Ball Mill Audit and Optimization

Ball mill optimization
Dhaka, Bangladesh
21 March 2010
Introduction
Mr.Peramas Wajananawat
Experience: 13 Years (2 y in engineering,11 y in production)
Engineering department Kiln and Burning system
Siam Cement (Ta Luang) Kiln system, Raw material grinding and Coal grinding
Siam Cement (Lampang) Cement grinding and Packing plant
The Siam Cement (Thung Song) Co,Ltd

Production Engineer
Cement grinding 7 lines

2 x Conventional mill 150 t/h (OPC)

2 x Pre-grinding 100 t/h (OPC)
2 x Semi-finish grinding 270 t/h (OPC)
1 x VRM 120 t/h
Cement bag dispatching
Contact e-mail: peramasw@scg.co.th
KHD
Fuller
KHD
Loesche (LM46.2 +2C)
Contents
1.
2.
3.
4.
Objective of Ball mill optimization

Mill performance test
Air flow and diaphragm
Separator performance test
Objective
1. Audit performance of grinding system
2. Show the key areas for optimization the ball
mill system
3. Provide the basic information for changes or
modifications within grinding system
4. Reduce power consumption, Quality
improvement or Production improvement

Mill charge
1. Mill sampling test
2. Charge distribution
3. Regular top-ups
Air flow & Diaphragm

1. Mill ventilation
2. Water injection
3. Diaphragms
Separator
1. Tromp curve
2. Separator air flow
3. Separator sealing
When: Do optimization
1.
2.
In some period (1 month, 1 Quarter, 1 Year or ???)

To assess the reason/cause of disturbance

3.
When abnormal operation

Poor performance of grinding system
Low mill output or poor quality product
High operation or maintenance costs
Keep operation in a good efficiency
Conventional grinding system
Clinker
Gypsum Limestone
To Cement Silo
Cement Mill
1.
2.
3.
4.
5.
Main Machine
Feeding system
Tube mill
Dynamic separator
Dedusting (BF/EP)
Transport equip.
Mill charge optimization
Clinker
Gypsum Limestone
To Cement Silo
Cement Mill
What is function of mill?
Size reduction along the mill

-Coarse grinding 1st compartment
Normal feed size 5% residue 25 mm.
Max feed size 0.5% residue 35 mm.
-Fine grinding
2nd compartment
Coarse material grinding
Fine material grinding
Piece weight (or knocking weight)
Specific surface
Average weight/piece of grinding

media in each compartment
(g/piece)
Piece weight
Impact force
Average surface area of (ball)

grinding media in each compartment
(m2/t)
Specific surface
Attrition force
Need small ball size
Need large ball size

10
Ball charge composition

Calculation (for steel ball)
Piece weight
: i = [3.143/6] x d3 x 7.8 ;g/pcs.
Specific surface : o = 123 / i (1/3)
; m2/ton
Note : d = size of ball (cm)
11

Check piece weight and specific surface
Compartment
1
Fraction
(mm), d
90
80
70
60
50
40
Total #1
Charge calculation
(t)
5.0
11.0
13.6
15.3
5.6
2.5
53.0
%
9%
21%
26%
29%
11%
5%
100%
Compartment
2
Fraction
12
Specific surface,
Surface, O
o
pcs.
(m2/t)
(m2)
1,673
8.5
43
5,240
9.6
106
9,671
11.0
149
17,277
12.8
196
10,927
15.4
86
9,528
19.2
48
54,317
11.8
628
Weight, W weight Piece weight, I no., n

(g)
2,989
2,099
1,406
886
512
262
976
Piece weight: 976 g/piece

Specific surface: 11.8 m2/t
Charge calculation
Specific surface,
Surface, O
o
pcs.
(m2/t)
(m2)
0
15.4
0
0
19.2
0
45,170
25.6
128
749,309
30.7
1,476
1,143,35
38.4
1,441
4
2,308,58
45.2
2,102
5
4,246,41
37.6
5,147
7
Weight, W weight Piece weight, I no., n
(mm), d
50
40
30
25
(t)
0.0
0.0
5.0
48.0
%
0%
0%
4%
35%
(g)
512
262
111
64
20
37.5
27%
33
17
46.5
34%
20
Total #1
137.0
100%
32
Piece weight: 32 g/piece

