POLYSIUS – TECHNICAL TRAINING 2011

PLANT OPTIMISATION (POLYCOM)

A PROCESS PERSPECTIVE
By Vijay, Arumugam

Polysius

Technical Training – 2011 Polasia 06th & 07th July 2011

 PLANT OPTIMISATION (POLYCOM) – A PROCESS PERSPECTIVE

GOOD PROCESS
+ = GOOD QUALITY PRODUCT
GOOD MACHINERY

GOOD PROCESS
+ = AVERAGE QUALITY PRODUCT
BAD MACHINERY

BAD PROCESS
+ = POOR QUALITY PRODUCT
GOOD MACHINERY

BAD PROCESS
+ = CATASTROPHE
BAD MACHINERY

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
2 Polysius
PLANT OPTIMISATION (POLYCOM) – A PROCESS PERSPECTIVE

What do we understand by plant optimisation?

The plant optimisation is a service of the process
technology and the target is to optimise the complete
or partial cement production line relative to:

Operating Cost

Productivity

Product quality

Availability

Enabling the use of AF & Raw Materials

Addressing Emission Issues
And or to cater to the customer individual request.

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
3 Polysius
PLANT OPTIMISATION (POLYCOM) – A PROCESS PERSPECTIVE

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
4 Polysius
PLANT OPTIMISATION (POLYCOM) – A PROCESS PRESPECTIVE

PROCEDURE FOR PLANT OPTIMISATION

IDENTIFYING THE CLIENT‘S NEED

PLANT AUDIT & ASSESSMENT

COLLECTING OPERATIONAL DATA & CIRCUIT SAMPLES

TESTING OF CLINKER & CIRCUIT SAMPLES AT OUR R&D LAB IN GERMANY

EVALUATION OF OPERATIONAL PARAMETERS WITH A HELP OF TEST REPORTS

IDENTIFYING THE WEAK SPOTS IN THE PROCESS

IMPLEMENTING PLANT OPTIMISATION

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
5 Polysius
PLANT OPTIMISATION (POLYCOM) – A PROCESS PERSPECTIVE

STOCK TAKING:

Evaluation of the relevant process data like

pressure, temperature, mass flows etc.

Material analysis with chemical and physical

cheracteristics

Calculation of gas, mass & energy balances

Weakpoint and availability analysis

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
6 Polysius
PLANT OPTIMISATION (POLYCOM) – A PROCESS PRESPECTIVE

CASE STUDY

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
7 Polysius
Plant optimisation in 03/2011

1. Introduction
2. Results of grindability test in Polysius laboratory
3. Operational data before optimisation
4. Inspection Results and Modifications
4.1 POLYCOM
4.2 SEPOL POLYCOM
4.3 SEPOL Ball Mill
4.4 Ball Mill
5. Measurement and sampling points
6. Measurement and sampling results
7. Operational data after optimisation
8. Further optimisation options

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
8 Polysius
1. Introduction

- During a plant visit client reported about a reduced production

- The reported average capacity was 115 t/h only
- Plant Manager requested Polysius to submit quotation for a plant audit
aiming at achieving a higher production.

- On 16.11.2010 the respective quotation for the plant audit /

“Appraisal and optimisation for Cement Grinding Plant” was submitted

- Clinker samples were send to Polysius for grindability test and were
registered in Polysius laboratory on 03.01.2011
- On 05.01.2011 detailed operation data were submitted by plant engineer
(production data on that day is in the range of 105 t/h to 120 t/h)

- Plant audit on site was performed from 01.03.2011 until 15.03.2011

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
9 Polysius
2. Results of grindability Test in Polysius laboratory

General information on Zeisel Test

Procedure

Evaluation

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
10 Polysius
 Copy from test protocol
Clinker - A

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
11 Polysius
 Copy from test protocol
Clinker - B

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
12 Polysius
 Grindability of Clinker acc. to Zeisel @ 3000 Blaine

45

Statistic data from 2002 until 2009:

