Grinding Plant For Cement: Operating Manual en-D000091-5C-6C-A

Operating manual
en-D000091-5C-6C-A
Grinding plant for cement
Code word
SAMANFA
Order no.
D000091
POLYSIUS Order Code (POC)

5C – 6C
Operating manual Contents
Grinding plant for cement
Contents
1 Technical Data......................................................................................... 1-1

1.1 Technical data of the plant........................................................................ 1-1
1.2 List of machines ........................................................................................ 1-4
2 Safety ....................................................................................................... 2-1
3 Components and mode of functioning ................................................. 3-1
3.1 Process technological functions of the plant components........................ 3-1
3.2 Mode of functioning of the grinding plant.................................................. 3-2
3.3 Flaps/dampers in the grinding plant.......................................................... 3-4
3.4 Control loops of the grinding plant ............................................................ 3-5
3.5 Conveying equipment to the cement silos ................................................ 3-6
3.6 Electrical interlock ..................................................................................... 3-6
4 Commissioning ....................................................................................... 4-1
4.1 Checking the mechanical equipment........................................................ 4-2
4.2 Checking the electrical equipment ............................................................ 4-3
4.3 Test run ..................................................................................................... 4-4
4.4 Charging the tube mill with grinding media............................................... 4-5
4.5 Setting and checking the plant.................................................................. 4-6
5 Starting and stopping the plant............................................................. 5-1
5.1 Starting...................................................................................................... 5-1
5.2 Shutting down under normal circumstances............................................. 5-3
5.3 Shutting down in case of emergency........................................................ 5-3
6 Operation ................................................................................................. 6-1
6.1 Checks during operation ........................................................................... 6-1
6.2 Plant operation monitoring ........................................................................ 6-1
6.3 Plant operation log .................................................................................... 6-2
6.4 Optimising the plant .................................................................................. 6-4
7 Trouble shooting..................................................................................... 7-1
8 Appendix.................................................................................................. 8-1
8.1 Flowsheets ................................................................................................ 8-1
en-D000091-5C-6C-A
Operating manual Technical Data
Grinding plant for cement 1-1
1 Technical Data
NOTE
For the technical data of the individual machines, refer to the machine manuals or
operating instructions of the respective machines. The principal machines are
listed with reference to their associated item numbers under point 1.2. To find the
documentation of the respective machines, use the Table of contents of the
folders.
Consult the technical documentation of the respective manufacturer or supplier for
the technical data of machines not supplied by POLYSIUS AG Beckum.
1.1 Technical data of the plant
NOTE
The following description relates to the first grinding plant (item designation 5F1),
but equally applies to the identical second and third grinding plants (item
designations 5F2, 5F3).
NOTE
All data and values given in this operating manual are to be regarded as
recommended values only. They are not to be understood as warranty figures.
The relevant warranty data are contained in the contractual documents.
Information regarding the compilation of records and notes, as well as the
performance of analyses, is to be regarded as a recommendation only. The
information must not be understood as a basis for the preparation of acceptance
reports for the verification of performance figures.
en-D000091-5C-6C-A
Technical Data Operating manual
1-2 Grinding plant for cement
Basic data
Number of grinding plants 3 (identical)
Year of manufacture 2009
Product
Throughput 160 tph OPC
Fineness 3,200 cm2/g acc. Blaine
Energy consumption 38.0 kWh/ at the counter of the main units
Grinding aid Grinding aid is permitted in cases of
agglomeration.
Clinker temperature ≤ 125 °C
Feed material
Clinker 95 %
Gypsum 5%
Feed grain size range 0 – 30 mm, max. 10 % ≤ 50 mm
Principal machines
Mühle
Ball mill (2 compartments) Ø 5 m x 15 m
Length of compartment 1 4.25 m
Length of compartment 2 9.75 m
Speed 14.52 min-1
Filling ratio max. 34 %
Installed power 5800 kW
Type of drive Combiflex
Mill system fan
Nominal air flow rate at 95 °C 80,000 m3/h
Static pressure increase 45 mbar
Water injection system
Capacity (1st + 2nd compartment) 5950 l/h
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Separator
1 SEPOL® NSV 250 / 4
Speed (shaft) 33 – 198 min-1
Installed power 288 kW
Separator fan
Nominal air flow rate at 90 °C 240,000 m3/h
Static pressure increase 34 mbar
Drive power 380 kW
Dedusting cyclones 4 x Ø 2.75 m
Use in explosive atmosphere Not permitted
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1.2 List of machines
NOTE
For a correct description of the plant and of the plant operation it is also
necessary to consider plant components and machines not included in the scope
of supply of POLYSIUS AG.
Figure 1 Clinker silo and conveyors to the feed bins
Customer's
Designation POC Code 1
Conveyors to feed bin 5C1 130
Steel apron feeder 5C1.AY01 130 04
Steel apron feeder 5C1.AY02 130 05
Distribution box 5C1.DB01 130 04
Clam shell valve 5C1.SV01 130 04
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Figure 2 Feed bins
Customer's
Feed bins 5D1 160 02-09
Conveyor belt 5D1.BC01 160 02
Bin weighing device 5D1.BN01 160 03
Feed bin for gypsum 5D1.FB01 160 03
Feed bin for clinker 5D1.FB02 160 04
Feed bin for additives 5D1.FB03 160 05
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Figure 3 Conveyors to the ball mill
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Customer's
Conveyors to the ball mill 5E1 160 02-09
Conveyor belt 5E1.BC01 160 10
Bag filter 5E1.BF01 160 09
Weighbelt feeder 5E1.WE01 160 06
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Figure 4 Cement grinding plant
Customer's
Cement grinding plant 5F1 160 11-91
Bucket elevator 5F1.BE01 160 13
Bag filter 5F1.BF01 160 19
Mill filter 5F1.PB01 160 20
Diverter gate 5F1.CF01 160 25
High-efficiency separator SEPOL NSV 5F1.DS01 160 15
Fresh-air flap 5F1.FA01 160 26
Separator fan DS01 5F1.FN01 160 15
Mill system fan 5F1.FN02 160 16
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Customer's
Flowmeter 5F1.FW01 160 18
Monorail trolley 5F1.MC01 160 22
Process bag filter 5F1.PB01 160 20
Trough screw conveyor 5F1.SC01
Trough screw conveyor 5F1.SC02
Stack 5F1.SK01 160 91
FLUIDOR pneumatic trough conveying
system 5F1.TC01 160 12
Tube mill 5F1.TM01 160 11
Water injection system AM 5F1.WJ01 160 11
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Figure 5
Customer's
Conveyors to cement silo 5J1
AEROPOL vertical conveyor 5J1.AC01 170 03
Bag filter 5J1.BF01, BF02
Diverter gate 5J1.CF01
Sampling system 5J1.QS01 170 02
Rotary blower 5J1.RB01 170 04
Rotary blower 5J1.RB02
Pneumatic trough conveyor 5J1.TC01 160 21
Pneumatic trough conveyor 5J1.TC05
Pneumatic trough conveyor 5J1.TC06
Conveying piping 5J1.VP01 170 03
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Operating manual Safety
2 Safety
NOTE
Be sure to comply with the general safety instructions in the supplement Important
notes on the documentation.
Use
• The plant is exclusively intended for the grinding of cement clinker and
additives to cement.
Be sure to comply with the specification of the intended use in section
Technical data.
• Any use other than the intended use, such as grinding minerals which may
produce combustible or toxic gases or vapours during grinding, is forbidden.
POLYSIUS AG is not responsible for damage resulting from any use other
than the intended use. All other use is at the owner's own risk.
• The intended use also includes compliance with the instructions in the
operating manual, the machine manuals, and the operating instructions.
Operation
General
• Hearing protectors have to be worn in the mill building, as the noise level can
exceed 90 dB(A).
• Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and
recording of such checks.
• If changes in the plant or its operating behaviour occur that are relevant to
safety, shut it down immediately.
• Be sure to stay at an adequate safety distance from all moving plant
components.
• Be sure to comply with all warning signs and safety instructions on the
machines as well as in the machine manuals and operating instructions.
• Switch off the power supply to the electrical components before beginning any
inspection work.
• Make absolutely sure that all machines and motors whose operation might
endanger persons or equipment are switched off and safeguarded against
restarting for the entire duration of the inspection work.
• Ensure that all rotating parts of the machine have come to a complete
standstill before you remove any protection devices or open any covers.
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Safety Operating manual
• Before performing any work on the machine, make sure that there is no
danger of suffering burns when touching the machine and that no hot material
is in the machine when inspection and service covers are opened.
• Make absolutely sure that the interior of the machines has cooled down so far
that the personnel will not suffer any burns on entering.
• It is forbidden to stand on or climb protective installations such as railings,
protective gratings or covers. . Appropriate ladders and/or scaffolds must be
used to gain access to normally inaccessible parts of machines or plants.
• Remount all protection devices and properly close all inspection and service
covers after the inspection work has been finished.
• Make absolutely sure that the pneumatic piping is relieved of pressure before
disconnecting it.
Work in and on the ball mill

