molomax pendular mills - manfredini & schianchi srl · average levels of hardness (clay,...

MANFREDINI & SCHIANCHI Srl Via G.M. Dallari, 2 - 41049 Sassuolo (MO) - Italy - Tel. +39-0536-801207 Fax: +39-0536-807248 Web: http://www.manfredinieschianchi.com - Email: [email protected] 1/13

MOLOMAX PENDULAR MILLS


The MOLOMAX Pendular Mills are used to crush raw materials of various kinds, specific weight and humidity right up to average levels of hardness (clay, calcium carbonate, bentonite, chalk, dolomite etc.) with extremely high levels of production and exceptional quantities of fine material. Thanks to the dual feeding system and the presence of specific internal plough-share distributors, loading in the crushing chamber is optimised with a level of performance that is much higher than similar kinds of mills.

Crushing is performed by large pendulum that, under the action of the centrifuge power, apply huge pressure to the track fitted in the base of the mill.

Once the material has been crushed it is transferred to the top of the mill by the air that is circulated by the fan or suction by a filter located at the bottom. The material is also classified by the separator configured at the bottom of the crushing process to be created.


Active handling of the feeding is combined with parameters identified in real time by different process sensors, therefore automatically guaranteeing the highest level of performance in time.


MOLOMAX PENDULAR MILL -CYCLONE INSTALLATION

In the MS-CYCLONE pendular type of mills, the solid-air separation process occurs in the cycle reduction collector. This is placed between the pendular mill and the fan, connected by a whole range of tubes: this system is also known as closed cycle.

This process is used in special conditions: for example in the presence of explosive materials or materials with an electrostatic charge. In the case of the presence of raw materials with a high percentage of humidity, this system may be integrated with a warm air generator.

MOLOMAX PENDULAR MILL - AIR INSTALLATION

In the MS-AIR type pendulars, the crushed material is extracted and collected by a process filter, that subsequently downloads it to the following stage of the engineering cycle. This kind of plant is also known as open cycle.

This technique allows for further optimisation of performance of the machine by increasing the final values of production, especially in the presence of fine particles previously pre-treated. In MS-AIR pendular type mills it is also possible to insert hot gases into air veins with excellent results in terms of heat yield.


MOLOMAX PENDULAR MILL - GRAIN SIZE SELECTION

Adjustable bell shaped classifier Ranging from 200 to 500 microns

Selection accuracy: 94%

Regulated using micrometric screw

Centrifugal classifier with fins Ranging from 40 to 250 microns


Regulated using frequency adjusters

Classifier of the cell type Ranging from 20 to 40 microns


Regulated using frequency adjusters

MOLOMAX PENDULAR MILL - TYPICAL GRAIN SIZE CURVE

Mixture of raw materials for the production of roof tiles P.I.G. + Molomax


Mixture of ceramic raw materials for the production of red body tiles

Mixture of ceramic raw materials for the production of porcelain stoneware


Calcium carbonate grinding

Barite grinding


Coal grinding

MOLOMAX PENDULAR MILL INSTALLATION - FLOW CHART


MOLOMAX PENDULAR MILL - TECHNICAL DATA

Rated Power (kW) Model A B C D

N. Rollers

Ø Grinding Ring

Cons. (kCal/lt) Mill Filter Class. Feed.

3/90 1550 3120 1980 1690 3 900 37 37 5,5 3

3/120 1850 3490 2110 2030 3 1200 45 55 9 3

4/150 2430 4200 2190 2820 4 1500 132 132 11 3+3

4/150/RS 2430 4200 2190 2820 4 Maxi 1500 160 132 11 3+3

6/190 2830 4300 2300 3700 6 1900 160 160 11 3+3

6/190/RS 2830 4300 2300 3700 6 Maxi 1900 200 160 11 3+3

4/230 2950 5200 2800 4000 4 1900 250 315 11 3+3

5/230 2950 5200 2800 4000 5 1900 315 315 11 3+3

6/230 2950 5200 2800 4000 6 1900 315 315 11 3+3

6/500 3350 6500 3200 4500 6 2500

650

400 450 18,5 4+4

Upon request, we can build MoloMax Pendular Mills with larger dimensions up to 6000 mm in the track diameter.


