SITE REPORT

OPERATIONAL SERVICES
FLSmidth Inc., Cement Services
2040 Avenue C, Bethlehem, PA, 18017
TEL 610-264-6011 FAX 610.264.6170
www.flsmidth.com

Cementos Pacasmayo S.A.A

Pacasmayo, Peru
Finish Grinding System Audit
April-May 2007
Finish Mill # 5

Prepared by:
A.Srinivasan

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Index
Finish Mill # 5 System Description...........................................................................................................3
Process Description ............................................................................................................................3
Mill Audit ............................................................................................................................................4
Visual inspection and Observations of the mill circuit .................................................................4
Axial Sample Results..........................................................................................................................5
Clinker Feed Granulometry ..............................................................................................................5
Mill circuit sample analysis...............................................................................................................8
Tromp Curve and analysis................................................................................................................9
Power Draw Calculations..................................................................................................................9
Mill Vent Systems.............................................................................................................................10
Recommendations ............................................................................................................................11
Annexure I .................................................................................................................................................
Mill Power Calculations ..................................................................................................................13
Annexure II................................................................................................................................................
FLS Power equation and mill dimensions ....................................................................................14
Annexure III ..............................................................................................................................................
Mill Circuit Process Measurements ...............................................................................................15
Annexure IV ..............................................................................................................................................
Mill Vent Pitot Flow Measurements .............................................................................................16
Annexure V ...............................................................................................................................................
Separator efficiency and Circulating Load ...................................................................................17
Annexure VI ..............................................................................................................................................
Tromp Curve.....................................................................................................................................18
Annexure VII.............................................................................................................................................
Axial Sample Results........................................................................................................................19
Annexure VIII ...........................................................................................................................................
Recommended Ball Charge.............................................................................................................20
Annexure IX ..............................................................................................................................................
FLS Power equation for maximum ball charge............................................................................22

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Finish Mill # 5 System Description

The system consists of a 3.35 m X 9.22 m FLS Unidan mill operating in closed circuit with
Sturtevant separator. The mill is vented by single dust collector fan, initially through grit
separator. The grit separator catch combines with mill discharge and fed to the Sturtevant
separator through the bucket elevator. The fresh feed and the separator rejects enter the mill
feed end. The cement produced is type 1 CO grounded to a specific surface area of ~ 4800
cm2/gm.

Type of Cement

1 CO

Clinker, %

76.4

Gypsum, %

4.7

Limestone, %

15.5

Diatomita, %

3.5

Blaine, cm2/gm

4800

Residue, +325

6.9

Process Description
The feed components as per the type of cement ground are weighed and conveyed to the
mill feed end by belt weigh feeders. The mill discharge is screened for any nibs in a screen
and enters the Sturtevant separator. The coarse from the separator is returned back to mill
inlet along with fresh feed and fines collected from the separator sent to product silos. Mill is
vented through Heavens bag filter.

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Mill Audit
Air flow measurements were taken at the exit of the mill vent fans that are running about 4550 % of FLA, fan inlet damper is 80% open. In addition to the two sets of circuit samples,
samples were collected at the mill discharge, separator discharge and at the discharge of the
dust collectors. The suction at the mill inlet was measured at 8-10 mmwg, mill exit at 134
mmwg.

Date

Location

30-Apr-07

of

Design

flow

Actual

Measurement

(m3/min)

(m3/min)

Mill vent fans exit

368

Flow

Table 1. Airflow measurements

The mill was crash stopped on 30 April 07, mill was stable enough for a crash stop. Free
height, mill internal dimensions, grinding media sampling, axial sampling & mill internal
inspection was carried out in both compartments,
Visual inspection and Observations of the mill circuit
Compartment I:
On 30th April 07, the mill internals were inspected and the measurements were taken. The
effective dimensions are 3.213 m diameter and 3.124 m length. The calculated average liner
thickness is 68.5 mm. The average free height measured above the charge was 2.20 m and the
chord width above the material averaged to 2.98 m, this gives a calculated volume load of
26.9% charge.
The charge was clean with no coating and the mill liners also had no coating. Lifter liners in
the first compartment are badly worn out conditions. The outer most slots in the partition
diaphragm measured an average width of about 7.5 mm and the mid section slots about 8.5
mm. The slots that are close to the center averaged about 10.8 mm. The diameter of the center
section is 29 and the center screen slots averaged a width of 15 mm. The outer most
4

