Client name: Cement - Saudi Arabia

Section: Cement Mill

Overview of Data Collected at Site

Data collected on: 22.11.2014

Data Summary

Cement Mill Production [tph] 133.0

Cement Mill Product Type PPC

Product Fineness [cm2/g] 3,800

Specific Power Consumption - Ball Mill Only [kWh/t PPC] 40.60

Specific Power Consumption - BM, Separator, Separator fan & Mill vent fan [kWh/t PPC] 47.62

Ball Mill Filling Degree - Chamber 1 [%] 27.49

Ball Mill Filling Degree - Chamber 2 [%] 28.06

Overview 1/9
 Client name: Cement - Saudi Arabia 0
Section: Cement Mill 0

Site Conditions

Altitude above mean sea level, m 10

Barometric pressure, mbar 1,012

Temperature, 0C (range) 8 to 50

Relative humidity, % 80 (max.)

Wind velocity, km/h 8.2

High voltage, kV 13.8

Low voltage, V 440

Control voltage, V 220

Frequency, Hz 60

Site conditions 2/9

 Client name: Cement - Saudi Arabia
Section: Cement Mill

Data Collected at Site

Cement Production 133.0 tph

Product Type PPC

Product Fineness 3800 cm2/g

Input Data 3/9

 Client name: Cement - Saudi Arabia
Section: Cement Mill

Flow Measurement
Equipment: Separator Fan Inlet
Equipment No: ---

Duct effective diameter 2.100 m Site altitude 10 m

Pitot tube constant 0.836 Barometric pressure 10,320 mmWG
Static pressure difference -591 mmWG Cement Mill production 133.0 tph
Temperature 104 0
C Product Fineness 3,800 cm2/g
Gas density (assumption) 1.293 kg/Nm3 Gas density 0.88 kg/m3

Dynamic pressure Avg. Dp (SQRT) Dp measured values, mmWG Count

20.00 26.00 23.00 27.00 29.00 32.00 30.00 35.00
31.00 37.00 25.00 31.00 28.00 25.00 34.00 32.00
30.03 39.00 28.00 35.00 32.00 39.00 33.00 29.00 26.00 29
25.00 29.00 30.00 32.00 34.00

Duct area 3.46 m2

Velocity 21.61 m/s
269,492 m3/h
Gas volume
183,756 Nm3/h
Material to Air loading (product basis) 0.494 kg/m3 (maximum limit - 0.8 kg/m3)

Additional Information:
Fan design volume 241,500 m3/h
Fan design pressure 61 mbar
Fan installed power 650 kW
Fan operating draw power 627 kW
Percent draw power 96.5 %
Fan damper open % 41 %
Fan design speed 890 rpm
Fan operating speed 890 rpm

Flow-Separator fan 4/9

 Client name: Cement - Saudi Arabia
Section: Cement Mill

Flow Measurement
Equipment: Separator Vent Fan (Stack)
Equipment No: ---

Duct effective diameter 1.500 m Site altitude 10 m

Pitot tube constant 0.836 Barometric pressure 10,320 mmWG
Static pressure difference -15 mmWG Cement Mill production 133.0 tph
Temperature 95 0C Product Fineness 3,800 cm2/g
Gas density (assumption) 1.293 kg/Nm3 Gas density 0.96 kg/m3

Dynamic pressure Avg. Dp (SQRT) Dp measured values, mmWG Count

12.00 13.00 7.00 10.00 9.00 10.00 12.00 8.00
14.00 11.00 10.00 13.00 11.00 7.00 10.00 12.00
10.23 10.00 9.00 7.00 13.00 9.00 21

Duct area 1.77 m2

Velocity 12.11 m/s
77,027 m3/h
Gas volume
56,992 Nm3/h
Velocity inside mill Given in mill filling degree calculation

Additional Information:
Fan design volume 70,000 m3/h
Fan design pressure 35 mbar
Fan installed power 96 kW
Fan operating draw power 65 kW
Percent draw power 67.7 %
Fan damper open % 100 %
Fan design speed 1760 rpm
Fan operating speed 1760 rpm

Flow-Separator vent fan 5/9

 Client name: Cement - Saudi Arabia
Section: Cement Mill

Flow Measurement
Equipment: Mill Vent Fan (Stack)
Equipment No: ---

Duct effective diameter 1.500 m Site altitude 10 m

Pitot tube constant 0.836 Barometric pressure 10,320 mmWG
Static pressure difference -10 mmWG Cement Mill production 133.0 tph
Temperature 102 0C Product Fineness 3,800 cm2/g
Gas density (assumption) 1.293 kg/Nm3 Gas density 0.94 kg/m3

Dynamic pressure Avg. Dp (SQRT) Dp measured values, mmWG Count

5.00 4.00 4.00 3.00 2.00 4.00 3.00 4.00
3.00 3.00 4.00 2.00 3.00 4.00 3.00 5.00
3.44 16

Duct area 1.77 m2

Velocity 7.09 m/s
45,109 m3/h
Gas volume
32,769 Nm3/h
Velocity inside mill Given in mill filling degree calculation

Additional Information:
Fan design volume 70,000 m3/h
Fan design pressure 45 mbar
Fan installed power 114 kW
Fan operating draw power 114 kW
Percent draw power 100.0 %
Fan damper open % 40 %
Fan design speed 1760 rpm
Fan operating speed 1760 rpm

Flow-Mill vent fan 6/9

 Filing Degree - Cement Mill
Mill Parameters Units Chamber-I Chmaber-II

Mill diameter, m (shell inner dia) m 5.00 5.00

Shell liner thickness, mm mm 85 95
Length of mill (effective grinding path), m m 5.21 9.55
H Free height, measured values m 3.310 3.270 3.280 3.260 3.250
3.270 3.280 3.320 3.270 3.240
Free height, measured (avg.) m 3.288 3.252
H Mill effective diameter, inside liner, m m 4.83 4.81
R Mill radius (effective) m 2.42 2.41
 h Height from grinding media top level to mill C m 0.87 0.85
h d Length as shown in the figure m 2.25 2.25
R

d
A Cross sectional area of mill (effective) m2 18.32 18.17
q Angle as shown in the figure Deg 68.80 69.39
AGM+2Δ Area of grinding media & two triangles m2 7.00 7.00
A2Δ Area of two triangles m2 1.97 1.91
AGM Area of grinding media m2 5.04 5.10

% FillingGrinding media filling degree % 27.49 28.06

ρGM Grinding media bulk density t/m 3
4.40 4.60
TGM Grinding media tonnage (to cross check) t 115.35 223.87
TGM Velocity inside mill (above media) m/s 1.00 0.96

Mill filling degree 7/9

ng Degree - Cement Mill
Chmaber-II Total

5.00 -
95 -
9.55 14.75
3.290 -
3.200
3.252 -
4.81 -
2.41 -
0.85 -
2.25 -
18.17 -
69.39 -
7.00 -
1.91 -
5.10 -

28.06 -
4.60 -
223.87 339.2
0.96

Mill filling degree 8/9

 Client name: Cement - Saudi Arabia
Section: Cement Mill

Specific Power Consumption Data - Cement Mill

Power Drawn @ meters Installed Power Load Percentage Specific Power Consumption Production 133.0 tph PPC
S. No. Equipment Description
[kW] [kW] [%] [kWh/t PPC] @ meters Fineness 3800 cm2/g
1 Ball Mill Drive 5400 6000 90.00 40.60
2 Separator 240 240 100.00 1.80
3 Separator Fan 627 650 96.46 4.71
4 Mill Vent Fan 66 114 57.89 0.50

TOTAL 6333 7004 47.62

Specific power data 9/9