Specific surface: 37.6 m2/t

General we use (Product Blaine 4,500 cm2/g) for Conventional
Cpt.1 : Piece weight 1,500-1,600 g./piece
Cpt 2 : Specific surface 30-35 m2/t
For Pre-grinding system R/P + Conventional

Cpt.1: PW ~1,100-1200 g/pc
Cpt.2: SS ~35-40 m2/t
**depend on product fineness!!
13
Maximum steel ball size (Bond equation)

B=36 x (F80)1/2 x [(SgxWi)/(100xCsxDe1/2)]1/3
Where

14
B : Maximum ball size (mm.)

F80 : Feed material size for 80% pass (m)
W i : Bond work index (kWh/t)
C s : N/Nc (normally ~ 0.7-0.75)
Sg : Specific gravity of raw material (t/m3)
D e : Effective diameter of mill (m.)
F80 = log [(0.20) size residue(mm.)]/log(%residue)
Example;
Given
Feed size = 5% res. 25 mm.
Wi = 13.0 kWh/t
Cs = 0.7
Sg = 3.0 t/m 3
De = 4.0 m.
F80 = log(0.20)25/log(0.05)
F80 = 13.4 mm.
Find : Maximum ball size
1/2
1/2 1/3
B = 36x(13.4) x[(3x13)/(100x0.7x4 )]
Maximum ball size = 86 mm.
Maximum steel ball size

Maximum ball size (mm.) : Clinker Wi 13.0 kWh/t, Cs 0.7, Sg 3
Max Ball Size (mm.)
180
160
140
120
100
80
60
40
20
0
10
15
20
Feed Size (mm.), F80
** Typical fresh clinker : 5% residue 25 mm. or F80 = 13.4 mm.

15
25
30
Example
Given
Feed size = 5% res. 20 mm.

Wi = 12.0 kWh/t
Cs = 0.7
Sg = 3.0 t/m3
De = 2.5 m.
Find: required maximum ball size

F80
Maximum ball size (mm.)
16
Mill performance test

Steps
1. Recording of related operational data
2. Air flow measurement
3. Crash stop and visual inspection in mill
4. Sampling in mill
5. Evaluation of test
17

Tube Mill
Feed rate, Return, Grinding aids, Water injection, Mill drive
power (kW)
Static separator
Vane position
Mill ventilation fan

Damper position, Air flow rate (if have instrument), Pressure
Fan drive power
18

Air flow measurement
Air flow rate
Temperature
Static pressure
Mill ventilation air
Clinker
Gypsum Limestone
To Cement Silo
Cement Mill
19
Mill ventilation air

Purpose
Forward movement of the material retention time
Take out fine particles and so diminish the risk of coating
Cooling of the material in mill Diminish coating / dehydration
of gypsum
Usual ranges of ventilation:

Air speed in mill
Open circuit : 0.8 to 1.2 m/sec
Closed circuit : 1.2 to 1.5 m/sec
m/sec
**Min 0.5 m/s tend to result inefficient over grinding and excessive
heat generation with possible coating problem.
**Max > 1.4 m/s drag particle out of mill before they have been
sufficiency ground.
20
Agglomeration and ball coating

Cause:
Temperature too high tendency of the
material forming agglomerates/coating on
grinding media and liner plates
Grinding efficiency will be reduce
Temperature outlet mill range 110-120 C.
21
Test 2
Mill dimension
Inside diameter 3 m.
Degree of filling 28% in both compartment
Mill ventilation check

Flow 22,000 m3/h
Check Air ventilation speed in mill ?

m/sec
22
3. Crash stop and visual inspection

Stable operation before crash stop
Emergency stop or Crash stop
Tube mill / All auxiliary equipment
Mill Ventilation
Disconnect main circuit breaker (Safety !)