40
Total no. of Zeisel Test: 387
Average Value: 33,4 kWh/t
35

30

25
Number

Clinker A
44
20 42
Clinker B
33 34 32
15
26 28 28
23
39,1 kWh/t 44,7 kWh/t
10 22
18
Original plant
5 9 8
design: 33,8 kWh/t
7 8 8 7
3 4
2 2 1
0 0 0 0 0
< 26 26 - 27 - 28 - 29 - 30 - 31 - 32 - 33 - 34 - 35 - 36 - 37 - 38 - 39 - 40 - 41 - 42 - 43 - 44 - 45 - 46 - 47 - 48 - 49 - > 50
27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
Grindability [kWh/t]

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
13 Polysius
2. Results of grindability Test in Polysius laboratory

Evaluation of Zeisel Test result

Zeisel Test Result [kWh/t]

design sample results
33,8 39,1 44,7
Spec. power requirement, ball mill shaft [kWh/t] 27,5 32,2 37,2
Increase in spec. power requirement [-] 1,00 1,17 1,35
Expected calculated production [t//h] 140 119 103
(assuming same plant set up)

Conclusion:
- Present type of clinker is very difficult to grind.
- Additional investigations in Polysius R&D centre revealed a high amount of Belite and free lime
- The analysed samples indicated a very exceptional clinker
- Production of 140 t/h is not achievable using the analysed types of clinkers

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
14 Polysius
3. Cement Mill Operation Data, Before Optimisation

Before Optimisation
average
from to from to from to
Date 26.02. 27.02. 27.02. 27.02. 01.03. 01.03. 26.02. 01.03.
Time 07:00 06:00 07:00 18:00 14:00 00:00
Operation Time [h] 24 11 10 45
Silo 1 [%] 10 10 40
Silo 2 [%] 30 30
Silo 3 [%] 60 60 60
Total feed [t/h] 115,3 120,0 103,1 113,7 *
Clinker [%] 91,0 89,9 92,6
Gypsum [%] 5,4 5,4 5,5
Limestone [%] 3,5 4,7 1,9
Fineness
Blaine [cm²/g] 3132 3083 3042 3086
R 45 µm [%] 14,8 16,7 14,8 15,4
Power draw
Ball mill [kW] 2110 2110 2110
Polycom Fix [kW] 390 346 368
Polycom Mov [kW] 249 208 229

* Average production considers the respective operating hours

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
15 Polysius
Calibration clinker weight feeder

Weigh Feeders were calibrated recently

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
16 Polysius
3. Cement Mill Operation Data, Before Optimisation

Analysis of production data:

- Average production output of 113,8 t/h was achieved for a span of 45 hours

- Abnormal difference in power draw of Polycom drives

- Power draw of Polycom is on the lower side

- Stable operation periods with production of 103 t/h as well as 120 t/h were
recorded using basically the same plant setup

- This indicates varying clinker grindability

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
17 Polysius
 4. Inspection Results and Modifications
4.1 - POLYCOM

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
18 Polysius
Polycom rollers

Polycom roller surface

Looks good after 7000 h
of operation

Almost no concave
wear pattern visible

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
19 Polysius
Polycom rollers – compound cast, operation time ~ 7000 hours

Polycom fix roller

Non drive
side
- In good shape

- Autogenous wear protection

of ~ 60 %

- Material deposits
indicate a not optimum
mixing of feed components

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
20 Polysius
Polycom rollers

Polycom – Wear pattern is higher on the fixed side roller as a result of not optimal mixing of
fresh feed material and separator reject material

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
21 Polysius
Polycom rollers

Polycom movable roller

Non drive
side
- In good shape

- Autogenous wear protection

- of ~ 80%

- Material deposits
indicate a not optimum
mixing of feed components

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
22 Polysius
Polycom rollers

Polycom rollers – good autogeneous wear protection is observed,

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
23 Polysius
Polycom rollers

Intermediate
Profiling recommended

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
24 Polysius
Polycom rollers

Fix roller
Intermediate profiling
recommended

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
25 Polysius
Polycom rollers

Intermediate profiling
recommended

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
26 Polysius
Polycom rollers

Damaged wear surface

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
27 Polysius
Polycom rollers

Damaged wear surface

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
28 Polysius
Polycom rollers

Polycom Roller surface

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
29 Polysius
Polycom feed chute

Polycom feed chute adjustment.

