1

CEMENT GRINDING PLANT

BLAINE FINENESS FACTOR
POLYSIUS Coefficient

49 , 0 *
1000
|
.
|

\
|

=
Blaine Reference Blaine Required
e K


Exemple



Mill output : 100 t/h

Fineness according to Blaine: 3000 cm/g



New fineness required: 3500 cm/g

K = exp ((3500-3000)/1000*0,49)

K= 1,278

Expected mill output = 78,3 t/h

CEMENT GRINDING PLANT


COMPOSITE CEMENT
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OPC (Ordinary Portland Cement)

Composition

96 % CLINKER
4 % GYPSUM
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CPC (Composite Portland Cement)

Type of additives:
Limestone, pouzzolane, trass, slag, fly ash, .

Properties:
increase of fineness and output, decrease of initial and final strength, increase of concrete plasticity and workability, colour
modification
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2

CEMENT GRINDING PLANT
Exemple of the additive influence on the mill output

Production of cement with 15 % of limestone

Composition
81 % CLINKER
4 % GYPSUM
15% LIMESTONE

Cement Mill
Output = 100 t/h of OPC (96 % Clinker 4% Gypsum)
Fineness = 3200 cm/g
CPC cement (81% Clinker 4% Gypsum 15% Limestone))
Fineness required 3200 cm/g according to blaine
Calculation of equivalent clinker fineness
We consider that the limestone gives 2 times more fineness.
X = equivalent clinker fineness
2.X = limestone fineness
3200 = (0,81+0,04) X + 0,15 2.X
X = 2783 cm/g
Limestone fineness = 5565 cm/g
CEMENT GRINDING PLANT
Expected cement mill output with 15% limestone
Fineness factor
K = exp ((3000-2783)/1000*0,49)
K=1,11
Expected mill output = 111 t/h at 3200 cm/g with 15% limestone

BALL MILL ABSORBED POWER

Absorbed power at mill shaft / Polysius Formula
P(kW) = G x C x Di x 0,736

P = Mill power absorbed (kW)
G = Ball charge weight (tons)
C = POLYSIUS C Factor (-)
Di = Internal mill diameter (m)
Lu = Effective grinding length (m)
F = Filling degree of ball charge (%) normal range : 24 32 %
d = Bulk density of grinding balls (t/m
3
) 4,5 4,6
Ball charge weight

G (tons)= ( x Di / 4) x Lu x F x d

Absorbed power at mill motor shaft

Pmotor(kW) = P(kW)/

= Drive efficiency
= Girth gear (0,98) x Combiflex (0,97) x motor coupling (0,99)
= 0,94

POLYSIUS C Factor
Depends on different parameters: ball charge, kind of material, type of process, type of mill

3


Cement mill / closed circuit
26 % C = 9,8 28 % C = 9,6
30% = C = 9,4 32% = C = 9,1
CEMENT GRINDING PLANT

HIGH EFFICIENCY SEPARATOR SEPOL

A












F

R

Separator efficiency

f r
a r
f
a

= .
1
1



a = % passing cumulated in fresh feed
f = % passing cumulated in finish product
r = % passing cumulated in separator rejects
CEMENT GRINDING PLANT

TROMP Curve


%
100



50



by pass

40

Aa = % passing between 2 sieves in the fresh feed
Ar = % passing between 2 sieves in the grits
Af = % passing between 2 sieves in the finish product


SEPOL

4

Sa = % passing sieve: 10 20 > 100
Sr = % passing sieve: 10 20 > 100
Sf = % passing sieve:: 10 20 > 100
100 *

=
Sr Sf
Sr Sa
Vf



100 *

=
Sr Sf
Sa Sf
Vg



100 *
. .
.
Vf f Vr r
Vr r
T
A + A
A
=


Tau = By pass %
This percentage represents the % of fines which has been considered by the Separator as rejects.
Normal range for a high efficiency separator SEPOL with OPC cement
: 5 15%

Separation cutting : diameter m
This point gives where is the limit of accuracy of the SEPOL for the cement produced.
Normal value for standard OPC: 10 20 m
Imperfection
Polysius formula
kapa = d30/d70
Lafarge formula
I = (d75 d25 ) / 2 (d50)