Tanjung Jati B Training

VERTICAL BALL MILL

REAGENT PREPARATION
VERTICAL BALL MILL

Tanjung Jati B Training

PT Central Java Power

Tanjung Jati B Units 1 & 2
Flue Gas Desulfurization (FGD) System

Absorber Area

Dewatering
Area

Reagent Preparation
Area

Limestone Jetty
And Conveyor

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill

THE INTENT OF THIS SECTION IS TO DISCUSS BASIC

PROCEDURES FOR STARTING UP THE VERTICAL BALL
SYSTEM.
THIS SECTION, BY NO MEANS ESTABLISHES OPERATING
PROCEDURES, THEREFORE IT IS THE RESPONSIBILITY
OF THE OPERATORS TO FULLY UNDERSTAND THE
OPERATING PROCEDURES PROVIDED IN THE
OPERATION & MAINTENANCE MANUALS.

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill

Prior to starting the Vertical Ball Mill section, lets

first review the Reagent Preparation flow paths and
related components.

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Limestone
Silo

Bin Activator

Limestone
Feeder

Mill
Hydroclone

Limestone
Pre-Crusher

Limestone Slurry
Storage Tank

Mill
Recirculation
Sump

Seawater
Vertical
Ball Mill

Mill Recycle
Pump

Mill Outlet
Sump
Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
The function of Reagent Preparation is to
process raw limestone stored in the Limestone
Silos into a limestone slurry which is ultimately
stored in the Limestone Slurry Storage Tank.
Limestone Slurry, produced by the Vertical Ball Mills
and classified by the Hydroclones, will have a solids
content of 30%.
95% of those solids will pass through a 325 mesh
screen.

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Limestone
Silo
95% of solids
through a 325 mesh screen
Bin Activator

Limestone
Feeder

Mill
Hydroclone

Limestone
Pre-Crusher

Limestone Slurry
Storage Tank

Mill
Recirculation
Sump

Seawater

30%
SOLIDS
Vertical
Ball Mill
Mill Recycle
Pump

Mill Outlet
Sump
Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
The Limestone Slurry produced by the Reagent
Preparation System, by design, will have a
solids content of 30%.
Control of the Reagent Preparation System
is from the main control room. The system is
operated most efficiently as a batch process
with a constant design feed rate of limestone
to the vertical ball mills.

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
The Hydroclone is an integral part of the Reagent
Preparation system as well as being integral to the
operation of the Vertical Ball Mill.
Lets first take a look at the Vertical Ball Mill
components.

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill

DRIVE
MOTOR

GEAR
REDUCER
RAW
MATERIAL
INLET
BALL FILL

MILL
RECIRCULATION
SUMP

TO MILL
OUTLET SUMP

SCREW
TO MILL
RECIRCULATION
PUMP

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Reagent Preparation
Vertical Ball Mill

LOW LEVEL
SWITCH

SLURRY FEED
WASH CONNECTION
BALL
DISCHARGE

DRAIN

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Reagent Preparation
Vertical Ball Mill
AIR
VENT

CLAMP
ASSY

AGITATOR
MOTOR

SLURRY
OUTLET

AGITATOR
BLADES

MILL RECYCLE SUMP

(PLAN VIEW)

AGITATOR
(300 RPM)

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
RAW
MATERIAL
INLET

SLURRY OUTLET
TO RECIRC SUMP

VERTICAL BALL
MILL FLOW PATH
RECYCLE SLURRY
FROM RECIRC PUMP

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill

VERTICAL BALL MILL INTERNALS @ TJ-B

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
An Oil Lubrication Unit is required for the operation
Ball Mills Gear Reducer. This Lube Oil Unit requires
a cooling water source and has instrumentation for
measuring oil flow, temperature and differential
pressure.
The source of cooling water is Service Water. The
cooling water exiting the Lube Oil Unit goes to
the drain (trench).

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
DUPLEX
FILTER

OIL
INLET

OIL
OUTLET

OIL
PUMP

FLOW
METER

MOTOR
DIFFERENTIAL
SWITCH

OIL
COOLER

THERMOMETER
(WITH SWITCH)

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Prior to discussing the start-up of the Vertical Ball
Mill, lets look at the Alarms

Mill Trip
Recycle Pump Trip
Recirculation Sump Agitator Trip
Mill Liquid Level Low
Mill & Mill Motor Bearing & Winding Temperatures High
Mill Motor Current (amps) High
Gear Reducer Lube Oil Pump Trip
Gear Reducer & Bearing Temperatures High
Gear Reducer Lube Oil Flow Low
Gear Reducer Lube Oil Temperature High

