Impact of free lime on grinding efficiency

If free lime in clinker is >2% or <0.8%, then how will it effect on grinding efficiency???

All other factors being equal, low free lime clinker (hard burned) is generally harder to grind than clinker with higher free lime. This is
due to physical changes in clinker mineralogy and porosity caused by over-burning rather than the presence of the free lime itself.

Hard burning causes the following mineralogical changes which have a detrimental effect on clinker grindability;-

1. An increase in both Alite and Belite crystal sizes.

2. An increase in clinker density associated with a reduction in clinker porosity. In particular, a reduction in the percentage of open
pores (ie microscopic pores that penetrate from the surface of a clinker nodule well into the interior.)

There are a couple of other secondary microstructural properties of clinker that are variously mentioned in the literature as having a
negative effect on clinker grindability;-

(a) An increase in the quantity of Belite and its distribution (ie an over-abundance of clusters, particularly large dense clusters
caused by coarse silica.)

(b) The presence of coarsely crystalline C3A, caused by very slow cooling.

(c) An increase in the quantity of fine clinker particles. (<5mm).

As clinker nodules form they are initially quite porous structures. However as more liquid phase infiltrates the nodule and CaO
dissolved in the liquid phase migrates toward areas of high silica. The creation of C2S and ultimately C3S (which both involve an
increase in volume) cause the pores to become smaller and fewer, making the nodules therefore denser and harder.

The harder the clinker is burned the denser the nodule becomes as liquid phase is drawn into the nodule by surface tension, filling
the open pores.

The presence of open clinker pores and micro cracks in the clinker mineral crystals greatly assists grinding. If pores and cracks are
absent, the clinker is harder to grind.

re cement blaine and media coating

You could check the following issues

1) Type of grinding aid being used/change in grinding aid

2) Shell lining profile( if has been worn out there would be less grinding impact hence low blaine and a smooth surface)

3) Not sufficient Grinding media charge( take a crash stop analysis to check the performance of the mill)

4) Clinker hardness( grindability would be difficult hence low blaine)

High temperatures promote coating (Coating is best prevented by keeping the mill cool by 1. mill ventilation 2.water injection
3. cooling the rejects. 240°F is generally considered to be a safe maximum mill discharge temperature of finish mill)

Coating will increase if the mill is ground out (When small material particles are reduced further in size, they have a tendency to
“stick” together again, or re-agglomerate)
Coating may be as result of too much moisture as well
Grinding aids combat coating, thus preventing the
re-agglomeration of material