Preparation of sampling equipment (shovel, scoop, plastic bag, meter,
lighting etc.)
23
Preparation of sampling equipment

Lock switch
Plastic bag
PPE
Crash stop
Meter
Lighting
Shovel
Meter
Scoop
24

Visual inspection

Liner and Diaphragm condition wear, block

Ball size distribution along the mill classify liner
Water spray nozzle condition clogging
Foreign material ?
Ball charge condition agglomeration, coating
Liner
Diaphragm
Ball charge
25
Clogging
Clean block slot

Material level in compartment #1 and #2
26

Ball charge quantity (Filling degree)
Measurement by free height
Measure average internal diameter, Di
Measure height, h, in three different points along axis for each grinding
compartment
Effective length, L
Free height, h
M
Inside diameter, Di
27
Ball charge quantity (Filling degree)
De
h
Ball level
h = H- (De/2)
Degree of filling (%)
60.0
50.0
40.0
30.0
N ormal range 28-32%
20.0
10.0
0.0
Meter
28
0.000
0.100
0.200
0.300
h/De
0.400
0.500
4. Sampling inside mill (mill test)

Sampling of material
Take ~1 kg sample every 1 m along mill axis
Each sample collected from 3 point in the same cross section
Removed some balls and taken sample
First and last sample in each compartment should be taken
from 0.5 m off the wall or diaphragms
0.5 1m 1m 1m 0.5 0.5 1m 1m 1m 1m
1.1
1.1
1.2
1.2
1.3
1.3
1.4
1.4
2.1
2.2
2.3
2.4
1m 1m 0.5
2.5
Material sampling point in mill
29
Deep 20 cm.
2.6
2.7
Take sampling
0.5 1m 1m 1m 0.5 0.5 1m 1m 1m 1m
1.1
1.1
1.2
1.2
1.3
1.3
1.4
1.4
2.1
2.2
2.3
2.4
1m 1m 0.5
2.5
2.7
2.6
Front view
Side view
0.5 m.
0.5 m.
1
1
0
1
0
1
1
1
0
1
1
Take 1 sample
30
Top view
1
1
Get total 11 collected

samples along the mill
1 kg per sample
4. Sampling inside mill (mill test) cont.

After work inside the mill
Calculation quantity of ball charge and filling degree
Sample sieve analysis
1st compartment
Sieve : 16 , 10 , 6 , 2 , 1.25 , 0.5 , 0.2 mm
2nd compartment
Sieve : 1.25 , 0.5 , 0.2 , 0.12 , 0.09 , 0.06 mm., Blaine Fineness
Plot size reduction chart (graph)
31
Sieve test equipment
32
Results: Sieve and Fineness analysis from mill test

Sample Location
% residue on sieve (by weight)
Blaine
Position m. cm2/g
32
16
0.50
0.20
0.09
mm
mm
mm
mm
mm
mm
mm
mm
mm
0.5
7.00
18.00
34.00
47.00
57.00
64.00
71.00
81.00
90.50
1.0
9.00
21.00
36.00
45.00
52.00
60.00
69.00
79.00
89.00
2.0
3.00
7.00
13.00
18.00
20.50
31.00
48.00
67.00
83.00
3.0
0.50
1.00
3.00
5.50
8.00
19.50
29.50
52.00
71.00
pt.2
4.0
0.10
3.00
5.00
7.00
8.00
10.50
22.00
46.00
65.00
pt.3
4.5
0.05
4.00
7.50
9.00
10.50
12.50
28.00
48.50
68.00
Partition
**
Compt 1 pt.1
Compt 2 pt.1
0.5
940
1.00
8.00
32.00
56.00
pt.2
1.0
1080
2.00
9.00
33.00
59.00
2.0
1260
0.50
7.00
24.00
50.00
3.0
1300
0.01
4.00
18.00
42.00
4.0
1500
0.00
1.50
12.00
39.00
5.0
1600
0.00
1.00
9.00
32.00
6.0
1700
0.00
0.50
5.00
27.00
pt.3
7.0
1880
0.00
0.22
4.00
21.00
pt.4
8.0
2000
0.00
0.01
3.00
19.50
9.0
2120
0.00
0.01
1.50
18.50
0.00
0.00
2.00
19.00
pt.5
33
9.5
0.5 1 2 3 4 4.
5
0. 1 2 3 4 5 6 7 8 9 9.5
5
0.5 m
Size Reduction Progress
100
90
80
70
60
50
40
30
20
10
0
2800
2600
2400
2200
2000
1800
1600
1400
1200
1000
800
0.5 m
32.000 mm
16.000 mm
8.000 mm
Blaine (cm^2/g)
% Residue on sieve
Typical grinding diagra m : OPC 3000 cm2 /g
4.000 mm
2.000 mm
1.000 mm
0.500 mm
0.200 mm
0.090 mm
Blaine cm2/g
0.5 1.0 2.0 3.0 4.0 4.5 ** 0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 9.5 Length (m.)
34
Comp. 1
Comp. 2
5. Evaluation of performance test

