Process & Production Department

Annual Audit of Cement Mill 1

September 2015
BMIC

Contents:
1- Filling Degree
2- Ball weight Method
3- Power Drawn
4- Axial test ( granulometry curve )
5- Separator Efficiency
6- Wear rate calculation
7- Ball charge sampling ( classification curve )
8- Quality Audit
9- Mill Visit results
10- Mill photos
11- Conclusion of audit

1- Filling Degree
Cement Mill 1
Charge
Effective Comp. Diameter
Effective Comp. Length
Free Height , H
Center Distance h = H-D/2
H/D
Filling Degree Q
Bulk Weight [ W ]
Volume Of Compartment [ V ]
Charge F=q/100 W V

%
m
m
m
m
%
%
t/m3
m3
t

Chamber 1
90
4.44
4.5
3.07
0.850
0.691
26.9
4.3
68.86
79.7

Chamber 2
90
4.47
9.75
3.006
0.771
0.672
29.0
4.5
152.93
199.6

Original Charge

86.75

204.85

Charge Difference

7.1

5.25

2- Ball weight Method

Ball weight method
Useful length
Type of lining
Type of diaphragm
Diaphragm slots width ( Design )
Diaphragm slots width ( Actual )
Ball charge in metric tons ( Original)
Current Calculated Charge by ball sampling Method
Diameter 90mm
Diameter 80mm
Diameter 70mm
Diameter 60mm
Diameter 50mm
Diameter 40mm
Diameter 30mm
Diameter 25mm
Diameter 20mm
Diameter 17mm
Total
Filling degree
required tonnage
Total charge required , ton

Chamber 1
4.45
Step shell , lifting
Intermediate
Not Determined
Not Determined
86.75

mm
mm
t

Current
21.17
27.55
20.01
11.65
0

80.39
26.9
-6.36

Chamber 2
9.75
Corregator , classifying
Outlet
Not Determined
Not Determined
204.92
Original
23.00
28.90
21.25
13.60

86.75
%
ton
-16.27

mm
mm
t

Current

Original

20.05
10.05
9.84
20.08
28.46
48.71
57.82
195.01
29
-9.91

20.35
10.25
10.20
20.40
30.60
51.05
62.05
204.90
%
ton

3- Mill Power Calculation

NET KW = 0.2846 DAWN
D
A
W
N

4.44
0.804
79.66
15

Net KW
Gross KW

1213.9
5200

D
A
W
N

4.47
0.783
199.57
15

Net KW
Gross KW

2981.92
5200

Chamber 1
Internal Diameter of Mill
1.073 - J
Charge weight in Tonnes
Mill speed in RPM
0.23
Chamber 2

Internal Diameter of Mill

1.073 - J
Charge weight in Tonnes
Mill speed in RPM
0.58

Total mill
Total Net absorbed Power, kw

4195.81

Net KW / Gross Kw ( mill)

0.81

Estimated power loss

power loss %
Conclusion :

0.073
7.3

higher KW/t by 7.3 %

7.3 % power loss means that the consumption has increased by about 2 3 kw/t due to running mill with low
filling degree (Ch. 1) or low feed rate

4- Axial test ( granulometry curve )

Note: Axial test has been done for 2 chambers using complete sieve shaker ( 7 sieves )
150
46.4
46.8
39.0
41.6
41.2

90
50.2
50.8
44.6
50.8
44.4

75
60.8
59.4
54.4
60.4
53.6

36

chamber(1)

212
39.8
40.2
32.2
33.8
33.2

45

1
2
3
4
Diaphragm

850
22.2
17.0
11.8
5.4
5.0

Blaine
cm2/gm

chamber(2)

5
6
7
8
9
10
11
12
13
14
Diaphragm

2.0
1.6
1.8
1.0
0.8
0.4
0.6
0.4
0.2
0.2
0.2

21.0
18.8
17.2
13.4
9.2
11.2
7.0
6.4
5.8
5.2
1.4

30.0
28.6
25.6
20.4
15.8
17.8
13.2
13.2
10.2
9.2
5.8

38.4
38.2
33.4
26.8
21.8
24.4
19.4
20.6
14.2
14.4
10.2

47.8
48.2
43.2
35.6
32.0
34.8
28.0
31.2
23.8
22.4
17.6

46.4
48.2
63.8
62.0
54.6
52.8
53.8
53.6
50.6
39.2
46.6

58.6
56.4
68.4
67.8
59.8
60.8
62.0
60.8
59.0
47.8
54.2

1417.0
1361.0
1470.0
1757.0
1925.0
2004.0
1925.0
2004.0
2485.0
2422.0
2223.0

No

Axial test and Blaine Curve

70.0

60.0

50.0

30.0

Outlet Diaphram

Intermediate Diaphram

40.0

20.0

10.0

0.0
1

Diaphram

10

11

12

13

14

Diaphram

850
212
150
90
75

2nd Chamber Chart (Blaine cm2/g)

