ATOX raw mill

Grinds virtually anything while saving space and energy

Key benefits
- Handles all types of raw material - Reliable, long-lasting operation - Big rollers reduce need for crushing - Low installation costs - Easy maintenance - Easy, simple and flexible operation - Steep particle size distribution of raw meal - Low mill vibration - Low specific energy consumption
An efficient, reliable performer Vertical roller mills are widely accepted as the most efficient means of preparing most moist raw materials for the production of cement clinker. The flexible ATOX raw mill can prepare virtually any kiln feed material to your required fineness in an energy-efficient process regardless of variations in grindability, drying requirements and abrasion. In fact, the ATOX can be adapted to a wide variety of specific requirements. Our continuous development of the mill over the years has resulted in todays ATOX raw mill a compact mill featuring a unique design that delivers superior reliability and performance. Working principle The ATOX raw mill uses pressure and shear generated between the rollers and the rotating table to crush and grind raw materials. Feed material is directed onto the grinding table by the feed chute. The rotation of the grinding table accelerates the material towards the grinding track and passes it under the rollers. Partially ground material passes over the dam ring encircling the grinding table and into the hot gas stream coming from the nozzle ring. The moisture in the materials evaporates almost immediately, while the finer portion of material is carried by the gas stream to the separator and the coarser portion deflected directly back to the table. The separator allows material that has reached the required fineness to leave the mill, while it rejects oversized material and sends it back to the table for further grinding. The coarsest fraction of the material that spills over the dam ring may fall through the nozzle ring and be conveyed back to the feed material inlet by a mechanical recirculation system.

100%

Recirculation 10 - 25% New feed 100%

100 200%

200 300%

Feed chute

1500 - 3000% Nozzle ring

45 - 60 m/s

Internal and external material circulation

10 - 25%

Many applications, many adaptations The ATOX raw mill has demonstrated its suitability for grinding virtually all types of raw materials: - From very easy-to-grind to very hard-to-grind material roughly from less than 3 kWh/t to more than 11 kWh/t - From less than 1% moisture to more than 20% moisture in feed material - From non-abrasive to very abrasive materials - From non-sticky to very sticky feed material Raw materials that are easy to grind for example, high capacity for the specific mill size, or with high moisture content may require an increased gas flow through the mill. The ATOX mill is easily adapted to this situation, as it comes with an oversize nozzle ring and an oversize separator.

Basic design concept The grinding table of the ATOX raw mill has a flat, horizontal grinding track encircled by an adjustable dam ring and an adjustable nozzle ring equipped with an air guide cone. The dam ring is made up of stacked, bolted-on, segmented rings and is easily adjusted by adding or removing one or more segmented rings. The height of the dam ring determines the thickness of the grinding bed on the table. The roller assembly is kept centred on the grinding table and prevented from rotating by three torque rods attached

to the mill housing. The grinding pressure is exerted hydraulically through three pull rods attached to the outer ends of each roller shaft. This unique ATOX roller suspension ensures the grinding forces are transmitted vertically by the pull rods directly into the hydraulic cylinder and foundation, and horizontally by the torque rods into the mill housing. The latest generation separator is located above the grinding rollers. The high efficiency of the separator is due to the rotor equipped with an outer ring of louvre plates. The fineness is controlled by adjusting the rotor speed.

The three cylindrical rollers are rigidly connected to a common centerpiece

Hard-working features and components

Easy to accommodate force variations Since the grinding track is horizontal and the centre of gravity of the roller system only moves vertically, all impact forces and dynamic reactions are mainly vertical and thus easy to accommodate. The extremely low mass of the roller suspension system means low total inertia and thereby low dynamic forces.
HiCr segment HiCr with ceramic inserts

In the event of excessive vibrations of the roller system, the lower inertia also limits the dynamic loads on the grinding table and thrust bearing in the gear box as well as on the surroundings. The variation in hydraulic force is greatly limited by means of the nitrogen-filled accumulators connected to the cylinders, which act as springs. Even though the variation in the grinding bed takes place during operation, the hydraulic force varies within only a few bars. The horizontal force into the mill housing normally accounts for 10-15% of the hydraulic force. The required raw meal quality and capacity are obtained by easily adjusting the grinding pressure, separator speed, gas flow and dam ring height. Great wear resistance Segmentation of wear parts means low risk of cracking. Therefore, wear-resistant but relatively brittle segments in HiCr for both the rollers and table can be used. Furthermore, the HiCr segments are suitable for repetitive hardfacing, resulting in double life of the hardfaced layer. In case of very abrasive materials, HiCr segments with embedded

