ATOX 42.

5 RM
Raw Meal Grinding Inspection
Plant name: DG Khan Cement, Dera Ghazi Line II
Country: Pakistan
Project number:

Site Visit Report

21-01-2022
 Site Visit Report

Table of Contents
1. Safety .................................................................................................................................. 1
2. Grinding Circuit .................................................................................................................. 2
Installed Equipment ...................................................................................................... 2
3. Raw Mill .............................................................................................................................. 3
Mill Internal ................................................................................................................... 3
Rollers ....................................................................................................................... 3
Table ......................................................................................................................... 4
Dam Ring .................................................................................................................. 4
Nozzle Ring .............................................................................................................. 5
Housing..................................................................................................................... 6
Scraper Room ........................................................................................................... 7
Separator ....................................................................................................................... 7
Static Louvres ........................................................................................................... 7
Rotor Cage................................................................................................................ 7
Top Seal .................................................................................................................... 7
Mill Fan .......................................................................................................................... 9
4. Mill Operation .................................................................................................................. 11
Mill Data Sheets .......................................................................................................... 11
False Air ....................................................................................................................... 11
Expectation of Reduced False Air ......................................................................... 12
Specific Power Consumption (SPC) ............................................................................ 13 Page
Comparison to Line 1 ............................................................................................. 13
II
5. Mill Fan ............................................................................................................................. 14
Air Flow ....................................................................................................................... 14
Fan Efficiency .............................................................................................................. 14
Damper/VFD Upgrade................................................................................................. 15
Proposed Action Plan.................................................................................................. 16
6. Appendix A ....................................................................................................................... 18
7. Appendix B ....................................................................................................................... 21
8. Appendix C ....................................................................................................................... 23
9. Appendix D ....................................................................................................................... 24

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

 Site Visit Report

Preface
It has been agreed between DG Khan Cement in Dera Ghazi, Pakistan (DGK) and FLSmidth DK
(FLS) to carry out a 4-day site visit to study the raw mill fan. It has been installed without any
inlet damper or variable speed drive (VFD) and a suggestion has been given to add one of these
to save power.

The mission for this process report is to gain a perspective that IF a damper or VFD was installed
on the fan, could power be saved and how much.
Further, if time permits, an overall inspection was suggested into the state of the mill system.

NOTE:
Any note

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PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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Visit log
What activities was done and on which day(s)?

16JAN, 2022 20JAN, 2022

• Travel to site • Gas, pressure & temperature
measurements
17JAN, 2022 • Collected data from CCR – line 2
• Travel to site + first meeting
21JAN, 2022
18JAN, 2022 • Collected data from CCR – line 1
• Gas, pressure & temperature • PCR test
measurements • Travel
19JAN, 2022 22JAN, 2022
• Internal inspection • Travel
• Separator inspection
• Mill fan inspection 23JAN, 2022
• Travel home

Comments:
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PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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1. Safety
A word about safety.
It is important to keep the working area in outstanding condition and up to date on safety codes
so that staff and crew can feel confident while working knowing that they are being taken care
of.

In safety, we generally talk about different aspects of safety, and they can be prioritized as follows:
1. Human Health & Safety
2. Machine Safety
3. Process Safety*

*: By "process safety" it is meant in terms of uptime and what is holding back the process to
optimize, increase or expand.

There shall be no doubt that personal safety by far outweighs everything else!
By human health & safety is meant all measures and procedures to protect human injuries or
death.

"As a specialist called to a site anywhere in the world, we put an abundant

amount of trust in the people we work with and trust in that their safety systems
work as intended. We often do not speak the native language and therefore
put our trust in a few contact persons, on our own good judgement and in what
we see on site."
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This is a testament that the best safety procedures are visual, logical and understandable by any
relevant persons working in the industry, across culture and language. 1
The next important thing is machine safety. Machine safety is ensuring that the machine is being
operated and maintained within limits and tolerances. Everything should be done to keep the
machine running safely within its specifications so not to overload and possibly cause extensive
and/or unplanned shutdowns or reduce its overall lifetime (playing the long game).

