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=
] [
1
(11)
where:
f
i
- feed rate of size fraction i (t/h)
p
i
- product flow of size fraction i (t/h)
a
ij
- the mass fraction of size that appear at size i after breakage
r
i
- breakage rate of particle size i (h
-1
)
s
i
- amount of size particles inside the mill (tonnes)
d
i
- the discharge rate of particle size (h
-1
)
The model consist two important parameter, the breakage function (a
ij
) that describe the
material characteristic and breakage/discharge rate function (r
i
/d
i
) which defines the
machine characteristics and can be calculated when feed and product size distribution are
known and breakage function is available.
The air classifier controls the final product quality. Therefore, the air classifier has a
crucial role in the circuit and a lot of attention is paid on the design and operation of the
air classifier. The classification action is modeled using the efficiency curve approach
(Lynch, 1997). Effect of the classifier design and operational parameters on the efficiency
is complicated and work is in progress to improve the current models.
THE CASE STUDY
Potential benefits of using the Barmac crusher for clinker pre-crushing were studied for a
cement plant. Figure 2 shows the proposed cement grinding circuit.
Double-deck
screen
Barmac
crusher
Clinker
Storage
Storage
Two-compartment
dry ball mill
Air
classifier
Finished
cement
Figure 2. Simplified cement grinding circuit with precrushing stage
Barmac B-series VSI (vertical shaft impactor) crushers are applied to a broad range of
materials in minerals and aggregate industry. Due to the autogenous grinding action it
is especially efficient for high abrasive materials such as cement clinker. The crushing
action is schematically presented in Figure 3.
When the incoming rock passes over the distributing plate the rock is divided in three
separate streams and is forcefully impacted on the rock lining at the distributing plate.
The material is being rapidly accelerated by the centrifugal force of the rotor action and is
compressed against the rock lining which is formed in the crushing chamber. Multiple
events occur and a variety of forces act on the individual particles as they proceed. The
crushed rock is discharged through the clearance between the crusher chamber and the
rotor wall.
Figure 3. Schematic of Barmac crusher operation
0
10
20
30
40
50
60
70
80
90
100
0.01 0.1 1 10 100
size (mm)
c
u
m
%
p
a
s
s
Clinker
case A
case B
case C
Figure 4. Clinker and the crushed clinker size distribution (case A, B, C) using
Barmac crusher
Figure 4 shows the clinker size distribution and predicted Barmac crusher size
distributions. These data are based on Barmac pilot testing and the simulations. It can be
observed that the crushed clinker has a significant amount (10-20%) of -75 micron
material. As the cement size is in this size range, it could be concluded that the Barmac
crusher produces a significant amount of finely ground cement.
Table 1. Bond method power calculation for two-compartment mill
Mill feed F
80
(mm) EF
4
Power required (kW) Difference (%)
15.5 1.06 3564 0.0
4.5 1.01 3251 8.8
3.0 1 3133 12.1
1.8 1 3018 15.3
It can be seen that a reduction in two-compartment mill power in the order of 915% is
calculated for different crushed clinker feed F
80
sizes. Corresponding to the change in
factor EF4, a 5-6% reduction comes from improving the milling efficiency with finer
feed. In order to get this improvement, the ball charge size distribution in the first
compartment needs to be adjusted for finer feed.
As energy is consumed in pre-crushing stage, the total power required will be sum of
two-compartment ball mill and Barmac crusher power. Figure 4 shows how the total
comminution energy consumption depends on the Barmac crusher product size. It can be
seen that the total energy consumption would reduce with reducing the product size of the
Barmac crusher. This indicates that the cement grinding efficiency may be improved up
to 10% compared to a conventional circuit without pre-crushing. The alternative benefit
of introducing the Barmac crusher in pre-crushing stage is increasing the circuit capacity,
as the capital investment is relatively low compared to HPGR.
25
26
27
28
29
30
31
32
33
34
35
0 2 4 6 8 10 12 14 16
Barmac product P80 (mm)
T
o
t
a
l
g
r
i
n
d
i
n
g
k
W
h
/
t
Figure 4. Specific power requirement for cement grinding circuit including pre-
crushing stage with Barmac crusher
The PBM modelling of the clinker grinding was carried out using the principles described
earlier. It should be noted that in order to obtain the site specific model constants,
detailed surveys of the milling circuit are required: the size distribution of the material in
each stream as well as from different points inside the mill. In this study the model
constants published in the literature (Benzer et all, 2001, 2003) were used. The base case
flowsheet generated in the J KSimMet grinding simulation software is shown in Figure 5.
The first compartment was modeled as two ball mills in series, diaphragm between the
first and second compartments was represented as a screen and the second compartment
is represented as one ball mill. Information given in the flowsheet is solids throughput
(t/h), 80% passing size and % passing 0.01 mm.
Figure 5. Greens Island base case JKSimMet simulation flowsheet
Using the above base case model, simulations with different feed size distributions (raw
clinker, and pre-crushed clinker using the Barmac crusher) were carried out, keeping the
product size constant at P
80
=0.038 mm. The resulting increase in throughput is shown in
Table 2.
Table 2. Simulated increase in throughput
F
80
(mm) Simulated throughput
(t/h)
Increase (%)
15.5 110 0.0
4.5 125 13.6
3.0 135 22.7
1.8 140 27.3
Table 3 summarises the potential increase in throughput from using a Barmac crusher to
pre-crush the cement clinker. It should be noted that this result does not consider any
circuit physical limitations such as conveying, aeration and air classifier capacity.
