Anh hưởng độ mịn xm

The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret
laws.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 2
22 March 2019 3
GRINDING PROCESS
CATARACTING ACTION
Crushing by Impact
Ball Mill 1st Compartment
Breaking of particles by
balls impact due to falling
22 March 2019 4
GRINDING PROCESS
CASCADING ACTION
Grinding by Attrition
Ball Mill 2nd Compartment
Efficient grinding by attrition
22 March 2019 5
GRINDING PROCESS
Rotation
Rotation
Release points
Re le ase Points
3
2
1 1 2 3
Lift
Lift Zo ne
Zone
Grinding
Grinding
Zone
Zone
1 - Cascading (tumbling)
1 - Cascading (tumbling) Liners digs into charge.
Liners digs into charge.
2 - Cataracting (free fall - max impact)
2 - Cataracting (free fall
3 - Excessive Lift - max.
(impact impact)
on liner) Some
Some slipslip occurs
occurs.
3 - Excessive Lift (impact on liner)
22 March 2019 6
GRINDING PROCESS
Energy transmitted by the Balls

 Mass  Ball sizes, Specific Weight
 Speed  Movement, Mill Speed, Filling, Liners
 Probability  Number, Size, Material Filling, Contact Type
Contact
 Cataract - Impact, Low Number of contacts
 Cascading - Friction, High Number of contacts
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BALL MILL COMPONENTS
Gas + dust
outlet
Intermediate diaphragm
Outlet diaphragm
Reject return Inlet head C2 liners Discharge box
chute C1 liners
Fresh feed
Outlet seal
Material discharge
Shell
Central or ventilation ring
Fresh air inlet
Central Ventilation ring grate
Supports
Trunnion
22 March 2019 9
2
5
4
7
6
8
1. Mill inlet
2. Mill shell w. welded on slide rings & gear flange
3. Slide shoe bearing
4. Stanex diaphragm with adjustable lifters
5. Outlet diaphragm with adjustable lifters
6. Lining of coarse grinding compartment
7. Lining of fine grinding compartment
8. Cast gear with guard
TYPICAL FLS BALL MILL
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MILL INLET
11
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DRIVE TYPES
CENTRAL DRIVE
SIDE DRIVE
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BEARINGS - TRUNNION
13
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BEARINGS – SLIDE SHOE
14
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LINER TYPES
2ND COMPARTMENT
1ST COMPARTMENT
CLASSIFYING /
STEP LINER
CORRUGATED LINER
Rotation
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CENTRAL DIAPHRAGM
1) Diaphragm Slots – 10 to 12 mm
2) Ventilation Ring
3) Scoops
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22 March 2019
HOW A PARTITION WALL WORKS
Feed End View of Partition without Grate Segments

Side View of a Partition
3. Material gravity drops through
the center hub and into the next Material is lifted by
compartment. mill rotation and is
then gravity dropped
into the next
compartment.
2. Material is lifted by Gas Flow
1 2
mill rotation.
BM Load Level
Material passes
through the slots
1. Material fills the chamber ,
and fills the lifter
in between the slotted plates
. blind plates chamber.
and
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22 March 2019
OUTLET GRATE
1) Outlet Grate Slots – 6 to 8 mm
2) Ventilation Ring
3) Water Spray Pipe
18
22 March 2019
STUFFING BOX ARRANGEMENT FOR
WATER SPRAY IN CENTRAL DRIVE
19
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GRINDING MEDIA
Coarse Balls Fine Balls
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TYPES OF CIRCUIT
OPEN CIRCUIT
 Little or no control of fineness
 Not adapted to high fineness
 Wide Possibility for over grinding
 Higher temperature of products
 Broad particles size distribution
 Higher specific power consumption of mill
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22 March 2019
TYPES OF CIRCUIT
CLOSED CIRCUIT
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22 March 2019
TYPES OF CIRCUIT
CLOSED CIRCUIT
 Better regularity because of a real control of the fineness