Finally comes process safety. The reason for process safety coming last is because it is heavily
dependent on the two previous; if people is getting hurt there is no one to operate the equipment
and if machine safety is compromised, then it cannot perform adequately and has uncontrollable
downtimes.
Process safety also covers how the process is being controlled: variations in chemistry, variations in
fuels, quality standards etc. all important for downstream processes and eventually clients.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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2. Grinding Circuit
The raw meal grinding circuit at DGK line 2 consists of a vertical roller with a dynamic separator
commissioned approx. 1996.

The scope is mainly about the raw mill fan and its efficiency.

Installed Equipment
Equipment
The raw mill is an ATOX 42.5 raw mill with a RAR 42.5 dynamic separator.

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The installed mill fan is a HAF315/345 (without inlet damper or variable speed drive) and the filter
fan is a MT-355 S.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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3. Raw Mill

Mill Internal
On 19JAN, the mill was inspected internally. The inspection was done not for a specific reason but
to make sure nothing stood out and had negative influence on the performance and efficiency of
the mill.

Rollers
Neither of the roller segments were newly installed and when seen in profile, wear can be
observed. The wear does not look unusual or to be progress too far.

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Picture 1 - Profile of roller 2. Looks like other Picture 2 - Clamp are found intact and with near-
rollers as well. full contact to the segments.

Picture 3 – Oil spill on the back of roller 2. Picture 4 - Oil spill on the back of roller 2.

Roller 1 has wear covers that are worn and no longer complete.

Roller 2 was observed to have some oil leak on the outer side. This should be corrected at next
available stop. Oil seals come as a split-seal so that it can be installed without having to take the
joint head off. This might help expedite the repairs.
Further, the wear covers on the outside are worn and no longer complete.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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Roller 3 has a very big gap for the roller seals. The gap is supposed to be <1mm, but it not and the
seal air as escaping too easy. The seal air is supposed to build over-pressure inside the roller to
push raw meal dust out of the roller, but the big gap lets the air escape too easy.

Table
The table had been made mainly clean – only a little material remained under the rollers. The
segments had been (not recently) hardfaced and the exposed segments indicated no abnormal
wear.

Picture 5 - Table segments. Picture 6 - Table segments and water lance

position.

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Picture 7 - Nozzle ring viewed from beneath and

the outside diameter surface of the table casting.

From the scraper room underneath, the table casting can be inspected. Especially the surface by
the nozzle ring can have excessive wear, but this was not the case here. That surface is straight
and vertical as expected.

Dam Ring
The dam ring was not inspected in detail but didn’t look to have any issues with separation or
tilting.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

 Site Visit Report

Picture 8 - Definition of dam ring height.

Picture 9 - Dam ring in the mill.

The definition of the dam ring height is measured from the top of the table segments to the top
of the dam ring. This measurement was ~230mm and is equivalent to 5,4% relative dam ring
height.
FLS standard is to stay within a range of 2,5-4% relative dam ring height, BUT there could be
reasons for deviating from that. One of the main indicators for evaluating the dam ring height is
the layer thickness indicated while the mill is running; that was found to 62-77mm in the prior 2
weeks of operation, variating every day.

If not already tried in the past to prove otherwise, there is space to try and lower the dam ring.
Whenever changing the dam ring, the layer thickness obviously also changes. A guideline of ¼ to Page
½ of the dam ring change can be assumed, so if the dam ring in changed 10mm, the layer thickness 5
changes 2,5-5mm in the same direction (up or down).
Shaving 20mm off the current dam ring could be possible.

The effect of a lower dam ring is better grinding efficiency, lower kW on the main motor and/or
higher capacity and more. But is can also cause the mill to be more unstable, sensitive to feed
material changes, higher vibrations and more. A compromise must be found between
performance and production stability.
However, with the low grinding pressure used, the “high” 90µm target and enough “headroom”
in the layer thickness, it should be possible to reduce the current dam ring height from 230mm to
210mm. This should help mill performance but is impossible to quantify and would need to be
tested.

Nozzle Ring
One section of the nozzle ring was measured for free area. On section is defined as part of the
nozzle ring between two rollers, so effectively a third of the circumference of the table.
In some situations, the nozzle ring openings under the torque arms have been blocked to minimize
risk of wear on the torque arms. This was NOT the case on this mill.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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Picture 10 - Nozzle ring after a roller. Picture 11 - Nozzle ring before a roller.

However, as seen from the picture, the width of the nozzle ring changes behind the rollers and
this has been accounted for in the calculation.