Grinding efficiency
Data for evaluation
Result from visual inspection inside tube mill
Sample analysis from longitudinal sampling inside tube mill Size
reduction graph
Cement Mill
35
Evaluation of mill test standard reference

Size reduction along mill axis
Sieve residues and Blaine value in front of the diaphragms
Compartme
nt
First comp.
Particle size
FLSmidth
Holderbank
Slegten
+0.5 mm.
15-25%
12-25%
+0.6 mm.
10-20%
+1.0 mm.
7-14%
+2.0 mm.
Max 4%
Max 3%
Max 5% (at 2.5

mm.)
+0.2 mm.
20-30%
20-30%
15-25% (at 0.1

mm.)
Second comp.
36
+0.5 mm.
Max 5%
Max 5%
Blaine
(cm2/g)
2,100
Size Reduction Progress
100
90
80
70
60
50
40
30
20
10
0
2800
2600
2400
2200
2000
1800
1600
1400
1200
1000
800
0.5 1.0 2.0 3.0 4.0 4.5 ** 0.5 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 9.5
Comp. 1
Compartm
ent
First comp.
32.000 mm
16.000 mm
8.000 mm
Blaine (cm^2/g)
% Residue on sieve
Evaluation of mill test
4.000 mm
2.000 mm
1.000 mm
0.500 mm
0.200 mm
0.090 mm
Blaine cm2/g
Length (m.)
Comp. 2
Particle
size
FLSmidth
Holderban
k
Slegten
Mill test
Result OK?
+0.5 mm.
15-25%
12-25%
28%
+0.6 mm.
10-20%
+1.0 mm.
7-14%
12.5%
+2.0 mm.
Max 4%
Max 3%
Little much
coarse
particle size
from
compartmen
t1
Max 5%
(at 2.5
10.5%
mm.)
+0.2 mm.
20-30%
20-30%
15-25% (at 0.1
2%
mm.)
Second
comp.
37
+0.5 mm.
Max 5%
Max 5%
0%
Blaine
(cm2/g)
2,100
2,120
Good!
Evaluation of mill test

Test result : provide information to
Improvement of ball charge composition
Maximum ball size and composition
Charge composition (PW and SS)
Modification/Replace inside grinding compartment

Liners
Diaphragms
Operation
Mill ventilation
Clear diaphragm slot
38
Good condition liner
Broken liner
Inspection
Bad condition step liner
39
Slot blockage
Common problems!
Compartment
First comp.
Second comp.
40
Liner/Diaphragm
Result
Ball charge
Over limit of
particle size in
front of diaphragm
1 st comp.
-Increase impact
force in 1 st comp.
-Revise ball
charge and need
larger ball size
(piece weight)
-Low lifting
efficiency (visual
inspection)
-Clean block at
diaphragm (nib)
Over limit of
particle size in
front of diaphragm
2 nd comp.
-Wait for revise

charge in 1 st
comp.
-Wait for improve

liner in 1 st comp.
1 st comp. OK but
2 nd comp. over
limit of particle size
in front of
diaphragm
-Revise ball
charge and may
need to increase
specific surface
or Piece weight
-Check ball
charge
distribution along
the mill
-Classifier liner
efficiency
-Clean block at
diaphragm
Operation
Mill vent.
-Feed too much

