MILLS

Lining plates for mill heads and mill shell

Installation

Approved date:

Created by:

Approved by:

Doc. No.: 23941-06-2.0

 MILLS
23941-06-2.0

Table of contents:
Page
1  General information ....................................................................................... 3 
1.1  Materials ...................................................................................................... 3 
1.2  Transportation and handling ........................................................................... 3 
1.3  Machining ..................................................................................................... 3 
1.4  Fixation ........................................................................................................ 3 
2  Installation .................................................................................................. 4 
2.1  Parts of manganese steel ................................................................................ 4 
2.2  Parts of chromium-molybdenum steel and Ducrodan .......................................... 4 
2.3  Lining parts for plane mill heads and diaphragms .............................................. 4 
2.4  Lining plates for conical mill heads ................................................................... 4 
2.5  Mill shell liners .............................................................................................. 4 
2.5.1  Dry-process mills ............................................................................... 4 
2.5.2  Wet-process mills .............................................................................. 5 
2.5.3  Stepped liners ................................................................................... 5 
2.6  Angle iron spacers ......................................................................................... 5 
2.7  Seals............................................................................................................ 6 
2.8  Alignment and installation............................................................................... 7 
2.8.1 ....................................................................................................... 7 
2.8.2 ....................................................................................................... 7 
2.8.3 ....................................................................................................... 7 
2.8.4 ....................................................................................................... 7 
2.8.5 ....................................................................................................... 7 
2.8.6 ....................................................................................................... 7 
2.8.7 ....................................................................................................... 7 
2.8.8 ....................................................................................................... 7 
2.8.9 ....................................................................................................... 7 
2.8.10 ....................................................................................................... 7 
2.9  Re-tightening ................................................................................................ 8 
2.10  Diaphragms .................................................................................................. 8 
3  Dismantling of worn lining parts ...................................................................... 8 
4  Operation .................................................................................................... 8 

List of figures:

Figure 1 ....................................................................................................................... 5 
Figure 2 ....................................................................................................................... 6 
Figure 3 ....................................................................................................................... 6 

2/8 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
MILLS
23941-06-2.0

NOTE!
The present instruction manual is concerned with the situations which, according to the
experience of FLSmidth, are the most likely to occur. An exhaustive enumeration of all
conceivable situations, which may occur during manufacture, installation, operation and
maintenance of the equipment, cannot be provided.
Consequently, if a situation should arise, the occurrence of which is not foreseen in the
instruction manual, and which the operator is/or feels unable to handle, it is
recommended that FLSmidth is contacted without undue delay for advice on
appropriate action.

1 General information
1.1 Materials
The lining parts are manufactured from one or several of the following
materials:
Manganese steel Mat. 330
Chromium-molybdenum steel Mat. 33D
Ducrodan Mat. 361
Ducrodan Mat. 362
Ducrodan Mat. 363

1.2 Transportation and handling

Chromium-molybdenum steel and Ducrodan are cast steels with excellent
characteristics in terms of wear resistance and hardness, whereas the
toughness characteristics are limited.
Because of the brittleness of these materials, it is essential that lining parts
fabricated from such materials are handled with extreme care during
transportation and handling at site. These lining parts must never be thrown
about or hurled casually into a pile on top of one another, since impact and
pressure loads may cause the lining parts to crack.
However, correctly installed, lining parts manufactured from chromium-
molybdenum steel and Ducrodan will have a very long lifetime in comparison
with lining parts made of other materials.

1.3 Machining
Where machining of parts made of chromium-molybdenum steel and Ducrodan
is required, this must only be done by grinding, and the operation must always
be performed in manner preventing localized heating, which may give rise to
crack formations.
Operations involving welding and usage of cutting torch not allowed!

1.4 Fixation
At stage where the lining parts are fixed they must be supported in such
manner that major bending stresses are avoided when the bolts are tightened,
since such stress forces will often result in fractures.
The fastening bolts for the lining plates must be tightened to the specific
torque level. See erection drawing or parts list.
Bolts to be re-tightened until the torque remains constant.

The information transmitted by this document is the proprietary and confidential property of FLSmidth 3/8
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
 MILLS
23941-06-2.0

Note!
Any superfluous bolt holes on mill shell and slide rings must be closed with
rubber plugs. The holes must not be closed by welding since such welding
would leave stress concentrations so substantial that destructive crack
formations would be developed.

