AREA REPORT

RAW MILL

Submitted by:
Zohaib Ahmed Memon (96658)
SMT (PRODUCTION)
FLOW SHEET:

Bridge type Reclaimer long Proportionating

Reclaimer belt Bins

Mill feeding Mill feeding long

Weigh feeders
inclined belt belt

Gridning Ball Grinding Ball

Mill drying drum
Mill Chamber 1 mill Chamber 2

V Air slide Bucket Elevator Dedusting Fan

Dynamic
Bag Filter Fine Air Slide
Seperator

Raw Meal
Pnuematic Air
Homogenizing
lift
Silo
AREA DISCRIPTION (PROCESS):
Raw Mill section starts from Reclaimer it is the second equipment belongs to the pre-homogenization
of raw materials. After the material is stacked the stacker, the reclaimer starts reclaiming the material.
The reclaimer has a harrow which make the material fall at the reclaimer bottom. Here, the material is
taken over by a scraper conveyer, discharged into the reclaiming belt conveyer. Finishing the pile, the
reclaimer will be automatically stopped by means of a limit switch. The material is transported to
proportioning bins. The proportioning bins (mixture bin, shale bin, iron ore bin) are used to control the
mixture that is fed into the raw mill with the help of weigh feeders.

After the raw material is reclaimed it is transferred into the Proportioning bins via conveyor belt. The
opening and closing of the proportioning bin weigh feeder is controlled by the main CCR and amount of
raw material is defined by Laboratory. The weigh feeder installed for this purpose is Schenck weigh
feeder and electric load cell which shows the load of feed coming from bins. There are 3 proportioning
bins:

 Mixture Bin 250 tons capacity

 Iron Bin 150 tons capacity
 Shale Bin 150 tons capacity

The fine material is charged into the Ball Mill, The purpose of ball mill is to reduce the size of the coarse
material. Ball mill has two chambers. Each chamber is loaded to one-third of its capacity with grinding
media (balls) of different sizes. The first chamber is filled with balls of sizes from 60 mm to 100 mm,
while the second chamber is filled with balls of sizes from 30 mm to 50 mm. The two chambers of the
ball mill are followed by a drying drum in which hot gases are coming from the outlet of ID fan to
remove moisture from raw material.

There is Dedusting fan which is creating a negative draft inside the ball mill, and the output of the
grinding chambers of the ball mill is collected in a bucket elevator that takes grinded raw material up
into an air slide and is taken to the Dynamic Separator.

Separation process of coarse and fine material takes place in dynamic separator there are 8 cyclones in
dynamic separator and a classifier from which coarse particles separated and send into the grids air slide
from which it is recycled and goes into the ball mill for fineness. The fine material is collected in fine air
slide and sent to a blending silo via a network of multiple air slides and pneumatic airlift.

BALL MILL SPECEFICATION:

TYPE BALL MILL
CAPACITY 170-250 TPH
GRIDNING MEDIA STEEL BALLS
DIAMETER 4.4M
LENGTH 11.6M
ROTATION 15.4 RPM
 DRIVE #1 / DRIVER #2 2000 KW, 1000 RPM

AREA OBJECTIVE:
The objective of Raw mill is to Grind the raw material coming from bins and increase the fineness of
grinding material for the storage in raw meal silos. Main objectives are as follows:

 Remove Moisture
 Fine Grinding
 Coarse and Fine Separation
 Increase Reactivity
 Proper Mixing
 Raw Meal Storage

EQUIPMENT LIST (RATING/ALARMING/TRIPPING)

CURRENT:
SR.NO. NAME KW/RATED ALARM TRIPPING NORMAL
AMP: RUNNING
LOAD
1 RECLAIMER 18.5/37.5 27 30 22
LONG BELT
2 RECLAIMER 30/63.5 55 59 53
INCLINED BELT
3 MILL MAIN 2000/220 190 215 N/A
MOTOR #1
4 MILL MAIN 2000/230 190 215 N/A
MOTOR #2
5 DEDUSTING 315/40 36 37.5 30
FAN
6 BUCKET 90/198 150 170 140
ELEVATOR
7 SEPERATOR 400/51.7 42 45 35
FAN
8 SEPERATOR 55/112 90 100 70
BAG FILTER
9 DYNAMIC 200/390 150 390 100
SEPERATOR

