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MillScan DSP

Using vibrations to measure mill fill level

MillScan DSP is a field instrument that uses the vibrations measured in the bearing
housing of ball mills to calculate the fill level of material inside it.

MillScan DSP technology is unlike any other fill level instrument existent in the
market. Developed by Digital Control Lab (Texas Instruments partners since 1990),
the instrument uses the latest Digital Signal Processing technology to bring a real-time
and highly accurate fill level signal.

Knowing the instantaneous fill level allows a plant to increase material throughput
at traditional power levels. Thus a plant can produce more material for the
same amount of power or the same material for less power, thereby reducing
production costs.






















Benefits:
More precision than similar equipments;
Zero cross talk(interference) from adjacent or
equipment;
Useful way of increasing production and lowering
operational costs;
Greatly assist the automated control loops for mill
control;
Increase ROI, ball and liners operation time;
Eliminate Mill output obstructions;
Increase quality from reductions in Blaine standard
deviation;
More efficient production control.
Features:
Precise and instantaneous mill fill level measurement;
Fast and easy installation and calibration (Installation is
done will mill running);
3 times more resolution than traditional sound based
equipments;
All digital system, no component drift;
Communicates with existent PLCs with a 4-20mA
output;
Up to 5 different types of products calibration allowed
for the same unit.


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System Description:
The MillScan DSP system is comprised of two major components: a high resolution vibration sensor (magnetic mounted in
the mill bearing housing) and the main unit where the signal is processed and a 420mA signal is generated (see figure 3).


Figure 3: MillScan DSP, typical installation layout

Principle of operation:

Studies show that the vibrations measured in ball mills bearing housing corre-
late with the fill level of material inside it. For example: less material causes
more vibrations (balls strike into the wall instead of crushing the material).

Vibration signals from the sensor are converted to digital values in the main
unit. MillScan DSP measures the vibration in a frequency from 1 to 12.000Hz
and generates a frequency spectrum of the mill.

With the calibration process the system will automatically recognize which
vibrations are related with the fill level and which vibrations are noise caused
by other vibration sources. After calibration the system will create a filter that
will automatically disregard this external vibrations and will only take into
account the parts of the spectrum that have a perfect correlation between
vibration and fill level. Figure 4: Example of a full and empty Mill spectrum
and the filter automatic created by the software

Technical details:

Main Unit: General dimensions: 280mm (11.7) high x 250mm (9.9) wide x 122mm (4.7)deep (NEMA 4).
Bracket and screw mounted.
Power supply: 90220 Vac, 5060Hz, 0,5A.
420mA communication: 2 wire connection, 24Vdc external supply.
PC Connection for calibration: 4 conductors cable, 0,51,5mm diameter.

Vibration Sensor: General dimensions: cylindrical body, diameter 76,2 mm (3") height 76,2 mm (3").
Magnetic mount.
Connection cable: 10 meters.





LNV Technology Private Limited
V Floor, Sigappi Aachi Building
18 / 3 Rukmani Lakshmipathy Road, Egmore, Chennai 600 008, India.
Ph : + 91 44 43990000/43990100 , Fax : + 91 44 42049289
Email : lnvtechnology@lnvt.com , anjani@lnvt.com
Contact Person : K.V.Anjani Kumar



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Characteristics Unit Manual Millscan
Feed Rate TPH 170.29 177.59
Mill Power kW 4092.97 4112.50
Specific Power Consumption kW/T 24.04 23.16
Silo Bucket Elevator Current Amp. 199.10 204.59
Separator Speed RPM 15.94 15.23
Separator Fan Power kW 59.93 59.53
0.04
% Increase in Output %
% Decrease in Specific Power Consumption. %
4.29
3.70
Characteristics Unit Manual Millscan
Feed Rate TPH 77.04 78.61
Main Drive Power kW 2278.57 2276.07
Specific Power Consumption. kW/T 29.58 28.95
Mill outlet Bucket Elevator Current Amp. 18.54 20.03
Residue on 45 mic % 15.95 16.09
% Increase in Output %
% Decrease in Specific Power Consumption %
2.04
2.11
Characteristics Unit Manual Millscan
Feed Rate TPH 111.93 125.07
Mill Power kW 2688.93 2694.47
Specific Power Consumption. kW/T 24.02 21.54
Silo Bucket Elevator Current Amp. 41.60 43.13
Separator Speed RPM 943.27 908.47
Osepa Fan Power kW 394.67 398.73
F.Ash Feed TPH 22 to 23 27 to 28
% Increase in Output %
% Decrease in Specific Power Consumption. %
11.74
10.32
COMPARISION DATA OF MCL RR-NAGAR

