https://cementl.com/ Coal pulverizers are essential equipment in large steam power plants, where consistent and finely ground fuel must be supplied to the boiler burners. GE Steam Power, Mitsubishi, and Babcock technologies have each developed roll wheel grinding machines that are widely applied in 500 MW to 1,300 MW coal-fired boilers. These machines share the same principle: raw coal is crushed between heavy grinding rolls and a rotating ring, while hot primary air dries the material and transports pulverized coal to the boiler furnace.
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In a typical configuration, a roll wheel pulverizer processes 40–100 tons of coal per hour, depending on unit size and coal quality. The feed size is normally below 50 mm, with a moisture content of 8–12%. The grinding force is applied hydraulically, with roll loading pressures reaching 80,000–120,000 lb per assembly. The rotating grinding ring has a speed of 20–30 rpm, creating a coal bed under the rolls. This grinding zone reduces the coal to fine particles, while primary air from the air preheater (250–320°C) dries the material in-process.
Above the grinding zone is an integrated classifier, which separates fine fuel particles from coarse ones. Fineness requirements differ by boiler design: for subcritical boilers, 70–75% passing through 200 mesh (75 μm) is standard; for supercritical boilers, operators target 80–85% passing 200 mesh. Proper classification ensures complete combustion and stable furnace flame.
GE Steam Power roll wheel pulverizers are known for robust gear drive assemblies and flexible classifier designs. Mitsubishi systems emphasize hydraulic loading stability and compact grinding housings. Babcock machines often integrate explosion venting and inertization systems for high-capacity boilers. Despite design variations, all units share critical performance targets: steady throughput, uniform fineness, and high reliability.
Wear resistance is a major factor in pulverizer availability. Grinding rolls and rings are exposed to continuous abrasion from mineral matter in the coal. Here, Magotteaux wear parts are applied. With high-chromium alloys and ceramic composite inserts, Magotteaux components extend roll and ring service life by 30–50% compared to conventional steels. In practice, this means service intervals of 8,000–10,000 operating hours before refurbishment is required. Stable wear profiles also help maintain consistent grinding pressure and fineness over time.
In operation, several parameters must be monitored closely:
Mill differential pressure (10–15 inches w.g.) to track coal circulation.
Outlet temperature (70–80°C) to prevent moisture condensation and fire risk.
Classifier vane position for controlling particle size distribution.
Vibration levels as an early signal of roll imbalance or bearing wear.
Mill rejects (pyrites, stones, tramp iron) are discharged automatically into a reject hopper to protect the grinding components. To prevent fire or explosion, inerting systems with CO₂ or N₂ are activated during startup and shutdown. Continuous CO monitoring in the outlet stream provides an additional safety layer.
A large 1,000–1,300 MW unit may use eight to ten roll wheel pulverizers, each connected to a group of burners. Balanced fuel distribution across the burners is critical for flame stability and to reduce NOx formation. Advanced control systems automatically adjust feeder rate, roll pressure, and primary air flow according to boiler load demand.
When fitted with Magotteaux wear parts, GE, Mitsubishi, and Babcock pulverizers benefit from extended component life, fewer forced outages, and predictable maintenance schedules. This reduces operating costs and improves overall boiler efficiency. Reliable fuel preparation ensures that the steam generator operates at design pressure and temperature, supporting stable turbine output.
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