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
The Reagent Preparation System is started in the
following sequence. Note, the Limestone Slurry
Storage Tank must be ready to receive slurry
1. Mill Outlet Sump, Agitator & Pump
2. Tower Mill System

Lube Oil System

Mill Main Drive
Mill Recycle Pump & Recirc Sump Agitator
Limestone Pre-Crusher
Limestone Weigh Feeder & Silo Gate Valve
Limestone Bin Activator
Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
The Reagent Preparation System is started in the
following sequence
3. Limestone Slurry Storage System
Slurry Storage Tank (Level not Hi-Hi)
Tank Agitator
Limestone Slurry Feed Pumps

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
We have discussed system alarms and the start-up
sequence, now lets look at the basic steps for starting
the Vertical Mill and related equipment
Please consult the O&M Manuals for the details for
starting and stopping the Vertical Mill and related
equipment.

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Starting the Ball Mill System (Mill Outlet Sump)
Open the Mill Outlet Sump Recycle Valve
Close Sump Pump Common Discharge Valve
Open manual Feed Valve to the Hydroclone
Verify that the manual Flushing Valve to the
Hydroclone Overflow is closed
Verify that the manual seawater Flushing Valve is
closed

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Reagent Preparation

SUMP VALVE
ARRANGEMENT
DURING START-UP

Vertical Ball Mill

FLUSH

FEED

To Vertical Mill
Recirculating Sump

Mill
Hydroclone

To Limestone
Slurry Tank
Seawater Fill
From Vertical Mill
Recirculating Sump
(Flush Water)

C
O
C

Seawater Flush

C
C*

* Open Valve if sump

level is low

Pumps A & B

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Starting the Ball Mill System (Mill Outlet Sump)
Place the Mill Outlet Sump Pump in Automatic
Place the Mill Outlet Sump Agitator in Automatic
Once Sump level is achieved, the Pump & Agitator
will start.
The Sump Pump discharge flow will remain in the
Recycle Mode until the entire mill system is in operation.

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Reagent Preparation

SUMP PUMP AND

AGITATOR TO AUTO
(SHORT RECYCLE)

Vertical Ball Mill

FLUSH

FEED

To Vertical Mill
Recirculating Sump

Mill
Hydroclone

To Limestone
Slurry Tank
Seawater Fill
From Vertical Mill
Recirculating Sump
(Flush Water)

C
O
C

Seawater Flush

C
C

C
O

Pumps A & B

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Starting the Ball Mill System (Hydroclone)
Verify that 4 of 5 Cyclone Isolation Valves are open
Mill Hydroclone Recycle Valve to manual and open
Open Sump Pump Common Discharge Valve
Close Mill Outlet Sump Pump Recycle Valve
Mill Hydroclone Recycle Valve to automatic

Tanjung Jati B Training

Reagent Preparation

MILL HYDROCLONE
IN THE
RECYCLE MODE

Vertical Ball Mill

FLUSH

FEED

To Vertical Mill
Recirculating Sump

Mill
Hydroclone

To Limestone
Slurry Tank
Seawater Fill
From Vertical Mill
Recirculating Sump
(Flush Water)

C
O
C

Seawater Flush

O
C

O
O

Pumps A & B

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill

4 of 5 Cyclones open
for normal operation

CYCLONES
CYCLONE

MILL HYDROCLONE
(PLAN VIEW)

MILL HYDROCLONE

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Reagent Preparation
Vertical Ball Mill
OVERFLOW

INLET

MILL HYDROCLONE
UNDERFLOW
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Reagent Preparation

CYCLONES

Vertical Ball Mill

MILL
HYDROCLONE
or
CLASSIFIER

UPPER
LAUNDER

LOWER
LAUNDER

KREBS U.S.A.
Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Starting the Ball Mill System (Lube Oil Unit)
Verify Lube Oil Shutoff Valves are Open
Verify Cooling Water Shutoff Valve is Open
(Observe cooling water discharging into trench)
Start the Lube Oil Pump
Verify Lube Oil Flow is above minimum, temperature
below maximum and differential pressure below
maximum
Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
DUPLEX
FILTER

OIL
INLET

OIL
OUTLET

OIL
PUMP

FLOW
METER

MOTOR
DIFFERENTIAL
SWITCH

OIL
COOLER

THERMOMETER
(WITH SWITCH)

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Starting the Ball Mill System (Vertical Mill)
Verify Mill Flush & Drain Valves are closed
Seawater Flow Control Valve to manual and open fully
Open Seawater Make-Up Isolation Valve
If Mill is empty, open seawater isolation valve.
Fill Mill until water is seen overflowing into the
Mill Outlet Sump
Verify Seawater Valve to Mill Hydroclone Underflow
is open
Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill

MILL HYDROCLONE

O
O

SEAWATER
MAKE-UP

O
VERTICAL MILL

MILL OUTLET SUMP

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Starting the Ball Mill System (Vertical Mill)
Once water from the Mill Recirculating Sump is seen
discharging into the Mill Outlet Sump, the Mill can be
started (manually).
If the Mill is in Automatic, the Mill will start when the
level in the Mill Recirculating Sump is above the low
level (switch).