(visual
inspection)
-Too high velocity

(check air flow)
-Feed too much

(visual
inspection)
-Too high velocity

(check air flow)
Case mill test, CM6 STS (Aug,2008)

70.0
2500
2,314
2,058
abnormal
1,927
60.0
1,739
2000
1,807
1,626
Diaphragm
50.0
40.0
30.0
1,487
1500
1000
20.0
500
10.0
0.0
0
0
5.6 mm.
41
2 mm.
0.5 mm.
0.212 mm.
0.09 mm.
10
0.075 mm.
12
0.045 mm.
14
blaine
Blaine (cm2/g)
2,333
Diaphragm
% residue
80.0
Evaluate and correction

Reference standard
Compartme Particle
nt
size
FLSmidth
Holderba
Slegten
nk
Mill
test
+0.5 mm.
15-25%
12-25%
31%
+0.6 mm.
10-20%
+1.0 mm.
7-14%
+2.0 mm.
Max 4%
Max 3%
Result OK?
Abnormal size reduction
(in front of diaphragm),
should clear blockage
diaphragm slot
First comp.
Second
comp.
42
Max 5%
(at 2.5 mm.)
15-25%
23%
+0.2 mm.
20-30%
20-30%
(at 0.1 mm.)
52%
+0.5 mm.
Max 5%
Max 5%
51%
Blaine
(cm2/g)
2,100
2,314
Abnormal size reduction

(in front of diaphragm),
should clear blockage
diaphragm slot
Case Mill test from : VDZ congress 2009

Cement plant in Europe
Chamber 1 : good size reduction efficiency

Chamber 2 : 45 micron shown results that grinding has
stopped midway through the 2nd chamber
43
Evaluate and correction
Average ball size in chamber 2 is too small (average 16 mm, PW 17 g.)

Take charge distribution more coarse to increase PW and average ball
size diameter (to 42 g. and 22 mm.)
44
Clinker
Gypsum Limestone
To Cement Silo
Cement Mill
45
What is separator?
46
Advantage of grinding system

with separator
Reduce the number of fine particle to
be ground in mill
Increase production capacity and
Reduce mill power consumption
Increase % of Active particle in fine
particle of Cement
Advantage of grinding system with separator
Maximized separator performance Maximized power saving

47

Steps
3. Sampling within grinding system
4. Evaluation of test
48

Tube Mill
Feed rate, Return, Grinding aids, Water injection, Mill drive
power (kW)
Dynamic separator
Rotor speed, Damper/vane position
Separator drive power (kW)
Separator circulating fan & Separator ventilation

Flow rate (if have instrument), Damper position
Separator fan power (kW)
49

Air flow measurement
Air flow rate
Temperature
Static pressure
Separator circulating air
Clinker
Gypsum Limestone
To Cement Silo
Cement Mill
50
Dynamic Separator circulating air

Purpose
Distribute and disperse cement dust
Classify cement dust at rotor
Take out fine particle from separator to be product
Separator feed
(t/h)
Usual ranges of circulating air

Depend on separator feed and production rate
Separator load 1.8-2.5 kg feed / m3
= Separator feed / Circulating air
Circulating air
flow (m/h)
Dust load (fine) less than 0.75-0.8 kg fine / m3

= Fine product / Circulating air
Return
51
Fine
product
(t/h)
3. Sampling within grinding system

Operation period
Determined suitable sampling point
Stable operation
6-12 hours duration of performance test
Taking samples every ~1 hour
52
Sampling plan (stable operation period)

1
Clinker
Gypsum Limestone
3
2
To Cement Silo
Cement Mill
53
Sampling
Sampling point in process
Return (reject)
Separator feed
or mill output
54
Scoop
Fine product
Sampling test
Point
55
Sampling point
Weight
Required sieve analysis
Separator feed m
0.5 kg
PSD Laser test, Blaine (cm2/g)
Separator return g
0.5 kg
Separator fine f
0.5 kg
PSD analysis equipment
Particle size distribution analysis
56
Thung Song Plant

