12 views

Uploaded by sheizareh

Comparison of the Overall Circuit Performance in the Cement Industry High

- Description of Cement Industry in Mexico
- JLRB-JKMRC SC 20 Simulation jKsimet
- Cascade Air Separator KVT En
- Wet Pulveriser
- Reducing the Energy Required in Grinding Clinker to Cement—Benzer Aydogan Dundar and Lynch
- Mill.4
- CMP2011-DollBarratt-GrindingTests
- Vario Manual en v2.1 SmallSize
- Let Us Employ SRG and PSRG Technology
- Grinding Technology of Limestone With Ball Mills
- 148-FP
- GM 1.2 Fineness
- Synthesis of Al- Sic Composite Prepared By Mechanical Alloying
- 04 Grinding GD Hammer mill V002.doc
- 8035668 Cast Thermite
- Chapter 0
- Hinges
- Cryo
- 57601135969
- Assignment Questions on Linear Programming

You are on page 1of 5

Minerals Engineering

journal homepage: www.elsevier.com/locate/mineng

compression milling vs. ball milling technology

Namk A. Aydogan *, Hakan Benzer

Mining Engineering Department, Hacettepe University, 06800 Ankara, Turkey

a r t i c l e i n f o a b s t r a c t

Article history: In cement production, tube mills having multi-chambers are traditionally used either in open or closed

Available online 6 September 2010 circuit operations. After the introduction of high compression grinding mills (High pressure grinding rolls

(HPGR), vertical roller mill (VRM) and Horomill), various circuit congurations have been developed for

Keywords: energy efcient grinding. In this study, in order to evaluate and compare the performances of these

Horomill cement grinding technologies, industrial scale data were collected from HPGR-ball mill, VRM, Horomill

Vertical roller mill and multi-chamber ball mill closed circuits.

High pressure grinding rolls

The grind abilities of the raw materials of all circuits were varying in a narrow range of 1420 kWh/t.

Ball mills

The specic energy consumptions of the grinding equipment and the standard bond work indexes, used

100 lm screen, of raw materials are given below.

HPGR-ball mill 14.7 20.0

VRM 19.6 27.5

Horomill 14.4 17.5

Ball mill 14.4 32.5

The results show that high compression grinding mill circuits are more energy efcient than conven-

tional single stage multi-chamber ball mill circuits. The circulating load ratio around the circuit is much

higher compared to conventional ball milling. The reason is less ne and slime production of the high

compression technology which prevents the over-grinding.

2010 Elsevier Ltd. All rights reserved.

In particular, it has been claimed that the advantage of the high

Tube mills having multi-chambers are traditionally used for ce- pressure grinding roll is its lower specic energy consumption

ment grinding either in open or closed circuit operations. In the (Schnert, 1979). Compressing a particle bed between two counter

rst chamber, larger balls (10060 mm) are used for coarse grind- rotating rolls was achieved by the invention of the high pressure

ing while the smaller balls (4015 mm) are used for ne grinding. grinding rolls (HPGR) (Schnert, 1988).The rst commercial appli-

The chambers are separated by an intermediate diaphragm which cation of HPGR was in 1985 and its success resulted in increasing

allows the passage of the ne particles to the second chamber numbers of applications since then, particularly in the cement

while keeping the coarse particles in the rst compartment. Differ- industry (Kellerwessel, 1990).

ent types of air classiers are used in closed circuit operations. The In a vertical roller mill the interparticle comminution takes

cut size of the separator is the critical control parameter and is place in a material lled gap between the rotating table and the

mainly controlled by the rotor speed (Duda, 1985). grinding rollers. The mill feed is charged to the center of the table

The High pressure grinding rolls (HPGR) developed by Schnert and moves by centrifugal forces and friction towards the tables

has been offered as a comminution technology with claims of im- edge. On its way it is nipped by two rollers installed at the outside

rim of the table. The rollers are attached to hydraulic cylinders

* Corresponding author. Tel.: +90 312 297 76 00. which provide grinding forces for comminution of the material.

E-mail address: naydogan@hacettepe.edu.tr (N.A. Aydogan). The ground particles leave the table by an air stream and taken

0892-6875/$ - see front matter 2010 Elsevier Ltd. All rights reserved.

doi:10.1016/j.mineng.2010.08.005

212 N.A. Aydogan, H. Benzer / Minerals Engineering 24 (2011) 211215

Standard bond work indexes of the fresh feeds. techniques. Mass balancing studies were performed to calculate

Circuit Bond work index (kWh/t) the adjusted data and the tonnages of all streams in the circuits. To

HPGR-ball mill 14.7 compare the circuits with each other, material characteriza-

VRM 19.6 tion achieved by standard bond work indexes of the fresh feeds

Horomill 14.4 (Table 1).