Initial measurement – 170 mm

Slide gates and adjustable tongues

in Polycom feed chute are in
good shape

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
30 Polysius
Polycom feed chute

Polycom slide gate after

Adjustment – 250 mm

Feed chute in centre position

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
31 Polysius
Polycom slide gate limit switches

Polycom – Slide gate

Proximity sensor were adjusted.

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
32 Polysius
Polycom – uneven power draw on fix roller and movable roller

Operation data revealed a high difference in power draw of > 40%

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
33 Polysius
Polycom – uneven power draw on fix roller and movable roller

Motor ampere reading revealed a much lower difference in power draw of ~ 15% only

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
34 Polysius
Polycom – uneven power draw on fix roller and movable roller

Transducers for both roller drives were exchanged, as measurement range of new transducers
was different compared to old ones
Old: 0 – 800 kW
New: 0 – 952 kW

Result:
Indicated power draw difference
came down to ~ 15 %, which
is still on the higher side

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
35 Polysius
Polycom – uneven power draw on fix roller and movable roller
Aiming at further equalising the power draw modifications inside Polycom feed chute were made,
which are supposed to improve the mixing of fresh feed material and separator rejects

Clinker Rejects

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
36 Polysius
Polycom – uneven power draw on fix roller and movable roller

Modification carried out in 2001 – Installation of restriction plate in Polycom feed chute

clinker rejects

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
37 Polysius
Polycom – uneven power draw on fix roller and movable roller

Restriction plate is still in good shape – view from Polycom roller upwards

Restriction Plate

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
38 Polysius
Polycom – uneven power draw on fix roller and movable roller

Polycom feed bin after installation

Of metal rod
Clinker Rejects

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
39 Polysius
Polycom – uneven power draw on fix roller and movable roller

Material accumulation on rods

Polycom feed bin after
installation Of metal rod below
Existing restriction plate

clinker rejects

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
40 Polysius
Polycom – uneven power draw on fix roller and movable roller

Rods prior assembly in to

Polycom feed bin

Diameter: 50 mm
High wear resistant steel
Same material as installed
in Limestone hopper

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
41 Polysius
Polycom – uneven power draw on fix roller and movable roller

End connection fixed on one end and screw mounting

On the other end

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
42 Polysius
Polycom – uneven power draw on fix roller and movable roller

Polycom feed bin

Rod installation

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
43 Polysius
Polycom – uneven power draw on fix roller and movable roller

Polycom feed bin after installation

Of metal rod

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
44 Polysius
Polycom – uneven power draw on fix roller and movable roller

Result:
Polycom roller power draw
almost equal after installation
of rods

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
45 Polysius
 Values on 01.03.2011
240 MPa
18 mm 245 MPa
2 mm 230 MPa
550 kW
3 mm
New implemented

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
46 Polysius
Polycom Basic setting, before optimisation

Basic gap measured:

Average: 17 – 18 mm

New setting in POLCID: 18 mm

(before 16 mm)

16 mm 18-19 mm 16 mm

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
47 Polysius
Hydraulic spring curve, before optimisation

Calculation of grinding pressure

Calculation of grinding pressure POLYCOM 180 300
Code word : KUWAL
Inquiry-no. : Cement Grinding Plant
Client : 170 290

Polycom : 15/8-5
Material : clinker Combi Grinding 160 280
Diameter : 1500 mm 1500 mm
Width : 800 mm 800 mm
150 270
vu : 1,53 m/s 1,53 m/s
Size (0 - 9) : 5 5

hydraulic pressure [bar]

grinding pressure [MPa]

hydr. cylinder : 400 mm 400 mm 140 260
N2 -cylinder : 26,4 l 26,4 l
Rho b : 1,80 t/m³ 1,80 t/m³
Rho c : 2,50 t/m³ 2,50 t/m³ 130 250
mDot : 220 ts/m³h 220 ts/m³h
pmax allowable : 280 MPa 280 MPa
120 240
s0 : 18
p N2 : 70 bar
p0 : 112 bar 110 230

MDot : 404 t/h

sma x : 36,67 mm 36,67 mm
100 220
pm at s0 : 242,81 MPa 31,16666667
pm at sma x : 237,71 MPa 0,85
90 210