Result: from Laser analysis
-Range 1.8-350 um
-Test time <5 mins/sampling
57
Particle Size Distribution (PSD)
58
Rm
Rf
Rg
Size (um)
Feed
%residue
Fines
%residue
Rejects
%residue
96.4
95.1
98.1
93.9
91.7
96.5
89.0
85.3
93.7
81.5
74.6
89.9
16
68.8
55.1
85.6
24
60.3
41.2
83.9
30
32
52.2
28.9
80.9
20
48
39.4
13.0
71.9
10
64
32.3
7.4
62.9
96
18.2
0.0
40.5
200
4.9
0.0
11.0
TOTAL:
636.9
492.3
814.9
100
90
80
% Residue
70
60
50
40
1
Feed %residue
10
100
Sieve size (um)
Fines %residue
1000
Rejects %residue
59
Rm
Rf
Rg
Size (um)
Feed
%residue
Fines
%residue
Rejects
%residue
96.4
95.1
98.1
93.9
91.7
96.5
89.0
85.3
93.7
81.5
74.6
89.9
16
68.8
55.1
85.6
24
60.3
41.2
83.9
32
52.2
28.9
80.9
48
39.4
13.0
71.9
64
32.3
7.4
62.9
96
18.2
0.0
40.5
200
4.9
0.0
11.0
TOTAL:
636.9
492.3
814.9
Meaning sieve size 32 um

52.2% of separator feed
residue on sieve size 32 um
80.9% of reject residue on

sieve size 32 um
4. Evaluation of performance test

Separator efficiency
Data for evaluation
Particles size analysis of sample within grinding system
- Separator feed
- Separator fine
- Separator tailing or Reject
Rm
Rf
Rg
Tromp curve or Fractional recovery

The tromp curve shows what fraction of particles of different sizes in the
feed material is going in to the coarse fraction (often called Return or
Tailing)
Separator specific loads / Dust Load
60
Tromp curve
Calculation
Circulation factor (CF)
CF = (Rf - Rg)/(Rm - Rg)
where
Rf = % residue on sieve of fine
Rg = % residue on sieve of coarse
Rm = % residue on sieve of feed
In this case (size 48 um)

Circulation Factor = 1.81
61
Tromp curve
Calculation
Tromp value
Tromp (range d1,d2) = [(Rg1-Rg2)/(Rm1-Rm2)]x[1-(1/CF)]x100
where
Tromp (range d1,d2) : Fraction of particles size between d1 and d2
Rg = % residue on sieve of coarse (return/reject)
Rm = % residue on sieve of separator feed
In this case
Tromp value (32-48 um) = 31.5%
62
Example
Rm
Rf
Rg
Feed
%residue
Fines
%residue
Rejects
%residue
96.4
95.1
98.1
93.9
91.7
96.5
89.0
85.3
93.7
81.5
74.6
89.9
16
68.8
55.1
85.6
24
60.3
41.2
83.9
32
52.2
28.9
80.9
48
39.4
13.0
71.9
64
32.3
7.4
62.9
96
18.2
0.0
40.5
200
4.9
0.0
11.0
TOTAL:
636.9
492.3
814.9
Size (um)
63
Find Circulation factor (CF) of

particle size 32 um and 48 um
CF = (Rf - Rg)/(Rm - Rg)
where
Rf = % residue on sieve of fine
Rg = % residue on sieve of coarse
Rm = % residue on sieve of feed
Find Tromp value of size in range

32-48 um
Tr (d1,d2)=[(Rg1-Rg2)/(Rm1-Rm2)]x[1(1/CF)]x100
where
Tromp (range d1,d2) : Fraction of particles size
between d1 and d2
Rg = % residue on sieve of coarse (return/reject)
Rm = % residue on sieve of separator feed
Tromp value meaning Tromp value (32-48 um) = 31.5%