Ball mill 14.4

3. Performance evaluation

up to the separator incorporated in the casing of the mill. The ne

product is taken as the mill discharge and the reject of the separa- 3.1. Closed circuit ball mill grinding circuit

tor falls back onto the table as the circulating load.

The Horomill consists of a horizontal cylinder supported on- In this conguration, a multi-chamber ball mill was operated as

slide-shoe bearings and driven through an open gear train. The closed circuit with an air classier (Fig. 1). Design parameters of

Horomill can be described as a bed material compression mill, a the circuit are presented in Table 2. As a result of the mass balanc-

multi-compression mill and as high capacity mills (Cornille, 1999). ing studies, the tonnages around the circuit and the measured and

The introduction of high compression grinding technology the calculated size distributions are presented in Figs. 2 and 3.

brought many different applications and circuit layouts using high

pressure grinding rolls (HPGR), vertical roller mill (VRM) and 3.2. Closed circuit HPGR closed circuit ball mill grinding

Horomills.

In this study, in order to evaluate and compare the perfor- In this exercise the HPGR operates in closed circuit with an air

mances of different cement grinding technologies using the ball classier to prepare ball mill circuit feed. Since HPGR product is

milling and high compression technology, industrial scale data in the form of weak agglomerates which are referred to as cake,

were collected from HPGR-ball mill, VRM, Horomill and multi- a simple impact type disagglomerator is used before classication.

chamber ball mill closed circuits. Since the product of the HPGR circuit is rather ne, the cut sizes of

both classiers used in the circuit and the ball size distribution

2. Sampling and experimental studies within the ball mill should be optimized. While design parameters

of the circuit are presented in Table 3, the simplied owsheet of

The simplied owsheet of the various circuit congurations the circuit sampled and the measured and adjusted size distribu-

are given below. tions are shown in Figs. 4 and 5.

The sampling studies were conducted at a conventional ball

mill closed circuit, closed circuit HPGR pre grinding system with 3.3. Closed circuit vertical roller mill grinding

a closed circuit ball mill. The other case studies, VRM, Horomill

and single stage closed circuit ball mill circuits, do not include In this study, a compact design and partial external recycling

any pre grinding systems. type vertical roller mill circuit was sampled. VR mills are widely

During the sampling surveys, all variables measured were re- used in cement industry especially for raw material and coal

corded at the control room. Size distributions of the samples were grinding.

(a) (b)

(c) (d)

Fig. 1. Different circuit congurations where sampling was performed: (a) conventional ball milling circuit, (b) HPGR closed circuit with ball mill closed circuit, (c) vertical

roller mill circuit and (d) Horomill circuit.

N.A. Aydogan, H. Benzer / Minerals Engineering 24 (2011) 211215 213

Table 2 Feed

Closed ball mill circuit design parameters. 447 t/h

150 t/h

Ball mill diameter (mm) 4,660 570 t/h

Ball mill length (mm) 14,000

Ball mill motor power (kW) 5,200

Separator motor power (kW) 50

150 t/h

720 t/h

297 t/h

Ball Mill

150 t/h

Product 160 t/h Fig. 4. Sampling points and tonnages of the streams around the closed circuit HPGR

closed circuit ball mill grinding.

237 t/h

Fig. 2. Sampling points and tonnages of the streams around the closed ball mill

circuit.

Fig. 5. The measured and calculated size distributions around closed circuit HPGR

closed circuit ball mill grinding.

Fig. 3. The measured and calculated size distributions around the closed ball mill

circuit.

Table 4

Vertical roller mill grinding circuit design

parameters.