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill

MILL HYDROCLONE

O
O

SEAWATER
MAKE-UP

O
VERTICAL MILL

MILL OUTLET SUMP

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Starting the Ball Mill System (Recycle Pump & Sump
Agitator)
Verify Mill Flush and Drain Valves are closed.
Verify Mill Recycle Pump Isolation Valves are open
Verify Mill Recycle Feed Valve is open
Place Pump & Agitator in automatic. Both will start
if the level within the Recirculating Sump is above
the minimum (low level switch)

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
TO MILL
OUTLET SUMP
MILL
RECIRCULATING
SUMP

MILL
RECYCLE PUMP
Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Starting the Ball Mill System (System Dust Collector)
Verify Instrument Air Isolation Valve is open
Verify Isolation Valves at the Mill and Limestone
Feeder are open
Start the Dust Collector
Verify Differential Pressure is not excessive

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill

REAGENT PREPARATION
AREA DUST COLLECTOR

LIMESTONE SLURRY TANK

(UNDER CONSTRUCTION)
Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill

INSTRUMENT
AIR

O
FROM TOWER MILL A
C
FROM TOWER MILL B
O
FROM LIMESTONE FEEDER A
C
FROM LIMESTONE FEEDER B

REAGENT PREPARATION SYSTEM DUST COLLECTOR

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Starting the Ball Mill System (Crusher, Feeder and
Bin Activator)
Pre-Crusher will start after a short time delay after
the Mill is started (automatic)
Verify Silo Discharge Gate Valve is open
Limestone Feeder will start after a short time delay
after the Pre-Crusher is started (automatic)
Bin Activator will start (if in automatic) when Feeder
is running and Gate Valve is open.

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Limestone
Silo

Bin Activator
Slide Gate
Limestone
Feeder

Mill
Hydroclone

Limestone
Pre-Crusher

Limestone Slurry
Storage Tank

Mill
Recirculation
Sump

Seawater
Vertical
Ball Mill

Mill Recycle
Pump

Mill Outlet
Sump
Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
When the Limestone Slurry Storage Tank Level
reaches the high level set point, the Mill Outlet
Sump Pump will stop.
When the Sump Pump Stops, this will stop the
following equipment if in automatic mode
Pre-Crusher Limestone Feeder Bin Activator
The Vertical Mill will remain in service for flushing
and proper shutdown (approximately 60 minutes).

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
SHUTDOWN ORDER
Limestone
Silo

Bin Activator (4)

Limestone
Feeder
(3)

Limestone
Pre-Crusher
(2)

Seawater
Vertical
Ball Mill
(5)

Mill
Hydroclone

Limestone Slurry
Storage Tank

Mill
Recirculation
Sump

Mill Recycle
Pump

High Level
Set Point

Mill Outlet
Sump Pump (1)
Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
The Vertical Mill is required to operate or run for
60 minutes after the Mill Outlet Sump Pump has
stopped.
This is required so that the slurry within the Mill
will become finer (smaller) and not settle rapidly
if the Mill were shutdown earlier.
The Mill will shutdown automatically after 60 minutes
if the Mill is in Automatic.

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
The Mill Recycle Pump and Mill Recirculating Sump
Agitator will continue to operate and slurry will be
recycled back to the Vertical Mill.
It is recommended that the Vertical Mill be run for a
5-minute period every 4 hours. This will prevent the
compacting of ground limestone within the Mill.

Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
TO MILL
OUTLET SUMP
MILL
RECIRCULATING
SUMP

MILL
RECYCLE PUMP
Tanjung Jati B Training

Reagent Preparation
Vertical Ball Mill
Emergency Shutdown of the Vertical Ball Mill
In case of emergency stop due to electrical failure
or other cause, the Mill is to be drained and washed
of all slurry to prevent the cementation of the hard
particles.
For next start-up, the Vertical Mill must be filled with
water until the water is seen overflowing into the Mill
Outlet Sump.

Tanjung Jati B Training

REAGENT PREPARATION
VERTICAL BALL MILL
(END)

Tanjung Jati B Training