Scribd
Upload
90 views29 pages

Cement-Separator-Ball-Mill-Optimization 2

Uploaded by

La Kubaisi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
90 views29 pages

Cement-Separator-Ball-Mill-Optimization 2

Uploaded by

La Kubaisi
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 29

Cement Separator & Ball Mill

Optimization
When: Do optimization
1. In some period (1 month, 1 Quarter, 1 Year or ???)
2. To assess the reason/cause of disturbance
– When abnormal operation
– Poor performance of grinding system
– Low mill output or poor quality product
-High operation or maintenance costs
3. Keep operation in a good efficiency

Conventional grinding system

Main Machine

1. Feeding system
2. Tube mill
3. Dynamic separator
4. Dedusting (BF/EP)
5. Transport equip.
Mill charge optimization

What is function of mill?

Size reduction along the mill

-Coares grinding —> 1st compartment


Normal feed size 5% residue 25 min
Max feed size 0.5% residue 35 min
-Fine grinding —-> 2nd comparment

Coarse material grinding


Piece weight (or knocking weight)
-Average weight / piece of grinding
media in each compartment
(g/piece)
– Piece weight Impact force

—> Need large ball size

Fine Material grinding

Specific surface
Average surface area of (ball)
grinding media in each compartment
(m2/t)

Specific surface Attrition force

—-> Need small ball size

Ball charge composition


Calculation (for steel ball)
-Piece weight : i = [3.143/6] x d3 x 7.8 ;g/pcs.
-Specific surface : o = 123 / i (1/3) ; m2/ton

*Note : d = size of ball (cm)

Ball charge composition

Ball charge composition


-General we use (Product Blaine 4,500 cm2/g) for “Conventional”
-Cpt.1 : Piece weight 1,500-1,600 g./piece
-Cpt 2 : Specific surface 30-35 m2/t
– For “Pre-grinding system” “R/P + Conventional”
– Cpt.1: PW ~1,100-1200 g/pc
-Cpt.2: SS ~35-40 m2/t
**depend on product fineness!!

Maximum steel ball size (Bond equation)


B=36 x (F80)1/2 x [(SgxWi)/(100xCsxDe
1/2)]1/3
Where
-B : Maximum ball size (mm.)
-F80 : Feed material size for 80% pass (Qm)
– Wi : Bond work index (kWh/t)
– Cs : N/Nc (normally ~ 0.7-0.75)
-Sg : Specific gravity of raw material (t/m3)
– De : Effective diameter of mill (m.)
-F80 = log [(0.20) size residue(mm.)]/log(%residue)
– Example;
Given
• Feed size = 5% res. 25 mm.
• Wi = 13.0 kWh/t
• Cs = 0.7
• Sg = 3.0 t/m3
• De = 4.0 m.
• F80 = log(0.20)25/log(0.05)
• F80 = 13.4 mm.
Find : Maximum ball size
B = 36x(13.4)1/2x[(3×13)/(100×0.7×41/2)]1/3
Maximum ball size = 86 mm.

Maximum steel ball size


** Typical fresh clinker : 5% residue 25 mm. or F80 = 13.4 mm.

Example

– Given
• Feed size = 5% res. 20 mm.
• Wi = 12.0 kWh/t
• Cs = 0.7
• Sg = 3.0 t/m3
• De = 2.5 m.

-Find: required maximum ball size


– F80
– Maximum ball size (mm.)

Mill performance test


Steps
1. Recording of related operational data
2. Air flow measurement
3. Crash stop and visual inspection in mill
4. Sampling in mill
5. Evaluation of test

1. Recording of related operational data


-Tube Mill
. Feed rate, Return, Grinding aids, Water injection, Mill drive
power (kW)
-Static separator
Vane position
-Mill ventilation fan
. Damper position, Air flow rate (if have instrument), Pressure
.Fan drive power

2. Air flow measurement


– Air flow measurement
– Air flow rate
-Temperature
-Static pressure
Mill ventilation air
Purpose
– Forward movement of the material –> retention time
– Take out fine particles and so diminish the risk of coating
– Cooling of the material in mill –> Diminish coating / dehydration
of gypsum
Usual ranges of ventilation:
Air speed in mill
– Open circuit : 0.8 to 1.2 m/sec
– Closed circuit : 1.2 to 1.5 m/sec
**Min 0.5 m/s —> tend to result inefficient over grinding and excessive
heat generation with possible coating problem.
**Max > 1.4 m/s —> drag particle out of mill before they have been sufficiency ground.

