PROJECT

INTRODUCTION OF COOLING SYSTEM IN CEMENT GRINDING UNITS

TO KEEP CEMENT TEMPERATURE BELOW 115℃.

SUBMITTED BY

MUHAMMAD MUNEEB WAHEED

SOHAIB AHMED

SHAHRYAR MANZOOR

UMAR SHAKOOR

SHAHEER AKMAL

CHERAT CEMENT COMPANY, NOWSHERA

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 SUMMARY
This report covers the problems caused by high temperature in cement mills and the possible
solutions to control the temperature to prevent gypsum dehydration. Water spray in the cement
mill is the widely used process to control cement temperature. The amount of water to be
sprayed per hour is calculated based on the heat balance calculations which comes to be around
2100 lit/hr. Water spray system is designed to control the cement mill temperature by spraying
water at the inlet and outlet of the cement mill. The system designed works on the temperature
feedback from two temperature sensors, one sensor is installed at the mill discharge which
senses the temperature of cement flowing over it and second sensor senses the temperature at
the diaphragm of the mill. The system works completely on automatic control and the volume
of water being sprayed inside the mill can be continuously varied according to temperature
requirements.

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 TABLE OF CONTENTS

1 INTRODUCTION ............................................................................................................. 7
1.1 Temperature Problem in Cement Grinding ................................................................. 7
1.2 Methods for Cooling Cement ...................................................................................... 7
1.3 Water Injection System ............................................................................................... 7
1.3.1 General Description ............................................................................................. 8
1.3.2 Explanation .......................................................................................................... 9
1.3.3 Compressed Air ................................................................................................. 10
1.4 Mill Ventilation ......................................................................................................... 10
1.5 Water Cooling of the Mill Shell ................................................................................ 10
1.6 After Cooling of the Cement ..................................................................................... 10
1.6.1 Specifications ..................................................................................................... 11
1.7 Cement Cooling in Mechanical Air .......................................................................... 12
1.8 Cooling in Fuller’s Cement Cooler ........................................................................... 12
1.8.1 Construction ....................................................................................................... 12
1.9 Stoppages Caused by High Temperature in Cement Mill ......................................... 14
1.10 Faults in already installed Spray System ............................................................... 14
1.11 Damages Caused by Choking due to water spray ................................................. 16
2 LITERATURE REVIEW ................................................................................................ 17
3 HEAT BALANCE OF CEMENT MILL ......................................................................... 18
3.1 Introduction ............................................................................................................... 18
3.2 Principle .................................................................................................................... 18
3.3 The three basic parameters ........................................................................................ 18
3.3.1 Temperature of the product at mill outlet .......................................................... 18
3.3.2 Ventilation of the mill ........................................................................................ 19
3.3.3 Cooling of the mill ............................................................................................. 19
3.4 Problem of coating .................................................................................................... 19
3.5 Dedusting of the mill ................................................................................................. 19
3.6 Water to inject ........................................................................................................... 19
3.7 Heat Balance Calculation .......................................................................................... 20
3.7.1 Hypothesis.......................................................................................................... 20
3.7.2 Equations of the heat balance ............................................................................ 20
3.7.3 Shell area calculation ......................................................................................... 21

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 3.7.4 Production data .................................................................................................. 21
3.7.5 Water contents ................................................................................................... 22
3.8 Heat Calculation ........................................................................................................ 22
3.8.1 Heat in: ............................................................................................................... 22
3.8.2 Heat Out: ............................................................................................................ 22
3.8.3 Water Flow Rate Required................................................................................. 23
3.9 Solution ..................................................................................................................... 23
4 WATER SPRAY SYSTEM DESIGN ............................................................................. 24
4.1 Water Spray System Circuit Diagram ....................................................................... 24
4.1.1 General ............................................................................................................... 24
4.1.2 Combinations: .................................................................................................... 24
4.2 Structure: ................................................................................................................... 25
4.2.1 Water Tank: ....................................................................................................... 26
4.2.2 Outlet End: ......................................................................................................... 26
4.2.3 Inlet End: ............................................................................................................ 27
4.3 Operating Principle: .................................................................................................. 30
4.4 Starting and Operation .............................................................................................. 31
4.4.1 Explanation: ....................................................................................................... 31
4.4.2 Water Pump WPLO for Lubricating Water to Stuffing Box ............................. 31
4.4.3 Solenoid Valve SOAO for Cleaning Air ........................................................... 31
4.4.4 Mill Motor.......................................................................................................... 32
4.4.5 Operation............................................................................................................ 32
4.5 List of Equipment ...................................................................................................... 32
5 DESIGN OF NOZZLE .................................................................................................... 34
5.1 Theoretical Back Ground of Nozzle.......................................................................... 34
5.1.1 Liquid Spray as Process ..................................................................................... 34
5.2 Spray nozzles............................................................................................................. 35
5.2.1 Techniques for Spray Production....................................................................... 35
5.3 Types of nozzles depending upon shape of Jet ......................................................... 36
5.3.1 Standard full cone (turbulence nozzle) .............................................................. 36
5.3.2 Spiral full cone (deflection nozzle) .................................................................... 36
5.3.3 Multiple full cone (turbulence nozzle, air atomizer) ......................................... 37
5.4 Design procedure for Nozzle..................................................................................... 37
5.4.1 Effect Of different parameters on Nozzle Performance .................................... 43
5.4.2 Effect of Variation in Inlet Slot Angle β ............................................................ 43

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 5.4.3 Effect of Variation in Trumpet Angle θt............................................................ 44
5.4.4 Effect of Variation in Spin Chamber Convergence Angle θc............................ 45
5.5 Flow Patterns in Ansys .............................................................................................. 46
6 CONCLUSION ................................................................................................................ 47
7 REFERENCES ................................................................................................................ 48

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 LIST OF FIGURES
Figure 1-1 Methods of spraying water in tube mill ................................................................... 8
Figure 1-2 Temperature variations............................................................................................. 8
Figure 1-3 Water Spraying system ............................................................................................ 9
Figure 1-4 Cement cooler schematic diagram ......................................................................... 11
Figure 1-5 Flow diagram for mechanical air cooler ................................................................ 12
Figure 1-6 Fuller cement cooler flow diagram ........................................................................ 13
Figure 1-7 Damage to the conveyor belt.................................................................................. 15
Figure 1-8 Condition of the present water spray system ......................................................... 15
Figure 1-9 Damage to the rollers of belt conveyor .................................................................. 15
Figure 4-1 Temperature variations by spraying system ........................................................... 25
Figure 5-1 Dimensional thickness and discharge coefficient with inlet slots angle ................ 44
Figure 5-2 Dimensional thickness and discharge coefficient with Trumpet angle .................. 44
Figure 5-3 Dimensional thickness and discharge coefficient with Spin chamber convergence
angle ......................................................................................................................................... 45
Figure 5-4 Start of flow............................................................................................................ 46
Figure 5-5 Developing of flow ................................................................................................ 46
Figure 5-6 Start of swirl in nozzle ........................................................................................... 46
Figure 5-7 fully Developed flow.............................................................................................. 46
Figure 5-8 Spray Pattern .......................................................................................................... 46

