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Innovative Technology
Introduction
• Crusher Parts
• Blow Bars
• Hammers
• Preheater Parts
• Dipping Tubes
The Story So Far
• Ball Mills
• 350,000+ mt Grinding Media Used
• 75,000+ mt High Chrome Liners Supplied
• 400+ Ball Mills Retrofitted
• 140+ Diaphragms Installed
• Vertical Mills
• 35000+ mt Wear Parts Supplied
• 400+ Mills Retrofitted
• 2000+ Inserted Rolls Used
• Group
• 2000+ Mills Studied & Audited
• 80 Engineers World-Wide
• Global Contracts with Cement Groups
• Supplier to many OEMs
• 30 Years Experience, $45m+ Turnover
Offices World-Wide
• United Kingdom
• United States of America
• Canada
• United Arab Emirates
• India
• Vietnam
• Philippines
Introduc tion
MANUFACTURING LOCATIONS
AIA Engineering
Ahmedabad
Paramount
Nagpur
Welcast
Bangalore
Previous/next/Top
11
Introduction
13
EU
Warehouse
Facility -
Felixstowe UK
Introduc tion
FLS
Krupp Polysius
KHD
Kawasaki Heavy Industries
Larson and Toubro (Licensee of FLS)
Alstom Power (Stein Industrie)
BHEL
Pfeiffer
14
Introduc tion
Holcim
Lafarge
Heidelberg
Cemex
Dyckerhoff
Butzzi
Italcementi
India - ACC/Gujarat Ambuja
Grasim/Larsen & Toubro
15
Introduction
Up to 1 MT single piece
Blow bars & hammers 700
VEGA PLUS
Vegatough-18 Vegaplus
C 2.3% Avg. 2.9% Avg
Cr. 17% Avg. 21% Avg
Other alloying 2.0% Max 4.0% Max
elements
Hardness > 59.5 RC > 63.5 RC
RA < 6% < 5%
47
Pro duct
Grind ing m edia
VEGAPLUS
MANUFACTURING SPECIALISATION
48
Product
Grinding media
46
Grinding Media
• Second Chamber
• Vegahard 12 Standard Grade
• High level of Physical Integrity Through Rigorous Process Control
• Non-Automated Quality Inspections
• No Breakages or Mismatch
• Vegahard 15 High Performance Grade
• Higher Hardness and Cr Content
• Excellent Wear & Good Corrosion Resistance
• Vegahard 18
• Highly corrosion resistant grade
Product
Grinding media
50
Product
Grinding media
GRINDING MEDIA
DURING SERVICE
53
59
Design conc ept
24
Product
Ball mill liners
71
Products
Ball mill liners
75
Products
Ball mill liners
- Mill Dia
- Speed Of Rotation Hardness
- Material To be Ground Feed Size
- Volume Load Composition
- Max. Ball Dia
- The Length Of The Chamber
77
Products
VARIOUS PROFILES
Profile Feature and Application Sketch
Step liners- Continuous and sufficient lifting action.
Different
profiles like -Standard application where some amount of
smooth or fine generation is expected in the crushing
wavy zone also.
working face
and high lift -For hard feed materials
depending on
the operating -For mills showing high wear of internals due
conditions to slippage phenomenon.
78
Products
VARIOUS PROFILES
79
Products
Ball mill liners
VEGALITE LINERS
Ease of handling
82
Products
Ball mill liners
VEGALITE LINERS FOR
MILL DIA. 4.0 TO 4.4 M
84
Products
Ball mill liners
FIRST CHAMBER LINERS -
BENEFITS OF DOUBLE WAVE LINERS
86
Products
Ball mill liners
ADVANTAGE OF DOUBLE
WAVE LINERS
Dead zone
Dead zone is
minimized
87
Products
WEAR PROFILE OF DOUBLE WAVE Ball mill liners
Weight Lifting % of % of
(KG.) height Weight Lifting
(MM ) height
Worn-out 37.63 51.7 53% 72.8%
liner
100
Product
Partition diaphragm
LEVEL CONTROL DIAPHRAGM –
CYLINDRICAL LIFTERS
109
Product
Ball mill liners
71
Products
SECOND CHAMBER LINER - Ball mill liners
VARIOUS PROFILES
VARIOUS PROFILES
Profile Feature and Application Sketch
Conveying Improved material transport in the
Classifying mill alongwith the normal
Liner classification function.