Table 3

Closed circuit HPGR closed circuit ball mill grinding circuit design parameters. Table diameter (mm) 4700

Table rotation (rpm) 25.7

Roll length (mm) 1450 Roll length (mm) 700

Roll diameter (mm) 1000 Roll diameter (mm) 2360

Roll speed (m/s) 1.50 Roll speed (m/s) 1.50

Roller motor power (kW) 1200 Motor power (kW) 2200

HPGR circuit separator. motor power (kW) 60 Separator motor power (kW) 80

Ball mill diameter (mm) 3600 Fan motor power (kW) 500

Ball mill length (mm) 10,000

Ball mill motor power (kW) 1800

Ball mill circuit seperator. motor power (kW) 50

Disagglomerator motor power (kW) 80

3.4. Closed circuit Horomill grinding

Horomill is very new grinding process and used for cement and

Design parameters of the circuit are presented in Table 4. As a raw grinding in cement industry. Design parameters of the circuit

result of the mass balancing exercise, the tonnages around the cir- are presented in Table 5. As a result of the mass balancing exercise,

cuit and the measured and the calculated size distributions are the tonnages around the circuit and the measured and the calcu-

presented in Figs. 6 and 7. lated size distributions are presented in Figs. 8 and 9.

214 N.A. Aydogan, H. Benzer / Minerals Engineering 24 (2011) 211215

Feed

80 t/h

43 t/h 917 t/h

Fig. 6. Sampling points and tonnages of the streams around the VRM circuit.

Fig. 7. The measured and calculated size distributions around VRM circuit. Fig. 9. The measured and calculated size distributions around Horomill circuit.

Table 5 The 80% passing sizes for the circuits feed and product are gi-

Horomill grinding circuit design parameters. ven in Table 6.

The specic energy consumptions based on power draws of the

Motor power (kW) 1500

Separator power (kW) 45 grinding equipments and all main equipment are given with stan-

dard bond work indexes and operational work indexes (Rowland

and Kjos, 1980) in Table 7.

As it can be seen from the data high compression milling has

4. Discussion low energy consumption when it is compared with ball milling

technology. Wio/Wi value is a performance parameter indicating

A comparison of the fresh feed and product size distributions of the grinding performance. If this value is low, it shows that the

the circuits is given in Fig. 10. It can be seen that despite the fact efciency of this process is high. Horomill grinding technology

that the feed size varied signicantly, the variation in the product has energy advantages over the other high compression grinding

size distributions were relatively small. circuit. But on the other hand, the energy efciency of the HPGR

510 t/h

75 t/h

Product 85 t/h

Fly ash 10 t/h

Sep reject

425 t/h

Fig. 8. Sampling points and tonnages of the streams around the Horomill circuit.

N.A. Aydogan, H. Benzer / Minerals Engineering 24 (2011) 211215 215

Table 8

Circulating load ratio around the circuits.

Ball mill 160 237 148

HPGR in HPGR-ball mill circuit 150 570 380

Ball mill in HPGR-ball mill circuit 150 297 198

Horomill 85 425 500

VRM 80 960 1200

when the compression of the grinding efciency of HPGR and ball

mill circuits separately, it can be seen that HPGR circuit is very ef-

cient. Although VRM is also very effective grinding equipment, it

consumes too more energy to transport the material from grinding

table to dynamic separator by air inside the mill. External material

transportation using mechanical methods is more effective than

internal air transportation method.

The circulating load ratio around the circuit is much higher

Fig. 10. Fresh Feed and Final Product Particle Size Distributions of the Circuits. compared to conventional ball milling (Table 8). The reason is less

ne and slime production of the high compression technology

which prevents the over-grinding.

Table 6 5. Conclusion

80% passing sizes of feed and product.

Circuit fresh Circuit F80/P80 In this paper, the performance evaluation studies of four differ-

feed product ent cement grinding circuits containing HPGR, VRM, Horomill and

HPGR-ball mill 21.0 mm 0.029 mm 724 ball mill in different congurations were presented.

HPGR in HPGR-ball mill circuit 21.0 mm 0.054 mm 389 Results show that high compression milling technology (HPGR,

Ball mill in HPGR-ball mill circuit 0.054 mm 0.029 mm 1.8

VRM, Horomill) has lower energy consumption than ball milling

VRM 12.8 mm 0.029 mm 441

Horomill 15.5 mm 0.025 mm 620 technology. When all performances of the circuits compared with

Ball mill 17.5 mm 0.032 mm 547 each other, the performance of the Horomill circuit is the best.

Acknowledgments

Table 7

Grinding performance parameters of the circuits. Unit and Turkish Scientic and Technical Research Council (MISAG

160) for their nancial support.

Circuit Bond Operating Wio/Wi Specic Over all

work work energy specic

index index consump- energy References

(kWh/t) Wi (kWh/t) Wio tion consump-

(kWh/t)a tion Duda, W.H., 1985. Cement Data Book International Process Engineering in

(kWh/t)b Cement Industry, French and European Pubns; ISBN: 0828802041, 3. Edition 1.