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 1 INTRODUCTION
1.1 Temperature Problem in Cement Grinding
Ball mill generally produces a lot of heat, as the material advances in the mill, the temperature
increases. If the temperature increases beyond 110℃ different problems are encountered, they
are,

1. Fall of fluidity of the material.

2. Production of superfine particles.
3. Coating of the balls and linings.
4. Blockage of slots of the outlet diaphragm.
5. De-hydration of gypsum.
6. False and Flash set of cement.
7. Cement storage problem in silo.
8. Block formation in silo.

By these above mentioned problems the mill grinding efficiency, production decreases and
additional cost of maintenance and stoppage of mill.

1.2 Methods for Cooling Cement

Following are some possible solutions for controlling high temperature in cement mills.

1. Water injection into the mill

2. Mill ventilation
3. Water cooling of the shell
4. After cooling of the cement
5. Cement cooling in Mechanical air
6. Cooling in Fuller’s cement cooler

1.3 Water Injection System

To solve these problems the mill is ventilated properly and if heat generation is high the water
injection is done to maintain the temperature inside the mill.

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 Figure 1-1 Methods of spraying water in tube mill

Water injection is done in the mill 3 ways, as shown in the figure below

The quantity of water injection per hour is calculated from the heat balance of the system.
Normally the water is injected in first chamber where the temperature of the clinker is on higher
side i.e. above 100℃.

Figure 1-2 Temperature variations

1.3.1 General Description
The water is to be pumped from a supply tank via pipelines to the tube mill. The water is mixed
with compressed air and then sprayed into the mill under high pressure via an atomizer nozzle
while it will be injected into the mill in gas-flow direction. Inside the mill, the grinding heat
causes that the injected water evaporates directly. The change of the aggregation state and so
the originating vapor volume causes a high reduction of the grinding heat and thereby prevents
an agglomerate formation of the grinding material. Thus beside the heat reduction, an increase

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of the grinding capacity is achieved. The resulting mixture of air and water escapes from the
mill and is discharged via dust filter. It is important for this procedure, that the proportioned
quantity of water and compressed air pressure are optimally adapted to the process and that the
pressure parameters of the atomizing firing nozzle are kept over a large operating range. The
injected water must evaporate immediately, since otherwise incrustation can be caused at the
nozzle due to drop formation as well as gluing of grinding media and lining plates. This would
lead to the impairment of the grinding capacity.

1.3.2 Explanation
The water injection comprises of two main groups: the internal and external zones.

1.3.2.1 External Zone

The external area consists of a water tank mounted on frame with all appropriate components.
The water tank is filled with normal tap water. By means of a pump unit, the required water
quantity is taken from the tank, supplied with pressure and conveyed into the piping system. If
a too large quantity of water reaches the piping, it will be led back to the tank via a discharge
valve. In addition, the pressure and flow rate are measured.

Figure 1-3 Water Spraying system

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1.3.3 Compressed Air
The compressed air lines are supplied via the locally existing compressed air ductwork system.
The air pressure is controlled by manometers and regulated by manometer switches. A solenoid
valve will release the compressed air for its way to the mill. The position of the check valve
after the solenoid valve prevents the intrusion of water into the compressed air branch. Water
and air are now merged. Through this, the water is additionally supplied with pressure and is
conveyed from the outside area to the mill. This is the interface between internal and external
zone. The connection to the rotating mill is effected by a rotary transmission feedthrough. The
pipelines are fed into the mill inlet where they are branched out in the grinding chamber 1 and
2 of the tube mill. A filling jet nozzle is mounted at the end of each pipe line that effects the
requested injection.

1.4 Mill Ventilation

Normally about 0.2 m3 (min of air per mill KW is drawn through a single compartment mill,
compared to 0.12-0.4 m3/min per mill KW in a multi compartment mill.

For effective cooling of multi compartment such as 2 compartment tube mills, an air exchange
rate of 300 m3/ton of cement/ hour.

1.5 Water Cooling of the Mill Shell

If mill ventilation is not sufficient to lower the grinding temperature, cooling of the mill shell
can be done. For this a water sprinkle system can be installed along the longitudinal axis of the
tube mill for spraying water on the mill shell. This kind of mill cooling lowers the temperature
of the mill discharge by 30-40℃.

1.6 After Cooling of the Cement

The above methods can control the cement temperature to just above 100℃ according to heat
balance calculations. As it is known by experience, storage of cement and packing into the
paper bags, require a reduction of the cement temperature down to 65℃.

Due to its high specific heat, a significant drop in temperature can be achieved only by the
application of an appropriate cooling method.

During conveying from the mill to the cement silo, the temperature of the cement is lowered
only by 5-10℃ and cooling process in cement silo lasts several weeks. When packing hot
cement 80-100℃ the fiber deteriorates, and the bags often tear apart. When storing hot cement

10
in silos, lumps are often formed as a result from the reaction between the clinker minerals and
the water dehydration of the gypsum.

During companies such as FLSmidth provide cement cooler to reduce the cement temperature
from 110℃ to 65℃ when applying cooling water of 15℃.

Figure 1-4 Cement cooler schematic diagram

The hot material is feed from the bottom of the cooling tank, and picked up by internal rotating
spirals flights. By the combination of the vertical movement with the centrifugal force acting
upon the material, the cement forms a thin, upward moving layer, pressed against the inside of
the tank shell.

The heat is transferred through the tank shell carried off by the cooling water, distributed evenly
over the circumference of the shell, and cascading continuously as a thin film downwards, to
be collected in a trough below the tank, and discharged.

This cooler can be inserted into existing installations.

1.6.1 Specifications
This cooler is manufactured for the capacities up to 100 t/hr, for this cooler the consumption
of water is 65m3/hr and the power input is around 90kw.

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1.7 Cement Cooling in Mechanical Air
In this process the cement cooling is attainable at the low power consumption. For this kind of
cooling the end product and circulating loads are cooled simultaneously, thus avoiding heating
to the dehydration temperature of the gypsum.