JK-LAKSHMI CEMENT SIROHI CM - 5

JK-LAKSHMI CEMENT SIROHI CM - 2



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Country Units Country Units Country Units
Argentina France Cemex, Sant Feliu, Spain 1
Loma Negra Barker 1 Holcim Altkirch 2 Cemex LLoseta, Spain 1
Australia Groups Cosmos Cement - Niebla 2
Australian Cement, Kandos 2 FLSmith Automation USA 6 Prtland, El Alto 1
Brazil LVT Group 4 South Africa
Camago Correa Bodoquena 1 SGS Group 2 PPC Dualboom 1
Camargo Correa Jacare 1 India PPC Durban 2
Camargo Correa Suape 1 J.K Lakshmi Cements - Sirohi 2 Afrisam Ulco 2
Camargo Correa Pedro Leopoldo 2
Madras Cements Ltd-R.R
Nagar
1 Lafarge 2
Camargo Correa Apia 2 Ireland Tunis
Camargo Correa Ijaci 1 Quinn Mfg., Ballyconnell 2 Colacem, Jebel Jellourd 3
Cia de Cimento Itamb 2 Italy Jbel Oust 1
Cimentos Liz 1 Cementir Arquata 1 Turkey
Cimento Planalto 2 Buzzi Unicem, Riva del Garda 2 Nuh Beton 1
Cimpor Candiota 1 Cementir Spoleto 1 Lafarge Cement, Umraniye 1
Cimpor Campo Formoso 3 Cementir Taranto, Italy 4 Cimpor orum 1
Cimpor So Miguel Campos 4 Holcim Ternate 3 Cimpor Sivas 1
Cimpor, Paraba 2 Japan Cimpor Yozgat 1
Cimpor Cajati 2 Lafarge Kanda 1 USA
Cimpor, Goias 5 Mitsubishi Materials, Aomori 1 Lehigh Cement, Union Bridge 1
Cimpor Nova Santa Rita 2 Korea Tarmac, Miami 2
Holcim Barroso 1 Sungshin Cement 2 St. Marys, Votorantim 4
Itapissuma, Nassau 1 Malaysia Mountain Cement, Wyoming 2
Itautinga, Nassau 1 NSCI Bahau 1 USA (Cont.)
Itabira, Grupo Nassau 1 Mexico Arizona Portland, Tuscon, USA 2
Itapessoca, Nassau 3 Cemex, Monterrey 1
Holcim St. Laurence, Catskil,
USA
2
Itaguassu, Nassau 1 Cemex, Tepeaca 2 Barrick Gold, Nevada, USA 4
Canada
Cruz Azul, Hidalgo 2
Cemex Victorville, California,
USA
3
Colacem Cement, Montreal 4 GCC Chihuahua 2 GCC Dacotah 2
Unimin, Nepton Plant 1 GCC Samalayuca Plant 3
Florida Rock (Vulcan
Materials),
2
Unimin, Blue Mountain plant 1
Morroco