Table 3. Predicted increase in throughput using the Bond and grinding modelling
method base case throughput 110 t/h
Feed
F80(mm)
minus 75 microns in
Barmac product (%)
% throughput increase,
Bond method
% throughput
increase, PBM
15.5 0 0 0
4.5 12.1 9.1 13.6
3.0 15.4 14.3 22.7
1.8 20.5 18.2 27.3
It can be observed that Bond calculations gave less throughput increase than PBM
simulations. This could be because the PBM simulation results may have been
overoptimistic as the separator performance was kept the same. A model capable of
simulating changes in performance with different air separator loads was not available.
STIRRED MILLING POTENTIAL
As the product size decreases the energy required for particle breakage increases rapidly.
The pre-crushing stage increases the milling efficiency in the first compartment of the
two-compartment mill where coarse milling takes place. Pre-crushing however does not
affect milling in the second compartment apart from producing significant amount of
final product size (10-15 %). In order to produce the final product size, the length of
second compartment is usually double that of the first compartment. Smaller grinding
balls are also used in the second compartment. The efficiency of fine grinding in the
second compartment is largely controlled by the size of grinding balls. Due to limitation
of the mills rotational speed, the smallest ball size is usually restricted to about 15 mm.
Cement grinding using stirred mills (Pilevneli and Azizli, 1999) indicates that using
smaller media (5-8 mm range) improves grinding energy efficiency up to 50% using
stirred mills. For specialized types of cement, which are finer than Portland, this figure
would be even higher. Significant benefits of using Tower mill were also reported
(Shibayama et all, 2000) as well as the industrial applications for production of fine
12000 Blane cement. The stirred mills can be used in different roles and it is expected
that their application in the future will be significant.
CONCLUSION
There is a scope for significant optimisation of the traditional cement grinding circuits.
Grinding process modelling and simulation methods can be used for optimisation. A case
study conducted using the data from an industrial cement plant indicates that:
Pre-crushing of cement clinker using a Barmac crusher offers realistic benefits to a
cement plant in terms of process efficiency.
The introduction of the Barmac crusher can increase the cement circuit throughput in
order of 10-20%, providing that there is no capacity limitation in other parts of the
circuit. This is an attractive option due to relatively low capital investment of the
Barmac crusher. The overall energy efficiency of the circuit can also be improved in
order of 5-10%.
The stirred milling technology could further improve energy efficiency of cement
grinding. Initial work indicates great potential and significant development in this
direction should be expected.
REFERENCES AND BIBLIOGRAPHY
Austin, L. G., Weymont, N.P., and Knobloch, O., 1980. The simulation of air-swept
cement mill. Proceeding of European Symposium., Particle Technology. Amsterdam
Bond, F.C., 1985. Testing and Calculations. SME Mineral Processing Handbook ,
Norman L. Weiss, Editor in Chief.
Bond, F.C., 1961. Crushing and Grinding Calculations Parts I and II, British Chemical
Engineering, Vol 6., No 6 and 8.
Bond, F.C., 1962. Crushing and Grinding Calculations - April 1962 Additions and
Revisions. Allis-Chalmers Manufacturing Co., Milwaukee, Wisconsin.
Brugan, M.J ., 1991. Mills at grinding edge. Pit and Quarry. Pp 34-41
H. Benzer, L. Ergun, M. Oner and A.J . Lynch, 2001. Simulation of Open Circuit Clinker
Grinding. Minerals Engineering, vol 14. No 7, pp 701-710.
H. Benzer, L. Ergun, M. Oner and A.J . Lynch, 2003.Case Studies of Models of Tube Mill
and Air Separator Grinding Circuits, Proceedings: XXII International Mineral Processing
Congress, Chief Editors: L. Lorenzen and D.J . Bradshaw, pp 1524-1533.
Lynch, A. J . (1977). Mineral Crushing and Grinding Circuit Their Simulation,
Optimisation, Design and Control. Amsterdam, Elsevier Scientific
Magdalinovic, N., 1990. Mathematical Model for Determination of an Optimal Crusher
Product size. Aufbereitungs-Technik 31, Nr 5,
Morrell,S. and Shi,F.,and Tondo,l997., Modelling and Scale-up of High Pressure
Grinding Rolls, In the proceedings of the XX International Mineral Processing
Congress(IMPC), Aachen, Germany, September 1997.
Pilevneli, C.C., Khairun Azizi Mohd Azizli, 1999. Semi-Batch Dry Grinding Tests of a
Pilot Scale Vertical Stirred Mill. Proceedings of VIII Balkan Mineral Processing
Conference, Belgrade, Yugoslavia.
Rowland, C.A., 1975. "The tools of power: How to evaluate grinding mill performance
using Bond Work Index to measure grinding efficiency" AIME Annual Meeting, Tucson,
Arizona.
Shibayama, A., Mori, S., Bissombolo, A., 2000. Studies on Comminution Mechanism of
the Dry Tower Mill KD-3. Proceedings of the XXI International Mineral Processing
Congress, Rome.
Zhang, Y. M., Napier-Munn, T. J ., and Kavetsky, A., 1988. Application of comminution
and classification modelling to grinding of cement clinker. Transaction Institution of
Mining and Metallurgy (Section C: Mineral Processing and Extractive Metallurgy). C207
- 213
Zhang, Y. M., Napier-Munn, T. J ., 1995. Effects of particle size distribution, surface area
and chemical composition on Portland cement strength. Powder Technology 83, pp 245-
252