The cooling air amounts from 0.20 to 0.30 kg/kg of cement depending upon the temperature of
the cooling air and the circulating load. The thermodynamic conditions and the amount of
cooling must be determined by a separate heat balance for each grinding mill.

The figure below shows the flow chart of a finish mill working in closed circuit with an air
cooled mechanical air separator.

Figure 1-5 Flow diagram for mechanical air cooler

1.8 Cooling in Fuller’s Cement Cooler

The figure below shows a cement grinding circuit where cooling of the circulating load is
performed in a special cement cooler which the manufacturer calls Fluidized Material cooler.

1.8.1 Construction
This cement cooler is basically a circular tank containing cooling tubes. The tubes are
connected to form a circuit. The number of tubes and circuits vary with the diameter of the
cooler. Water enters each circuit from a supply header and exits to a discharge header that may
either be connected to a sewer or recycled through a cooling tower. At the bottom of the tank

12
below tubes is a sloping bottom equipped with a porous medium. The fluidization material
cooler reduces the temperature of the material throughout the grinding circuit to approximately
80℃ and thus minimize the possibility of gypsum dehydration.

Figure 1-6 Fuller cement cooler flow diagram

At the same time the finished cement temperature is between 50℃ to 65℃ depending upon the
cooler size, capacity and temperature of the cooling water.

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1.9 Stoppages Caused by High Temperature in Cement Mill

In cement mill most of the stoppages were recorded for the year 2017-2018, the detail of
which is given below:
Stoppages of Cement Mill Due to High Temperature

2017-2018
STOPPAGES

Sr. No. Stoppage duration Hrs.

1 5.75
2 2.50
3 10.75
4 3.17
5 3.75
6 12.16
7 3.67
8 4.25
9 8.17
10 3.00
11 2.42
12 2.25
13 3.25

Total Hours = 65 Hrs.

Average Feed = 235 Tons/hr.
Total lost Tonnage = 65*235= 15,275 Tons

1.10 Faults in already installed Spray System

The already installed system to control the temperature of the clinker is the water spray directly
on the common belt from clinker silo to dosing silo. Direct contact of water with belt results in
the wear of belt as well as roller installed. In addition this system is not efficient because the
volume of the sprayed water cannot be controlled, spray is not in the form of fine mist as in

14
cement mill and it can also cause wet clogging in the dosing silos. FA81 Power consumption
increases due to low density of air.

The condition of the belt and the idler rollers is shown in the below pictures.

Figure 1-7 Damage to the conveyor belt

Figure 1-8 Condition of the present water spray system

Figure 1-9 Damage to the rollers of belt conveyor

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1.11 Damages Caused by Choking due to water spray for year 2017-2019
Sr.No Equipment Qty replaced Time Span Price
1 Buckets BE41 99 1 year 2,000,000
Bag filters
2 360 10 months 194,400
BF33
Bag filters
3 180 6 months 97,200
BF46
4 Rollers of BC38 15 8 months 90,000
BC 38 belt
5 1 11 months 570,000
conveyor
Endless Belt
Clinker
6 1 15 days 150,000
weighfeeder
416 WF 26
Endless Belt
Clinker
7 1 5 months 150,000
weighfeeder
416 WF 26
BC 27 belt
8 1 1 year 522,000
conveyor
TOTAL DAMAGE PRICE 3,773,600

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 2 LITERATURE REVIEW

During the process of finish grinding of clinker, lot of heat is generated inside the cement mill.
The heat generated in excess has to be dissipated so that the mill discharge temperature is kept
at desired level (90℃-110℃) to prevent the deterioration of the quality of cement. The increase
in temperature beyond 120 ͦ C leads to dehydration of gypsum which changes the property of
setting time of cement. The decrease in temperature below 80 ͦ C leads to wet clogging of the
gypsum and the cement strength is affected. Internal water cooling in a cement mill serves to
maintain the mill outlet temperature constant at present values. Cement mill water spray system
consists of complete set of pumps, valves, spray nozzle and all relevant accessories, assembles
as one unit making it user friendly and easy to install.

Water cooling in cement mill is accomplished by injecting and evaporating water at outlet/inlet
end of the mill. The water vapor is removed from the mill together with the ventilation air,
which must be so ample that the temperature does not drop below the dew point anywhere in
the pipes and dedusting filters after the mill. The system ensure the precise control of
temperature in both the chambers of the cement mill by regulating the volume of injecting
water through motorized control valves. The design of the injection nozzles and the compressed
air used for the atomization gives a very good turn down ratio in the entire range of the water
flow regulation. When the water injection is disconnected, compressed air purging keeps the
injection nozzles clean. The system may be interfaced and operated through the existing
PLC/DCS or may be provided with standalone control panel. [3]

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 3 HEAT BALANCE OF CEMENT MILL

3.1 Introduction
It is well known that the biggest part of the energy introduced in a ball mill is converted into
heat. Only around 5% of this energy is used to grind the material at the required fineness. As a
consequence, this heat can induce very high temperatures inside the cement mill. These
temperatures can affect the grinding process if they reach a certain limit. Therefore, it is
important to make the heat balance of the installation in order to solve possible problems. [8]

3.2 Principle
For all heat balances, there must be equilibrium between what goes in and what goes out of the
system. Of course, it is also the case for the cement mill heat balance.

This principle is illustrated below:

HEAT IN SYSTEM HEAT

OUT

3.3 The three basic parameters

Regardless to the characteristics and production data of the installation that we have to know,
the heat balance turns principally around 3 values:

3.3.1 Temperature of the product at mill outlet

It is generally accepted that beyond 105‐110 degrees centigrade, adverse reactions to the
grinding process can take place. This can also affect the quality of the cement. These reactions
are:

 Trouble of gypsum dehydration which may cause cement "false set".

 Particles agglomeration due to electrostatic charges which causes coating phenomenon
on balls and linings.

The exact temperature which must not be exceeded varies from case to another. It depends of
the kind of circuit, the material properties, the ambient temperature, the required fineness, the
separator efficiency, the ball charge...etc. We consider that 105°C is a good reference.

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3.3.2 Ventilation of the mill
The Ventilation has 3 objectives:

 To insure the cooling of the mill and the material

 To dedust the mill
 To remove the fine particles from the mill

3.3.3 Cooling of the mill

A good cooling of the mill and the material inside the mill is necessary to maintain a proper
working temperature. The temperature of reference is the one of the material at the mill outlet.