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diaphragm slots were plugged to an extent of 25 to 30% and the midsection slots to about
15% with metal.
Compartment II:
The effective dimensions are 3.20 m diameter and 5.537 m length. The calculated average
liner thickness is 75 mm. The average free height measured above the charge was 2.17 m and
the chord width above the material averaged to 2.99 m, this gives a calculated volume load of
27.75% charge.
The charge was clean with no coating as was the mill liners. No classification of the charge
was apparent by visual inspection. The discharge diaphragm slots have been plugged about
40%, mostly with broken media. Slot width of discharge grates averaged between 8 and 11
mm. The diameter of center screen of the discharge diaphragm is 35.3 and the center screen
slot width averaged about 22 mm.

Separator: The mill system is provided with first generation separator type of Sturtevant
separator, where the expected efficiency will be normally low. The separator is installed with
112 kW motor.

Axial Sample Results

After mill was crash stop, the axial material samples were collected. The first compartment
had little material to collect axial samples. We could see traces of nips of rocks and fine
clinker about feet below the charge level.
The axial sample results are plotted in annexure IX, Last two meter in compartment II has no
grinding effect, possibly due to daming effect at discharge. In general compartment II
grinding is okay except for at the discharge end. The two samples collected in compartment I
5

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and compartment II are analyzed in pacasmayo cement particle size analyzer & resulted
plotted.
Clinker Feed Granulometry
The fresh clinker feed to the mill is coarser with 15.4% + 25mm against the generally
accepted feed size of 5%+25mm. The clinker feed size distribution based on cumulative %
retained tabulated as follows,
Screen Size
25.4 mm
19.1 mm
12.7 mm
9.5 mm
4.75 mm
2.36 mm
1.18 mm
600 m
300 m
212 m
150 m
90 m
45 m

Cumulative %
Retained
15.44
36.30
63.54
74.26
89.17
95.35
97.47
97.92
98.16
98.32
98.48
98.65
99.12

Cumulative % Retained

Clinker Granulometry
120.00
100.00
80.00
60.00
40.00
20.00
0.00
25.4 19.1 12.7 9.5 4.75 2.36 1.18 600 300 212 150
mm mm mm mm mm mm mm m m m m

90
m

45
m

Screen Size

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Analysis of the results of circuits sampling done on 30/04/07

Two sets of samples were collected at the separator circuit and analyzed at Pacasmayo
cements laboratory to evaluate its performance. The average separator efficiency calculated
on 45 is 66.3%, this is low efficiency when compared to high efficiency separators range of
80-85 %.

The Circulation factor (C) and separator efficiency (Vs) are calculated using the following
formula:
C= (Rg Rf) / (Rg Rm)

Ro + (C 1) * R g
Ro
C * log
Rf
R f + (C 1) * R g
Vs =
* 100
Ro + (C 1) * 100
Ro
log
C * log
Rf
R f + (C 1) * 100
log

where,
Ro =
Rf

% Residue on 45 micron of new feed

=

Rg =
C =

% Residue on 45 micron of fines product from separator

% Residue on 45 micron of coarse product from separator
Circulating factor
Circulating factor is defined as the separator feed divided by the
fresh feed

Results of the sampling based on 45 / 325 mesh were as follows.

Separator efficiency = 66.3 %
Separator efficiency (Vs): This is a measure of the efficiency of the separator. Vs is
defined as the reduction in specific power consumption when converting from Open
7

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circuit to closed circuit with the actual separator in relation to the reduction obtainable
with an Ideal separator. Separator efficiency was determined to be 66.3%. Normal
separator efficiency for a high efficiency separator ranges between 80 to 85 %.
Please refer to annexure V for further details.
Tromp curve and analysis.
Using the circuit samples collected on 30/04/07 samples were run through
Laser particle size analyzer and a tromp curve was generated. Tabulation of tromp curve
results and tromp curve is enclosed annexure VI.

