Tube mill

To increase the efficiency of your tube mills, Magotteaux developed the widest range of liners and diaphragms. With more than 7,100 tube mills equipped all over the world, you will benefit from the best experience in the cement industry. Our focus: reducing energy consumption and optimizing performance!

Tube mills & liners

To increase the efficiency of your tube mills, Magotteaux developed the widest range of liners and diaphragms. With more than 7,100 tube mills equipped all over the world, you will benefit from the best experience in the cement industry.

Mill liners protect the mill shell and transmit energy from the rotating mill to the ball charge. Liner design is a compromise between lifetime and grinding efficiency, guided by the grinding mechanisms required for the specific mill.

Our focus: reducing energy consumption and optimizing performance!

Crusher

Magotteaux, market leader in the design and manufacturing of wear parts, has also become the leader for both Horizontal and Vertical Shaft Impactor applications. Our multibusiness experience in crushing benefits our customers as we offer safer and proven technology solutions to all applications.

Equipment & technology

Magotteaux offers equipment such as MagoClass, ball sorters, ball loaders and water injection systems to optimize grinding efficiency and operational safety.

Heat resisting castings

As the kiln is considered the heart of the cement plant, any failure of heat resisting castings installed in the kiln or directly connected equipment leads to immediate shutdown. Magotteaux develops solutions that optimize wear-part lifetime and process efficiency, reduce energy consumption and inventory, and ensure safe handling.

Vertical mill

Magotteaux provides a complete range of vertical roller mill castings, hollow balls and rings designed to improve wear resistance and grinding efficiency for vertical mills.

Applications

Streamlining the cement industryMore than 500 HPGRs are in use in the cement industry today, mostly for the pre-grinding of ball mill feed. This technology enhances the capacity of the downstream ball mill and reduces the total energy consumption of the grinding process by up to 50%. The adoption of high-pressure grinding throughout the cement industry has generated enormous savings in energy and wear-material costs.
However, in many applications, excessive wear of the rollers limits the economical use of HPGRs. The HEXADUR® wear protection system, developed and produced by Köppern, is the optimal solution for all customers experiencing excessive roller wear. As a universal industry solution, HEXADUR® tires can be fitted to HPGRs of all suppliers.
Correct sizing of HPGRs is important in order to meet throughput requirements and achieve the desired product fineness. The parameters for selecting the machine sizes to be used have been accurately evaluated through scientific research work. For cement plants which generally treat similar feed materials, grinding test work is normally not required because equipment layout can be reliably determined using a process database based on the utilization of HPGRs in many commercial plants.

Pilot Plants

Helping you find the best solutionThe parameters for selecting the machine sizes to be used have been accurately evaluated through scientific research work. For cement plants, which generally treat similar feed materials, grinding test work is normally not required because equipment layout can be reliably determined using a process database based on the utilization of HPGRs in many commercial plants.

Grinding test work may be required if the feed material in question has not been previously encountered or documented. Testing is also necessary to evaluate the degree of wear inflicted on the rollers by special feed materials. The results of such trials are needed to select the most suitable roller surface from Köppern's wide range of solutions for the required application.

Plant and Machinery

High-pressure grinding rollers (HPGR)During the high-pressure comminution process, rather than being crushed between the roller surfaces, individual grains or particles are in effect compacted to a dense flake through exposure to relatively high pressures. Following de-agglomeration, the flake normally shows a substantial amount of completed or incipient cracking emanating from the particle surfaces. This highly efficient comminution process requires considerably less energy compared to conventional crushers and mills, due to:

- relatively uniform loading of the material in the compression zone
- very short retention time
- minimal energy requirement for material transport in the HPGR.

The movement of the floating roller constitutes the basic principle of high-pressure comminution with a roller press. In HPGRs, the roller gap adjusts itself automatically when subjected to a given pressure between the rollers. The extent of the roller movement at the gap is a function of the 'stiffness' of the hydraulic system in relation to the reaction forces exerted by the processed material, and therefore varies accordingly. This design feature guarantees that during the comminution process, all the feed material passes through the roller gap under the same process conditions, thus ensuring that the HPGR output quality remains constant.

The applied specific pressing force influences the ease with which the comminution process can be controlled and the ability of the machine to respond quickly to operator adjustments. The HPGR drive system is made up of electric motors and planetary gear boxes installed at the drive end of each roller. The gear boxes are connected to a system of torque arms. Depending on the application, an HPGR may be laid out for constant-speed operation or fitted with a variable-speed drive.

The main parameters for controlling the comminution process and press throughput are:
- the process-specific pressing force generated by the hydraulic system
- roller speed (when a VSD is fitted).

In addition to these parameters, the throughput of an HPGR also depends on:
- machine width
- the operating gap, which is a function of...
- ...the roller diameter
- ...feed material characteristics and particle size distributions.

Machine Frame
Köppern has developed and patented different hinged-frame designs in order to facilitate the rapid exchange of rollers and minimize maintenance shutdowns.

Wear Protection
Rapid wear is the central issue in grinding, which means that wear protection is of paramount importance in high-pressure comminution, too. Today, almost all HPGRs for grinding applications of minerals are equipped with tires. Tire-shaft solutions are used in combination with conventional wear protection systems such as hardfacing or Köppern’s own innovative HEXADUR® and HYBRIDUR® systems.

References

Established throughout the worldSince its launch in 1996, Köppern’s unique HEXADUR® wear protection solution for high-pressure grinding rollers in the cement industry has established itself throughout the world.

Our customer community for HEXADUR® tires, for use on Köppern’s or other suppliers’ high-pressure grinding installations, has ordered a total of more than 200 tires and is growing rapidly. Below is a selection of references where customers use Köppern HPGRs equipped with HEXADUR® tires in their cement-making processes and are therefore already benefiting from a significantly higher consistency in operational conditions, in combination with an extremely long service life of the wear-protected HEXADUR® tires as well as the HPGRs themselves..