80 200
15 20 25 30 35 40 45
working gap [mm]

hydr. pressure at pmax allow. actual hydr. Pressure grinding pressure pmax actual

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
48 Polysius
Hydraulic spring curve, Status 09.03.2011

Calculation of grinding pressure POLYCOM Calculation of grinding pressure

Code word : KUWAL 180 300
Inquiry-no. : Cement Grinding Plant
Client :
Polycom : 15/8-5 170 290

Material : clinker Combi Grinding

Diameter : 1500 mm 1500 mm 160 280
Width : 800 mm 800 mm
vu : 1,53 m/s 1,53 m/s
150 270
Size (0 - 9) : 5 5
hydr. cylinder : 400 mm 400 mm

hydraulic pressure [bar]

grinding pressure [MPa]

N2 -cylinder : 26,4 l 26,4 l 140 260
Rho b : 1,80 t/m³ 1,80 t/m³
Rho c : 2,50 t/m³ 2,50 t/m³
mDot : 220 ts/m³h 220 ts/m³h 130 250

pmax allowable : 280 MPa 280 MPa

s0 : 18 120 240
p N2 : 80 bar
p0 : 130 bar
110 230
M Dot : 404 t/h
sma x : 36,67 mm 36,67 mm
p m at s0 : 281,83 MPa 31,16666667 100 220
pm at sma x : 277,64 MPa 0,85

90 210

80 200
Operation with increased grinding force 15 20 25 30 35 40 45

to cater for clinker with higher grindability working gap [mm]

hydr. pressure at pmax allow. actual hydr. Pressure grinding pressure pmax actual

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
49 Polysius
Operation of POLYCOM with poor spring characteristics

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
50 Polysius
Operation of POLYCOM with good spring characteristics

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
51 Polysius
Polycom rollers – inspection on 15.03.2011

Polycom fix roller

Autogeous wear protection

of ~ 90 %

Material deposits
indicate improved
material mixture

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
52 Polysius
POLYCOM SEPOL - fan

Fan impeller

Exchanged and in
operation since 06/2010

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
53 Polysius
POLYCOM SEPOL - fan

Separator – ID Fan

Excessive dust
deposits on impeller

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
54 Polysius
POLYCOM SEPOL – fan impeller

Separator – ID Fan

Fan impeller

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
55 Polysius
POLYCOM SEPOL – fan impeller

Separator – ID Fan

High wear observed

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
56 Polysius
POLYCOM SEPOL - Cyclone

Sepol cyclone outer surface

Badly damaged.
Possible false air intake

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
57 Polysius
POLYCOM SEPOL - Rotor

Rotor & Fixed guide van

Rotor blades were exchanged

in 12/2006

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
58 Polysius
POLYCOM SEPOL – Guide vanes

Wear pattern on fixed guide vane

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
59 Polysius
POLYCOM SEPOL – Rotor blades

Rotor blade measurement

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
60 Polysius
POLYCOM SEPOL

Sepol inside – damaged area

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
61 Polysius
POLYCOM SEPOL

Sepol inside – damaged area

Cyclone inlet

Worn areas were repaired by patching plates from outside (reject side) on 04.03.20011

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
62 Polysius
POLYCOM SEPOL – Cyclone, worn dip tube

Damage on SEPOL
Cyclone dip tube

Leads to a significantly reduced cyclone efficiency

High dust load in circulation air
Reduced separator efficiency
Increased wear, especially on fan impeller

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
63 Polysius
POLYCOM SEPOL – worn areas, labyrinth sealing

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
64 Polysius
POLYCOM SEPOL – worn areas, labyrinth sealing

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
65 Polysius
POLYCOM SEPOL – worn areas, labyrinth sealing

Rotor cage

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
66 Polysius
4.3 Ball mill

Activities:

1. Inspection after mill was ground empty

2. Inspection after mill crash stop, meter samples across the grinding path were
taken

Results Step 1:

Grinding media filling level was as follows:

Chamber 1: 28 %
Grinding media size: between 80 mm to 50 mm
Chamber 2: 33 %
Grinding media size: between 15 mm to 25 mm

