Factors Influencing The Grinding Efficiency

Factors influencing the grinding efficiency
- Ventilation
- Moisture
- Water injection
- Coating
- Grinding Aid
- Product addition:
limestone
slag
Slegten grinding course

Ventilation
Purpose:
Fluidization / progress of the material
Removal of fine particles
risk of coating
Cooling of the material
coating / gypsum dehydration
Usual ranges of ventilation:

Air speed
Amount of air:
Open circuit : 0.8 to 1.2 m/sec
Open or closed circuit:
Closed circuit: 1.2 to 1.5 m/sec
0.3 to 0.45 Nm3/kg

Ventilation
Comparison between m/sec et Nm3/kg:
AIR FLOW
0,70
0,60
0,45 Nm3/kg
Quantity in Nm3/kg
0,50
0,3 Nm3/kg
0,40
0,7 m/sec
0,30
1,0 m/sec
0,20
1,2 m/sec
0,10
1,0
1,8
2,0
3,0
4,0
5,0
6,0
7,0
1,5 m/sec
Mill diameter in m

Ventilation
Limits
Open circuit
The filter product goes directly to the finished product.
Open or closed circuit

A high ventilation
can result in a transportation of uncrushed particles from Cpt 1 to Cpt 2
can have a bad influence on the material level in Cpt 1
is necessary if fresh feed is moist
In general, it is necessary:
.
to limit to 20-25 m/sec at mill feed entrance

.
to limit to 15 - 25 m/sec in the diaphragms
.
to provide a feeding chute with air passage
.
to provide an isolation device at mill
discharge

Inlet Chute
Ventilation

Moisture
Influence of the moisture on the ginding efficiency

Moisture
Solutions to high moisture
-
Use hot clinker
Control rejects temperature (closed circuit)
Work at high circulating load
Dry the material

Water injection
Purpose
EFFECT OF TEMPERATURE ON GYPSUM DEHYDRATION
Maintain the outlet temperature

< 105 C (115 C
max)
130C
80
Dehydration of gypsum
in the mill: short stay
not too bad effect
In the silo: long stay
extremely serious
DEHYDRATION %
dehydration of gypsum
140C
120C
coating
150C
100
60
110C
40
20
0
0
10
20
30
40
TIME OF EXPOSURE (minutes)

Water injection
Rules :
Cpt 1
If clinker temperature > 80 C at mill inlet ---> max 1 % H20 (on fresh feed)
The water has to be dropped on the fresh feed or at mill inlet
No spray, just drop
Cpt 2
The water has to be sprayed close to 2nd Cpt inlet
The water can be sprayed from intermediate or outlet diaphragm
A PID regulation and a security device has to be foreseen


Water injection
10

Water injection
Thermal balance
KW
AIR
WATER
AIR
Equilibrium: IN = OUT
WATER
MATERIAL
FEED
Shell
3 parameters:
.
Mill outlet temperature

. Necessary amount of water
.
Mill ventilation
Also take into account: thermal balance on the separator

11

Water injection
Thermal balance
Example of calculation - Open Circuit

Basis
4m x 13m
2900 kW
97 t/h
Feed temp: 90 C
Air and water temp: 15 C
3
Air amount through mill: 26900 Nm /h
Cement temperature: 105 C
IN
Energy
Material
Air
Water
2900 kW x 0,85 x 860 Kcal/kW / 97000 kg cem

0,19 kcal / kgC x 90C
3
3
0,31 kcal / Nm C x 26900 Nm /h x 15C / 97000 kg cem
1597 l/h x 15C / 97000 kg cem
OUT
Shell
Cement
Air
Water
750 Kcal / m h x 188 m / 97000 kg cem

0,19 kcal / kgC x 105C
3
3
0,31 kcal / Nm C x 26900 Nm /h x 100C / 97000 kg cem
1597 l/h x [ 537 kcal/kg + 100 kcal/kg + 0,44 kcal/kgC x(100C - 100C) ] / 97000 kg cem
= 21,85 kcal/kg cem

= 17,10
= 1,29
= 0,25
40,49
= 1,45
= 19,95
= 8,60
= 10,49
40,49
12

Water injection
Thermal balance
Feed: 102C
PROCESS AND THERMAL FLOW-SHEET
194 t/h
recirculated air:
135 000 m 3/h
18 980 m 3/h
FAN
at 86C
BAG FILTER
Process:
dp filter:
18 980 m 3/h
150 mmWG
HD
FAN
fresh air:
feed/air ratio:
15 000 m 3/h
1,29 kg/m 3
78C
at 15C
SEPARATOR
at 91C
CYCLONE
300 m m WG
material flow:
air flow:
A/F= 2
Fines: 91C
Process:
filter product
air-material flow:
150 000 m 3/h
97 t/h
155 858 m 3/h

at 91C
500 m m WG
dp cycl:
dp sep:
100 mmWG
250 mmWG
Product:
97 t/h
3000 Blaine
at 86C
E
L
E
V
A
T
O
R
MILL FILTER
Tails: 92C
FAN
97 t/h
dp filter:
impact
150 mmWG
flow meter
clinker
add.1
add.2
Design:
47 000 m 3/h
400 m m WG
add.3
at 90C
26 908 m 3/h
at 15C
43 649 m 3/h
at 91C
dp mill: 200 mmWG
MILL
ch.1
ch.2
air speed: 1,34 m/sec