• Never operate the tube mill with grinding ball charge if there is no mill feed
material in the grinding compartment.
• Before beginning any work in and around the shutdown tube mill, wait until it
has swung to a complete stop and then secure it with the holding brake.
• Before inspecting the mill, make absolutely sure that it is secured against
being switched on. Moreover, all machines in the material route upstream and
downstream of the mill have to be secured against restarting.
• Grinding compartments and grinding media are electrically conductive. Only
use 24 Volt lamps for illuminating the grinding compartments.
• Only enter the mill in protective clothing and make sure that no grinding balls
or mill feed material can fall down.
• When work is being performed inside the machine, make absolutely sure that
fresh air is supplied continuously (by injection or suction), so that the inhaled
air remains free from noxious constituents. Aeration with pure oxygen is
forbidden.
• When samples from the inside of the tube mill are taken, make absolutely sure
that fresh air is supplied continuously by opening the fresh-air dampers and
the manholes.
• Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily inflammable substances for cleaning the
machine.
• Only use hydraulic oil that complies with the requirements in the subsection
Lubrication.
• Make sure that the hydraulic piping is depressurised before disconnecting it.
• Never use the pumps of the hydraulic system for emptying or filling the oil
tank.
• If you drain hydraulic oil at operating temperature, you risk scalding yourself.
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Operating manual Safety
• After all inspection work, check that there are no leaks in joints and
connections.
• The hydraulic system is specially designed for the supplied machine and may
therefore not be used for any other machine without the express consent of
POLYSIUS AG.
SEPOL® high-efficiency separator

