INTRODUCTION TO BOWL MILLS

Coal is the one of the most dominating energy source because of its cost, availability
and transportability. Pulverized form of coal has made modern steam generating units
highly thermal efficient, reliable, safe and able to efficiently use of low-grade coals. It
provides coal-air fuel control, flame stability, effective utilization of carbon and thus
reduction in cost and flexibility of operation. The efficiency of combustion depends upon
efficiency of pulverizing.

The machine used for particle size reduction is called pulverizes or mill. In 1919 at
combustion Engineering U.S.A., Raymond Mill was developed. The early mills were built
with maximum capacity of 6 tons per hour. By 1930 the maximum capability of this mill
design had been increased to 15 and then to 25 tons per hour.

Grinding mills use one , two or all three of the basic principles of particle size reduction
namely impact, attrition and crushing. With respect to speed these machines may be
classified as low speed, medium speed and high speed. The characteristics of commonly
used pulverizes are shown in the table below

Speed

Low

Medium

High

Type

10 to 20 RPM

40 to 70 RPM

900 TO 1000 RPM

Ball Tube Mill

Ring Roll Mill

Impact or Hammer
Mill

Ball and Race Mill

Bowl Mill

Predominant

Attrition

Crushing

Impact

Principle

BOWL MILL

This is a medium speed vertical mill with conical grinding rolls 3no.s per mill. The race
will be either deep or shallow like saucer covered with liner called bullring segment. The
bowl is rotated by a gearbox have reducing gear like worm gear set or bevel helical
gears.

CE Raymond Mills were first developed for pulverizing coal for cement and mining
industry. Subsequently, they found extensive use in the Power Plants for Pulverizing
coal. BHEL entered in to technical collaboration with Combustion Engineering, USA for
the manufacture of these mills called XRP mills in India.

Subsequently technology for HP mills with withdraw-able was also acquired from CE.
Upto 1978 the Bowl Mills were manufactured at BHEL-Tiruchirapalli. From 1978 to 1984
these were manufactured at both BHEL-Tiruchirapalli and BHEL-Hyderabad. From 1984
onwards total product has been with BHEL-Hyderabad.

Nomenclature
583 XRS/803 XRP Bowl Mills.
58,80 Stands for Bowl diameter in inches.
If the number is even then its Shallow Bowl Mill.
If the number is odd then its Deep Bowl Mill
3-Number of Rollers
X- Frequency of Power supply(50 cycles).
R- Raymond Name of the inventor
S- Suction type with Exhauster after mill

P- pressurized type with P.A. FAN before mill

The above mills have saucer type bowl (approx. 20 angle to horizontal).There are few
Bowl Mills initially supplied by CE in india. They have been discontinued.

Range:
BHEL manufactures Bowl Mills in the following Ranges (corresponding to Bowl diameter
in inches):
1. 60" Series : 583, 603 & 623 XRP/XRS
2 66" Series : 663 XRP
3 70" Series : 703 XRP, 703 HP
4 80" Series : 763, 783,803 XRP, 803 HP
5 90" Series : 883 XRP
6 100"Series : 1003 XRP
Principle of Operation
Bowl Mill is driven by AC motor, coupled with flexible coupling to the worm shaft. The
worm shaft drives worm gear, mounted on the Main Vertical Shaft. A bowl mounted on
the top of the shaft rotates at a speed of 40 to 65 rpm. For a particular mill the speed is
constant .Integral coolers are provided in the mill base with circulating water for
removing heat from the oil. External lube oil systems are also used for cooling the oil in
the gear box, which consists of a motor driven pump, cooler and filter. To prevent coal
entering in to the Gear case, an air sealing system is provided.

Hot primary air for drying and carrying pulverized coal, enters through insulated Mill
side and Liner Assembly. Tramp Iron, pyrites and stones coming in the mill with raw
coal move out of the bowl and being heavy, fall into the mill side and linear assembly.
These are scraped and dumped in the pyrite hopper assembly through the Tramp Iron
and Spout valve.

The journal assembly consisting of Grinding Rolls is mounted on Separator Body.

Grinding force is applied by pressure spring adjustment. The roller assembly can be
moved up and down depending upon the roll condition and coal bed. Separator Body
consisting of linear assemblies deflects the air stream to the center of bowl.

Mill is equipped with the stationery classification with adjustable vanes for adjustment
of coal fineness. The coarser particles in the in the pulverised coal are separated in the
classifier and returned back to the bowl for further grinding.

Mill Discharge Valves mounted on the Separator top consist of Flap type closure plates
operated by pneumatic Cylinders, which can be tilted out of the path of coal stream.
This is used to isolate the mill from Boiler during maintenance.

