Ball mill manufacturers globally have recognized that balls mills and the energy industry are perfect fit than anyone could imagine.
Using Ball Mills in the Energy Industry
Already in the industrial sphere, there is some decent experience in the use of extremely fine ground coal in producing energy- as a cost-effective fuel to replace fossil oil at energy production plants (in China, Germany, and the USA). Powered by extremely-fine ground coal, the USA has a good experience in deploying it at 600 MW UNIT found in North Carolina for firing a boiler.
Extremely fine ground coal is also used to power boilers operated by the Steinmuller Corporation in Germany, for whom a particularly designer unit to maximize the power source was built. The outcomes were remarkable.
In 2000 at an experimental thermic energy plant, the Institute of Thermal Physics of the Russian Academy of Sciences held a preliminary study on coals of various metamorphic grades and different fractional states. These demonstrate that finely ground coal, milled to a particle size of 15-30 microns, improves a very reactive element that is similar to fuels oil- to which it can be an option.
The experimental plant rated up to 1000 kW, and strapped for use with extremely-fine ground coal (manufactured with an extremely-fine ball mill); burning (pre-furnace and furnace tools); a plasma system and gas starter for ignition and additional firing; combustion control and cleaning. The outcomes resulted in these experiments can be used to establish the limits required in technological facilities for ignition systems and additional burning using coal-dust-boilers- an alternative fuel to gas and fuel-oil boilers.
The main technological plants for using this new technology are equipment for extremely fine milling (ball mills) and the additional equipment for supplying and combustion of coal. Technical designs for the additional equipment have been manufactured, which are essential for taking out the new technology (muffle furnace equipment, the coal dust’s input nozzles, accelerating devices for igniting the main fuel mixtures, hoppers, feeders for fuel discharge etc.)
Plants that can make the new additional equipment are in Russia already. Energia LLC, Biysk Boiler Plant, and the Samara Strommashina factory, and Novosibirsk Heavy Engineering factory are some of the Russian factories. The Strommashina Plant makes milling equipment as well, especially ball mills for extremely-fine milling processes.
In not more than 2 to 3 years, the new technology that is cost-effective with a short return-on-investment (RoI) pattern will reach the break-even point.
For pilot industrial use alone, the new Plasma-fuel technology has now passed the final phase of certification. This permits the examination of the new technology’s risks, and if needed, it can be used to improve its operation before completing the business case, which can be pitched to potential investors by a Ball mill manufacturer.
Converting oil-fired boilers to run on extreme-fine ground coal
The main work for Ball mill manufacturers is moving to decline the use of fuel oil by the plant in future. It is reasonable to revert to using natural gas where it is available. But where a free option is not available, such facilities can be converted to run on fine ground coal. The economic outcome of changing from fuel oil to extreme-fine ground coal will be in the drastically reduced cost of fuel.
Having considered these, there is an environmental plus here- since a significant decline in the emission of sulfurous oxides into the atmosphere. This also has an economic gain as regards the decrease in payments to be made for the type of emissions.
In the process of changing over to extreme-fine coals, the matter of ash waste disposal should be considered. For facilities presently making use of fossil oil, this could be frustrating. In the initial example, the matter could be fixed by making agreements to dispose of the slag and ash wastes from the boiler room to close by industrial sites or ash dumps. However, this could also result in a loss of some of the cost gains for the Ball mill manufacturer.
Evaluating the efficiency
This can be determined by comparing operation of fuel oil costs and the projected costs of transferring the plant;’ operation to extreme-fine coal. To arrive at the estimates for the current costs, it means that the cost of current in purchasing of fuel oil should be compared to the costs of buying coal, plus the added power costs incurred in the process of grinding.
Especially considering the latter cost, it is good for Ball mill manufacturers to think about the choice of grinding machinery as it relates to energy consumption costs. Buying machinery with the cheapest energy operating costs is a logical decision. Also, when considering the option to change from fuel oil to extreme-fine coal, the operation of installing the supplemented equipment required for ignition of the extreme-fine coal must be considered well.