Ball mill inspection procedure

Ball mill inspection

p procedure
p
General
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
p
Ventilation
Weighfeeder
Instrument
C t l lloop
Control

Navigation
I.E.E.E West Coast

© Christian Pfeiffer
Conference 2009
8th – 9th October
Tim Nowack
Victorville// CA
Victorville
U.S.A
Senior Process Engineer
The Green Tree
Convention Center Christian Pfeiffer Maschinenfabrik GmbH
 Ball mill inspection procedure

General:
General
Material
The process engineer should be the
sampling
Longitudinal
doctor of the system.
system
sampling
Filling degree The “doctor” is required for:
Material level
Internals
condition 1) implementation of “Health checks”
Ball charge
Î Regular action
Trompcurve
p
Ventilation 2) urgent investigations of actual
Weighfeeder process problems
Instrument Î Non-regular action
C t l lloop
Control

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This presentation focuses on the regular
Conference 2009
8th – 9th October
“Health check” procedure.
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 Ball mill inspection procedure

General:
The “Health checks”consist of standard
General
measurements on a frequent basis
Material
sampling
Type of measurement: 12 months schedule
Longitudinal
sampling Circuit mat. granulometry Q
Filling degree Mill longitudinal sieving Q Q Q Q
Material level
Ball charge filling degree Q Q Q Q
Internals
condition Mill material level Q Q Q Q
Ball charge Mill internal conditions Q Q Q Q
Trompcurve
p
Ball charge sampling Q
Ventilation
Weighfeeder
Separator Tromp curve Q

Instrument Separator ventilation Q

C t l lloop
Control Mill ventilation
til ti Q

Navigation Weigh feeder calibration Q

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Control loop verification Q

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 Ball mill inspection procedure

General:
General
“Healths checks” are important in order to:
Material
sampling
Longitudinal
sampling
• build up a knowledge and data base about the
Filling degree system performance
Material level
• record the data and display them in trends for fast
Internals
condition and easy diagnostic of problems
Ball charge
Trompcurve
p
Ventilation
The main advantage:
ad antage
Weighfeeder
Instrument Knowledge basis allows to investigate the root
C t l lloop
Control
cause of problems and to avoid problems by
Navigation early reaction based on the trend results.
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 Ball mill inspection procedure

General:
General
For each measurement make sure you have:
Material
sampling
Longitudinal
sampling
• design data of the machines/equipment available.
Filling degree
• constant/stable operation condition for at least 2 hours.
Material level
Internals • recorded the actual operation data like:
condition
Ball charge • Production rate [t/h], Product type, composition [M-%]
Trompcurve
p
Ventilation
• Actual
A t l and
d ttargett fineness
fi off product
d t [Blaine
[Bl i or Residue]
R id ]
Weighfeeder
• Actual mass flow rate (e.g. separator grits, water demand,
Instrument
etc.)
C t l lloop
Control

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• Electrical power consumption of the main equipment
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8th – 9th October
• Actual operation parameter of the main equipment
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(e.g. separator speed, damper positions)
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 Ball mill inspection procedure

Circuit material g
granulometry:
y
General Sampling points
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
p
Ventilation
Weighfeeder
Instrument
C t l lloop
Control

Navigation
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 Ball mill inspection procedure

Circuit material g
granulometry:
y
Sampling point: r Procedures
General
Material Clinker feed à Sieving
sampling
Gypsum feed 1 x per H 2O
Longitudinal 10 kg 50, 25, 16, 8, 4, 2,
sampling Additive No.1 feed Test H 2O
1, [mm]
Filling degree Additive No. 2 feed H 2O
Material level
Mill outlet
tl t material
t i l Ã
Internals
Pre-screening with
condition Separator feed material Ã
450 µm sieve
Ball charge
Separator grits material Ã
Trompcurve
p
S
Separator fifines cyclone
l 1 Ã PSD from 1-450
Ventilation
Separator fines cyclone 2 1x à µm with Laser
Weighfeeder
0.5 kg every equipment (e.g.
Instrument Separator fines mix hour à Cilas, Malvern,
C t l lloop
Control à Sympatec)
Filter dust 1 (weighfeeder)
Navigation Filter dust 2 (circuit dedusting) Ã
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Conference 2009 Filter dust 3 (mill dedusting) Ã
8th – 9th October Blaine [cm
[cm²/g]
/g]
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Cement Ã
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 Ball mill inspection procedure

