HNDLE GmbH Maschinen und Anlagenbau Mhlacker (Germany)

Phone +49 7041 891-1 Fax +49 7041 891-232 info@haendle.com www.haendle.com

Fine roller mills Alpha II WFZH

Maximum fineness of grind at minimum roller gap -

HNDLE's Alpha II:

The standard in hydraulic high-performance roller mills

for effective roller gaps down to 0.5 mm.

PRODUCT INFORMATION WFZH FINE ROLLER MILLS

Laboratory and Pilot Plant

Conveying and Storing

Screening

Feeding and Dosing

Crushing

Mixing and Homogenizing

Shaping - Extruding

Shaping - Molding

Spare and Wear Parts

Roller CrusherWet and Mixing Pan MillDisintegratorFine Roller Mill BetaFine Roller Mill Alpha II

HNDLE a leading global partner

to the ceramic industry basedin Mhlacker (Germany)

HNDLE counts among the world's leading manufacturers of machines and equipment for the preparation and shaping of ceramic raw materials,

particularly in the heavy clay sector.

Offering the market premium, technically advancedproducts, HNDLE maintains its market position by

also providing first-class customer services and spare parts of the highest quality.

In-depth know-how, fast service and maximum reliability of spare and wear parts count among the

capability characteristics for which HNDLE will continue to stand. We promise!

Main merits at a glance

Precise retention of roller-gap settings thanks to an

optimized roller support system

Structure-optimized system permitting only minor

fluctuation in the results of grinding at narrow roller gaps

Longer lifetime for all wear parts and accordingly less

maintenance required thanks to modern scraper

technology, including optimized design of the hard-

wearing scraper

Highly reproducible grinding thanks to high-resolution

electronic roller-gap settings

Minimal deformation and stress spikes in all components

thanks to application of the finite-element method

2

3Maximum fineness of grind at minimum roller gap

Fine Roller Mill Alpha II Type WFZH 10120d

Fine Roller Mill Alpha II Type WFZH 8120d

The new "Alpha II" is the result of consistent, continuous

evolution in the fine grinding of plastic and semi-plastic

ceramic raw materials in roller mills set to effective roller

gaps of 0.5 mm. The "Alpha II" is designed for use as a

second or third roller mill in series downstream of

suitable primary and/ or fine roller mills. This machine

was specially designed for high throughputs with optional

adjustment down to non-varying, super-narrow roller

gaps for continuous operation. The "Alpha II" is available

in widths of 1,000, 1,200 and 1,500 mm and diameters of

800 and 1,000 mm for volumetric throughputs ranging

from 41 to 79 m/h on rough-rolled material and roller

gaps of approx. 1 mm.

PRODUCT INFORMATION WFZH FINE ROLLER MILLS 4

Design

The frame assembly consists of a robust welded

structure in a hollow-box design with integrated bearing

blocks (for the fixed roller and the adjustable (loose)

roller's rockers), cross supports for the roller turning

machines and fitted drive-motor rockers for automatic

tensioning of the loose roller via hydraulic cylinders.

The geometry of the scraper arms was calculated using

the finite-element method and thus optimized so that they

are reliably positioned and able to scrape even at narrow

roller gaps and high speeds. In order to ensure optimal

force distribution, the torque is introduced centrally via a

shaft. The use of cast aluminum means that the heat

generated during the scraping process is quickly

dissipated. The hydraulic swivel motors allow the

scrapers to be swiveled out towards the rear, hence

providing easy access and allowing their quick, easy

replacement. The angle of incidence and the contact

pressure are adjustable so that they can be adapted to

the material's requirements. The setting is monitored by

proximity switches. When the flow of material through the

roller gap is interrupted, the scrapers swing slightly out

and away from the rollers.

Scrapers and scraper assembly

Frame assembly

Sturdy lateral uprights for maximum

smoothness of operation

Easy access and comfortable and rapid changing

of the very tough scrapersScraper assembly

5The desired roller gap is entered at the electronic

operating terminal to set the single rockers. The adjust-

ment is achieved with two threaded spindles and gear

motors. The previous setting method based on motor

speed has been replaced; now, the roller gap is precisely

set by directly measuring the roller's position with respect

to the spindle by means of a linear scale.

The advantage of single-rocker adjustment

The settings on each side can be fine-tuned separately

as necessary.

Adjusting mechanism

Single-rocker setting -

linear scale

The auxiliary drives, in their space-saving "piggyback"

arrangement, drive the rollers via V-belts for the turning

process. This eliminates the time-consuming installation

and removal of the V-belts. The V-belt pulley of the

auxiliary drive is equipped with a freewheel mechanism.

As an alternative to equipping the roller mill with an

auxiliary drive, the main drives can be fitted with motors

that use frequency converters. Consequently, the rollers

would be powered by the main drive motor during the

turning process.

Auxiliary drivesMain and auxiliary drives in a

"piggy-back arrangement"

Parallel adjustment

Single-rocker setting

Alternatively, there is the simpler parallel adjustment with

a gear motor, a corner gear and two threaded spindles.

The settings are made via the gear motor. The loose

roller's movement can be read off of a display on the

panel.

PRODUCT INFORMATION WFZH FINE ROLLER MILLS 6

Design

Pressure accumulator

The hydraulic system consists of a pump assembly, two

hydraulic cylinders and a symmetrically arranged

pressure accumulator. Lines of equal length between

the hydraulic cylinders and the pressure accumulator

guarantee that the roller gap remains parallel even under

extreme load conditions.

