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Performance tests should be carried out

on the following occasions :


After start-up of a new mill
to verify the guarantee figures
Abnormal mill Operation
High operation or maintenance costs
Implementation of new processes and
techniques
Planned capacity increase

Complete Mill Performance Test


Comprises Basically The Following Work:
Determination of mill output and
power consumption
Sampling within grinding system
Sampling inside mill

Complete Mill Performance Test


Comprises Basically The Following Work:
Gas flow measurements
Recording of operational data
Visual inspection of equipment
Evaluation of test results
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Methods For Output Measurement :

Indications from weigh feeders or belt


scales
Table feeders
Silo Measurement
Energy Consumption
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Sampling Points Within Mill System :

Sampling quantities and analysis :


Sampling point
A/B Mill feed

Weight
10 kg each

Required sieve analysis


e.g. 30, 25, 16, 8, 4, 2, 1 mm

C Samples within mill See longitudinal sieving


D

Mill discharge

e.g. 30, 60, 90, 150, 200 m

Separator tailings

Blaine

Separator feed

e.g. 4, 8, 15, 20, 30, 60, 90,

Separator tailings

150, 200 m

Separator fines

Filter dust

0.5 kg

Blaine
e.g. 30, 60, 90, 150, 200 m

K Filter dust

Blaine

e.g. 4, 8, 15, 20, 30, 60, 90,

Final product

150, 200 m
Blaine

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Sampling Procedure :

Sampling Analysis :

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Temperature, Air Flow and Pressures :

Type of Air Measurement :

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Type of Air Measurement :

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Operational Data :
Mill
Separator
Static Separator
Mill Ventilation
Conveyors

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Visual Inspection Within Mill :

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The Results of Performance Test Provide


The Basic Information For required
changes or modifications:

Grinding Efficiency
Separator Efficiency
Cooling with respect to grinding
Efficiency
Weak Point Analysis
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Mill Optimization Procedure :

Abnormal Operation

Abnormal Operation

Check List abnormal Operation


INDICATION
Mill:

POSSIBLE REASON

ACTION

* )

- Sound dull

- Mill overfilled

- Lower feed rate

- Sound loud

- Mill underloaded

- Increase mill feed rate

- Clinker temp. too high

- Check clinker cooling

- Low mill/separator

- Adjust venting rate

Cement temperature:
- Too high

venting
- Lack of water injection

- Adjust flow rate


- Mechanical replacement
- Repair

- Cement cooler failure

Check List abnormal Operation


INDICATION

POSSIBLE REASON

ACTION

Mill Output:
- Too low

- Unsuitable ball charge

- Change ball charge

composition or badly worn

- Replace or clean

balls

diaphragm

- Diaphragm unsuitable or

- Replace liners

Clogged

Further investigations

- Unsuitable or worn liners

required

- Change of feed grindability

- Improve cooling/use

- Coating of balls

grinding aids

- Adjustment of separator

- Adjustment

- Operators error

- Instruction/training

Mill Exhaust Pressure:


- Too high

- Too low

- Inlet/outlet clogged

- Clean

- Diaphragm clogged

- Clean diaphragm

- Diaphragm broken

- Replace broken plate

- Major false air penetration

- Seal sources

Check List abnormal Operation

Control Elements
Control Element
Weigh feeder

Adjustment Of
Speed

Effect On
Feed rate (= mill output)
Proportions of components
Circulating load

Separator

Rotor speed,

Product fineness,

Dampers,

Granulometry,

Rotor blades,

Spec. surface,

Fan damper

Circulating load

Static separator

Position of vanes

Granulometry of filter dust

Water injection

Regulating valve

Mill discharge temp.,


Coating

Mill venting fan

Position of damper

Mill cooling,
Dust granulometry