CKHC LA LETTRE AUX CIMENTIERS Les Cahiers Techniques Cahier Technique "Grinding" * May 1995 Contents Introduction— Chapter 1: Clinker grindability 1 - Objectives 2 - Factors influencing grindability 3 - Influence of different factors 8-1 - Major factors Lime saturation - belie level: Percentage of S03. Burning level 3-2-Other factors Pore size Crystal size Raw Mix bumabiity 56 Of MgO) aan Reducing buming conditions: 4 - Diagnosis and actions to be taken 4-1 - Clinker grindabilty measurement 4-2. Buming level assessment 4-3 Lime saturation 4-4 Reducing atmosphere 4-5 - Raw Mix consistency: Chapter 2: First compartment 1 - Objectives and function: 2 - Diagnostic check list 3 - Influence of different factors 3-1 = Major factors: Residue leaving the first compartment -—- Material level: SSsasessuuceaanenenecestannEnEEEE Partition (diaphragm) S10 ewan nnen nen e nn Power absorbed: SrnREEEE! Largest ball diameter (and %) 3-2 Other factors. Average ball weight and design: Ball coating UD ratio. — Ball charge gradation. 10 Granulometry 10 Feed grindability 10 Liner type and wear. 10 Feed temperature and moisture 10 4 Diagnosis and actions to be taken Appendix 1: Crash Stop———_— $12 Appendix 2: Absorbed power (Slegten formula) / Optimization of 1st compartment ‘Appendix 3: Largest ball determination: ‘Appendix 4: Ball charge sampling: Appendix 5: — Mill granulometry: Figure Mill with Os 4 m- [al Figure 2: Mill with @ 2 4 m- ‘aon (CONFIDENTIEL - Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoCKHC LA LETTRE AUX CIMENTIERS Les Cahiers Techniques Cahier Technique "Grinding" * May 1995 Contents (continued) Chapter 3 : Second compartment 1 + Objectives and function~ 2 - Diagnostic check list 3 - Influence of different factors 9-1 - Major factors: Liner and ball coating Ball charge classification Presence of oversize particies Material level Discharge partition 3-2 Other factors. Classifying liners. Mill air sweep-——— ‘Size and % of smallest balls—————————————- Size of largest ball and distribution of ball size- Ball volume loading Particle size reduction (PCFR)———~ Grinding aid Mill temperature Water injection 4 Diagnosis and actions to be taken Appendix 1: PCFR (Slope of adjusted fineness curves) Chapter 4 : Separator: 1- Objectives and function 2 - Diagnostic check list ~ 3 - Influence of different factors. 3-1 - Major factors Circulating Load Tromp Cun 3-2- Other factors Separator settings —————————-----__—. Condition of separator internals —-—- Granulometry curve of finished product 4-- Separator settings. 5 - Adjustment table———_—————— ‘Appendix 1: Plotting the Tromp Curve: Table 1: BATH plant example Figure 1: Tromp Curve: Appendix 2 : Caloulation of separator effCien yen ‘Appendix 3: Checks to be made during separator inspection ‘Appendix 4: By-Pass corrected for Circulating Load- Appendix to the Technical journal "Grinding": Selection of cases illustrating well the recommendations in the Technical Journal “grinding"-———— CONFIDENTIEL - Usage interne / CONFIDENTIAL - Intemal use / CONFIDENCIAL - Uso iterno 25 26 26 26 26 26 27 27 27 27 27 28 30 33 33 33 33 33 33 33 34 34 34 35 35 36 37 39 40 42 43 45LA LETTRE AUX CIMENTIERS CKHGC Les Cahiers Techniques Cahier Technique "Grinding" * May 1995 Introduction TWO TECHNICAL JOURNALS... ON A SINGLE SUBJECT ! Performance analysis of the Lafarge plant over the last years has shown that while the percentage of fuel in the cement manufacturing cost was decreasing the percentage of power, on the other hand, was increasing to an alarming level. The power bill exceeds the fuel bill in an increasing number of plants. The situation stems from two compounding factors: the cost of power and the specific power consumption which are both on the increase. There are many excuses: * a precalciner kiln has a higher power consumption than a long dry kiln, * Customers want more cement requiring more grinding energy, The time had came to ring the alarm bell. This is why Power became a theme of the second Three Year Technical Plan. The objectives are clear: * reduce the power consumption by 5% on a three year period, * at least hold constant the cost of power expressed in current hard currency. Grinding consumes 60% of the power needed to produce one tonne of cement (Group average). This is why the Technical Journal dealing with power consumption will be published in two stages: © The first stage is devoted to power savings originating with the optimization of: * the grinding mill process, particularly the two compartment, closed circuit ball mills (see table below showing the breakdown of the various types of cement mills in the Group) + the factors impacting clinker grindabilty, Trl process WorkW nstalled —| % of fonnes produced ‘Compound clased creat 743 74.5 Birotators 9 