ሺ280 × 255 × 8 + 280 × 170 × 5ሻ × 3 → 2,43݉ଶ

*Measurements are in mm, but the result is shown in m2.

The measurement is not outside the expected opening for the mill. It is also not the biggest
possible opening and combined with not being able to throttle the airflow, the velocity through
the nozzle ring is likely higher than it is supposed to. The conclusion is supported by the fact the
mill is running with little to no reject. Page

As the mill is running without reject, the nozzle ring could be opened. This will be discussed later
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in this report, but IF the nozzle ring opening is changed, it is important that it is “evenly” opened.
Closed some sections more than others are generally a bad idea unless it is done to protect torque
arms and/or joint heads.

Housing
When inspecting the inside of the mill, the wear marks on housing can tell if rogue, concentrated
airstreams are existing. The was no such tell-sign found.

The return pipe from the separator is made in several pieces that are bolted together. It was
noticed that at least one bolt was mossing as two were loose. They should be replaced with new
bolts and nuts next time mill is stopped.

Picture 12 - Return pipe from separator. Picture 13 - Pull rod seal box.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

 Site Visit Report

When the mill is running, the seal around the pull rods can be seen dragging in false air. This can
easily be seen when standing at the hydraulic pistons and looking up.
This obviously introduces false air to the system and is normally undesired, but as there is no way
to throttle the airflow with the fan, this might be helpful. More on this later.

Scraper Room
Because the mill table had been emptied from material, the scraper room was now full. The entire
circumference couldn’t be inspected, but no issues were found. The scrapers that could be
inspected were complete.

Picture 14 - Complete scraper in the scraper room. Picture 15 - Material that was removed from the
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table was filling the scraper room.
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Separator
The separator was inspected internally at the same time as the mill. It was informed that most of
the internals of the separator was the original (assuming not including wear plates) which is
impressive.

Static Louvres
The static louvres were for the most part intact. Some had small wear holes and others were sitting
at a different angle (opening up) but there was nothing alarming.

Rotor Cage
The rotor cage didn’t have any severe wear either other than in the very top of the vertical plates,
it is becoming a little conical. Considering that the rotor is the same as original, that is very good.

Top Seal
The top seal is preventing course material to bypass the separator and get into the final product.
Therefore, the top seal has maximum allowed tolerances.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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Figure 1 - Top seal cross section.

Picture 16 - Top seal of the RAR 42.5.

The “H1” gap indicated above could not be measured due to space constraints. However, the
distance between the very top of the rotor to the ceiling of the top seal was measured and
indicated in the table below.
The gaps were measured:

TOP SEAL TOLERANCES:

Position 0° 90° 180° 270°
Bi [mm] 27 27 12 20
Bo [mm] 30 40 29 30
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H2 [mm] -20 * -35 * -29 * -35 *
Top of rotor [mm] 78 69 50 70 8
*: The values are negative as the horizontal plate of the rotor is below the top seal.

Nominal tolerances for Bi and Bo are <10mm. Also, the H2 needs to be at least a positive number.

It almost looks like the separator has sunk over the years making the H2 numbers negative and
the Bx numbers bigger). The separator sits on a shrink disk and that sometimes is falling down with
operation, heat and vibrations. The rotor can be lifted back up hydraulically, and the shrink disk
would then be re-positioned so the gap at the top seal would again be much closer to design.

Picture 17 - Top of the top seal where the seal Picture 18 - To illustrate the material bypass, light
rope/rubber gasket has been pushed out. was capture bypassing the separator using a torch.

On top of the top seal, there is a seal rope or rubber gasket to close the top seal to the separator
body. In several places, that seal rope/rubber gasket was either missing or exposed which is

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

 Site Visit Report

another source of material bypass. However, after explaining to mill mechanics, the seal
rope/rubber gasket was fixed during the inspection and is no longer an issue.

Picture 19 - Top of the top seal after the seal Picture 20 - Top of the top seal after the seal
rope/rubber gasket has been fixed. rope/rubber gasket has been fixed.

Mill Fan
The fan was inspected at the same time as the rest of the mill.
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Picture 21 - Raw mill fan. Picture 22 - Raw mill fan.