• The feed material must be free from tramp metal.
• Excessively moist feed material causes incrustations in the rotor system,
which may result in dangerous unbalances.
Welding
• Strictly observe the welding instructions when performing any welding work.
• When electric arc welding or cutting are being performed, you must ensure
that personnel cannot come into contact with electrically conductive
components. Use insulating underlays for this purpose.
• Never situate the source of the welding current in a confined space where
walls have conductive properties.
• If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
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Safety Operating manual
Inspection
• Make absolutely sure that all machines and motors whose operation might
endanger persons or equipment are switched off and safeguarded against
restarting for the entire duration of the inspection work.
• Make absolutely sure that all rotating parts of the machines have come to a
complete standstill before you remove any protection devices or open any
covers.
• Make absolutely sure that no material accumulations have remained in the
machine which could fall down and injure personnel who enter the machine
sections.
• Remount all protection devices and properly close all inspection and service
covers after the inspection work has been finished.
• Make sure that the personnel use adequate safety equipment.
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Operating manual Components and mode of functioning
3 Components and mode of functioning
3.1 Process technological functions of the plant components
Exhaust air
Separation Separation
Bag filter Bag filter
Cyclones
Cement silos
Dynamic
Separator
Classifying
Grit
Mill feed material components

I II
Fresh air
Electric energy Tube mill
Water injection Water injection
Comminution
Drying process
Cooling
Figure 6 Schematic view of the cement grinding plant
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Components and mode of functioning Operating manual
3.2 Mode of functioning of the grinding plant
NOTE
The following description relates to the first grinding plant (item number 5D1,
5F1), but applies equally to the identical second and third grinding plant (item
number 5D2, 5D3, 5F2, 5F3).
Conveying clinker and grinding additives to the feed bins

The three grinding plants are fed by two clinker silos. Clinker silo I supplies
material to the first and the second cement grinding plant, silo II supplies material
to the third and the second grinding plant. The material supply from silo I is
described by an example. The supply of material from silo II is analogous.
The clinker is discharged from the clinker silo and fed onto the steel apron feeder
5C1.AY01. The subsequent distribution box 5C1.DB01 conveys the material
direct to the feed bin 5D1.FB02 of the first grinding plant or via a second steel
apron conveyor 5C1.AY02 to the feed bin 5D2.FB02 of the second plant.
The customer is responsible for the supply of gypsum and additives.
Dosing and conveying to the grinding plants

The mill feed material component clinker is discharged via the weighbelt feeder
5D1.WE02 and supplied to the collecting belt 5D1.BC01 which conveys the
material to the feed unit of the tube mill 5F1.TM01.
The components gypsum and additives are discharged at a controlled flow rate
via the weighbelt feeders 5D1.WE01 and WE03 and are also fed onto the
collecting belt 5D1.BC01.
The plant section is dedusted by means of the bag filter 5D1.BF01.
Mill
The mill feed material is comminuted in two grinding compartments that are
separated by a transfer diaphragm.
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Water injection system

If the supplied amount of cooling fresh air is not sufficient, the material can be
cooled down further by means of the installed water injection system 5F1.WJ01
which injects water into the two grinding compartments. The water injection
system is switched on when the mill exhaust air temperature exceeds an
adjustable limit value. This can occur in cases of high clinker temperatures or at
high outside temperatures during the summer.
Depending on the mill exhaust air temperature, the water is injected into the 1st
and 2nd compartment by means of one injection lance each.
Water is first injected into compartment 2. If the maximum water quantity
envisaged for compartment 2 has been injected and the exhaust air temperature
nevertheless increases, water is also injected into compartment 1.
Mill discharge material

The coarser mill discharge material is conveyed from the discharge device of the
2-compartment tube mill via the pneumatic trough conveyor 5F1.TC01 to the
bucket elevator 5F1.BE01.
The mill discharge material is further conveyed via the pneumatic trough
conveyor 5F1.TC02 to the dynamic separator 5F1.DS01. The pneumatic trough
conveyor upstream of the separator is equipped with a foreign body trap, in order
to protect the separator against any foreign bodies coming from the grinding
plant. The tramp material trap consists of the two pneumatically actuated flat slide
valves TC02.FGJ01 and FGJ02.
SEPOL® dynamic separator and fine dust transports

The granular separator feed material falls onto a distributing plate in the centre of
the dynamic separator, which evenly distributes the material in the separating
chamber. Under the effect of gravitational and airflow forces, the material is
separated into fine and coarse material in the separating chamber.
The separating air stream is generated by an individual fan 5F1.FN01. The dust-
laden separating air is pre-dedusted in four cyclones.
The separator can be supplied with fresh air to cool the cement via a fresh air
flap. The dust that has been collected in the cyclones (finished material) is fed to
the cement silos via flap valves and the pneumatic trough conveyors 5J1.TC04,
TC05 and TC06.
The coarse material (grit) from the separator 5F1.DS01 is conveyed to the grit
cone that is provided with a flap valve serving as an airlock at its bottom end.
From the collecting cone, the grit is returned by the pneumatic trough conveyor
5F1.TC03 and the flowmeter 5F1.FW01 to the tube mill.
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Fine mill product and process filter

The fine mill product is conveyed with the air stream to the mill system filter
5F1.PB01 and dedusted there. The mill system fan 5F1.FN02 generates the gas
flow that is required for the mill venting. The collected dust is conveyed by means
of the material diverter gate 5F1.CF01 either to the product transport (5F1.SC01
and 5J1.TC03) or via the bucket elevator 5F1.BE01 and the subsequent
pneumatic trough conveyor to the separator feed bin.
3.3 Flaps/dampers in the grinding plant
The following table gives an overview of the flaps/dampers in the cement grinding
plant.
Designation Control Positionable Function
Damper No Yes Control of the mill venting

FN02.TVJ01
Fresh-air flap No Yes Setting the fresh air flow volume

5F1.FA01 for cooling the separating air
Fresh-air flap No Yes Control of the separating air flow