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
67 Polysius
Ball mill – ball charge and power calculation based on findings
Produkt, Produktfeinheit und Produktrate Kugelmühle Nennabmessungen und Drehzahl
Produkt Zement DNenn 3,80 m VTK DNenn 0,00 m
Produktfeinh. 3100 m²/kg LNenn 12,00 m VTK LNenn incl.
0,00 m
Produktrate 130 t/h LNenn /D Nenn 3,158 Wand
Kammer 1 Kammer 2 Kammer 1+2 n 16,23 1/min 73,2 %nkrit
Di 3,64 m 3,64 m Berechnung c-Faktor und Leistungsaufnahme
Li 4m 7,63 m 11,63 m 2-Ka-Sichter Zement 6,874 für FG 30%, n Wu(Di)=31,7
Li /Di 1,099 2,096 3,195 0,9690 für n Wu(Di) = 30,96
Proz. Anteil 34,4% 65,6% 0,9519 für Blaine = 3100 m²/kg
Dichte Kugeln 4,5 t/m³ 4,65 t/m³ 4,60 t/m³ 6,7426 für FG = 31,5%
Füllungsgrad 28,0% 33,00% 31,5% c-Faktor 6,219 m 1,5/s3
Kugeln 52,45 t 121,84 t 174,29 t Faktor W/Z 0,926 VTK gesamt
wsp a.W. 4,79 kWh/t 11,12 kWh/t 15,91 kWh/t P a.W. 2068,0 kW 0,0 kW 2068,0 kW
wsp a.Z. 17,18 kWh/t P a.Z. 2233,3 kW 0,0 kW 2233,3 kW
Kugelfüllung Kammer 1 Kugelfüllung Kammer 2
Kugel-D Anteil Menge Reserve Kugel-D Anteil Menge Reserve
100 mm 0,0% 0,0 t 0,0 t 60 mm 0,0% 0,0 t 0,0 t
90 mm 0,0% 0,0 t 0,0 t 50 mm 0,0% 0,0 t 0,0 t
80 mm 10,7% 5,6 t 0,0 t 40 mm 0,0% 0,0 t 0,0 t
70 mm 62,4% 32,7 t 0,0 t 30 mm 0,0% 0,0 t 0,0 t
60 mm 19,0% 10,0 t 0,0 t 25 mm 10,0% 12,2 t 0,0 t
50 mm 6,0% 3,1 t 0,0 t 20 mm 41,0% 50,0 t 0,0 t
40 mm 1,9% 1,0 t 0,0 t 17 mm 9,0% 11,0 t 0,0 t
30 mm 0,0% 0,0 t 0,0 t 15 mm 40,0% 48,7 t 0,0 t
Summe 100,0% 52,5 t 0,0 t Summe 100,0% 121,8 t 0,0 t
Gewicht/Stück 1,115 kg 0,0% Gewicht/Stück 21,13 g 0,0%
mittl. Kugeld. 64,7 mm mittl. Kugeld. 17,3 mm
hydr. Durchm. 31,65 mm hydr. Durchm. 7,79 mm

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
68 Polysius
Ball mill – recommended new ball charge

Ball charge chamber 1 is much to coarse for efficient fine grinding

Ball charge chamber 2 almost equal to Polysius recommendation

Recommended ball charge for both chambers:

Size Part
[mm] [%]
20 40
17 40
15 20

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
69 Polysius
Ball mill after crash stop, chamber 2

Ball mill second chamber

After crash stop

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
70 Polysius
Ball mill after crash stop, chamber 2

Ball mill second chamber

After crash stop

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
71 Polysius
Ball mill after crash stop, chamber 2

Ball mill second chamber

After crash stop

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
72 Polysius
Ball mill after crash stop, chamber 2

Ball mill second chamber

After crash stop

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
73 Polysius
Ball mill after crash stop, chamber 1

Ball mill first chamber

After crash stop

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
74 Polysius
Ball mill after crash stop, chamber 1

Ball mill first chamber

After crash stop

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
75 Polysius
Ball mill after crash stop, longitudinal seiving

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
76 Polysius
Ball mill after crash stop, longitudinal seiving

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
77 Polysius
Ball mill SEPOL Rotor

Separator rotor blade

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
78 Polysius
Ball mill SEPOL

