This action might not be possible to undo. Are you sure you want to continue?
CEMENT GRINDING PLANT
BLAINE FINENESS FACTOR
POLYSIUS Coefficient
49 , 0 *
1000

.

\

· ÷ ·
=
Blaine Reference Blaine Required
e K
Exemple
Mill output : 100 t/h
Fineness according to Blaine: 3000 cm²/g
New fineness required: 3500 cm²/g
K = exp ((35003000)/1000*0,49)
K= 1,278
Expected mill output = 78,3 t/h
CEMENT GRINDING PLANT
COMPOSITE CEMENT
____________________________________________________________________________________
OPC (Ordinary Portland Cement)
Composition
96 % CLINKER
4 % GYPSUM
_____________________________________________________________________________________
CPC (Composite Portland Cement)
Type of additives:
Limestone, pouzzolane, trass, slag, fly ash, ….
Properties:
increase of fineness and output, decrease of initial and final strength, increase of concrete plasticity and workability, colour
modification …
_____________________________________________________________________________________
2
CEMENT GRINDING PLANT
Exemple of the additive influence on the mill output
Production of cement with 15 % of limestone
Composition
81 % CLINKER
4 % GYPSUM
15% LIMESTONE
Cement Mill
Output = 100 t/h of OPC (96 % Clinker – 4% Gypsum)
Fineness = 3200 cm²/g
CPC cement (81% Clinker – 4% Gypsum – 15% Limestone))
Fineness required 3200 cm²/g according to blaine
Calculation of equivalent clinker fineness
We consider that the limestone “gives” 2 times more fineness.
X = equivalent clinker fineness
2.X = limestone fineness
3200 = (0,81+0,04) X + 0,15 2.X
X = 2783 cm²/g
Limestone fineness = 5565 cm²/g
CEMENT GRINDING PLANT
Expected cement mill output with 15% limestone
Fineness factor
K = exp ((30002783)/1000*0,49)
K=1,11
Expected mill output = 111 t/h at 3200 cm²/g with 15% limestone
BALL MILL ABSORBED POWER
Absorbed power at mill shaft / Polysius Formula
P(kW) = G x C x Di x 0,736
P = Mill power absorbed (kW)
G = Ball charge weight (tons)
C = POLYSIUS C Factor ()
Di = Internal mill diameter (m)
Lu = Effective grinding length (m)
F = Filling degree of ball charge (%) normal range : 24 –32 %
d = Bulk density of grinding balls (t/m
3
) 4,5 – 4,6
Ball charge weight
G (tons)= (π x Di² / 4) x Lu x F x d
Absorbed power at mill motor shaft
Pmotor(kW) = P(kW)/ ŋ
ŋ = Drive efficiency
ŋ= ŋ Girth gear (0,98) x ŋ Combiflex (0,97) x ŋ motor coupling (0,99)
= 0,94
POLYSIUS C Factor
Depends on different parameters: ball charge, kind of material, type of process, type of mill
3
Cement mill / closed circuit
26 % C = 9,8 28 % C = 9,6
30% = C = 9,4 32% = C = 9,1
CEMENT GRINDING PLANT
HIGH EFFICIENCY SEPARATOR SEPOL
A
F
R
Separator efficiency
f r
a r
f
a
÷
÷
÷
÷
= .
1
1
a = % passing cumulated in fresh feed
f = % passing cumulated in finish product
r = % passing cumulated in separator rejects
CEMENT GRINDING PLANT
TROMP Curve
%
100
50
by pass
40 µ
Aa = % passing between 2 sieves in the fresh feed
Ar = % passing between 2 sieves in the grits
Af = % passing between 2 sieves in the finish product
SEPOL
4
Sa = % passing sieve: 10 – 20 µ ……> 100 µ
Sr = % passing sieve: 10 – 20 µ ……> 100 µ
Sf = % passing sieve:: 10 – 20 µ ……> 100 µ
100 *
¿ ¿
¿ ¿
÷
÷
=
Sr Sf
Sr Sa
Vf
100 *
¿ ¿
¿ ¿
÷
÷
=
Sr Sf
Sa Sf
Vg
100 *
. .
.
Vf f Vr r
Vr r
T
A + A
A
=
Tau = By pass %