FRESH FEED:
T/H:
C:
%H2O:
Clinker
92,15
90
Gypse
4,85
18
15
w ater injection:
0 l/h
86,4
0,75
tot fresh feed: 97
Company:
Plant:
15,0% false air
2900kW
105 C cem ent
filter product
475 l/h
Mill:
Separator:
SD 100
13

Water injection
Thermal balance
% of each component IN and OUT heat balance

according to mill (30 kWh/t - 1,2 m/s - clinker 100C)
60%
50%
40%
30%
IN :
% energy
IN :
% material
IN :
% air
IN :
% water
OUT : % shell
OUT : % cement
OUT : % air
20%
OUT : % water
10%
0%
1,8 2 2,2 2,4 2,6 2,8 3 3,2 3,4 3,6 3,8 4 4,2 4,4 4,6 4,8 5 5,2 5,4 5,6 5,8 6
Diameter (m)
14

Water injection
Thermal balance
Water requested in % according to mill
for different air speeds - 30 kWh/t - clinker 100 C

3,0%
2,5%
2,0%
0.7 m/sec
1 m/sec
1.2 m/sec
1.5 m/sec
1,5%
1,0%
0,5%
0,0%
1,8 2 2,2 2,4 2,6 2,8 3
3,2 3,4 3,6 3,8 4
4,2 4,4 4,6 4,8 5
Diameter (m)
5,2 5,4 5,6 5,8 6
15

Coating
Definition:
Agglomeration of fine particles (on lining and/or on grinding media)
grinding efficiency decrease
Reasons:
*
Overgrinding (often in O.C., fine cement grinding and limestone addition)
Too high outlet temperature in Cpt 2 ( > 110 C at mill outlet)
Fresh feed moisture
Solutions:
*
limit the fines
good mill ventilation
good separator
Avoid outlet temperatures > 105 C (ventilation, water injection, separator)
Use grinding aids
If coating is due to moisture, dry by hot clinker, hot rejects or hot gas
16

Grinding Aids
Purpose :
fight coating
produced Blaine is directly

proportional to grinding efficiency
in theory, grinding efficiency
(cm2/j) constant
in reality, not constant because of
agglomeration negative
effects
Mill efficiency (cm2/j)
Rittinger Law :
Rittinger
With
G.A.
Without
G.A.
Mill outlet fineness SSB (m2/kg)
17

Grinding Aids
Function principles:
Coating : due to static electricity on the generated areas
make them stick together
G.A.:
contain components which neutralize cement grain

superficial charges
decrease these electrostatic forces
better grinding efficiency

production gain 5 - 30 %
Disadvantage: high price

18

Grinding Aids
19

Grinding Aids
Other advantages:
.
Improve cement flow
One can use finer ball charge

.
Easier cement transport to silos
.
Allow a higher amount of additional

Silo buildcomponents
up elimination other than clinker
Improve product quality

* Optimize cement particle size distribution
* Improve cement strengths 1, 2 and 28 days
Way of use:
GA sprinkled on fresh feed (diluted with water)
In general .01 % to .08% are added (250 gr/t)
Quantity (and efficiency) increase with Blaine fineness
20

Slag grindability
Slag
Thionvilloise (100 %
laitier)
Thyssen (100 % laitier)
Sidmar (100 % laitier)
Atlantic (100 % laitier)
Ssang Yong (100 %
laitier)
Nittetsu (100 % laitier)
21

Slag
Clinker grindability
Consommation spcifique (kWh/t)
Consommation spcifique (kWh/t)
Slag grindability
Surface spcifique Blaine
Surface spcifique Blaine
22

Slag Vs Clinker: Grindability
Slag
23

Slag
Properties of slag grinding:
- Beneficial on kWh/t if slag < 15 %

- Moisture problems (if slag not dried)
- Higher wear (balls / liners)
24

Slag
slag influence - increase of the spec.grinding energy vrs slag

content and blaine
100
90
80
70
20%
60
40%
100%
50
Log. (100%)
Log. (40%)
40
Log. (20%)
30
20
10
0
2200 2400
2600 2800
3000 3200
3400 3600
3800 4000
4200 4400
4600 4800
5000 5200
5400 5600
blaine
25

Limestone
- prone to coating
- increase artificially the Blaine value
- mind slot sizes and moisture
26

Limestone
Influence of the pozzolana on the specific grinding energy

Source Holderbank
80
70
60
kWh/t (mill shaft)
50
100% clinker
95% cl + 5 % gypsum
40
85%cl.+ 5% gyp.+ 15% poz.

75%cl.+ 5%gyp.+ 20% poz.
65%cl.+5%gyp.+30% poz
30
20
10
0
2000
2500
3000
3500
4000
4500
blaine
27

Factors Influencing The Grinding Efficiency

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Factors influencing the grinding efficiency

Slegten grinding course