Longitudinal
g sampling:
g
General Sampling points at crash stop
Material
sampling 0.5 1m 1m 1m 0.5 0.5 1m 1m 1m 1m 1m 1m 0.5

Longitudinal
sampling 1.1
1.1 1.2
1.2 1.3
1.3 1.4
1.4 2.1 2.2 2.3 2.4 2.5 2.6 2.7

Filling degree
Material level
Internals
condition
Ball charge Sample weight:
Trompcurve
p
1st compartment: 1-2 kg
Ventilation
Weighfeeder 2nd compartment: 0.5 kg
20 cm
Instrument
C t l lloop
Control

Navigation
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 Ball mill inspection procedure

Ball charge
g filling
g degree:
g
General Measurement by free height
Material
sampling
Longitudinal
sampling
Filling degree M

Material level
Internals
condition
Ball charge
Trompcurve
p 1. Measure averageg internal diameter,, Di
Ventilation 2. Measure height, h, in three different points along
Weighfeeder axis for each grinding compartment
Instrument
C t l lloop
Control For best results the measurement takes place in an
Navigation empty mill (mill feed stopped for approx. 10 min).
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 Ball mill inspection procedure

Mill material level:

General Inspection only at crash stop
Material Record the material level approx. each meter along axis
sampling
Longitudinal
sampling
Filling degree
Material level
M
Internals
condition
Ball charge
Trompcurve
p
Ventilation
Weighfeeder
Too high =
Instrument
above charge
C t l lloop
Control
Good = ½ Ø
Navigation below charge
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Too low = >1
1Ø Good material level
U.S.A below charge for 1st compartment
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 Ball mill inspection procedure

Mill material level:

General Inspection only at crash stop
Material Record the material level approx. each meter along axis
sampling
Longitudinal
sampling
Filling degree
Material level
M
Internals
condition
Ball charge
Trompcurve
p
Ventilation Too high = > 50mm
Weighfeeder above charge
Instrument
C t l lloop
Control
Good = approx.
pp 20 mm
above charge
Navigation
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8th – 9th October ball charge Good material level
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 Ball mill inspection procedure

Mill material level:

General Inspection only at crash stop
Material Record the material level before and after transfer points
sampling
Longitudinal
sampling
Filling degree
Material level
M
Internals
condition
Ball charge
Trompcurve
p
Ventilation
Weighfeeder
Instrument
C t l lloop
Control

Navigation
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8th – 9th October
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 Ball mill inspection procedure

Mill internals condition:

General Crash stop information: M a in m ill driv e :
power installed 1495 [kWh]
power absorbed n.a. [kWh]
Material Type of product: OPC mill speed 16,72 [r.p.m.]
sampling critical speed 72,67 [%]
T o t a l m ill f e e d: n.a. [t/h] Finish mill No. 2
n.a. [t/h] Free heightcalculation:
Longitudinal F re s h f e e d:
n.a. [t/h] Ø 3,5 m x 9,6 m
C o a rs e re t urn: Pabs= 1247 kW
sampling
Filling degree 2nd
1st compartment comp. 3rd compartment
Material level
1-4 1-2 1-8
Internals
condition
M
Ball charge
+
Trompcurve
p
2,115 mm 1,290 5,380 mm -
Ventilation
Weighfeeder
Instrument
C t l lloop
Control

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Conference 2009
8th – 9th October
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 Ball mill inspection procedure

Mill internals condition:

General
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
p
Ventilation
Weighfeeder
Instrument
C t l lloop
Control

Navigation
I.E.E.E West Coast
Conference 2009
8th – 9th October
Victorville// CA
Victorville
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The Green Tree

Convention Center
 Ball mill inspection procedure

Mill internals condition:

General
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
p
Ventilation
Weighfeeder
Instrument
C t l lloop
Control

Navigation
I.E.E.E West Coast
Conference 2009
8th – 9th October
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 Ball mill inspection procedure

