IMPROVED CEMENT QUALITY AND GRINDING EFFICIENCY BY MEANS OF CLOSED MILL CIRCUIT MODELING. A Dissertation by GLEB GENNADIEVICH MEJEOUMOV Submitted to the Office of Graduate Studies of ‘Texas ARM University in partial flfillment of the requirements forthe degree of DOCTOR OF PHILOSOPHY December 2007IMPROVED CEMENT QUALITY AND GRINDING EFFICIENCY BY MEANS OF CLOSED MILL CIRCUIT MODELING. A Dissertation by GLEB GENNADIEVICH MEJEOUMOV Submitted to the Office of Graduate Studies of ‘Texas ARM University in partial flfillment of the requirements forthe degree of DOCTOR OF PHILOSOPHY Approved by: Chair of Committee, Dan Zollinger Committee Members, Dallas Litle Donald Saylak: Sergiy Butenko Viadimir Zhukov Head of Department, David Rosowsky December 2007 ‘Major Subject: Civil EngineeringABSTRACT Improved Cement Quality and Grinding Efficieney bby Means of Closed Mill Circuit Modeling. (December 2007) Gleb Gennadiovich Majeoumov, BS. Ivanovo State Power University, Russia; MS. Ivanovo State Power University, Russia Chair of Advisory Committee: Dr. Dan Zollinger Grinding of clinker isthe last and most energy-consuming st ‘manufacturing process, drawing on average 40% of the total energy required to produce of the cement ‘one ton of cement, During this stage, the clinker particles are substantially reduced in size to generate a certain level of fineness as it has a direct influence on sch performance characteristics of the final product as rate of hydration, water demand, strength development, and other. The grinding objectives tying together the energy and fineness requirements were formulated based on a review of the state of the at of clinker arinding and numerical simulation employing the Markov ehain theory. The literature survey revealed that not only the specific surface of the final product, but also the shape of its pasticle size distribution (PSD) is responsible for the ‘cement performance characteristics. While itis feasible to engineer the desired PSD in the laboratory, the provess-specific ree SD in the industrial mill are not availabe, Based on a population balance principle and stochastic representation of the rendations on how to generate the desired particle movement within the grinding system, the Markov chain model forthe ci ‘consisting ofa tube ball mill and high efficiency separator was introduced through the ‘matrices of grinding and classification. The grinding matric was calculated using the selection and breakage functions, whereas the classification matrix was defined from the ‘Tromp curve of the separator, The resulls of field experiments carried out at pilot ‘cement plant were used to identify the models parameters. The retrospective processdata pertaining tothe operation ofthe pilot grinding circuit was employed to validate the ‘model and define the process constraints ‘Through numerical simulation, the relationships between the controlled (fresh feed rate; separator cut size) and observed (fineness characteristics of cen prochcton rate; specifi energy consumption) parameters of the circuit were defined. The analysis of the simulation results allowed formulation of the process control procedures withthe objectives of decreasing the specific energy consumption of the mill, ‘maintaining the targeted specific surface area of the final produet, and governing the shape ofits PSD,DEDICATION ‘To my mother and fatherACKNOWLEDGMENTS First ofall, T would like to thank my academic advisor Dr. Dan Zollinger and the rest of the committee members: Dr. Dallas Little, Dr. Don Saylak, Dr. Sergiy Buteako, ‘and Dr. Viadimir Zhukov for thei expert advice in the preparation of this dissertation | would like to express particular gratitude to my teacher and mentor, Dr. Saylak, for his faithful support of all of my undertakings: during, my studies at Texas ASM University. Without his fatherly advice, timely jokes, and sound auspices, my stay in the rogram would not have been the same, His remarkable eloquence, tireless perseverance, and strong affection for applied research will always keep me enthused. I thank Dr. Saylak for his