Superior Performance

Through

Innovative Technology

IhrAnsprechpartner in Österreich:

Cement Products

• Tube Mill Parts:• Grinding Media

• Ball Mill Liners

• Partition Diaphragm

• Discharge Diaphragm

• Vertical Mill Parts:• Grinding Elements incl. Monometal/Inserted/Sintercast-11

• Crusher Parts• Blow Bars

• Hammers

• Preheater Parts• Dipping Tubes

10

PRODUCTS FOR CEMENT INDUSTRY

RANGE & CAPACITIES

ProductsAnnual cap.

M.T.Range

High chrome grinding

media40000* 12 mm to 110 mm dia,

Diaphragms 50 Nos.

Heat resistant castings 300Dipping tubes

VSM parts static casting 1800 Up to 16.5 MT single piece

Blow bars & hammers 700Up to 1 MT single piece

Mill liners 5500 1.8 to 5.8 M dia.mills

Introduction

1.8 to 5.8 M dia.mills

*GM capacity proposed to go upto 55000 MTPA in India and 45000 MTPA in Canada

Centrifugally cast rolls 3000 Raymond/CE mills

29

Grinding Media

• First Chamber• Vegatough 18 - Standard Grade• Hardness >60 RC, RC Range <1%, RA <6%

• Outperforms Competition by Ave 10%

• Batch Check of Quenched Properties Allows Fine Tuning of Tempering

• All Media is Batch Tempered with 18000mt Capacity/Annum

• VegaPlus - High Performance Grade• Hardness >63.5 RC, RC Range <1%, RA <5%

• 40-70% Improvement in Wear Rates

• High Carbide Content

• Multiple Tempering Cycles to Achieve Optimum RC & RA

47

> 63.5 RC> 59.5 RCHardness

< 5%

4.0% Max

21% Avg

2.9% Avg

Vegaplus

< 6%RA

2.0% MaxOther alloying

elements

17% Avg.Cr.

2.3% Avg.C

Vegatough-18

Product

Grinding media

VEGA PLUS

48

VEGAPLUS

MANUFACTURING SPECIALISATION

Product

Grind ing media

Manufacturing of Vegaplus requires special facilities.

This grade has very high carbide content and hencespecial precautions are required during cooling of poured

moulds.

In order to get optimum combination of hardness and RA,

this grade requires multiple stress relieving/temperingcycles which drastically reduces production capacity.

Thanks to special slow mould cooling techniques and largetempering capacity available at AIAE - it is possible toproduce this material commercially.

46

VEGAPLUS COMPARISON WITH

VEGATOUGH 18

Product

Grinding media

3500

3200

3340

Blaine

49257

655748

699396

Materia l

ground

DWL

Step liner

DWL

Liner

profile

3.4 m

4.8 m

4.4 m

Mill

diameter

52.33gms/t105.00gms/t

PSC

(50% slag)

Durgapur

Cement

44.48gms/t92.76gms/t

PPC

( 20% fly ash)J P Rewa

5.97gms/t27.48gms/tOPCGACL Kodinar

Vegaplus

consumption rate

Vega tough 18

consumption rate

Produc tPlant (India)

Additional feature of Vegaplus is that at the end of the trial

there was no deshaping/ tear which is observed in normal

grinding media. This means that there is no need of regrading

every year and mill can perform consistently for long duration.

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

50

GRINDING MEDIA FOR

SECOND CHAMBER

Product

Grinding media

ModerateExcellentGoodWear resistance

17-2014-1610-13Cr%

62-6666-6964-68Hardness (HRC)

Vegahard-19Vegahard-15Vegahard-12Vega alloy

58

WEAR RATE OF GRINDING MEDIA

Product

Grinding media

Wear rate figures given below are expected wear rate for Vegatough-18 &

Vegahard-12, for both the chambers taken together. Normally, both the

chambers contribute equally to the wear rate

120-15017%R/90 MicronsCoal (>25% ash)