55F1.FN01.FNJ01 volume
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3.4 Control loops of the grinding plant
The cement grinding plant is provided with three control loops in order to
guarantee stable grinding operation.
1st control loop (new material feed)

Provided that the sum of the new feed material rate and the grit feed rate remains
constant, the feed rate to the ball mill is uniform. The new material feed rate is
controlled by dosing devices 5D1.WE01 - WE03 in accordance with the grit
quantity determined by flowmeter 5F1.FW01.
2nd control loop (temperature after mill)

When the exhaust gas temperature upstream of the mill exceeds an adjustable
setpoint value, water is first injected into the second grinding compartment. If the
injected water quantity is not enough to adequately reduce the temperature,
water is additionally injected into the first grinding compartment.
3rd control loop (temperature before filter)

When the gas temperature upstream of the process filter 5F1.BF01 exceeds an
adjustable setpoint value, the fresh-air valve at the SEPOL opens and fresh air
cools the gas mixture upstream of the filter.
Aim of the control loop Controlled variable Manipulated variable
Constant material feed Material quantity: new Speed of the weighbelt

New feed material + grit = constant feed material + grit, drives
feed to tube mill additional monitoring by
means of the power con-
sumption of the bucket
elevator
Constant temperature downstream Temperature downstream Controlling the injected

of the tube mill of the tube mill water 5F1.WJ01
Constant air flow rate downstream Static pressure down- Flap positioning upstream
of the mill stream of the mill of the mill system fan
5F1.FN02FNJ01
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3.5 Conveying equipment to the cement silos
The cement from the cement grinding plant is fed by the pneumatic conveyor
AEROPOL 5J1.AC01 into the distribution system of the pneumatic trough
conveyors 5J1.TC04 to TC06 which transport it to the four cement silos. It is
possible to feed each individual silo separately by means of setting the
corresponding diverter gates 5J1.CF01 and the pneumatic trough diverters
TC05.TRV01 and TC06.TRV01.
Dedusting of the transfer from the troughed belt conveyor 5J1,TC03 to the
Aeropol is performed by means of the bag filter 5J1.BF01. The dedusting of the
transfer from the Aeropol to the pneumatic trough conveyor TC04 is performed by
means of the bag filter 5J1.BF02. The collected dust is then returned to the
trough conveyors.
Figure 7 Cement conveyance to the cement silos
3.6 Electrical interlock
The drives of the machines in the plant or in a plant section are interlocked with
one another. If one machine fails (e.g. due to overloading), then all drives in the
process sequence upstream of the failed machine are switched off automatically.
This arrangement prevents blockages and machine damage.
Refer to the process functional diagrams for information on the start-up and
shutdown sequences for the individual drives. In case of emergency, you can
shut down the plant instantaneously by means of an EMERGENCY OFF
pushbutton.
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Operating manual Commissioning
4 Commissioning
NOTE
It is a prerequisite of our warranty that the first commissioning is carried out in the
presence of specialists from POLYSIUS AG and in accordance with their
instructions.
For information about commissioning the conveying units, packing machines and
loading and unloading plants, refer to the documentation of the respective
manufacturer.
DANGER
The inside of the mill is hot.
Also, the mill may rotate.
There is mortal danger.
Always wait until the mill has cooled down before entering the mill interior.
Let the mill swing to a complete stop and then secure it against turning.
Safeguard the drives against unintentional restarting.
DANGER
Grinding balls or mill feed material may fall down.
You could suffer severe injuries.
Only enter the mill in protective clothing and check that no grinding balls or
mill feed material can fall down.
DANGER
Grinding compartments and grinding media are electrically conductive.
You may get an electric shock.
Only use 24 Volt lamps for illuminating the grinding compartments.
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Commissioning Operating manual
4.1 Checking the mechanical equipment
NOTE
Be sure to also perform the checks specified in the machine manuals of
POLYSIUS AG and in the operating instructions of the respective manufacturers.
After having completed the assembly work and prior to the first test run, be sure
to remove all material remnants, tools and assembly appliances and check and/or
calibrate the plant components again. Be sure to carry out the following
particularly important checks and actions:
Prepare measurement records (log books) as specified in the machine
manuals.
Fill the machines/plant components with the required consumables
(e.g. oils, greases).
(The qualities and quantities are specified in the respective machine manuals)
Perform test runs of the auxiliary units and check their interlock system.
Visually inspect all piping and screwed pipe joints for leaks.
Check all drive motors for correct direction of rotation.
Check that all the necessary protection devices (e.g. guards) and warning
signs have been properly mounted.
Check all flaps, dampers and discharge devices for proper functioning and
setting,
Check the compressed air supply system (e.g. water separator, lubricator).
Check the anti-runback devices for correct installation (blocking direction).
Check that all manholes, inspection doors and covers are properly closed.
Check the liner plates in the grinding compartments for correct installation,
Check the adjustment of the lifter flights (adjustable diaphragm),
Check the rotor including distributing plate in the SEPOL® high-efficiency
separator for ease of rotation,
Check the rotor for correct direction of rotation.
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4.2 Checking the electrical equipment
Calibrating
Calibrate the dosing devices of the grinding plants.
If possible, also calibrate with feed material.
Signal check
Check the monitoring devices (e.g. speed monitors, true-run switches, filling
level monitors, gas analyser) for proper functioning.
Check and calibrate all measuring points (e.g. pressures, temperatures,
speed).
Check the individual plant components and machine groups started up
together for correct interlocking and proper functioning.
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4.3 Test run
NOTE
The test run must be carried out in the presence of representatives of
POLYSIUS AG and in accordance with the instructions given by them.
CAUTION
There is potential danger for both the personnel and the plant.
Do not start the commissioning until all the checking and adjusting opera-
tions have been completed.
Make a test run with all other units of the grinding plant.
During the test run, pay special attention to the following:
• abnormal noise at plant components,
• higher temperatures than normal at bearings, gear units, motors or other plant
sections
• severe vibrations at rotating plant sections
• tightness of all piping and screwed pipe joints
CAUTION
The plant may suffer serious damage.
Interrupt the test run immediately if one of the abnormal conditions men-
tioned above occurs.
Eliminate the cause without delay.
From the very beginning, pay particular attention to the following points:
• adequate supply of grease and oil to the bearing points
• adequate oil cooling
• tightness of the mill bearing assembly and the mill drive
• limit values of the bearing temperatures
The limit values of the bearing temperatures are specified in the machine
manuals or in the manufacturers' documentation.