every day encouragements and editorial input to this dissertation. ‘1am greatly indsbted to my dear teachers, Dr. Vadim Mizanov and Dr. Vladimir Zhukov, whom [frst me inthe classroom in my freshman year of high s oo, for their ‘enormous contiibution to my scholastic attainments and their patient guidance in my search for scientific selfactalization. I wuly admire their great passion and novel approach for teaching and research. Iwill always dwell onthe special atmosphere they ‘created atthe Department of Applied Mathematies at lvanovo State Power (Engineering) University andthe enlightening conversations they inspired at the department's tea table. Without thei direction and suppor, this work simply would not have been possible, 1 arateflly acknowledge the role Ms, Dorit Hammerling and Mr. Mark Morgan, played! in granting me the opportunity to perform this research and gain the invaluable hhands-on experience in the field. My special thanks go to my fiend and colleague, Ross ‘Taylor, for his generosity in sharing with his profound knowledge and experience in ‘mamufacturing and process control | Would like to express my sincere appreciation to my close friends: Tracy Lostak, Bogusia Styblinski, Tomasz Styblinski, Ania Kaminski, Tatyana Paramonova, Xenia Sharonova, Kim Tessanne, Edith Arambula, Nina Britt, Anna and Stanislav Glagoleako, Amaury Vuillaume, David Havbrich, Reza Ashtiani, Jose Gavinha, and everybody else ‘who cares about me, for ther faithful support of my endeavors during the past years. Finally, Iam endlessly grateful to my parents for their love, support and patience.ASTM Blaine cL. fx) GEC M PDH PsD Qe pm siD wie NOMENCLATURE American Society for Testing and Materials Flow sate of a material stream, mass per time unit Specific surface aren value as per ASTM C 204, Matrix of classification Circulation load Particle size distribution state vector Density probability (frequency) function, percent or faction Matrix of grinding Grade efficiency curve High efficiency separator Matrix ofthe closed grinding circuit Process data historian Particle size distibution ‘Cumulative passing flmetion, percent or fraction Revolutions per minute Rosin Rammler Standard deviation ‘Tons per hour ‘Water to cement ratio Particle size, um Cut size ofthe separatorABSTRACT. DEDICATION. ‘TABLE OF CONTENTS ACKNOWLEDGMENTS. NOMENCLATURE, ‘TABLE OF CONTENTS, LIST OF FIGURES. LIST OF TABLES 1 INTRODUCTION, La 12, 13 1a, ‘Cement as « Construction Material. ‘Cement Manufacturing Process Description, Finish Milling Efficiency Improvement. Research Objectives and Outline ofthe Dissertation, 2, STATE OF THE ART OF CLINKER GRINDING AND SIMULATION. ‘Cement Fineness and Its Significance ‘Cement Grinding Teelnolony (Clinker Grindability Simulation and Contrl of Clinker Grinding 3, DEVELOPMENT OF THE MARKOV CHAIN MODEL. 31. 32. 33 Matrix of Grinding ‘Matrix of Classification ‘Matrix Model of the Closed Grinding Circuit. 4. FIELD DATA COLLECTION AND ANALYSIS. 4a, 42. 43 4a. Finish Grinding Circuit ot the Pilot Plant, In-Situ Sampling Procedure. Laboratory Testing and Data Analysis, Sources of Exror Page 10 10 40 2 2 98 9s tot 106 an 114 125 145, NUMERICAL SIMULATION AND ANALYSIS. Sl. Model Identification, 52. Ideal Grade Efficiency Curve 53, Parametric Response of the Cireuit 6. CONTROL ALGORITHM SUGGESTIONS. Gl. Rejects-Fresh Feed Space 62. Boundary Concitions 63. Control Strategy Objectives. GA. Clinker Griadability Pattern 7. CONCLUSIONS AND RECOMMENDATIONS FOR FUTURE WORK. TL. Conetusions. 72. Recommendations for Future Wark. REFERENCES. APPENDIX A LASER PARTICLE SIZE DISTRIBUTION DATA, APPENDIX MATLAB CODE FOR THE MARKOV CHAIN MODEL. via Page 138 138 ry 146 156 136 1ST 158 160 12 162 165 167 173 175 18sLIST OF FIGURES Page Figure 11. Portland Cement (after Bhatt eta, 2004), 1 Figure 1.2. A Simplified Schemati of a Dry Cement Manufacturing Process. 3 Figure 13. Energy Distibution among Cement Manufacturing Equipment. 