CM 1 Annual Audit

Arish Cement Company
Production Department
Ball Mill Testing

Axial Testing
CM1 Crash stop test ( 1st Compartment)
Sample
90
1
2
3
4
5
6
7
8
9
10
11
12
40.8
45.7
51.7
51.4
50.5
50.2
45.7
50.3
50.2
47.6
49.83
49.75
Sample
90
212
Separator reject Rg
Airslide Rm
Cement Rf
22.3
5.5
0.4
7.3
4.3
0
90
60
50
40
30
20
10
90
40
90
Arish30Cement Company
20
10
0
1
10
11
12
120
100
80
% Retained
60
40
20
0

esting
212
17.7
30
44.1
33.8
33.2
29.9
23.1
30.7
27.3
27.7
30.5
29.3
= (f/a*u) *100
Circulation factor
1.30
90 fine
Feed /Hr
150
77.7
94.5
99.6
Circulation load (t/h)
357.4
Circulation load %
238.2
Separator Efficiency
80.85
212
50
45
40
35
30
25
20
15
10
5
0
40
35
30
25
20
15
10
5
0
212
90
Position Along Mill (m)
10
11
12

a*u) *100
212
212
212
212
90
10
11
12
Mill Testing
Axial Testing
CM1 Run out test ( 2st Compartment)
Sample
90
10
11
12
13
14
15
16
17
18
19
20
22.6
20.4
20
21.3
24.2
23.5
19.7
24.7
31.2
37
41.9
90
45
40
35
30
90
25
20
15
10
5
0
1
45
40
35
30
10
11
20
18
16
14
12
10
8
6
4
2
0
1
45
40
35
30
25
% Retained
20
15
10
5
0
10
11
12
13
14
15
16
Position along Mill (m)
esting
212
5.6
4.3
3.5
4.8
5.7
5.4
4.4
6.4
8.5
11.1
18.6
212
20
18
16
14
12
10
8
6
4
2
0
212
10
11
90
212
15
16
sition along Mill (m)
17
18
19
20
Annual Inspection of cemen
TECHNICAL DATA
Cement plant
Mill number
Supplier
Plant process
Mill diameter
Mill length
Installed power
Speed of rotation
BMIC
CM 1
KHD
Dry
4.6
17.11
2600 * 2
15
Type of circuit
Rotation
Water injection ch.1
Close
anti - clockwise
No
yes
Volume load ( Filling Degree ) , 2 methods ( H/D
1 - H/D Method
Compartment 1
Free height H1(m)
Free height H2(m)
Free height H3(m)
Average H(free space)
length of compartment(L)
Internal Diameter of compartment (D)
Volume of compartment (m3)
3.07
3.06
3.08
3.07
4.45
4.44
68.86
free space from G.media to centerline of

mill (h)
H/D
Charge q(%)
Bulk weight W(t/m3)
Charge F(t)
Original charge F(t)
New charge required (t)
0.850
0.691
26.9
4.3
79.7
86.75
-7.1
Total charge required
-7.3
2- Ball weight method

Usefull length
Type of lining
Type of diaphragm
Diaphragm slots width ( Design )
Diaphragm slots width ( Actual )
Ball charge in metric tons ( Original)
Chamber 1
4.45
Step shell , lifting
Intermediate
Not Determined
Not Determined
86.75
Current Calculated Charge by ball sampling Method

Current
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Total
90mm
80mm
70mm
60mm
50mm
40mm
30mm
25mm
20mm
17mm
Filling degree
required tonnage
21.17
27.55
20.01
11.65
0
80.39
26.9
-6.36
Quality
Feed components
percent %
cement Temperature
Clinker mineralogy
Clinker
88.5
115 - 125 C
% C3S
% C2S
Note : C2S is little higher which need more grinding efficieny

Blaine
Residue 90
Residue 45
3136
0.6
14.5
VISIT OF THE MILL

Cement type
Chamber 1
Measured volume load
Lining condition
Maximum ball diameter
Minimum ball diameter
Ball charge condition
Material level under/over balls
Coating on lining
Coating on balls
Uncrushed particles at the diaphragm
Diaphragm condition
Maximum width of slots
Slots blocked
Central screen condition
26.9
good but there is Dispalcement
90
56
regular with worn out
moderate/little Over
very slight
slight
abit
Semi- Blocked
Not Determined
Semi- Blocked
Fabricared new one with higher slot width 1
Chamber 2
Lining condition
Balls classification
Coating on lining
29
regular
58
15
over balls 4-5 cm
unclassified well
abit
l Inspection of cement mill No.1

Date : Sep. 2015
TECHNICAL DATA
m
m
kW
rpm
g Degree ) , 2 methods ( H/D & Ball weight Method )
od
Compartment 2
2.99
3.1
2.97
3.09
3.03
3.02
3.006
10
4.47
156.85
0.771
0.672
29
4.5
204.7
284.3
204.85
291.6
-0.2
7.3
-7.3
all weight method