This percentage represents the % of fines which has been considered by the Separator as rejects.
Normal range for a high efficiency separator SEPOL with OPC cement
: 5 –15%
Separation cutting : diameter µm
This point gives where is the limit of accuracy of the SEPOL for the cement produced.
Normal value for standard OPC: 10 – 20 µm
Imperfection
Polysius formula
kapa = d30/d70
Lafarge formula
I = (d75 – d25 ) / 2 (d50)
type of mill 2 .6 ŋ = Drive efficiency ŋ= ŋ Girth gear (0.94 POLYSIUS C Factor Depends on different parameters: ball charge.97) x ŋ motor coupling (0.X = limestone fineness 3200 = (0.X X = 2783 cm²/g Limestone fineness = 5565 cm²/g CEMENT GRINDING PLANT Expected cement mill output with 15% limestone Fineness factor K = exp ((30002783)/1000*0. X = equivalent clinker fineness 2.81+0. kind of material.99) = 0. type of process.736 (kW) (tons) () (m) (m) (%) (t/m3) P = Mill power absorbed G = Ball charge weight C = POLYSIUS C Factor Di = Internal mill diameter Lu = Effective grinding length F = Filling degree of ball charge d = Bulk density of grinding balls Ball charge weight G (tons)= (π x Di² / 4) x Lu x F x d Absorbed power at mill motor shaft Pmotor(kW) = P(kW)/ ŋ normal range : 24 –32 % 4.98) x ŋ Combiflex (0.15 2.CEMENT GRINDING PLANT Exemple of the additive influence on the mill output Production of cement with 15 % of limestone Composition 81 % CLINKER 4% GYPSUM 15% LIMESTONE Cement Mill Output = 100 t/h of OPC (96 % Clinker – 4% Gypsum) Fineness = 3200 cm²/g CPC cement (81% Clinker – 4% Gypsum – 15% Limestone)) Fineness required 3200 cm²/g according to blaine Calculation of equivalent clinker fineness We consider that the limestone “gives” 2 times more fineness.04) X + 0.5 – 4.49) K=1.11 Expected mill output = 111 t/h at 3200 cm²/g with 15% limestone BALL MILL ABSORBED POWER Absorbed power at mill shaft / Polysius Formula P(kW) = G x C x Di x 0.
8 30% = C = 9. 1 f r f a = % passing cumulated in fresh feed f = % passing cumulated in finish product r = % passing cumulated in separator rejects CEMENT GRINDING PLANT TROMP Curve % 100 50 by pass 40 a r f = % passing between 2 sieves in the fresh feed = % passing between 2 sieves in the grits = % passing between 2 sieves in the finish product 3 .4 28 % 32% = C = 9.Cement mill / closed circuit 26 % C = 9.6 C = 9.1 CEMENT GRINDING PLANT HIGH EFFICIENCY SEPARATOR SEPOL A SEPOL F R Separator efficiency 1 a r a .
Sa Sr Sf = % passing sieve: 10 – 20 ……> 100 = % passing sieve: 10 – 20 ……> 100 = % passing sieve:: 10 – 20 ……> 100 Vf Sa Sr *100 Sf Sr Vg Sf Sf Sa *100 Sr T r. Normal range for a high efficiency separator SEPOL with OPC cement : 5 –15% Separation cutting : diameter µm This point gives where is the limit of accuracy of the SEPOL for the cement produced. Normal value for standard OPC: 10 – 20 µm Imperfection Polysius formula kapa = d30/d70 Lafarge formula I = (d75 – d25 ) / 2 (d50) 4 .Vf Tau = By pass % This percentage represents the % of fines which has been considered by the Separator as rejects.Vr *100 r.Vr f .
This action might not be possible to undo. Are you sure you want to continue?
We've moved you to where you read on your other device.
Get the full title to continue listening from where you left off, or restart the preview.