Results from the Tromp curve:

P70 / P30

= NA

P50

= 8.1

Apparent Bypass

= 46.8 %

E60 micron

= 97 %

WACL

= 259 %

P70 / P30: This is the ratio of the 70 % recovery particle size (microns) and the 30%
recovery particle size (microns). For a perfect separation the ratio is 1.0. For this
separator the steepness of the curve is in the bad range, hence the P70/P30 ration
could not be determined.
P50: This is the cut size which is the size of the particle, in microns, distributed with
equal quantities in the separator coarse and the separator fines. The cut size for this
separator was determined to be 8.1 micron.
8

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Apparent Bypass: This is the short circuit, which indicates relative amount of fines
that are in the coarse material exiting the separator. The apparent bypass is an
indication of the leakage of fine material into tailings, either by agglomeration, or by
poor classification. For Ideal separation this number is zero. Although anything less
than 8 % is very good.

The apparent bypass for this separator was determined to be 46.8 %. This is higher
than expected for this type of separator. In this case if we rule out agglomeration then
there is poor classification.

E60 micron: This is the percent recovery of the material with a particle size of 60
micron and it is taken directly from the tromp curve. It is generally called the coarse
end recovery and any coarse particle size that is significant for the product can be
selected. This value should be greater than 90 %.

E60 micron for this separator was determined to be 97%. The coarse end recovery is
excellent with 97% passing on 60 m screen.

WACL: This is the weighted average circulating load fraction for the particular
separation shown in the tromp curve. This number is the production weight ratio of
the separator coarse and the separator fines.

WACL for this separator was determined to be 259 %. This means that this separator
would yield 259 kg of coarse for every 100 kg of fines generated.

Typical high

efficiency separator in a closed circuit grinding circuit is designed for a WACL of 200
% to 300 %.

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Power Draw Calculations

Charge measurements taken inside of the mill were used to calculate the mill power draw.
The full description of the calculations is included annexure II. For these calculations, 27.7
mtph is used as the mill production.

Calculated Shaft
Compartment

Power Draw
(kWh)

Power Draw in
kW / mt

First

378

13.7

Second

708

25.6

Total

1086

39.2

Table 2. Calculated Mill Power Draw

The mill power calculated based on the V/I meter indications in the MCC do not correspond
with the power reading in the CCR. The CCR indication is based on the KWH pulse
indicator, which according to the plant personnel is fairly accurate. The voltage is taken from
the incoming feeder and the current and power factor from the drive panel.

3V I Cos

motor

= 3*6.0*140*0.71 = 1033 kW/ 1384 Hp

The theoretical net power calculated from FLS equation is 1087 kW/ 1457 Hp and the gross
power using 95% motor efficiency and 2% losses in the gearbox is 1087 kW/ 1457 Hp.

The gross power draw indicated at the CCR was 1118 kW/ 1499 Hp, which is within
measurement tolerance of the calculated value.

10

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Mill Vent System

Measurements of the mill vent volume were made after the dust collector vent fans.
Measurements indicate the total volume was 368 m3/min. Assuming 25% leakages through
the, mill exit duct, grit sep. and dust collectors, the mill internal gas velocity works out to 0.87
m / sec velocity above the ball charge inside of the mill.
This value is within the normal operating range of 0.8 1.0 m/sec.
Recommendations
1.

The mill internal inspection indicated that the liner condition was too bad in
compartment-I, we recommend to replace the compartment-I liner with new FLS step
liners.

2.

The mill internal inspection indicated the presence of lot of nibs of river rocks in
compartment I & II, these nibs to be screened and completed removed before mill
entry to improve the mill efficiency.

3.