Chamber 2
10
Corregator , classifying
Outlet
Not Determined
Not Determined
mm
mm
204.92
t
Original
23.00
28.90
21.25
13.60
86.75
%
ton
-16.27
mm
mm
Current
Original
20.05
10.05
9.84
20.08
28.46
48.71
57.82
195.01
29
-9.91
20.35
10.25
10.20
20.40
30.60
51.05
62.05
204.90
%
ton
Gypsum
6.5
52
23.4
inding efficieny
cm2/gr
%
%
VISIT OF THE MILL
1
H/D Method
mm
mm
1/4 ball appear
Need to clean
ed new one with higher slot width 10 mm
2
H/D Method
mm
mm
Additives
5
%C4AF
%C3A
11.83
7.85
Annual Inspection plan for cemen

TECHNICAL DATA
BMIC
Cement plant
Mill number
Supplier
Plant process
Mill diameter
Mill length
Installed power
Speed of trotation
Type of transmission
Type of circuit
Rotation
CM2
KHD
Dry
4.6
17.11
2600* 2
15
Close
anti - clockwise
No
yes
Volume load ( Filling Degree ) , 2 me

Usefull length
Type of lining
Type of diaphragm
Chamber 1
4.5
Step shell
Intermediate
6-8
8
86.75
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Total
19.64
26.64
19.09
12.06
0
90mm
80mm
70mm
60mm
50mm
40mm
30mm
25mm
20mm
17mm
77.43
Filling degree
25.7
9.3
required tonnage
2 - H/D Method
Compartment 1
Free height H1(m)
3.09
Free height H2(m)
3.1
Free height H3(m)
3.12

mill (h)
H/D
Charge q(%)
Bulk weight W(t/m3)
Charge F(t)
3.103
4.5
4.45
69.95
0.878
0.697
25.5
4.3
76.7
Last charge F(t)
86.75
10.0
%other1
35.9
OPC
16
0.4
3000-3100
110
-17
VISIT OF THE MILL

Cement type
End discharge
Chamber 1
Lining condition
Coating on lining
Coating on balls
Diaphragm condition
Slots blocked
25.7
good
88
58
moderate
normal
No
Small
abit
Regular
8
abit
regular
Chamber 2
Lining condition
26.7
regular

Coating on lining
Coating on balls
Diaphragm condition
Slots blocked
58
15
over balls 6-8 cm
abit unclassified well
abit
small
abit
good
9 mm
abit
good
Other comments
For
26.7
No
Crash stop test
Samples taken inside the mil
Chamber 1 / Seive micron
212
43.2
43.8
32.1
31.8
27.7
1
2
3
4
4.5
4.5
Typical grinding Diagram for 1st C

100
90
78.1
80
70
56.2
60
50 %
Retained
40
78.9
58.6
71.9
51.3
Typical grinding Diagram for 1st C

100
90
78.1
80
70
56.2
60
50 %
Retained
40
43.2
30
20
10
0
1
78.9
71.9
58.6
51.3
43.8
32.1
3
Effective length ( m )
Note : As seen from the figure , we have a bit problem at the beginnig of the m
90 mm located , so we must load the mill with 90 m
Chamber 2 / Seive micron
212
1
2
3
4
5
6
7
8
9
9.5
10
19.8
19.5
14.7
12.5
8.4
7.9
6.9
2.7
3.3
2.6
3.4
Typical grinding Diagram for 2nd Co

70
61.1
60
50
40.5
40
Retained % & Blaine
30
19.8
20
61
57.9
52.9
45.8
24.9
23.7
8.4
7.9
40.5
35.1
19.5
14.7
31
12.5
10
0
47
Effective Length ( m )
10
0
8.4
7.9
2nd Chamber Digram (Blaine

3000
2500
2000
Blaine cm2/g
1500
1000
500
0
Note : As seen from the figure , we have a bit problem Between the area 6 m
which meet the loss of both diameter in ball weight method , we have to top up
Samples takenthrough the mill circuit ( sepa

Sample
Mill outlet
Separator Reject
Separator outlet ( fine )
Circulation load
Seive ( 90 Micron )
residue
5.5
22.4
0.4
1.30
low circulation load improve the feed for mill is less and not as mentioned in C
which also improve the sep. Efficieny of separator at that low circulation
Circulation load
Seive Method
1.30
Feed& reject Me
feed
134
1.30
Difference between the circulation load in two methods mean the weight fe
additives have a big variation & need for calibration weekly ( seive methos tr
Mill power calculation

