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1.1 Grinding Unit Optimization

Size reduction is the most energy intensive unit operation in cement industry accounting for about 70
percent of the total power consumed. Further, it is a highly inefficient operation with only one-percent of
the energy input being actually used for production of new surfaces. The operation is also has lot of
product quality variation due to recycle material from the separator. Therefore there is significant incentive
and scope for optimization of size reduction operations in a cement plant to achieve consistent product
quality and reduction in specific energy consumption. Along with energy optimization and smooth
operations, product quality control is a critical requirement. One of the key product quality parameters is
particle size, which is usually measured in terms of Blaine (a representative specific surface area), and/or
residue on a given mesh. This quality parameter is usually not measured online due to a lack of reliable and
affordable sensors. In practice, product quality is analyzed in the laboratory by taking samples periodically
and the results are used for any corrective action. Irregularity in sampling and delays in analysis coupled
with inherent errors in collecting a representative sample, make quality control a challenging task.
CemPac Mill Optimizer is a state-of-the-art multivariable predictive control software package for the
optimization of closed-circuit raw mill and finish grinding circuits. The solution provides supervisory control
for the fresh material feed rate and classifier operating parameters in the circuit.
The key operating advantage provided by the Mill Optimizer is the smooth running of the circuit with
minimal operator intervention. The Mill Optimizer is thus a powerful tool to realize production goals in this
critical operation in the cement manufacturing process. The case below details the implementation on a
standard finish circuit ball mill..
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1.1.1 Results and Discussion

This section summarizes control strategy and performance of CemPac Mill Optimizer from an
implementation at Grasim Cements, Bathinda Grinding Unit in India. Figure 1 is a schematic of the target
Mill Circuit.

To Vent

Sep. Fan Step

RPM

Clinker Gypsum

To silo
Rejects Blaine

TPH Mill Fan rpm

Flyash Draft

Filling B.E Amps

In Draft

CV Controlled / Monitored Variable

MV Manipulated Variable

Figure 1: Mill Circuit Schematic

1.1.1.1 CONTROL PHILOSOPHY

The control solution described here has been designed to address following basic issues of mill control.
Maintain cement quality parameters i.e. Blaine & residue on 32 micron.
Maintain mill accumulation and mill discharge bucket elevator load.
Minimize specific power consumption
Maximize throughput
The important manipulated variables are fresh feed, separator RPM, separator fan steps, mill fan RPM.
Major controlled variables are throughput, specific power consumption, product blaine , product particle
size (3 to 32 micron), mill accumulation, elevator load, separator rejects, separator fan load
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1.1.1.2 MILL ACCUMULATION AND DISCHARGE ELEVATOR LOAD CONTROL

To operate mill at optimal level it should be ensured that mill should always be optimally filled. It results in
maximum accumulation & maximum bucket elevator load. It should be ensured that there is less variance
in accumulation, which minimize wear and tear of grinding media. From Figure 2 it is observed that with
CemPac Mill Optimizer the mill gets stabilized rapidly and variance in elevator load is also reduced. A
reduction in % standard deviation in bucket elevator load from 15.16% to 8.8% was recorded.

Figure 2: Mill Stabilization Trend

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1.1.1.3 BLAINE CONTROL

CemPac Optimizer has a unique feature for controlling quality through a novel Soft Sensor, which predicts
Blaine on a minute-to-minute basis and also tracks laboratory measurements whenever updated. The
following figure shows how Blaine is controlled around the target Blaine value i.e. minimum possible Blaine.

Figure 3: Blaine Control with Soft Sensor

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1.1.1.4 CLOSING THE LOOP WITH ONLINE PARTICLE SIZE ANALYZER

The Grasim Bathinda grinding unit is equipped with online particle size analyzer supplied by Malvern.
CemPac Mill Optimizer is also configured to use this information for controlling particle size between 3 to 32
microns. Following figure shows control of Particle size around the target i.e. minimum possible %passing.

Figure 4: Particle Size Control with On-Line Analyzer

1.1.1.5 THROUGHPUT AND SPECIFIC POWER OPTIMIZATION

Improvement in throughput was a natural result of tight control of mill accumulation and product quality. A
net increase of 5% in throughput and 6% reduction in specific power consumption was
recorded at this plant as a result of this implementation.