3.4 Problem of coating

The coating is an agglomeration of material on the lining and/or grinding media. It is due to
the superficial cohesion forces and the forces generated by the static electricity. Coating is an
agent of efficiency loss which can be very important (up to 30%) because coating is disturbing
the segregation of the ball charge in case of classifying lining. Coating is also reducing the
attrition efficiency of the small balls which are not more in contact with the material.

3.5 Dedusting of the mill

This function seems to be evident if we want to avoid the accumulation of dust in the whole
system.

3.6 Water to inject

Water is the solution in order to keep the right temperature inside the cement mill. Generally,
water is injected in the second chamber from the outlet diaphragm (in case of two
compartments ball mill). In some cases, it is also required to inject water in the first chamber
when the temperature of the feed (clinker) is very high (higher than 120°C).

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3.7 Heat Balance Calculation

3.7.1 Hypothesis
These hypotheses are based on the standard values and with some approximation. These
values are used for further calculations.

Hypothesis

1 Efficiency of the energy 0.85

2 Specific heat of the cement Kcal/kg °C 0.19
3 Specific heat of the water Kcal/kg °C 0.44
4 Specific heat of air Kcal/kg °C 0.31
5 Dissipation Shell Kcal/m2 760
6 Vapor/kg H20 @ 100⁰C Kcal 537
7 1KWh = 3600 KJ 860
8 Volume % loading inside Mill 32

3.7.2 Equations of the heat balance

Solutions of all these equations are in: kcal
Heat In:

Heat Out:

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3.7.3 Shell area calculation
The following data for ball mill is taken from the Drawings:

Data of Ball Mill

Mill Dia 4.2
Inside mill Dia 4
Total length of Shell 12.5
Useful length of 1st chamber 3.4
Useful length of 2nd chamber 9
Ball charge in chamber 1 54
Ball charge in chamber 2 150
Speed of rotation 16
Absorbed Power 3679.674028
Shell Area Calculation 192.5448
Volume % loading 32.2
Units
Length m

The formula shown below is used to calculate the shell surface area

Total Surface Area of Ball Mill = 192.5448 m2

3.7.4 Production data

Production Data
Output 240 TPH
Circulating Factor 2.2
Temperature of Ambient Air 35OC
% False air after mill 0.05
Temperature of water 25 OC

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 3.7.5 Water contents
Components %total %H2O Temperature ⁰C
Clinker 90 150
Gypsum 5 2
Limestone 5 2
Total 100 4

3.8 Heat Calculation

3.8.1 Heat in:
Heat In Units
Energy = M 2668674.639 Kcal
Material = F 24282000 Kcal
Air = A Cp air *Ta*(V-1.25*Ww) Kcal/lit/hr
Water = W Tw*Ww
Ww is the weight of water vapor that is unknown

3.8.2 Heat Out:

Heat Out
Shell Dissipation = S 146334.048
Product = C 26334000
Air = Aₒ (C.P. air *(Tc-3)*(V -1.25*Ww))
Water = Wv (537+(TC-5)+(C.P. water*(TC-3-100)))*Ww
Natural convection Co efficient
4.1 W/m2*K
Forced Convection Co efficient 9.205774 W/m2*K
Convection Loss 60974.82 kcal
Radiation heat loss 33404.42 kcal

Tc Temperature of the material at the mill discharge in ⁰C 105

V Volume of the dry air in Nm3/hr 18393.2
WW Weight Of Water Vapors
`

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3.8.3 Water Flow Rate Required

With Ww as unknown data

Now from putting value in the above equation we can calculate the only unknown which is
our required mass flow rate.

weight of water required 3263 L/hr

Already present water content 1200 L/hr
water required for spray 2063 L/hr

3.9 Solution
We found that we need 3263 L/hr of water. As we already have 1200 L/hr of moisture in the
fresh feed, we need to inject 2063 L/hr in the second chamber of the mill.

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 4 WATER SPRAY SYSTEM DESIGN
4.1 Water Spray System Circuit Diagram
4.1.1 General
Internal water cooling in cement mill serves to maintain the operating temperatures constant at
the present values. This is on the account of cement properties and mill operation.

A cement temperature in excess of 125℃ may cause dry clogging in the mill and dehydration
of the crystal water of the gypsum, which involves the risk of false setting and poor storage
resistance. Conversely, if the cement temperature falls below approx. 110℃, there is a risk of
wet clogging in the mill beginning hydration and consequently reduction of cement strength.

Water cooling in cement mill is accomplished by injecting and evaporating water. Either at the
both ends of the mill or solely at the outlet end of the mill. The water vapor is removed from
the mill together with the ventilation air which must be so ample that the temperature does not
fall below the dew point temperature anywhere in the pipes, bag filters etc.

Figure below shows the temperature variation by spraying water in the cement mill.

4.1.2 Combinations:
Curve a: Cold clinker - no water cooling.

Curve b: Cold clinker - water cooling at outlet.

Curve c: Hot clinker - water cooling at outlet.

Curve d: Hot clinker - water cooling in inlet and outlet.

24
 Figure 4-1 Temperature variations by spraying system

4.2 Structure:
The equipment described is used for mills of central drive. The equipment is either used for
water injection at the mill outlet or at the both ends of the mill.

Water injection takes place without the use of compressed air for atomization. The required
spreading of water inside the mill is accomplished by means of water pressure and shape of the
nozzle.

Compressed air must however be used to keep the nozzles clean when there is no water
injection. The equipment at either mill end consist mainly of identical components. At the
outlet end the equipment has been supplemented by a water lubricated stuffing box with
lubricating water pump to match. [3]

25
4.2.1 Water Tank:
The water tank WT for the two types holds approx. 500 and 800 liters of water respectively.
The water is fed through float valve FO. The water supply can be stopped with stop valve SVS
and the tank, which is provided with the overflow, can be emptied through stop valve SVD.

4.2.2 Outlet End:

The cooling water to the outlet end of the mill is pumped from tank WT by means of WPMO
through motorized valve MRWO to a stuffing box around the torsion shaft between the mill
and the gear unit. From here, the water is forced through a nozzle which is positioned in the
center axis of the outlet end of the last mill compartment.

The cooling water is sprayed upstream the ventilation air, and the nozzle shape is such that the
water is partly given the rotary motion and consequently spread in the mill when leaving the
nozzle.

Between pump WPWO and the motorized regulating valve MRWO there is return flow to
water tank through pressure control valve PRWO. Same maintain the constant pressure ahead
of regulating valve and hence favorable regulating characteristics.