- DAWN Formula
NET KW = 0.2846 DAWN
Chamber 1
D
4.45
0.816
77.43
15
Net KW
1200.29
Gross KW
5200
Chamber 2
D
4.45
0.806
186.92
15
Net KW
2862.05
Gross KW
5200
Total mill
Net KW / Gross Kw ( mill)
0.78
Reference Net KW / Gross Kw ( mill)
0.89 - 0.95
power loss
0.17
power loss %
17.0
It means , If the design 36kw/t , so 17% morepower loss means that the cons
has increased by 6.12(17%), so the total consumption will be 42.13 kw/t ap
one ball original weight

(gr)
size
90
80
70
60
3000
2100
1410
888
Total ( 1st chamber )
888
514
263
111
64.2
32.8
20.2
60
50
40
30
25
20
17
Total mill
Total wear
Total mill production
wear rate for mill
(0,002mm)
(0,004mm)
(0,008mm)
(0,012mm)
(0,018mm)
(0,035mm)
(0,063mm)
(0,21mm)
(0,09mm)
(0,25mm)
(0,5mm)
(1mm)
(2,5mm)
(5mm)
(10mm)
(25mm)
212
pection plan for cement mill No.2

TECHNICAL DATA
m
m
kW
rpm
lateral
bi-lateral
central
annular
l/h
l/h
me load ( Filling Degree ) , 2 methods
t method
mm
mm
t
t
t
t
t
t
t
%
Chamber 2
Corrugator
Outlet
8-10
9
mm
mm
204.92
18.39
9.08
9.19
14.68
25.76
49.49
60.32
186.92
t
t
t
t
t
t
t
t
26.7
ton
18
ethod
Compartment 2
3.1
3.1
3.09
3.097
10
4.45
155.45
0.872
0.696
25.59
4.5
179.0
204.85
25.8
35.9
VISIT OF THE MILL
% , Ball weight method

mm
mm
1/4 ball appear
mm
% , Ball weight method
ton
Crash stop test
Samples taken inside the mill
90
45
56.2
58.6
51.3
51.4
47.2
78.1
78.9
71.9
70.5
67.5
Cement mill
digram
9.5
10
ing Diagram for 1st Compartment

71.9
70.5
51.3
51.4
67.5
47.2
45
90
ing Diagram for 1st Compartment

71.9
70.5
51.3
51.4
67.5
45
47.2
90
212
32.1
31.8
27.7
4.5
Effective length ( m )
problem at the beginnig of the mill especially between meter 1 to 2 , where

must load the mill with 90 mm to ease the crushing
90
45
40.5
40.5
35.1
31
24.9
23.7
22.4
18.2
14.7
21.6
14.6
Blaine cm2/g
61.1
61
57.9
52.9
47
45.8
43.7
40.6
36.4
34.8
37.8
1417
1470
1620
1758
1925
2080
2042
2223
2390
2586
2486
g Diagram for 2nd Compartment
7.9
5.1
4.7
52.9
47
45.8
43.7
40.6
36.4
31
24.9
12.5
8.4
23.7
7.9
22.4
6.9
18.2
34.8
21.6
14.7
2.7
3.3
2.6
9.5
10
45
90
212
8.4
7.9
6.9
2.7
3.3
2.6
9.5
10
mber Digram (Blaine cm2/g)
Blaine cm2/g
9.5
10
t problem Between the area 6 m to 8 m , where the location of 30 and 25 ,

eight method , we have to top up these diameters to improne the bline & seive
hrough the mill circuit ( separator Efficiency )
Seive ( 90 Micron ) Fine

94.5
77.6
99.6
80.96
is less and not as mentioned in CCR panel

separator at that low circulation load
irculation load
Feed& reject Method
Reject
133.6
test before Crash

stop 20 June
2.00
wo methods mean the weight feeder of clinker , gypsum ,

bration weekly ( seive methos trusted than weight method)

- DAWN Formula
846 DAWN
er 1
Internal Diameter of Mill
1.073 - J
Charge weight in Tonnes
Mill speed in RPM
0.23
er 2
1.073 - J
Mill speed in RPM
0.55
mill
High power loss
higher KW/t by 17 %
epower loss means that the consumption