6 Figure 14. Factors ofthe Finish Grinding Influencing the Cement Performance... Figure 2.1. Graphical Representation of Patticle Size Distribution B Figure 2.2, Typical Particle Size Distribution of a Type I Portland Cement Sample. ....16 Figure 2.3. Rosin- Rammler Representation of Cement PSD. a1 Figure 24. Blaine Calculation within the Particle Sie Fraction, 4 Figure 2.5. Effet of Blaine Fineness on Concrete Strength (after Neville, 1998). .....38 Figure 2.6 Schematic of the Most Common Cement Mills. Al Figure 2.7. Tube Ball Mills Used for Cement Finish Grinding, “4 Figure 2.8. Arrangement of a Two-Compartment Tube Ball Mill 4 Figure 2.9. Intemal Dynamics ofthe Grinding Media. 46 Figure 2.10. Liner Design ofthe Tube Ball Mill 46 Figure 2.11. Action of the Separating Force (after Drzyunala, 2003) 0 Figure 2.12, Schematies of the Most Common Ai Separators, 2 Figure 2.13. Intemal Arrangement of the High Efficiency Separator. 58 Figure 2.14, Material Streams Surrounding Separator 59 Figure 2.15. PSD ofthe Material Streams Surrounding Separator Cy Figure 2.16, Tromp Curve of the High Efficiency Separate. a Figure 2.17. Efficioney of the Separator Using eal Tromp Curve, ot Figure 2.18, Different Types of Cement Grinding Cireuits 65 Figure 2.19. Closed Finish Milling Cirent, oa Figure 2.20. Graphical Representation of the Process Data Historian 7” Figure 2.21. Grindability vs. Blaine Value by Zeisel Method 16 Figure 2.2. Specific Energy Consumption of the Tube Ball Mill. 80 Figure 2.23. Comparison of Different Types of Grinding Simulation Methods. 2Figure 2.24. Types of Process Control (afer Fuerstenau and Han, 2003) Figure 3.1. Typical Sampling Points of the Closed Milling Circuit. Figure 3.2. Conversion of the Measured PSD to the Set of Computational Sieves. Figure 33. Selection and Distribution Breakage Functions Figure 3.4. Two-Dimensional Cell Model ofthe Grinding Process Figure 3.5. Mattix Mode of the Closed Grinding Citcut. Figure 4.1. Actual Closed Milling Circuit tthe Pilot Plant, Figure 42. Process Ranges of the Separator Parameters. Figure 4.3. Duet Pressure Measurement Using Pitot S-Tube. Figure 44. Traverse Points for Pressure Measurement in a Round Duct. Figure 4.5. Test Set-Up forthe Cement Density Determination. Figure 46, Sieve Analysis ofthe Fresh Feed Materials. Figure 4.7. Horiba Laser Scattering Particle Size Distribution Analyzer LA-910. Figure 4.8, Final Product PSDs in Different Testing Regimes Figure 49. Separator Tromp Curves in Different Testing Regimes. Figure $1. Step Distibution Breakage Function Figure 5.2. Identification of the Markov Chain Model Parameters. Figure $3. Simulation of the Ideal Classification, Figure 5.4. Model Response to the Fresh Feed Adjustments. Figure 5.5. Product Fineness Response to the Fresh Feed Adjustments Figure 5.6 Correction Coefficient forthe Rejects Rate Conelation, Figure 5.7. Model Response to the Separator Cut Size Adjustments, Figure 5.8. Product Fineness Response tothe Separator Cut Size Adjustments Figure 59. Simulation ofthe Specific Surface Area Control Figure $10. Selection Funetion a-Parameter vs. Cieulation Load ofthe Citeut, Figure 6.1. Rejects-Fresh Feod Operational Space Figure 6.2, Variation of Clinker Grindablity with Time. Page 93 95 96 9 102 107 mm 116 120 121 125 126 re 130 131 139 ue us MT ur 150 151 151 152 1st 1st 160LIST OF TABLES ‘Table 2.1. Tabular Representation of Particle Size Distribution. ‘Table 2.2. Two Parameter Particle Size Distibution Functions, ‘Table 2.3. ASTM Specification Requirements for Cement Fineness. ‘Table 24, Most Co qvon Mills Employed in the Cement Industey ‘Table 2.5. Most Common Air Separators Employed in the Cement Industry “Table 2.6, Process Parameters ofthe Closed Finish Grinding Cireit, ‘Table 4.1. Design Parameters ofthe Grinding Equipment at the Pilot Plant. ‘Table 4.2. Experimental Design for the Separator Performance Analysis. ‘Table 4.3. Process Data Pertaining to the Material Sampling Procedure. ‘Table 44. PSD, Rosin-Rammler, and Tromp Curve Parameters Results, Table 45. Variability ofthe Blaine Measurements as per ASTM C 204, ‘Table 5.1. Model-Calculated Specific Surface Area vs. Measured Values. ‘Table 5.2. Model Calculations for Different