BUA GROUP –OBU CEMENT PLANT

Date: 12th Feb, 2019.

Process Inspection of Cement Mill 1

Process Observations:
(i) Intermediate Diaphragm Slot
a. Condition And Thickness: Slot looks good from physical inspection. No crack or
breakage.
b. Size and Shape of slot: 80% of the outer grate slots are plugged with grinding-media
while about 40% Inner grate segment are plugged as well.
 IMPLICATION :
Low mill ventilation
Less sweep in the mill with high cement temperature
Low output
High Mill temperature & Cement temperature

 Possible Root Cause:

Wearing out grind media (New Grinding media should be charging every 5 years)
Low feed-rate

 Recommendation :
Slot should be unplugged before the start of the mill.
Mills should d be run at designed through-put
Build considerable clinker stock
Change bag filters in the mill vent fan bag-house.
Follow rule of thumb in mill operation (air before water in cooling of the mill)
Exhaust the mill vent fan before increasing water injection

Sections of outer grate segment slot were plug by grinding media.

 BUA GROUP –OBU CEMENT PLANT

(ii) Centre Screen

i Centre screen is clean with no blockage or plug, no broken mesh, little wear and clean aperture

(iii) Chamber 1 Liner:

Thickness of mill liner varies between 50 to 70mm along the length of chamber 1 .Replacement
is advisable at about 25mm
 BUA GROUP –OBU CEMENT PLANT

(iv) Chamber 2 Liner:

Thickness of mill liner looks good from physical examination. Moderate to minimal wear.
 BUA GROUP –OBU CEMENT PLANT

(v) Inlet Diaphragm: Clean diaphragm with very little wear. Thickness ranges between 100 to 90
mm

(vi) Media balls: Media balls are well sorted, Material well classified.
Ball visible, material evenly distributed over grinding-media on ball charge in both compartments.
Reduction of average size of balls due to wear. Free Height was measure at 3.66 and 3.58m respectively representing
media ball wear of 0.15m and 0.08m for chamber 1 and 2 respectively. 7.9tons and 10.37 tons of grinding media will be
for chamber 1 and 2 top-up respectively.
 BUA GROUP –OBU CEMENT PLANT

Calculation :
Mill Charge calculation

Chamber 1 chamber 2
Effective diameter(D)m 5.4 5.4
Effective Length (L)m 4.67 11.23
Free Height(H)m (standard) 3.56 3.5
Centre Distance(h) m 0.87 0.83
Bulk Weight (W) 4.3 4.5

chamber 1 free height chamber 2 free height

3.57 3.72
3.8 3.61
3.61 3.5
Average 3.66 3.5
3.58

Designed Volume ChargeUsing the Fomular above

F = q/100.W.V where F is charge and V=volume

V= Pi* r2 * L where D is the effective diameter and r = D/2

Chamber 1 Designed charge at Optimal Output (100% charge)

V= 106.9m3
W= 4.3 t/m3
q= 29.2% (0.292)
F= 134.2 tons

Chamber 2 Designed charge at Optimal Output (100% charge)

V= 257.02m3
Ball Top-up Charge W = 4.5 t/m3
Wear = charge at commissioning - Charge at inspection q= 30.4 % (0.304)
Wear at inspection F= 351.6 tons
chamber 1 chamber 2
D=5.4 - 0.15 (5.23m) D = 5.4 - 0.08 (5.32m) Total wear = actual free height - standard free height
V = 100.59m3 V =249.64m3 Total Wear
q= 29.2% (0.292) q= 30.4 % (0.304) chamber 1 Chamber 2
F = 126.3 tons F=326.3 tons 0.15m 0.08m

Top-up for chamber 1

134.2 - 126.3
7.9 tons

Top-up for chamber 2

351.87 - 341.5
10.37 tons
 BUA GROUP –OBU CEMENT PLANT

Feed End View of Partition with Grate Segments

Outer Grate Segment

Inner Grate Segment
Center Hub or Cone
Center Sc reen (Mill Sweep)

Ty pical Chamber Filling Level

Outlet Diaphragm: 90% Outlet grate diaphragm slot of chamber 1 and 2 are plugged with
grind media balls. Very moderate level of wear was observed with no significance. Center
screen is free aperture are open, free of buildup/ media plug
Inner grate segment has minimal slot plug with grinding media balls and caked cement.
 BUA GROUP –OBU CEMENT PLANT

 IMPLICATION :
Low mill ventilation
Less sweep in the mill with high cement temperature
Low output
High Mill temperature & Cement temperature

 Possible Root Cause:

Wearing out grind media (New Grinding media should be charging every 5 years)
Low feed rate

 Recommendation :
Slot should be unplugged before the start of the mill.
Operate mill at optimal capacity.
Build considerable clinker stock to avoid feeding of hot clinker.
Change bag filters in the mill vent fan bag-house .
Follow rule of thumb in mill operation (air before water in cooling of the mill)
Exhaust the mill vent fan before increasing water injection