When there is no water injection in the mill, the nozzle is kept clean by the compressed air
which is blown through the nozzle. Injection of compressed is started and stopped by solenoid
valve SOAO. The air pressure in the nozzle is regulated by reduction valve RVAO. On account
of the seals of the stuffing box there is a pressure stat PMH in the pneumatic pipe giving alarm
and interlocking at too high air pressure. At the outlet end there is also a separate lubricating
pump WPLO for the lubrication of the seals of the stuffing box when there is no water spray
in the mill.

In the pipes for water injection and compressed air respectively, non-return valves CVWO and
CVAO ensure that water and air, respectively are not forced back into the system when the
equipment changes between water injection and air injection. The non-return valves CVLO in
pipe for lubricating water fulfill the same function.

Start and stop of water injection and the volume of injected water is controlled by material
temperature TO3 in the mill discharge casing where the material flows over the temperature
sensor.

26
If temperature controller or motorized control valve is out of operation water injection can be
controlled manually by means of manual regulation valve HRWO, but this should be avoided
by extent possible.

4.2.3 Inlet End:

The water injection equipment at the inlet end is designed in the same manner as the equipment
at the outlet end, with the following exceptions:

 The nozzle, which does not rotate with the mill, is designed so as the water is partly
given a rotary movement, and hence is spread as a cone-shaped spout after the nozzle,
and partly sprayed down into the mill charge in the ascending side of the mill at an
angle of 60 degree to the vertical.
 Operating temperature TO1 is recorded directly in the diaphragm of the mill. From here
the signal is transferred to the temperature controller by means of wireless transmission
system, INDUTHERM.
 There is no stuffing box with matching equipment for lubrication of seals or monitoring
of air pressure. [3]

27
28
29
4.3 Operating Principle:
Cooling is based on injection and evaporation of so much water that the required temperatures
of the mill diaphragm and the outlet are kept constant. Water injection takes place at the outlet
and or inlet end when the measured temperature is higher than the set minimum value in the
matching controller. However, water injection cannot start before the temperature has reached
a reference value which is set in the controller.

The injected water volume depends on the deviation between measured temperature and
reference temperature.

Deviation entails up or down regulation of the motorized regulation valve. If the measured
temperature above the set maximum value an alarm is tripped.

If the measured temperature drops below the set minimum value the water pump stops and
solenoid valve opens, thus starting air injection through the nozzle.

On account of the regulating characteristics for motorized regulating valve, the pressure ahead
of the same is kept relatively constant by the pressure control valve, irrespective of the opening
degree of the motorized valve.

As long as there is no water injection, compressed air is blown through the nozzle to keep it
clean. Compressed air is blown through the nozzle during the start and when mill temperature
is so low during operation that cooling is unnecessary. Irrespective of the temperature during a
stopping situation, there is always compressed air injection through the nozzle for one hour
after mill stoppage.

30
4.4 Starting and Operation
4.4.1 Explanation:
1. Motor for Pump WPMO for outlet starts when:
2. Mill motor runs.
3. And when temperature TO3 is higher than the set point.
4. And when water valve is more than 10% open.

During operation with water spraying, the pumps stops when operating temperature TO3
becomes lower than the minimum temperature set in the controller.

Motor for water spraying to the inlet starts and stops with the outlet but with the diaphragm
temperature as the reference temperature.

The water injection pump must be stopped in all other conditions.

4.4.2 Water Pump WPLO for Lubricating Water to Stuffing Box

Motor for the lubricating water pump WPLO starts when the water level in the floater chamber
of the stuffing box is below minimum value. The pump would operate for 3 minutes and would
stop when the water level is above minimum.

If water level is still below minimum after three minutes the pump will continue to run for
additional 2 minutes and if still water level is below minimum then alarm will trip and mill
motor will be stopped.

The alarm indicates that either the stuffing box is too leaky or the level switch in the floater
chamber of the stuffing box is defective and water is injected into the mill.

During operation with the water injection, the water level in the packing bush will be sufficient
for the lubrication of the seals.

4.4.3 Solenoid Valve SOAO for Cleaning Air

Coil in the solenoid valve SOAO opens and compressed air is injected in:

1. Mill motor operates.

2. Pump motor is stopped i.e. during operation without water injection.

31
4.4.4 Mill Motor
Mill motor cannot start if:

1. Level switch in the stuffing box indicates too low level in the floating chamber of the
stuffing box.
2. Air pressure exceeds 1.2 bar set on the PMH.

During operation the mill stops if:

1. The water level in the stuffing box is below minimum level for more than 3 minutes or
if the air pressure in the stuffing box becomes higher than 1.2 bar.

4.4.5 Operation
The water injection system should always run with controller in Automatic Mode, which
ensures the safest mill operation.

When injection starts or stops, minor changes may occur in the material volume in the mill,
particularly at the outlet end. This is recorded by changes in the Folaphone signal, load or under
pressure.

Manual regulation of water injection should be avoided, because excessive regulations may
cause unsteady mill operation, obstructions in diaphragm or outlet and irregular product
quality. [3]

4.5 List of Equipment

GST Total
Sr.No Equipment Description Quantity Price Remarks
17% Cost
KSB WKL 2500 l/hr
1 02 Local
32/6 Pump 100 mHead
500,000 85,000 585,000
5 KW, 3000
2 Drive Motor 02 Local
rpm
KSB WKL 2500 l/hr
3 32/2 10 mHead 01 Local
Pump 300,000 51,000 351,000
3 KW, 1500
Drive Motor 01 Local
rpm
4 Stop Valves DN40 7 15,000 2,550 17,550 Local
Pressure DN32
5 2 6,950 1181 8,131 Local
relief valve
Motorized DN32
6 2 15,000 2,550 17,550 Local
Valve
7 Globe Valve DN32 2 3,400 578 3,978 Local

32
 Solenoid DN25
8 2 4,500 765 5,265 Local
Valve
Regulating DN25
9 2 4,000 680 4,680 Local
Valve
Non return DN25
10 4 2,200 374 2,574 Local
Valve
Non return DN32
11 6 3,100 527 3,627 Local
Valve
DN32
Pressure
12 Pipeline 3 1,500 255 1,755 Local
Gauges
mounted
DN25
Pressure
13 Pipeline 2 1,500 255 1,755 Local
Gauge
mounted
1 wireless,
Temperature
14 1 pipeline 2 2,400 408 2,808 Local
sensor
mounted
Stainless DN 32, S40
15 20 33,600 5,712 39,312 Local
Steel Pipe STD
Stainless DN 25, S40
16 20 28,000 4,760 32,760 Local
Steel Pipe STD
90 degree DN32,DN25
17 50 1,625 277 1,900 Local
elbow
45 degree DN32,DN25
18 50 1,350 230 1,580 Local
elbow
19 Water Tank 800 liters 1 - - - Local
Stuffing box
for water
20 spray system - 1 - - - Import
in cement
mill

TOTAL COST 924,125 157,101 1,081,226

33
 5 DESIGN OF NOZZLE

5.1 Theoretical Back Ground of Nozzle

5.1.1 Liquid Spray as Process
The process of spraying a liquid can be described as composed of two phases, namely:

1. Breaking up the liquid into separated drops.

2. Directing the liquid drops onto a surface or an object, to achieve the desired result.

The above two phases are normally performed, by the types of nozzles being used in industrial
processes, at the same time by means of different techniques which shall be illustrated in the
following.

