Cement & Power Generation - PULVERIZING SYSTEMS

Mavrix manufactures a series of equipment for cement and coal pulverizer tables and rolls. We break our products into three categories: tables, rolls or combination systems. The equipment can be custom configured to meet your current processes or use our off‐the‐shelf designs to get running fast. Many of the machines are designed to be portable and set up quickly at your equipment. Get in. Get out. And Get Running!

Pulverizer Tables
The system for coal and cement may vary widely in their configurations but the process and controls remain the same. See below to view details on table resurfacing systems. The example's primary focus is on coal tables. Cement tables, given the typically larger diameters, may require a beam design that straddles the diameter and can be configured with one or two torch and carriage systems.

Pulverizer Rolls
The system for rolls are generally similar with the exception of the profile of the roll. Controls and processes remain the same. All that is required is to determine how the roll will be presented and rotated. See below to view additional details on table resurfacing systems.

Combination Systems
The combination systems require additional mounting by the customer but allowed the user to purchase a single system that is capable of welding both rolls and tables through some creative mounting. A cost saver on the up front purchase is just what customers need when they have a talented organization to fabricate the rest. See below to review the combination system known as our 8040 model.

COAL TABLE REBUILDING SYSTEMS

We have over 18 years of experience designing and building systems to rebuild tables and rolls for many styles of pulverizers. Our systems are portable, easy to use and can be operated by most maintenance crews who do not weld every day. The system includes operating pendants with weld power supply control, automatic weld shutdown and limit stops for automatic weld shutdown. It is available in a single or dual torch.

  

ROLL REBUILDING SYSTEMS

This is a simple system utilizing a tilt positioner with fixturing to hold a 1500 lb pulverizer roll. A vertical post with weld arm is used to apply welds. For larger pulverizer rolls the positioner can become quite expensive. This picture shows a typical tilt positioner with fixturing to hold CE Style rolls.

While many companies use tilt positioners for roll rebuilding there are many simpler and less expensive techniques. Most of the techniques utilize leaving the roll on the journal and welding the roll surface prior to bearing and seal replacement. A separate gearmotor with sprockets and chain or a drive shaft with universal joints can be used to turn the roll at weld speeds.

This photo shows the simple system for rotating a typical CE Pulverizer Roll. The simple roll support is fabricated to support the roll and present the welding surface horizontal. An external gearmotor with drive shaft is used to rotate the roll at welding speeds. The customer supplies a floor mounted support to hold the roll to obtain a horizontal weld line as you see in the picture. The particular roll shown here is a CE Model 923 pulverizer.

CE PULVERIZER ROLL

This photo shows the simple system for rotating a typical CE Pulverizer Roll. The simple roll support is fabricated to support the roll and present the welding surface horizontal. An external gearmotor with drive shaft is used to rotate the roll at welding speeds. The customer supplies a floor mounted support to hold the roll to obtain a horizontal weld line as you see in the picture. The particular roll shown here is a CE Model 923 pulverizer.
The weld arm can be tilted the opposite way to weld rolls in the pulverizer chamber. This picture also shows a low-profile weld nozzle with wire feeder located on the opposite end.

MPS PULVERIZER ROLL

These pictures show an MPS Pulverizer roll located on its mill mounting chock. The weld automation was mounted off the chock as shown using a custom angle plate. A stanchion was built to hold the 2 clevises that support the roll in the pulverizer. A large sprocket with a gear motor is used to rotate the roll at weld speeds and was supplied by the customer although it is controlled by the Mavrix control.

COMBINATION PULVERIZER ROLL AND TABLE REBUILD SYSTEM VERS-O-WELD 8040

This picture shows the standard system set up with a fixed travel beam and a moving carriage assembly. In this case the x-travel carriage carries the vertical slide and wire feeder. This arrangement places the wire feeder directly in-line with the weld nozzle. It is also possible to locate the wire feeder remotely and use a wire feed cable to connect the feeder mechanism to the weld nozzle. See our video for more information.

MOVING WELD ARM AND FIXED CARRIAGE ASSEMBLY

This arrangement can be used to rebuild the table from the door opening. The two powered axes can also be used to stairstep a curved bowl like an MPS. It is also possible to rearrange the components and fix what would have been the Z-axis slide plate and place the torch arm at your desired angle using the X-axis carriage to drive the torch arm in and out.

The weld arm can be tilted the opposite way to weld rolls in the pulverizer chamber. This picture also shows a low-profile weld nozzle with wire feeder located on the opposite end.

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