PRODUCTIONS

Clay + Feldspar

Model Max incoming piece

size (mm) Max moisture content

at entrance Max fineness at exit

(microns) ton/h

3/90 1 - 4

3/120 5 - 9

4/150 12 - 31

4/150/RS 14 - 35

6/190 18 - 40

6/190/RS 20 - 45

4/230 23 - 50

5/230 26 - 56

6/230 29 - 62

6/500

30 20% < 200

40 - 70

Limestone Magnesite Coal




(microns) ton/h

3/90 0,5 - 2

3/120 2,5 - 4

4/150 5 - 11

4/150/RS 6 - 12,5

6/190 8 - 16

6/190/RS 9 - 17,5

4/230 11 -19

5/230 12,5 - 22

6/230 13 - 24

6/500

30 20% < 90

18 - 30

Gypsum Talc




(microns) ton/h

3/90 0,3 - 0,9

3/120 0,6 - 1,2

4/150 2,5 - 5,0

4/150/RS 3 - 6

6/190 3,5 - 7,5

6/190/RS 3,8 - 8,5

4/230 4,2 - 10

5/230 5,0 - 11,5

6/230 5,5 - 12,5

6/500

30 20% < 45

7,0 - 15


MOLOMAX PENDULAR MILLS – ANALYSIS OF RUNNING COSTS

The following example is based on a Manfredini & Schianchi complete raw materials preparation plant with a MOLOMOX pendular mill and a non M&S process with a rotating track mill which has the same throughput of 30 T/h for the same single

fired ceramic composition.

ELECTRICAL CONSUMPTION COMPARISON

MOLOMAX Rotating track mill

Pregrinding 132 kW (*) 55 kW

Main motor 250 kW 315 kW

Separator motor 11 kW 22 kW

Process filter motor 315 kW 250 kW

Wetting machine 2 x 18,5 kW 132 kW + 11 kW

Environmental filter fan Not necessary (**) 55 kW

Total

Total power installed 745 kW 840 kW

Power consumed 475 kW (***) 672 kW

Production consumption 15,8 kW/ton 22,40 kW/ton

(*) Pregrinding with Hammer mills type P.I.G. (**) The process filter also carries out this operation (***) Technology with inverter

THERMAL CONSUMPTION COMPARISON


Thermal consumption 500 kCal/lt 850 kCal/lt

Ceramic mixture with 6 % humidity

Maximum humidity permitted for optimal functioning 3,5% 1%

Burner installed 750.000 kCal 2.000.000 kCal

Maximum consumption 2 Nm3/h/t 5,2 Nm3/h/t

Temperature of material at filter exit 24°C Max 70°C

Ceramic mixture with 12 % humidity

Maximum humidity permitted for optimal functioning 3,5% *

Burner installed 1.500.000 kCal *

Maximum consumption 6,7 Nm3/h/t *

Temperature of material at filter exit 30°C Max *

(*) With a humidity higher than 6 % , the rotating track is not able to handle the composition.


TECHNICAL & MAINTENANCE COSTS COMPARISON


Maximum feed size at entrance beyond which a further pregrinding is needed.

200mm 100mm

Insulation of downstream machinery after milling Not necessary Necessary

Average cost of spare part 0,8 - 1,2 €/ton 1,2 - 1,5 €/ton

Machine stoppage time for maintenance 8 h 48 h

Necessary hoisting equipment Fork lift with 3,5 ton

capacity Crane with 10 ton

capacity

END PRODUCT COMPARISON


The data shown is indicative and may vary without notice

molomax pendular mills - manfredini & schianchi srl · average levels of hardness (clay,...

Documents