60-10017% R/90 MicronsCoal (15% ash)

190-220-Limestone (10% SiO2)

75-100-Limestone (6% SiO2)

20-25-Limestone (<1% SiO2)

120-2104500PSC (70% slag)

160-1904500PSC (55% slag)

160-1904500PPC (25% fly ash)

120-1603800PSC (55% slag)

80-1603800PPC (25% fly ash)

60-1004500OPC

30-503000OPC

Range of wear rate gm/TFineness (Bl)Material

53

Product

Grinding mediaPROBLEMS ENCOUNTERED WITH

GRINDING MEDIA

DURING SERVICE

Selecting the correct grinding media for a particular applicationis important to avoid potential problems, such as:

High wear rate Deshaping

Spalling

Breakage

These problems can usually be traced to either quality of ballsor peculiar working conditions.

59

24

THE GOLDEN TRIANGLE

Design concept

There has to be total compatibility between application,

metallurgy and design.

71

Product

Ball mill liners

75

ALLOYS FOR FEED HEAD LINERS AND

FIRST CHAMBER SHELL LINERS

Vega Alloy Vegaline-107 Vegaline-125Vegaline-112

Hardness (HRC) 49-52 54-5648-52

C % 0.2-0.5 2.2-2.61.0-1.5

Cr % 6-9 22-2611-14

Wear resistance Moderate ExcellentGood

Impact resistance Excellent ModerateGood

Products

Ball mill liners

77

Choice of design of liners depends on mill operating

parameters such as :

- Mill Dia

- Speed Of Rotation Hardness - Material To be Ground Feed Size

- Volume Load Composition - Max. Ball Dia

- The Length Of The Chamber

FIRST CHAMBER LINER -

FEATURES

Products

Ball mill liners

78

Sketch Feature and ApplicationProfile

Step liners-

Differentprofiles like

smooth or

wavy

working face

and high lift

depending onthe operating

conditions

Continuous and sufficient lifting action.

-Standard application where some amount of

fine generation is expected in the crushing

zone also.

-For hard feed materials

-For mills showing high wear of internals due

to slippage phenomenon.

Double wave

Liner-Crushing efficiency remains constant

throughout its working life. The dead zone

is minimum.

When the material to crush is extremely hard

and high lifting action is required

FIRST CHAMBER LINER –

VARIOUS PROFILES

Products

Ball mill liners

79

Doublestep

Liner

Crushing efficiency remains constant

almost throughout its working life.

When high lifting action is required but

the mill has high speed of rotation

Sketch Feature and ApplicationProfile

Products

Ball mill linersFIRST CHAMBER LINER –

VARIOUS PROFILES

82

Unit weight of individual liner is restricted to 25 kgs.

Ease of handling

Modular design for fitment in wide range of mill sizes

Supply of liners at reduced delivery time

VEGALITE LINERS

Products

Ball mill liners

84

VEGALITE LINERS FOR

MILL DIA. 4.0 TO 4.4 M

Products

Ball mill liners

86

FIRST CHAMBER LINERS -

BENEFITS OF DOUBLE WAVE LINERS

Reduces the slippage of balls

Reduction in the SPC of the first chamber.

The grooving phenomenon is much less

More lift results in better crushing efficiency.

The dead zone is reduced.

Due to uniform wear, the lifting action is consistent

throughout the life time

Boltless design benefits in elimination of breakage,

falling of liners, more uniform metallurgy etc.

Products

Ball mill liners

87

ADVANTAGE OF DOUBLE

WAVE LINERS

Dead zone

Mill equipped with S&W Liner

Dead zone is

minimized

Mill equipped with DWL Liner

Products

Ball mill liners

91

WEAR PROFILE OF DOUBLE WAVE

LINER - LAKSHMI CEMENT

CM#1: 4000 dia. X 15050 L

Date of Installation : 26.05.1996

Date of Removal : 19.07.2001Running hours : 31,000 hrs.