Perform the cold test run of the SEPOL® high-efficiency separator over a period
of 5 hours at full rotor speed (without interruption).
If any interruptions occur, or after elimination of discovered faults, you must
repeat the test run.
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4.4 Charging the tube mill with grinding media
CAUTION
When commissioning the mill with 80% of the grinding media charge, you
have to feed in mill feed material so that the grinding media charge in the
grinding compartment does not work without material. Otherwise, damage
to the wear lining may be caused. Moreover, the gear unit and the motor
need an adequate basic loading. The grinding media filling ratio of the mill
must not fall below 24 % because otherwise the shell wear protection suf-
fers damage.
CAUTION
When commissioning the mill, you have to feed in material within approx.
5 minutes so that the grinding media charge in the grinding compartment
does not work without feed material, as otherwise damage to the wear lining
may be caused.
NOTE
The provided grinding ball charge, including reserve grinding media, is stated in
the table of the machine manual of the 2-compartment tube mill.
Fill some tonnes of feed material into the first grinding compartment.
This prevents the liner plates from being subjected to more impact than
necessary when the grinding balls are charged.
Charge compartment 1 with grinding balls to at least 24 % of the grinding
media filling ratio.
Fill the 80 % of the specified grinding ball charge into the second grinding
compartment classified according to size: large balls on the inlet side, small
balls on the outlet side.
During no-load operation also check the electrical interlock of all components of
the mill and the drive for proper functioning.
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4.5 Setting and checking the plant

Start up the grinding plant with the following initial settings
(approximate values, which are precisely determined during commissioning):
• Material feed rate: approx. 60 % of the rated throughput
• Pressure downstream of the ball valve -15 mbar
• Separator rotor speed: approx. 70 - 75 % of the maximum speed
• Position of the curved guide vanes at the SEPOL® dynamic separator: initially
fully opened
Figure 8 Initial setting of the curved guide vanes
To also obtain the optimum throughput in continuous operation, you must always
operate the plant at the circulating load which was determined by tests. For this
reason, the quantity of grit is weighed and new material is controlled in
accordance with the following equation:
new feed material including filter dust and additives + grit quantity =
constant
NOTE
Also see the information about the control loops of the grinding plant in section 3.
If the setpoint value defined for the total feed rate is exceeded, the new material
feed rate is automatically reduced.
When you have obtained stable mill operation, you can set the required fineness
of the finished product.
To assess the functioning of the grinding plant and set the fineness of the finished
material, take the following samples:
• dust from the mill filter
• separator feed material
• separated grit
• separator fines (finished product)
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Determine the residue of the material samples on the 0.09 mm, 0.075 mm and
0.045 mm screens and the specific surface according to Blaine.
For instructions about increasing or reducing the fineness of the finished product
refer to the machine manual of the SEPOL® high-efficiency separator.
You can calculate the efficiency of the separator and the recycle ratio with the
equations below. You need the following values for this calculation:
f = separator fine material
a = separator feed material
g = separated grit
Use the passing values (100 % minus residue) of the 0.09 mm, 0.075 mm or
0.045 mm screens.
Efficiency of the separator

f a-g
Efficiency of the separator = x x 100 (%)
a f-g
Recycle ratio
f-g
Recycle ratio =
a-g
Assessment of the characteristic values is made by the commissioning personnel

during commissioning.
Tube mill - metre sampling for preparation of a grinding diagram

Pay particular attention to the grain size of the feed material. The grinding media
charge specified by us is harmonised with the grindability of the mill feed material.
Start the grinding plant with a grinding media charge of at least 24%. Wait until it
has run continuously with stable conditions, then carry out metre sampling and
increase the grinding media charge proportionally with coarser or finer grinding
media, depending on the results.
DANGER
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DANGER
Grinding balls or mill feed material may fall down.
You could suffer severe injuries.
Only enter the mill in protective clothing and check that no grinding balls or
mill feed material can fall down.
DANGER
Grinding compartments and grinding media are electrically conductive.
Abruptly stop the tube mill in normal operation (crash stop).