 High fineness is possible
 Higher flexibility and possibility of optimization by product
 Possibility of higher mill ventilation
 Better control of the temperature (cooling or drying is
possible in the separator)
 Higher output, better efficiency
 Narrow particle size distribution
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TYPES OF CIRCUIT
CLOSED CIRCUIT – 2 FAN SYSTEM
25
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TYPES OF CIRCUIT
CLOSED CIRCUIT – 3 FAN SYSTEM
26
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BALL MILL POWER CONSUMPTION
POWER DRAW FORMULA
N=CxFxnxμxD xa
N = Mill Power Draw (kW)
C = Mill Constant (0.514) = g x π / 60
g = Acceleration of gravity
F = Ball Charge (MT)
n = Mill Rotational Speed (rpm)
µ = Torque Factor
D = Mill Effective Diameter (m)
a = Arm of Gravity in relation to mill diameter
= Distance between center of the mill and center
gravity of charge The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 28
MILL SPEED
The operating speed of a mill may be expressed as a percentage of its critical
speed.
The critical speed nc is the speed, where the centrifugal force at the mill
lining is equal to the gravitational force.
Normal mill speeds are 70 – 80% of the critical speed.
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MOVEMENT OF GRINDING MEDIA
Two factors determine the

movement of the grinding
media:
• The specific charge of balls (q)
in percentage of the internal
volume of the mill.
• The mill speed measured in

revolutions expressed as
percentage of the critical speed.
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MILL CHARGE
The mill charge is defined as amount of grinding media in the mill compartment.
Where,
q = Percentage media filling
W = Bulk Density of media (Based on media shape, size and proportion)
V = Effective Volume of the compartment
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PERCENTAGE FILLING
The percentage filling is the percent volume occupied by media in the mill
compartment. It can be found from the mathematical cylindrical segment
concept.
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PERCENTAGE FILLING
or
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MEDIA BULK DENSITY & TORQUE FACTOR
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POWER CALCULATION - EXAMPLE
Compartment 1st 2nd
Gross Diameter, m 4.6 4.6
Gross Length, m 6.1 9.9
Liner Thickness, mm 95 42
Eff. Length, m 5.9 9.4
Mill RPM 15.33 15.33
Eff. Dia, m 4.4 4.5
Eff. Volume, m3 89.9 150.2
Free Height, m 3.02 3.03

h/D 0.185 0.171
% Filling 27.0 28.8 From Table

Arm of Gravity 0.630 0.613 From Table
Bulk Density, t/m3 4.3 4.5 From Table
Torque Factor 0.73 0.69 From Table
Charge, tons 104 195

Power, kw 1668 2929
Net Power, kw 4598
Critical Speed, RPM 19.72

% Critical Speed 77.73
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GRINDING MEDIA SIZE DISTRIBUTION
BALL CHARGE – COMPARTMENT 01
 Emphasis on crushing and less on grinding
 Typical top size:
 80 mm Ø if easy to crush, small feed size
 90 mm Ø is the most common
 100 mm Ø in rare cases; very hard, coarse feed
 Coarser ball charges, gives good crushing capability but:
 Too porous - shorter retention
 Less surface, less grinding
 Can result in poor preparation for second chamber if you overfeed
 Extra wear
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FEED SIZE Vs BALL SIZE
1000
B= Max Ball Size (mm)
100
90
15
10
1
0.1
0,5
1 10 15 100
F = FEED SIZE, X80 (mm) 3.0 *Wi

B  36 * F * 3
75 * 4
3.0  Specific Weight of Feed Material
75  Mill Speed as % of Critical Speed
D  Inside Mill Diameter (m)
Wi  Bond' s Work Index
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BALL CHARGE PROPORTION – COMPARTMENT 01
Typical Recommendation For Smaller Feed Size
40 %
40 % 25 %
20 %
30 %
15 %
20 %
10 %
Size Size
Ø 90 / 80 / 70 / 60 mm Ø 90 / 80 / 70 / 60 mm
Bond : Equal Number of Balls

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BALL CHARGE – COMPARTMENT 02
 Top size depends on how much preparation is done in the first chamber.
Recommendation : 30 ... 40 mm
 Smallest size depends on the discharge grate slot size
Practical rule of thumb; smallest Ø = 2 X slot width
E.g. slot width = 8-10 mm; smallest Ø = 16-20 mm
 Non-classifying liners limits compartment 02 to 3 sizes
 Classifying liners allow a large variety of sizes
 Best Practice “Ball Charge Optimization”
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22 March 2019
BALL CHARGE POROSITY
Coarse Balls - Large Voids Fine Balls - Small Voids