Separator – fixed guide vane

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
79 Polysius
Ball mill SEPOL, feed area

Seaparator – top portion

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
80 Polysius
Ball mill SEPOL, guide vanes

Separator – Fixed guide vane

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
81 Polysius
5. Measurement and sampling points

Polycom SEPOL:
Feed, Rejects, Fines
(intermediate product)

Polycom bin level:

Measurement
Checked Ball mill SEPOL:
Feed, Rejects, Fines
(Cement)

Measurements:
Volumetric flow
Static pressure
Filter dust sampling Temperature

Inside ball mill:

Meter Samples

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
82 Polysius
 6. Measurement results, first findings
Measured Pressure drop baghouse filter: 24 mbar

Polycom Sepol dedusting Assumed false air intake

measured

Ball mill dedusting via bag house filter E.P. off Volumetric flow bag filter inlet: 146. 072 m³/h
Volumetric flow downstream Sepol: ~ 140.000 m³/h
Design volumetric flow of SEPOL: 164.000 m³/h
Result: separation air too low, which reduces efficiency
Title: Technical Training – 2011 @ Singapore
Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
83 Polysius
Measurement and sampling – First findings

Polycom bin level measurement:

Checked and found o.k.

Ball mill SEPOL:

High amount of fines in separator rejects
Reject Blaine value 1400 cm²/g indicated a poor efficiency
Separation air below design

Ball mill meter sampling:

Low grinding progress in chamber 1 due to coarse ball charge

Fineness E.P. filter dust:

Very fine,
Blaine value: 7020 cm²/g
R 45 µm: 4,6 %

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
84 Polysius
Modification of bag filter cleaning cycle

Cycle time:
Old: 10 s Pressure Drop reduced from 24 mbar to 16 mbar
New: 5 s - Increased separation air volume
- Separator efficiency increased,
Pulsing time: - Reject Blaine reduced from 1400 to 1040 Blaine
Old: 70 ms
New: 100 ms

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
85 Polysius
Recommended bag filter quality

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
86 Polysius
Recommended bag filter quality (especially in case grinding aid is used)

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
87 Polysius
Measurement results, during optimisation on 12.03.2011, E.P. on
Measured Pressure drop baghouse filter: 16 mbar

Polycom Sepol dedusting

measured

Ball mill dedusting via E.P. Volumetric flow bag downstream SEPOL: 158.751 m³/h

Design volumetric flow of SEPOL: 164.000 m³/h

Result: separation air increased, but still on low side
Title: Technical Training – 2011 @ Singapore
Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
88 Polysius
Circuit samples, 05.03.2011

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
89 Polysius
Circuit samples, 08.03.2011

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
90 Polysius
Circuit samples, 12.03.2011

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
91 Polysius
Check of Polycom bucket elevator conveying capacity

Empty 8 buckets after crash stop

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
92 Polysius
Check of Polycom bucket elevator conveying capacity

Weight per bucket [kg] 24,71

Bucket spacing [mm] 360
Bucket per meter [-] 2,78
Weight per meter [kg/m] 68,64
Conveying speed [m/s] 1,56
Conveying capacity [t/h] 385
Bucket size [l] 65
Material density [t/m³] 1,94
Bucket filling level [%] 20
Power draw drive motor [A] 120
Motor design [A] 168

Bucket elevator is suitable for operation with 20% increased circumferential roller speed

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
93 Polysius
7. Cement Mill Operation Data, After Optimisation

Stabile operation periods recorded during optimisation

average
from to from to from to from to from to from to from to
Date 08.03. 09.03. 07.03. 08.03. 09.03. 09.03. 09.03. 10.03. 11.03. 12.03. 12.03. 13.03. 08.03. 13.03.
Time 20:00 09:00 15:00 04:00 14:00 17:00 21:00 10:00 21:00 10:00 15:00 07:00
Operation Time [h] 13 14 3 13 13 16 72
Silo 1 [%] 100 40 40
Silo 2 [%]
Silo 3 [%] 100 100 100 60 60
Total feed [t/h] 132,5 133,1 114,5 130,8 132,1 131,0 131,2 *
Clinker [%] 90,3 90,1 92,7 89,7 92,7 92,7 91,4
Gypsum [%] 5,3 5,2 5,4 5,4 5,4 5,4 5,4
Limestone [%] 4,4 4,7 1,9 4,9 1,9 1,9 3,3
Fineness
Blaine [cm²/g] 3133 3141 3127 3143 3113 3077 3122
R 45 µm [%] 17,3 17,3 12,4 17,4 15,9 16,2 16,1
Power draw
Ball mill [kW] 2108 2112 2118 2109 2131 2118 2116
Polycom Fix [kW] 423 434 421 450 447 446 437
Polycom Mov [kW] 417 430 427 448 456 457 439