onsumption will be 42.13 kw/t approx.
Wear rate Calculations
Tonnage
Quantity of Balls
Quantity of
collected samples
from mill
1st Chamber
23.00
28.90
21.25
13.60
7667
13762
15071
15315
86.75
51815
10
9
10
8
2nd Chamber
20.35
10.25
10.20
20.40
30.60
51.05
62.05
22917
19942
38783
183784
476636
1556402
3071782
204.9
5370245
291.7
5422060
7
19
16
41
41
40
94
27,301,089
gr
1st chamber
1,024,671
2nd chamber
26.6
gr/t
total
Other...
Other...
Other...
weight of
total charge
average wt.
total balls
samples
loss on one ball % of wear
weight
of one ball
weight in mill
colected from
(gr)
per ball
required
(gr)
( ton)
mill (kg)
( ton)
25618
17424
12666
6298
5618
8656
3790
3274
2216
1272
1846
9.1
17.5
2561.8
1936
1266.6
787.25
803
456
237
80
54
31.8
19.6
438.2
164.0
143.4
100.8
85.4
58.4
26.1
31.1
10.2
1.0
0.6
14.61
7.81
10.17
11.35
9.62
11.37
9.93
28.06
15.81
3.05
2.78
19.64
26.64
19.09
12.06
3.36
2.26
2.16
1.54
77.43
9.32
18.39
9.08
9.19
14.68
25.76
49.49
60.32
1.96
1.17
1.01
5.72
4.84
1.56
1.73
186.92
18.0
264.3
27.3
26.6
Other...
850
212
39.8
40.2
32.2
33.8
33.2
150
46.4
46.8
39.0
41.6
41.2
2.0
1.6
1.8
1.0
0.8
0.4
0.6
0.4
0.2
0.2
0.2
21.0
18.8
17.2
13.4
9.2
11.2
7.0
6.4
5.8
5.2
1.4
30.0
28.6
25.6
20.4
15.8
17.8
13.2
13.2
10.2
9.2
5.8
Reject
Out let
Fine pro,
850
0.8
0.2
0
212
12.2
1.6
3.2
850
99.2
99.8
100
212
87.8
98.4
96.8
1
2
3
4
Diaphram
22.2
17.0
11.8
5.4
5.0
5
6
7
8
9
10
11
12
13
14
Diaphram
Regard
Reject
Out let
Fine pro,
90
50.2
50.8
44.6
50.8
44.4
75
60.8
59.4
54.4
60.4
53.6
45
36
850
212
150
38.4
38.2
33.4
26.8
21.8
24.4
19.4
20.6
14.2
14.4
10.2
47.8
48.2
43.2
35.6
32.0
34.8
28.0
31.2
23.8
22.4
17.6
46.4
48.2
63.8
62.0
54.6
52.8
53.8
53.6
50.6
39.2
46.6
58.6
56.4
68.4
67.8
59.8
60.8
62.0
60.8
59.0
47.8
54.2
150
20.2
6.8
3.4
90
32.8
12.6
4.4
75
48
22.8
7
45
48.6
23
7.4
36
60.6
39
25
fine
49.4
61
75
Blaine
1303
2004
3241
150
79.8
93.2
96.6
90
67.2
87.4
95.6
75
52
77.2
93
45
51.4
77
92.6
36
39.4
61
75
fine
50.6
39
25
Blaine
1303
2004
3241
77.8
83.0
88.2
94.6
95.0
60.2
59.8
67.8
66.2
66.8
53.6
53.2
61.0
58.4
58.8
98.0
98.4
98.2
99.0
99.2
99.6
99.4
99.6
99.8
99.8
99.8
79.0
81.2
82.8
86.6
90.8
88.8
93.0
93.6
94.2
94.8
98.6
70.0
71.4
74.4
79.6
84.2
82.2
86.8
86.8
89.8
90.8
94.2
90
75
45
49.8
49.2
55.4
49.2
55.6
39.2
40.6
45.6
39.6
46.4
61.6
61.8
66.6
73.2
78.2
75.6
80.6
79.4
85.8
85.6
89.8
52.2
51.8
56.8
64.4
68.0
65.2
72.0
68.8
76.2
77.6
82.4
53.6
51.8
36.2
38.0
45.4
47.2
46.2
46.4
49.4
60.8
53.4
36
41.4
43.6
31.6
32.2
40.2
39.2
38.0
39.2
41.0
52.2
45.8
Annual Inspection of cemen
TECHNICAL DATA
Cement plant
Mill number
Supplier
Plant process
Mill diameter
Mill length
Installed power
Speed of rotation
BMIC
CM 1
KHD
Dry
4.6
17.11
2600 * 2
15
Type of circuit
Rotation
Close
anti - clockwise
No
yes
Volume load ( Filling Degree ) , 2 methods ( H/D
1 - H/D Method
Compartment 1
Free height H1(m)
Free height H2(m)
Free height H3(m)
3.09
3.06
3.11
3.08
4.45
4.44
68.86

mill (h)
H/D
Charge q(%)
Bulk weight W(t/m3)
Charge F(t)
Original charge F(t)
0.858
0.693
26.7
4.3
79.1
86.75
-7.7
-13.0

Usefull length
Type of lining
Type of diaphragm
Chamber 1
4.45
Step shell , lifting
Intermediate
Not Determined
Not Determined
86.75
Current Calculated Charge by ball sampling Method

