Ball Mill Checking Compatibility Mode

Slegten grinding course
1
Mill check up
I n thenameof Allah, theBeneficent, theM erciful
2
Preparation of the visit
1. mill must be running steadily (4h)
2. mill must be crash stopped
3. ask for the coarsest cement to be produced
(generally highest mill output)
Equipment to foresee
Circuit : thermometer / anemometer
plastic bags
Cpt 1 : buckets of 5 to 10 L / scoop / light
Cpt 2 : buckets of 1 L / plastic bags / sieve, scoop
Mill check up
3
Check up Procedure
1. Technical data sheet
2. 2 to 3 hours survey when mill steady
3. Parameters are collected every hour
4. Samples are collected every hour and before crash stop.
The installation is visited at work.
5. Mill must be crash stopped
6. Both compartments are visited and examined
7. Samples are collected in the mill
8. Separator visit
Mill check up
4
Survey before crash stop
Technical Data Sheet
Flow sheet
Ball charge history
Dailyproduction time
Sheet history
Auxiliary capacities
Control systems (if any)
5
C PJ 3 5 C PJ 4 5
C I R CU I T F E E DI N G
Output ( duri ng the vi si t ) 30 tph
A verage i n J une ( 28.9 tph ) ( 27.09 tph )
% H20 T C
Cl i nker ambient 61% 77 %
Gypsum 2.5% ambient 6% 6 %
L i mestone 3.5% ambi ent 33% 17 %
F I N I SH P RO DU CT
F ineness (target) 2 0 - 2 4 % R 4 0 1 5 - 2 0 % R 4 0
A B SO RB E D P O W E R
M otor amps
(A bsorbed power)
60 A mp
( 710 kW )
60 A mp
( 710 kW )
Speci fi c power 23.6 kWh/t
(24.5 kWh/t) (26.2 kWh/t)
S E P AR AT O R
T ype
F resh ai r damper 50 % open 50 % open
A i r flow 36000 m3/h 36000 m3/h
A i r reci rcul ation damper 100 % open 100 % open
Rej ect output
Cage speed (10-40rpm) 20 rpm 24 rpm
M I L L
D E DU ST I NG
A ctual ai rfl ow 25000 m3/h 25000 m3/h
Damper posi ti on 100 % 100 %
Depression at mi l l i nl et
Depression at mi l l outl et
M I S CE L L A NE O U S
Ear yes yes
Water i nj ecti on no no
Gri ndi ng ai d yes yes
C3S-C2S-C3A -C4A F 60-13-10-10 60-13-10-10
Main parameters
6
0
9 mm 10 mm
1
2
3 4
Sampling : separator & filter
5
6
7
7
Internal Visit of the Mill
Sampling in the mill
To excavate !
3x on the width
4x on the length Cpt 1
6x on the length Cpt 2
8
Collecting of
samples
9
Grinding balls
characteristics
10
Filling
degree
11
A
H
1
S
T
H
S
T
= p x D
2
/4 m
2
H
1
= H - D/2 m
A = 2ARCOS(2 x H
1
/D)
S
1
= D
2
/8 x (px A/180 - sinA)
R = S
1
/S
T
x 100
m
2
%
S
1
Filling
degree
12
Measured filling degree
Filling degree (%) / H/D
0.55
0.6
0.65
0.7
0.75
0.8
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Remplissage (%)
H
/
D
D
H
13
Grates slots size
check up
14
Cpt. length and
liner thickness
15
Discovery of unground
particles &
untightened grates
16
Material level and
filling degree in 2
nd
cpt.
17
Other various
measurements
18
Space between blades and external casing
Fan general condition
Sealsand valvesgeneral condition
Holes in distribution plate
Coating
Wear follow up.
Separator Inspection
19
Separator Inspection
20
Theoretical curves
CUMULATIVE PERCENT RETAINED
0
5
10
15
20
25
30
35
1 2 3 4 5 6 7 8 9 10
1/2"
1/4"
8 M
16 M
30 M
50 M
100 M
200 M
21
0,0%
5,0%
10,0%
15,0%
20,0%
25,0%
30,0%
35,0%
40,0%
45,0%
50,0%
55,0%
60,0%
65,0%
70,0%
75,0%
80,0%
85,0%
1 2 3 4 5 6 7 8 9 10 11
Posi ti on i n Mi l l
%

R
e
t
a
i
n
e
d
1/2
#4
#8
#16
#30
#50
#100
#200
P
a
r
t
i
t
i
o
n
3.66 m x 10.97 m 2162 kW
Conclusions from findings
22
0,0%
5,0%
10,0%
15,0%
20,0%
25,0%
30,0%
35,0%
40,0%
45,0%
50,0%
55,0%
60,0%
65,0%
70,0%
75,0%
80,0%
1 2 3 4 5 6 7 8 9 10 11
%

R
e
t
a
i
n
e
d
1/2
#4
#8
#16
#30
#50
#100
#200
P
a
r
t
i
t
i
o
n
3.66 m x 10.97 m 2162 kW
23
0,0%
5,0%
10,0%
15,0%
20,0%
25,0%
30,0%
35,0%
40,0%
45,0%
50,0%
55,0%
60,0%
65,0%
C1-1 C1-2 C1-3 C2-1 C2-2 C2-3 C2-4 C2-5 C2-6 C2-7 C2-8 C2-9 C2-10
P
e
r
c
e
n
t

