Audit of Ball Mill Circuits PDF

Viviers Center
D. JUNIQUE
PROCEDURE FOR
THE AUDIT OF BALL MILL CIRCUITS
OCTOBER 1996
TABLE OF CONTENTS
I- Introduction p1
II- Finishing mill follow-up p2
III- Operating problems and their analyses p3
IV- Internal mill inspection p4
1- Internal inspection objectives p4
2- Material analysis methods p5

1- Material levels p5
2- Material sampling p5
3- Equipment analysis methods p7

1- Typical compartment dimensions p7
2- Compartment liners p7
3- Diaphragms and inlet and outlet heads p8
4- Grinding charges p 12
4- Interpretations of results p 15
1- Material levels p 15
2- Particle-size evolution within the mill p 16
3- Liners p 19
4- Diaphragms p 21
5- Grinding charges p 25
6- Retention time p 27
Practical guide for the audit of grinding mills - 96/10 Department of Studies - Viviers
V- Separation balance p 29
1- Objectives p 29
2- Method of analysis - Distribution curve p 29
3- Distribution curve calculation p 29
4- Rosin-Rammler slope p 35
5- Separator Inspection p 36
1- Static separator p 36
2- 1st or 2nd generation separator or both p 37
3- 3rd generation separator p 40
1- Mesh selection p 41
2- Sampling locations for the distribution curve p 41
3- Average values of the distribution curve p 45
4- 3rd generation separator p 45
VI- Material balance p 46
1- Objectives p 46
2- Calculation principle p 46
3- Junction calculation method p 47

1- From the distribution curve p 47
2- From Blaine, temperature p 47
3- Other methods p 48
4- Selection of sampling locations p 49
5- Numerical example p 50
1- Static separator p 52
2- Sample representativity p 52
VII- Air flow balance p 54
1- Objectives p 54
2- Selection of measuring locations p 54
3- Air flow measurements p 55

1- Anemometric measurements p 55
2- Pitot tube, Strauscheib measurements p 56
3- Gas analysis p 59
1- Anemometric measurements p 60
2- Pitot tube, Strauscheib measurements p 60
3- Gas analysis p 63
4- Calculation of air inleakage from gas analysis p 64
5- Mill ventilation ratios p 66
VIII- Drying / Heat balance p 67
1- Objectives p 67
2- Drying and heat balances p 67

1- Drying balance p 68
2- Heat balance p 68
1- Drying balance p 70
2- Heat balance p 71
IX- Energy balance p 72
1- Objectives p 72
2- Energy balance p 72
1- Energy balance p 74
2- BB10 Test p 74
X- Conclusions p 75
List of computer analysis programs p 77
1
I - INTRODUCTION
This document is intended for the diagnosis and analysis of problems with ball mill circuits, in order to
bring about the required modifications for a suitable operation.
Various types of grinding will be covered:
clinker grinding
raw mix grinding
fuel grinding
All grinding mills are designed to reduce the size of the material at the lowest possible cost and for the last 2
types of mills, to dry the material.
For a given mill with 1, 2 or 3 compartments or birotator, the types of analysis are similar.
A typical finishing mill generally consists of: grinding mill

static separator (in certain installations)
dynamic separator(s)
filter(s)
A roller press or crusher may be installed ahead of the grinding mill. In that case they perform somewhat like a
grinding mill fist compartment (they would be treated as such).
The following balances will be fully covered: sampling and internal mill observations
separation (dynamic separator distribution curve)
material
air flow
energy
drying (raw mix and fuel)
The calculation formulae will be developed as well as the computer programs for the calculations.
Important:
All the analyses must be conducted on stable operation.
Measuring devices and various collectors (power, material and air flows, temperature) must be reliable
and calibrated.
2
II - FINISHING MILL FOLLOW-UP
A file should be completed for each finishing mill, updated after each modification and containing the
following process parameters:
☞ A diagram of the finishing mill - material and gas circuits
☞ Equipment characteristics (type, make, power, dimensions, typical outputs, etc.)
☞ Grinding charges (charge classification, reloading sequences and dates)
☞ Background of process modifications (liner replacements, separator modifications)
☞ Accounts of installation problems (output, power, etc.)
☞ Process balances even if sketchy (air flow, material, internal mill investigation, etc.)
☞ Operating data for each product (equipment adjustments, various power draws, air flows,
pressures, composition, fineness, etc.)
☞ Source and type of drying gases (essentially raw or fuel mills), type and volume of fuel (in the case
of an auxiliary furnace)
This list is not complete and any parameter modifications that could improve the understanding of the finishing
mill operation can and should be recorded.
This follow-up gives an idea of the evolution of the finishing mill performances.
The audit, involving the techniques presented in this document, consists of a series of prompt measures that
provides a more precise insight of the grinding mill operation at a given time.
3
III - OPERATING PROBLEMS AND THEIR ANALYSES
The Table hereunder reviews the principal causes of a finishing mill operation problems, the effects
produced and the analyses that should be undertaken to highlight and quantify the problems.
Causes Main effects produced Analyses to be given priority

