Mill calculation

D..
Plant : Prachovice Date : 02.10.2008
Mill : CM1 Visa : AWE

M..
Mill Dimensions
Diameter D 4.40 m ● Drying compartment
Length L 15.00 m No drying compartment
Motor power inst. P 4,500 kW
L/D - Ratio l 3.4 - ● One compartment
Two compartments
Compartment lengths L1 100 %
Three compartments
(Mill chambers) L2 %
L3 %
Data Drying compartment 1.Comp.
Internal diameter Di 4.21 m
Internal length Li 4.67 m
Filling degree f 26.0 %
Spec. grinding media weight r 4.40 t/m3
Mill speed n 15.3 min -1

Reducer efficiency eta_g 0.960 -

Drive electr. efficiency (up to counter) eta 0.950 -
Abs. power at counter (measured) P 3150 kW
Production G 80.0 t/h
Fineness product 3,420 cm²/g Blaine
% R45 µm
Relative mill speed % n crit 74.2 %
Volume drying compartment V tr .0 m3
Factor c 0.239 - - -
Grinding media weight Q 74.4 - - t
Abs. power at mill shell Pm 2,874 - - kW
Spec. energy consumption at mill shell E sp_mill 35.9 - - kWh/t
Grinding media weight total Q tot 74.4 t
Abs. power at motor shaft P mot 2994 kW Friction factor 2.52 -
Abs. power at counter (calculated) P 3150 kW
Spec. energy consumption at counter E sp 39.4 kWh/t
Energy utilization w 24.1 cm²/J
Filling Degree Calculations 1.Comp. 2.Comp. 3.Comp.
Mill Internal diameter Di 4.21 0.00 0.00 m
Free Height h 3.15 m
In / Outlet Diameter d 1.63 m
Filling Degree Present f pres. 19.7 0.0 0.0 %
Maximum f max. 26.0 0.0 0.0 %
H/D - Ratio 0.75 0.00 0.00 -
Free Height max. 2.92 m

Holcim Group Support Ltd / MPT

 equidist

B_1 50.8 first equilibrium-distribution (acc. to FLS grinding manual)

s_1 10 wear exponent is 2 calculated values for perfect equilibrium distribution :
20.07 [m2/t] spec. surface worn down from B_1 to S_1
166.41 [g] av. piece wt. at equilibrium (worn down to s_1)
av. wt. [g] 175

sums 1 175.0667 100

analyt. aus Wi*Ni (refined->
size x' Ni Ni [%] Wi Wi * Ni m [%] calculated values:
50.8 Col. H Col. I
50.8 44.45 0.15563725 15.56 535.4074 83.32934 41.44 47.60 47.19 19.94 19.84 [m2/t] spec. surface
38.1 34.95 0.23284314 23.28 225.875 52.59344 36.27 30.04 30.08 182.28 175.07 [g] av. piece wt.
31.8 28.6 0.15563725 15.56 131.3332 20.44034 12.38 11.68 11.64
25.4 23.8 0.11764706 11.76 66.92592 7.873638 5.24 4.50 4.48
22.2 20.625 0.07781863 7.78 44.68401 3.477248 2.10 1.99 1.97
19.05 10 0.26041667 26.04 28.23437 7.352702 2.57 4.20 4.64
10 0 0.00 0 0 0.00 0.00 0.00
10 0 0.00 0 0 0.00 0.00 0.00
10 0 0.00 0 0 0.00 0.00 0.00
10 0 0.00 0 0 0.00 0.00 0.00

B_2 25.4 second equilibrium-distribution (acc. to FLS grinding manual)

s_2 10 wear exponent is 2 calculated values for perfect equilibrium distribution :
38.85 [m2/t] spec. surface worn down from B_2 to S_2
26.93 [g] av. piece wt. at equilibrium (worn down to s_2)
av. wt. [g] 36

sums 1 35.64568
analyt. aus Wi*Ni (für Erstfüllung)
size x' Ni Ni [%] Wi Wi * Ni m [%] calculated values:
25.4 Col. H Col. I
25.4 23.8 0.1038961 10.39 66.92592 6.953343 23.48 19.51 36.04 36.93 [m2/t] spec. surface
22.2 20.625 0.20616883 20.62 44.68401 9.21245 34.44 25.84 38.28 35.65 [g] av. piece wt.
19.05 10 0.68993506 68.99 28.23437 19.47988 42.08 54.65
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00

B_3 19.05 third equilibrium-distribution (acc. to FLS grinding manual)

s_3 10 wear exponent is 2 calculated values for perfect equilibrium distribution :
49.84 [m2/t] spec. surface worn down from B_1 to S_1
13.73 [g] av. piece wt. at equilibrium (worn down to s_1)
av. wt. [g] 28.23

sums 1 28.23437
analyt. aus Wi*Ni (für Erstfüllung)
size x' Ni Ni [%] Wi Wi * Ni m [%] calculated values:
19.05 Col. H Col. I
19.05 10 1 100.00 28.23437 28.23437 100.00 100.00 40.38 40.38 [m2/t] spec. surface
10 0 0.00 0 0 0.00 0.00 28.23 28.23 [g] av. piece wt.
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00
10 0 0.00 0 0 0.00 0.00

combined: calculated values for perfect equilibrium distribution :