With the exception of the welds specifically indicated on drawings and in

instruction manuals no welding, nor repair welding, must be performed on mill
shell unless prior approval has been obtained from FLS.

2 Installation
2.1 Parts of manganese steel
Cast lining parts manufactured from the comparatively tough manganese steel,
Mat. 330, can be installed directly.
Despite the excellent resistance of this material against impacts and bending
stresses, endeavours are needed to ensure optimum contact between the lining
parts and the support base.

2.2 Parts of chromium-molybdenum steel and Ducrodan

In connection with the installation of lining parts made of chromium-
molybdenum steel Mat. 33D and Ducrodan Mat. 361, Mat. 362 and Mat. 363, it
is essential to ensure that the contact faces of the lining parts around the bolt
holes are lying true against the support base.

2.3 Lining parts for plane mill heads and diaphragms

As far as parts manufactured from chromium-molybdenum and Ducrodan are
concerned, it is essential that plates and grates have been ground at the
foundry in such manner that the contact face is lying true against a plane
surface. However, a warpage of 2 mm can be tolerated for chromium-
molybdenum steel.
During the installation it must be checked that the area which is to be covered
by the plate or grate is plane and without any projections and that the plate or
grate rests only on the contact faces around the bolt holes.

2.4 Lining plates for conical mill heads

Since conical mill heads are turned off on the surface where the lining plates
are to be mounted, the conical shape of the mill head is always correct. The
plates are designed so that they are equipped with contacting faces, on the
back side around the bolt holes, and these are the only contact faces of the
places against the mill head. Consequently, it must be checked when mounting
the lining plates that they bear only against the mill head on the said contact
faces. All other points on the back side of the plates which may potentially get
into contact with the mill head must be removed by grinding.

2.5 Mill shell liners

2.5.1 Dry-process mills
In dry-process mills the liners are fitted directly on the mill shell.
Optimization of contact level between liners and mill shell must always be
ensured.

4/8 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
MILLS
23941-06-2.0

Standard lining plates are designed so that one lining plate can be
deployed for a wide range of mill diameters.
Therefore, two different radii are used for the contact faces of the liners up
against the mill shell. Consequently, the contact faces at the centre of the
liner (in the longitudinal direction of the mill) will bear against the support
base when the lining plate is mounted in the largest mill shell for which the
liner can be deployed, whereas the contact faces outside the centre area
will bear against the support base when the liners are installed in the
smallest mill shell.
The liners must be mounted firmly against the mill shell, without any
tilting. Otherwise, adjustive measures will be needed.
The cylindrical shape of the mill shell is rarely quite accurate. Welded
seams and other irregularities may prevent the liners from lying truly
against the mill shell. Consequently, it may become necessary to remove
such irregularities by grinding, and adaptation of the contact faces by
grinding may likewise be required.
2.5.2 Wet-process mills
Wear on the mill shell will be incurred in case slurry is able to penetrate to
the backside of the lining plates. In order to avoid this situation, a 3 mm
rubber plate must be inserted between the lining plate and the mill shell.
The rubber plate is supplied in sections having a width of approx. 1 metre
and in lengths corresponding to the length of the compartment.
Bolt holes in rubber plate to be punched by means of a hollow punch or
with the pane of a ball-pane hammer.
The liners are bolted on in rows in accordance with the generatrices of the
shell, and the rubber plate is stretched out as the work progresses.
Filling material other than the said rubber plates must not be used.
2.5.3 Stepped liners
Stepped liners to be mounted so that the thin end of the liners is facing
forward in the rotational direction of mill. See Fig. 1.

Figure 1

2.6 Angle iron spacers

Angle irons (01) are supplied together with the lining parts; these angle irons
can be inserted in the recesses of the lining parts, as shown in Fig. 2.
The angle irons are fitted in order to prevent that the lining parts are twisted
from their correct position in connection with the tightening-up procedure or
during operation. Wherever possible, the angle irons must be fitted in all
recesses.

The information transmitted by this document is the proprietary and confidential property of FLSmidth 5/8
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
 MILLS
23941-06-2.0

Figure 2

In event that the cast lining parts are underdimensioned to such an extent that
the angle irons are unable to prevent twisting of the lining plates, plates (02)
must be welded onto the angle irons; the plates must have the required
thickness to prevent twisting of the lining part.

