SOLUTIONS OFFERED

Improved Productivity, Sustainable and Safe!

AIA Engineering Ltd. and Vega Industries are world leaders in manufacturing wear parts for cement plants. Our in-depth knowledge of the industry and continuous investments get our customers best in class grinding efficiency, better productivity and sustainable operations.

Grinding Media plays a critical role in the Ball Mill operations as it is the only mill internal contributing to energy / specific power consumption. AIA Engineering Ltd. / Vega Industries is globally the largest producer of High Chromium Grinding media.  As a pioneer in this field AIA/ Vega adds value to this product with its decades of experience and expertise. We have dedicated high pressure moulding lines for higher and lower size Grinding Media, resulting in required soundness of the products.

Big balls, ranging from 100 mm to 60 mm, are essentially used in the first chamber of the mills for crushing the feed material. These balls impart potential energy for crushing and thus required to possess a combination of wear and impact resistance

  • AIA Engineering Ltd. / Vega Industries have special grades suiting various applications
  • Physical properties are meticulously designed to resist impact wear
  • Eco friendly grades for reduction in Chromium hazards
  • Chrome range from 10% – 28%
  • Optimal Hardness ranging from 57 – 66 Rc
  • Big balls are manufactured on Horizontal moulding lines, ensuring good internal soundness, minimum inclusions and good as cast metallurgical structure
  • Perfect metallurgical controls which ensures optimum combination of hardness, retained austenite (RA) and microstructure
  • Finished balls are subjected to rigorous test mill run

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Grinding Media plays a critical role in the Ball Mill operations as it is the only mill internal contributing to energy / specific power consumption. AIA Engineering Ltd. / Vega Industries is globally the largest producer of High Chromium Grinding media.  As a pioneer in this field AIA/ Vega adds value to this product with its decades of experience and expertise. We have dedicated high pressure moulding lines for higher and lower size Grinding Media, resulting in required soundness of the products.

Grinding by attrition is accomplished by numerous small balls of varying sizes   in second chamber. These balls contribute significantly to the grinding efficiency of the mills. Residue/blaine control of the final product depends much on the quality of the balls used.

  • At Vega/AIA utmost care is taken in design of physical properties
  • Ball Sizes from 60mm to 12.5mm
  • Unique manufacturing technique / design concept for reduction in deformation tendencies
  • Variety of alloys for different applications
  • Chrome range from 10% – 32%
  • Optimum Hardness ranging from 60 – 69Rc without fear of breakage
  • Finished balls are subjected to rigorous test mill

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Mill internal design plays an important role in production efficiency. They not only protect the mill shell but also transfer the energy from the mill shell to the rotating charge of grinding media. The internal castings contribute upto 5% of the Ball Mill operating cost while the remaining 95% is from energy.

AIA Engineering Ltd. /Vega Industries products follow the golden triangle philosophy of Design, Metallurgy and Application for tailor-made solutions based on multiple parameters such as feed characteristics, product specification and operating conditions resulting in –

  • Improved operating life and mill availability.
  • Savings in power consumptions to the tune of 5 – 10%.
  • Savings in operations and maintenance costs
  • Ease in installation with bolted and semi boltless configuration

Optimum grinding requires effective crushing. First chamber liners are designed to achieve size reduction at optimal power.

AIA / Vega Liners provide –

  • Strong implication on process aspects.
  • Affects mill productivity and specific power consumption.
  • High crushing efficiency at desired wear life

Attrition is the most important part of the grinding process. AIA Engineering Ltd. /Vega Industries offer a variety of classifying liners to choose from for specific applications.

  • Ensure effective ball classification
  • Upto 20% reduction in overall weight lowering initial costs
  • Improved grinding efficiency
  • Reduction in specific power consumption

Tube Mill Diaphragms

Diaphragm is a partition wall restricting the metallic content within the chamber and controlling the movement of feed material through the mill.

Level Control Diaphragm

  • Flexible frame structure.
  • Special overlapping design to avoid bypassing of material from one chamber to another.>/li>
  • Improved mill ventilation.
  • Maintains optimum material level in both chambers.
  • Superior metallurgy of cast parts for extended time.

Outlet Diaphragm

  • Ensures free passage of material from grinding chamber to mill outlet.
  • The frame consists of several strong independent sectors which grant the diaphragm required mechanical strength. Each sector supports its own cast parts.
  • All items are sized to fit through the manhole, the discharge openings or the feed trunnion.
  • Slotted plates with overlaps to avoid gaps and provide a tight fit.
  • Optimum metallurgy and design for higher lifetime.

AIA Engineering Ltd. /Vega Industries have been at the forefront of developing solutions for vertical mill castings for all applications, types and makes, constantly upgrading on its own products.

The latest innovation V cast addresses the industry demand for a suitable solution for highly abrasive applications. This is a result of focused field and R & D efforts, resulting in following demonstrated benefits

  • Improved wear life
  • Smoother mill operations
  • Easy adaptability to varying operational demands
  • Higher mill availability
  • Consistency in operational and performance parameters
Marked Ball Test
  • Marked Ball test is carried out to determine the most suitable alloy, based on the mill working and operating condition
Design of Liners
  • Tailor-made design of liners through R&D and simulation, replicating the actual operating condition followed by field trials
VRM Optimization
  • Based on the operating conditions and required performance parameters, fine tuning of Grinding elements geometry is carried out in consultation with the OEMs
  • Alloy selection is done on the basis of feed characteristics, working condition and product requirement
  • Vega Industries provides on-site installation support for every site
  • Vega Industries provides a site/equipment specific installation manual and pre-requisite before the installation
  • Assistance for achieving stable operation after installation of new designs

The purpose of a mill study is to collect information about the mill running conditions. These data help us in redesigning the mill internals and grinding media pattern (Ball Mills).

  • Data Collection
  • Study of Mill Circuit
  • Internal Inspection and Collection of Samples
  • Classification Test
  • Flow and Pressure Drop Measurement
  • Plotting of TROMP curve, Axial Curve, Log-Log Curve
  • Heat and Mass Balance
  • Study of gas and mass flow using Computational Fluid Dynamics (CFD) simulator to achieve optimised milling system

Analysis of audit result to identify bottlenecks and areas of improvement. Implementation of corrective action and monitoring for improvement.

  • Wear measurement and profile analysis for design improvement
  • Assessment of residual life for maintenance planning and spare management
  • Rectification or corrective measures if any
Vcast Grinding Elements for VRM

Vega developed V-cast, a new solution for abrasive grinding conditions. The product is specially designed for providing longer durability based on feed material characteristics of Limestone raw material, Coal, Clinker and Slag.

V-cast: A tailor-made solution for grinding Green Cement

Vega developed V-cast, a new solution for abrasive grinding conditions. The product is specially designed for providing longer durability based on feed material characteristics of Limestone raw material, Coal, Clinker and Slag.