Ball charge
g sampling:
g
General Solution 1) Total sorting of ball charge
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
p
Ventilation
Weighfeeder
Instrument
C t l lloop
Control

Navigation
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8th – 9th October
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Ø 18 Ø 20 Ø 25 Ø 30 Ø 40 Ø 50 Ø 60 Scrap
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 Ball mill inspection procedure

Ball charge
g sampling:
g
General Solution 2) Analysing the actual grinding media
Material composition by spot samples.
sampling
Longitudinal 1st compartment:
t t
sampling
Filling degree
50 balls per sample
M
Material level 2nd compartment:
p
Internals
condition 200 balls per sample
Ball charge Avg. Piece weight Date: 23.02.2006
Input Table Prepared by: Now

Trompcurve
p Cu stom e r D ata:
Grinding balls
Project-No.: 3 3.4 2 0
-
Ventilation Project:

Customer: -

Weighfeeder Plant: -

Installation: Ø2.4m x 5.0m w ith QDK 8,5-F

Compartment: Monochamber (1/3 lifter - 2/3 class.)

Instrument
Ball - Ø 60 50 40 30 25 20
C t l lloop
Control Std. 886 g 513 g 262 g 111 g 64 g 33 g
Max 1400,0 g 681,0 g 374,0 g 176,0 g 80,0 g 44,0 g
Min 682,0 g 375,0 g 177,0 g 81,0 g 45,0 g 14,0 g
891.80 g
Piece Mass
Navigation 1 891,8 g 891,8 g
2 886,2 g 886,2 g
I.E.E.E West Coast 3 879,6 g 879,6 g
4 878,0 g
Conference 2009 878,0 g
5 873,5 g 873,5 g
8th – 9th October 6 873 3 g
873,3 873 3 g
873,3
Victorville// CA
Victorville 7 861,0 g 861,0 g
8 860,6 g 860,6 g
U.S.A
9 858,2 g 858,2 g

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 Ball mill inspection procedure

Ball charge
g sampling:
g
General Solution 2) Analysing the actual grinding media
Material composition by spot samples.
sampling
Results of grinding media sampling
Longitudinal Sampling Point
1 2 3 4 5
sampling Ball Ø
pc. weight mass-% pc. weight mass-% pc. weight mass-% pc. weight mass-% pc. weight mass-%
60 24 19920 53,56% 3 2552 10,54% 3 2353 9,68% 0 0 0,00% 0 0 0,00%
Filling degree 50 23 11112 29,88% 20 9269 38,28% 10 4651 19,13% 0 0 0,00% 0 0 0,00%
40 18 4293 11,54% 35 8468 34,97% 19 4592 18,88% 5 1209 11,58% 4 952 4,96%
30 13 1384 3,72% 28 2997 12,38% 59 6328 26,02% 28 2943 28,19% 63 6617 34,46%
Material level 25 8 481 1,29% 14 835 3,45% 73 4369 17,97% 66 3923 37,57% 144 8576 44,67%
20 0 0 0,00% 3 93 0,39% 66 2025 8,33% 76 2366 22,66% 98 3056 15,91%

Internals Total 86 37190 100,00% 103 24215 100,00% 230 24316 100,00% 175 10441 100,00% 309 19200 100,00%

condition
Ball charge 60,0%

Trompcurve
p 50,0%

Ventilation 40,0%

Weighfeeder 30,0%

Instrument 20,0%

C t l lloop
Control
10,0%

Navigation 0,0%
0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5
I.E.E.E West Coast Ø 60 mm Ø 50 mm Ø 40 mm Ø 30 mm Ø 25 mm Ø 20 mm
Conference 2009
8th – 9th October N ame
Avg P iece Weight
Avg.
Ins t a lla t io n -
Now -
Victorville// CA
Victorville M ill dim e ns io ns
D ate P ro je c t . N o . 33.420 C us t o m e r -
U.S.A 23.02.2006 C o unt ry - P la nt -

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 Ball mill inspection procedure

Separator tromp curve:

General Define the sampling points
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
p
Ventilation
Weighfeeder
Instrument
C t l lloop
Control