Figure 3

2.7 Seals
All through-going bolts, both at mill heads and on mill shell, to be packed in
such manner as to ensure tightness of the mill body.
The seals consist of a rubber washer (03).
The rubber washer is inserted in a machined standard washer (04), which is
bored to diameter slightly exceeding the diameter of the rubber washer.
The standard washer is thinner than the rubber washer, and the hole in the
rubber washer is somewhat smaller than the outside diameter of the bolt
thread, so that the washer fits tightly on the thread. The bolt is also equipped
with a plain retainer washer (05). When the nut of the bolt is tightened, the
rubber washer is compressed so that it is packed tight, both around the thread
and up against the mill shell.

6/8 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
MILLS
23941-06-2.0

2.8 Alignment and installation

2.8.1
Start by mounting the lining plates on the inlet bottom.
2.8.2
During the alignment phase maximum efforts are needed to ensure that
the gaps between the liners have the same width.
Mount the angle irons where it is possible to do so. See sub-section 2.6.
2.8.3
The bolts must be able to pass through the holes without any impediments,
and the bolts must be placed at right angles to lining plate and mill head.
2.8.4
Bolts to be mounted with rubber sealing rings and washers as described in
sub-section 2.7.
2.8.5
Smear the thread with a small amount of oil containing molybdenum
disulphide additive (Molykote or the like) before the nut is screwed onto
the bolt.
2.8.6
It must always be ensured that the bolt is led all the way through the lining
plate so that the bolt head bears firmly against the bottom of the recess.
2.8.7
Use a hammer to apply a few heavy blows to the bolt head when tightening
the nut.
2.8.8
Then tighten the bolts with a torque spanner until the specified torque level
is attained. For torque level, see erection drawing.
2.8.9
Then proceed on the same lines with the mounting of the lining plates on
the mill shell. Initially, mount the lining plates adjacent to the mill head.

Note!
In UMS mills the first ring of lining plates on the mill shell, nearest
the inlet bottom (the inlet slide ring), is fitted without usage of bolts.
These liners are held in place by the outermost ring of liners on the
inlet bottom and the second ring of liners on the mill shell.

After the installation of the entire bolted-on lining has been completed, it is
of paramount importance to ensure that the boltless liners are wedged
firmly in place!
This is achieved by driving a sufficient amount of the flat irons - included in
the supply - in between the plate joints.
2.8.10
Once all lining parts have been mounted, or at the latest just prior to the
start-up of mill, an inspection must be performed to make sure that all
bolts are tightened to the correct torque level. Use a torque spanner.

The information transmitted by this document is the proprietary and confidential property of FLSmidth 7/8
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
 MILLS
23941-06-2.0

2.9 Re-tightening
Bolts to be re-tightened at the latest 2 hours after the charged mill has been
put into operation, and subsequent re-tightening is required for every 12 hours
of operation until the torque level remains constant.

2.10 Diaphragms
The mounting procedure for grates and sectors on double diaphragms and
Combidan diaphragms is described in separate instruction manuals for these
diaphragms.
Re-tightening procedure as follows:
Bolts to be re-tightened at the latest 2 hours after the charged mill has been
put into operation, and subsequent re-tightening is required for every 12 hours
of operation until the torque level remains constant.

3 Dismantling of worn lining parts

On worn-out lining parts the bolt heads are normally so hammered down that it is
almost impossible to dismantle the bolts in normal manner.
However, since the lining bolts cannot be re-used it is possible to dismantle the lining
plates in accordance with one of the methods outlined below:
Either
- through melt-off of bolt head with a cutting torch whereafter the bolt is driven
out with a mandrel
or
- cut-off of nut and bolt end with a cutting torch whereafter the lining part is
removed together with the remaining bolt length.

Note!
Caution must be exercised when lining bolts are removed by means of a cutting
torch. The operation must not leave any scars on the mill shell. However, in the event
of any scars, smooth grinding of the scars must be undertaken, with even transitions
to the liner. See sub-section 1.4.

4 Operation
Where the mill is equipped with lining plates of Ducrodan (Mat. 361, Mat. 362 and
Mat. 363) it is essential to avoid operation with grinding media in mill, unless, prior
to such operation, feed material has been supplied to the mill in appropriate quantity
and provided that feeding is in progress. Otherwise, the liners will be subjected to
massive impact loading from the grinding media, and this situation will often result in
breakage of the liners.
Consequently, when the initial filling of grinding media takes place and in connection
with subsequent replenishing, it is essential that feed material is added
simultaneously, corresponding to about 25% of the weight of the grinding media
charge.

8/8 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.