How can a refurbished and used tube mill be brought back to life through professional refurbishment?

Publish Time: 2025-10-14

In heavy industries like cement, metallurgy, mining, and power generation, tube mills, as core equipment in grinding systems, are subject to constant high-load, high-intensity operating conditions. The procurement cost of a new tube mill can easily reach several million yuan, representing a significant capital investment for small and medium-sized enterprises or projects with limited budgets. However, with equipment upgrades and technological advances, a large number of refurbished and used tube mills, which still perform well but have been retired, are being left idle or eliminated. Professional refurbishment technology is becoming a key way to address cost constraints and achieve resource recycling. Through a systematic and standardized refurbishment process, refurbished and used tube mills can be brought back to near-new performance and stable and reliable operation.

1. Comprehensive Assessment: Accurately diagnose the equipment's "health"

The first step in refurbishment is a comprehensive technical assessment. A professional team will perform on-site or in-plant disassembly and inspection of refurbished and used tube mills, focusing on assessing the wear, deformation, and structural integrity of core components such as the tube body, hollow shaft, gears, liners, bearing housings, reducers, and motors. Non-destructive testing methods such as ultrasonic thickness measurement, magnetic particle inspection, and laser alignment testing are used to determine whether the tube body contains cracks, corrosion, or localized thinning, ensuring the equipment's refurbishment value. Only equipment that passes this rigorous evaluation will enter the refurbishment process, avoiding the safety hazards associated with "renovation with defects."

2. Thorough Disassembly and Cleaning: Restoring the Equipment to Its Original State

Once the assessment is passed, the equipment will be completely disassembled. The old liners and grinding media inside the tube body are removed, the hollow shaft and bearings are separated, and the transmission system is disassembled piece by piece. All components undergo high-pressure cleaning, rust removal, and degreasing to expose their original condition, paving the way for subsequent repair and inspection.

3. Repair or Replacement of Core Components: Restoring the Equipment's Accuracy and Strength

This is the core step in the refurbishment process. Based on the inspection results, key components are categorized and processed:

Cylinder Repair: If the cylinder shows minor deformation or localized wear, steel plate repair welding, rounding, and inner wall grinding are used to restore its roundness and strength. Severe damage requires partial replacement or reinforcement.

Hollow Shaft and Bearings: Hollow shafts are vulnerable parts. If they show signs of strain, wear, or ovalization, they require precision turning repair or replacement. The matching sliding or rolling bearings are typically replaced with new, high-precision components to ensure smooth operation.

Transmission System: If the large and small gears are worn beyond the specified range, they must be replaced with new, high-precision gears to ensure smooth engagement and low noise. The reducer is disassembled and the bearings, seals, and lubricant replaced. The gear set is also replaced if necessary.

Liners and End Caps: All are replaced with new, wear-resistant liners to improve grinding efficiency and extend service life.

4. Electrical System Upgrade: Towards Intelligent Operation

The original control system of the refurbished and used tube mill was outdated, resulting in high energy consumption and inconvenient operation. During the refurbishment process, the equipment is typically upgraded to a modern electronic control system equipped with a PLC and touchscreen control cabinet, enabling start-stop control, fault alarms, load monitoring, and remote communication. Some high-end refurbishment projects may also incorporate variable frequency drive and load optimization systems for energy-saving operation and automated management.

5. Overall Assembly and Factory Testing: Ensuring Operational Reliability

After all repairs and replacements are completed, the equipment enters the final assembly phase. Alignment, leveling, and tightening are performed in strict accordance with assembly process requirements to ensure the precise fit of all components. After assembly, a no-load test run is conducted to check for compliance with parameters such as vibration, temperature, noise, and lubrication systems. Some manufacturers also conduct load-tested grinding to simulate actual operating conditions and verify equipment performance.

The "rebirth" of a refurbished and used tube mill goes beyond simple repair or assembly; it involves a systematic process encompassing evaluation, disassembly, repair, upgrade, and testing. Through professional refurbishment, companies can not only significantly reduce equipment procurement costs (typically only 40%-60% of new equipment) but also achieve near-new performance and reliability, achieving a win-win situation for both economic benefits and sustainable development. Under the background of "dual carbon" goals and circular economy, refurbishing tube mills is becoming an important choice for updating industrial equipment.