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FOR THE
PRODUCTION PROCESS
#10 BALL CEMENT MILL
MONITORING, INSPECTION & EVALUATION
16/10/2007
Page 2 of 41
1.
SAFETY GUIDELINES FOR BALL CEMENT MILL INSPECTION...................................3
2.
BALL CEMENT MILL MONITORING................................................................................6
2.1.
Flow sheet.................................................................................................................... 6
2.2.
Performance................................................................................................................ 7
2.2.1. Material Sampling.................................................................................................. 11
2.2.2. Gas measurement.................................................................................................. 11
2.2.3. Radiation & Convection.......................................................................................... 11
2.2.4. Heat Balance......................................................................................................... 12
2.2.5. Process flow sheet.................................................................................................14
3.
BALL CEMENT MILL INSPECTION...............................................................................15
3.1.
Circuit efficiency......................................................................................................... 15
3.2.
Separator efficiency................................................................................................... 17
3.3.
Grinding efficiency...................................................................................................... 23
3.3.1. Guideline for Crash Stop........................................................................................ 24
3.3.2. Guideline for Empty Grinding Stop........................................................................29
4.
BALL CEMENT MILL EVALUATION...............................................................................31
4.1.
Relative mill speed calculation...................................................................................32
4.2.
Axial sampling............................................................................................................ 33
4.3.
Ball charge calculation............................................................................................... 35
4.4.
Ball charge Management........................................................................................... 37
4.4.1. Recommended Ball Charge Sorting Frequency.....................................................37
4.4.2. Ball Mill Loading..................................................................................................... 37
4.4.3. Ball charge record keeping....................................................................................38
4.4.4. Ball sorting............................................................................................................. 39
4.5.
Conclusions................................................................................................................ 40
Introduction
The purpose of the respective Valid Practice is to outline the parameters that
should be included in a Ball Cement Mill Evaluation as well as the appraisal of
the findings in order to identify the bottlenecks and suggest the necessary actions
that would result in the Ball Cement Mill Optimization.
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1. SAFETY GUIDELINES
INSPECTION
FOR
BALL
CEMENT
MILL
Initially, it should be noted that each Plant is responsible for the implementation of
the own safety procedures and the following are suggestive general guidelines
that could be included.
SAFETY FIRST
The workers should be trained for the job, work always in pairs and should be
equipped with the following safety equipment (Personal Protection Equipment,
PPE):
Uniform
Safety Boots
Fireproof/heatproof Gloves
Helmet
Mask
Safety glasses
Body belt with rope
Portable scaffolding with barriers
Fork lift vehicle
Danger of unwanted mill start-up during the mill inspection. The power of the
main motor should be cut off from the main power supply and the fuses
should be removed.
Danger of unwanted material entry to the mill interior during the mill stoppage.
The power of the main raw material belt conveyors should be cut off from the
main power supply and the fuses should be removed. Also the respective
pipes should be blocked mechanically from the dampers or using steel
sheets. Given the dusty environment inside the mill, anyone entering the mill
must be wearing a face shield and goggles.
Danger of severe burning in case hot gases enter the mill. The safety damper
at the hot gases duct should be closed, its power should be cut off from the
main power supply and the fuses should be removed. Also the damper should
be blocked mechanically.
Prior to dismantling any doors and guards, make sure that the following
equipment has been stopped and interlocked to prevent starting:
Mill main motor
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The power supply for the above mentioned equipment must be effectively
locked by means of padlocks in the MCC (motor control center) room to
prevent accidental starting of the motors. The supervisors in charge of the
inspection team undertaking work inside the mill must keep the key for the
lock. The padlocks must remain fitted until all personnel have left the mill
and all doors and guards have been remounted.
Apart from the respective Plants safety procedure, everybody should keep in
mind:
Ensure Safe Isolation:
Mill drive, auxiliary drive, feed belts, etc
Physical barrier (locked closed/de-activated)
Comply with local Permit to Work procedure
Ensure Safe Access:
Consider fall hazard (e.g. access door on top of mill)
Confined space someone outside mill
Maintain ventilation to cool air space
In case of a ball mill inspection there is danger of speeding balls from the
pavement due to contact with the fork lift wheels. The pavement should be
properly cleaned.
