VALID PRACTICE

FOR THE
PRODUCTION PROCESS

#10 – BALL CEMENT MILL

MONITORING, INSPECTION & EVALUATION

Athens, December 2007

 Valid Practice #10

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 Valid Practice #10

BALL CEMENT MILL

MONITORING, INSPECTION & EVALUATION

1. SAFETY GUIDELINES FOR BALL CEMENT MILL INSPECTION...................................3

2. BALL CEMENT MILL MONITORING...............................................................................6
2.1. Flow sheet.................................................................................................................... 6
2.2. Performance................................................................................................................ 7
2.2.1. Material Sampling.................................................................................................. 11
2.2.2. Gas measurement................................................................................................. 11
2.2.3. Radiation & Convection.........................................................................................11
2.2.4. Heat Balance......................................................................................................... 12
2.2.5. Process flow sheet.................................................................................................14
3. BALL CEMENT MILL INSPECTION...............................................................................15
3.1. Circuit efficiency......................................................................................................... 15
3.2. Separator efficiency................................................................................................... 17
3.3. Grinding efficiency...................................................................................................... 23
3.3.1. Guideline for Crash Stop........................................................................................ 24
3.3.2. Guideline for Empty Grinding Stop........................................................................29
4. BALL CEMENT MILL EVALUATION..............................................................................31
4.1. Relative mill speed calculation...................................................................................32
4.2. Axial sampling............................................................................................................ 33
4.3. Ball charge calculation............................................................................................... 35
4.4. Ball charge Management........................................................................................... 37
4.4.1. Recommended Ball Charge Sorting Frequency.....................................................37
4.4.2. Ball Mill Loading..................................................................................................... 37
4.4.3. Ball charge record keeping....................................................................................38
4.4.4. Ball sorting............................................................................................................. 39
4.5. Conclusions................................................................................................................ 40

Introduction
The purpose of the respective Valid Practice is to outline the parameters that
should be included in a Ball Cement Mill Evaluation as well as the appraisal of
the findings in order to identify the bottlenecks and suggest the necessary actions
that would result in the Ball Cement Mill Optimization.

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1. SAFETY GUIDELINES FOR BALL CEMENT MILL

INSPECTION
Initially, it should be noted that each Plant is responsible for the implementation
of the own safety procedures and the following are suggestive general guidelines
that could be included.
SAFETY FIRST
The workers should be trained for the job, work always in pairs and should be
equipped with the following safety equipment (Personal Protection Equipment,
PPE):
 Uniform
 Safety Boots
 Fireproof/heatproof Gloves
 Helmet
 Mask
 Safety glasses
 Body belt with rope
 Portable scaffolding with barriers
 Fork lift vehicle

Guideline for safe entry

 Danger of unwanted mill start-up during the mill inspection. The power of the
main motor should be cut off from the main power supply and the fuses
should be removed.
 Danger of unwanted material entry to the mill interior during the mill stoppage.
The power of the main raw material belt conveyors should be cut off from the
main power supply and the fuses should be removed. Also the respective
pipes should be blocked mechanically from the dampers or using steel
sheets. Given the dusty environment inside the mill, anyone entering the mill
must be wearing a face shield and goggles.
 Danger of severe burning in case hot gases enter the mill. The safety damper
at the hot gases duct should be closed, its power should be cut off from the
main power supply and the fuses should be removed. Also the damper should
be blocked mechanically.
 Prior to dismantling any doors and guards, make sure that the following
equipment has been stopped and interlocked to prevent starting:
 Mill main motor
 Mill and separator fan
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 All feeding equipment

 Water spraying and grinding aid addition
 Heat generator
 The power supply for the above mentioned equipment must be effectively
locked by means of padlocks in the MCC (motor control center) room to
prevent accidental starting of the motors. The supervisors in charge of the
inspection team undertaking work inside the mill must keep the key for the
lock. The padlocks must remain fitted until all personnel have left the mill
and all doors and guards have been remounted.
 Apart from the respective Plant’s safety procedure, everybody should keep in
mind:
 Ensure Safe Isolation:
 Mill drive, auxiliary drive, feed belts, etc
 Physical barrier (locked closed/de-activated)
 Comply with local “Permit to Work” procedure
 Ensure Safe Access:
 Consider fall hazard (e.g. access door on top of mill)
 Confined space – someone outside mill
 Maintain ventilation to “cool” air space
 In case of a ball mill inspection there is danger of speeding balls from the
pavement due to contact with the fork lift wheels. The pavement should be
properly cleaned.
Mill door opening
 Danger of load displacement during the mill door opening. Ensure that the
ball charge is leveled horizontally using the auxiliary mill drive, the mill door is
at the correct location for opening and finally before opening the door ensure
that the mill is not linked to the auxiliary drive.
 Danger of mill door falling in case of hoist malfunction. After lifting the mill
door it should be placed on the mill shell.
 Danger due to high dust concentration as well as high level of hot material.
After opening the door the leveling of the ball charge as well as the level of
hot material is checked with a flash light.

 Case 1: Ball Mill entry through the top of the mill

 Scaffolding and protective barrier placement: Danger of fall during
getting in or out of the mill. Ensure that the scaffolding and the

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protective barriers are safely placed at the top of the mil shell and that
they are firmly attached at least to two different points.
 Ladder placement: Danger of fall during getting in or out of the mill.
Ensure that the ladder is safely placed at the top of the ball charge
and that it is tightly connected to the mill shell or the protective
barriers.
 Case 2: Ball Mill entry through the side of the mill
 Installation of false-door: Danger of ball charge falling. A false-door
(temporary for easy in/out) is installed and the loading displacement is
taken into consideration.
 False door removal: Danger of load displacement during the mill door
opening. Ensure that the mill door is at the correct location and
remove the false-door.
During Inspection
 Danger of faint. In case somebody faints, he should be wearing the body-belt
in order to facilitate easier taking out.

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