Hydraulic system

Hydraulic unit

When the raw material contains extra-hard inclusions,

the roller gap must be able to open very quickly in that

the adjustable (loose) roller yields way and then quickly

returns to its prescribed position. This is where the

hydropneumatic system comes in. The adjustable roller

has a maximum preload of 115 t (depending on the type

of roller mill), so the roller gap only widens if something

extremely hard gets between the rollers and is able to

resist the preload. The pressure accumulator arranged

between the two hydraulic cylinders enables a yield time

of less than 0.2 seconds.

Overload prevention

7The adjustable roller possesses two individual rocker

arms that have been optimized using the finite-

element method. They are held in place by the hydro-

pneumatic system, which serves overall for adjusting

the roller gap and providing protection against over-

loads.

Rocking

The deformation behavior of the geometrically

optimized rollers was dynamically simulated for

various load cases. The results show that

conventional ideas about roller deformation and

stress in rollers do not conform to reality. The new

insights were incorporated into the mill's design and

are now being implemented in cooperation with our

partners in the materials technology sector.

Deformation behavior

FEM-optimized rocker

Pressure loaded for less

deformation of the bearing bore

Deformation of the roller shell

PRODUCT INFORMATION WFZH FINE ROLLER MILLS 8

Within the scope of ongoing product innovation, the

Alpha II roller mills have also been equipped with a

new control system. The Siemens S7 automation

system with Siemens Color Touch Panel and

Ethernet connection is now standard equipment,

hence enabling hook-up to the using company's local

computer network. Users of Siemens standard

software have access to and can communicate with

the control system.

Control system

Control with Siemens Color Touch Panel

Design

HNDLE roller shells guarantee

top quality

The roller shells with double conical retaining rings are

secured to the roller inserts and sturdy roller shafts, the

self-aligning roller bearings of which have a only 0.12

mm play. This means that the two rollers will never con-

tact each other, even if the roller gap is set to 0.5 mm.

Rollers and support system

9Options

Keeping in mind increasingly stringent standards and

expectations, we steadily optimize the design of our

roller turning machines. For example, we developed

an optional anti-vibration and decoupling system that

doesnt transmit the mills vibrations onto the turning

machine, thus enabling permanent installation of the

lathe on the roller mill.

Roller turning machines

Support frame

Elastic suspension between roller mill and displace-

ment frame

Anti-vibration device

Anti-vibration and decoupling system

Designed as a sectional-steel assemblyDesigned as a concrete foundation

* Volumetric throughput and throughput capacity assuming precomminuted material and a roller gap of approx. 1 mm.

Subject to technical modification due to ongoing development.

TYPE

WFZH 8100d

WFZH 8120d

WFZH 8150d

WFZH 10120d

WFZH 10150d

Technical data

PRODUCT INFORMATION WFZH FINE ROLLER MILLS 10

Roller diameter/ width

mm

800/ 1000

800/ 1200

800/ 1500

1000/ 1200

1000/ 1500

Barrel thicknessinside/ outside

mm

120

120

120

140

140

Roller preload

t

110

123

123

123

123

Volumetricthroughput*

m/h compact

41 - 52

50 - 63

62 - 79

47 - 63

59 - 79

Throughputcapacity*

t/h wet

72 - 92

88 - 111

109 - 139

83 - 111

104 - 139

Powerrequirement

kW

2 x 75 - 90

2 x 90 - 110

2 x 110 - 132

2 x 90 - 110

2 x 110 - 132

FunctionThe mill feed is ground down by force of pressure

between two contra-rotating rollers: Crushing opens

up the clay, allowing the hard inclusions (quartz, lime,

pyrite, ...) to be finely comminuted.

The rollers are housed in an enclosure with an

integrated feed hopper, two removable end hoods

and two side seals. The vertically extractable side

seals, with their revolving, externally adjustable

wearing liners, conceal the ends of the roller gap and

prevent loss of material.

Depending on how fine the production body has to

be, the Alpha II is usually operated at roller gaps

situated between 0.5 and 0.8 mm. The crushing ratio

is usually set at 1:2. This means that, for a roller gap

of 0.5 mm, the material to be processed should be

precomminuted to around 1.0 mm. For a roller gap of

0.8 mm, precomminution should yield roughly

1.6 mm.

The Alpha II is mainly employed in "conventional"

processing lines consisting of a pan mill and a roller-

mill train, with the Alpha II constituting the final stage.

Depending on the type of raw material and the

targeted fineness, the material must be milled a time

or two beforehand, e.g. in a Beta roller mill from

HNDLE.

11

Practical examples

Alpha II WFZH 10150d employed as a

second fine roller mill

Preparation: 92 t/ h wet

Roller gap: 0.8 mm

Alpha II WFZH 8150d employed as a

second fine roller mill

Preparation 2: 90 t/ h wet

Roller gap: 0.8 mm

WFZH 8120d fine roller mill employed as

a third roller mill

Preparation: 35 t/ h wet

Roller gap: 0.5 mm

HNDLE GmbH Maschinen und Anlagenbau

Industriestrasse 47

75417 Muehlacker (Germany)

Phone ++49 7041 891-1

Fax ++49 7041 891-232

24-hour Service Helpline +49 171 7323636

info@haendle.com

www.haendle.com

08

/ 2011