When a high volume loading is required
which in turn leads to problem of
material flowability due to higher level
of restriction by the balls.
Lifting High air volumes can be utilized in the
Classifying circuit since possibility of changing to
Liner mono chamber configuration.
Usually for applications where it
becomes necessary to have both crushing
and grinding in the same chamber.
Thin For mills requiring a very high
Classifying volume loading to absorb maximum
Liners available power. 112
Products
Ball mill liners
C% 1.5-2.0 2.2-2.6
Cr % 11-14 22-26
Wear resistance Good Excellent
Both the grades are suitable only for non-lifting liners and ball charge with
<60 mm dia balls.
113
115
Product
Discharge diaphragm
116
Product
Discharge diaphragm
OUTLET DIAPHRAGM -
FEATURES
The design is adapted for any type of shell drilling pattern and
sizing of parts is such that they can be easily carried inside
the mill through manhole also.
117
Product
Discharge diaphragm
ANTI-CHOKING GRATES
118
Designing &
retrofitting
ACC TIKARIA – CM#1
Breakage observed in CM# 3 internals supplied by competition.
No breakage in CM#1 internals designed and supplied by AIAE in suitable
metallurgy.
125
Competition internals AIAE internals
Designing &
retrofitting
LAFARGE SEATTLE FM#2,USA
After AIAE designed internals were installed, significant
reduction in power was noticed.
Mill no. Before After
Diameter 4.0 m
2nd chamber liner Dragpeb Classifying
Absorb power 1613 KW 1497 KW
Output 40 tph 40 tph
128
Designing &
retrofitting
LAFARGE ARASMETA CM#1, INDIA
Initial design was by FLS. After detailed study,we decided to change
chamber lengths, partition wall diaphragm and second chamber liners.
These steps resulted in significent improvement in performance.
Mill no. Before After
Diameter 4.0m
Length 10.93m
RPM 16.54
1st chamber liner Block type Block type
Intermediate dph. Combidan LCD
2nd chamber liner Dragpeb Classifying
Absorb power 2756 KW 2644 KW
Blaine (OPC) 3000 3200
Output 65 tph 76 tph
Superiority in Production 16.9%
Saving in Specific power 21.8% 127
Products
Ball mill liners
LIFE GUARANTEES
The table below gives guarantees for OPC grinding at 3600 Blaine.
Description of parts and a lloys Gua rantee Expected
life
LIFE GUARANTEES
98
Products
Vertical mill parts
AIA/VEGA TODAY
MANUFACTURING CAPACITY –
MAXIMUM WEIGHT PER PIECE
Inserted rollers – 12 MT
Table liners – 10 MT
Products
Vertical mill parts
POLYSIUS TABLES
Location
Sr. No OA No. Plant Mill ID Roller Specification
(State)
24
Products
Sintercast-11
PERFORMANCE OF SINTERCAST 11
WEAR PARTS IN ATOX 27.5 COAL MILL
Parameters AIAE conventional roll AIAE Sintercast-11 roll
3 AVERAGE LIFE 2000 - 2500 Hrs 5000 - 6000 Hrs 10000 - 12000 Hrs
WITH > 35 % ash COAL
WEAR RATE 22 - 24 mm 10 - 12 mm 5 - 6 mm
4
WITH > 35 % ash COAL per 1000 Hrs per 1000 Hrs per 1000 Hrs
GRINDING ELEMENTS > Two times than > Four times than NI
5
LIFE NI Hard rolls Hard rolls
Consistent and consistent and best due
Reduced due to
6 GRINDING ABILITY better due to to Honey-comb type
slippage of rolls
serrations on rolls structure on rolls
7 COLLAR FORMATION High Negligible Negligible