EXemg | GRINDING MEDIA Benefits of ceramic grinding Te ec ne et Umer Mele ec rr Ce Rss ecu as ele a MOR OR Teter ae Tee Sree acne hcl au Pal en ee ee Distt tnessin een radon nology, power consumption currently stands at around 30kWhyt of cement, Therefore, the reduction of power demand isa key objective for cement producers worldwide. significant part of i power consumption is accounted for by ‘inding operations. Advances in grinding technology, therafore, can significantly help to reduce a plant's need for electricity ‘One company, Colombia-based Satarem Latin America, has contributed to these advances by developing newtype of grinding media -a ceramic ball specially designed for the cement industry This ceramic grinding balls made from non-organic material with a95-58 per cent ALO, content and a material density of .5- | 3.8gler. Its key features include: i * a high hardness around HRA 85-90 or nine on the Mohs hardness scale + an abrasive performance of 266 times | lower than 26Mn13 or 171 times loner than high-chrome cast metal, Furthermore, the change to ceramic ‘media can also be carried out ina simple process, Mis do nat require an extensive i ‘overhaul or civil works, only some minor ‘modifications to the millinternals and replacing the metal media with ceramic ‘ones. This work could be carried out during _amonthly maintenance stoppage. Benefits of ceramic medi Experience with Satarem’s ceramic able to: 15.30 per cont by over 50 per cent by 10-20°C, ‘To.nderstand the reasons fortis eR OCTOBER 2017 ringing media in more than 30 cement plants in China have shown that they are + reduce mill current by as much as + decrease chrome content in cement * lower the temperature ofthe cement Improved performance, a closer look at the grinding process is useful. Grinding isa ‘multi-step process. When clinker, additives and gypsum enter the cement mil, coarse srinding takes place, carried out by coarse nding media that crush the material Once the cement reaches an acceptable fineness, finer grinding media ill be used to.complete the process. This set-up places different requirements on each part ofthe grinding process and the grinding media, nthe first chamber ofthe mill grinding media with ahigh density areneeded to impact ‘on the material and crush it. However, in the second chamber, the coment powder isfine and media density is less important. ‘surface area becomes the kay element inefficient grinding, Therefore, grinding ‘media in the second chambered to have a high surface area and be sufficiently hard ‘to grind cement. In practical terms, this means that while metal-based media can be used inthe frst chamber, they do not deliver an eficient performancein the second chamber. Ceramic grinding balls havea density almosthalf of theirmetal counterparts, leading to a grinding media weight some 1530 per cent lower than metal media, The lower mill load in terms of grinding mediaee errr Parameter ‘Steel media Ceramic media Variation (%) Parameter Ceramic media ‘Variation (%) [Third chamber weight) | 70 2 40 ee ee eee Parameter Steel media ic media | Variation (%) —vipatign) | 1820 a | a0] iil curent 4) qo ey “0 Secondmil weight) [| ___30 a 43 ect ee Parameter Steel media | Ceramiemedia Variation (06) 105.110 100.105 5 rent (A) 213 151 29 Third chamber weight 4 42 eae ceramic media | Yaron (6) [_ouwatton ana [3 Mill current (A) | 146 [ Second chamber weit eee pocioeierat nee parr) a I GRINDING MEDIA has a positive impacton the mill motor current, which sees a similar decrease an reduces power consumption ofthe mil Furthermore, due to theirlawer densi ‘ceramic grinding media help to reduce ‘over grinding and improve the quality ‘of the final cement. The share of 0-2 particles will fall while the share of 3-401 particles willincrease, Ths leads also to reduced water demand in the production ‘of mortar and delivers an improved concrete quality. Ceramic media are also harder than their metal counterparts eliminating the need to add chrome to the medium’s ‘material to achieve equivalent levels of abrasion resistance and wear. Asa result, grinding operations in the second chamber are chrome-free and therefore, considerably reduce the chrome content. the final cernent. In addition, due to their high hardness ceramic media have a longer lifetime tha metal media Optimising ceramic performanc ‘Twokey conditions need to be met to achieve optimum performance of cerami media, Firstly, due to theirlow density ceramic media will perform best at a Bla fineness of more than 2000em*/g, In case where Blaineis below 2000cm'/g, more Crushing by matal media is required first The raw materials fed into the mil -ie clinker, additives and gypsum ~ need to hhave a combined moisture content of les ‘than two percent, IF moisture content is igher, cement powder will cover the surface ofthe media, This coating wil decrease the grinding capability of ceram media Cement industry applications Ceramic media have been applied in citferent cement grinding canfigurations, ranging from simple open-circuit mils ‘to-complex closed-cireitsystems with aller press. inall cases ceramic media have improved circuit performance and ‘cement quality (see Tables 1-5). Conclusion Ceramic grinding media not only exhibit a Longer grinding life due to ther increased hardness but also reduce the chromium Content ofthe final product. n addition, their lower density helps to reduce mill loads and asa result, lowers power consumption of cement mils, leading tosignificant savings in power costs for ‘cement producers.