Material ground : 2,945,000 Mt

Weight

(KG.)

Lifting

height

(MM)

% of

Weight

% of

Lifting

height

Worn-out

liner37.63 51.7 53% 72.8%

Worn-outportion

32.55 19.3 47% 27.2%

Original

liner70.18 71 100% 100%

Products

Ball mill liners

70

QUICK RESPONSE : AN EXAMPLE

Products

Ball mill liners

6th February 2004 unloaded at port Odessa for mill 1.

23rd February 2004 unloaded at port Odessa for mill 2.

Committed delivery

16th October 2003Date of receipt of

order

15th September 2003Date of submission of

techno – commercial

offer

27th August 2003Date of receipt of

enquiry

Complete mill internals (AIAE design) with grinding

media and water spray system.

Product

Kryvy Rih Cement (Heidelburger Zement), UkraineCustomer

99

100

LEVEL CONTROL DIAPHRAGM -FUNCTION

To keep the material level in the 1st

chamber at an optimum level.

The material entering the diaphragm

chamber through the slotted grates

exits into the second chamber only

through the rotating cylindrical lifters.

Product

Partition diaphragm

101

LEVEL CONTROL DIAPHRAGM –

CYLINDRICAL LIFTERS

These lifters can be easily adjusted by turning them on their axis.

Q (Lifter output/mill through put) = S (Effective c/s area) x h (Effective

material height in the lifter)

= constant

Product

Partition diaphragm

109

ALLOYS FOR WEARING PARTS OF

LEVELCONTROL DIAPHRGM

Vega Alloy Vegaline-107 Vegaline-125Vegaline-112

Hardness (HRC) 49-52 54-5648-52

C % 0.2-0.5 2.2-2.61.0-1.5

Cr % 6-9 22-2611-14

Wear resistance Moderate ExcellentGood

Impact resistance Excellent ModerateGood

Product

Partition diaphragm

71

Product

Ball mill liners

111

Sketch Feature and ApplicationProfile

Standard

Classifying

Liner

A very high level of attrition

leading to maximum

grinding efficiency.

Standard application for 2nd

chamber of ball mills where

highest level of grinding

efficiency is required.

Deep Wave

Classifying

Liner

Improved wear resistance by

reducing the ball slippage.

When a coarse final product is

desired and some amount of

crushing is also needed in the

2nd chamber.

Products

Ball mill linersSECOND CHAMBER LINER -

VARIOUS PROFILES

112

Conveying

Classifying

Liner

Improved material transport in the

mill alongwith the normal

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

Classifying

Liner

High air volumes can be utilized in the

circuit since possibility of changing to

mono chamber configuration.

Usually for applications where it

becomes necessary to have both crushing

and grinding in the same chamber.

Thin

Classifying

Liners

For mills requiring a very high

volume loading to absorb maximum

available power.

Sketch Feature and ApplicationProfile

SECOND CHAMBER LINER -

VARIOUS PROFILES

Products

Ball mill liners

113

Vega alloy. Vegaline-212

1.5-2.0 2.2-2.6

ALLOYS FOR SECOND CHAMBER

SHELL LINERS

C %

11-14 22-26Cr %

Good ExcellentWear resistance

55-57 59-61Hardness (HRC)

Vegaline-225

Products

Ball mill liners

Both the grades are suitable only for non-lifting liners and ball charge with

<60 mm dia balls.

115

116

Free passage of material from

chamber to the mill outlet

Ensure maximum opening

area for optimum ventilation

Prevent escape of small size

grinding media from the mill

Product

Discharge diaphragm

OUTLET DIAPHRAGM - FUNCTION

117

AIAE outlet diaphragm has important features like peripheral

ring bolted to the shell ensuring perfect sitting of the frame

and overlapping grate plates to prevent leakage of materials.

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.

Product

Discharge diaphragm

OUTLET DIAPHRAGM -

FEATURES

118

ANTI-CHOKING GRATES

Product

Discharge diaphragm

125

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.

