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MINING AND WET GRINDING

FGD SYSTEM FOR VARIOUS PLANTS AND

ROLE OF CHRISTIAN PFEIFFER INDIA PREPARED BY: SUMIT TUTEJA

BRIEF INTRODUCTIONWe, CPIL (M/s Christian Pfeiffer India Pvt. Limited) is a Joint Venture Company between M/s

Christian Pfeiffer Maschinenfabrik GmbH, Germany & M/s Chanderpur Works Private Limited

with an equal equity Participation of 50:50.

M/s Christian Pfeiffer India Pvt Ltd shall be catering to the various needs of Cement & Power

Industries.

The product range starts from Ball Mill, Dynamic Separator, Diaphragm for Ball Mill & other

associated equipments for the FGD plants as well as cement plants.

CPI Shall be manufacturing key technological products in workshop of its Indian parent company i.e.

M/s Chanderpur Works Pvt Ltd.

M/s Christian Pfeiffer Maschinenfabrik Germany – Technology Licensor

Headquarters:Sudhoferweg 110-11259269 BeckumGermany

Technology Licensor

MFL GROUP CROSSED 300 MILLION EURO TURNOVER IN 2017

M/s Chanderpur Works Pvt. Ltd. – Indian Mother Company

Regd. Office Address:Jorian, Delhi roadYamuna Nagar-135001Haryana, INDIA

CPW was established in the year 1962, is an ISO 9001: 2008 certified company engaged in the business of

Design, Manufacture & Supply of Heavy Machineries and Complete Plants on EPC basis for Cement,

Fertilizer, Chemical, Lime, Mineral Processing, Biomass Gassifiers & Material Handling Systems etc.

CPW has 3 (Three) state of art manufacturing facilities for fabrication & machining covering a total area of65,000 m2.

• Facilities for SMAW, CO2, MIG, MAG, TIG, SAW welding, vertical boring lathes, horizontal borers, stressrelieving facilities.

• Facilities for Destructive and Non-destructive testing

CPW has an ultra-modern computerised design & drawing office. Equipment manufactured under theinspection of reputed inspection agencies like LLYODS, SGS, Bureau Veritas, LRIS, RITES, M N Dastur &Co., Dalal Consultant, FEDDO, Grifiths, MECON, Tata Projects Ltd. etc.

Technology Licensor

COMPLETE FGD SYSTEM

ROLE OF CHRISTIAN PFEIFFER IN FGD

ROLE OF CHRISTIAN PFEIFFER IN FGD Christian Pfeiffer is main supplier for Limestone Slurry Preparation System.

Limestone Slurry is heart of FGD.

During the planning phase we will go through all the important parameters using semi-industrial tests,simulation systems and laboratory analysis of the materials in order to develop the perfect solution forgrinding plants.

Every FGD EPC Supplier has it’s own requirement for Product fineness say some suppliers haverequirement of Product Size as 90% passing 325 mesh, Some have requirement of 90% passing 200mesh depending upon their technology.

Any variation in Product Size and density can affect efficiency of the system.

Our solution for wet grinding system proves their worth in many areas of application . no matter whatbase material you use. When work with us , the finished product is characterized by highest possiblequality and efficiency.

Christian Pfeiffer has the expertise and designing capability as per the requirement of the main FGDsystem supplier.

Latest Development of Ball Mill Design

Latest development on ball mill design

© Christian Pfeiffer MaschinenfabrikGmbH

• Working principle

• Size selection

• Ball mill design

• Design features

Categories and field of applicationBall mill grinding

© Christian Pfeiffer MaschinenfabrikGmbH

Latest development on ball mill design

© Christian Pfeiffer MaschinenfabrikGmbH

• Subject• Working principle• Size selection• Ball mill design• Design features

Working principle

© Christian Pfeiffer MaschinenfabrikGmbH

• The ball mill is a horizontal tube, rotating around its horizontalaxis

• The tube / shell is protected by liners, made of wear resistant rubber liners

• The rotating tube is filled with grinding media• The grinding balls are lifted by the rotation of the tube causing

the comminution effect by crushing and attrition

• The power consumption of a ball mill is determined by diameter and length of the mill, as well as the filling degree and rotation speed and not by the throughput / grinding capacity

Latest development on ball design

© Christian Pfeiffer MaschinenfabrikGmbH

• Subject• Working principle• Size selection• Ball mill design• Design features

Size selection - Main parameters

© Christian Pfeiffer MaschinenfabrikGmbH

• Feed material(s)• Feed size• Product size• Type of grinding• Grindability of feed material

Specific power consumption requirement for grinding

• Necessary absorbed mill power:

• Pabs [kW] = Pspec [kWh/t] x Capacity [t/h]

Mill parameters

• Diameter (inside lining)• Effective grinding path length (EGL)• Mill speed / % of critical mill speed• Filling degree• Bulk density of grinding media