Pulverizer
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A pulverizer or grinder is a mechanical device for the grinding of many different types of materials. For
example, they are used to pulverize coal for combustion in the steam-generating furnaces of fossil fuel power
plants.
Contents
[hide]

1 Types of pulverizers

1.1 Low Speed

1.1.1 Ball and tube mills

1.2 Mill Constructions And Details

1.3 Working

1.4 Medium Speed

1.5 Vertical spindle roller mill

1.4.1 Ring and ball mill

1.5.1 Bowl mill

1.6 High Speed

1.6.1 Attrition Mill

1.6.2 Beater Wheel Mill

1.6.3 Hammer Mill

1.7 Demolition pulverizer

2 See also

3 References

4 Bibliography

Types of pulverizers[edit]
Coal pulverizers may be classified by speed, as follows: [1]

Low Speed

Medium Speed

High Speed

Low Speed[edit]
Ball and tube mills[edit]
A ball mill is a pulverizer that consists of a horizontal rotating cylinder, up to three diameters in length,
containing a charge of tumbling or cascading steel balls, pebbles, or rods.
A tube mill is a revolving cylinder of up to five diameters in length used for fine pulverization of ore, rock, and
other such materials; the material, mixed with water, is fed into the chamber from one end, and passes out the
other end as slime (slurry).
Both types of mill include liners that protect the cylindrical structure of the mill from wear. Thus the main wear
parts in these mills are the balls themselves, and the liners. The balls are simply "consumed" by the wear
process and must be re-stocked, whereas the liners must be periodically replaced. The ball and tube mills are
low-speed machines that grind the coal with steel balls in a rotating horizontal cylinder. Due to its shape only,
people call it as Tube Mill and due to use of Grinding Balls for crushing, it is called Ball Mill. Hence, is the name
Ball Tube Mill. These Mills are also designated as BBD-4772, Where- B Broyer (Name of inventor). B

Boulet (French word for Balls). D Direct firing. 47 Diameter of shell (in Decimeters) i.e. 4.7m dia. 72
Length of shell (in Decimeters) i.e. 7.2 m length
By the name the grinding in the ball and tube mill is produced by rotating quantity of steel balls by their fall and
lift due to rotation of tube. The ball charge may occupy one third to half of the total internal volume of the shell.
The significant feature incorporated in the BBD mills is its double end operation, each end catering to one
elevation of a boiler. The system facilitated entry of raw coal and outlet of pulverized fuel from same end
simultaneously. This helps in reducing the number of installations per unit.

Mill Constructions And Details[edit]

A ball Tube mill may be described as a cylinder made of steel plate having separate heads or trunion attached
to the ends with the trunion resting on suitable bearings for supporting the machine. The trunion are hollow to
allow for the introduction of discharge of the materials undergoing reduction in size. The mill shell is lined with
chilled iron, carbon steel, manganese steel, High Chrome liners attached to shell body with counter sunk
bolts.These liners are made in different shapes so that the counter inside surface of the mill is suited for
requirement of application.
The Shells are of three pieces. The Intermediate shell connects to the end shells by flange joints and the total
length of shell is 7.2 m. The liners are fastened to the inner side of mill shell (cylindrical part) to protect the shell
from the impact of steel balls. There are 600 nos. of liners of ten variants in each shell weighing 60.26 MT. The
original lift value of the liners is 55 mm. and the minimum lift allowed is 20 mm.

Working[edit]
Primary air in the case of Tube Mill have dual function to perform. It is used as drying as well as transporting
media and by regulating the same the Mill output is regulated. Governed by the pulverize fuel outlet
temperature requirement the combination of cold air and hot air dampers are regulated to have proper primary
air temperature. In addition to raising the coal temperature Inside the Mill for drying and better grinding the
same air works carrying media for pulverized coal through annular space between fixed trunnion tube and
rotating hot air tube on way to classifier. Coal-laden air passing through Double cone static classifiers with
adjustable classifier vanes for segregation Into pulverized fuel of desired fineness and coarse particles
continues its journey towards coal burners for combustion. Coarse particles rejected in classifier find their way
back to mill for another cycle of grinding. In order to avoid excess sweeping of coal from Mill Only Part Of the
primary air, directly proportional to the boiler load demand is passed through Mill. Further to ensure and
maintain sufficient velocity of pulverized fuel and to avoid settling in P.F. pipes an additional quantity of primary
air is fed into mixing box on raw coat circuit. This by-pass air tapped from the primary air duct going in Mill
makes appreciable contribution for drying of raw coal by flash drying effect in addition to picking pp the
pulverized fuel from Mill outlet for its transportation towards classifiers. Tube mill output while responding to
boiler load demand is controlled by regulating primary air-flow. Such regulation by sweeping away of pulverized