The mill internal inspection and ball sampling in compartment-I showed grinding
media sp.surface as 8.11 m2/ton & in compartment-II grinding media sp.surface was
24.6 m2/ton., these values are low when compared to normal ranges of 10.5-11.5
m2/ton in compartment-I & 38-40 m2/ton in compartment-II. The grinding media size
distribution is not okay. We recommend sorting the compartment I & II charge and
reload the mill as per the grinding media charge recommendation in Annexure-VIII. A
revised ball charge with ratio of balls (not the weight of balls) will give a specific surface
of 10.43 m2/ton in the first compartment and 38.00 m2/ton in the second compartment.

4.

Presently this mill is grinding one type of cement grade (type 1 CO) of product blaines
with product Blaine of 4800 cm2/gm. Considering this high fineness cement grinding
we recommend to use grinding aid (Diethylene Glycol). Normally grinding aid can be
used after diluting with water in the ratio 1:8 (grinding aid: water). The grinding aid
control should be based on the fresh feed rate to the mill, on a fixed ratio. The automatic

11

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control loop should be able to increase or decrease the amount of grinding aid
according to the variation in the fresh feed rate.
5.

Internal mill inspection revealed that in the first compartment, the diaphragm slots had
about 20% covered in total open area, with the outermost segments nearly completely
closed off by small balls and spitzers. The discharge diaphragm slots had only about a
15% covered in total open area, with the outermost segments nearly completely closed
off by small balls. Cleaning the diaphragm grate slots is to be done on first priority.

6.

The mill air passage screen is completely plugged, which needs to be replaced with
slots type. Present one is with hole type.

7.

The axial samples results reveals that there is no grinding effect in the last two meters
of compartment-II, possibly due to daming effect at discharge.

8.

The expected mill gross power with maximum filling in both the compartments is
~1000 kW or 1500 Hp, which is 91% of the installed (2000 Hp) mill motor power as
shown in annexure IX. If required to charge the mill to maximize power for higher
production levels, it has to be further seen the possibility of installing a dam ring at the
partition diaphragm.

9.

We recommend replacing the existing first generation separator to high efficiency

separator such as the O-Sepa. This would result in power savings and an increase in
cement quality and strengths. The production on the mill may then be increased by
reducing the Blaine target to maintain the same strengths. There is a potential for an
increase in production by seeing the available power in the mill drive.

10.

Clinker to the mills should be sampled and screened on coarse sieves regularly.
Maintain a residue of less than 5% on a 25mm sieve in the clinker (adjust clinker breaker
and/or replace as necessary).

12

Annexure - I
Mill Power Calculations
The following are average mill power calculations:
a)

From V / I meter

=
=
=

3 V I Cos motor
3 x 6.0 x 140 x 0.71
1033 kW / 1384 Hp

b)

From CCR

1118 kW / 1499 Hp

c)

FLS equation: (annexure )

Power, net
where:

d)

=
F
n
u
Deff
a

0.515 ( F ) ( n ) ( u ) ( Deff ) ( a )
Grinding media weight (mt)
Mill Speed (rpm)
Torque factor
Diameter effective (m)
Arm of gravity

1109 kW / 1487 Hp

Slegten's equation:
Power, net

0.0762 ( n )1.27 [ Vn (1.36 - 1.2 Vn ) Ln

where:

Vn

Grinding Media fractional volume

Ln

Compartment effective length (m)

Deff
n
By Slegten's equation:
Description
Effective Diameter
Effective Length
Mill Speed
Grinding Media fractional volume
Grinding Media bulk density
Power at motor shaft

] Deff3.014

Grinding Media bulk density (t/m3)

Compartment effective diameter (m)
Mill Speed (rpm)
1086 kW / 1456 Hp
Units
m
m
rpm
%
t/m3
kW

Compartment I
3.213
3.124
17.86
26.90%
4.3
378

Compartment II
3.2
5.537
17.86
27.75%
4.5
708

Annexure - II

Plant : Cementos Pacasmayo

Mill type : Cement Mill 5 - FLS Unidan - 11' x 30'3", Symetro Gearbox. 2000 HP
Date:
4/30/2007
Units
m
m
mm
m
m
m
m

