Ring-geared mill drive system

Video explaining ABB ring geared mill drive technology

High performance and flexibility in grinding

Decreasing global mineral resources, exploitation of lower ore grades in more remote locations and extreme environmental conditions lead to increased material processing and potential rise in CAPEX.

The need for reliable and robust grinding solutions is driving the development of new technologies able to cope with larger equipment generating higher throughput. If in the past single pinion mills were enough to process all material, today dual pinion or gearless driven mills are necessary. Not only the mill equipment was adapted to exceed its technical and performance limits. Also, the drive solution experienced continuous developments, influenced by the newest trends, that permit reaching new grinding frontiers. Nowadays more and more mills are fed by frequency converter systems, allowing for higher performance and flexibility of operation.

ABB continuously extends technical and performance frontiers of ring-geared mill drive (RMD) technology to fit your site requirements. We provide optimized mill drive solutions for all types of ring-geared mills: low and high speed, single and dual pinion, with and without a gearbox — all designed for reliable, long life and low maintenance operation.

eBook: Grinding transformation

Solutions

RMD^fsd

Cost effective solution for projects with very constant ore grade throughout life cycle of the mine or for small ball mills that do not require variable speed.

RMD^vsd

Variable speed solution, including softstarting and optimum torque control for entire speed range. Suitable for any kind of grinding mill.

RMD^plus

Full variable speed solution, additionally including mill application features providing highest operational flexibility and optimizing maintenance actions.

RMD^EO

Combines all features from RMDplus with the advanced process control - ABB Ability™ Expert Optimizer for grinding, providing the ultimate control strategy. Ideal to increase productivity and energy efficiency.

Features and benefits

Mill application features mapping

New Human Machine Interface - RMD Cockpit

Operational advantages, mechanical, electrical and maintenance benefits

ABB Ability™ Cascade Monitoring for grinding - Measure online key grinding features with ABB’s wireless solution

RMD operation and maintenance training

New Human Machine Interface - RMD Cockpit

With the RMD^plus solution, operations and maintenance activities are fully optimized with the newly developed Human Machine Interface “RMDcockpit”.

Based on ABB’s 800xA platform, the RMDcockpit is a specific mill application tool comprised of a touch screen panel allowing full access to the main parameters of the drive system as well as to the mill application features such as automatic positioning and creeping modes.

The user-friendly interface was developed with focus on the most important operation and maintenance activities. From one single place, the system can be monitored, operated and troubleshooted. The tool also provides direct links to the user’s manual where operators can access the information they are looking for, just with a click of a button.

RMDcockpit provides the following functions:

Parameterization of the system from one platform
Monitoring of the main system parameters such as power, speed, current, overloads, etc.
Access to the operation of the mill application features
Different user rights for different operation modes
Troubleshooting tools like a transient recorder
Mill starting curves

The variable speed RMD solutions offer the ability to minimize the wear of mechanical components of the mill. As an example, the impact of the balls on the liners of the mill can be avoided by reducing the rotation speed.

Several other benefits can be achieved, as such:

Operational advantages

Operator can rapidly react to changes in ore characteristics due to variable-speed
Process optimization leads to a more efficient use of grinding power, resulting in significant energy savings.
Fine-tuning of the speed in ball mills increases metals recovery
Dedicated mill controller performs critical monitoring, protecting the mill
Frozen charge protection for safe operation

Mechanical benefits

High starting torque availability
Reduced mechanical stress on the ring gear, gearboxes and pinions
Smooth starting and precise torque control due to DTC technology, even at low speed
Load sharing between pinions is controlled actively and accurately

Electrical benefits

Suited for weak networks, due to system's low starting current
Power factor > 0.95, even leading as an option
Resilient to voltage dips very common in remote mines

Maintenance benefits

Easy maintenance and direct communication with drive via mill local control panel (MLCP)
Reduced maintenance time and no need for auxiliary motor due to creeping and automatic positioning modes
Quick return to operation with frozen charge remover
Fast and easy technical support via remote supervision and diagnostic options

Improved grinding with advanced process control at Boliden Aitik mine in Sweden

Particle size controlled
Mill loads stabilized (standard deviation decreased by 79%)
Autopilot for operators
No constraint violations with respect to power, torque, mill load

^{*Results gathered over a six month evaluation}

Monitor what’s happening inside your mill with a wireless vibration solution to improve grinding profitability

ABB Ability™ Cascade Monitoring for grinding

ABB’s ring-geared mill drive system (RMDplus) offers optimized solutions for grinding applications such as AG, SAG, pebble mills, rod mills and ball mills.

RMDplus courses

Reference highlights

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