Agglomeration and ball coating


Cause:
-Temperature too high tendency of the
material forming agglomerates/coating on
grinding media and liner plates
-Grinding efficiency will be reduce
-Temperature outlet mill range 110-120 C.
Test 2
.Mill dimension
-Inside diameter 3 m.
-Degree of filling 28% in both compartment
.Mill ventilation check
-Flow 22,000 m3/h

– Check Air ventilation speed in mill ?

3. Crash stop and visual inspection


-Stable operation before crash stop
– Emergency stop or Crash stop
.Tube mill / All auxiliary equipment
.Mill Ventilation
– Disconnect main circuit breaker (Safety !)
-Preparation of sampling equipment (shovel, scoop, plastic bag, meter,
lighting etc.)

Preparation of sampling equipment

3. Crash stop and visual inspection

Visual inspection
-Liner and Diaphragm condition –> wear, block
-Ball size distribution along the mill –> classify liner
– Water spray nozzle condition —> clogging
– Foreign material ?
-Ball charge condition —> agglomeration, coating
3. Crash stop and visual inspection

-Material level in compartment #1 and #2


3. Crash stop and visual inspection

– Ball charge quantity (Filling degree)


-Measurement by free height
-Measure average internal diameter, Di
-Measure height, h, in three different points along axis for each grinding
compartment

Ball charge quantity (Filling degree)


4. Sampling inside mill (mill test)
Sampling of material
– Take ~1 kg sample every 1 m along mill axis
– Each sample collected from 3 point in the same cross section
– Removed some balls and taken sample
-First and last sample in each compartment should be taken
from 0.5 m off the wall or diaphragms
4. Sampling inside mill (mill test) –cont.
– After work inside the mill
-Calculation quantity of ball charge and filling degree
-Sample sieve analysis
. 1st compartment
◊ Sieve : 16 , 10 , 6 , 2 , 1.25 , 0.5 , 0.2 mm
2nd compartment
◊ Sieve : 1.25 , 0.5 , 0.2 , 0.12 , 0.09 , 0.06 mm., Blaine Fineness
Plot size reduction chart (graph)

Sieve test equipment


Results: Sieve and Fineness analysis from mill test
5. Evaluation of performance test
-Grinding efficiency
-Data for evaluation
-Result from visual inspection inside tube mill
-Sample analysis from longitudinal sampling inside tube mill Size
reduction graph
Evaluation of mill test standard reference
– Size reduction along mill axis
-Sieve residues and Blaine value in front of the diaphragms

Evaluation of mill test


Evaluation of mill test
– Test result : provide information to :
– Improvement of ball charge composition
-Maximum ball size and composition
Charge composition (PW and SS)
– Modification/Replace inside grinding compartment
-Liners
-Diaphragms
– Operation
-Mill ventilation
-Clear diaphragm slot
Common problems!
Case mill test, CM6 STS (Aug,2008)
Evaluate and correction
Case Mill test from : VDZ congress 2009

• Chamber 1 : good size reduction efficiency


• Chamber 2 : 45 micron shown results that grinding has
stopped midway through the 2nd chamber

Evaluate and correction


• Average ball size in chamber 2 is too small (average 16 mm, PW 17 g.)
• Take charge distribution more coarse to increase PW and average ball
size diameter (to 42 g. and 22 mm.)

Separator performance test


What is separator?
• Advantage of grinding system
with separator
• Reduce the number of fine particle to
be ground in mill
• Increase production capacity and
Reduce mill power consumption
• Increase % of Active particle in fine
particle of Cement
Advantage of grinding system with separator

You might also like

pFad - Phonifier reborn

Pfad - The Proxy pFad of © 2024 Garber Painting. All rights reserved.

Note: This service is not intended for secure transactions such as banking, social media, email, or purchasing. Use at your own risk. We assume no liability whatsoever for broken pages.


Alternative Proxies:

Alternative Proxy

pFad Proxy

pFad v3 Proxy

pFad v4 Proxy