Current
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Diameter
Total
90mm
80mm
70mm
60mm
50mm
40mm
30mm
25mm
20mm
17mm
Filling degree
required tonnage
21.17
27.55
20.01
11.65
0
80.39
26.7
-6.36
Quality
Feed components
percent %
Temperature
Clinker mineralogy
Clinker
91.5
52
23.4
Note : C2S is little higher which need more grinding efficieny
Blaine
Residue 90
Residue 45
3136
0.6
14.5
VISIT OF THE MILL

Cement type
Chamber 1
Lining condition
Coating on lining
Coating on balls
Diaphragm condition
Slots blocked
26.7
90
56
moderate/little Over
very slight
slight
abit
Semi- Blocked
Not Determined
Semi- Blocked
Fabricared new one with higher slot width 1
Chamber 2
Lining condition
29
regular
58
15
over balls 4-5 cm
unclassified well
Coating on lining
Coating on balls
Diaphragm condition
Slots blocked
abit
layer of Coat
abit
good
Not Determined
abit
good
No
ch
am
be
r(
2)
ch
am
be
r(
1)
1
2
3
4
Diaphram
5
6
7
8
9
10
11
12
13
14
Diaphram
70.0
60.0
40.0
30.0
20.0
Intermediate Diaphram
50.0
aphram
30.0
20.0
10.0
0.0
1
Diaphram
3000.0
2500.0
2000.0
Blaine cm2/g
1500.0
1000.0
500.0
0.0
Conclusion of figures :
Chamber 1: The reduction seems to be good up to the fourth sample where a m 4
chamber , Note : there is no Clinker nibs at Diaphram
Chamber 2 : A flat curve at the beginning of chamber 2 due to poor grinding of

50 at the middle of chamber
Passing %
36
45
75
90
150
212
850
Sum
Seperator feed a , Mill

outlet ( % )
18.8
24.8
50
64.8
81
90
99.4
428.8
Blaine
Sample
Mill outlet , a
Separator Reject , g
Separator outlet ( fine ) , f
Circulation load
2004
Seive ( 90 Micron )
residue
35.2
99.7
92.2
0.12
Separator Efficiency by seive 90

Separator Efficiency by all samples
Particle size
Micron
Separator feed (a)

36
45
75
90
150
212
850
a (%)
18.8
24.8
50
64.8
81
90
99.4
tromp tG = g/a ( 1-1/u)*100
t f = f /( a *u )* 100
NET KW = 0.2846 DAWN

Chamber 1
D
A
W
N
4.44
0.806
79.06
15
Net KW
Gross KW
1207.87
5200
Chamber 2
D
4.47
0.783
199.57
15
Net KW
Gross KW
2981.92
5200
Total mill
Total Net Power kw
Net KW / Gross Kw ( mill)
Reference Net KW / Gross Kw ( mill)
Estimated power loss
power loss %
Higher Power Consumption by
4189.78
0.81
0.89 - 0.95
0.074
7.4
3-4 Kw/t
size
one ball original weight

(kg)
90
3.00
80
70
60
2.10
1.41
0.888
60
50
40
30
25
20
17
Total mill
0.888
0.514
0.263
0.111
0.064
0.033
0.020
Current Ball charge

Original charge
Ball Added to mill till now
Total mill production , 2013 -2015
weared ton during operation
Mill wear rate g/t
1st chamber wear rate
2nd chamber wear rate
Ch 1 ball samples
total wt , kg
90
80
70
60
Total Chamber 1 samples
total mill charge samples No. tested

total mill charge samples wt. tested
118.759
88.09
66.38
11.414
284.643
6638
543.5

90
80
70
60
60
50
40
30
25
20
17
total
wt of total ball
118.759
88.09
66.38
11.414
25.38
9.58
10.41
44.79
45.68
70.10
52.91
543.5
Total No.of samples
90
80
70
60
60
50
40
30
25
20
17
total
37
75
75
75
75
75
75
75
75
75
37
748.8
Balls Number Comparison

80
70
75
60
5043
Axis Title
75
75
75
75
75
50
44
41
40
30
3037
20
15
20
10
0
90
80
70
60
60
50
40
balls number theor
balls number Actua
l Inspection of cement mill No.1

Date : Sep. 2015
TECHNICAL DATA
m
m
kW
rpm
g Degree ) , 2 methods ( H/D & Ball weight Method )
od
Compartment 2
3.09
2.99
3.1
3.06
2.97
3.09
3.11
3.03
3.02
3.005
9.75
4.47
152.93
3.05
0.770
0.672
29
4.5
199.6
278.6
204.85
291.6
-5.3
13.0
-13.0
all weight method