Low Retention High Retention
22 March 2019 41
MEDIA MANAGEMENT
Volume Load vs. Specific Power
25
Specific Grinding Energy
20
[kWh/t]
15
10
5
15 20 25 30 35
Volume load [%]
Best Practice “Ball Charge Level Management“

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22 March 2019
EQUILIBRIUM CHARGE
 An equilibrium charge is the distribution of media sizes that will be

realized when operating a ball mill for a long time.
 Compensation for wear by adding media of a specific size.
 Remove the media which are smaller than half the diameter of the largest
media size used for compensation.
 Equilibrium charges may be mixed to adjust the required piece weight and
surface area.
 Two or more media sizes are then used for compensation.
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EQUILIBRIUM CHARGE – COMPARTMENT 01
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EQUILIBRIUM CHARGE – COMPARTMENT 02
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MEDIA PATTERN
BALL SIZE – 1ST COMPARTMENT
90 mm 80 mm 70 mm 60 mm
23% 32% 21% 24%
Compensation 90 mm
Initial Piece Weight 1533 g
BALL SIZE – 2ND COMPARTMENT
Equilibrium Piece Weight 1295 g
Mill System 25 mm 20 mm 15 mm
Open 20% 40% 40%
Closed 40% 40% 20%
Mill System Open Closed
Compensation 20 & 25 mm 25 mm
Initial Piece Weight 23 g 30 g
Equilibrium Piece Weight 21 g 28 g
22 March 2019 46
BALL SAMPLING
The piece weight - determines the grinding by impact
The specific surface - determines the grinding by attrition.
Where,
d = Diameter of the ball
ρ = Specific Weight of ball = 7.8 g/cm3 (Normal Steel)
These parameters are determined on the basis of ball sampling
22 March 2019 47
BALL SAMPLING PROCEDURE
 Compartment 01 - min 200 Pieces
 Compartment 02 - min 50 kg
 Extract from under the centreline and dig as deeply as possible
 Sort out the broken media
 Separate in fractions as shown in the table
 Weigh each separated fractions
 Count the number of pieces in each fraction
 Difference between Initial charge weight and weight during ball
sampling gives the wear rate The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 48
BALL SAMPLING
Ball Charge, Compartment 1 compensated for wear with 90 mm balls
22 March 2019 49
BALL SAMPLING
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22 March 2019
KEY NUMBERS
Wear in g/kWh
Large Balls 2 to 5
Small Balls 1 to 3
Transport Capacity of material through grates

Approx. 5 t/(dm2.h)
Transport Capacity of material through mill body

20 to 30 t/h/m2
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MILL GRINDING PERFORMANCE
MATERIAL SAMPLING
 The mill grinding performance can be evaluated by material sampling over the
length of each compartment.
 Mill performance is evaluated based on analyzing the PSD of sampled material.
 Sampling shall be made near the beginning and end of each compartment.
 Compartment 01 – Sampling at equal distance with about 50 cm spacing.
 Compartment 02 – Sampling at equal distance with about 0.75 – 1 m spacing.
 Minimum of 4 to 5 locations per compartment.
 Using a sampling scoop dig deeply over a half diameter of the lifting side.
 In Compartment 02 use 10 mm sieve to facilitate material & ball classification.
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MATERIAL SAMPLING
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MATERIAL SAMPLING
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MATERIAL SAMPLING
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SAMPLE ANALYSIS
The residue of collected samples are to be analysed on the following sieves
10 mm
5 mm
2 mm
COMPARTMENT 01
1 mm
500 μm
200 μm
5 mm
2 mm
1 mm
COMPARTMENT 02 500 μm
200 μm
90 μm
45 μm
22 March 2019 57
NORMAL FINENESS
The normal fineness of grinding material in the mill
25 – 40% + 0.2 mm
At Partition in Two 8 – 16% + 0.5 mm
Compartment Mill 2.5 – 4% + 1.0 mm
Max 0.5% + 2.0 mm
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Proper evolution of the particle-size distribution of the material

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Compartment 01 – No more evolution between samples 4 & 5

