BALL MILL

OPERATION, INSPECTION &

OPTIMIZATION

Jakarta, 14-15 Juni 2012

-RBSTM-
 PARAMETER OF QUALITY FINISH
MILL(1)

† STRENGTHÆ clinker minerals: C3S , C2S +additive

materials (trass & LS) ; SIA
„ 1 day : 125 kg/cm2
„ 3 day : 220 kg/cm2
„ 7 day : 280 kg/cm2
„ 28 day : 380 kg/cm2
† BLAINEÆ Classifier
„ PCC : 3700 – 4200 cm2/g
„ OPC : 3200 – 3500 cm2/g
† Residue 45µ : 7 – 10 % (max) Æ Mill
PARAMETER OF QUALITY FINISH
MILL(2)

† SO3 : 1.7 – 2.1 % Æ Gypsum

† Free lime : max 1.5 % Æ Clinker
† IL (Ignition Lost)Æ limestone
„ OPC : 3.2 % (max)
„ PCC : 5 – 7 %
† IR (Insoluble Residue)Æ fly ash & trash
„ OPC : 2.5 %
„ PCC: 8 – 10 %
† Fall set Æ temperature
† Pack set (flow ability) Æ CGA
PARAMETER OF QUALITY FINISH MILL(3)
INSOLUBLE RESIDUE

† ‘Non Cement’ material there are in cement Portland.

† Constrain ASTM < 0.75 %
† Constrain British Standard < 1.5 %
† Effect IR: addition IR to 7% will decrease early
strength ( 1 day) to 11.5%. Final strength will only
experience of the degradation of 5.5%
† To minimalist degradation of strength: increase Blaine
& use optimal gypsum. Clinker used must have a high
with quality. Using SIA.
PARAMETER OF QUALITY FINISH MILL(4)
IGNITION LOST

† Content of organic & carbonate in sediment.

† Reaction at T: 500-5500CÆ organic components will
oxidized to CO2 & ash.
† Reaction at T: 900-10000CÆall part of carbonate will
be change to CO2.
† Limestone decrease compressive strength, specially
for late strength.
† To minimalist degradation of strength: increase
Blaine, kept residue 30/45 micron as low as possible
& use optimal gypsum. Clinker used must have a
high with quality. Use of Strength Improver Agents
(SIA).
PARAMETER OF QUALITY FINISH MILL(4)
SO3

† Content of SO3 in Portland cement.

† Influenced by additional of gypsum, even clinker itself
has a little percentage.
† Optimal usage can influence to increase early strength
of cement concrete.
MILL INSPECTION
OBJECTIVES:

† To establish and to maintain an optimal material

load/level within the 2 compartments.

† To achieve an optimal particle size reduction along the

mill to the discharge.

† To maintain performance of the mill always on optimal

condition.
MILL INSPECTION
PARAMETERS:

† Weigh feeder (%), (T/Hrs)Æ control quality & system load. Must be
accurate, recalibrate: zero (every Preventive Maintenance stop) &
using dump truck (twice a year).
† Soundness (%), (dB)Æ used for alarm purposed, indication of
material level inside mill specially on first chamber. Must be
accurate, on several condition of mill (full-empty-normal).
† Mill motor power (kW)Æ indication of material load in mill (average
first & second chamber).
† Bucket elevator power (kW)Æ indication of material load in mill &
retention time in mill.
† Tailing to the mill (T/Hrs)Æ indication mill load & adjust circulating
factor. Must be accurate, always check & recalibrate every
Preventive Maintenance stop.
† Outlet Gas Temperature (ºC)Æ indication of cooling & heating needs.
Ideal temperature: 100 - 120 ºC. Material temperature normally 5
ºC higher than outlet gas temperature.
† Static pressure mill discharge (mbar/mm H2O)Æ magnitude of
draught, can use as indication: mill on good/bad condition, mill
ventilation rate.
MILL INSPECTION
ACTIVITIES:

† Dumping steel balls / classification : once in 1-2 years

(ch.1); 3-5 years (ch.2)
† Steel balls replenishment (measure filling degree) : once in
3 months
† Take samples for longitudinal analysis : twice a year
(material and steel balls)
† Inspection inside mill after crash stop : twice a year
† Inspection wearing part inside mill : every preventive
maintenance
a. Liners
b. Screen diaphragm
c. Water spray system
MILL INSPECTION
INTERNALS:

† Breaks / wear on liners

† Inlet / outlet wall thickness

† Control of diaphragm
on:
„ Slot width
„ Obstructions (clogging) on the
wall.
„ Material thickness