© Christian Pfeiffer MaschinenfabrikGmbH

Latest development on ball mill design

© Christian Pfeiffer MaschinenfabrikGmbH

• Subject• Working principle• Size selection• Ball mill design• Design features

Principle mechanical design of ball mills

1. Mill support2. Mill shell3. Drive system4. Mill feed5. Mill discharge6. Girth gear lubrication7. Water injection8. Motor9. Mill internals

© Christian Pfeiffer MaschinenfabrikGmbH

State of art ball mill with slide shoe bearing & girth gear / pinion drive

© Christian Pfeiffer MaschinenfabrikGmbH

State of art ball mill with slide shoe bearing& lateral gear drive

© Christian Pfeiffer MaschinenfabrikGmbH

Latest development on ball mill design

© Christian Pfeiffer MaschinenfabrikGmbH

• Subject• Working principle• Size selection• Ball mill design• Design features

caption caption

Mill supportTrunnion bearing

© Christian Pfeiffer MaschinenfabrikGmbH

Slide shoe bearing or trunnion bearing: always a good choice.

High stress levels, vibrations and dust place extreme demands on the bearing design in

particular.

Christian Pfeiffer manufactures well-proven mills with trunnion bearings or slide shoe

bearings Everything is designed with the highest stability and availability in mind, also taking

into account the need for short maintenance times.

The trunnion bearing with plain bearing or roller bearing enablesa short erection time, also offering a very simple lubrication system

Mill supportSlide Shoe Bearing – Section with axialbrackets + lifting jacks - CAD

© Christian Pfeiffer MaschinenfabrikGmbH

Mill supportSlide Shoe Bearing – Section with axialbrackets + lifting jacks - workshop

© Christian Pfeiffer MaschinenfabrikGmbH

Mill support:Slide shoe bearing with self aligning via spherical plain bearing

© Christian Pfeiffer MaschinenfabrikGmbH

Mill body

Standard manhole size: 540 x 640 mm

© Christian Pfeiffer MaschinenfabrikGmbH

Mill – Rubber Lining

© Christian Pfeiffer MaschinenfabrikGmbH

• Lifter bars with integrated rails forfixing bolts.

• Shell/Head plates, clampedbetween the lifter bars

• (Central Rings, Fillings Pieces)

• Mill is equipped with slow auxiliarydrive for positioning (LocalOperation Panel)

• Replacing with charged millpossible.

• Refer to rubber lining manual.

Drive system configurationsGirth gear/pinion

caption caption© Christian Pfeiffer MaschinenfabrikGmbH

Drive system configurationsCentral drive – direct to mill shell

© Christian Pfeiffer MaschinenfabrikGmbH

Drive system configurationsCentral drive – with distance shaft

© Christian Pfeiffer MaschinenfabrikGmbH

Drive system configurationsLateral drive

caption© Christian Pfeiffer MaschinenfabrikGmbH

Drive systemLateral drive vs. double pinion

© Christian Pfeiffer MaschinenfabrikGmbH

Drive system

© Christian Pfeiffer MaschinenfabrikGmbH

Lateral drive vs. double pinion

Advantages lateral side drive vs double pinion drive:• Only one mill motor• Torque split• Self aligning pinions• Integrated lubrication system• Less civil work• Less space requirement

Mill support – Lubrication systems

Float bearing side

• integrated oil conditioning system

• screw pump for low pressure supply of slide shoes

• radial piston pump for high pressure supply of slide shoes

© Christian Pfeiffer MaschinenfabrikGmbH

Mill support – Lubrication systems

Fixed bearing side

• integrated oil conditioning system

• screw pump for low pressure supply of slide shoes + Gearbox

• radial piston pump for high pressure supply of slide shoes

© Christian Pfeiffer MaschinenfabrikGmbH

Mill support – Lubrication systems

© Christian Pfeiffer MaschinenfabrikGmbH

Mill feeding system

© Christian Pfeiffer MaschinenfabrikGmbH

Mill feeding system

• Feed Chute with grinding waterconnection and inspection opening.

• Feed box with autogenous wear protection and wear liner (Yellow)

• HC underflow connection• Spout Feeder• Make-up Balls charging connection• Inlet seal (should be always wet and

clean)• Inlet cone• Leak chute

© Christian Pfeiffer MaschinenfabrikGmbH

SOME OF RUNNING REFERENCES

CPB has supplied more than ball mills in FGD System worldwide.

Presently 8TPH Limestone slurry preparation system is successfully running in NTPCVindhyachal in India.

Presently working with GE Power for 2x 800 MW NTPC Telangana Power Project

Innovative strength and reliability with almost 90 years of experience.

Fast implementation from planning to commissioning

Wide range of complete crushing and grinding systems for each application

High flexibility through own manufacturing

Today Christian Pfeiffer system stand for quality and reliability. Our focus and expertise in grindingtechnology enable us to be innovative and provide the tailor made solution to solve the mostcomplex challenges

THANK YOU FOR

YOUR KIND ATTENTION!!!