32 ‘Compound open circuit 17.5 16.2 Monochamber_ L 1.0 0.4 Roller presses (integral) 03 0.7 Breakdown of cement mill ypes in the group - 1994 data Note some ofthe bail mils operates with a roller press as a pre-grinder @ All other types of improvement leading to power savings and to power cost reduction will be dealt with in a second stage. [a a “Sue (CONFIDENTIEL - Usage interne / CONFIDENTIAL Internal use / CONFIDENCIAL - Uso internoLA LETTRE AUX CIMENTIERS Les Cahiers Techniques Cahier Technique Grinding « May 1995 Vasntinney KNOW HOW IN GRINDING Process optimization of ball mill operation has been presented in four sections: + Clinker grindability (Cement mills: 41.4% of Group power consumption) * 1st compartment operation * 2nd compartment operation * Separator operation. All the above aspects interact in the grinding circuit, particularly the last three. However, the objective and the operation of the three steps of the grinding process: preparation, fine grinding and separation can be well treated individually, which has determined the organization of this document. Originating with, but not directly focusing upon the energy consumption aspect, this Technical Journal became in fact a synthesis on our knowledge on the ball mill operation. It is a practical guide of the points to check or monitor, the measurements to conduct, the methods to use and the target values to establish in order to operate a mill properly. Without long and theoretical mathematical arguments, the minimum required to understand the recommended actions are given. Most recommendations can be extended to raw mills. It is not so strange that a treatment on grinding processes be included in a joumal on the theme of power. The power absorbed by a mill is roughly constant. Any action taken to increase the production rate or optimize the product fineness will result in a reduction of the specific power consumption. This Technical journal is the result of the work of the "grinding" sub committee of the theme “Power" of the 3-Year Technical Plan. Group members were: ‘Sam FUJIMOTO, Corporate Technical Services, Lafarge Corporation. Salvador GUTIERREZ MAINAR, Direccion Tecnica, Asiand. Jean-Christophe SALEK then Olivier BERNARD, Ciments Lafarge Viviers, Ciments Lafarge. Pierre REIF, Centre Technique Inter-Unités. Wolfgang STROIBER, Perimooser. and Jean MAUMENE, replaced after he retired (in June 1994) by Maurice PALIARD, Direction des Performances Cimentiares, Lafarge Coppée. 2. CONFIDENTIEL - Usage inteme / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoLA LETTRE AUX CIMENTIERS Les Cahiers Techniques CLINKER GRINDABILITY Chapter 1 1+ OBJECTIVES ‘+ To establish parameters and their ideal level to obtain clinkef with good grindabilty. ‘+ To identity poor situations which could be detrimental to grindability levels and list the actions to be taken to improve them, ‘The grindability of the clinker dealt with in this document is different from the BB10 test which is also usually called a grindabilty test. e@ This guide deals with industrial grindability and how it can be improved, 2- FACTORS INFLUENCING GRINDABILITY The factors to be checked when there is a degradation of grindabilty are as follows: MAJOR FACTORS OTHER FACTORS * Lime saturation in clinker + Pore size *% of SOs + Crystal size + Buming level + Burnability * MgO content * Burning in reducing conditions 3.- INFLUENCE OF DIFFERENT FACTORS 3.-1- Major factors + LIME SATURATION - BELITE LEVEL Belt, the image of C2S, represents a major factor in cinker grindabilty. For a given clinker, an increase in belite by one point leads to an increase In consumption of between 0.3 and 0.4 kWh/t of clinker. Belite can be seen using a microscope but initially it is possible to obtain an estimate from the C2S, determined using Bogue's formulae. On the other hand, the level of alite, the image of C3S, exerts a posi hence the more the better. influence on grindability and ‘The actions to be taken for improving grindabilty, in connection with belite and alite, are as follows: * Good proportioning of lime to maximize the amount of alite ‘+ Making sure that the raw material is of a regular composition to avoid variations in raw mix composition e ‘+ Minimizing rejects at 100 and 200 microns to optimize alte formation ‘+ Rapid cooling of the clinker (quenching) in order not to dissociate alite into belite and free lime [4 s ‘con CONFIDENTIEL - Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoCKHC LA LETTRE AUX CIMENTIERS Les Cahiers Techniques CLINKER GRINDABILITY (continued) Chapter 1 + PERCENTAGE OF SO3 A high evel of S03 is detrimental to clinker grindabilty, ‘The S03 which saturates the alkalines has no effect on grindabilty ‘The excess SOs reduces grindabiliy and industria results