Schnert, K., 1979. Aspects of the physics of breakage relevant to comminution,

HPGR-ball mill 14.7 11.2 0.76 20.0 21.2 Fourth Tewksbury Symposium, University of Melbourne, pp. 3.13.30

HPGR in HPGR- 14.7 6.2 0.42 8 8.9 Schnert, K., 1988. A rst survey of grinding with high-compression roller mills,

ball mill circuit International Journal of Mineral Processing, 22, pp. 401408.

Ball mill in HPGR- 14.7 24 1.63 12 12.3 Kellerwessel, H., 1990. High-pressure material-bed comminution in practice,

ball mill circuit Translation ZKG, No. 2/90, pp. 5764.

VRM 19.6 15.5 0.79 27.5 34.8 Cornille J.P., 1999. Horomill: latest developments and results, European Cement

Horomill 14.4 9.1 0.63 17.5 18.2 Conference 1999, pp. 21.121.2

Rowland, Jr., C.A., Kjos, D.M. 1980. Rod and ball mills, in Mineral Processing Plant

Ball mill 14.4 19 1.32 32.5 32.8

Design, Mular A.L. and Bhappu, R.B. (Eds.), second ed. SME-AIME, New York, pp.

a

Grinding equipment motor power included. 239278

b

All main equipments (fan, disagglomerator and separator) motor power

included.

- Description of Cement Industry in MexicoUploaded byAdit Kadakia
- JLRB-JKMRC SC 20 Simulation jKsimetUploaded byTeobaldo Roque Huaman
- Cascade Air Separator KVT EnUploaded bykamjulajay
- Wet PulveriserUploaded byjasenterprise
- Reducing the Energy Required in Grinding Clinker to Cement—Benzer Aydogan Dundar and LynchUploaded byhuangyuan33
- Mill.4Uploaded byMohammed Abdo
- CMP2011-DollBarratt-GrindingTestsUploaded byaghilif
- Vario Manual en v2.1 SmallSizeUploaded byKriyalover
- Let Us Employ SRG and PSRG TechnologyUploaded byD S Venkatesh
- Grinding Technology of Limestone With Ball MillsUploaded byanrulo
- 148-FPUploaded byKenny Ruiz
- GM 1.2 FinenessUploaded byJosé Urday
- Synthesis of Al- Sic Composite Prepared By Mechanical AlloyingUploaded byInternational Organization of Scientific Research (IOSR)
- 04 Grinding GD Hammer mill V002.docUploaded byEwin Septian Guntur
- 8035668 Cast ThermiteUploaded byMike Wienhold
- Chapter 0Uploaded byarnold
- HingesUploaded byskarmy07
- CryoUploaded byJainy Shah
- 57601135969Uploaded byArvin Bhurtun
- Assignment Questions on Linear ProgrammingUploaded byjeganrajraj
- Sime IngenierosUploaded byAuraElsaSogamosoHurtado
- Saurabh Mishra Training ReportUploaded bySaurabh Mishra
- 09PRM Chapter 1 03Uploaded byProfesor Waldo Valderrama
- 23 May 2017 175605867F50QA5LQprefeasibilityreportUploaded bySwarup Nayak
- Birla CementsUploaded byHarish Sankar Ni
- NonmetallicUploaded byAbhishek Jain
- Simple-Pewter-casting.pdfUploaded byJanF
- Energy Efficiency of Processing Joe Pease 2007Uploaded byhuangyuan33
- 08_PRM_C2_A5Uploaded byAngel Canales Alvarez
- Vc New Granite EnUploaded byMirela Hodžić