The continuous progress in the manufacturing techniques in recent years has requested the
nozzle manufacturer to make available to the industry an always more complete range of spray
nozzle types to perform the different processes in a more efficient way. It is the interest of the
engineer using spray nozzles in manufacturing processes to become familiar with the different
types of nozzles which are available today and with their individual characteristics, in order to
be able to choose the nozzle which performs with the highest possible efficiency on a given
application.

Spraying a liquid through a spray nozzle can serve different purposes, among which the most
important are the following:

1. Cooling, by means of heat transfer between the product itself and the liquid running on
its surface.
2. Washing, where the water directed onto the product takes away dirt or undesired
substances from the product surface.
3. Humidifying, with sprays carrying very little liquid quantities to the product surface,
into a chamber or into a room.
4. Metering the desired liquid quantity in a unit of time into the product being handled.
5. Applying a product on a surface, as in the case of spray painting or surface pre-treatment
before painting.
6. Increasing the liquid surface to speed up heat transfer processes or chemical reactions
and many others in numerous applications throughout modern industry.

34
It is self-evident that the best results for every application are only obtained when the right
choices in terms of nozzle type, flow value, spray angle, drop dimensions and nozzle material
are made.

5.2 Spray nozzles

A spray nozzle is a device which makes use of the pressure energy of a liquid to increase its
speed through an orifice and break it into drops. Its performances can be identified and
described precisely, so that the design engineer can specify exactly the spray nozzle required
for a given process.

The relevant characteristics which identify the performances of a nozzle are the following:

1. The liquid flow delivered as a function of the nozzle feed pressure.

2. The opening angle of the produced spray.
3. The nozzle efficiency, as the ratio between the energy of the spray and the energy used
by the nozzle.
4. The evenness of the flow distribution over the target.
5. The droplet size distribution of the spray.
6. The jet impact of the spray.

5.2.1 Techniques for Spray Production

Many different techniques can be used to produce a spray, and most of them are used today for
nozzles to be applied in industrial processes. Based on the different techniques, the following
nozzle types can be used in industrial applications to generate a liquid spray.

5.2.1.1 Pressure nozzles

This is the simplest type of nozzles, where an orifice is opened into a chamber where the liquid
to be sprayed is fed under pressure. A spray is produced through the orifice with spray pattern,
flow rate and spray angle depending upon the orifice edge profile and the design of the inside
pressure chamber.

5.2.1.2 Turbulence nozzles

In these nozzles the liquid moving towards the chamber preceding the orifice is given a
rotational speed component, so as to open up in a conical shape as soon as it leaves the orifice
edge because of centrifugal force. Based on the nozzle design and the technique used to
generate the rotational speed, the drops produced can be confined to the cone outer surface

35
(hollow cone spray) or be evenly distributed to fill the entire volume of the cone (full cone
spray).

5.2.1.3 Impact nozzles

Here the desired spray shape is obtained producing an impact of the liquid jet onto a properly
designed surface. The liquid jet is subsequently changed into a fluid lamina and then broken
into drops with the desired spray pattern after leaving the nozzle edge.

5.2.1.4 Air assisted atomizers

Fine and very fine sprays can be obtained by means of air assisted atomizers, working upon
various different principles.

5.3 Types of nozzles depending upon shape of Jet

5.3.1 Standard full cone (turbulence nozzle)
These nozzles use a specially shaped vane placed at the nozzle inlet, to give a rotational speed
to the fluid flowing through the nozzle.

Because of the rotational speed of the fluid, water exiting the nozzle orifice is subjected to
centrifugal force and opens up in the shape of a full cone. The extent of the angle of the cone
is a function of both exit speed (created from the inlet pressure) and the internal design of the
nozzle. It can vary in practice from 15° to 120°.

These nozzles can be also produced as square full cone nozzles, where the square shape of the
pyramidal spray is obtained by a special design of the outlet orifice. Two important details have
to be noted from the system designer when using these types of nozzles:

• The spray angle is measured on the side of the square section

• The square section of the spray rotates within the distance from the nozzle orifice to the
target area.

5.3.2 Spiral full cone (deflection nozzle)

This is not properly a full cone, but rather a continuous liquid curtain evolving with the shape
of a spiral inside a conical volume. The disadvantage of a scarcely even distribution is
compensated by an exceptionally good resistance to plugging, which makes this nozzle the best
choice in those applications where safety or system reliability are the prime concern, e.g.
firefighting systems.

36
5.3.3 Multiple full cone (turbulence nozzle, air atomizer)
This spray pattern is used in two cases, that is:

• When a wide spray angle is to be reached with nozzles which inherently can only
produce a narrow one, or in such cases where small size droplets and rather high capacities are
required. Therefore, several nozzles are grouped in a cluster with different spray directions: the
resulting spray pattern occurs from the additional group of single nozzle sprays and the droplet
size of the spray remains the same as one of single nozzle. It must be noted that a smaller nozzle
will normally make smaller drops as compared to a larger size nozzle of the same type operating
under the same conditions.

• When it is necessary to obtain a wide-angle jet using nozzles which inherently deliver
a limited angle spray. In the case of a wide-angle air atomizer, for example, the droplet
distribution is obviously not homogeneous and the result is rather a number of small angle
sprays with different directions, but still the liquid is atomized towards all the parts of the
volume to be treated.

5.4 Design procedure for Nozzle

Design procedure for nozzle starts with identifying Degrees of freedoms available and
constraints we have to meet. According to our project we had already identified the constraints
to be met and by using those constraints as baseline we designed the spray nozzle for our
system. Degree of freedoms are those variable which are in our control and we can select the
desirable value to get optimized The theoretical model, whose exactitude seems to be
confirmed by scientific research, considers that the liquid flowing through the nozzle and past
the orifice edge evolves into a liquid lamina. This lamina, because of instability induced by
aerodynamic forces, breaks up first into elongated ligaments more or less cylindrical, and later
into droplets.