ceramic inserts ensure considerably increased life. The segments must be replaced when worn out. Roller segments can be reversed, enabling high material utilisation, also in case of uneven wear. The ATOX mills rollers are larger in diameter than most other vertical roller mills, compared to the diameter of the table. This larger roller diameter means that operation with a proportionally thicker grinding bed is less critical as regards uneven wear and foreign bodies in the mill feed. The large diameter rollers further allow a proportionally coarser mill feed, which reduces the requirements of pre-crushing. No auxiliary mill drive required The rollers are lifted hydraulically before start, so no auxiliary mill drive is required. Starting torque requirements to the mill are modest, since it starts unloaded. Low gas speed saves fan power The roller suspension system permits the hot gas inlet section to be designed

virtually, without restrictions to the gas flow below the grinding table. The nozzle ring area is adjusted by inserting or removing shims on top of the vanes. Thereby the gas speed can be reduced to a minimum allowed by the amount of external circulation. The benefit of the low gas speed in the nozzle ring is a significant reduction in pressure loss across the nozzle ring and thus a significant saving in power for the mill fan. Maintain mill size for easy materials The beneficial design of the hot gas inlet with low pressure loss enables the mill to be fitted with an oversize nozzle ring. That makes the standard ATOX mill operate with the extra amount of gas required by specially wet or easyto-grind materials. It is not necessary to involve a larger mill size just to accommodate the gas flow only the nozzle ring and the separator must be adapted to the higher gas flow. Due to the relative large diameter grinding rollers the ATOX can handle up to 200 mm feed lumps. This feature reduces energy and wear in the crusher.

Optimised separation process

Rotor seal

Seperator top view

Optimum mill performance depends on optimum separator performance. Therefore the ATOX raw mill is equipped with the most updated version of the dynamic separator, which features: - Cutsize and fineness adjusted by change in rotor speed - Low bypass to reject ensures high separation efficiency

- Sharp separation curve ensures steep particle size distribution - Effective top seal ensures raw meal without oversized particles This highly efficient separator results in the following benefits: - Lowest specific power consumption for the mill motor - Highest mill capacity

- Low sieve residue for 200 micron and good burnability of raw meal - High grinding bed thickness and low vibrations - Lowest pressure loss across the nozzle ring due to low reject bypass The required fineness of the raw meal is obtained by adjusting the rotor speed.

Efficient feed sluice

The rotary feed sluice is an essential part of the ATOX raw mill installation. Its main functions are to ensure: - Uniform flow of feed to the mill for stable mill operation - Low ingress of false air to decrease fan kW usage and cost The sluice handles all new feed and material coming from the external circulation system. For normal raw mills this material flow accounts for 115-150% of the new feed rate; for bigger mills it can represent more than 1,000 t/h. Compared to other types of feed sluices, the rotary sluice ensures a uniform feed of material to the feed table. This is crucial for stable mill operation, since lack of feed will lead to reduced grinding bed thickness and to a corresponding increase in vibration level. Therefore, the uniform feed rate keeps the grinding bed stable and the vibrations low, ensuring steady operation and high availability withoutrisk of mill stop. The rotary sluice also minimises the amount of false air entering the mill. Due to the high underpressure in the range 40-70 mbar inside the raw mill, even small gaps at the inlet will cause a considerable flow of cold air into the mill. As the gas flow to the mill inlet must be constant independent of the amount of false air, every percentage in false air savings through the sluice results in a considerable cost savings, due to less gas flow sucked out of the mill and through the mill fan.

The FLSmidth rotary sluice delivers: Sturdy design and low speed Alignment with feed belt Split sluice for normal materials Heated sluice for very sticky materials - Friction coupling, preventing overload of sluice - Easy adjustment of sealing plates - Easy access and easy replacement of wear parts
Split sluice

For trouble-free operation and long life, the feed sluices design is based on a low-speed rotor. The low speed, ability to feed big lumps and high rate of feed material have resulted in relatively big rotary sluices. Sluices for ATOX raw mills are in the range 800 to 2200 mm. To ensure proper filling and distribution inside the rotary feed sluice, the sluice and the incoming feed belt are aligned. The circular bottom flange of the sluice and feed chute to the mill enables proper connection, independent of the direction of the feeding belt relative to the ATOX mill. In case extraordinary foreign bodies such as big wood blocks, timber or similar materials enter and block the rotor in the feed sluice, friction coupling ensures that the sluice parts are not damaged. A speed monitor stops the material belt and prevents overfilling of the sluice.

