https://cementl.com/ Coal pulverizers such as the L-type vertical or roll-wheel mills are critical for preparing fuel for combustion. These machines operate under high mechanical stress and handle combustible coal dust, which makes reliable lubrication and explosion prevention essential for safe operation. Two key systems in this context are the lubrication station for bearings and gears, and the CO₂ anti-combustion system that prevents coal fires or explosions.
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The lubrication station supplies oil to all critical moving parts of the pulverizer, including gearbox bearings, grinding table bearings, and motor couplings. Modern stations use forced lubrication with pumps, filters, and coolers to maintain consistent oil flow, temperature, and pressure. Typical oil pressure ranges from 2–5 bar, and oil temperature is kept below 70–75°C to ensure proper viscosity and cooling. Continuous monitoring of oil flow, pressure, and temperature is essential to prevent bearing overheating, roller seizure, or gearbox failure.
For a pulverizer operating at 500–1000 kW, the lubrication system is designed for redundancy. Dual pumps and oil tanks ensure that even in case of a pump failure, critical components continue to receive lubrication. Filters remove wear particles, while sight glasses and temperature sensors provide operators with real-time feedback. Scheduled oil sampling and particle analysis help detect early signs of bearing or gear wear, improving reliability and extending maintenance intervals.
Coal pulverizers also face a high risk of spontaneous ignition due to the fine, dry coal dust inside the grinding chamber. The CO₂ anti-combustion system is designed to mitigate this risk. CO₂ is injected into the mill housing or along coal transport lines during startup, shutdown, or emergency conditions. The injected gas reduces oxygen concentration, preventing the coal from reaching its ignition point. In many plants, CO₂ flow is automatically triggered by temperature or CO sensors inside the pulverizer.
Operationally, CO₂ injection must be carefully controlled. Excessive gas can disrupt mill airflow and reduce coal drying efficiency, while insufficient CO₂ may not prevent ignition. Typical targets maintain oxygen levels below 8% by volume in the mill housing during inerting. CO₂ is stored in pressurized cylinders or a dedicated liquid storage tank, with solenoid or pneumatically actuated valves for rapid response.
Integration of the lubrication station and CO₂ system ensures continuous, safe operation of the pulverizer. Proper lubrication reduces mechanical failure, while CO₂ prevents combustion, together allowing mills to run at high capacity without interruption. Safety interlocks in modern control systems prevent mill startup unless both systems are operational. Operators can monitor oil pressure, temperature, CO₂ flow, and mill differential pressure from the control room, allowing quick response to abnormal conditions.
In addition to safety, these systems also improve operational efficiency. Well-lubricated bearings and gearboxes reduce energy losses and vibration, maintaining consistent grinding pressure. The CO₂ system prevents unplanned shutdowns due to fires, which can save hours of production time. Combined, they enhance the overall reliability of the coal pulverization process.
Maintenance schedules typically include checking lubrication pumps, cleaning filters, replacing worn hoses, testing pressure relief valves, and inspecting CO₂ piping and solenoid valves. Periodic functional tests ensure that in an emergency, CO₂ injection will activate and extinguish any potential ignition before it escalates.
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