* Average production considers the respective operating hours

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
94 Polysius
 Cement Mill Operation Data, Before And After Optimisation

Before Optimisation Stabile operation periods recorded during optimisation

average average
from to from to from to from to from to from to from to from to from to from to
Date 26.02. 27.02. 27.02. 27.02. 01.03. 01.03. 26.02. 01.03. 08.03. 09.03. 07.03. 08.03. 09.03. 09.03. 09.03. 10.03. 11.03. 12.03. 12.03. 13.03. 08.03. 13.03.
Time 07:00 06:00 07:00 18:00 14:00 00:00 20:00 09:00 15:00 04:00 14:00 17:00 21:00 10:00 21:00 10:00 15:00 07:00
Operation Time [h] 24 11 10 45 13 14 3 13 13 16 72
Silo 1 [%] 10 10 40 100 40 40
Silo 2 [%] 30 30
Silo 3 [%] 60 60 60 100 100 100 60 60
Total feed [t/h] 115,3 120,0 103,1 113,7 132,5 133,1 114,5 130,8 132,1 131,0 131,2
Clinker [%] 91,0 89,9 92,6 90,3 90,1 92,7 89,7 92,7 92,7 91,4
Gypsum [%] 5,4 5,4 5,5 5,3 5,2 5,4 5,4 5,4 5,4 5,4
Limestone [%] 3,5 4,7 1,9 4,4 4,7 1,9 4,9 1,9 1,9 3,3
Fineness
Blaine [cm²/g] 3132 3083 3042 3086 3133 3141 3127 3143 3113 3077 3122
R 45 µm [%] 14,8 16,7 14,8 15,4 17,3 17,3 12,4 17,4 15,9 16,2 16,1
Power draw
Ball mill [kW] 2110 2110 2110 2108 2112 2118 2109 2131 2118 2116
Polycom Fix [kW] 390 346 368 423 434 421 450 447 446 437
Polycom Mov [kW] 249 208 229 417 430 427 448 456 457 439

Ball mill E.P. OFF, ball mill dedusting via ball mill Sepol baghouse filter, reduced separation air ON, E.P. in operation E.P. OFF
Ball mill dedusting [m³/h] ~ 7.000 ~ 4.000 ~ 7.000
Gypsum feed Gypsum feed to ball mill Gypsum to Polycom

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
95 Polysius
7. Cement Mill Operation Data, After Optimisation
Analysis of production data:

- Average production output of 131,28 t/h was achieved for a span of 72 hours

-Power draw on Polycom drives lowered down to < 2 %

-Power draw is around 450 kW each drive whereas 650 kW installed

-Stable operation periods with an average production of around 130 t/h were
recorded using different plant setups

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
96 Polysius
9. OPTIMISATION POINTS FOR FURTHER CAPACITY INCREASE
- Ball mill dedusting by bringing E.P. back into operation and feeding filter dust to cement
transport

-As filter dust fineness is around 3200 Blaine only, which is much below cement fineness when
grinding masonary cement the installation of a static separator before E.P. is recommended.

- Increase volumetric flow of ball mill SEPOL separator by tipping of impeller

- Install dam ring on ball mill SEPOL feed section (drawing handed over to client)

- Change of smaller ball charge in chamber 1 together with installation of Diapol intermediate
diaphragm and outlet diaphragm.

- Installation of VFD drive for Polycom motors to attain higher circumferential speed
and higher power draw on Polycom drives.

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
97 Polysius
 Thank you for your attention

Title: Technical Training – 2011 @ Singapore

Date: 06th & 07th July 2011
Presented By: Vijay, Arumugam
98 Polysius