Diameter
Effective length
Liner thk.
Empty height (H)
Empty height
(h)
Effective dia. (De)
Effective volume
h/De
%Filling, calc. (q)
Torque factor (u)
Bulk weight
(g)
Arm of gravity (a)
Mill speed
Critical speed (Nc)
% Critical speed
Grinding media (F)

tons/m
m
rpm
rpm
%
tons

Compt. I
3.350
3.124
68.5
2.20
0.597
3.213
25.33
0.186
26.90
0.73
4.30
0.628
17.86
23.60
75.66
29.30

Compartment power
Power at motor shaft
Gross motor Power

Kwh
Kwh
Kwh

397
401
426

Assumptions:

Gear loss:
Motor loss:
Line Loss:

Compt. II
3.350
5.537
74.8
2.17
0.572
3.200
44.54
0.179
27.75
0.69
4.50
0.621
17.86
23.65
75.51
55.62

Total
84.9

701
708
753

1098
1109
1179

1%
5%
1%

H
C

Compt. I
1.01
2.98
68.19
3.82
2.18
26.90%

Gm height, (De-H)
Chord width, C
Angle, Q
Length of arc
Area
Charge filling

1472
1487
1581

HP
HP
HP

Compt. II
1.03
2.99
69.08
3.86
2.23
27.75%

m
m
deg
m
sq.m

1080 kw ccr

Annexure - III

Plant : Cementos Pacasmayo

Mill type : Cement Mill 5 - FLS Unidan - 11' x 30'3", Symetro Gearbox. 2000 HP
Date: 4/30/2007

DP = 14.5

mmWg

o
T = 83 C
P = -212 mmWg

25% False Air

F=
T=
P=

Clinker Feed Rate =

Gypsum Feed Rate =
Limestone Feed Rate =
Diatomata Feed Rate =
Fresh Feed Rate =

20.5
1.03
1.5
0.98
24.0

mtph
mtph
mtph
mtph
mtph

Temp =

o
89 C

3
F = 302 m /min
o
T = 104 C
P = -134 mmWg

Velocity =
Total Feed Rate =

o
T = 95.6 C
P = -197 mmWg
Cyclone DP = 63 mmWg

0.87 m/s

24.0 mtph

Power = 1080 kW
Specific Power Consumption = 45.0 kW/mt

T=

o
110 C

kW
3
368 m /min
o
76.7 C
17 mmWg

Annexure - IV
Plant:
Location of port:

Cementos Pacasmayo
Cement Mill 5 Stack

Elevation:
Barometric pres:
Duct dimensions:
Circular (dia):
Pitot tube factor:

15 m
10314 mmwg

Pressure
Temperature
Gas density
Gas density

17
76.7
1.284
1.003

Velocity pressure, Vp

0.621 m
0.86

mmWg
1
2
3
4
5

Gas Composition
Oxygen
Nitrogen
Carbon di oxide
Water Vapor
Sum

Area:

mmwg
C
Kg/Nm
Kg/m
mmWg

26.00
27.00
31.00
27.00
31.00

Average Vp
Velocity
Volume flow
Volume flow
Volume flow
Volume flow
Volume flow
Mass flow

Date:
Time:

%Volume
21.0%
78.5%
0.0%
0.5%
100.0%

0.303 m

-41.88 inwg
170 F
0.0626 # /lb
mmwc
26.00
27.00
31.00
27.00
31.00

5.325
m/sec
m/min
m/hr
Nm/hr
acfm
scfm
Kg/hr

3-May-07
18:20

20.26
368
22077
17231
12994
10717
22135

Density
1.428
1.249
1.963
0.803
1.284

(mmwc)^.5
5.099
5.196
5.568
5.196
5.568

Annexure - V
Finish grinding system with Sturtevant Separator - Separator efficiency
Sample - 1 on 30-04-07, 10:00 AM
Mill
Separator
Separator
Separator
Separator
discharge
Feed
Fines
filter
Returns
0.00
0.00
0.00
0.00
0.00
25.4 mm
0.00
0.00
0.00
0.00
0.00
19.1 mm
0.00
0.00
0.00
0.00
0.00
12.7 mm
0.00
0.00
0.00
0.00
0.00
9.5 mm
0.00
0.00
0.00
0.00
0.00
4.75 mm
0.00
0.00
0.00
0.00
0.00
2.36 mm
0.00
0.00
0.00
0.00
0.00
1.18 mm
0.00
0.00
0.00
0.00
0.00
600 um
1.20
0.00
0.00
0.00
0.00
300 um
1.60
2.00
0.00
0.00
3.60
212 um
4.80
4.40
0.00
0.00
5.60
150 um
16.80
15.20
0.00
0.80
17.20
90 um
40.00
39.20
3.60
10.40
58.00
45 um
Efficiency Based on 44 um / 325 mesh
Sep feed
Rm
=
39.20
New feed
Ro
=
100.00
Sep prod
Rf
=
3.60
Sep reject
Rg
=
58.00
Circulation Factor

2.89

Vs

Log( Ro / Rf ) - C * Log ( ( Ro + (C-1) * Rg)/( Rf + (C-1) * Rg))

100 x ---------------------------------------------------------------------------------- =
Log( Ro / Rf ) - C * Log ( ( Ro + (C-1) * 100)/( Rf + (C-1) * 100))

0.6707
-------- =
0.935

71.77 %

Bmax

C * Log ( ( Ro + (C-1) * 100)/( Rf + (C-1) * 100))

100 x ( 1 - ----------------------------------------------------------------------- ) =
Log( Ro / Rf )

0.5092
-------- =
1.444

64.73 %

Mill
discharge
25.4 mm
19.1 mm
12.7 mm
9.5 mm
4.75 mm
2.36 mm
1.18 mm
600 um
300 um
212 um
150 um
90 um
45 um

0.00
0.00
0.00
0.00
0.28
0.34
0.50
0.69
3.08
4.27
10.23
20.16
45.38

Sample - 2 on 30-04-07, 11:30 AM

Separator
Separator
Separator
Feed
Fines
filter
0.00
0.00
0.00
0.00
0.07
0.11
0.22
0.66
2.64
5.43
9.00
20.13
44.37

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.20
3.20

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
1.60
14.00

Separator
Returns
0.00
0.00
0.00
0.54
1.36
1.48
1.66
2.17
4.12
6.47
10.38
24.08
49.13

Efficiency Based on 44 um / 325 mesh

Sep feed
New feed
Sep prod
Sep reject

Rm
Ro
Rf
Rg

Circulation Factor

=
=
=
=

44.37
100.00
3.20
49.13

9.65

Vs

Log( Ro / Rf ) - C * Log ( ( Ro + (C-1) * Rg)/( Rf + (C-1) * Rg))

100 x ---------------------------------------------------------------------------------- =
Log( Ro / Rf ) - C * Log ( ( Ro + (C-1) * 100)/( Rf + (C-1) * 100))

0.640595
-------- = 60.902 %
1.052

Bmax

C * Log ( ( Ro + (C-1) * 100)/( Rf + (C-1) * 100))

100 x ( 1 - ----------------------------------------------------------------------- ) =
Log( Ro / Rf )

0.443
-------- = 70.365 %
1.495

Annexure - VI

Tromp Curve
Sieve Size

Feed

Tails

Products

Circ. load

WACL

Avg. sieve
Microns

Tails
%retained

Product
%retained

Incremental
% Recovery

174
146
122
102
86
72
60
50
42
36
30
25
21
18
15
12
10
8.6
7.4
6.2
5.2
4.4
3.6
3
2.6
2.2
1.8

100.00
97.66
94.91
91.65
87.96
83.57
78.61
73.31
68.06
63.43
58.16
53.32
49.09
45.79
42.30
38.29
35.25
32.97
30.93
28.79
26.79
24.92
22.57
20.25
18.30
15.89
12.94

97.86
95.17
91.58
87.15
82.33
76.78
70.61
64.07
57.67
52.18
46.21
41.06
36.89
33.81
30.72
27.42
25.05
23.37
21.92
20.46
19.13
17.87
16.25
14.62
13.23
11.51
9.40