Chamber 2
9.75
Corregator , classifying
Outlet
Not Determined
Not Determined
mm
mm
204.92
t
Original
23.00
28.90
21.25
13.60
86.75
%
ton
-22.23
mm
mm
Current
Original
19.39
9.55
9.84
20.08
26.65
49.98
53.57
189.05
29
-15.87
20.35
10.25
10.20
20.40
30.60
51.05
62.05
204.90
%
ton
3.01
Gypsum
5.5
% C3S
% C2S
cieny
cm2/gr
%
%
VISIT OF THE MILL
1
H/D Method
mm
mm
1/4 ball appear
Need to clean
ed new one with higher slot width 10 mm
2
H/D Method
mm
mm
Additives
3
11.83
7.85
%C4AF
%C3A
Need to clean
Crash stop test

Samples taken inside the mill
850
212
150
22.2
17.0
11.8
5.4
5.0
39.8
40.2
32.2
33.8
33.2
46.4
46.8
39.0
41.6
41.2
2.0
1.6
1.8
1.0
0.8
0.4
0.6
0.4
0.2
0.2
0.2
21.0
18.8
17.2
13.4
9.2
11.2
7.0
6.4
5.8
5.2
1.4
30.0
28.6
25.6
20.4
15.8
17.8
13.2
13.2
10.2
9.2
5.8
Outlet Diaphram
ram
aphram
Diaphram
10
11
2nd Chamber Digram (Blaine cm2/g)
10
11
12
the fourth sample where a m 43.5 - 4 , and by wear rate calculation and visual inspection it seems
am
ber 2 due to poor grinding of 60 in 1st chamber , sample 10 & 12 showing a shart raise due to un
( separator Efficiency )
Fine fraction f ( % )
55.8
64.6
83.8
7.8
93.6
97
99.8
502.4
Coarse fraction g , tail

(%)
65.9
77.9
97.3
0.3
99.8
99.9
100
541.1
3241
Circulation factor
0.2
0.3
0.3
0.1
0.3
0.3
0.3
0.3
1303
Circulation
Seive ( 90 Micron ) Fine

64.8
0.3
7.8
0.12
103.52
1007.61
Seive Method
u=( f-g ) /( a-g )

Eta = f /(a*u)*100
0.12
( separator Tromp Curve )
Separator feed (a)
Fine fraction (f)

a (%)
18.8
6
25.2
14.8
16.2
9
9.4
f(%)
55.8
64.6
83.8
7.8
93.6
97
99.8
f (%)
55.8
8.8
19.2
-76
85.8
3.4
2.8

DAWN
1
1.073 - J
Mill speed in RPM
0.23
2
1.073 - J
Mill speed in RPM
0.57
High power loss

3-4 Kw/t
7.43%
Wear rate Calculations
Tonnage
23.00
Quantity of Balls
1st Chamber
7667
Quantity of collected
samples from mill
43
28.90
21.25
13.60
86.75
13762
15071
15315
51815
2nd Chamber
22917
19942
38783
183784
476636
1556402
3071782
5370245
5422060
20.35
10.25
10.20
20.40
30.60
51.05
62.05
204.9
291.7
269.4
291.6
14.7
1,882,369
36.81
19.6
7.34
12.24
ton
ton
ton
ton
ton
gr/t
gr/t
gr/t
44
50
15
30
20
41
410
817
2183
3034
tons to 1st chamber

tons to 2nd chamber
Ball Charge Sampling
No.
43
44
50
15
152
No.
Kg
Avr. Wt , kg
2.76
2.00
1.33
0.76
Single wt ball ( kg)

2.76
2.00
1.33
0.761
0.846
0.479
0.254
0.109
0.056
0.032
0.017
Total No. of samples as calculated , N =

Total No. of samples as calculated , N =
Total No. of biggest and smallest balls =
Single wt ball ( kg)
2.76
2.00
1.33
0.761
0.846
0.479
0.254
0.109
0.056
0.032
0.017
90
80
70
60
60
50
40
30
25
20
17
total
parison
Balls w
160.00
75
75
140.00
120.00
41
balls number theory
100.00
balls number Actual

Axis Title
60.00
20
50
80.00
40.00
20.00
40
0.00
90
80
70
40.00
20.00
0.00
90
80
70
3.03
3.02
3.01
3.01
3.01
3.01
2.99
2.99
2.98
3
3.005
mill
90
75
45
50.2
50.8
44.6
50.8
44.4
60.8
59.4
54.4
60.4
53.6
38.4
38.2
33.4
26.8
21.8
24.4
19.4
20.6
14.2
14.4
10.2
47.8
48.2
43.2
35.6
32.0
34.8
28.0
31.2
23.8
22.4
17.6
36
blaine
cm2/gm
fine
1417.0
1361.0
1470.0
1757.0
1925.0
2004.0
1925.0
2004.0
2485.0
2422.0
2223.0
Outlet Diaphram
850
212
150
90
75
45
36
Column J
ram
45
36
Column J
10
11
12
13
14
Diaphram
e cm2/g)
11
blaine
cm2/gm
12
13
14
Diaphram
al inspection it seems the 60 balls is not enough which make the high seive result at the end of
a shart raise due to unclassified ball charge in that areas where by visual inspection the 60 and
Separator
Efficiency
1384.1
1040.0
587.2
103.5
350.4
367.9
301.2
340.0
Circulation load
feed
150
Feed& reject Method