Circulation Loads ofthe Cireuit. ‘Table A.1. Separator PSD Data Collected During Sampling Procedure (Day 1). Table A.2. Separator PSD Data Collected During Sampling Procedure (Day 2). Page 2 18 28 41 si or a 7 128 129 136 us 155) 173 141. INTRODUCTION 1.1. CEMENT AS A CONSTRUCTION MATERIAL Cement is a common construction material; a binder in mortars and concretes that hardons in the prosonce of water. Cement is called Jydhaulic, when the hardened product is stable in an aqueous environment. The most widespread hydraulic cement today is portland cement —a finely ground gray-to-white powder composed primarily of calcium silicates, calcium sluminates, and calcium ferrites, derived from mineral ingredients (Figure 1.1) Figure 1.1. Portland Cement (after Bhaty etal, 2004). ‘When mixed with water, portland cement sets (stiffens) ia a few hours and hardens over a period of weeks aud months. These phenomena are caused by chemical reactions associated with hydration between the components of cement and water. ‘The most common use of portand cement is in the production of concrete Concrete is composite consisting of agerepate (gravel and sand), cement, and water. ‘Asa construction material, concrete can be cast in almost any shape desired, and once hardened, can become a structural (load bearing) clement. Portland cement i also used {in mortars (with sand and water only) for plasters and screeds, and in grouts (cement- ‘water mixes) placed into gaps to consolidate brick walls, foundations, etc. “The format of this dissertation follows the Journal of Materials in Civil Engineering.1.2. CEMENT MANUFACTURING PROCESS DESCRIPTION ‘There are three fundamental stages in the coment manuficturing process: + Raw mis preparation + Clinker formation + Cement grinding 1.2.1. Raw Mix Preparation ‘The chemical analysis of the raw materials is expressed in terms of oxides and the most important of these are CaO, SiO>, Fe,0s, and, ALOs. Theoretically, any ‘material that can contribute these oxides may constitute the raw mixture “The major raw mineral used in cement production that provides CaO is limestone (CaCO}). It usually quarried fiom a caleareons rock, which in some locations already hhas the desired mineralogical composition. The rest of the oxides are obtained by the ‘addition of clay or shale, which are complementary with limestone in meeting the stoichiometric needs for developing portland cement. Minor adjustments tothe chemistry ‘of the cement are made by adding sand (Si0:), iron ore (Fe.0%), and/or bauxite (Al:03) Affer the raw materials have been quarried and brought fo the plant, the individual row oméx ingredients are crushed to particle sizes below 100-120 mm, proportioned to produce the desired cement chemistry, and supplied toa row mill shown, in Figure 12. This schematic illustrates dry cement manufacturing process, which ‘operates with a nearly dry raw mix containing less than 20% moisture by mass. This is ‘opposed to a wet process, in which water is added to the raw mix to fonm a slum, wiih is then ransported to the kiln, ‘The raw mill shown in Figure 12 is a vertical roller mill with an internal particle 0, the specific surface area of fraction jean be calculated as 220) where, Blaine, Specific surface area of fraction i Equation (220) detemnines the specific surface area of the individual ration in the size interval of [x coal As per (2-14) by adding the Blaine values across all size factions, the total specifi surface area ofthe whole sample can be determined as = Slo') ea where, x1 —Lower size boundary of faction i: 11 —Upper size boundary of fraction i ‘The computation of the specific surface area ofthe material by means of the PSD data delivers a unique Blaine value result. It is not the ease, however, if a reverse assessment of the PSD is attempted based on the measured Blaine value. The total specific surface area is an integral characteristic of the sample fineness, and a single ‘number can not effectively represent the entire cement PSD. In fact, two cements with different ratios of fine and coarse particles and therefore