100.00
100.00
100.00
100.00
99.67
99.17
98.40
97.15
95.39
93.38
90.55
87.29
83.60
80.08
75.68
69.88
65.09
61.29
57.69
53.65
49.74
46.04
41.50
37.14
33.50
29.09
23.79

0.94
1.53
1.86
2.08
2.30
2.47
2.58
2.63
2.66
2.71
2.77
2.83
2.86
2.88
2.91
2.93
2.95
2.97
2.98
3.00
3.00
3.00
3.00
3.00
3.01
3.06

0.03
0.05
0.07
0.09
0.11
0.13
0.14
0.12
0.14
0.13
0.12
0.09
0.10
0.12
0.09
0.07
0.06
0.06
0.06
0.06
0.07
0.07
0.06
0.07
0.09
0.40

160.0
134.0
112.0
94.0
79.0
66.0
55.0
46.0
39.0
33.0
27.5
23.0
19.5
16.5
13.5
11.0
9.3
8.0
6.8
5.7
4.8
4.0
3.3
2.8
2.4
2.0

2.7
3.6
4.4
4.8
5.6
6.2
6.5
6.4
5.5
6.0
5.2
4.2
3.1
3.1
3.3
2.4
1.7
1.5
1.5
1.3
1.3
1.6
1.6
1.4
1.7
2.1

0.0
0.0
0.0
0.3
0.5
0.8
1.3
1.8
2.0
2.8
3.3
3.7
3.5
4.4
5.8
4.8
3.8
3.6
4.0
3.9
3.7
4.5
4.4
3.6
4.4
5.3

100.0
100.0
100.0
97.4
96.6
95.4
93.1
90.4
87.6
84.5
80.3
74.5
69.4
64.5
59.5
56.1
53.3
51.0
48.3
46.8
46.8
48.0
49.2
49.7
50.2
50.7

R / R - 44/11

0.862

0.978

0.864

2.65

259%

Incremental %Recovery

Tromp Curve : CM-5,Sturtevant Separator

120.0
100.0
80.0
60.0
40.0
% Recovery

20.0
0.0
1.0

10.0
Average Sieve size, m

100.0

Annexure - VII
Ball Charge Recommendation for the first & second compartment
Compartment 1
Compartment 2
ball size
Wt Perc
ball size
Wt Perc
90 mm
23
50 mm
0
80 mm
32
35 mm
0
70 mm
21
40
30 mm
60 mm
24
25 mm
40
50 mm
0
20 mm
0
40 mm
0
15 mm
20
sum
100
100
Sum
Sp.surface, m2/t
10.43
Sp.surface, m2/t
38.0

Present Ball charge distribution as measured

0-meter 1-meter 2-meter
Piece Wt
1883.6
1012.4
893.0
Sp Surf
9.61
12.13
2.01
Ball Sizes
100
33.0%
0.0%
0.0%
90.0
29.6%
0.0%
5.3%
80.0
4.8%
16.8%
13.4%
70.0
15.4%
12.1%
80.9%
60.0
17.2%
71.1%
0.0%
50.0
0.0%
0.0%
0.3%
<45
0.00%
0.33%
0.00%