The fan has been installed without a VFD or inlet damper. However, an inlet damper can be
installed if necessary; the space is available.
The rotational direction of the fan rotor matches the fan housing, it is correct.

Inside, the fan housing looked fine; no open holes were found, and the rotor was intact and
undamaged.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

 Site Visit Report

Picture 23 - Fan rotor. Picture 24 - Gap between inlet cone and fan rotor.

The gap between the inlet cone and the fan rotor could not be measured, but it looked OK.
Expected gap is ~10mm and should be as small as possible to increase efficiency of the fan.
The fan does not seem to be limiting the mill production, which is indicated by no reject from the
mill, so it creates plenty of flow.

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PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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4. Mill Operation
Operation data was recovered during the visit; two weeks’ worth of data leading up to the visit
plus the running data available of the week of the visit.

Mill Data Sheets

The separator power was only indicated with Amps in CCR and is indicated as such in the
datasheet. kW is preferred but wasn’t available.

The silica ratio in the feed has an influence on the final through put of the mill. This is normal as
silica is harder to grind; the ratio is between 1-3% by weight and can give up to 15t/h difference
in mill production.

The calculated torque factor (see attached datasheets) is above expected range. The torque factor
is sort of a ratio between grinding pressure and main motor kW and a high torque factor means
the grinding pressure is low compared to the kW used, so the main motor might be using “some”
kW for other than grinding. This would be a main indicator to discuss reducing the dam ring to
improve the grinding efficiency.
Expected torque factor range for an ATOX raw mill is 0,09-0,11.

The layer thickness while running is variating between 66-77mm which is not unusual. The
grinding layer for ATOX mills are usually in the 40-75mm range. But the layer thickness does
indicate that there is enough headroom to accommodate a lower dam ring. Page

The grinding pressure is only around 115-120 bar – the design of the system and the mill would 11
allow a grinding pressure of maximum 170bar. If capacity is lacking, one of the levers to be
adjusted is grinding pressure – increasing the grinding pressure helps improve capacity, separator
load and/or product quality.

The venturi flow meter pressure sensor was checked using handheld sensor and was found
indication too low. It was corrected by instrument staff immediately, but that means the data
sheet values before 19JAN were showing wrong values (too low). After the correction, it is
showing more reasonable values.

False Air
Measuring false air on a raw mill will help indicate if the mill fan is running as efficient as possible.
False air is caused by the likes of open holes in compensators, ducts, man-doors not closed entirely
etc. Excessive false air means that the mill fan must do extra work yet false air does not contribute
to material drying (at least very little) or to lifting the material up through the mill. If mill fan
efficiency is important, false air is the first thing to address.

False air is calculated based on doing gas analysis in three places: mill -inlet, -outlet and cyclones
outlet. Based on those, the false air can be calculated across the mill, across the cyclones and across
both. The measurements were done twice; once on 18JAN and once on 20JAN (see Appendix B).

False air calculations are based on how the O2 and CO2 level changes throughout the system.

As the flu gas is kiln gas, the O2 level are lower than ambient so if ambient air mixes with flu
gasses, then % O2 must go up. The same is the case for CO2, but reversed.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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NOTE:
The false air is calculated for the mill body (inlet to
outlet), cyclones and for the entire system. Worth
noting; the whole system is NOT the sum of individual
equipment because of the relative calculation.

Remember, 100% false air means a mix of 50/50 flu

gasses and ambient air.

Both the false air calculations for the mill and cyclones combined are within a margin of error and
are basically the same (53,3% vs 48,7%). Interestingly, the ratio of false air between the mill and
the cyclones are very different on 18JAN and 20JAN. This is unexplained other than the
measurements on 20JAN were taken at a faster pace (shorter time between measurements) and
maybe slightly different operating conditions – if the kiln operating conditions changes in
between two measurements, that introduces an error. Often, measurements are taken on several
days to make some sort of average.

FALSE AIR RESULTS

18JAN 20JAN AVERAGE
Across mill % 23,1 38,7 30,9
Across cyclones % 24,5 7,2 15,9
Across mill & cyclones % 53,3 48,7 51,0

Of the 2 days of measurements, the 20JAN is likely mostly valid as there is less chance for false air
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across a cyclone (cyclones are generally closed equipment with very little possibility of false air).
The mill is much more likely to have false air due to many man doors, push rods seals, compensators 12
etc.

