ribbon and & tie rods, which results in choking of center pipe and emptying of mills. Small tramp iron acts as a charge, which takes, participates in coal grounding. In the absence of any coal reject system the coal ground in tube mills carries away stone powder metal dust (from wear of ball charge) etc. to furnace and so may damage the furnace tubes Dedicated seal air system for each mill (Trunnion seal air fan and Girth Gear Seal air fan system). Seal air requirement is more and hence seal air fan capacity is more. Primary air to Pulverized coal ration at normal operating load is lower (1.5 to 2). As the air coal ratio being low in the tube mills the pulverized fuel concentration is relatively higher compared to bowl mills and is much
Common seal air system catering to the need of all mills. Seal air required per mill is also less. Primary air to pulverized coal ratio at normal operating load is higher (1.75 to 2.5)
3 beneficial from combustion point of view. Such rich mixture of fuel and air added with good fineness is quite effective in curtailing the oil support generally required at low load operation Worn out parts replacement i.e. addition of balls is done online. Ball segregation done generally at the time of liner reversal or replacement time and needs S/D. The coal available in the mill is more and that too in pulverized form. Hence it is mandatory to put the mill immediately on barring as soon as the mill is tripped/shutdown till the mill is cooled to avoid chances of fire and explosion. In order to avoid development of hot spots in stored pulverized fuel due to sudden stoppage or due to long storage, the mill is rotated at lower speed with auxiliary motor. Auxiliary motor is also equipped with braking device/system to place the mill at desired angle for ease of maintenance. Normally in tube mills, the chances and reported cases of mill explosion are especially during mill start-up & shutdown operation are high. Hence it has to be made mandatory to carry out steam inerting at the time of start up and shutdown operation of ball mill. Manual operation facility of steam inerting/water quenching is also provided to operator for use during emergency.
Worn out parts replacement, ring setting and rebuild needs mill shutdown.
No inching facility. As the Coal available in the mill upon a shutdown is very less, there is no need of barring the mill. The coal has to be removed in case the mill is shutdown for long period.
Normally in Bowl mill chances of reported cases of mill explosion are remote. Also, mill fire quenching procedure needs to be followed only when it has taken place.
4 10 Auxiliary Power consumption is 7.0~7.5 KWHr/Ton. Energy consumed per Metric Ton of coal ground is low. No power consumption occurs when mill is in idle condition. Number of auxiliary equipment are too many. Aux. Power consumption is 20~25 KWHr/Ton. The energy consumed/MT of coal ground is high (nearly four times than bowl mill). Even in mill standby/idle condition lot of auxiliaries are running, like LP pump for spraying on segmental trunion Bearing, HP Pump for lifting of Trunion Bearing, Ball & Socket Pump for supplying lubricating oil in swivel or ball and socket arrangement. Reducer Lube Oil pumps for supplying Lube oil to speed reduction Gear Box, Baring/inching auxiliary drive system, Girth Gear Seal air fan and Greasing system. Also the numbers of drives and dampers per mill is more. PC pipe purging is essential during pre start (1 min.) and post shutdown purging (Ten Minutes). Necessary control and Instruments are provided for purging of all PC Pipes after stopping of corresponding Elevation or Mills, as such deposits if left unattended in the pipes may lead to fire. Changing the airflow through the mills varies the mill output. The difference of total PA flow to mill and the air flow through the mill is supplied as bypass air flow which does pre drying of raw coal in mixing box, and maintains the required air flow velocity in the PC pipes. Good amount of coal is fed in excess, during the mill startup and filling
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No operational steps for PC pipe purging during pre start and post shutdown of mills. In case of choking of PC piping, purging is done by running PA fan only and opening only one mill outlet gate at a time.
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Total airflow is passed through the mill. It is generally kept constant irrespective of the loading of the mill. Changing the feeder speed varies raw coal quantity, which in turn changes the boiler fuel input,
5 cycle to raise the mill level, and the same is maintained at constant nominal value varying the raw coal feeder speed controls the mill level. Ball mills have large reserve capacity (about 15 min. full load operation) and hence the response time is very fast, to take care of a load change (almost like oil/ gas firing). Availability of large pulverized fuel reserve helps to respond faster to sudden load demand. The mill operation is noisy. Tube mills using ball/ charge for grinding, create lot of noise. To keep noise pollution in control it requires an acoustic enclosure, there by restricting noise level to about 85 db at 2 meter from the mill. Acoustics enclosure is standard feature of Stein design Tube mills, and is always accounted for during costing of milling systems. However this characteristic of variable noise is taken as an advantage and measurement is used for initial filling and other mill operation. Mill level control comprising of system for monitoring of noise level (Electronic Ear). The noise level is inversely proportional to the coal quantity in the mill. Raw coal feeding control is done by monitoring mill differential pressure, which is direct reflection of coal particle concentration in cloud formed inside the mill. Raw coal feeding controls respond to mill level control and are totally independent
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The reserve capacity of the Bowl mill is negligible. Hence the mill response time is 5 to 6 times slower than of Ball and tube mill to take care of load change.
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Mill operation is quiet in both idle and loaded condition. There is no metal-to-metal contact in the grinding zone. The rolls dont touch the grinding bowl even when the mill is empty.
6 of Boiler fuel demand. Air control of mill comprises of two components namely air through mill and Bypass air. Whereas the former responds to boiler fuel demand and thus controls the mills output and the latter one is for predrying and maintaining the sufficient velocity of coal air mixture, to avoid any settlement of coal particles in the PC pipes. Normally availability factor of the Ball and Tube mill is high. Labour cost for maintenance is less. High availability and flexibility in operation. Complicated control and instrumentation is involved for starting and stopping of ball and tube mill.
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Normally availability factor of Bowl mill is low. Labour cost for maintenance is more as compared to Ball and Tube mill. Easy in operation. No complicated control and instrumentation is involved for starting and stopping of bowl mill. Outage of raw coal feeder Due to double ended feature, outage results in outage of bowl mill. of one elevation raw coal feeder does not affect the operation of the ball mill. Both end/elevation can be taken into service with only one raw coal feeder in service. Emptying of raw coal feeder Emptying of raw coal feeder online is is done online by simply risky (chances of fire/explosion). closing feeder inlet gate. Emptying of raw coal feeder is done offline, when mill is on barring.