Reject
155
2.03
Coarse fraction (g )
g(%)
g (%)
65.9
65.9
77.9
12
97.3
19.4
0.3
-97
99.8
99.5
99.9
0.1
100
0.1
Cir. Load
U
0.21
0.25
0.29
0.12
0.33
0.29
0.33
Efficiency
( %)
1384.1
1040.0
587.2
103.5
350.4
367.9
301.2
Tromp
tf
1384.13
585.56
266.95
-4416.22
1605.97
128.97
89.36
tg
-1284.1
-144.8
-97.1
1137.7
-249.6
-0.3
-0.2
weight of
samples
colected from
mill (kg)
118.759
average wt.
loss on one ball % of wear per
of one ball
(gr)
ball
(Kg)
2.76
0.24
7.9
Current Ball
Wt in mill
total charge
weight
required
( ton)
21.17
1.83
88.09
66.38
11.414
284.6
2.00
1.33
0.761
0.10
0.08
0.13
4.7
5.8
14.3
27.55
20.01
11.65
80.39
1.35
1.24
1.95
6.36
25.38
9.58
10.41
44.79
45.68
70.10
52.91
258.8
0.846
0.479
0.254
0.109
0.056
0.032
0.017
0.04
0.04
0.01
0.00
0.01
0.001
0.0028
4.7
6.8
3.5
1.6
12.9
2.1
13.7
19.39
9.55
9.84
20.08
26.65
49.98
53.57
189.05
269.4
0.96
0.70
0.36
0.32
3.95
1.07
8.48
15.8
22.2
2013
2014
2015
7.5
7.2
Ch 2 ball samples
total wt , kg
60
50
40
30
25
20
17
Ch2 samples
25.378
9.576
10.406
44.7892
45.6753
70.10396
52.9114
258.83986
No.
30
20
41
361
817
2183
3034
6486
Avr. Wt , kg
0.846
0.479
0.254
0.124
0.056
0.032
0.017
467442
728772.40
686154.2
N/2* 90 +N*( 90+ 80+ 70+ 60+ 50+ 40+ 30+ 25+ 20)+N/2* 17 = 543.5
74.88
37.44
balls number
theory
weight , kg
theory
balls number
Actual
weight , kg
actual
37
75
75
75
75
75
75
75
75
75
37
748.8
103.40
149.91
99.41
56.98
63.34
35.85
19.00
8.18
4.19
2.40
0.65
43
44
50
15
30
20
41
410
817
2183
3034
118.76
88.09
66.38
11.41
25.38
9.58
10.41
44.79
45.68
70.10
52.91
Balls weight Comparison
60.00
40.00
20.00
00.00
weight , kg theory
80.00
weight , kg actual
60.00
40.00
20.00
0.00
90
80
70
60
60
50
40
40.00
20.00
0.00
90
80
70
60
60
50
40
39.2
40.6
45.6
39.6
46.4
58.6
56.4
68.4
67.8
59.8
60.8
62
60.8
59
47.8
54.2
nough which make the high seive result at the end of
that areas where by visual inspection the 60 and
No
r(
2)
5
6
7
8
9
10
11
12
13
14
Diaphram
ch
am
be
ch
am
be
r(
1)
850
1
22.2
2
17.0
3
11.8
4
5.4
Diaphram
5.0
2.0
1.6
1.8
1.0
0.8
0.4
0.6
0.4
0.2
0.2
0.2
212
39.8
40.2
32.2
33.8
33.2
21.0
18.8
17.2
13.4
9.2
11.2
7.0
6.4
5.8
5.2
1.4
70.0
60.0
50.0
40.0
30.0
20.0
30.0
20.0
10.0
0.0
1
size
90
80
70
60
60
50
40
30
25
20
17
Total mill
Current Ball charge
Original charge
Ball Added to mill till now
Total mill production , 2013 -2015
weared ton during operation
Mill wear rate g/t
1st chamber wear rate
2nd chamber wear rate
150
46.4
46.8
39.0
41.6
41.2
90
50.2
50.8
44.6
50.8
44.4
75
60.8
59.4
54.4
60.4
53.6
45
36
blaine
cm2/gm
30.0
28.6
25.6
20.4
15.8
17.8
13.2
13.2
10.2
9.2
5.8
38.4
38.2
33.4
26.8
21.8
24.4
19.4
20.6
14.2
14.4
10.2
47.8
48.2
43.2
35.6
32.0
34.8
28.0
31.2
23.8
22.4
17.6
46.4
48.2
63.8
62.0
54.6
52.8
53.8
53.6
50.6
39.2
46.6
58.6
56.4
68.4
67.8
59.8
60.8
62.0
60.8
59.0
47.8
54.2
1417.0
1361.0
1470.0
1757.0
1925.0
2004.0
1925.0
2004.0
2485.0
2422.0
2223.0
70.0
60.0
40.0
30.0
20.0
50.0
Diaphram
30.0
20.0
10.0
0.0
1
one ball
original
weight
(kg)
Tonnage
Diaphram
Quantity weight of
average
of
samples
Quantity
wt. of
collected colected
of Balls
one ball
samples from mill
(Kg)
from mill
(kg)
3.00
23.00
2.10
28.90
1.41
21.25
0.888
13.60
tal ( 1st chamber ) 86.75
7667
13762
15071
15315
51815
0.888
20.35
0.514
10.25
0.263
10.20
0.111
20.40
0.064
30.60
0.033
51.05
0.020
62.05
tal ( 2st chamber ) 204.9
Total mill
291.7
22917
19942
38783
183784
476636
1556402
3071782
5370245
5422060
1st Chamber
43
118.759
44
88.09
50
66.38
15
11.414
284.6
2nd Chamber
30
25.38
20
9.58
41
10.41
410
44.79
817
45.68
2183
70.10
3034
52.91
258.8
Current Ball charge