Designing &

retrofitting

AIAE internals Competition internals

128

LAFARGE SEATTLE FM#2,USADesigning &

retrofitting

After AIAE designed internals were installed, significant

reduction in power was noticed.

37.45 KWh/T40.75 KWh/TSpecific Power consumption

10.4 % Saving in Specific power

40 tph40 tphOutput

1497 KW1613 KWAbsorb power

ClassifyingDragpeb2nd chamber liner

4.0 mDiameter

AfterBeforeMill no.

127

LAFARGE ARASMETA CM#1, INDIA

16.9%Superiority in Production

21.8% Saving in Specific power

76 tph65 tphOutput

32003000Blaine (OPC)

2644 KW2756 KWAbsorb power

ClassifyingDragpeb2nd chamber liner

LCDCombidanIntermediate dph.

Block typeBlock type1st chamber liner

16.54RPM

10.93mLength

4.0mDiameter

AfterBeforeMill no.

Designing &

retrofitting

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.

97

LIFE GUARANTEES

Products

Ball mill liners

Description of parts and a lloys Guarantee Expected

life

 

Head liner Vegaline125

Head liner Vegaline112

Grates for LCD – Vegaline 107

Back plate for LCD – Vegaline 112

Discharge grates – Vegaline 112

1st Ch. lifting liner Vega line 112

1st Ch. lifting liner Vegaline 125

1st Ch. Double wave liner- Vegaline 107

2nd Ch. Classifying liner - Vegaline 212

 

20,000 h

15,000 h

12,000 h

25,000 h

30,000 h

25,000 h

30,000 h

25,000 h

50,000 h

 

25,000 h

20,000 h

18,000 h

30,000 h

35,000 h

30,000 h

40,000 h

30,000 h

60,000 h

The table below gives guarantees for OPC grinding at 3600 Blaine.

OPC at 4500 Blaine, less 15%.

PSC with 3600 Blaine less 25%.PSC with 4500 Blaine less 40%

Dry lime stone with <1% SiO2 add 30%

Dry lime stone with 6% SiO2, less 40% as per above.

The above figures of guarantees of liners are for guidance only.

98

LIFE GUARANTEES

Products

Ball mill liners

The actual wear rates are governed by various factors such as :

Hardness of clinker and its grindability.

Moisture in the additives.

Type of circuit (Roller press/ Separator/Pregrinder/Precrusher) 

Maximum ball size.

Volume loading.

Material level.

Condition of liners.

Type of diaphragm etc.

Products

Vertical mill parts

AIA/VEGA TODAY

30000 tons of wear parts for vertical mills used.

400 mills retrofitted with improved performance

More than 2000 inserted rolls used

Products

Vertical mill parts

MANUFACTURING CAPACITY –

MAXIMUM WEIGHT PER PIECE

Inserted rollers – 12 MT

Conventional (monometal) rollers – 16.5 MT

Table liners – 10 MT

ALLOYS FOR TABLE LINERS AND ROLLS

3563 RC263.2Vegaline V26

Composite of high chrome iron and nonmetallic

refractory oxides.