R
e
t
a
i
n
e
d
1/2"
1/4"
#8
#16
#30
#50
#100
#200
P
a
r
t
i
t
i
o
n
5.18 m x 10.36 m 4100 kW
24
CUMULATIVE OVERSIZE DISTRIBUTION (%)
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
CH1/1 CH1/2 CH1/3 CH1/4 CH2/1 CH2/2 CH2/3 CH2/4 CH2/5 CH2/6
10
2.36
1.18
0.6
0.3
0.09
0.044
25
Granulometric curves
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
1/1 2/1 3/1 4/1 5/1 1/2 2/2 3/2 4/2 5/2 6/2 7/2 8/2
%

c
u
m
u
l
a
t
i
v
e

r
e
s
i
d
u
e
18mm
11,2mm
8mm
4mm
2,8mm
1mm
0,5mm
0,25mm
0,15mm
0,1mm
26
1 10 100 1000
1
99
98
97
96
95
90
85
80
70
60
50
40
30
20
15
10
5
3
2
4
characteristics
d75..............: 78.90
d50..............: 60.58
d25..............: 46.52
Imperfection.....: 26.73 %
dl...............: 10.00
#N/A
27
99.9
99
95
90
80
70
63.2
50
40
30
20
15
10
5
4
3
2
1
0.5
0.1 1 10 100 1000
dimension
0.1
1
5
10
20
30
36.8
50
60
70
80
85
90
95
96
97
98
99
99.5
Filter
Rejects
Separator
feeding
finish
Product
Fines
28
Granul ometric curves
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
1/1 2/1 3/1 4/1 5/1 1/2 2/2 3/2 4/2 5/2 6/2 7/2 8/2
%

c
u
m
u
l
a
t
i
v
e

r
e
s
i
d
u
e
18 mm
11,2 mm
8 mm
4 mm
2,8 mm
1 mm
0,5 mm
0,25 mm
0,15 mm
0,1 mm
29
A H
1
S
T
H
S
T
= p x D
2
/4 m
2
H
1
= H - D/2 m
A = 2ARCOS(2 x H
1
/D)
S
1
= D
2
/8 x (px A/180 - sinA)
R = S
1
/S
T
x 100
m
2
%
S
1
Filling degree
30
PLANT : OBOURG SAMPLE : cement
SEPARATOR : SD150 DATE : 24/03/1994
dim. feed fines rejects efficiency dim effic. (i) tromp
% P % P % P % % %
2 5.92 12.93 3.03 77.83 1 63.77 29.74
4 10.26 22.95 4.78 79.71 3 72.2 24.04
8 15.87 36.26 6.13 81.41 6 84.58 15.43
16 23.67 55.23 7.69 83.15 12 87.12 12.97
20 27.32 63.23 8.72 82.47 18 82.5 18.79
25 32.33 72.6 11.03 80.02 22.5 71.44 30.87
30 37.73 80.74 14.64 76.25 27.5 59.74 44.42
45 55.39 95.67 33.21 61.55 37.5 21.27 69.21
60 70.56 99.99 52.25 50.49 52.5 7.49 88.83
75 81.55 100 66.6 43.7 67.5 0.01 99.98
80 84.25 100 70.13 42.3 77.5 100
90 88.65 100 76.37 40.2 85 100
120 94.83 100 85.95 37.57 105 100
200 96.6 100 94.51 36.89 160 100
210 96.6 100 95.01 36.89 205 100
Blaine : 1324 cm2/gr 3778 cm2/gr 715 cm2/gr
Circulating load : 2,81 correlation : 0,9681 vf : 0,356 vg : 0,644
31
1
10
100
1 10 100 1000
t
r
o
m
p

%
Characteri sti cs
d75...........: 36,32
d50...........: 26,45
d25............: 19,26
Imperfection : 32,25 %
dl................: 14,41
by-pass....: 11,28 %
d75
d50
d25
dl
b
y
-
p
a
s
s
32
PLANT : OBOURG Mill : 3 diam. 5,2m
Date : 25/03/1994
% passing
sep. inlet Fines sep. sep. rejects Filter blaus. finish product
Sieve ()
0.7 1.90 4.46 0.90
1.4 4.69 10.03 2.48
2 5.92 12.93 3.03
3.2 8.62 19.19 4.19
4 10.26 22.95 4.78
8 15.87 36.26 6.13
12 20.06 46.56 7.00
18 25.39 59.15 8.06
30 37.73 80.74 14.64
45 55.39 95.67 33.21
56 66.86 99.13 47.75
70 78.47 100.00 62.79
90 88.65 100.00 76.37
110 93.76 100.00 83.64
135 96.08 100.00 88.80
165 96.60 100.00 92.27
210 96.60 100.00 95.01
260 96.60 100.00 96.20
Blaine 1199 cm2/gr 2841 cm2/gr 1324 cm2/gr 3216 cm2/gr 3187 cm2/gr
33
0.10
1.00
10.00
100.00
0.1 1 10 100 1000 10000
dimension
P
a
s
s
i
n
g

%
sep. inlet
Fines sep.
sep. rejects

Ball Mill Checking Compatibility Mode

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Slegten grinding course

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