are quite consistent on this point. Excess S03 often comes with a dustaden clinker that is more dificult to grind (poorly adapted charge). ‘S03 improves clinker reactivity and this positive effect offsets the kWh lost through the degradation of rindi. Lowering S03 is not a good move to improve grindability because of the adverse effect on reactivity. (Improving clinker grindability by reduction of the SO3 content is usually not profitable due to clinker reactivity losses and to the higher cost of lower sulfur fuels). * BURNING LEVEL A high burning level decreases grindability. It can be seen through the formation of large alite crystals, visible under a microscope. It is characterized by: + alow level of free lime + ahigh literweight * a.coarse porosity (not measurable on site at present) Overbuming should be avoided at all costs. It is the cause of many problems: * decrease in first compartment efficiency * alteration of plant performance (kin) + reduction of cement compressive strengths + lengthening of cement setting time ‘The actions to be taken are as follows (see also the Technical journal *Combustion"): Obtain good raw mix burnabi Master burning conditions Use solid fuels with the right fineness Avoid overburning 3 or * PORE SIZE ‘The proportion of pores of less than 1 jum has a positive effect on grindability. It reflects the clinker bbuming level and cooling rate. ‘This parameter should be measured when grindabilty studies are made, [4 ” “ent CONFIDENTIEL - Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoLA LETTRE AUX CIMENTIERS e CKHC Les Cahiers Techniques CLINKER GRINDABILITY (continued) Chapter 1 * CRYSTAL SIZE ‘The presence of large alite and belte crystals degrades grindabilty. This explains why clinkers with deliberately arge crystals used for ol well cement are hard to grind. Large crystals reflect a high burning level or a raw mix that is too coarse and not homogeneous. Conversely, moderate buming level along with fine and homogeneous raw mix results in small crystals. and improves grindabiiy e + RAW MIX BURNABILITY ‘The improvement of bumabilty has a significant effect on grindability because it results in a moderate buming level. Bumabilty can be improved in several ways: * Maximizing raw mix passing 100 and 200 um * Having a good raw mix consistency - good IPL index Indice de Performance Lafarge, reler to the Technical Joumal on Raw Mix, chapter 1) + Adding mineraizers. + % OF MgO AMgO content below 1.2% improves clinker grindabilty. * REDUCING BURNING CONDITIONS Reducing atmosphere buming conditions often resuits in an excessive buming level which, as already noted, is detrimental to grindabilty. e Buming in an oxidizing atmosphere allows one to master buming conditions. 4- DIAGNOSIS AND ACTIONS TO BE TAKEN 4-1- Clin indability measu ‘This is the first action to be taken for an overall picture. =2- se ‘The burning level is one of the most important criteria for grindabilty. Overburing is to be avoided. Burming levels can be assessed in the following ways: * By the free lime content, to be maintained at a correct level, not having too low a level which is a sign of overbuming + The literweight, that should not rise too much. A high literweight is a sign of overburning e ‘+ However note that a burning level that is obviously too low will degrade grindability by raising the proportion of beite in relation to alte. [4 ” ‘oc ‘CONFIDENTIEL - Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoLA LETTRE AUX CIMENTIERS Les Cahiers Techniques CLINKER GRINDABILITY (continued) Chapter 1 4-3- Lime saturation A high level of belite reduces grindability. Action should be taken to control the alite - belite proportions, This can be achieved by: * having a potential mix composition that minimizes belite and maximizes alite * ensuring a maximum ratio of alite to belite Control of alite and belite proportions can be made by clinker microscopy. Furthermore, according to e Onoda, an increase in ime saturation increases fine porosity < 1 um and thus also improves grindabilty, 4-4 - Reducing a here ‘An oxidizing burning condition should be ensured. Reducing burning conditions leads to overburning which degrades grindability. Thanks to the help of current gas analyzers, kiln conditions can be determined and an oxidizing environment maintained. The permanent objective for increasing the grindability of clinker should be to avoid overbuming. 