Carmeuse Lime and Stone,
Kent.
3
Chile Asment Temara - Cimpor 3 Alamo Cement, Texas (Buzzi) 2
Cemento Bio Bio, Talcahuano 4 Philippines Ashgrove Cement, Inkom 4
TISA, Santiago 1 Solid Cement 1 Ashgrove Cement, Clancy, MT 3
China Polony Holcim, Mississippi 2
Fuyang Cement , Huarun 6 units 6 Gorka Cement 2 Ashgrove Cement, Louisville 4
Fuyang Cement, Huaxim 2 Portugal St. Marys Cement, Detroit 4
Colombia Cimpor, Souselas 4 LaFarge Cement, Ravena 8
Cementos Argos, Planta Valle 1 Cimpor, Alhandra 4 Rinker Cement, Brooksville 2
Cementos Argos, Planta Rio Claro 1 Secil, Outao 1 Lafarge Cement, Tulsa 4
Cementos Argos, Zona Franca 1 Puerto Rico Cal Portland, Mojave 3
Cementos Argos, Planta CPR 1 Puerto Rican Cement 4 SAC Votorantim, Branford 3
Croatia Spain Cal Portland, Colton Plant 4
Cemex - Dalmacija Cement 2 Uniland, Monjos 1 GCC Rio Grande, Tijeras Plant 4
Dominican Republic Uniland, Vallcarca 1 Cemex, Wampum (PA) 4
Cemex, Dominican Republic 3 Cemex, Buol 2 ESSROC, Bessemer 2
Egypt Cementos Molins, Barcelona 1 ESSROC, Nazareth 2
Armreyah Cement 3 Tudela Veguin, La Robla 1 Hanson Permanente, Cupertino 4
El Salvador Italcementi, Mlaga 3 Vietnam
CESSA Cemento el Salvador 2 Holcim, Gador 1 Cong Thanh 1


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MillScan DSP
Instructions for electrical installation

MIllScan Main Unit shall be installed nearby the mill. The connection cable between the sensor and the main unit is 10 meters
long, .

To correctly install the MillScan the required connections are the ones described below:
Cable 1: Power supply cable (90 220Vac; 50 60Hz; 0,5A);
Cable 2: Cable for the fill level analogical signal to existent PLC (420mA);
Cable 3: Cable for remote calibration. This cable shall be passed till an local MCC or PLC room where calibration will be
carried up. The USB adapter for connecting to a laptop is included in the MillScan supply.

Important points:
MillScan output signal is 420 mA and proportional to the mill fill level. The 0 % (4 mA) represents an empty mill,
meanwhile the 100 % (20mA) represents a full mill.
The 420mA signal requires and external voltage supply of 24 Vdc (2 wires connection).
It is NOT necessary to stop the mill for the installation and calibration.
For the calibration it is necessary that the mill is running in normal conditions and if possible producing the most
common material.
Figure 1: MillScan DSP, typical system configuration.






Figure 2: MillScan DSP Main Figure 3: Vibration sensor with magnetic Figure 4: USB adapter for Calibration
Unit. base and 10 meters cable long



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Installation examples:

















Figure 5: Example of installation of the main unit nearby the mill Figure 6: Example of the position of the vibration sensor in the
In a sliding shoe mill. bearing housing.


Technical information for the connections:

Cables (plant supply):

Cable 1 (Power supply): 3 conductors, 90220Vac, 5060Hz, 0,5A;

Cable 2 (420mA output signal): 2 conductors, 0,51,5 mm diameter (2416 gauge), 1,25mm preferred (16 gauge);
maximum length of 1.000 m (3000 ft.)

Cable 3 (Communication to PC Calibration): 4 conductors, 0,51,5 mm diameter (2416 gauge), 1,25mm preferred
(16 gauge); maximum length of 1.000 m (3000 ft.).

Equipment (LNV Technology supply):

Vibration Sensor: Cylindrical body, 76,2 mm diameter (3"), 76,2 mm high (3");
Magnetic base for bearing housing mounting;
Cable for connection to the main unit: 10 meters.

Main Unit: Box dimensions: 280mm (11.7) high x 250mm (9.9) wide x 122mm (4.7)deep;
Bracket & screw mounted.

For more information or doubts LNV Technology technical staff can be contacted in the following directions:






V Floor,
,




LNV Technology Private Limited
V Floor, Sigappi Aachi Building
18 / 3 Rukmani Lakshmipathy Road, Egmore, Chennai 600 008, India.
Ph : + 91 44 43990000/43990100 , Fax : + 91 44 42049289
Email : lnvtechnology@lnvt.com , anjani@lnvt.com
Contact Person : K.V.Anjani Kumar