A new ATOX mill installation is expected to have false air of 10-15% which is quite a bit less than
what was measured.
When the mill was running, false air can be heard entering the mill through man doors but
especially, it could be heard and seen when standing at the hydraulic cylinders and looking up to
the seal where the pull rods are entering the mill housing.

On an ATOX raw mill installation, false air is most commonly coming from:
• Pull rod seal
• Man-doors not closed completely
• Damaged compensators
• Rotary sluice at the feed chute
• Flanges between mill house and separator but also assemblies at duct installations
(dampers, flow meters)

Expectation of Reduced False Air

The dilemma of this mill is a fan that cannot be throttled and the mill has a substantial amount of
false air. Both are not ideal for the mill fan to be most efficient.

If the false air would be fixed tomorrow, the airflow could still not be throttled, however, the mill
would create more “resistance” to the fan and maybe slightly lowering power consumption BUT
the mill inlet pressure would go up (indicating higher draft in the mill).

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

 Site Visit Report

Specific Power Consumption (SPC)

The original process design refers to a laboratory test of grindability of the materials which
outcome (including a safety margin) was 7,15kW/t (net) expected on the main drive.

Depending on the feed ratio (and probably other factors), the actual is 7,3-8,0kW/t (net). The
original test is over 27 years old and there are natural fluctuations in nature, so the original result
may not be entirely accurate anymore – it is entirely possible that the materials used today are
slightly harder to grind.

As mentioned earlier, the dam ring is higher than normally expected and the torque factor is
higher than expected – it is possible that with some optimization of the dam ring height (and
maybe nozzle ring opening), the SPC of the main motor could be optimized to be closer to original
process design.

Comparison to Line 1
Data was taken from when the raw mill on Line 1 was operating, BUT that mill’s last run was two
months prior to the visit (NOV2021). That data is captured in Appendix C.
If comparing the specific power consumption, that mill is performing significantly better than Line
2 – unfortunately, data from Line 2 of the same period was not taken and grindability could have
changed in that time, but likely not up to 4 kW/t.

Why there is such a big difference in specific power consumption between Line 1 & 2 raw mills is
unknown but the high torque factor of the ATOX mill is not helping the grinding efficiency. This
means a dam ring change should be considered. Page
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PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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5. Mill Fan

Air Flow
There is a venturi flow meter installed at the cyclone outlet. The installed pressure sensor showed
a lower DP than the test-instrument. The installed sensor was later calibrated and after was
showing approx. the same differential pressure as the test-instrument. That meant that the flow
in CCR was showing a higher flow after the calibration and the calculated flow in CCR showed
approx. 11200 m3/min.

Fan Efficiency
If the venturi flow meter indication is considered correct, a fan efficiency can be calculated when
the flow, fan power and fan DP is known.

Fan flow = 11200 m3/min / 60 sec/min = 186,67 m3/sec.

Fan power = 2525 kW (gross) x 0,95 = 2399 kW (net).
Fan DP = 9300 Pa – 200 Pa = 9100 Pa.

9100 × 186,67
µ௙ = = 0,71
2399000
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When the fan efficiency is compared to the fan curve, it matches what is expected at this
operational condition. Without any means to throttle the fan, the operation point will be to the
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right of where the fan is most efficient.

Figure 2 - Fan curve for the installed HAF 315/345.

The fan curves can be found in Appendix D. The orange line above indicates the operating point
and the green is aligned to the efficiency curve.

If the air flow could be throttled, it would change the operating point of where the fan would
operate on the curve and improve efficiency.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

 Site Visit Report

Damper/VFD Upgrade
There are different possibilities of upgrading the raw mill fan:
• Installing a mill inlet damper
• Installing a VFD to vary the fan speed
• Installing a new fan rotor designed for actual conditions
• A combination of any of the above.

For any upgrade to make sense, the upgrade needs to result in a power saving. As the mill is
currently running stable and without excessive maintenance requirements, there is no other
reasonable reason to change the installation.

Of the above solutions, installing a damper is the easiest. Installing a VFD on a fan requires motor-
and gearbox combability etc., so it is assumed that installing a damper is also the cheapest.