PRESSURE:
SR.NO NAME RANGE ALARM REMARKS
1 SEPERATOR INLET 0 to -30 mbar -20 mbar LOW ALARM
PRESSURE
 2 SEPERATOR 0 to -40 mbar -10 mbar LOW ALARM
OUTLET PRESSURE
3 MILL INLET 20 to -20 mbar 0.5 to -7 mbar LOW/HIGH
PRESSURE ALARM
4 MILL OUTLET 0 to -70 mbar -52 mbar HIGH ALARM
PRESSURE
5 SILO AIR LIFT 0 to 1000 mbar 475 mbar HIGH ALARM
PRESSURE
SR.NO NAME RANGE ALARM TRIPPING DELAY
1 MILL 0 to 10 bar 1.2 1 10 sec
REDUCER 1
L.P
LUBRICATION
PRESSURE .
2 MILL 0 to 10 bar 1.2 1 10 sec
REDUCER 2
L.P
LUBRICATION
PRESSURE
3 MILL INLET 0 to 400 bar Nill Nill Nill
H.P PUMP
LUBRICATION
PRESSURE
4 MILL OUTLET 0 to 400 bar Nill Nill Nill
H.P PUMP
LUBRICATION
PRESSURE
5 MILL INLET 0 to 10 bar 1.2 1 10 sec
L.P PUMP
LUBRICATION
PRESSURE
6 MILL OUTLET 0 to 10 bar 1.2 1 10 sec
L.P PUMP
LUBRICATION
PRESSURE
7 SEPERATOR 0 to 10 bar Nill Nill Nill
GEAR BOX
LUBRICATION
PRESSURE
9 MILL MOTOR 0 to 10 bar 1.5 1 10 sec
2
LUBRICATION
PRESSURE

TEMPERATURE:
SR.NO NAME RANGE ALARM TRIPPING DELAY
1 MILL REDUCER 0 TO 200 C 90 C 120 C 10 SEC
1 BEARING
FROM (A TO F)
2 MILL MAIN 0 TO 200 C 100 C 120 C 10 SEC
MOTOR 1
WINDING
(A,B,C)
3 MILL REDUCER 0 TO 200 C 90 C 120 C 10 C
2 BEARING
FROM (A TO F)
4 MILL MAIN 0 TO 200 C 90 C 100 C 10 SEC
MOTOR 2
WINDING
(A,B,C)
5 SEPERATOR 0 TO 200 C 110 C 120 C 10 SEC
FAN WINDING
(A,B,C)
6 DEDUSTING 0 TO 200 C 110 C 120 C 10 SEC
FAN WINDING
(A,B,C)
7 E.P FAN 0 TO 200 C 110 C 120 C 10 SEC
WINDING
(A,B,C)
8 SEPERATOR 0 TO 200 C 100 C 120 C 10 SEC
SUPERIOR
BEARNING 1
AND 2
9 SEPERATOR 0 TO 200 C 100 C 120 C 10 SEC
INFERIOR
BEARING
10 MILL INLET 0 TO 200 C 60 C 65 C 10 SEC
BEARING (A, B)
11 MILL OUTLET 0 TO 200 C 60 C 65 C 10 SEC
BEARING (A,B)

POWER CONSUMPTION:
We have taken out power consumption of Raw Mill on 9th September and according to the electrical
department the record showed that Raw Mill 100400 units of electricity in 24 hours day and night shift
and in that time 4725 tons Raw material was grinded in Ball mill.

𝑢𝑛𝑖𝑡
𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛

100400/4725 = 21.24 𝐾𝑊
21.24
And if we take out hourly power consumption of Raw mill we will get 24
= 0.88𝑘𝑤/ℎ
TROUBLESHOOTING:

BALL MILL:
In ball mill we face many issues when we run it on full capacity. The most important thing in ball mill is
the ratio of media and feed. If the feed is high and media is low it will cause problems i.e.no proper
grinding will be done and the quantity of grids will be increased and we will not get fineness in raw
material. We perform following operation to check the efficiency of Ball mill.

AIR SLIDE PROBLEMS:

Air slides are used to convey material from one place to another just like in raw mill, bucket elevator
discharge material in v air slide which transport it into the Dynamic separator and there are more air
slides after that, the main issue we face in air slides is choking due to following reasons:

 Wear of canvas in air slide due to rush of raw material or high blower air pressure
 If the bag filter is not working properly and not taking out the excess air from air slide then air
slide will be positive and get choked.
 If the air slide blower pressure drops due to some reasons it will not move the material properly.
 There is always a inclination in air slide air and if there will be a problem in angle of inclination it
will also cause problems in moving material.

MECHANICAL PROBLEMS:
There are 2 main drives of ball mill and they play a very important role in running mill efficiently and
Lubrication system is also very important because in ball mill white metal bearing is used which is also
called U bearing, it is very sensitive and require proper lubrication there is High pressure pump which
make the oil film in the bearing and lift up the mill so that bearing cannot be damaged the following
problems we face from mechanical side:

 Motor Vibration
 Gear box Vibration
 Abnormal sound
 Increase in temperature of bearings if lubrication system is not working properly.

CONCLUSION:
From the above detailed report we found that if the raw mill is functioning properly and giving us
required results it can help us in further process and we can make clinker efficiently and in an optimized
way without facing any problems. If the Raw Meal is properly homogenized it will never cause any
problems in future process and we will meet our quality standards that is why Raw Mill area should
work properly and efficiently.