Grinding with Ball Mill Systems

Mill Ventilation
 Heating & Cooling - Possibilities

Cooling in Separator

Cement
Mill Ventilation Coolers

Heating Water
Injection
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HGRS Tikaria_Mill Workshop SEPT-07
Heating and Cooling – Units
 Mill Ventilation

 Water Injection

 Heating

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Mill Ventilation - Objectives
 Avoid the consequences of too high grinding
temperatures inside the mill (115 – 130 [°C]):
 Material coating on balls and liners resulting in a
performance loss of 5 – 10 [%]
 Cement false setting – gypsum dehydration
 Lump formation in the silos

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Mill Ventilation - Guidelines
False air
 Filter dimensioned for 1.5 [m/s]
airspeed above the ball charge
Optimum mill ventilation is a
compromise between : Fan
 Material level in the first chamber
 Mill outlet temperature
 Filter dew point (T >25 – 30 [°C])
 Product fineness at the filter

Mill fresh air

False air
 False air reduces the cooling
capacity of the mill tube
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HGRS Tikaria_Mill Workshop SEPT-07
 Additional ventilation cooling possibilities
False air

Separator fresh air

Fan

Clinker

Mill fresh air

False air
Cooler
Water
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HGRS Tikaria_Mill Workshop SEPT-07
 Separator fresh air

Separator fresh air

 A single pass separator with 0.7 [m3/kg cement] can cool down
the cement at the mill outlet 30 – 40 [°C].
 The mill tube is cooled down through the lower temperature
separator rejects
 A cyclone air separator only achieves marginal cooling of the
cement (5 – 10 [°C])

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HGRS Tikaria_Mill Workshop SEPT-07
Heating and Cooling - Units
 Mill Ventilation

 Water Injection

 Heating

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HGRS Tikaria_Mill Workshop SEPT-07
Water injection - Guidelines
 1 [m3/h] water = 15’000 – 30’000 [m3/h] air in heat dissipation
 Water acts like a grinding aid (mill capacity increase)
 Water increases the air dew point (watch out starts & stops) – must
maintain air temperature 25 to 30 oC higher than dew point in filter
 Not more than 1.0 – 1.5 [%] water injection on total mill feed basis

Water
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HGRS Tikaria_Mill Workshop SEPT-07
Water injection - Systems

 Water in 1st chamber only if mill feed > 100 [°C] and oriented towards
the ball charge
 If water is required in both chambers: 1/3 in the 1st chamber & 2/3 in the
2nd chamber, starting in 2nd
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Water injection - Devices

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HGRS Tikaria_Mill Workshop SEPT-07
Standard Installation

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HGRS Tikaria_Mill Workshop SEPT-07
Water injection – Control scheme

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HGRS Tikaria_Mill Workshop SEPT-07
Heating and Cooling - Units
 Mill Ventilation

 Water Injection

 Heating

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HGRS Tikaria_Mill Workshop SEPT-07
 Fresh feed moisture and mill performance
Clinker temperature & Hot gas generator
[t/h] dry proportion maximum capacity

100

90

2 3 4
[%] H2O in fresh feed
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Dying wet components without hot gas

+/- - +/-

-
> 90 - 95 [°C]

+
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HGRS Tikaria_Mill Workshop SEPT-07
Drying wet components with hot gas

- +/-
+/-

+
> 90 - 95 [°C]

+
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HGRS Tikaria_Mill Workshop SEPT-07
Drying wet components with hot gas
False air
Hot gas
+ Water steam
False air Fan gas

= Fan gas

False air
Water
steam
Hot gas

False air

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HGRS Tikaria_Mill Workshop SEPT-07
Hot gas generator
 Fuel type

 Nozzle adapted to the

operating range
 Control

 Hot gas generator type

(start/stop sequences)

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Drying wet components in a drying chamber

 Parameters to play with in a drying chamber:

 Gas flow path
 Material trajectory
 Material retention time
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