- Influence of Quartz Particles on Wear in Vertical Roller Mills Part I QuaUploaded bysheizareh
- [Elearnica] -636351884143785367-Loesche_vertical_roller_mills_for_the_comminution_of_ores_and_minerals_-_Sc.pdfUploaded bysheizareh
- How to Reduce Energy and Water Consumption in the Preparation of Raw MateriUploaded bysheizareh
- How to Reduce Energy and Water Consumption in the Preparation of Raw MateriUploaded bysheizareh
- asdasdUploaded byJulián Darío Barrera Pinto
- Investigation of the Comminution Process in Pendular Roller Mills - ScienceUploaded bysheizareh
- Investigation of the Comminution Process in Pendular Roller Mills - ScienceUploaded bysheizareh
- [Elearnica] -636351890513148509-Steady_state_modelling_and_simulation_of_an_indirect_rotary_dryer_-_Science.pdfUploaded bysheizareh
- [Elearnica] -636351890513148509-Steady_state_modelling_and_simulation_of_an_indirect_rotary_dryer_-_Science.pdfUploaded bysheizareh
- An Energy Based Comparison of Vertical Roller Mills and Tumbling Mills - ScUploaded bysheizareh
- An Energy Based Comparison of Vertical Roller Mills and Tumbling Mills - ScUploaded bysheizareh
- Grinding Process Within Vertical Roller Mills Experiment and Simulation -Uploaded bysheizareh
- Grinding Process Within Vertical Roller Mills Experiment and Simulation -Uploaded bysheizareh
- Grinding Process Within Vertical Roller Mills Experiment and Simulation -Uploaded bysheizareh
- etd-tamu-2004A-BAEN-Wang-1Uploaded byInstrumentasi Smart
- Process AutomationUploaded bysheizareh
- Processing Technology for Cosmetics EnUploaded bysheizareh
- [Elearnica] -636351884143785367-Loesche_vertical_roller_mills_for_the_comminution_of_ores_and_minerals_-_Sc.pdfUploaded bysheizareh
- How to Reduce Energy and Water Consumption in the Preparation of Raw MateriUploaded bysheizareh
- Spices Tea Dried VegetablesUploaded bysheizareh
- Solid PreCrushersUploaded bysheizareh
- Pharmaceutical Technology GMP EnUploaded bysheizareh
- Press AgglomerationUploaded bysheizareh
- [Elearnica] -636351888387810703-Research_of_iron_ore_grinding_in_a_vertical-roller-mill_-_ScienceDirect.pdfUploaded bysheizareh
- An Energy Based Comparison of Vertical Roller Mills and Tumbling Mills - ScUploaded bysheizareh
- Ro 20-12 Rotoplex GranulatorUploaded bysheizareh
- Pelletizing TechnologyUploaded bysheizareh
- Size Reduction TechnologyUploaded bysheizareh
- Powderplex 160 APPUploaded bysheizareh

- 2014 Research Summit Abstract BookUploaded byMisaeldpd
- Lab Experiment 2 l Resistance and Time Constant for Liquid Level SystemUploaded byRicky Jay
- Childrens Digest 0811Uploaded byGiao Con
- honda pptUploaded byVivek Dhande
- Sodium Chloride SlideUploaded byummi suraya
- Lecture_05 Properties of Walrasian DemandUploaded byAhmed Gouda
- 55845aUploaded byNaveenKumar
- zoology notes: 014 Chapter 10Uploaded byhumanupgrade
- 7-2010Uploaded bymkpasha55mp
- 3HAC2914-1 M98 IRB1400 Product Manual DSQC311 SMB Unit DescriptionUploaded byAnonymous smdEgZN2Ie
- Colin McPhee SPE London May 26 2015 & Backup_petrophysicUploaded byskywalk189
- Tactical Airlift A3Uploaded byStuff Newsroom
- Generala Motors FinalUploaded bySarath Sivadasan
- RESEARCHorignatotalga123 (2)Uploaded byRA Cortez
- Gladiolus Diseases0Uploaded bysallom1973
- The Hertz CorporationUploaded byPeaceLord
- GATE 2014 Question Paper & Answers - PHUploaded byaglasem
- History of Geothermal Exploration in IndonesiaUploaded byDeddy Wolley
- Solid WorksSolidWorksUploaded byborchec
- New GCE Sample Assesment Materials MathematicsUploaded bychequillas
- Stacy AdamsUploaded byModernManWaco
- 03-14 Updated Sets Kits Smc-hpc 100 Mk4 Cmo-hpo Mk2 Mk3Uploaded byzhyhh
- ddpqUploaded byZeyad Tareq Al Sarori
- BS 78-2 1965 Cast Iron Pipes.Uploaded bySalman M
- Dengan Metode Foam-mat Drying the MakingUploaded byFULAN FULAN
- AnemiaUploaded bythivyahsekar
- Namkeen Questionnaire Groupp 3Uploaded byDeepak Rawal
- CORNEAL ALTERATION IN EYES WITH PSEUDOEXFOLIATION SYNDROME.Uploaded byIJAR Journal
- Company Profile HondaUploaded byShams S
- Periodontal Disease RecognitionUploaded byMarothodi A Pula