CRUSHER & RAWMILL

Report no 01

IMPLANT TRAINEE
FACULTY OF ENGINEERING
UNIVERSITY OF RUHUNA
2011/08/15

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content

Content

page

1. Crusher
1.1 Wagons & Tippler

1.2 Crusher

1.3Belt Conveyours

1.4Raw Material Conveyed Yard

2. Raw mill
2.1Rawmill

6, 7

2.2Seperators

7, 8

2.3Twin cyclone & silos

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1.Crusher
1.1 wagons & tipplers
From the Aruwakkaru we bring the limestone according to the laboratory requirement (LSF value) of the
production by railway wagons.
Lime Saturation Factor

= CaO x 100/(2.80 SiO2 + 1.18 Al2O3 + 0.65 Fe2O3)

HGL means LSF= 15020

LGL means LSF= 8515

Holcim has 2 trains that contain 26 & 30 wagons.

Wagon capacity is around 22.5 tons of limestone. If
there is no restriction in the railway we can complete 8
turns of the trains and we bring 4000t per day to the
plant.

fig 01-wagons with limestone

By using a special gearwheel system which runs by a

motor, we turn the wagons on the tippler and feed
the limestone into the hopper of the crusher. The
hopper has a volume of 70m3.We always use 3 air
blasters to remove the limestone that fixed with the
inner surface of the hopper. One air blaster is set at
the bottom of the hopper & other 2 at the front
edges.
Fig02- wagon at the tippler

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1.2crusher
Then limestone is feed into a compact crusher through the apron 21x- AC1 at a rate of 180t/h,to the
counter direction of the rotating direction .This crusher is made in Germany.
Then limestone is crushed by the hammers which are fixed on the 8 axels at the circumference of the
rotor that is run by a motor powered of 237kw & rotor has 990 revolutions per minute.In an axel there
are 5 hammers.At the bottom half of the crusher are the grate bars that spacing of 25mm.It creates the
relevant rocksize for the belttransport.

Hammer crusher

1: Hammers
2: Rotor
3: Feed Plate
4: Upper Casing
5: Lower Casing
6: Grate
7: Feed
8: Product

.
fig 03 cross section of the hammer crusher

1.3 Belt conveyors

Therefore the limestones which diameter less than 25mm is felt into the 29x-BC1 belt conveyor. By
using the metal chains and rubber sheats we have restrict the limestone to smash away from the
crusher. Then the limestone felt onto the beltconveyour 29x-BC2from 29x-BC1 & then limestone felt
onto the 29x-BC3. These 3 belts are powered by the motors which have the power of 7.5kw, 5.5kw,
7.5kw.

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1.4 Raw material conveyed yard

Then the material is feed in to the belt 292BC4& as you can see in this figure at the trolley
the limestone felt into the mixbeds according
to the requirement what we are supply into the
automatic system which drive the trolley. As
you can see in this figure there are 14 columns
at the raw material conveyed yard. Between 35,5-7 we use to put LGL limestone &between 810,11-13 we use to put HGL limestone.

Fig 04 trolley at the raw material conveyed yard

By using the loaders we pre blend the mix beds & then the LSF value become close to our expectations.

Fig 05- preblending

After preblending we put the limestone into the bin 311-HP1 as you can see in the below. This operation
leads to the pre homogenizing. Then through the following belt conveyours 311-BC1,311-BC2,311BC3,311-BC4,311-BC5 & limestone is put into the rawmill hoppers.

Fig 06- preblended material put into the bin

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2.RAWMILL

Fig 07-structure of the raw mill

2.1 Raw mill

After fill the raw mill hoppers according to the LSF values of limestone as high or low. From the laterite
yard we put laterite into laterite hoppers. But before the limestone fell into belt 331-BC2 little amount
of laterite is put onto the belt according to relevant percentage. Through a flap valve the raw material is
feed into the raw mill. At the inlet we supply a hot gas connection to reduce the moisture of the
limestone to 7-8% & it increase the efficiency of the grinding. Normally the temperature of hot gas from
kiln is above 300 degrees. But the hot gas shoud not be above 450 degrees, because there may be
failures happen in bearings.
Grinding is done by the set of metallic balls which is put in the raw mill & there diameters are changing
from 30-90mm. The raw mill is separate into 2 parts & there are 2 types of liners inside the raw mill
shell. In inlet side there are lifting liners & in the outlet side there are classify liners. These liners directly
influence of welgrinding of the raw material. The raw mill is run by a motor which is connected to the
girth gear of the raw mill by the shaft of the motor.the length of the rawmill is 7.1m & radius is 3.5m.

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Material
feeding

Classifier
liners

Lifting
liners

Girth gear

Feed to the
seperator

Hot gas
inlet

Fig 08-Rawmill

2.2 Air separator

Fine material into the twin cyclones

Coarse particles re enter to

the raw mill
Limestone suction into
seperator
Fig 09 structure of the separator

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Guide vanes

The grinded material is sucked by an airblover through the path that meets air separator & twin cyclone.
At the static air separator we use in holcim fulfill the requirement of restrict the coarse particles &
return them back into rawmill & allow to blend & flow to twin cyclones to the fine particles. Coarse
material goes to the walls because of centrifugal forces generated by the distributor plate and counters
blades, slips down at the grit cone wall and leaves at the bottom tailings outlet.Fine material exits at the
bottom of the casing fine outlet. Product fineness is adjusted by counter blade position and rods (5) (No
counter blade speed adjustment is possible).

2.3 Twin cyclone & silos

After go through separator the fine particles suck into the twincyclone and blend in it. Due to the
centrifugal force of weight of the particles the material felt into a double screw that powered by a
motor beside of the screw. Then fine material is felt in to the FK pump & it pumps the material into the
blending silos at the top of storage silos. At the bottom of the blending silos are separate into 4 quarters
& in a quarter there are 76 tiles. Through these 304 tiles the air is smashed into the blending silos
according a sequence & blends the fine material. After that material is flow into a distribution box by
fluidizing with air slides .At the distribution box material is feed into the storage silos.

Feed

Immersion tube
Feed
Cylindrical part

Conical part

Fig -11 Particle moment inside the cyclone

Tailings
.

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Fig -10 Twin cyclone