Sintercast-11

3064 RC163.0Vegaline V16

2760 RC202.6Vegaline V20

% carbidesHardnessCr%C%Specification

Products

Vertical mill parts

QUALITY PLAN FOR PROCESS

CONTROL OF VERTICAL MILL PARTS

Products

Vertical mill parts

Each castingGaugesDimensionsFettling

Each batchRockwell hardness

tester

HardnessAnnealing

RandomMould hardness testerMould hardnessMoulding

Each castingMeasuring

instruments

DimensionsFirst machining

Continuous data

logging

Data logging on

computer

Time/Temperature

correspondence

Heat treatment

Each castingVisual inspectionPhysical defectsMould knock out

Each mouldCore setting gaugesCorrectness of

cores

Moulding

1 sample per dayTransverse strengthSand qualityMoulding

Each heatOptical spectrometerLM compositionMelting

Each heatImmersion pyrometerLM temperatureMelting

Frequency of checkTesting procedureProperty checkedStage of manufacturing

Products

Vertical mill parts

Each setAssemblyFitment for tablesFinal inspection

Each castingUTInternal soundnessFinal inspection

Each castingBlue matching gaugesCorrectness of

angle for rolls

Final inspection

Each castingVisual/DPPhysical defectsFinal inspection

Each castingPaintingSurface protectionFinal inspection

Each casting Measuring

instruments

DimensionsFinal machining

Each castingRockwell hardness

tester/Sigmameter

Hardness/RAQuenching

Frequency of checkTesting procedureProperty checkedStage of manufacturing

QUALITY PLAN FOR PROCESS

CONTROL OF VERTICAL MILL PARTS

Vasavadatta Cement

Gujarat Ambuja

Neer Shree Cement

RMK 23

Vasavadatta CementRMK 21/30

Krupp PolysiusRMK 17

CustomerMill type

SUPPLIES OF POLYSIUS

COAL MILL PARTS

JP Rewa CementRMK 25/12

Aditya Cement

Vikram Cement

RMK 2713

Product

Polysius mill parts

Krupp PolysiusRM43

India CementsRM43

India CementsRM39

Gujarat Ambuja EasternRM51

India CementsRM46

Gujarat Ambuja

Gajambuja Cement

India Cements

RM41

CustomerMill type

SUPPLIES OF POLYSIUS

RAW MILL PARTS

Product

Polysius mill parts

INSPECTION PRACTICE FOR

POLYSIUS TABLES

Product

Polysius mill parts

After machining, the tables are set on an inspection table.

Reference diameters are marked. The gap between two

segments is noted. The mating surfaces are numbered.

AIAE supply inserted rolls for Polysius Coal mills. The rolls have

composite construction. Hard high chromium iron inserts are

embedded on ductile iron. Such construction provides optimum

combination of wear resistance and safety against breakage.

POLYSIUS INSERTED ROLLS

Product

Inserted Grinding roll

Sr. No OA No. PlantLocation

(State)Mill ID Roller Specification

1 6233 Neer Shree Cement Rajasthan RMK 23 X B 17 10

2 6249 Vikram Super Cement Madhya Pradesh RMK 27/13 X B 17 10

3 6240 Vasavadatta Cement Karnataka RMK 23 X B 17 10

4 6995 JP Rewa Madhya Pradesh RMK 25 X B 17 10

5 6791 Aditya Cement Rajasthan RMK 27/30 X B 17 10

6 6239 Vasavadatta Cement Karnataka RMK 21 X B 17 10

7 7116 Vasavadatta Cement Karnataka RMK 23 X B 27 10

POLYSIUS COAL MILLS EQUIPPED

WITH INSERTED ROLLERS

Product

Inserted Grinding roll

6

12-

2

3

5

5

3

4

No. of sets

supplied (tables)

1Siam CityAtox-45

3GARL, Fuller KCP

GCCL, Binani

Atox-40

2Shree CementAtox-37.5

7L & T Awarpur, L & T

Hirmi

Prism Cement, Siam

Cement

Atox-27.5

7GARL, Binani,CCGLAtox-22.5

3Madras CementAtox-20

7DCC, Shree CementAtox-17.5

No. of sets

supplied (rolls)