„ Adjustment of diaphragm control

system (if adjustable).
MILL INSPECTION
FILLING DEGREE(1)
† Determination of filling degree also supports the internal
inspection of tube mill and its result is to be considered in
connection with the grinding diagram of the meter samples
(longitudinal test).
† We can use the graphical determination of the filling ratio or
by formula to determine filling degree.
† For the preparation, mill must be on ‘empty’ condition
(minimal material) before the determination. If not, the filling
degree must be reduced by 1 to 3% depending on the level of
the mill charge with material.
† To be determined:
„ Grinding level (h)
„ Clear grinding chamber diameter (Dli)
MILL INSPECTION
FILLING DEGREE(2)
MILL INSPECTION
FILLING DEGREE(3)

† We can use the following formula, for the range

0.65 < < 0.75:

f = 1.0678 – 1.164
 MILL INSPECTION
MATERIAL INSIDE MILL:

† First Chamber: half of Influence of Powder Filling on Mill efficiency

balls covered with 110

material. (Powder Void 100

Filling: 85%)

Mill efficien cy (%)

90

† Second Chamber: balls

80

covered with ~ 50 mm 70
Optimum Powder Filling at
of material. 60
85% of Voids

0 20 40 60 80 100 120 140 160 180

Void Filling (%)

MILL INSPECTION
LONGITUDINAL TEST(1):

STANDARD:

† Ch 1 before diaphragm 500 um : 12-25% R

† Ch 1 before diaphragm 90 um : <40%R
† Ch 2 before outlet diaphragm 200 um : <5%R
† Ch 2 before outlet diaphragm 90 um : 15-25%R
† Blaine development in chamber 2 : 100 cm2/g every meter
MILL INSPECTION
LONGITUDINAL TEST(2):

† For assessment of the grinding process along the mill

center, the meter samples will be evaluated.
† For this purpose, a material sample of 1 to 2 kg is taken in
meter intervals, starting at the inlet (0.5 m). The sampling
is not to be carried out directly at the surface, but form the
level of the third or fourth particle layer. After the partition
wall, it started again at 0.5 m. The last sample is also taken
before the outlet wall.
† Three samples are taken in each sampling meter:
„ on the center mill
„ approx. 1 m right of the mill center
„ approx. 1 m left of the mill center
MILL INSPECTION
LONGITUDINAL TEST(3):

1.0 m

0.5 m 0.5 m
MILL INSPECTION
LONGITUDINAL TEST(4):

Analysis and evaluation of Longitudinal Test

General:
† Sieves analysis for both chamber
„ 32/16/8/4/2/1/0.5/0.2/0.09 mm for first chamber.
„ 4/2/1/0.5/0.2/0.09/0.045 mm for second chamber.
† In second chamber also specific surface acc. Blaine

Evaluation:
Diagram of Residue (particle size) and Blaine as function of
mill length.
MILL INSPECTION
LONGITUDINAL TEST(5):
MILL INSPECTION
SURFACE AREA OF BALLS(1):

† Sampling in the fine grinding chamber:

„ Ball sampling each meter as in the case of material
meter sampling. The utilization of a corresponding
punched screen is recommended to separate still in
the mill the amount of ball samples from the
material.
„ The amount of taken samples should approximately
correspond to the volume of a 10 –l bucket.
„ Sampling device: robust shovel or similar
MILL INSPECTION
SURFACE AREA OF BALLS(2):

† To evaluate the condition of the ball charge and define the

ball charge with regard to grinding performance, the average
ball diameter is to be determined and examined in connection
with the results from the meter sampling (longitudinal test).
† Per meter sample, only the number of balls and the total
weight of the taken sample are to be determined. Out of this
determination, the average ball diameter at the sampling
point can be calculated when knowing the density of the steel
ball.
† Proceeding for evaluation
To be determined:
„ Total amount of balls per meter sample (number of balls)
„ Total weight of the meter sample (sample weight in Ton)
Given:
„ Steel ball density (ρ)Æ usually 7.85 T/m3
MILL INSPECTION
SURFACE AREA OF BALLS(3):

† Calculation of the average ball diameter of a

meter sample:

Dm =⎡ sample_ weight 1 1 ⎤
1/ 3
(m)
2.⎢ . . ⎥
⎣ number_ of _ balls ρ 4 / 3.π ⎦

The result should be converted into mm.

MILL OPTIMIZATION
OPTIMIZATION – PRODUCT QUALITY

Indication Possible reason Analysis to be given priority Action.

Too coarse Mill over-filled Chamber sampling Low mill feed rate

Separator Adjustment Tromp curve analysis. Proper sep. adjustment

Mill feed very coarse. Feed granulometry curve Improper precrushing.

Filter dust very coarse Air flow measurement Adjust static sep venting rate.

Less efficient liner Mill internal insp. Replace liner.

Too fine Mill under loaded Chamber sampling Increase feed rate

Separator adjustment Tromp curve analysis Proper sep. adjustment

Mill feed very fine Feed granulometry curve Further investigation required

Filter dust very fine Air flow measurement Adjust static separator.