Taking the above process as a guideline, one can easily appreciate that the average droplet
diameter is somewhat related to several factors, like:

• The thickness of the lamina itself

• The evenness of the lamina

• A steady flow and break up process

37
For what has been said above, and limited to hydraulic nozzles, the system designer looking
for fine droplet sprays should consider that the following results can be expected

 Impact nozzles best

 Centrifugal hollow cone nozzles,
 Multiple full cone nozzles good
 Turbulence nozzles fair
 Centrifugal Vaneless full cones worst

The above choice is obviously based on the droplet generation process, which changes from
one nozzle type to another and allows to forecast which type is best from the application. An
additional consideration of interest is that the expected droplet size changes, for the same type
of nozzle, with the nozzle size: it is possible to generate smaller drops spraying the same water
quantity at the same pressure using a greater number of smaller nozzles.

Design whereas constraints are the constants which we cannot change and depends on the
accuracy of heat balance and the overall system configuration.

Below table shows the constraints and Degrees of freedoms for our system.

Degree Of freedoms Constraints

Dia of the nozzle orifice −𝑑𝑜 Pressure (bar)
Length of orifice chamber−𝑙𝑜 Flow rate (Q)
Length of swirl chamber−𝑙𝑠 Cone angle (θ)
Dia of swirl chamber−𝑑𝑠 Drop size (D)
Distance of inlet tube from the center−𝑟𝑖
Width of inlet tube -w
Height of inlet tube -h
Number of inlet tubes -N

38
To start with design procedure, we begin with the analysis of Bernoulli’s equation. The
assumption embedded is that the fluid is inviscid.

1 2 1 2
∆𝑃 = 𝜌𝑢 + 𝜌𝜔 + 𝑝
2 2

Supply Axial Swirl Static

Pressure Velocity Velocity Pressure

To calculate swirl velocity at exit we need to know swirl velocity at inlet. Which is given by
the formula below.

𝜔𝑟 = 𝜔𝑖 𝑟𝑖

Where as

𝜔𝑖 = Inlet swirl velocity

𝑟𝑖 = Distance of inlet tube from the distance

𝜔𝑖 Can be obtained from the below equation.

𝑄𝑠𝑖𝑛𝛽
𝜔𝑖 =
𝐴𝑝

39
Where as 𝐴𝑝 is the total area of inlet tubes combined.

Next step is to apply Bernoulli’s equation between two points inside the nozzle. As far as
Bernoulli’s equation is concerned it is only applicable to a streamline but if the streamlines
originate from the same tank at the same pressure Bernoulli’s equation can be applicable
between the streamlines. So, applying Bernoulli’s equation between two streamlines inside
nozzle, one point is taken inside orifice diameter and the other one at the liquid air interface.
We get

1 1
∆𝑃 = 𝜌𝑢𝑡𝑎 2 + 𝜌𝜔𝑡𝑎 2
2 2

Axial velocity at Swirl velocity at

air liquid interface air liquid core

Whereas

𝑄
𝑢𝑜𝑎 = (𝐴 −𝐴 𝐴𝑡𝑎 = 𝐴𝑟𝑒𝑎 𝑜𝑓 𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑎𝑖𝑟 𝑐𝑜𝑟𝑒 𝑎𝑡 𝑡𝑟𝑢𝑚𝑝𝑒𝑡
𝑡 𝑡𝑎 )

𝐴𝑡 = 𝜋𝑟𝑡 2

𝑄𝑟𝑖 𝑠𝑖𝑛𝛽 𝑄
𝜔𝑜𝑎 = Whereas is linear velocity of liquid coming out.
𝐴𝑝 𝑟𝑡𝑎 𝐴𝑝

Substitute the value of 𝑢𝑜𝑎 and 𝜔𝑜𝑎 in Bernoulli’s equation we get

2
1 𝑄2 𝑄𝑟𝑖 𝑠𝑖𝑛𝛽
∆𝑝 = [ 2
+( ) ]
2 ((𝐴𝑡 −𝐴𝑡𝑎 )𝑐𝑜𝑠𝜃𝑡 ) 𝐴𝑝 𝑟𝑡𝑎

Discharge coefficient for nozzle can be calculated by following equation

2∆𝑃 1
𝑄 = 𝐶𝑑 𝐴𝑜 ( )2
𝜌

Substitute () and () in () we get

40
 1 𝐴𝑜 2 1
2 =( ) ( 2
𝐶𝑑 𝐴𝑡 𝑐𝑜𝑠 𝜃𝑡 (1 − 𝑋𝑡 )2
1 𝑟𝑖 2
+ ( ) 𝑠𝑖𝑛2 𝛽)
𝐾1 2 𝑋𝑡 𝑟𝑠

𝐴𝑡𝑎
Whereas 𝑋𝑡 is the area occupied by air core at trumpet end and is given by 𝑋𝑡 = and 𝐾𝑡 =
𝐴𝑡
𝐴𝑝
𝜋𝑟𝑡 𝑟𝑠

According to principle of maximum flow film thickness inside orifice will adjust itself to adjust
value of X to give out maximum flow for given pressure. Using this principle differentiate
above equation and equate it to zero.

𝑑 1
( 2) = 0
𝑑𝑥 𝐶𝑑

Resultant equation is given as

2 (1 − 𝑋𝑡 )3 𝑟1 2 2
𝐾𝑡 = ( ) 𝑠𝑖𝑛 𝛽
2𝑋𝑡 2 𝑟𝑠

Substituting () in () we have

(1 − 𝑋𝑡 )3 1
𝐶𝑑 = 1.17 ( )2
1 + 𝑋𝑡

41
We have value of 𝐶𝑑 we can calculate value of X which will be between (0-1). Another
parameter which is of great significance especially in cooling application is drop size which is
more or less in the order of film thickness. To find film thickness we have formula given below.