269.4 ton
Original charge
291.6 ton
l Added to mill till now 14.7
ton
ll production , 2013 -2015
1,882,369 ton tons to 1st chamber7.5
ed ton during operation36.81 ton tons to 2nd chamber
7.2
Mill wear rate g/t
19.6
gr/t
t chamber wear rate 7.34
gr/t
loss on
% of wear
one ball
per ball
(gr)
2.76
2.00
1.33
0.761
0.24
0.10
0.08
0.13
7.9
4.7
5.8
14.3
0.846
0.479
0.254
0.109
0.056
0.032
0.017
0.04
0.04
0.01
0.00
0.01
0.001
0.0028
4.7
6.8
3.5
1.6
12.9
2.1
13.7
10
d chamber wear rate 12.24
gr/t
Outlet Diaphram
850
212
150
90
75
45
36
Column J
phram
75
45
36
Column J
10
11
total
Current
charge
Ball Wt in weight
mill
required
( ton)
21.17
27.55
20.01
11.65
80.39
1.83
1.35
1.24
1.95
6.36
19.39
9.55
9.84
20.08
26.65
49.98
53.57
189.05
269.4
0.96
0.70
0.36
0.32
3.95
1.07
8.48
15.8
22.2
2013
2014
2015
467442
###
###
12
13
14
Diaphram

CM 1 Annual Audit

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CM 1 Annual Audit

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Arish Cement Company

Ball Mill Testing

Arish Cement Company

Circulation load (t/h)

Arish Cement Company

Position Along Mill (m)

Arish Cement Company

Arish Cement Company

Position along Mill (m)

sition along Mill (m)

Annual Inspection of cemen

Volume load ( Filling Degree ) , 2 methods ( H/D

free space from G.media to centerline of

Total charge required

2- Ball weight method

Current Calculated Charge by ball sampling Method

Note : C2S is little higher which need more grinding efficieny

VISIT OF THE MILL

l Inspection of cement mill No.1

g Degree ) , 2 methods ( H/D & Ball weight Method )

all weight method

VISIT OF THE MILL

ed new one with higher slot width 10 mm

Annual Inspection plan for cemen

Volume load ( Filling Degree ) , 2 me

Ball charge in metric tons ( Original)

Free height H2(m)

Free height H3(m)

Average H(free space)

Last charge F(t)

New charge required (t)

Total charge required

VISIT OF THE MILL

Maximum ball diameter

Crash stop test

Samples taken inside the mil

Chamber 1 / Seive micron

Typical grinding Diagram for 1st C

Typical grinding Diagram for 1st C

Chamber 2 / Seive micron

Typical grinding Diagram for 2nd Co

2nd Chamber Digram (Blaine

Samples takenthrough the mill circuit ( sepa

Mill power calculation

Reference Net KW / Gross Kw ( mill)

one ball original weight

Total ( 1st chamber )

wear rate for mill

pection plan for cement mill No.2

me load ( Filling Degree ) , 2 methods

VISIT OF THE MILL

% , Ball weight method

% , Ball weight method

Crash stop test

Samples taken inside the mill

ing Diagram for 1st Compartment

ing Diagram for 1st Compartment

problem at the beginnig of the mill especially between meter 1 to 2 , where

g Diagram for 2nd Compartment

mber Digram (Blaine cm2/g)

t problem Between the area 6 m to 8 m , where the location of 30 and 25 ,

hrough the mill circuit ( separator Efficiency )