Compartment 02 – No more evolution on the last 2 samples
Grinding charges in both compartments to be reviewed
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Compartment 01 – Curves are ascending at the end of the compartment. If the slots
are clean and of proper size, the solution is to upgrade the grinding media
Compartment 02 – Found OK
22 March 2019 61
OTHER FACTORS AFFECTING GRINDING PERFORMANCE
 Liners - Check the condition of the liners
 Scoops - Scoops at diaphragm and outlet grate can be adjusted
 Slots - Check for any blockage in slots and slot condition
 Water Spray - Fine atomized water spray is required
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SEPARATOR PERFORMANCE
SEPARATOR CONCEPTS
 No grinding function but increases the mills efficiency
 Optimizes the recuperation of fines
 Determines the maximum particle size of the finished product
 It decreases the retention time in the mill reducing coating and excessive
temperatures
 Air as a medium to separate coarse and fine particles
22 March 2019 64
SEPARATOR CONCEPTS
 [Qf /Qa] & [Qp /Qa] is an important parameter for all separators specifications
 Feed to Air Ratio is the ratio of separator feed (kg) to the total internal airflow
(m3) used.
Feed Load Normal Range : 2 – 2.5 kg/m³
 Product to Air Ratio is the ratio of separator product (kg) to the total internal
airflow (m3) used.
Product Load Normal Range : 0.85 kg/m³
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SEPARATOR CONCEPTS
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SEPARATOR CONCEPTS
22 March 2019 67
SEPARATOR CONCEPTS
 Bypass / Delta:
The minimum probability for the fines to be sent back to the mill
 Cut Size :
The limit beyond which the separator cannot see a difference between
particle size
 Kappa :
It varies like the inverse of the slope, the lower the kappa, the better the
separation
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SEPARATOR EFFICIENCY
 Operating in closed circuit with a separator results in specific power reduction.
 The size of reduction results on the separator efficiency, fineness level and CF
The Separator efficiency Vs is calculated according to the expression:
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22 March 2019
FIRST GENERATION SEPARATORS
Bypass : 30 – 60 %
Efficiency : 25 – 40 %
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SECOND GENERATION SEPARATORS
Feed
Bypass : 15 – 30 % Exhaust
Fresh air
Fines
Rejects
22 March 2019 71
THIRD GENERATION SEPARATORS
Fines
Material Feed
Secondary
Air
Bypass : 5 – 15 %
Primary
Air
Rejects
22 March 2019 72
FLS O-SEPA Feed Classification Zone
Feed
Cage rotation
Primary
Air Uniform
Inlet Flow distribution
Loovers guide vanes
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Resulting Change of Variable
Change of Parameter By pass Fines Fineness

Output
ROTOR SPEED
AIR FLOW
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TROMP CURVE
 Tromp Curve is used to evaluate the separator performance
 Describes the % of the feed material of any grain size in the return material
 Construction of Tromp Curve requires particle size distribution of material
going and leaving the separator
T D  
Amount _ of _ size _ D _ in _ returns
* 100
Amount _ of _ size _ D _ in _ separator _ feed
 D  
Amount _ of _ size _ D _ in _ fines
* 100
Amount _ of _ size _ D _ in _ separator _ feed
T ( D)  ( D)  100
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TROMP CURVE
Where,
C - Circulation Factor
△Rg - % of return material in the fraction in the interval representing
the particle size
△Rm - % of material leaving the mill in the interval representing the
particle size
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TROMP CURVE
Cut size (X50(μ)) - Grain size where 50% (by weight)

go to the coarse material
Typical values:
OPC (~300 Blaine) - cut-size 35 - 50 μm
RC (~400 Blaine) - cut-size 20 -30 μm
SRC (~500 Blaine) - cut-size 15 - 25 μm
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22 March 2019
TROMP CURVE
Sharpness (kappa) - Measure of the tromp curve

steepness, and is calculated as the
ratio between a grain size where
25% go to the coarse material and
a grain size where 75% go to the
coarse material
Typical values - 0.5 - 0.6
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22 March 2019
TROMP CURVE
Feed split (delta) - Measure of how much fines end up

