Page 1 Training THALOFA

Operation of the Cement grinding plant

Training

Polysius Headquarters / Germany

19. May – 13. June 2008
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Page 3 Training THALOFA

Control Loops
• Fresh fee (F) + Grits (G) = constant
• ball mill sound level / mill feed
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Control Loop
• Temperature mill outlet /
water injection chamber 1 & 2
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Additional monitoring:
Pressure behind ball mill [mbar]
• Pressure behind Separator [mbar]
• Amount of grits [t/h]
• Electrical ear for mill noise [%]
• Power of Bucket Elevator [A or kW]
• Speed of Separator rotor [rpm]
• Water flow chamber 1 & 2
[l/h]
Page 7 Training THALOFA

Start up of Cement Mill, process adjustments

• Material feed rate  60% of nominal
• Pressure after tube mill 15 mbar
• Position of guide fans at SEPOL 65 – 70 °
• SEPOL Rotor speed 70 -75 % of max.
• Damper before system fan: 60 – 80
• Jalousie dampers before SEPOL: 100 %
• Fresh air damper before SEPOL: 30 – 50 %
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Ball Mill

Ball Charge

Diaphragm
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Ball Mill Components - Intermediate Diaphragm

Adjustment tool

knee lever

Lifter
adjustment
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Intermediate Diaphragm

• for equal material flow of material from 1st to 2nd compartment.

• adjustable scoops to influence flow characteristics of mill.

• can be set to reduce or accelerate flow of material to second

compartment.

• Scoops adjustment influences material filling degree of compartment 1.

• Longitudinal samples should be taken to determine if scoops need

adjusting.
 
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Mill Outlet with Separation Cone

250-600 g/m3
(approx. 15 %)

Air

Material

approx. 85 %
 Page 12 Training THALOFA

Coarse grinding in chamber 1.

• Lifting liners for cataract movement.

• Cataract – grinding action by impact, crushing and friction.

Grinding balls lifted higher; more ejected from surface

at top of mill.
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Second compartment used for fine grinding.

• Grinding balls carried up by friction, rolls down surface.

• Cascade movement – grinding by friction (shear) and compression.

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Ball Movement depends on these factors:

• Mill Speed
• Ball Charge
• Liner Shape
• Mill Diameter

Critical Speed

Filling Degree
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Mill Speed

• Speed of ball mill is expressed as percentage of critical speed.

• Critical speed is attained when centrifugal force is high enough

that all media sticks to mill wall, rotating with the mill.

• Normal operating speed for finish grinding cement mills

averages about 75 % of critical speed.
 Page 16 Training THALOFA

Ball Charge

s for cement grinding normally operate at a

2% “filling degree”.

ing degree” is defined as volume of grinding media as percentage of total mill internal volume.

speed, liner shape and mill diameter are normally constant parameters.

efore, only an adjustment to filling level and ball size distribution can be made.
 Page 17 Training THALOFA

Ball Mill Liners

• Protect the mill shell and assist in grinding action.

• First Compartment – Lifting liners: “impact” grinding action for large particle reduction.

• Second Compartment – Classifying Liners – shifting finer media to discharge end of mill where fine grinding
is required; “friction” grinding.

Chamber 1: Chamber 2:
Lifting liners Classifying liners
 
 - Used mainly for coarse grinding in first

Page 18 compartment.

- Lifting liners must lift media high enough to allow

Training THALOFA
sufficient impact force for coarse grinding.
 Page 19 Training THALOFA

Classifying Liners

• Used in second or fine grinding compartment.

• The liner shape causes a classification of grinding media.

• Decreasing ball size along grinding path.

• Grinding efficiency is increased.

Theory is, that ball size should decrease with particle size being ground.
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Liner Shape
Classifying Liners
• Greater impact forces cause larger ball “jumps”
over the lining hill.
• Smaller balls retained by the lining hill.
-- Result: larger balls in the front of second compartment.
-- Smaller balls at discharge end of mill.
Page 21 Training THALOFA

Mill Optimisation

1. Optimise Chamber 1!!!

2. If chamber 1 is O.K. ---> Optimization of Chamber 2.

Page 22 Training THALOFA

SEPOL - Initial Settings

• Guide Vanes – 65 - 70 degrees

• Fresh Air Inlet Damper 30 -50 %

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SEPOL - Inlet Damper

NOTE: Dedusting system should be set to 1-2 mbar negative
pressure exists at SEPOL inlet.

Louvers are being

adjusted to wear pattern
at the rotor.

Separating
Air

Air channels
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SEPOL - Guide Vanes

clockwise rotation

counter-clockwise rotation
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SEPOL settings

• Guide vanes setting acc. to the

drawing or to 65 -70°.

~65 - 70° • Maximum separating air.

• Speed of separator rotor set to

suit the required cement fineness.
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SEPOL - Setting of Guide Vanes

• if residue ratio too low…

set guide vanes more tangentially.

• if residue ratio too high…

set guide vanes more radially.

Adjustments should be carried out in

5-10 degree steps.

After each adjustment samplings are necessary.

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SEPOL - Separator Formulas

Circulation Factor = SA / SF
= (f - g) / (a - g)
SA (a)

SA, SF SG [t/h]: separator feed,

separator fines, separator grits
SG (g)
a, f, g: fineness feed, fines, grits SF (f)
(Blaine or residue)
F

(100 - f) (g - a)
SEOPL efficiency = --------------------
(100 – a) (g – f)
Page 28 Training THALOFA

TROMP Curve

Separation
Fines

Coarse

X –Particle Size
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Typical TROMP Curve

Separation
100%

90%

80%
Fines
70%

60%

50%
40%
30% Coarse

20%
10%
0%
1 10 100 1000
Particle Size (Microns)
Page 30 Training THALOFA