If FLS was designing a new mill today that included a fan damper and assuming the same
preconditions as originally, the calculated operating scenario would look something like this:

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Figure 3 - Suggested calculated scenario after installing a fan inlet damper.

NOTE:
Disclaimer: the above scenario MUST NOT be
considered a performance guarantee if a damper was
installed. This is purely “playing” with the idea of “if a
damper was installed”.
If any sort of guarantees must be given, that would
require more information about grindability today, kiln
conditions etc.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

 Site Visit Report

The power consumptions noted in the scenario above are net-values (shaft power), NOT CCR
indicated values. It also assumes that the false air has been reduced to 10% and that the SPC of
the raw materials are the same as the original lab test.

Knowing that these calculations are based on assumptions and theory, the fan power would likely
be reduced. The prediction is 1652kW(net) / 0,95 = 1739kW(gross) compared to the
~2500kW(gross) that it uses today (CCR reading). That yields a power saving of +700kW, however,
due to assumptions, this is more likely to be around 500kW saved.

For this to be a realistic guess, there are preconditions that needs to be met:
• False air must be reduced, target is 10%
• Dam ring must be reduced to optimize the grinding efficiency
• Nozzle ring opening WILL require modifications to achieve correct velocity profile
• Separator top seal tolerances must be fixed (rotor lifted back into correct position)

The above scenario assumes a new mill – anything that is different from a new mill (false air, wear
etc.) will be working against power savings.

NOTE:
Should a damper be installed and because of the pre-
conditions listed above, it is recommended to do a re-
commissioning of the mill as the parameters (dam-,
nozzle ring size and operational) must be re-adjusted
according to new requirements. Page

FLS Mill Specialist is recommended at site for this. 16

A scenario for a VFD (variable speed) has not been done but is also not expected to yield an even
more significant power saving.

DGK is best equipped to make a business case of whether a potential power saving mentioned
above is enough the make the investment of a new damper make sense. FLS can provide both
damper and commissioning of such and upgrade.

Proposed Action Plan

As the fan is currently running without damper or VFD, there is no reference point of the real-
world conditions of throttling the fan flow. Therefore, it can be difficult to verify the effects of
what installing a damper and VFD would to quantify.
By default, FLSmidth would install both an inlet damper and a VFD on a new vertical roller mill
fan. Both damper and VFD are needed to achieve the best efficiency while maintaining adequate
pressure- and flow performance of the fan.

To see the effect of each proposed changes to the false air and mill fan, it is suggested to make to
modifications in a step-by-step approach:
1. Reduce false air as close to 10-15% as possible
2. Install fan inlet damper
After the damper installation, the process can be re-assed to evaluate the projected effect
of adding a VFD
a. A re-commissioning of the mill must be following the damper installation

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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3. (Optional) Install variable speed drive

After reducing the airflow, the fan power should reduce, however, maybe slightly. In turn, the
draft through the mill will increase and the mill inlet- and differential pressure will rise.
A gas analyzer should be used regularly to verify that the false air repairs are working.

Next the fan inlet damper should be installed. The fan damper is likely to do much of the job of
power saving on its own. Advantage of installing a damper is that the fan maintains its pressure-
and flow torque and is faster at reacting to changes in the process.

Reason for leaving the VFD as the last step is because on its own, changing the fan speed changes
both flow and achievable pressure and is slower at reacting to changes in the mill.
However, after installing the inlet damper, the process can be re-evaluated to see “how far” the
damper has reduced the power consumption. It can then be better estimated how much the VFD
would contribute to the power reduction.

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PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

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6. Appendix A

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End of appendix.

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7. Appendix B

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End of appendix.

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8. Appendix C

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End of appendix.

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9. Appendix D

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End of appendix.

PLANT: DG Khan Cement, Dera Ghazi Line II, Pakistan 21-01-2022

 Best Regards,

Rune Høgh Jensen

Audit & Process Specialist
BSc. Mechanical Engineer

Copyright © 2014 FLSmidth A/S. ALL RIGHTS RESERVED. FLSmidth is a (registered) trademark of FLSmidth A/S. This brochure makes no offers, representations or warranties (express
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Customer Services Denmark

FLSmidth A/S
Vigerslev Allé 77
DK-2500 Valby
Copenhagen
Tel: +45 3618 1000
Fax: +45 3630 1820
E-mail: internationalservice@flsmidth.com