Danger of load displacement during the mill door opening. Ensure that the
ball charge is leveled horizontally using the auxiliary mill drive, the mill door is
at the correct location for opening and finally before opening the door ensure
that the mill is not linked to the auxiliary drive.
Danger of mill door falling in case of hoist malfunction. After lifting the mill
door it should be placed on the mill shell.
Danger due to high dust concentration as well as high level of hot material.
After opening the door the leveling of the ball charge as well as the level of
hot material is checked with a flash light.
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False door removal: Danger of load displacement during the mill door
opening. Ensure that the mill door is at the correct location and
remove the false-door.
During Inspection
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2.2. Performance
Monitoring the Cement Mill (CM) performance is considered the most critical
aspect of a CM evaluation. The performance monitoring procedure for each
cement type produced should include:
i.
ii.
iii.
Collecting representative spot sample of each raw material used (~30 Kg)
after any change at the feeding of raw materials. All samples should be
safely kept for further analysis (Moisture, XRF, wet chemical analyses &
LOI).
iv.
v.
vi.
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Technical Details
Plant
Mill
Mill Supplier
Mill Type
Operating hours since installation
Operating hours since last ball charge refill
Operating hours since last inspection
Operating Parameter
Cement Type
Date
Time
Production rate (wet)
Composition (wet)
Unit
dd/mm/yy
hh:mm
t/h
Clinker
Natural Gypsum
Limestone
Pozzolana
Other
Water content
Water injection
Grinding aid
Iron Sulfate Heptahydrate (FeSO4.7H2O)
Production rate (dry)
Composition (dry)
Clinker
Natural Gypsum
Limestone
Pozzolana
Other
Grinding aid
Iron Sulfate Heptahydrate (FeSO4.7H2O)
Temperature
Mill inlet temperature
Mill outlet temperature
Mill filter outlet temperature
Pressure
Mill inlet pressure
Mill outlet pressure
Mill delta P
Mill filter delta P
Separator filter delta P
Gas Measurement
Flow at mill filter stack (wet)
Flow after mill (wet)
Flow at separator filter stack (wet)
Flow after separator (wet)
Flow fresh air (wet)
Flow hot gas (wet)
Operational Parameters
Folafon
Separator speed
Mill fan speed
Separator fan speed
Recirculation elevator
Mill fan damper
Recirculation damper
Fresh air damper
Energy Consumption
Mill motor
Mill separator
Mill fan
Separator fan
Mill bucket elevator
Specific Electrical Energy Consumption (SEEC)
Mill motor
Mill classifier
Mill fan
Separator fan
Mill bucket elevator
Mill motor, separator, mill fan & separator fan
Total
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t/h
t/h
t/h
t/h
t/h
%
lt / min
g/t
g/t
t/h
%
%
%
%
%
%
%
C
C
C
mbar
mbar
mbar
mbar
mbar
Nm3/h
Nm3/h
Nm3/h
Nm3/h
Nm3/h
Nm3/h
%
%
%
%
%
%
%
%
KW
KW
KW
kW
KW
kWh / t
kWh / t
kWh / t
kWh / t
kWh / t
kWh / t
kWh / t
Page 9 of 41
Quality Parameters
Gypsum moisture
Limestone moisture
Pozzolana moisture
Other moisture
Blaine
Unit
%
%
%
%
Mill outlet
CM Filter outlet
Separator Filter outlet
Separator inlet
Separator rejects
Separator fines
Final product
Corrected Final product Blaine (w/o effect of additives)
Fineness (Residue at 90m)
Fineness (Residue at 45m)
Water Demand (WD)
Setting Time (initial)
Setting Time (Final)
Strength (N/mm)
LOI
IR
SO3
Free CaO
SiO2
Al2O3
Fe2O3
CaO
MgO
K2O
Na2O
cm / gr
cm / gr
cm / gr
cm / gr
cm / gr
cm / gr
cm / gr
cm / gr
%
%
%
min
min
1day
2days
7days
28days
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
Rosin - Rammler
Slope, n
#
d
m
Production between 3 - 32 m
%
Tromp curve
Separator efficiency as recovery of fines, Uf
%
Circulation load based on laser
#
d50
%
d75
%
Kappa (k), slope of the curve in the interval 50%-75%
#
Cut size, particle size corresponding to the Tromp value 50%
%
By-pass, Tromp value at the lowest point of curve
%
Separator efficiency as reduction in power consumption, Vs (32 m sieve)
Circulation load
#
As reduction in power consumption, Vs
%