4:5 - Raw mix consistency The maintaining of good raw mix consistency is an important factor in the improvement of grindabilty. The consistency of raw mix is measured by the IPL. The raw mix residue at 100 um and 200 jum either consists of silica or of lime. In any event an excessive e value of % retained is detrimental to bumabilty and consequently to grindabilty. Tests carried out in several plants have shown the advantage of reducing the raw material residue at 100 um and 200 jum. Actions to be taken to improve raw mix consistency are as follows: ‘+ maintain the IPL at the level recommended by the Technical Centers * minimize the % raw material retained = 0-12% at 100 pm = inthe order of 3-3.5% at 200 um. [iq o “aaa (CONFIDENTIEL - Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoCKHC LA LETTRE AUX CIMENTIERS Les Cahiers Techniques Fi RST COMPARTMENT Chapter 2 1 - OBJECTIVES ‘* Crush the material fed into the mill ‘+ Grind the material sufficiently so that the second compartment performs efficiently. 2 - DIAGNOSTIC CHECK LIST 3 [4 To be used to monitor the mill regularly, develop optimization plan and devise permanent solutions to sudden but permanent change. - INFLU Check List A: (items to. check first) % residue (retained) at 2 - 2.5 mm (8 mesh to 10 mesh) < 5% before and after the partition. Material Level Partition Slots: width, area and condition. Nominally = 7 mm ‘Absorbed Power = 8 to 12 kWhit (Slegten Equation) Largest Ball Diameter Size Used Height of liner steps Cheek-list B.: (other items) ‘Average Ball Weight Ball Coating ‘Compartment L/D ratio Gradation of ball sizes, Granulometry Clinker Grindabitity Liner Type Temperature (Feed) Moisture ENCE OF DIFFERENT FACTORS 3-1- Major factors «RESIDUE LEAVING THE 1ST COMPARTMENT Nominally the residue found at the end ofthe fist compartment or at the beginning ofthe second should be < 5% retain 1ed on a2 to 2.5 mm sieve (8 mesh or 10 mesh) upon a crash stop (*). This is perhaps the best indicator of the compartment's performance. A higher value suggests poor material preparation. A low value sugg ests overgrinding. (() Voluntary instant stoppage of all the shop equipment pieces simultaneously (See Appendix 1 p. 12) ave CONFIDENTIEL - Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoCKHC LA LETTRE AUX CIMENTIERS Les Cahiers Techniques FIRST COMPARTMENT (continued) Chapter 2 Check before and after the partition. Use the lowest value to evaluate the effectiveness of the tst compartment. If there is a large difference: * Slots are too narrow + Liners are wor ‘+ Ball charge is wom or too fine ‘+ Feed is too coarse or too hard to crush * Ball charge volume loading is too low * Ball charge reverse classification © MATERIAL LEVEL This is a visual inspection after a crash stop (check procedure, see Appendix 1 p 12). Ideally the material level should be at the same level as the grinding media over the entire length of the compartment (tops of the balls should be just exposed or just covered). Over or underfiling will lead to inefficient operation. In the extreme case it could cause operational or quality problems. Look also for variable filing, where part of the compartment is full and other parts are underfiled. This may suggest a problem with the liners; or with the ball charge design/gradation or all of the above. ‘+ PARTITION (DIAPHRAGM) SLOTS For cement, the nominal width should be 6 - 7 mm (casting tolerance is usually + 1mm). The recommended minimum area should be 15 om? per tonne of mill throughput (twice for dry raw mills). The slots prevent oversize material from passing through to the second chamber as well as promote gas flow through the mill. Improper slot design will lead to either a restriction on flow in the mill; or permit too much material (and oversized material) to pass through and overwhelm the second compartment. (On inspection look to see if the slots are plugging (and how they are plugging). Check that the integrity Of the partition is good. The movement of material through this point is critical. It is a good idea to altemate inspections such that one exposed half of the diaphragm is inspected then the other on alternate inspection opportunities. * POWER ABSORBED (See Slegten formula, Appendix 2 p 13). The absorbed power together with the preceding criteria is a good way to evaluate the overall performance of the first compartment. Ideally the calculated absorbed Power should equal 8 - 12 kWhit, should the residue and material level be ideal. It the absorbed power is high, look to see if the residue and material level suggest overgrinding. If they are OK then it may be that the compartment is too long, (in such cases a detailed study may be warranted). If the absorbed power is too low, look to see if the residue and material level suggests insufficient grinding. Analysis of these findings should give you clues as to what sort of action is needed - adjustment to the ball charge; change liner type; modify the partition. [4 a CONFIDENTIEL- Usage interne / CONFIDENTIAL - Internal use /CONFIDENCIAL - Uso internoC LA LETTRE AUX CIMENTIERS CKH Les Cahiers Techniques FIRST