Large inspection doors enable the sluice to be easily cleaned and restarted. For normal raw materials, the standard split sluice with steel-lined rotor and lined housing is the optimum solution for steady operation and long life. The split design of the housing enables easy access and inspection of the interior of the sluice. When one side is opened, rotor lining replacement is a quick and easy job. The condition of the housing lining should be checked and replaced whenever required. To limit false air ingress, replaceable sealing plates at the tips of the rotor vanes can be adjusted to obtain a small gap between the rotor and housing. The heated rotary sluice is also the right solution for sticky mill feed. Hot gas from the mill inlet is guided through the rotor, thus preventing the sticky material from caking onto the rotor. Due to the change in rotor design, hardfacing is used for this version.

Split sluice with removable walls for easy maintenance

Heated rotary sluice for sticky materials

Makes life simple today and tomorrow

High-performance gear unit The standard main gear unit for an ATOX raw mill is the compact bevelplanetary type supplied by FLSmidth MAAG Gear. The axial thrust bearing supporting the grinding table and the grinding force is a reliable hydrodynamic/semi-hydrostatic bearing of segmented design. All the thrust pads are immersed in an oil bath. The lubricant for the thrust pads and for the internal gearings/bearings is conditioned and filtered in a separate pump station. Hydraulic stations protected For all ATOX mill installations the hydraulic and lubrication stations are located in indoor fascility. The benefit is that operation and maintenance takes place in clean and tempered conditions and that trouble free and long life can be obtained. Apart from the lubrication station for mill gear and grinding rollers also the hydraulic station for the tensioning system as well as pump station for the water injection is located in the hydraulic room. Low civil costs The very compact and efficient design of the ATOX mill offers a correspondingly low cost of foundation and mill building in case of clients demand for the latter. The possibility of customer supplied parts adds to the good economy of the ATOX raw mill. Easy maintenance The ATOX mill housing and separator are equipped with doors for easy access in connection with inspection and maintenance of all mill and separator parts. For more comprehensive overhaul the large maintenance door outside the grinding rollers can be removed for crane access. When the grinding wear parts eventually get partly or completely worn out, the roller segments can easily be reversed or replaced inside the mill, without taking the rollers out of the mill. The separator reject cone is provided with a rail and trolley for that purpose. When hardfacing of HiCr roller and table segments is selected the maintenance work is preferably carried out inside the mill. While maintenance drive for the table can be part of mill supply or installed when required, the maintenance drives for the individual grinding rollers are installed inside the mill. Normally both table and roller segments can be hardfaced simultaneously shortening the maintenance time to a minimum. For the grinding rollers in the ATOX 27.5 and bigger mills, the rotary oil seals can in case of an oil leak be replaced inside the mill due to the use of a split-seal design for the inner oil seal. Most vital mill parts are equipped with replaceable wear protection enabling long life even when abrasive raw materials are ground.

Bevel-planetary gear type

Replacing or reversing roller segments

Roller removal
Normally the grinding rollers will stay inside the ATOX mill several years until removal is required typically because of preventive replacement of bearings or because there are initial signs of bearing deterioration, which requires roller replacement. The rail and hoist system on all large ATOX mills provides a relatively simple way to remove the roller. With the maintenance door removed, the rail is bolted to the mill housing; for Atox 47.5-50, it is bolted to the support outside the mill. In case the grinding roller opposite the door needs removal, the entire roller assembly is rotated on the grinding table while turning the main gear manually or by means of a maintenance drive.
Beam and hoist installed for roller removal

Easy operation
The ATOX mill provides optimum operation for all kinds of raw material mixes and ensures a uniform product dried to the correct level. Adapting to different conditions is easy. Simply utilise the included facilities for dam ring adjustment (grinding bed control) by installing ring segments of varying thickness. To give the lowest pressure drop across the mill making it possible to operate with a controlled amount of re-circulated material the mill nozzle ring area can be adjusted by means of shims. Optimising these conditions results in the lowest fan power consumption. The hydraulic system for grinding pressure has been designed for operational flexibility. Grinding pressure can be varied over a wide range, making it possible to minimise the mill vibration level during operation. The mill is equipped with a water injection system to improve the grinding conditions, should this be required due to dry or unstable raw materials. The water flow rate can be adjusted from the control system in a step-less mode. To ensure easy and reliable operation, the FLSmidth automation control system offers several possibilities for control and surveillance. Several facilities can be useful in setting up the grinding system for the best and most energyefficient operation.