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Apart from the above, on monthly basis the following tables should be completed:
regarding operation:
Mills Stoppages
Available hours
Actual operating hours
Duration of Annual Maintenance
h
h
h
h
h
h
h
h
h
g/tCement produced
g/tCement produced
regarding quality:
Quality Parameters
CEMENT TYPE
Composition (dry)
Unit
Clinker
Natural Gypsum
Limestone
Pozzolana
Other
Grinding aid
Iron Sulfate Heptahydrate (FeSO4.7H2O)
Blaine
Fineness (Residue at 90m)
Fineness (Residue at 45m)
Water Demand (WD)
Setting Time (initial)
Setting Time (Final)
Strength (N/mm)
LOI
IR
SO3
Free CaO
SiO2
Al2O3
Fe2O3
CaO
MgO
K2O
Na2O
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MONTHLY AVERAGE
%
%
%
%
%
%
%
%
%
%
min
min
1day
2days
7days
28days
%
%
%
%
%
%
%
%
%
%
%
Page 11 of 41
2nd compartment
t
t/m3
90
80
70
60
50
40
30
20
mm
mm
mm
mm
mm
mm
mm
mm
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The dew point can be calculated using either the wet bulb temperature
method or gas measurement and applying the respective chart from the
bibliography (i.e. FLS manual).
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Cement quality. The contribution of the additives at the Blaine value, the
relationship between the separator and the mill fan speed and the RosinRammler (RR) slope as well as the effect to the water demand and the
strength profile.
Mass & Energy (heat) Balance. Based on the results, the weighing feeder
accuracy as well as the heat demand and the amount and location of false air.
Utilization & reliability. Even though, utilization is subject to the sales demand
(quantity) and scheme (peak and saturation), reliability is judged by the
reliability (run) factor which should lie above 90%.
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Mill outlet
2.
CM filter outlet
3.
Separator inlet
4.
Separator rejects
5.
Separator fines
6.
7.
Final product
The above locations should be sampled under stable operating conditions and at
least three times per location. Also is should be noted that ideally all sampling of
the above locations should be done at the same time.
Based on the sieve and Blaine values of the mill outlet and the filter outlet we
calculate the percentage of the separator feed that comes from the mill outlet.
Also, using the same principle we can calculate the amount of the separator filter
returns to the final product.
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Page 16 of 41
Based on the sieve and Blaine values of the mill outlet and the filter outlet we
calculate the percentage of the separator feed that comes from the mill outlet.
Also, using a mass balance we can calculate the amount of the separator filter
returns to the final product.
As far as the circulation loading is concerned, it is a function of:
Product fineness.
Chamber I ability to prepare the feed for chamber II.
In-mill fineness (mill exit Blaine) and hence the degree of particle
agglomeration and coating.
Separator loading and hence separation efficiency.
Grinding efficiency.
Each mill has its optimum circulation loading which is determined from operation
at different total feed set-points and will be higher for large diameter mill, large
separator and use of additive.
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Typical values for efficiency, Vs, relating to residues in the interval 32m-45m:
Vs:=40%-60%
rd
3 generation separators:
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Vs:=25%-40%
Vs:=75%-85%
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Based on CILAS (laser) analysis of the above samples the Rosin Rammler
Curve as well as, the Tromp Curve are constructed:
The Rosin Rammler Curve is the logarithmic chart of the particle size
distribution where the critical parameters are:
Rosin Rammler
The Tromp curve resulting from the Tromp curve values shows for each
individual particle size of the separator feed the percentage which gets into
the fine fraction.
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Tromp Curve
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Cut size:
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ii.
iii.
