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Tim Nowack
Senior Process Engineer Christian Pfeiffer Maschinenfabrik GmbH
Christian Pfeiffer
General:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation
General:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation
12 months schedule
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
General:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation
Healths checks are important in order to: build up a knowledge and data base about the system performance record the data and display them in trends for fast and easy diagnostic of problems The main advantage: ad antage Knowledge basis allows to investigate the root cause of problems and to avoid problems by early reaction based on the trend results.
General:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation
constant/stable operation condition for at least 2 hours. recorded the actual operation data like: Production rate [t/h], Product type, composition [M-%] Actual A t l and dt target t fineness fi of f product d t [Blaine [Bl i or Residue] R id ] Actual mass flow rate (e.g. separator grits, water demand, etc.) Electrical power consumption of the main equipment Actual operation parameter of the main equipment (e.g. separator speed, damper positions)
Sampling points
Sampling point:
Clinker feed Gypsum feed Additive No.1 feed Additive No. 2 feed Mill outlet tl t material t i l Separator feed material Separator grits material S Separator fi fines cyclone l 1 Separator fines cyclone 2 Separator fines mix Filter dust 1 (weighfeeder) Filter dust 2 (circuit dedusting) Filter dust 3 (mill dedusting) Cement
r
1 x per Test H 2O H 2O H 2O 1x every hour
Procedures
Sieving 50, 25, 16, 8, 4, 2, 1, [mm]
10 kg
Pre-screening with 450 m sieve PSD from 1-450 m with Laser equipment (e.g. Cilas, Malvern, Sympatec) Fineness acc. to Blaine [cm [cm/g] /g]
0.5 kg
Longitudinal g sampling: g
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation
1.1 1.1
1.2 1.2
1.3 1.3
1.4 1.4
2.1
2.2
2.3
2.4
2.5
2.6
2.7
20 cm
1. Measure average g internal diameter, , Di 2. Measure height, h, in three different points along axis for each grinding compartment For best results the measurement takes place in an empty mill (mill feed stopped for approx. 10 min).
Too high = above charge Good = below charge Too low = >1 1 below charge
Good material level for 1st compartment
Too high = > 50mm above charge Good = approx. pp 20 mm above charge Moderate = equal with ball charge Too low = >> 50 mm below charge
Good material level for 2nd compartment
M a in m ill driv e :
1st compartment
Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation
2,115 mm 1,290
1-8
M
+
5,380 mm
18 20 25 30 40 50 60 Scrap
Grinding balls
2.4m x 5.0m w ith QDK 8,5-F Monochamber (1/3 lifter - 2/3 class.)
Ball -
Std. Max Min Piece 1 2 3 4 5 6 7 8 9 Mass 891,8 g 886,2 g 879,6 g 878,0 g 873,5 g 873 3 g 873,3 861,0 g 860,6 g 858,2 g
60
886 g 1400,0 g 682,0 g 891,8 g 886,2 g 879,6 g 878,0 g 873,5 g 873 3 g 873,3 861,0 g 860,6 g 858,2 g
50
513 g 681,0 g 375,0 g
40
262 g 374,0 g 177,0 g
30
111 g 176,0 g 81,0 g
25
64 g 80,0 g 45,0 g
20
33 g 44,0 g 14,0 g
Navigation
1 weight mass-%
19920 11112 4293 1384 481 0 37190 53,56% 29,88% 11,54% 3,72% 1,29% 0,00% 100,00%
pc.
3 20 35 28 14 3 103
2 weight mass-%
2552 9269 8468 2997 835 93 24215 10,54% 38,28% 34,97% 12,38% 3,45% 0,39% 100,00%
pc.
0 0 5 28 66 76 175
4 weight mass-%
0 0 1209 2943 3923 2366 10441 0,00% 0,00% 11,58% 28,19% 37,57% 22,66% 100,00%
pc.
0 0 4 63 144 98 309
5 weight mass-%
0 0 952 6617 8576 3056 19200 0,00% 0,00% 4,96% 34,46% 44,67% 15,91% 100,00%
60,0%
50,0%
40,0%
30,0%
20,0%
10,0%
Now
D ate
23.02.2006
33.420 -
and
Check the stable condition of the circuit Record all main operation parameters
Procedures
Pre-screening with 450
m sieve PSD from 1-450 m with 1x Laser equipment (e.g. every hour Cilas, Malvern, Sympatec) Fineness acc acc. to Blaine [cm/g]
Separator Ventilation:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation
No correction factor needed Easy to operate within 15 angle Only in low vortex channel Not for high dust loaded channels
C ti f factor t required i d( (~0.84) 0 84) Correction Misalignment results in mistakes Preferred for high dust loaded h l channels
Separator Ventilation:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation
Measurement points:
Separator circuit with cyclones Separator circuit with filter
Mill Ventilation:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation
Instrument Verification:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation
1) Electronically
Check and adjust zero-point and span with e.g. mA-transmitter
2) Operation check
Compare control room indication with local manual measurement of temperature, pressure and flow Adjust transmitters
1) Operation check
record process parameters with control t ll loop i in operation ti over period of e.g. 6-8 hours with constant production record mill p power consumption p at counter (kWh)
Questions?