Take samples from the grinding compartments at distances of 1 m over the
total effective grinding length. Take the samples approx. 10 - 20 cm under the
mill feed material surface.
Take a quantity of at least 1 kg per sample from grinding compartment 1.
Take a quantity of at least 100 g per sample from grinding compartment 2.
Determine the residues of the samples on the 15 mm, 10 mm, 7 mm, 5 mm, 3
mm, 1 mm, 0.5 mm, 0.2 mm, 0.09 mm and 0.045 mm screens.
Enter the determined screen residues into the grinding diagram as a
percentage over the effective grinding length. Interconnect the dots from one
screen size so that you obtain a curve.
The curves of the residues on the screens show the grinding progress in the mill.
If the tube mill is optimally filled, the grinding diagram shows smooth curves,
indicating good grinding progress. If there are sudden changes or even horizontal
sections in the course of the curves, the grinding media charge should be
corrected. Another indicator for the grinding behaviour of the tube mill is the
material level in the two grinding compartments. The commissioning personnel
can draw conclusions from the above-mentioned indicators and modify the setting
and the grinding ball charge of the tube mill correspondingly.
NOTE
After approx. 8 to 12 hours of operation, you must retighten the bolts of the shell
liner plates (see data in the machine manual of the 2-compartment tube mill).
en-D000091-5C-6C-A
Operating manual Start
5 Starting and stopping the plant
NOTE
For information about starting up the conveying units, packing machines and
loading and unloading plants, refer to the documentation of the control system.
5.1 Starting
Prerequisites
The switch-on conditions of the downstream units of the grinding plant must be
fulfilled before the 2-compartment tube mill may be started.
These include
• auxiliary units of the tube mill
• dedusting system of the grinding plant
• fines conveyors
• grit conveyors
• separator
• setting of the dampers in the gas routes.
The plant is automatically started in starting groups via a programmed control

system. The following is an overview of the starting sequence of the individual
machines.
CAUTION
Only start the separator fan when the louvre damper is closed. Otherwise,
the drive motor of the fan is overloaded.
CAUTION
When the tube mill is operated without feed material for a longer period of
time, heavy wear or even damage to the grinding media and the wear lining
is caused.
The time between the start of the tube mill drive and the feed units for the
tube mill must be as short as possible in order to avoid operation of the
tube mill without feed material.
en-D000091-5C-6C-A
Start Operating manual
NOTE
The foreign body trap of the SEPOL® must be emptied at regular intervals. The
emptying intervals depend on the amount of foreign bodies collected. The
intervals must be defined during operation.
No. Machine/equipment
1 Mill hydraulic system
2 Finished product conveying equipment
3 Grit conveying equipment
4 SEPOL®
5 Recirculating conveying equipment
6 Mill drive
7 Mill feed system
8 Foreign body trap
9 Water injection system
10 Grinding aids system
NOTE
Certain after-running times between shutdowns of individual units need to be
considered when shutting down the plant. Be sure to comply with the afterrunning
times specified in the respective machine manuals.
Example
The time lag between the shutting down of the conveyor to the bucket elevator
and the shutting down of the bucket elevator drive itself must be long enough to
enable complete emptying of the bucket elevator.
en-D000091-5C-6C-A
Operating manual Start
5.2 Shutting down under normal circumstances
Shut down the plant sections in reverse order of the switching-on sequence.
CAUTION
When the tube mill is operated without feed material for a longer period of
time, heavy wear or even damage to the grinding media and the wear lining
is caused.
The time between stoppage of the feed units and stoppage of the tube mill
must be as short as possible in order to avoid operation of the tube mill
without feed material.
5.3 Shutting down in case of emergency
The control and monitoring devices installed in the system are designed to
ensure continuous plant operation on a permanent basis. Nevertheless,
unforeseen circumstances can lead to operating trouble.
EMERGENCY OFF
If personnel are in danger or damage to the plant threatens, shut down sections
of the plant or even the complete plant as quickly as possible to prevent
accidents. To shut down in case of emergency, actuate the EMERGENCY OFF
devices on the control panel or on the machines.
If danger threatens, proceed as follows:
Shut down the affected part of the plant immediately with EMERGENCY OFF.
Shut down the other plant components according the normal
shutdown sequence.
For the switch-on conditions of the grinding plant and the exact start sequence,
refer to the process functional diagrams.
en-D000091-5C-6C-A
Operating manual Operation
6 Operation
6.1 Checks during operation
Tube mill
DANGER
The grinding compartment and grinding media are electrically conductive.
DANGER
NOTE
For information about operating the conveying units, packing machines and
loading and unloading plants, refer to the manufacturers' documentation.
6.2 Plant operation monitoring
General
The operating personnel is obliged to inspect the plant at least once per shift for
externally visible damage and faults. If any damage, fault or change in the
operating behaviour is detected, the operating personnel must immediately inform
the responsible superior member of staff. The superior must ensure that the
ascertained damage or faults are eliminated without delay.
Be sure to comply with the instructions concerning inspection of the individual
machines in the respective machine manuals and operating instructions.
Good plant monitoring is essential to ensure a trouble-free production process.
The installed measuring devices, whose signals are transmitted to the control
room, enable you to monitor and suitably control each phase of grinding plant
operation. Proper monitoring, however, also necessitates constant on-the-spot
checking of the machines by the operating personnel.
Experience has shown that it is very important to have the operating personnel
keep operation logs of the grinding plant.
en-D000091-5C-6C-A
Operation Operating manual
6.3 Plant operation log

Good plant monitoring is essential to ensure a trouble-free production process.
The installed measuring devices, whose signals are transmitted to the control
room, enable you to monitor and suitably control each phase of grinding plant
operation. Proper monitoring, however, also necessitates constant on-the-spot
checking of the machines by the operating personnel.
Experience has shown that it is very important to have the operating personnel
keep operation logs of the grinding plant.
The purpose of the operation log is to provide information about the operation of
the grinding plant. You should keep hourly records, including all important data
such as throughput, fineness of finished product, temperatures, pressures,
electrical data etc.
All the data which must be known to assess the operating mode of the raw
grinding plant are stated in the following list.
Mill feed material
Throughput tph
Quantity of grit tph
Specific surface acc. to Blaine cm2/g
Composition of the mill feed material % clinker