(By-pass) in the coarse material, and is read
off as the curve minimum (lowest
point on curve)
Typical values - 5 - 15%
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22 March 2019
TROMP CURVE
Agglomeration - The “tail”, which tromp curves

typically have at the fine end, is an
expression of aggregation.
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TROMP CURVE
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PLOTTING TROMP CURVE
1) Collect sieve residue data for separator feed, reject and product.
2) Calculate the circulation factor for each fraction
3) Find the average circulation factor (C)
4) Recalculate the mill product residue for each fraction using the average
circulation factor value (RM, corr)
5) Calculate the separator efficiency (Vs) for each sieve
6) Calculate the average particle size (dm) of each fraction
7) Calculate Tromp Value (T)

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Ro R  C  1* Rg
log  C * log o
Rf R f  C  1* Rg
Vs 
Ro  C  1*100
*100
Ro
log  C * log
Rf R f  C  1*100
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22 March 2019
Sieve (d) Residues C RM, corr Vs Sieve(dm) Tromp
µm RF, % RM, % RG, % - % % μm %
2 88,9 92,0 95,4 1,93 91,88 19,4
4 79,1 85,1 91,4 1,96 84,75 23,2 3 25,97
8 69,0 78,3 88,2 1,94 77,86 32,2 6 21,52
12 57,5 70,9 85,9 1,89 70,63 45,1 10 14,71
18 46,8 64,2 84,3 1,86 64,18 55,3 15 11,13
21 41,7 60,9 83,7 1,85 61,12 59,6 19,5 9,85
25 35,6 57,1 82,9 1,83 57,50 64,3 23 9,58
30 28,9 52,7 81,9 1,82 53,45 68,6 27,5 11,54
36 22,1 48,0 80,2 1,80 49,00 71,8 33 17,90
45 15,8 42,9 77,0 1,80 44,12 73,3 40,5 29,88
63 5,9 31,7 64,0 1,80 32,78 71,8 54 53,40
90 1,1 21,2 44,6 1,86 21,26 69,9 76,5 77,72
C-average 1,86
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22 March 2019
Delta 9.58
Cut-size 52.1
Kappa 0.51
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OPTIMISATION OF MILL OPERATION
WHAT IS THE TARGET?

Lower Specific Power Consumption
HOW TO KNOW THE TARGET?
Fix target using
Grindability
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GRINDABILITY
Grindability shall be found from
 Laboratory testing in a standard test center
 Best operating data from the past
Target production from grindability
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GRINDABILITY - EXAMPLE
Assume,
Grindability of a OPC feed component = 28 kWh/t @ 3000 Blaine @ Shaft
Maximum available mill power** = 4598 kWh @ shaft
Maximum production can be achieved = 4598 ÷ 28 = 164 TPH
 Mill can give best specific power consumption @ 164 TPH OPC with 3000 Blaine.
 However the above production is the minimum to be achieved, higher the
production more the savings in power consumption.
** Maximum available power can be arrived from the mill power calculation using
optimum media charging.
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FACTORS INFLUENCING GRINDABILITY
The following are the factors influencing grindability,
Feed Size & Granulometry
Feed Components proportion
Feed Chemistry
Product Fineness
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22 March 2019
OPTIMISATION TO ACHIEVE THE TARGET
The optimisation to be done in the following areas,
 Ball Mill
 Separator
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22 March 2019
BALL MILL OPTIMISATION
The following are the areas in Ball Mill for optimisation,
 Fresh Feed
 Mill Performance
 Mill Ventilation
Separator Rejects
Fresh Feed
Ventilation
Flow Rate
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Fresh Feed
• Constant Feed Rate
• Low Moisture additives
• HAG in case of high moisture
• Less variation in feed chemistry
• Constant size and Granulometry
• Avoid frequent change in feed recipe
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Mill Performance
• Media Management by chamber sampling
• Good liners
• Proper slots in diaphragm
• Scoop adjustment based material distribution
• Fine atomised water spray
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Conventional Material Effect of the Material

Transport Flow Control
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Right level Overfilled compartment Empty compartment
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Mill Ventilation
• Insure the removal of fines
• Insuring heat removal
• Helps for material movement
• Normal gas velocity across the mill is 1.0 – 1.5 m/s
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22 March 2019
SEPARATOR OPTIMISATION
The following are the areas in Ball Mill for optimisation,
 Optimum Separator Seals (Horizontal & Vertical)
 Maintain Constant Air Flow Ventilation
 Separator Ventilation - flow rate
- temperature
Sep. fines
Constant 1
Mill throughput
Air circuit 2 Sep. rejects

constant
Speed of rotation
- fineness actuator
Fresh feed
Mill ventilation
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22 March 2019
KEY OPERATING PARAMETERS
The key operating parameters are