20

1 2 3 25 4 5 6 7 8 9

Mill motor Gear box Grinding table Split scrapers for external circulation Bottom plate for mill Reject sluice Rotary split sluice in heated or non heated version Feed chute with heated bottom Mill house with lining

22 7

21

10 Nozzle ring 11 Air guide cone 12 Segmented grinding roller

24 23

13 Roller hub and wear cover 14 Joint head 15 Torque rod 16 Connection to mill house

9 8

17 Air and material seal for tension rod 18 Tension rod 19 Hydraulic cylinder with accumulators 20 Variable speed drive for separator 21 Cage rotor 12 13 22 Guide vanes 23 Reject cone 16 11 24 Area in cone below separation zone protected with chromium carbide composite plate 25 Mill and separator outlet

14 17

15

10

18

3 5

6 19

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Three-fan systems most common

Three-fan system There are a number of arrangements for raw material grinding systems involving vertical roller mills. The various systems are different as regards placing of the gas conditioning tower and dedusting of the mill vent gas. However the most common solution today is the so-called three-fan system. The three-fan system uses cyclones to dedust the mill vent gas. This arrangement reduces the operating suction and usually also the gas volume for the filter, which may be either an electrostatic precipitator or a filter of the baghouse type. The three-fan system provides the best operational control with less interaction between operation of mill and kiln respectively. For the two-fan system, the required size of filter must be foreseen for the total mill gas flow, which is normally significantly higher than the kiln gas flow. As the mill requires significantly more gas than supplied by the kiln, a certain part of the gas flow is guided from the mill fan through the recirculation duct back to the mill. The raw material feeding system is equipped with a magnet separator and metal detector for protection of the mill parts. In case the raw material is significantly contaminated with metal, an optional secondary refinery system can be selected. The secondary system reduces the material to be rejected to a minimum, and at the same time the intermediate bin can be used as storage for external material during maintenance of the mill.

Two-fan system

Material flow

Mill air flow

Material + air flow

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Mill layout

As a one-source supplier of complete plants, FLSmidth supplies the ATOX raw mill as well as all other equipment needed for the raw mill department. Mill layout is based on a standardised concept and modules that ensure the most cost-effective raw mill installation. Because gas enters the ATOX mill from one side, the ducting arrangement is as small as possible, resulting in a very compact layout. The dimensioning and selection of cyclones, mill fan and connecting ducting are optimised for low energy consumption. The number of cyclones will be 2, 4 or 6, increasing with the mill size. The raw material feeding and recirculation system is preferably placed at the left side of the ATOX mill, seen from the mill motor. Lubrication stations for main gear, hydraulics and roller lubrication are placed with the pump station inside the structure, below the cyclones. The layout is furthermore prepared for easy access to machinery and components needing overhaul or replacement. The mill is per default designed to be operated without enclosure, and all maintenance can be conducted by mobile crane. As grinding rollers are taken out through the main mill door, only one small area is required next to the mill for positioning of the roller after dismantling.

When required by environmental regulations, for instance noise emissions, the entire mill installation can be closed, even when not required from an operating and maintenance point of view. When the installation is enclosed, a hoist and monorail is provided for lifting separator parts, feed sluice, mill motor and the top part of the mill gear box. The mill foundation is kept at floor level, ensuring easy access around the mill.

All equipment is located at floor level or above to avoid pits and thereby ensure easy cleaning and maintenance. The material reject system includes a reject bin and subsequent metal separation and back-feeding arrangement for dust-free reject material handling. A short belt conveyor feeding the mill and receiving the reject material ensures that the mill can start up without involving the long preceding mill feed conveyor.

Dimensions and characteristics

Atox Raw Mill Power minimum A Size 25 27.5 30 32.5 35 37.5 40 42.5 45 47.5 50 52.5 55 57.5 mm 7115 7415 7380 8420 8920 9855 9885 11450 11915 12500 13000 13800 14505 15190 B mm 3550 3900 4360 4694 5050 5380 5700 5960 6324 6694 7070 7440 7810 8190 C mm 6000 6000 6600 7600 8600 9600 9700 10300 10900 11500 12000 12700 13300 13900 D mm 9200 10000 10500 11300 12400 13400 14050 15000 15900 16200 17150 17860 18600 19330 E mm 3000 3500 3500 3800 4300 4800 4850 5150 5450 5750 6000 6350 6650 6950 installed, kW 665 844 1048 1280 1541 1832 2152 2505 2889 3307 3760 4248 4772 5333 F mm 4030 4490 4950 5440 5960 6460 6970 7490 8020 8570 9130 9690 10260 10830 G mm 4100 4600 5100 5500 6100 6600 7100 7600 8200 8700 9200 9800 10400 11000 H mm 3220 3620 4040 4460 4930 5380 5850 6330 6790 7250 7780 8290 8270 9310 Separator Power minimum installed, kW 45 56 69 83 99 116 136 156 179 204 232 260 292
C 05-11 300-10-ENG

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Copyright 2011 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express or implied), and information and data contained in this brochure are for general reference only and may change at any time.

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Project Centre Denmark FLSmidth A/S Vigerslev All 77 DK-2500 Valby Copenhagen Tel: +45 3618 1000 Fax: +45 3630 1820 E-mail: info@flsmidth.com

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