3000.0

Blaine cm2/g

2500.0
2000.0
1500.0

blaine
cm2/gm

1000.0
500.0
0.0
5

10

11

12

13

14

Effective Length ( m )

The results analysis from both curves :

It seems from the curve that the size reduction and Blaine are good through the mill chambers
but there are some points have to be taken in consideration as following:

1- Point 1 & 2 : A slight flat curve means that 90 & 80 need to be charged
2- Point 3 : means that the combination of 80 & 70 has a good performance
3- Point 4 : prove that the quantity of 60 is so less to play its role and from wear rate calculation

4567-

method shown the most high wearable balls is 60 and from visual inspection shown that amount
of 60 is less , so we have to add 60 grinding balls to Ch 1
Very small Clinker nibs at intermediate diaphragm and by adding 90 & 80 , it will disappear totally
Point 5 & 6 , Show a poor preparation of 60 from 1st chamber which make the curve little flat and
it will disappear by adding 60 to chamber 1
Point 10 & 12 show a sharp raise where by visiting mill in both points there is unclassified balls
where 60 & 50 was there which interrupt the curve
A size reduction at the last of chamber 2 shows the small balls 30 & 25 & 20 & 17 have a good
performance
Conclusion:

1- Chamber 1 : add 2 ton 90 and 2 ton 80 and 2 ton 60

2- Chamber 2 : not recommended to add grinding media as high filling degree 29 % also the level of
balls have reached to the outer diameter of the ventilation grid

5- Separator Efficiency
Separator
feed a , Mill
outlet ( % )

Fine fraction
f(%)

Coarse fraction
g , tail (%)

Circulation
factor

Separator
Efficiency

61
77
77.2
87.4
93.2
98.4
99.8

75
92.6
93
95.6
96.6
98.8
100

39.4
51.4
52
67.2
79.8
97.2
99.2

1.65
1.61
1.63
1.41
1.25
1.33
1.33

74.6
74.7
74.0
77.8
82.7
75.3
75.2

Sum

594

651.6

486.2

1.53

71.5

Blaine cm2/g

2004

3241

1303

Passing %
36
45
75
90
150
212
850

Conclusion of the test:

The circulation load of the mill is about 1.53 which show a good performance of both mill
chambers with feed 140 145 t/h also the Separator Efficiency is about 71.5 % which
show a good separator role

6- Wear rate calculation :

size

one ball
original
weight
(kg)

3.00
2.10
1.41
0.888

Tonnage

Quantity
of Balls

Quantity of
collected
samples
from mill

weight of
samples
collected
from mill
(kg)

average
wt. of
one ball
(Kg)

loss on
one ball
(gr)

% of
wear
per ball

Current
Ball Wt
in mill

total charge
weight required
( ton)

23.00
28.90
21.25
13.60

7667
13762
15071
15315

43
44
50
15

118.759
88.09
66.38
11.414

2.76
2.00
1.33
0.761

0.24
0.10
0.08
0.13

7.9
4.7
5.8
14.3

21.17
27.55
20.01
11.65

1.83
1.35
1.24
1.95

86.75

51815

80.39

6.36

20.35
10.25
10.20
20.40
30.60
51.05
62.05

22917
19942
38783
183784
476636
1556402
3071782

20.05
10.05
9.84
20.08
28.46
48.71
57.82

0.30
0.20
0.36
0.32
2.14
2.34
4.23

204.9

5370245

195.01

9.89

291.7

5422060

275.4

16.2

1st Chamber

90
80
70
60
Total ( 1st chamber )
Wear rate
2nd Chamber

60
50
40
30
25
20
17
Total ( 2st chamber )
Wear
Total mill

0.888
0.514
0.263
0.111
0.064
0.033
0.020

284.6

29
19
41
410
765
2240
2811

25.38
9.58
10.41
44.79
45.68
70.10
52.91
258.8

0.875
0.504
0.254
0.109
0.060
0.031
0.019

0.01
0.01
0.01
0.00
0.00
0.002
0.0014

1.5
1.9
3.5
1.6
7.0
4.6
6.8

Wear rate summary:

Current Ball charge

275.4

ton

Original charge

291.6

ton

Ball Added to mill till now

14.7

ton

Total mill production , 2014 -2015

1,414,927

ton

wearable tons during operation

30.85

ton

Mill wear rate g/t

1st chamber wear rate
2nd chamber wear rate

tons added to 1st

chamber
Tons added to 2nd
chamber

21.8

gr/t

9.76

gr/t

12.08

gr/t

7.5
7.2

7- Ball charge sampling ( classification curve )

/ meter
60
50
40
30
25
20
17

1m
31.9
8.9
2.8
0.0
15.6
15.8
24.9

2.5 m
7.4
4.1
10.6
18.0
23.1
22.7
14.1

Ball charge sampling ( mass % )