 Mill Feed - Constant Feed Rate
 Sound Level of Compartment 01 - Optimum Sound Level
 Diaphragm temperature - 105 deg C
 Mill outlet temperature - 110 deg C
 Separator Reject - Constant Reject
 Separator Air Flow - 2 – 2.5 kg/m3
 Separator Speed - Based on Product Fineness
 Final Product temperature - 85 – 95 deg C
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22 March 2019
MILL START-UP
Start the circuit on the following sequence

 Transport Group
 Separator Reject Air Slide
 Separator Lubrication and Drive
 Separator Ventilation
 Mill Ventilation
 Mill Lubrication and Drive
 Mill Feed Group
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22 March 2019
IRREGULARITIES ON MILL OPERATION
INDICATION REASON
Unsuitable ball charge composition
Badly worn balls
Mill output too low Diaphragm unsuitable or clogged
Unsuitable worn liners
Change in material grindability
Mill overfilled
Mill output too coarse Separator clogged
Feed size too large
Feed rate too low
Mill output too fine Feed size too small
Separator not adjusted
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22 March 2019
INDICATION REASON
Feed rate too high
Mill sound dull
Diaphragm clogged
Feed rate too low
Mill sound high
Inlet clogged
Mill inlet clogged
Diaphragm blocked
Inlet pressure low
Too low air draught through mill
Too much false air at mill outlet
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22 March 2019
INDICATION REASON
False air at mill outlet
Outlet pressure low Too little material in mill
Diaphragm broken
Mill inlet clogged
Outlet pressure high Diaphragm clogged
Too high feed rate
Material too wet
Outlet temperature low
Hot gas amount too low
Material temperature too high
Venting air flow too low
Outlet temperature high
Mill overfilled
Ball coating
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22 March 2019
INDICATION REASON
Mill feed high
Change in grindability
Separator Reject High
Poor mill performance
Low air flow
Mill Outlet above the limit
Product Temp High Less fresh air to separator
Problem in water flow
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22 March 2019
INSTRUMENTATION AND INTERLOCKING
CONTROL LOOPS
1) Mill Feed Vs Mill Sound Level
 Mill Sound decreases then mill feed will reduce
2) Diaphragm Temperature Vs Mill Inlet Water Spray
 Diaphragm temp increase above 105 deg C inlet water pump will ON
3) Mill Outlet Temperature Vs Mill outlet Water Spray
 Mill outlet temp increase above 110 deg C outlet water pump will ON
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22 March 2019
CONTROL LOOPS
4) Mill Inlet Draft Vs Mill Vent Fan
 Mill inlet pressure decreases then mill vent fan speed will increase
5) Separator Fan Outlet Pressure Vs Separator Vent Fan
 Separator fan outlet draft decreases then mill vent fan speed will increase
6) Mill Fan Power Vs Mill Fan Speed
 Mill fan power decreases then mill fan speed will increase
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CONTROL LOOPS
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22 March 2019
INTERLOCKS
Group Starting Interlock Start Sequence Operating Interlock
Lubrication Heating Oil Level Healthy Heating Elements Oil Level

Oil Level
Oil Level
Gear Lubrication Gear Lub Pump Oil Temperature
Oil Temperature
Oulet Pressure
Conditioning Pump Oil Level
Oil Level
Bearing Lubrication Low Pressure Pump Oil Temperature
Oil Temperature
High Pressure Pump Pressure > Max 2 / < Min2
Oil Level Gear Lubrication Oil Level
Separator Lubrication
Oil Temperature Bearing Lubrication Oil Temperature
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22 March 2019
INTERLOCKS
Group Starting Interlock Start Sequence Operating Interlock
Separator Reject Air Slide

Silo Level < max 2
Product Transport to silo Silo Level > Max 2
Silo Dedusting ON
Transport Dust transport from filter Downstream Equipment
Comp Air Pressure Healthy
Auto Sampler
Separator No Alarms Separator Drive Separator Bearing Temperature
Separator Separator Drive