% gypsum
% additives
Moisture content of the mill feed material %
Power consumption and specific power requirement (provided that meters

are installed)
Power consumption of the 2-compartment tube mill kW
Power consumption of the separator fan kW
Power consumption of the process filter fan kW
Power consumption of the remaining units kW
Power consumption, total kW
Spec. power requirement of the 2-compartment tube mill kWh/t
Specific power requirement of the separator fan kWh/t
Specific power requirement of the mill filter fan kWh/t
Specific power requirement of the remaining units kWh/t
Specific power requirement, total kWh/t
en-D000091-5C-6C-A
Temperatures
Exhaust air temperature downstream of the mill °C
Exhaust air temperature downstream of the separator °C
Pressures
Pressure after the 2-compartment tube mill mbar
Differential pressure across the mill filter mbar

®
Pressure upstream of the SEPOL mbar
Differential pressure across the cyclones mbar
Pressure after separator filter mbar
Miscellaneous
Fresh air to the mill %

®
Fresh air to the SEPOL %
Rotor speed of the SEPOL® min-1
en-D000091-5C-6C-A
6.4 Optimising the plant
Tube mill
When you have obtained stable mill operation, you can set the required fineness
of the finished product. To assess the functioning of the grinding plant and set the
fineness of the finished material, take the following samples:
• Dust from mill exhaust air filter
• Separator feed material
• Separated grit
• Separator fines (cement)
• Mill discharge material
Determine the residue of these samples on the 0.045 mm, 0.075 and 0.09 mm
screens.
Determine the specific surface in cm2/g according to Blaine.
Measures for increasing or reducing the fineness of the finished product are
contained in the instructions about the SEPOL® high-efficiency separator.
The optimum throughput of the grinding plant frequently depends on a specific
amount of material being in circulation. As it is not possible to calculate the
quantity in advance, it has to be determined by tests with different recycle ratios.
Metre sampling as the basis for a grinding diagram

Also see section 6.4, Optimising the plant

The setting of the SEPOL® high-efficiency separator parameters depends upon
the desired fineness of the finished product. The setting of the parameters not
only influences the fineness of the finished product but also the granulometric
distribution and the selectivity of the high-efficiency separator.
The material to be separated is fed onto a distributing plate in the centre of the
high-efficiency separator. The distributing plate uniformly distributes the feed
material in the separating chamber. With the aid of the separating air the feed
material is separated into coarse material and fines.
The separating air flow rate and the rotor speed can be changed without
interrupting the operation.
• To increase the fineness of the product
Reduce the separating air flow rate and/or increase the rotor speed.
• To make the product coarser
Increase the separating air flow rate and/or reduce the rotor speed.
en-D000091-5C-6C-A
Initial setting for ordinary cement

Separating air flow rate at maximum, adjustment of the required fineness of the
fines by means of the rotor speed.
Assessment criteria
Recycle ratio
The recycle ratio represents the ratio between the circulating material quantity
and the finished material separated by the separator.
The recycle ratio is calculated in accordance with the following formula:
separator feed rate
Uf = separator fine material
output
separator fine material output + separator grit output

Uf =
separator fine material output
Example
A SEPOL® separator is charged with 300 tph.
The grit quantity coming from the separator amounts to 180 tph.
The finished product quantity coming from the separator amounts to 120 tph.
The recycle ratio is calculated as follows:
120 tph + 180 tph 300 tph

Uf = = = 2.5
120 tph 120 tph
The recycle ratio is influenced not only by the efficiency of the separator but also
by the mode of operation of the plant unit responsible for comminution. The main
influential factors and their effect on the recycle ratio are as follows:
• the effective length of the tube mill
(short effective lengths result in a higher recycle ratio),
• the ball grading of the tube mill
(if the ball charge has too many large balls, the recycle ratio will be higher),
• agglomeration of material in the grinding compartment
(agglomeration results in a higher recycle ratio),
• the finished-material fineness
(a greater fineness of the finished material results in a higher recycle ratio).
NOTE
The optimum recycle ratio of the grinding plant depends on several different
parameters. It is set during commissioning.
en-D000091-5C-6C-A
Efficiency η of the SEPOL® high-efficiency separator

The separator efficiency is a measure for the effectiveness of separation. The
higher the separator efficiency, the more fines are separated from the separator
feed material, i.e. less fines are returned into the grinding process along with the
separator grit. This also produces a higher efficiency of the overall grinding plant.
Tromp curve
In order to completely assess the selectivity of a separator, it is necessary to
analyse and evaluate the material flow over a broad spectrum.
Samples from the separator material streams, the separator feed material, the
separator fines and the separator grit are usually examined for the following grain
sizes:
1 µm, 1,5 µm, 2 µm, 3 µm, 4 µm, 6 µm, 8 µm, 12 µm, 16 µm, 24 µm, 32 µm,
48 µm, 64 µm, 96 µm, 128 µm, 192 µm.
A particle size distribution curve, the Tromp curve, can be calculated from the
determined values. The diagram clearly shows the mode of operation of the
separator.
Figure 9 Tromp curve example
en-D000091-5C-6C-A
The separated fines are indicated by the upper part of the diagram above the
separation curve and the separator grit which is returned into the grinding
process is indicated below the separation curve. The separation curve shows the
percentage portions of the particle size fractions which remain in the separator
grit.
Selectivity Taumin
The value Taumin shows the percentage portion of the fines of the respective grain
size which still remain in the separator grit. The lower the Taumin value, the more
efficient is the separator operation.
The optimum value would be Taumin = 0
However, the value Taumin is, together with the selectivity, also dependent on the
fineness of the finished material to be produced. The higher the specific surface
according to Blaine, the higher is the Taumin.
Sharpness of separation Kappa κ