COMPARTMENT (continued) Chapter 2 * LARGEST BALL DIAMETER (AND %) If you suspect that there is insufficient crushing, check the largest diameter used against what Bond's formula recommends (see Bonds Largest Ball Equation, Appendix 3 p 16). This wil give you an estimate of whether the size corresponds or not. In most cases 90 mm @ (3.5") is OK. Be careful in evaluating this. You must also consider the liner type used (moderate vs. aggressive lif). Major liner suppliers should be able to help you in this area. For example a very large ball diameter Used in a mill wth an aggressive it will lead to broken balls or broken liners or both. ‘Altematively, one can also consider changing the percentage of the largest size used. 3-2- Other factors * AVERAGE BALL WEIGHT AND DESIGN This is a good measure as to the porosity (coarseness) of the ball charge. tis simply the total weight of the charge divided by the total number of balls. It can be determined by ball charge sampling or for the charge design sheet, (see Appendix 4 p 17). Often plants have mistakenly believed that they have coarsened the charge by adding more 90 mm @ balls (3.5") when at the same time they have added ‘some 50 mm @ balls (2°). The porosity could in fact be finer in this case, which will cause a restriction in flow. Itis worthwhile to keep a history ofthe average ball weight - so you will have a clearer picture of what works, how big of a change to make and when to change the ball charge. ‘Average value ranges between 1.5 to 1.7 kg/ball (normal cements). Values will be higher for harder tinding feed and vice versa. Volume loading should also be checked regularly. Itis better to top-up the ball charge in small quantities ‘frequently, rather than in large quantities occasionally. The ball charge will wear and become more fine (less porous), more rapidly by folowing the latter practoe. * BALL COATING Recognize that the first compartment, compared to the rest of the mil, does not generate a lot of heat in general. Thus itis very sensitive to moisture, temperature and grinding aid injection problems. Under these circumstances, ball and liner coating should be evident. In the worst case, slots will be plugged. If plugging is found look for the correct temperature and moisture level and check that there are no problems caused by water spray/grinding aid problems (mechanical or ow contr). + L/D RATIO {tis important to know your milfs compartment length. For comparison purposes this is expressed as the length: diameter ratio (L/D). Mis with short compartments will have different considerations than a rill with a long compartment. It has an impact on the compartment performance and depending on the ratio tt may alter the importance ofall other citi. [a os ‘oor CONFIDENTIEL - Usage interne | CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoCKHC LA LETTRE AUX CIMENTIERS Les Cahiers Techniques FIRST COMPARTMENT (continued) Chapter 2 For example, a compartment with L/D ratio < 1, will tend to mix very well. Thus ball charge gradation and mill granulometry will not mean very much except for very detailed studies. Short compartments however generate less heat and will be sensitive to moisture, temperature, water spray and grinding aid problems. The reverse is generally true for long compartments, L/D ratio > 1.5 - 2. In these compartments, more heat is generated but will also tend to reverse classify (without the correct liner). In severe cases it can influence your ball charge design. Where 1.5 > UD ratio > 1, one has a gray area which in some cases can resemble either a short or a long compartment. * BALL CHARGE GRADATION ‘The distribution of sizes vs. compartment length can give clues to possible solutions (charge design or liner selection). See also ball sampling procedure, Appendix 4 p17. Look for reverse or double reverse Classification in long compartments. This will not be as important in short compartments. * GRANULOMETRY See procedure, Appendix 5 p 21. This is less important in short compartments but more useful in long ‘compartments and should collaborate with the ball charge gradation results. The granulometry can give a clearer picture of the overall coarse grinding efficiency of the first compartment and can also be useful in making a better interpretation of the residue leaving the first compartment. + FEED GRINDABILITY AA first compartment can be well optimized for a certain feed grindability. However a change in coarse #50 297 wm e 3 = #100 149 um é > #200 74 um oe #925 44 um ot ° 5 10 15 Distance (m) 5% Maximum > 2.5 mm (#8) allowable @ partition This technique is extremely useful in evaluating ball charges before and after a design change. However, ‘odd results can occur and can be traced back to sampling errors. If done