Sep Vent Bag Filter Level < max 2 Fan Bearing Temp
Separator Vent Fan
Separator Vent Fan Inlet Dampers Closed Fan Vibration
Separator Fan
Fresh Air Damper Open Motor Bearing & Winding Temp
Recirculation Damper Open Separator / Filter Outlet Temp. > Max 2
Material Separator Drive

Separator Group Mill outlet to Separator
Separator Fan
Circulation Separator Vent Group transport equipments
Downstream Equipment
Fan Inlet damper close Mill Vent Fan
Mill Vent Group Dust transport to separator OFF
Dust transport to separator ON Mill Vent Bag Filter
Mill Lubrication Mill Lubrication & Gear Vibration
Mill Main Drive Mill Inlet Pressure > min 1 Mill Main Drive Bearing Temperature
Downstream Groups ON Mill Outlet temperature
Mill Feed All Groups On Mill Feed weigh Feeders All downstream groups
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22 March 2019
INTERLOCKS
Equipment Min 2 Min 1 Max 1 Max 2
Mill Sound Level 90% 80%
Mill Diaphragm temperature 105 deg C 110 deg C
Mill Outlet Temperature 110 deg C 125 deg C
Mill Inlet Pressure - 0.5 mbar
Mill Gear Vibration 3 mm/s 4 mm/s
Final Product Temperature 85 deg C 100 deg C
Separator Fan Outlet Pressure 0 2 mbar
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22 March 2019
112
22 March 2019

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Efficient grinding by attrition

3 - Excessive Lift (impact on liner)

Energy transmitted by the Balls

Feed End View of Partition without Grate Segments

1) Outlet Grate Slots – 6 to 8 mm

3) Water Spray Pipe

Coarse Balls Fine Balls

 Little or no control of fineness

 Not adapted to high fineness

 Wide Possibility for over grinding

 Higher temperature of products

 Broad particles size distribution

 Higher specific power consumption of mill

 Better regularity because of a real control of the fineness

Normal mill speeds are 70 – 80% of the critical speed.

Two factors determine the

• The mill speed measured in

Free Height, m 3.02 3.03

% Filling 27.0 28.8 From Table

Charge, tons 104 195

Critical Speed, RPM 19.72

F = FEED SIZE, X80 (mm) 3.0 *Wi

Typical Recommendation For Smaller Feed Size

Bond : Equal Number of Balls

Coarse Balls - Large Voids Fine Balls - Small Voids

Best Practice “Ball Charge Level Management“

 An equilibrium charge is the distribution of media sizes that will be

The piece weight - determines the grinding by impact

The specific surface - determines the grinding by attrition.

Ball Charge, Compartment 1 compensated for wear with 90 mm balls

Transport Capacity of material through grates

Transport Capacity of material through mill body

The residue of collected samples are to be analysed on the following sieves

The normal fineness of grinding material in the mill

Proper evolution of the particle-size distribution of the material

Compartment 01 – No more evolution between samples 4 & 5

 Liners - Check the condition of the liners

 Scoops - Scoops at diaphragm and outlet grate can be adjusted

 Slots - Check for any blockage in slots and slot condition

 Water Spray - Fine atomized water spray is required

 No grinding function but increases the mills efficiency

 Optimizes the recuperation of fines

 Determines the maximum particle size of the finished product

 Air as a medium to separate coarse and fine particles

Feed Load Normal Range : 2 – 2.5 kg/m³

airflow (m3) used.

Product Load Normal Range : 0.85 kg/m³

The Separator efficiency Vs is calculated according to the expression:

FLS O-SEPA Feed Classification Zone

Loovers guide vanes

Resulting Change of Variable

Change of Parameter By pass Fines Fineness

 Tromp Curve is used to evaluate the separator performance

 Construction of Tromp Curve requires particle size distribution of material

going and leaving the separator

Cut size (X50(μ)) - Grain size where 50% (by weight)

Sharpness (kappa) - Measure of the tromp curve

Feed split (delta) - Measure of how much fines end up

Typical values - 5 - 15%

Agglomeration - The “tail”, which tromp curves

2) Calculate the circulation factor for each fraction

3) Find the average circulation factor (C)

5) Calculate the separator efficiency (Vs) for each sieve