𝑟𝑡
𝑡 ∗ = 1 − √𝑋𝑡 ( ) 𝑐𝑜𝑠𝜃𝑡
𝑟𝑜

For cone half angle we have

𝜃 = 𝜃𝑡 + 𝜃 ′

Where

̅𝜔̅̅̅𝑡
𝑡𝑎𝑛𝜃 =
𝑢𝑡
̅̅̅

the mean velocity along with the trumpet direction at the trumpet end

𝑄
𝑢𝑡 =
̅̅̅
(𝐴𝑡 − 𝐴𝑡𝑎 )𝑐𝑜𝑠𝜃𝑡

At the trumpet end, the total angular momentum

The total mass flow at the trumpet end

𝜌𝑢𝑡 (𝐴𝑡 − 𝐴𝑡𝑎 )𝑐𝑜𝑠𝜃𝑡

⇒mean tangential velocity at the trumpet end

Substituting eq () and () into eq () we get

To determine other Degrees of Freedom there are some best practices available and we have
correlation called Jones correlation which tell us which parameters have most significant effect
on the performance of nozzle. The correlation is as follows
42
 𝜌𝑢𝑑𝑜 −0.02 𝑙0 −0.03 𝑙𝑠 0.05 𝐴𝑝 0.52 𝑑𝑠 0.23
𝐶𝑑 = 0.45 ( ) ( ) ( ) ( ) ( )
𝜇 𝑑0 𝑑𝑠 𝑑𝑜 𝑑𝑠 𝑑𝑜

From the above correlation that has been obtained experimentally it is evident that all the terms
have almost negligible effect on 𝐶𝑑 the only significant affect is produced by value of 𝐴𝑝 . So,
it doesn’t matter what are the values of other parameters so we need to maintain some best
practices criterion obtained experimentally which is as follows.

𝑙0
( ) > 0.5 𝑖𝑠 𝑠𝑢𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
𝑑0

𝑙𝑠
( ) > 0.2 𝑖𝑠 𝑠𝑢𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡
𝑑𝑠

𝜃𝑐 ≅ 90𝑜 − 120𝑜

𝑟𝑖
≅ 0.6 − 0.7
𝑟𝑠

5.4.1 Effect Of different parameters on Nozzle Performance

5.4.2 Effect of Variation in Inlet Slot Angle β
Experiments shows that with an increase of β from 40 to 90 deg, dimensionless thickness t∗
decreases about 25%, discharge coefficient Cd decreases about 35%, and spray cone half-angle
θ increases by about 15%. The higher swirl velocity that corresponds to a higher inlet slot angle
pushes the liquid to the atomizer walls, and the liquid film thickness in the exit orifice
decreases. The spray cone angle is governed by the ratio of axial-to swirl-velocity components
at the exit. The cone angle is seen to increase with inlet slot angle. This is because of the larger
centrifugal force caused by the higher swirl-velocity component. As the mass flow rate is kept
constant, thinner liquid film in the exit orifice section corresponds to higher axial velocity. A
combination of increased swirl and axial velocity leads to a higher pressure drop across the
atomizer, and the discharge

Coefficient decreases. As evident from Fig., the changes in spray cone angle, discharge
coefficient, and film thickness are large.

43
 Figure 5-1 Dimensional thickness and discharge coefficient with inlet
slots angle

5.4.3 Effect of Variation in Trumpet Angle θt

Note in this study the length of the trumpet lt has been held constant as θt is varied. Figure
indicates that as θt increases from 10 to 40 deg, dimensionless thickness t∗ decreases about
42%, spray cone half-angle θ increases from 22 to 40 deg, but discharge coefficient Cd remains
almost constant. This shows that the trumpet can be very effective in controlling the spray cone
angle and the film thickness without significantly affecting the pressure drop across the
atomizer. As pressure drop across the atomizer remains relatively steady, the axial velocity at
the end of the exit orifice is expected to exhibit little variation. However, trumpet diameter dt
increases with increase in θt so that the film thickness t∗ decreases when the flow rate through
the atomizer is kept constant.

Figure 5-2 Dimensional thickness and discharge

coefficient with Trumpet angle

44
5.4.4 Effect of Variation in Spin Chamber Convergence Angle θc
For the atomizer configuration considered, with an increase in θc from 45 to 90 deg,
dimensionless thickness t∗ increases about 16%, Cd increases about 34%, and spray cone half-
angle θ decreases about 9%. Earlier studies have shown that the flow field inside a simplex
atomizer has a region of recirculating flow. The majority of the liquid entering from the inlet
slots flows through a region close to the liquid–gas interface and enters the orifice. The location
and size of the recirculating flow affects the axial-velocity variations in the spin chamber and
consequently in the exit orifice. As the convergence angle changes, the recirculating region in
the spin chamber can change considerably. This is illustrated in Fig, which show flow
streamlines for two atomizer geometries with convergence angle 60 and 90 deg, respectively.
As the flow structure changes, the velocity variation in the atomizer is altered, and
consequently the film thickness at the exit, spray cone half-angle, and discharge coefficient
change.

Figure 5-3 Dimensional thickness and discharge coefficient with Spin chamber convergence
angle

45
5.5 Flow Patterns in Ansys
Nozzle for water spray inside the cement mill is designed and simulated in Ansys and
patterns observed are as under.

Figure 5-4 Start of flow Figure 5-5 Developing of flow

Figure 5-7 fully Developed flow Figure 5-6 Start of swirl in nozzle

Figure 5-8 Spray Pattern

46
 6 CONCLUSION
Cement Mill water spray system is the most effective and widely used solution for controlling
the cement temperature to avoid gypsum dehydration. The water spray system designed can be
used for spraying water solely at the outlet end or at the both ends of the ball mill. The water
spray system is based on temperature feedback from the temperature sensors installed at the
mill discharge and the diaphragm of the mill. When the temperature rises above set points for
the maximum allowable temperature, the feedback system gives signal to start the motor and
pump. The water flow rate can be continuously varied according to the requirement.
Compressed air is used to keep the nozzle clean the when there is no water being sprayed inside
the mill. The currently used method to control the clinker temperatures results in excessive
damage to the belt conveyor, buckets and bag filters of the cement area. These losses can be
reduced to minimum by using water spray system in cement mill.

47
 7 REFERENCES

[1] K.M. Bade, W.Kalata, and R.J. Schick. Spray analysis and research services spraying
systems Co. P.O. Box 7900 Wheaton, IL 60187 USA.
[2] VEL Engineering Services, www.velengineering.com/cementmill.html
[3] FLSmidth manual Mechanical Volume 6 for water spray system in cement mill.
[4] Water spray nozzles, www.pnr.eu
[5] Infinity cement, www.infinitycement.com
[6] CMPAG Cement and mining processing AG
[7] Cement Process engineering VADE-MECUM Lafarge Cement.
[8] SINOMA Technology and Equipment Group Co, Ball Mill Instruction.
[9] KSB pump Catalogue for pump selections.

48