Wrong chemical Wrong feed proportions Weight feeder calibration test Adjust proper proportion.
composition

Wrong feed components Chemical testing Change component quality

MILL OPTIMIZATION
OPTIMIZATION – SOUNDNESS

Indication Possible reason Analysis to be given priority Action.

Sound dull Mill overfilled Chamber inspection Lower mill feed rate

Chamber sample analysis Improve crushing in chamber by

adjustment in balls and /or
changing liner.

Mill dimensional check Adjust chamber length

Sound loud Mill under loaded Chamber inspection Increase mill feed rate

Chamber sample analysis Adjust level of material by

changing diaphragm position
and/or grinding media
adjustment.

Mill dimensional check Adjust chamber length

Adapt LCD.
MILL OPTIMIZATION
OPTIMIZATION – TEMPERATURE PRODUCT

Indication Possible reason Analysis to be given priority Action.

Too low Unsuitable ball charge Chamber sample analysis Adjust ball charge
composition or badly worn
balls

Diaphragm unsuitable or Mill internal inspection Replace or clean diaphragm

clogged

Unsuitable or worn out liner Replace liners

Change of feed grindability Grindability test Further investigation required

Coating of balls Airflow measurement Improve ventilation in mill

Lots of re-circulation of fines Separator tromp curve Adjustment in separator

analysis

Operators error Training/ Instruction

MILL OPTIMIZATION
OPTIMIZATION – TEMPERATURE PRODUCT

Indication Possible reason Analysis to be given Action.

priority

Too high Clinker Feed checking Check clinker

temperature too cooling
high.

Low mill/ Air flow Adjust venting

separating measurement rate
venting
Lack of water Heat balancing Adjust water flow
injection rate

Cement cooler Mechanical

failure adjustment

Repair of cement
cooler.
MILL OPTIMIZATION
OPTIMIZATION – MILL DRAFT/PRESSURE

Indication Possible reason Analysis to be Action.

given priority

Too high Inlet/Outlet Mill internal Clean inlet /outlet

clogged inspection trunion of the mill

Diaphragm clogged Clean diaphragm

Too low Diaphragm broken Replace broken plate

Major false air False air testing Seal sources.

penetration
 MILL OPTIMIZATION
OPTIMIZATION OF BALL CHARGE
Service
Suggesting optimum size
distribution of ball charge.
Suggesting optimum
metallurgical grade.
Service in optimum size
distribution maintenance
Service in lower inventory
targets
Reliability
How?
Initial loading of ball
charge.
Make-up suggestion base
on process study.
Our metallurgical expertise.
Mark ball test.
Ball sorting machine.
Make up charge
recommendation.
Ready stock at works
Warehouses at selected
locations
Lower wear rate.
Safety against de-shaping
and Breakage.
Goal
Increase in productivity.
Reduction in operation
cost.
Low wear rate.
Low grinding media cost.
Increase in productivity.
Reduction in operation
cost.
Lower inventory cost.
Sustained production.
Minimum break down
MILL OPTIMIZATION
CEMENT GRINDING AID(1)

† Purpose of CGA:
„ Increase of mill output
† Better material flow through mill.
† Reduce or avoid coating
† More efficient separation
„ Reduce specific energy consumption
„ Reduce pack-set / increase flow ability

† Effect of CGA on fines of cement with % gain

„ 300 m2/kg 5% gain
„ 350 m2/kg 10% gain
„ 400 m2/kg 15% gain
„ 450 m2/kg 20% gain
„ 500 m2/kg 30% gain
MILL OPTIMIZATION
CEMENT GRINDING AID(2)

Methods of test for optimal dosage rate:

† Typical dosing range 200-400 ppm (g/ton) product.
† Typical mix dosing with water: 1:1 ; 1:2 ; 1:3 ; etc
† Typical test procedure:
„ Calibration on instrumentation (weigh feeder, flow meter of CGA, etc)
„ Start up mill system Æ 1 to 2 hrs
„ Adjustment of parameters Æ 2 to 3 hrs
„ Stable mill operation for test Æ at least 8 hrs
„ Record all parameters
„ Test without & with CGA
„ Test with various dosages ; various mix dosage ; different type of CGA
Adjust only one parameter than wait for the result.
MILL OPTIMIZATION
CEMENT GRINDING AID(3)
MILL OPTIMIZATION
STRENGTH IMPROVER (1)
Grinding Aids Vs Strength Improvers
MILL OPTIMIZATION
STRENGTH IMPROVER (2)
MILL OPTIMIZATION
STRENGTH IMPROVER (3)
Benefit of Strength Improvers
Case Study SIA:
MILL OPTIMIZATION
STRENGTH IMPROVER (4)
THANK YOU