35.71 [m2/t] spec. surface worn down from B_1 to S_1
analytical 2 31.31 [g] av. piece wt. at equilibrium (worn down to s_1)
Exponent 2 2 for FLS Ni*Wi
Ni*Wi
< 3 required Ni*Wi refined 1 4 6
3 FLS distributions combined s 50.8 25.4 19.05 constraint Bestimmtheitsmass B (=SQF/SQM)
percentage 10 0.16686 0.83314 0 1.000001 SSQ 0.956346 SQF
sizes index1 index2 index3 mass1 mass2 mass3 sum 127.7848 soll [%] 1329.717
3104319
50.8 1 #N/A #N/A 47.60 0.00 0.00 7.94 7.50 34.08 [m2/t] spec. surface 55690.36993 76.1144
38.1 2 #N/A #N/A 30.04 0.00 0.00 5.01 6.00 41.11 [g] av. piece wt. 196935.4656 135.8126
31.8 3 #N/A #N/A 11.68 0.00 0.00 1.95 6.00 2079740.913 216.6328
25.4 4 1 #N/A 4.50 19.51 0.00 17.00 7.50 558885.1629 0.1127
22.2 5 2 #N/A 1.99 25.84 0.00 21.86 26.30 202917.2235 27.00724
19.05 6 3 1 4.20 54.65 100.00 46.23 46.70 10149.49141 874.0369
7 4 2 0.00 0.00 0.00 0.00
7 4 2 0.00 0.00 0.00 0.00
7 4 2 0.00 0.00 0.00 0.00

100.00 100.00 100.00 100.00 100.00

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 KHD

B_1 50 first equilibrium-distribution (KHD)

s_1 15 calculated values for perfect KHD equilibrium distribution :
21.58 [m2/t] spec. surface worn down from B_1 to S_1
137.52 [g] av. piece wt. at equilibrium (worn down to s_1)
av. wt. [g] 143

sums 1 142.9619 100 100

analyt. aus Wi*Ni (für Erstfüllung)
size x' Ni Ni [%] Wi Wi * Ni m [%] calculated values:
50 Col. H Col. I
50 45 0.08751071 8.75 510.51 44.67 27.85 31.25 21.48 21.36 [m2/t] spec. surface
40 35 0.20873763 20.87 261.38 54.56 39.67 38.16 144.12 142.96 [g] av. piece wt.
30 27.5 0.20030524 20.03 110.27 22.09 18.15 15.45
25 22.5 0.16667378 16.67 63.81 10.64 7.73 7.44
20 15 0.33677265 33.68 32.67 11.00 6.59 7.70
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00

B_2 30 second equilibrium-distribution (KHD)

s_2 15 calculated values for perfect KHD equilibrium distribution :
32.97 [m2/t] spec. surface worn down from B_2 to S_2
46.40 [g] av. piece wt. at equilibrium (worn down to s_2)
av. wt. [g] 51

sums 1 51.42896 100 100

analyt. aus Wi*Ni (für Erstfüllung)
size x' Ni Ni [%] Wi Wi * Ni m [%] calculated values:
30 Col. H Col. I
30 27.5 0.12553088 12.55 110.27 13.84 26.26 26.92 32.03 32.25 [m2/t] spec. surface
25 22.5 0.28950662 28.95 63.81 18.47 39.81 35.92 52.62 51.43 [g] av. piece wt.
20 15 0.5849625 58.50 32.67 19.11 33.93 37.16
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00

B_3 25 third equilibrium-distribution (KHD)

s_3 15 calculated values for perfect KHD equilibrium distribution :
37.68 [m2/t] spec. surface worn down from B_1 to S_1
32.65 [g] av. piece wt. at equilibrium (worn down to s_1)
av. wt. [g] 39.10

sums 1 39.09557 100 100

analyt. aus Wi*Ni (für Erstfüllung)
size x' Ni Ni [%] Wi Wi * Ni m [%] calculated values:
25 Col. H Col. I
25 22.5 0.20625535 20.63 63.81 13.16 34.57 33.67 35.80 35.87 [m2/t] spec. surface
20 15 0.79374465 79.37 32.67 25.93 65.43 66.33 39.30 39.10 [g] av. piece wt.
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00
15 0 0.00 0.00 0.00 0.00 0.00

combined: calculated values for perfect equilibrium distribution :

30.01 [m2/t] spec. surface worn down from B_1 to S_1
analytisch 2 56.06 [g] av. piece wt. at equilibrium (worn down to s_1)
ausNi*Wi
aus Ni*Wi

3 KHD distributions combined s 50 30 25 constraint Bestimmtheitsmass B (=SQF/SQM)

percentage 15 0.26 0.74 0 1 SSQ 0.997302 SQF
sizes index1 index2 index3 mass1 mass2 mass3 sum 0.51062 soll [%] 420.8614
1.252343 calculated values for charge in column H :
50 1 #N/A #N/A 31.25 0.00 0.00 8.12 8.00 29.42 [m2/t] spec. surface 0.124892 141.0182
40 2 #N/A #N/A 38.16 0.00 0.00 9.92 10.00 61.70 [g] av. piece wt. 0.077363 101.5532
30 3 1 #N/A 15.45 26.92 0.00 23.93 24.00 0.065645 15.47915
25 4 2 1 7.44 35.92 33.67 28.52 29.00 0.483163 72.53651
20 5 3 2 7.70 37.16 66.33 29.50 29.00 0.501279 90.2743
6 4 3 0.00 0.00 0.00 0.00 0
6 4 3 0.00 0.00 0.00 0.00 0
6 4 3 0.00 0.00 0.00 0.00 0
6 4 3 0.00 0.00 0.00 0.00 0

100.00 100.00 100.00 100.00 100.00

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