The sharpness of separation Kappa shows the slope of the separation curve of
fines and coarse material. The higher the value Kappa, the sharper the
separation. As a rule the Kappa value 25/75 is calculated, which means that the
respective particle size at a selectivity factor of 25 % is divided by the
corresponding particle size at a selectivity factor of 75 %. Use the following
calculation formula:
grain size at selectivity factor 25 %

κ= grain size at selectivity factor 75 %
Example
When the selectivity factor is 25 % the particle size is 32 µm, when the selectivity
factor is 75 % the particle size is 68 µm. Division produces a Kappa of:
32 µm
κ= 68 µm
= 0.471
en-D000091-5C-6C-A
Figure 10
Material
Separat- Coarse
to be Fines
ing air material
separated
en-D000091-5C-6C-A
Operating manual Trouble shooting
7 Trouble shooting
Provided that maintenance work is properly carried out and that the plant is
correctly operated, faults should not occur. However, if operating trouble does
occur, its cause must be determined and eliminated immediately.
NOTE
For trouble shooting regarding the individual machines and units, refer to the
respective machine manuals and manufacturers' documentation.
The trouble shooting instructions below refer to faults that affect the entire
installation described in this operating manual.
We know from experience that the following faults are possible:
2-compartment tube mill
Fault Cause Elimination
Full grinding The grinding Stop or throttle material feeding

compartment compartment has been until the normal filling level is
overfilled with feed reached.
material and can no Then increase the feed rate
longer grind. gradually until the nominal
throughput is reached.
If the mill often chokes up with
material, you must check the
grinding media charge (wear) or
correct the grinding media
grading.
Slotted diaphragm Check the slotted diaphragms and

clogged up clean if necessary.
Gradual decline of the Wear of the grinding Keep the grinding ball charge at
throughput rate media an optimum level.
When normal hard balls are
used: Check the grinding media
charge frequently and correct
accordingly.
When especially hard balls are
used, the wear is lower and you
can therefore perform the checks
at greater intervals.
Slotted diaphragm Check the diaphragms.

clogged up Clean if necessary.
en-D000091-5C-6C-A
Trouble shooting Operating manual
NOTE
Exhaust air temperature close to the dew point causes condensation in piping and
filters and consequently leads to caking of material.
Decrease in throughput rate Poor separating Take samples at the

efficiency separator and optimise the
separator setting.
Check the separator for
wear
FLUIDOR® pneumatic trough conveyors
The trough conveyor is The porous fabric Replace the porous fabric floor
clogged up floor is worn out
en-D000091-5C-6C-A
Operating manual Appendix
8 Appendix
8.1 Flowsheets
Designation Drawing no. Register
Flowsheet 65000414
pages 5C1 - 6V4
en-D000091-5C-6C-A

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Operating manual

Grinding plant for cement

POLYSIUS Order Code (POC)

1 Technical Data......................................................................................... 1-1

1.1 Technical data of the plant

1.2 List of machines

Figure 1 Clinker silo and conveyors to the feed bins

Figure 2 Feed bins

Figure 3 Conveyors to the ball mill

Figure 4 Cement grinding plant

Work in and on the ball mill

SEPOL® high-efficiency separator

3 Components and mode of functioning

3.1 Process technological functions of the plant components

Bag filter Bag filter

Mill feed material components

Electric energy Tube mill

Water injection Water injection

Figure 6 Schematic view of the cement grinding plant

3.2 Mode of functioning of the grinding plant

Conveying clinker and grinding additives to the feed bins

Dosing and conveying to the grinding plants

Water injection system

Mill discharge material

SEPOL® dynamic separator and fine dust transports

Fine mill product and process filter

3.3 Flaps/dampers in the grinding plant

Designation Control Positionable Function

Damper No Yes Control of the mill venting

Fresh-air flap No Yes Setting the fresh air flow volume

Fresh-air flap No Yes Control of the separating air flow

3.4 Control loops of the grinding plant

1st control loop (new material feed)

2nd control loop (temperature after mill)

3rd control loop (temperature before filter)

Aim of the control loop Controlled variable Manipulated variable

Constant material feed Material quantity: new Speed of the weighbelt

Constant temperature downstream Temperature downstream Controlling the injected

3.5 Conveying equipment to the cement silos

Figure 7 Cement conveyance to the cement silos

3.6 Electrical interlock

4.1 Checking the mechanical equipment

4.2 Checking the electrical equipment

4.3 Test run

SEPOL® high-efficiency separator

4.4 Charging the tube mill with grinding media

4.5 Setting and checking the plant

Figure 8 Initial setting of the curved guide vanes

Efficiency of the separator

Assessment of the characteristic values is made by the commissioning personnel

Tube mill - metre sampling for preparation of a grinding diagram

 Abruptly stop the tube mill in normal operation (crash stop).

5 Starting and stopping the plant

The plant is automatically started in starting groups via a programmed control

1 Mill hydraulic system

2 Finished product conveying equipment

3 Grit conveying equipment

5 Recirculating conveying equipment

Abruptly stop the tube mill in normal operation (crash stop).

Full grinding The grinding Stop or throttle material feeding

Slotted diaphragm Check the diaphragms.

Decrease in throughput rate Poor separating Take samples at the