By-pass:
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Reference Values
3.800
<2.000
~2.200
<900
1-2 for dynamic separator
2-3 for high efficiency separator
25%-40% for 1st generation
40%-60% for 2nd generation
75%-85% for 3rd generation
0,8-0,9 for Ball mill (open circuit)
0,9-1,0 for Ball mill (closed circuit)
1,0-1,1 for Ball mill (high efficiency separator)
1,1-1,2 for Vertical mill/roller press
10 - 30 m
5-15
cm2/g
cm2/g
cm2/g
cm2/g
Circulation load
Vs,
Separator efficiency as reduction in power consumption
0,5-0,6
Kg/Am3
max 0,85kgproduct/Amair3
max 2.5kgfeed/Amair3
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Step
Linin
g
Plates
Mill End
Wall
First
Chamber
Intermediate
Diaphragm
Coarse
Grinding Media
Second
Chamber
Classifying
Outlet
Lining
Trunnion
Plates
Fine
Grinding
Media
Outlet
Diaphragm
Maintaining the condition and effectiveness of the equipment relies on regular site
inspections and measurements around the system. Internal inspection of the mill
should take place on regular basis to assess the condition of the charge and the
liners. Periodically axial samples need to be taken in the mill to assess the
progression of fineness development along the grinding path. From this the
appropriateness of the media size grading for the fineness of the predominant
cement produced on the mill can be assessed. Samples also need to be taken
around the milling circuit to assess the recirculation load and the characteristics
and efficiency of the separator. Temperatures and pressures around the milling
system need to be measured to calculate air velocities and a mass and energy
balance. In combination this information will provide a comprehensive
assessment of the condition of the milling equipment. Periodic gathering of this
information is useful for detecting changes in the condition and the performance
of the mill.
Each ball mill should be inspected at minimum every month. Along with the
internal mill inspections, the ball charge should be monitored according to the mill
kilowatts. The mill should be inspected as soon as mill kW drops by 5% from the
targeted mill kW. During each inspection, a Monthly mill ball charge inspection
sheet should be filled out.
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ii.
The CM must be crash stopped while the mill is at maximum production and
has been running stable for at least 4hours to give consistent representative
samples.
iii.
The control room operators will crash stop the mill by stopping the mill and all
related equipment including all fans and bucket elevators. If possible, the mill
is stopped so that it can be entered without any further turning. It must be
ensured that material feeding is not stopped previously and that also the mill
fan stops simultaneously to prevent that fines are discharged with the air flow.
The product conveying equipment should remain running to convey the
remaining product from the lines and hoppers.
iv.
The mill will be prepared for inspection according to the respective safety
procedure. Estimated time for preparations is 2hours. It should be noted that
at all time the fuses should be removed from the respective motors and that
nobody should enter without clearance from the Production manager and the
Maintenance Manager.
v.
The mill is allowed to cool down. Estimated time for cooling is 5hours.
vi.
Take samples from below surface, below level of balls, along the mill axis.
Assess presence of nibs (e.g. coarse material, ~5mm) especially near the
outlet of the 2nd compartment.
The most important (Key) samples are those on either side of intermediate
diaphragm as well as at mill outlet.
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The result shows whether or not the grinding progress in the mill is good.
Furthermore, axial sampling can provide indications of possible causes in case of
disturbances.
A typical example of axial sampling is presented hereafter:
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vii. The grinding progress is not only influenced by the ball charge but also by the
material load.
viii. Parallel to the axial sampling and the material load evaluation, the mill internal
is being inspected for coating (on ball charge, liners and diaphragms) The
grading is presented hereafter:
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ix.
Finally the mill dimensions are checked by measuring the compartment length
and diameter.
x.
After internal mill inspection and material (axial) sampling the maintenance
department will close the doors and turn the mill over to the production
department for restart.
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ii.
The CM must be stopped after running for ~30minutes without fresh feed so
that all material to be ground between the grinding media is discharged from
the mill.
iii.
The grinding plant is then stopped with EMERGENCY STOP, while the mill
fan should continue operating in order to cool the mill interior.
iv.
The mill will be prepared for inspection according to the respective safety
procedure. Estimated time for preparations is 2hours. It should be noted that
at all time the fuses should be removed from the respective motors and that
nobody should enter without clearance from the Production manager and the
Maintenance Manager.
v.
The mill is allowed to cool down. Estimated time for cooling is 3 hours.
vi.
b. the chord length should be measured on top of the ball charge level
(minimum 3 locations in 1st compartment and 4 locations in 2nd
compartment).
c. the number of free liner plates should be measured (minimum 3
locations in 1st compartment and 4 locations in 2 nd compartment). Make
sure that the first and last plates (% plate) are estimated with as much
accuracy as possible.