3-meter
1773.8
8.68

Average
1390.70
8.11

39.8%
21.6%
28.6%
10.0%
0.0%
0.0%
0.00%

18.2%
14.1%
15.9%
29.6%
22.1%
0.1%
0.08%

Piece Wt
Sp Surf

0-meter
718.9
13.6

1-meter
271.5
17.8

2-meter
110.8
24.3

3-meter
67.2
29.4

4-meter
61.7
30.3

5-meter
51.4
32.4

Average
213.6
24.6

Ball Sizes
60.0
50.0
39.5
30.5
25.0
20.5
15.5

70.2%
29.8%
0.0%
0.0%
0.0%
0.0%
0.0%

23.2%
33.4%
28.0%
13.2%
1.8%
0.4%
0.0%

0.0%
9.0%
30.4%
40.7%
15.1%
4.8%
0.0%

0.0%
0.0%
4.7%
48.8%
28.3%
18.0%
0.1%

0.0%
0.0%
4.7%
38.9%
34.7%
21.7%
0.0%

0.0%
0.0%
0.9%
23.9%
38.7%
36.4%
0.1%

15.6%
12.0%
11.4%
27.6%
19.8%
13.6%
0.03%

Rosin-Rammler

%Residue

10.00

1.00
1.0

10.0

100.0

products

0.10
Sieve size, m

FM5-ANNEXURES.xls : RR

Annexure - VIII

Plant : Cementos Pacasmayo

Mill type : Cement Mill 5 - FLS Unidan - 11' x 30'3", Symetro Gearbox. 2000 HP
Date:
4/30/2007
Units
m
m
mm
m
m
m
m

Diameter
Effective length
Liner thk.
Empty height (H)
Empty height
(h)
Effective dia. (De)
Effective volume
h/De
%Filling, calc. (q)
Torque factor (u)
Bulk weight
(g)
Arm of gravity (a)
Mill speed
Critical speed (Nc)
% Critical speed
Grinding media (F)

tons/m
m
rpm
rpm
%
tons

Compt. I
3.350
3.124
68.5
2.12
0.513
3.213
25.33
0.160
30.00
0.73
4.30
0.600
17.86
23.60
75.66
32.68

Compartment power
Power at motor shaft
Gross motor Power

Kwh
Kwh
Kwh

423
427
454

Assumptions:

Gear loss:
Motor loss:
Line Loss:

Compt. II
3.350
5.537
74.8
2.00
0.400
3.200
44.54
0.125
34.25
0.69
4.50
0.562
17.86
23.65
75.51
68.66

Total
101.3

784
792
842

1207
1219
1296

1%
5%
1%

H
C

Compt. I
1.09
3.04
71.36
4.00
2.43
30.00%

Gm height, (De-H)
Chord width, C
Angle, Q
Length of arc
Area
Charge filling

1618
1634
1737

HP
HP
HP

Compt. II
1.20
3.10
75.53
4.22
2.76
34.25%

m
m
deg
m
sq.m

Annexure - IX
Finish Mill # 5, 30-04-07 Axial Sample Results
Mesh

PE

PF

PE

P.F.

25.4 mm

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

19.1 mm

6.01

5.95

1.48

0.82

0.00

0.00

0.00

0.00

0.00

0.00

12.7 mm

15.38

13.32

5.25

1.67

0.00

0.00

0.00

0.00

0.00

0.00

9.5 mm

18.12

15.58

7.37

2.42

0.34

0.00

0.00

0.00

0.24

0.61

4.75 mm

20.84

16.93

10.64

3.30

1.39

0.24

0.38

0.98

4.12

6.96

2.36 mm

22.62

17.73

14.02

4.02

1.59

0.51

0.54

1.21

4.35

7.12

1.18 mm

25.34

19.53

17.68

5.79

2.93

1.16

0.88

1.47

4.56

7.30

600 m

28.91

22.75

20.51

10.55

6.36

3.30

2.22

2.12

5.11

7.70

300 m

34.59

27.07

24.01

15.91

12.35

6.78

5.35

2.91

5.49

7.89

212 m

35.45

32.02

26.55

18.42

16.47

10.64

9.26

4.86

7.38

10.29

150 m

38.57

34.65

31.95

23.07

22.09

16.83

14.74

9.56

11.94

13.98

90 m

47.67

44.38

42.13

35.95

33.70

28.44

26.08

20.13

21.43

22.84

45 m

65.59

64.16

62.48

60.64

54.68

49.71

47.59

43.23

44.20

46.47

70.00
60.00

% Retained

50.00
40.00
30.00
20.00
10.00
0.00
PE

PF

PE

Compartment Position
25.4 mm
600 m

19.1 mm
300 m

12.7 mm
212 m

9.5 mm
150 m

4.75 mm
90 m

2.36 mm
45 m

1.18 mm

P.F.