fuel from Mill being very fast rather well comparable with oil firing response, needs coal level to be maintained
in the Mill. Mill level control circuit sensing the decreased coat level in Mill increases the speed of raw coal
feeder and vice avers. Maintaining the coal level in Mill offers built-in-capacity cushion of pulverized fuel to take
care of short interruption in raw coal circuit. The mill is pressurized and the tightness is ensured by plenum
chambers around the rotating trunnion filled with pressurized seal air. Bleeding seal air from plenum chamber
to Mill provides air cushion between pulverized fuel in the Mill and the outside atmosphere. Inadequacy or
absence of seal air will allow escape of pulverized fuel into atmosphere. On the other hand excess of seal air
leaking into Mill will affect the Mill outlet temperature. As such the seal air is controlled by a local control
damper by maintaining just sufficient differential pressure for sealing.

Medium Speed[edit]
Ring and ball mill[edit]
This type of mill consists of two types of rings separated by a series of large balls, like a thrust bearing. The
lower ring rotates, while the upper ring presses down on the balls via a set of spring and adjuster assemblies,
or pressurised rams. The material to be pulverized is introduced into the center or side of the pulverizer
(depending on the design). As the lower ring rotates, the balls to orbit between the upper and lower rings, and
balls roll over the bed of coal on the lower ring. The pulverized material is carried out of the mill by the flow of
air moving through it. The size of the pulverized particles released from the grinding section of the mill is
determined by a classifier separator - if the coal is fine enough to be picked up by the air, it is carried through
the classifier. Coarser particles return to be further pulverized.

Vertical spindle roller mill[edit]

Similar to the ring and ball mill, this mill uses large "tires" to crush the coal. These are usually found in utility
plants.
Raw coal is gravity-fed through a central feed pipe to the grinding table where it flows outwardly by centrifugal
action and is ground between the rollers and table. Hot primary air for drying and coal transport enters the
windbox plenum underneath the grinding table and flows upward through a swirl ring having multiple sloped
nozzles surrounding the grinding table. The air mixes with and dries coal in the grinding zone and carries
pulverized coal particles upward into a classifier.
Fine pulverized coal exits the outlet section through multiple discharge coal pipes leading to the burners, while
oversized coal particles are rejected and returned to the grinding zone for further grinding. Pyrites and
extraneous dense impurity material fall through the nozzle ring and are plowed, by scraper blades attached to
the grinding table, into the pyrites chamber to be removed. Mechanically, the vertical roller mill is categorized
as an applied force mill. There are three grinding roller wheel assemblies in the mill grinding section, which are
mounted on a loading frame via pivot point. The fixed-axis roller in each roller wheel assembly rotates on a

segmentally-lined grinding table that is supported and driven by a planetary gear reducer direct-coupled to a
motor. The grinding force for coal pulverization is applied by a loading frame. This frame is connected by
vertical tension rods to three hydraulic cylinders secured to the mill foundation. All forces used in the pulverizing
process are transmitted to the foundation via the gear reducer and loading elements. The pendulum movement
of the roller wheels provides a freedom for wheels to move in a radial direction, which results in no radial
loading against the mill housing during the pulverizing process.
Depending on the required coal fineness, there are two types of classifier that may be selected for a vertical
roller mill. The dynamic classifier, which consists of a stationary angled inlet vane assembly surrounding a
rotating vane assembly or cage, is capable of producing micron fine pulverized coal with a narrow particle size
distribution. In addition, adjusting the speed of the rotating cage can easily change the intensity of the
centrifugal force field in the classification zone to achieve coal fineness control real-time to make immediate
accommodation for a change in fuel or boiler load conditions. For the applications where a micron fine
pulverized coal is not necessary, the static classifier, which consists of a cone equipped with adjustable vanes,
is an option at a lower cost since it contains no moving parts. With adequate mill grinding capacity, a vertical
mill equipped with a static classifier is capable of producing a coal fineness up to 99.5% or higher <50 mesh
and 80% or higher <200 mesh, while one equipped with a dynamic classifier produces coal fineness levels of
100% <100 mesh and 95% <200 mesh, or better.
In 1954 a Jet Pulverizer was developed in which operates like a Vertical Pulverizer only the item is pulverized
by the high speed air action. For example forcing coal against coal. [2]

Bowl mill[edit]
Similar to the vertical roller mill, it also uses tires to crush coal. There are two types, a deep bowl mill, and a
shallow bowl mill.

High Speed