4m
4.5 m
0.0
1.7
0.0
2.9
0.0
2.0
8.2
16.4
21.9
30.3
69.9
30.6
0.0
16.1

6m
6.5
2.8
1.4
9.2
16.3
30.6
33.1

7.5 m
4.8
1.1
4.4
40.6
12.1
21.9
15.1

9m
0.0
0.0
0.0
13.2
13.4
29.2
44.3

Curve of balls gradation in 2nd chamber ( 60,50,40 )

40.0
35.0
30.0
25.0

60

20.0

50

15.0

40

10.0
5.0
0.0
1m

2.5 m

4m

4.5 m

6m

7.5 m

9m

Curve of balls gradation in 2nd chamber ( 30, 25, 20, 17 )

70.0
60.0
50.0

30

40.0

25

30.0

20
17

20.0
10.0
0.0
1m

2.5 m

4m

4.5 m

6m

7.5 m

9m

Summary of curve:
Classification of the balls in 2nd chamber is unclassified well where some bigger balls at end of
chamber and smaller at beginning of the chamber

8- Quality Audit
Quality
Feed components

Clinker

Gypsum

Additives

percent %

88.5

6.5

cement Temperature

115 - 125 C

Clinker mineralogy

% C3S

50 - 52

%C4AF

11.83

% C2S

21 24.0

%C3A

7.85

Note : C2S is little higher which need more grinding efficiency and draw more
power consumption
Blaine
Residue 90
Residue 45

3136 cm2/gr
0.6 %
13 - 14.5 %

9-Mill Visit results : 1st Chamber

Measured volume load
Lining condition
Maximum ball diameter
Minimum ball diameter

26.7 %

Ball charge condition

Regular with normal worn out

Material level under/over balls

Moderate/little Over , 1/4 ball appear

Coating on lining

Very slight

Coating on balls

Slight

Uncrushed particles at the

diaphragm

A bit

Diaphragm condition

Semi- Blocked and Need to routine clean

Maximum width of slots

there is displacement in some rows and a Domino Effect appear in plates

90 mm
56 mm

Not Determined

Wear rate of lining plates

Not Determined

Slots blocked

Semi- Blocked

Central screen condition

No Screen found and new fabricated one has a large Slot width ( 9 13 mm )

1st Chamber Photos:

9- Mill Visit results : 2nd Chamber

Measured volume load
Lining condition
Maximum ball diameter
Minimum ball diameter

29 %

Ball charge condition

Regular with normal worn out

Material level under/over balls

Over 4 -6 cm

Coating on lining

Slight Coat

Coating on balls

There is a coat layer on Balls due to High CM temp + Higher water flow

Uncrushed particles at the diaphragm

A bit

Outlet Diaphragm condition

Good and slight blocked

Maximum width of slots

Wear rate of lining plates

Not Determined

Ball Classification

Un Classified Well

Central screen condition

Good

Water Nozzle

5 cm gap between diaphragm and flange / allow for escaping small balls

Regular , but a slight Coat there

58 mm
15 mm

Not Determined

2nd Chamber Photos:

11 - Conclusion of Audit: Recommended actions

1- Addition of 2 tons for each 90 & 80 & 60 for 1st chamber
2- Not recommended now to add grinding media to 2nd chamber as high filling degree and level of
balls near to ventilation grid
3- Measuring Slots width for both diaphragms not determined ( Recommended )
4- A good Separator Efficiency which is about 71 % and By- pass 19 %
5- A circulation factor is about 1.53 which is good
6- Mill wear rate is about 22 gr/t
7- High C2S phase means more energy for grinding
8- High Power consumption by 2- 3 kwh/t
9- Physical Condition of grinding balls in 1st chamber is good except 60 mm where more
deformation there
10- Displacement of some rows in 1st chamber is observed , fast action to adjust it is
recommended
11- Measuring the lifting lining wear rate nor determined , ( recommended )
12- Observed wear rate for head liner of 1st chamber
13- A bit clinker nibs at intermediate diaphragm has observed
14- Condition of intermediate diaphragm is semi blocked and need routine cleaning

15- Intensive follow up of metal trap to eliminate the scrap from mill which block the diaphragm
16- The new fabricated ventilation grid has a higher Slot width bigger than inter. diaphragm slot
width which allow for escaping the oversize particle to 2nd chamber
17- Physical Condition of grinding balls in 2nd chamber is good
18- Observed coat formation layer on the 2nd chamber grinding media & liners due to operation
mill with higher cement temperature or higher water flow or low ventilation, recommended
controlling temp. or using a grinding aid
19- The classification of the grinding media in 2nd chamber is not good but can consider accepted
20- The space 5 cm between water nozzle flange and outlet diaphragm will allow for escaping
more fine media to the 1st chamber, recommended to close the gap.
21- The condition of diaphragm is accepted but need a routine cleaning for improving the
performance
22- Slot width of outlet diaphragm not determined , recommended to measure
23- Lining wear rate for 2nd chamber not determined , recommended to measure

CM 1 Audit 2015