CustomersMill

Designation

Product

Atox mill parts

SUPPLIES OF ATOX MILL PARTS

20

23

LIST OF LOESCHE MILL INTERNALS

SUPPLIED BY AIAE

Product

Loesche mill parts

Aso Kanda,LM18/20

India

India

Thailand

India

India

Philippines

India

India

Thailand

India

Country

Maihar CementLM26/30D

JP Rewa, JP Bela,GACLD, TISCO

LM26/30

Siam CementLM25/20

Rajashree CementLM24/23

Rassi CementLM24/20

Alson CementLM21/20D

Fuller, Negeri

Simbilen

LM21/20

Lafarge ArasmetaLM20/15

Vikram CementLM19/20

Siam CementLM18/20

NCCL, KCPLM17/20

CustomerMill designation

24

LIST OF LOESCHE MILL INTERNALS

SUPPLIED BY AIAE

Product

Loesche mill parts

IndonesiaPadang CementLM38/40

Thailand

India

India

India

India

India

India

Malaysia

Country

Siam CityLM38/41

Maihar CementLM38/40

Lafarge ArasmetaLM36/41

DCC Sikka, NarmadaLM36/40

Lakshmi CementLM34/40

Saurashtra, Vikram

Manikgarh Cements

LM32/40

Orissa, Madras,

Dalmia Cements

LM30/31

APMC KanthanLM30/30

CustomerMill designation

SINTERCAST 11 WEAR RESISTANT PARTS

For grinding material with high abrasivity we recommend

Sintercast-11 parts.

Sintercast-11 parts are a composite product involving hard

refractory oxides mixed with high chrome irons.

Sintercast-11 has proved a very effective in extending life of

wear parts.

Products

Sintercast-11

56

SINTERCAST-11 ROLL IN ATOX 27.5 MILL

Products

Sintercast-11

Photographs after 700 RH. Sintercast parts are expected to to give

double the life of conventional high chrome parts.

PERFORMANCE OF SINTERCAST 11

WEAR PARTS IN ATOX 27.5 COAL MILL

Products

Sintercast-11

>6000 (expected)2500Life

4.313.5 *Table wear rate (g/t)

1139 *Table average wear (mm)

2.56.0 *Roll wear rate (g/t)

8.524.0 *Roll average wear (mm)

7600086000*Production (tons)

10321181Running hours

AIAE Sintercast-11 rollAIAE conventional rollParameters

Plant : L & T Hirmi (India)

* Parameters at 1181 running hours

SR.

NOPROPERTIES

NI HARD

ROLLS

HIGH CHROME

INSERTED

ROLLS

SINTER CAST

GRINDING ROLLS

1 HARDNESS 56 Rc 60 – 64 RcHigh wear resistant due

to hard ceramics

2CHEMICAL

COMPOSITION

C : 3.2 % ,

Cr:2.5 % ,

Ni:4.0 %

C: 3.0 % ,

Cr:15.25 %

C:2.5 - 3.5 % ,

Cr: 18 - 27 % ,

& Ceramic Grains

impregnated with metal

3AVERAGE LIFE WITH > 35 % ash COAL

2000 - 2500 Hrs 5000 - 6000 Hrs 10000 - 12000 Hrs

4WEAR RATE

WITH > 35 % ash COAL

22 - 24 mm

per 1000 Hrs

10 - 12 mm

per 1000 Hrs

5 - 6 mm

per 1000 Hrs

5GRINDING ELEMENTS

LIFE

> Two times than

NI Hard rolls

> Four times than NI

Hard rolls

6 GRINDING ABILITYReduced due to

slippage of rolls

Consistent and

better due to

serrations on rolls

consistent and best due

to Honey-comb type

structure on rolls

7 COLLAR FORMATION High Negligible Negligible

8 MILL THROUGHPUT Reduced with Life Consistent Consistent

9RING ROLLER SETTING

WITH > 35 % ash COAL Twice in a month Once in a Month Once in a Month

COMPARISON OF PROPERTIES

COMPARISON OF INSERTED ROLL AND SINTER

CAST GRINDING ROLLS

12E

44D

56C

66B

45A

Running Hrs: 6627

Wear depth in mm

Roller

no: J2

Measuring Point

7E

11D

21C

23B

12A

Running Hrs: 6627

Wear depth in mm

Roller

no: J1

Measuring

point

Plant : GEB WANAKBORI

HAMMERS FOR CRUSHERS

DIPPING TUBES