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TheCementGrindingOffice
The Art Of Sharing and...Imagination

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Dierentwaystogetanecientgrindingplant

1 Introduc on
Everybodyknowsthatthecementindustryisahugeconsumerofenergy.
Theglobalcementproduc onwasabout3,6billiontonnesin2012.
Ifwetakeanaverageof110kWhtoproduce1tonofcement,itmeansaconsump onofelectricityofabout
400billionsofkWh.
Consideringthatgrindingdepartmentsareresponsiblefor65%ofthetotalconsump on(23%Rawmeal
and42%Cement),itisthennecessarytoop mizetheseinstalla ons!
Theworld'seetisdividedintofourtypesofgrindingmachines:
*TubeMills
*RollerPresses
*Ver calRollerMills
*HorizontalRollerMills
Youcanseeonthefollowingtablethees matedgrindingeciencyforeachtype:

Thegrindingeciencyofthesemachinesisverypoorandthegreaterpartoftheenergysuppliedbythe
absorbedpowerofthedevicesislostintoheat,vibra on,fric onwearorsoundnoise.
Thetubemillisthelessecientbutiss llthemostcommonequipmentintheworlddespitetheemergence
ofmoreecientdeviceslikethever calrollermill.
Anditisalsocommonlyacceptedthatthereiss llahugepoten alforpossibleimprovementsregardingballmills.
Wewillnowreviewallthesolu onstoimproveaballmillcircuit.
Hereisthelist:
*Increasethellingdegree
*Rightli inglininginchamber1
*Flowcontrolintermediatediaphragm
*Classifyinglininginsecondchamber
*Rightballchargegrada on
*Fromopentoclosedcircuit
*HighEciencyseparator
*Precrushingsystem
*Pregrindingsystem
*Automatedcontrol
*Predic vemaintenance
*Grindingaids

2 Increasethellingdegree
Itseemstobeevidentbutnotforeverybody.
Thisisanexample:
*Ballmilldiameter:4m
*Totallength:13m
*Speed:15,8rpmor74,7%Vcr
*183tofballsor28%VL=>2440kW
Now,ifthellingdegreeis32%.
*210tofballsor32%VL=>2660kW
Represen ngagainof9%whichwillbeamaximuminthiscase.Whyamaximum?
Thiscanbeexplainedbythefactthatthegrindingeciencyalsodependsofthellinglevel.
Seethegurebelowwhereitispossibletoseethattheeciencyisop mumat2728%volumeload:
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Seethegurebelowwhereitispossibletoseethattheeciencyisop mumat2728%volumeload:









3 Rightli inglininginchamber1
Theliningmusthaveagoodli ingeectinordertocrushproperlythefreshmaterial.
Onthegurebelow,oneseestheballsfallingincataractandadeadzonethatmustbethesmallestpossible:











Thechoiceoftheliningdependsofthekindofmaterial,freshmaterialgranulometryandhardness.
Whilethechoiceofthealloyisimportanttoavoidbreakage,decreasethewearrateandincreasethelife me.
Thedierentliningsare:STEP,Singlewavelining,Doublewavelining,Lorainlining,li ingclassifyinglining...etc

4 Flowcontrolintermediatediaphragm
Aowcontroldiaphragmiso ennecessarybecausetherstchamberisemptyofmaterial,especiallynearthe
diaphragm.








Laboratorytrialsandindustrialtestsshowedthattheop mumofeciencyisreachedwhenthera oweightof
material/weightofballsisaround18%.
Prac cally,itmeansthatthematerialmustbeattheleveloftheballs(tollthevoidswhichrepresent42%).










Dierenttypes:
*AdjustableringFCD(Ch.Pfeier)
*AdjustablescoopsFCD(Slegten)
*Adjustableli ersFCD(FLSmidth)

5 Classifyinglininginsecondchamber
Aclassifyingliningisnecessarybecauseattheinletofthesecondchamber,thematerialiscoarser.
Then,weneedimpactforces,thenbiggerballstocrushthelastbigpar cles.
Atthecontrary,atthechamberoutlet,thematerialisner,weneeda ri onforcesandsmallestballs.
Theclassifyingliningisthemostwidelyusedintheworld.
Herebelowasketchofthislining.





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6 Rightballchargegrada on

Itisveryimportantbuto enneglected!
Therstcompartmenthasthefollowingobjec ve:CRUSHING,thenimpactforces.Ballsfrom90to60mmare
recommended.
Factorsinuencingthecomposi onare:
*granulometry
*hardness
*typeoflining
*specicpowerconsump onofthechamber
*slag
*addi ves
*moisture
*clinker
Thesecondcompartmenthasthefollowingobjec ve:FINISHING,thena ri onforces.Ballsfrom(605040)30to
15mmarerecommended.
Factorsinuencingthecomposi onare:
*nenesstargetofthecement
*ra olength/diameter(L/D)
*Typeofcircuit
*Typeofseparator
Usedballsarewelcome,butballsofdiameter90mmmustbeNEW!

7 Fromopentoclosedcircuit
Inthepast,themajorityoftubemillswereopera nginopencircuit.
A erthat,separatorsoftherst,secondandthirdgenera onhavebeendeveloped.









Dependingoftheseparatorandthenenessofthecement,thegaininkWh/tcanbeveryimportant:













8 HighEciencyseparator
Abigjumpinqualitywasachievedwiththeemergenceofhigheciencyseparators.
Wewillnotinsisttodayontheprincipleofthethreeforcesandtherotor.
Butwecanseethedierencesonthefollowingsheets:















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9 Precrushingsystem
Theseequipmentshavebeendevelopedinthe8090 es,liketheVSI(Ver calSha Impactor).
Onthefollowinggure,youcanseetheopera ngmodewiththerotoranditsimpellerswhichsendthematerial
againsttheanvilsandcausethebreakage.














Thiskindofsystemisopera nginopencircuitorclosedcircuitwithavibra ngscreen.
Thisisaverysimplesystem,withsmallinvestmentbutbigproblemofwear!
Thenthesuccesswasverylimited.

10 Pregrindingsystem
EverybodyknowsRollerPressesusedforclinkerandothermaterials,withveryhighpressuresbetween2rollers
(onex,onemoving).









DierentcircuitsarepossiblewithRP,fromopencircuituptocompletegrindingsystem.
Heretwocircuits:














11 Automatedcontrol
Thetargetoftheautomatedcontrolistoop mizetheinstalla onwithasteadysystem.
Solu onsareRPfeedcontrol,Elevatorcontrol,Earcontrol,Rejectowcontrol,Totalfeedcontrol...etc
Toolsare(thislistisnotexhaus ve):
*controllerONOFF
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*controllerONOFF
*controllerPID
*fuzzylogic
*Expertsystem
Suppliersare(thislistisnotexhaus ve):
*SCAP
*Milltronics
*ECS
*KTron/Hasler
*SlegtenGoControl

12 Predic vemaintenance
Arigorousmethodofpredic vemaintenancewilldecreasedown mevolumeandwillallowaproduc onatastable
levelover me.

13 Grindingaids

Asyouknow,theac onofaGAistodecreasethesurfaceenergyforcescreatedonthecementpar clesduring

thecomminu onwork.

Inotherwords,ithelpstocounteractthechargespresentonthesurfaceofcementpar cles.

Grindingaidsac onconsequencesarethefollowing:

*Eliminatecoa ngonballsandlinings

*Improvethecementowability

*Improvetheseparatoreciency

*Increasetheproduc on

*Improvethecementquality

*Preventcementpacksetuponstorage


14 PossibleimprovementsSummarytable




















(*)Onthetotalproduc on

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