described by different PSD's, ‘cam have the same Blaine value (Mizonov eta, 1997) ‘This ambiguity presents a significant obstacle for the adequate control of the ‘cement quality if the fineness of the product is assessed solely by the Blaine As it will be shown later, the performance characteristics of ci lopend not oaly on the surface area of the material, but alsa the proportion of the fine and coarse particles, ie, the shape of the PSD of cementa 2d. (0,325 Sieve Percent Passing ASTM C 430 prescribes the test method for determination of hytdraulic cement fineness by moans of the 4S-ymm (No. 325) sieve. In principal, the described methed resembles the conveational si ing technique discussed earlier with the exception that ASTM C 430 employs a wet sieving procedue. (One gram of the cement is frst placed on a clean, dry 45-um (No. 325) sieve and thoroughly wet with a gentle stream of water. Then, the spray nozzle is adjusted to produce certain pressure, and the sieve containing the sample is washed withthe jet of ‘water ina cieular motion for | minute, After this, the sieve and the residue ae dred in an ‘oven o over a hot plate. The residue is then brushed off of the sieve, woighed, and the corrected percent ofthe material passing the 45-ya (No. 325) sieve is reported as a result ‘The amount of the material below 43-um ean also be estimated using the ‘cumulative PSD of the cement sample (see Figure 2.2). However, this estimation may be lightly diferent fiom that of the ASTM C 430 test result due to the differences in the principles underlying the two measurement techniques. 2.4.2. ASTM Fineness Requirements ‘There are several ASTM standards concerning fineness of cement. The following list summarizes the test methods for measuring different aspects ofthe portland cement fineness: PSD, specific surface area, and percent passing through the standard sieves, ‘+ ASTMC 115—Fineness of portland cement by the turbidimeter: ~ Specific surface area and PSD; + ASTM C 204 Fineness of hydraulic cement by ar-permeability apparatus: > Specific surface area: Blaine value, ‘+ ASTM C430 Fineness of hydraulic cement by the 451m (No. 325) sive: > No. 325 sieve % passing by mass; ‘+ ASTM C 786 —Fineness of hydraulic cement and raw materials by the 300-pm (No. $0), 150- zn (No. 100), and 75-pm (No. 200) sieves by wet methods: >No. 50, 100, and 200 sieves % passing by mass28 ‘The ASTM methods above merely describe the measuring procedures, ie, they do not prescribe any particular fineness values as the targets. The only two ASTM specification type publications covering requirements for the cement fineness ae: + ASTMC 150. — Standard specification for portland cement; + ASTM C 1157 ~ Standard performance specification for hydraulic cement. ASTM € 150 describes eight types of portland cement and their uses. It ists test ‘methods for cement characterization and specifies some of the chemical composition and physical properties requirements. The fineness requirements (see Table 2.3), however, are very scaree and prescribe only a single value of a minimum specifi surface area for all 8 types of cement. ASTM C 150 does not provide any recommendation forthe 45-pn_ (No, 325) sieve percent passing value ‘Table 23, ASTM Specification Requirements for Cement Fineness Test Methods ‘Specification Pubileatons asmcits | astacac4 | astuc430 Turbidimeter | "Blaine | Sieve No. 325 ASTMC 150 Yes Yes! tie Portland Cement min 160mg | min 280 nko aSTMC 1187. we Yes Yes Performance of Hydraulic Cement Novalue Novae ASTM € 1157 presents the performance requirements (strength range limits, fe), place any restrictions on the compestion of the cement as well a its constituents to time of satting, in some cases heat of hydration and sulfate resistance, ut does not achieve these requirements. It presses thatthe manufacturer repets both the amount retuned, when wet sieved onthe 4S-um (No, 325) mesh, and the specific surface area (Blaine value) by the air permeability apparatus. However, it does not set auy specific tarmets forthe determined fineness characteristics (see Tale 2.3)