Navigation
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8th – 9th October
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 Ball mill inspection procedure

Separator tromp curve:

General Define the sampling points
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals Separator fines
condition Separator feed material material from
Ball charge before splitter each cyclone
Trompcurve
p
Ventilation
Separator rejects
Weighfeeder
Instrument material and
C t l lloop
Control Check the stable
condition of the circuit
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 Ball mill inspection procedure

Separator tromp curve:

General Define the sampling points
Material
sampling
Sampling point: r Procedures
Longitudinal Separator feed
sampling à Pre-screening with 450
material µm sieve
Filling degree
Separator grits
Material level
1x à PSD from 1-450 µm with
Internals material 0.5 kg Laser equipment (e.g.
condition every
Ball charge
Separator fines hour à Cilas, Malvern,
cyclone 1 Sympatec)
Trompcurve
p
Separator fines Fineness acc
acc. to Blaine
Ventilation à [cm²/g]
Weighfeeder cyclone 2
Instrument
C t l lloop
Control

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 Ball mill inspection procedure

Separator Ventilation:
General Basics: Air flow measurement
Material
sampling
Select your equipment
Longitudinal Prandtl-Pitot Tube S-Type Tube
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
p
Ventilation
Weighfeeder
Instrument
C t l lloop
Control C ti ffactor
•Correction t required
i d ((~0.84)
0 84)
•No correction factor needed
Navigation
•Easy to operate within 15° angle •Misalignment results in mistakes
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8th – 9th October •Only in low vortex channel •Preferred for high dust loaded
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channels
U.S.A •Not for high dust loaded channels
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 Ball mill inspection procedure

Separator Ventilation:
General Measurement points:
Material
sampling
Separator circuit with cyclones Separator circuit with filter
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
p
Ventilation
Weighfeeder
Instrument
C t l lloop
Control

Navigation
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= Air flow, Static pressure,
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Temperature
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 Ball mill inspection procedure

Mill Ventilation:
General
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
p
Ventilation
Weighfeeder
Instrument
C t l lloop
Control

Navigation
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Remark: Consider minimum
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= Air flow, Static pressure, 10% false air intake after mill.
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Temperature
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Convention Center
 Ball mill inspection procedure

Weigh
g Feeder Calibration:
General a) Static calibration - feeder not in operation
Material
sampling • Zero-point - adjustment (local
Longitudinal control box, no load)
sampling
• Span adjustment with calibration
Filling degree
weight (local control box)
Material level
Internals
condition
b) Calibration with feeder in operation
Ball charge (preferred if possible)
Trompcurve
p
• operate weigh feeder with defined
Ventilation
setpoint and load material into truck
Weighfeeder
for e.g. 10 minutes, while mill is shut
Instrument
down
C t l lloop
Control
• weigh truck empty and loaded,
Navigation calculate throughput and adjust
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 Ball mill inspection procedure

Instrument Verification:
General
Material
sampling
1) Electronically
Longitudinal
sampling • Check and adjust zero-point and span with
Filling degree e.g. mA-transmitter
Material level
Internals
condition
Ball charge 2) Operation check
Trompcurve
p
Ventilation
Weighfeeder • Compare control room indication with local manual
Instrument measurement of temperature, pressure and flow
C t l lloop
Control

Navigation
Î Adjust transmitters
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 Ball mill inspection procedure

Control loop Verification:

General 1) Operation check
Material
sampling • record process parameters with
Longitudinal control
t l lloop iin operation
ti over
sampling period of e.g. 6-8 hours with
Filling degree constant production
Material level • record mill ppower consumption
p
Internals at counter (kWh)
condition
Ball charge
Î Adjust control loop
Trompcurve
p
parameters
t if necessary
Ventilation
Weighfeeder
Instrument
Information on:
C t l lloop
Control
• Available information at the CCR
Navigation
• Control system
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• Control strategy
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Convention Center
 Ball mill inspection procedure

Thank you for your attention

General
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Questions?
Trompcurve
p
Ventilation
Weighfeeder
Instrument
C t l lloop
Control

Navigation
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Conference 2009
8th – 9th October
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