well it should correlate back to a ball charge sampling result. [4 ie i ‘CONFIDENTIEL - Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoi C LA LETTRE AUX CIMENTIERS Les Cahiers Techniques FIRST COMPARTMENT (continued) Chapter 2 Figure 1 MILL WITH DIAMETER < 4 METERS (0.5m) ccs wa oF cz cu cis cr i i Figure 2 MILL WITH DIAMETER > 4 METERS (0.5m) sfefeleteletete pepe 1, | -++ te 4 - ar es cso C—O ce cd cis ca coz etka -2- “cunee CONFIDENTIEL - Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoLA LETTRE AUX CIMENTIERS Les Cahiers Techniques SECOND COMPARTMENT Chapter 3 1+ OBJECTIVES The second compartment in the mill has the following functions: + to ensure finish grinding efficiency creating fine particles with the best possible grinding efficiency + to obtain the best flow of fines to the discharge end of the grinding department sending the fines as quickly as possible to the separator or filter + if necessary, to complete the work of the first compartment reducing the amount of grits in the product. The operational quality of the second compartment depends closely on the preparation in the first compartment and on the separator selection efficiency (see relevant section). 2- DIAGNOSTIC CHECK LIST The criteria for analyzing the efficiency of the second compartment are as follows. They can be divided into two categories, the first providing a quick analysis of the situation, the others a more precise diagnosis. ITEMS TO CHECK FIRST OTHER ITEMS TO CHECK Liner and ball coating Classifying liners Ball charge classification Mill venting Presence of oversize particles Size and % of smallest ball Material level Size of largest ball Discharge partition (diaphragm) Distribution of ball sizes Ball volume loading Particle size reduction Grinding aid Mill temperature Water injection [a wa. ‘oma (CONFIDENTIEL - Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL-- Uso internoLA LETTRE AUX CIMENTIERS Les Cahiers Techniques SECOND COMPARTMENT (continued) Chapter 3 3- INFLUENCE OF DIFFERENT FACTORS Ma. ac * LINER AND BALL COATING Coating (or agglomeration) is an indication of inefficient grinding. It means that fines are not extracted properly and are subject to overgrinding. This can often be observed in the case of cement with soft Additives (such as limestone) where fine particles are created quickly. Poor extraction of fines can be caused by insufficient mill ventilation, poor permeability at the discharge partition, a tendency to stick (wet material or water injection). ‘The phenomenon will be made worse by an inefficient separator that sends back fines into the mill (bypass). * BALL CHARGE CLASSIFICATION The classifying liners allow different sized balls to work together: medium-sized balls for intermediate tinding and small balls for finish grinding. In theory there is an ideal ball diameter for each particle size. Correct classification of the ball charge, along with an adequate ball size distribution, will result in efficient grinding of particles as their size reduction evolution is matched with the ball size reduction. The ball charge classification can be assessed visually or even better, by sampling. * PRESENCE OF OVERSIZE PARTICLES Any accumulation of oversize paiticles (about 5 mm) in the second compartment is to be avoided. This can offen be found with an insufficient ball charge classification. The usual cause is insufficient grinding by the 1st compartment, along with malfunctioning of the center partion which allows coarse Particles to get through. Another factor can be a high circulating load. The condition of the discharge Partition can make things worse if the rule for the slot openings is not complied with (stot openings in discharge partition = slot openings in center partition + 2 mm). * MATERIAL LEVEL There is no well defined optimum for the material level. Any noticeable underfilling or overtilling is to be avoided, and the material level must be evenly spread over the surface of the compartment. * DISCHARGE PARTITION (DIAPHRAGM) The slots in the discharge partition must have wider openings (+ 2 mm) than those in the center partition, in order to permit the exit of coarse particles from the first compartment. A discharge partition with a good permeability (slots and air ring) assures that the fines will be correctly conveyed through to the discharge end of the mill (separator or dust collector). = 25- CONFIDENTIEL- Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoCKHC LA LETTRE AUX CIMENTIERS Les Cahiers Techniques SECOND COMPARTMENT (continued) Chapter 3 3-2- Other factors * CLASSIFYING LINERS The step height should be measured. The wear rate of classifying liners is very slow, with some exceptions. A poor ball charge classification does not necessarily mean that the