For separator feed size between 32-48 um = 100 %
Separator feed
Separator
31.5% to coarse fraction

Reject/Return
64
68.5% to fine fraction

Fine product
Tromp value Plot Tromp curve

Rm
Size (um)
65
Rf
Rg
Feed
Fines
Rejects
%residue %residue %residue
CF
Size avg
(um)
Tromp
value
1
2
4
96.4
93.9
89.0
95.1
91.7
85.3
98.1
96.5
93.7
1.76
1.85
1.79
0.5
1.5
3
22.9
29.3
25.2
8
16
81.5
68.8
74.6
55.1
89.9
85.6
1.82
1.82
6
12
22.8
15.2
24
60.3
41.2
83.9
1.81
20
8.9
32
48
64
96
52.2
39.4
32.3
18.2
28.9
13.0
7.4
0.0
80.9
71.9
62.9
40.5
1.81
1.81
1.81
1.82
28
40
56
80
16.6
31.5
56.9
71.4
200
4.9
0.0
11.0
1.80
148
98.8
TOTAL:
636.9
492.3
814.9
1.81
TOTAL:
Plot Tromp curve

Particle size in range 32-48 um
-31.5% go to be Return
-68.5% go to be Fine product
% recovery to return (reject)
100
90
80
70

60
50
40

30
20
10
0
1
10
100
Sieve size (um)
66
1000
Tromp curve of Ideal and Actual separator

100
90
Ideal separator
No coarse in product and No fine in
return/reject
80
70
60
Actual separator
Have some coarse in product and Have
some fine in return/reject
50
40
30
20
10
0
1
Sieve size (um)
Actual separator
67
Ideal separator
Tromp curve
100
Cut size : d50 = 60 um

The cut size of the separation
being made is the particle size
where the tromp value is 50%
Meaning : Size 60 um has an
equal chance to go either to
product or to rejects
90
80
70
60
50
40
30
20
10
0
1
10
d50
100
Sieve size (um)
68
1000
Tromp value meaning Cut size (d50)

For separator feed size between 48-64 um = 100 %
Separator feed
Separator
50% to coarse fraction

Reject/Return
69
Size ~ 60 um: equal chance to go

either to product or to rejects
50% to fine fraction

Fine product
Tromp curve
100
Sharpness = d25/d75
Sharpness = 0.38
Steeper tromp curve, the better
the separation
90
80
70
60
Ideal separator sharpness = 1
50
40
30
20
10
d75
0
1
10
d25
100
Sieve size (um)
70
1000
Tromp curve
100
Bypass = 8.9%
Meaning : Bypass is an
indication of the amount of
material that essentially
bypasses the separator.
The lower the bypass, the more
efficiency the separation.
90
80
70
60
50
40
30
3rd generation bypass < 15%
20
10
Minimum value
0
1
10
100
Sieve size (um)
71
1000
Evaluation of separator performance test

Item
Units
Typical range
Result
Evaluate
2-3
1.81
little less
micron
depend on rotor speed

and fineness level
0.5
0.38
little less
5-15%
8.90%
OK
Separator load
kg/m3
1.8-2.5
1.7
OK
Product load
kg/m3
0.75
0.6
OK
Circulation factor
Cut size(d50)
Sharpness (d25/d75)
Bypass
60 micron seems high
Action :
1. Increase circulation factor (CF) Separator load has available
2. Need to increase speed of rotor (due to higher CF coarser separator feed)
3. Tromp curve move to finer side and d50 change to be less than 60 um.
4. Bypass slightly increase
5. Power consumption of mill went down.
72
Improvement Tromp curve

100
1. Improve product: Reduce cut size

-Increase circulation factor to 2-3
-Increase rotor rotation speed
-%Bypass may slightly increase OK
-Check separator load and dust load ?
90
80
70
60
50
Result:
-Better active particle size of product
-Strength improve
40
30
20
10
0
1
10
100
1000
Sieve size (um)
Actual separator
73
Ideal separator
Improvement Tromp curve