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vii. To check the ball charge quality and composition, ball charge sampling is
performed at the same principle as material axial sampling. Cement bags are
filled with balls after every 1m from the mill inlet to the mill outlet.
viii. After internal mill inspection and material (axial) sampling the maintenance
department will close the doors and turn the mill over to the production
department for restart.
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The third factor that must be taken into consideration is the complexity
of the grinding circuit as well as the respective mill and separator type.
Recognize the overriding importance of quality and focus the process control on
the whole process of cement grinding rather than simply the fineness.
The results of the mill inspection measurements need to be compared with
accepted norms and benchmarks from within the Group or elsewhere in the
cement industry. Certain benchmarks, or rules of thumb, are well established:
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length to diameter ratio should be close to 3.5 for a closed circuit mill
1.5m/s-2.0m/s air velocity through the mill is normal for closed circuit
mill
4.1.
The mill speed should typically range from 70% to 75% of the critical speed.
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4.2.
Axial sampling
At first, any metal parts (balls or ball scrap) must be removed from the
sampled material. The samples are then divided and thus reduced to suitable
quantities for analysis.
It should be noted that:
The axial sampling results must always be evaluated taking into account
the loading of the mill with material to be ground. Evaluation of the axial
sampling is done according to the following scheme:
In the 2nd grinding compartment, the residue values should drop steadily
and the specific surface of the samples should constantly increase.
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4.3.
The ball charge is being calculated according to the following formulas, using
the measurements performed during the empty grinding stop. The calculated
ball charge should be compared to the one given by the Plant and should be
confirmed with the power consumption measurements.
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The ball charge should be confirmed (both periodically i.e. monthly or after every mill
inspection) by the power measurement using the FLS formula:
N=F*D**a*n*g*/60= F*D**a*n*0,514
a= the arm of gravity in relation to the mill diameter=0.009*(96.7-specific ball charge%*100)
N=power consumption [kW]
F=charge [t]
n=rotational speed of the mill
=torque factor
D= effective diameter
Wherever it is necessary, the following tables are used for finding the specific charge & torque
factor:
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4.4.
The objective of this manufacturing best practice is to optimize production in a soldout market and to reduce the overall kWh/t consumption in a non sold-out market, by
maintaining the optimum ball charges level in all operational mills.
The ideal volume loading is dependent upon the individual plant priorities. The plant
must decide whether their main goal is either to reduce mill power consumption
(kWh/t), or to maximize production (t/h). The recommended volume loading are as
follows:
Minimum kWh/t
Maximum Production
It is important to realize that there is higher power consumption (kWh/t) when the
maximum production rate is the first priority.
Some mills will be limited to lower volume loading due to mill motor power, stress
on mill shell or stress on the gearing.
Mill inlet trunion size is another possible limiting factor. Ball level in the trunion
should not be higher than 2 to 3 inches.
With a volume loading above 34% classifying liners often lose their beneficial
effect.
4.4.1. Recommended Ball Charge Sorting Frequency
The minimum frequency for ball charge sorting for mills is recommended as follows:
Raw and Coal Mills
Finish Mills
Ball Sorting
1st Compartment 2nd Compartment
Every year
Every year
Every year
Every two years
This is the recommended minimum ball charge sorting. Some plants may require
sorting more often. For mills with very low utilization, the ball sorting may be less
frequent.
4.4.2. Ball Mill Loading
After sorting add 85 to 90% of ball charge initially. Run ~100 hours before
topping up the ball charge, this allows addition of larger or smaller balls according
to mill inspection and fineness obtained at the partition for the 1st compartment.
Do not mix different types and metallurgical compositions of balls together, i.e.:
o forged steel and chromium
o low chrome and high chrome balls in the 1st compartment
o balls from different supplier, unless proven effective by extensive testing and
quality control
Exception: Used first compartment balls could be recycled in the second
compartment, if they have the appropriate size (Not mandatory)
Do not add balls that are wet or snow covered to cement mills.
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Add a layer of material to the first compartment only before adding balls to an
empty mill, in order to protect the shell liners.
The following items should be kept as records in plants for proper ball charge
management:
Monthly mill ball charge inspection sheet.
Ball additions.
Ball charge sorting results.
Ball charge design.
Any unusual occurrence or problem that affected mill performance.
Dates of liner and partition changes
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4.5.
Conclusions
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