classifying liners do not function efficiently (see Presence of oversize particles p.25). + MILL AIR SWEEP The mill air sweep has two objectives: to extract the fines as soon as they are obtained and to cool the. inside of the mill (thus avoiding water injection). Mill air sweep is generally expressed in terms of air velocity on top of the ball charge (useful section between ball level and liners) It is considered that a velocity of under 1 m/s indicates that the mill is under-ventilated. This objective can be varied according to the technological features of the mill (trunnions or shoe bearings) and the target fineness of the product. + SIZE AND % OF SMALLEST BALL The size of the smallest ball determines to a large extent the overall permeability of the second compartment. The choice of this size is obtained from a compromise in the following parameters: Separator efficiency Mill air sweep Nature of product ground Mill ength Slot size in discharge partition In the case of a poorly vented mill with a first-generation separator, the size of the smallest ball will be limited to 20 or even 25 mm. With a well-vented mill and a second or third generation separator, smaller balls can be used (to 17 mm). These are standard sizes which can be adapted, for example in the case of products with a high Coating tendenoy, or for mills with temperature problems. An open circuit mill will require balls of 17mm or even 15mm (or small cylpebs) to ensure a Satistactory product residue at 100 ym. + SIZE OF LARGEST BALL AND DISTRIBUTION OF BALL SIZE The choice of the largest ball size depends on the grinding quality of the first compartment and on the center partition. “If coarse particles from the first compartment can be found at the beginning of the second, 60 mm balls should be installed. Otherwise 50 mm balls will be sufficient. Itis important to ensure a regular progression in ball size inside the compartment. The distribution of ball size can be based on general models (SLEGTEN, POLYSIUS) but must always be adapted to each specific mill. Ideally, any topping or sorting of the’ charge should be preceded by sampling of ‘material and balls in the mill, in order to analyze the actual grinding efficiency of the existing charge. Ht the mill is not fitted with classifying liners, only a few ball sizes should be used (maximum of 3 or 4 sizes). [4 = ‘Seon (CONFIDENTIEL - Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso internoCKHC LA LETTRE AUX CIMENTIERS Les Cahiers Techniques SECOND COMPARTMENT (continued) Chapter 3 [a * BALL VOLUME LOADING The ideal ball volume loading is around 30%. it is obtained from a balance of the two criteria of power consumption and fines production. The ideal volume can be obtained by filling the compartment progressively after sorting the ball charge. The upper limit is set by the diameter of the discharge trunnion ‘and the air rings, as well as by the maximum power that can be absorbed by the mill drive system. * PARTICLE SIZE REDUCTION The work of particle size reduction by the ball charge can be assessed by material sampling over the length of the compartment. This is necessary for plotting the set of fineness curves and for calculating their slopes (slopes of reduced fineness curves - Appendix 1 p 30) The slopes of reduced fineness curves at 45 um range from: + 10 to 70 in CPJ (blended cements) (mean = 40) + 10 to 40 in CPA (pure cements) (mean = 25) It is important to quantify the work of the charge before and after any significant modification (charge sorting, replacement of discharge partition grates in first and second compartments, liners, etc.). * GRINDING AID The grinding aid acts on the surface of the particles to annihilate any electrostatic forces that may develop. The proportioning should be determined through specific testing. It depends on the following criteria: Nature of the grinding aid Type of cement produced Mill ventilation temperature + MILL TEMPERATURE Itis important to measure the temperature. The temperature level inside the mill (always higher than at the discharge end), combined with the retention time and the ambient hygrometry, govern gypsum dehydration and thus has a direct impact on the cement quality. The temperature set point at the discharge end of the mill must be situated between 90°C and 110°C in the event of sulfating with gypsum. * WATER INJECTION When no other solution is available, water injection allows to reduce the mill temperature. It must be strictly controlled to avoid too much degradation of cement quality (beginning of finest particle hydration with strength losses at early ages). The condition of the spray nozzle should be closely monitored. -27- CONFIDENTIEL - Usage interne / CONFIDENTIAL - Internal use / CONFIDENCIAL - Uso interno