100
2. Improve production rate: Reduce

%bypass
-Improve separator feed distribution
-Check separator load and dust load ?
-Separator ventilation flow
-Check mechanical seal or leak
-Check guide vane and rotor blade ?
90
80
70
60
50
40
Result:
-Increase production rate
-Reduce power consumption
30
20
2
10
0
1
10
100
1000
Sieve size (um)
Actual separator
74
Ideal separator
Test result : provide information to :

Adjustment of separator settings
Circulation load
Separating air flow, fan speed ,etc
Modification inside separator

Mechanical adjustment ,etc
Mechanical seal
Dispersion plate
Guide vane and rotor
75
General separator improvement

Separator feed chute
o 100% feed on dispersion plate
(over the rotor) good distribution
Feed point and dispersion plate
76

Make sure symmetry feed on rotor
good distribution
KHD Sepmaster and Fuller O-Sepa
77

Adjust guide vane good air flow
distribution to rotor
Guide vane
78

Check rotor blade condition (wear and
deform) normal classification
Rotor blade condition
79

Upper and Lower seal condition good
classification
Grinding aids good
classification/reduce bypass
80
Summary
Mill charge
81
Air flow & Diaphragm
Separator
1. Mill sampling test

2. Charge distribution
3. Regular top-ups
1. Mill ventilation
2. Water injection
3. Diaphragms
1. Tromp curve
2. Separator air flow
3. Separator sealing
1. Every 6 months
2. Every 1 Year
3. 1,000 hours
1. Check and maintain

2. 1,000 hours check
3. 1,000 hours check
1. Every 3 months
2. Optimized and maintain
3. Every 3 months
Q&A
Performance test
Mill test and Separator test
Evaluation

Visual inspection
Size reduction graph and Tromp curve
Improvement
Charge composition, Operation, ect.
Results
82
Energy saving, Quality improvement

Ball Mill Audit and Optimization

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Ball Mill Audit and Optimization

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Ball mill optimization

The Siam Cement (Thung Song) Co,Ltd

2 x Conventional mill 150 t/h (OPC)

Cement bag dispatching

Contact e-mail: peramasw@scg.co.th

Objective of Ball mill optimization

Ball mill optimization

Air flow & Diaphragm

In some period (1 month, 1 Quarter, 1 Year or ???)

When abnormal operation

Keep operation in a good efficiency

Conventional grinding system

Mill charge optimization

What is function of mill?

Size reduction along the mill

Coarse material grinding

Fine material grinding

Piece weight (or knocking weight)

Average weight/piece of grinding

Average surface area of (ball)

Need small ball size

Need large ball size

Ball charge composition

Note : d = size of ball (cm)

Ball charge composition

Weight, W weight Piece weight, I no., n

Piece weight: 976 g/piece

Weight, W weight Piece weight, I no., n

Piece weight: 32 g/piece

Ball charge composition

For Pre-grinding system R/P + Conventional

Maximum steel ball size (Bond equation)

B : Maximum ball size (mm.)

Maximum steel ball size

Max Ball Size (mm.)

Feed Size (mm.), F80

** Typical fresh clinker : 5% residue 25 mm. or F80 = 13.4 mm.

Feed size = 5% res. 20 mm.

Find: required maximum ball size

Mill performance test

1. Recording of related operational data

Mill ventilation fan

2. Air flow measurement

Mill ventilation air

Mill ventilation air

Usual ranges of ventilation:

Agglomeration and ball coating

Mill ventilation check

Check Air ventilation speed in mill ?

3. Crash stop and visual inspection

Disconnect main circuit breaker (Safety !)

Preparation of sampling equipment

3. Crash stop and visual inspection

Liner and Diaphragm condition wear, block

Clean block slot

3. Crash stop and visual inspection

3. Crash stop and visual inspection

Ball charge quantity (Filling degree)

Degree of filling (%)

N ormal range 28-32%

4. Sampling inside mill (mill test)

0.5 1m 1m 1m 0.5 0.5 1m 1m 1m 1m

Material sampling point in mill

0.5 1m 1m 1m 0.5 0.5 1m 1m 1m 1m