Grinding charges poorly Drop in output • Internal sampling
adapted or worn out (ball Increase in kWh/t • Material balance
diameter, filling rate)
Grains • Energy balance
• BB10 grindability
• Retention time
Poor internal conditions (liner Drop in output • Internal inspection
and diaphragm wear) Grains found at the outlet • Internal sampling
Increase in kWh/t • Energy balance
• BB10 grindability
Poorly set separator Variations of the circulating charge • Distribution curve
(elevator power draw, volume of rejects) • Material balance
Drop in output • (Air flow and separator
Change in the particle size distribution inspection)
of the finished product
Poor ventilation Ball or liner coating or both • Air flow balance
Drop in output • Internal inspection
Poor ventilation (drying mill) High residual moisture on the finished • Air flow balance
product • Drying / heat balance
Drop in output
No matter the type of operating problem, it generally produces a drop in output causing an increase in energy
consumption per tonne of finished product. The drop in output is not necessarily outstanding, often it is a time-
dependent drift. Hence it is important to keep an operating record for each product in the finishing mill.
Certain particular signs will sometimes allow quick spotting of the source of the problem (see 2nd column in the
above Table).
In this case, the analyses indicated in the column should be undertaken as a priority. When the cause of the
operating problem is not clear, a complete audit should be done.
Note: If time and means are not available, the two priority actions to take are :
- Internal inspection and material sampling
- Distribution curve of the dynamic separator
4
IV - INTERNAL GRINDING MILL INSPECTION
The grinding mill is the machine that reduces the size of the materials. The role of the separator is to
classify the grains according to their size.
The grinding mill plays therefore a key function in the finishing mill.
IV - 1 - Internal Inspection Objectives
The internal mill inspection is an important step in the audit. It should provide a qualitative evaluation of the mill
operation.
The reduction of the particle size of the material which is dependent upon the conditions of the mill parts must
be qualified.
This can be done through:
- observations and material sampling
- observations of the parts: liners, grinding charge, ventilation ring, etc.
The results can be recorded in a typical form (see appendix).
An internal inspection must be made during a crash stop of an installation (all equipment, ventilation and
material feeds having completely stopped) so as to reflect the condition of the mill in operation.
Safety instructions must be kept in mind before making any move.
It is strongly recommended to take pictures of the overall compartment and also detailed pictures of all the
essential items covered by the internal audit (liners, diaphragms, charge, etc.).
For each mill, “typical shots” can be systematically taken at the same locations each year.
For example: - General view of each compartment in both directions

- Liner details
- Global view of the diaphragm
- Details of the grates and their openings
- Ventilation ring detail
- ...
5
IV - 2 - Material Analysis Methods
IV - 2 - 1 - Material Levels
☞ Evaluate the material level of each compartment
- Compartment 1, generally short and equipped with lifting liners, the material level with respect to the balls is
homogeneous and therefore a simple average value is sufficient for characterization
- Compartment 2, generally long and equipped with classifying liners, three evaluations must be made (inlet,
center and outlet)
Suitable material level

Part of the balls must emerge from the material
☞ Check if there is an accumulation of unground grains at the outlet grate of the compartment and try to
quantify it (no grains, a few grains, large accumulation).
IV - 2 - 2 - Material Sampling
☞ Sample material in order to characterize the evolution of the particle-size distribution over the length of
each compartment.
- Determination of the sampling locations (see diagram hereafter)
Sampling shall be made near the beginning and end of the compartment (a few cm from the diaphragms)
The other locations should be at equal distance one another with about a 50 cm spacing in compartment 1 and
0.75 to 1 m maximum in compartment 2 (modulation as a function of the compartment length to obtain a minimum
of 4 to 5 locations per compartment, up to 7 or 8, even more, for a good-size compartment 2).
6
Compartment no 1 Compartment no 2
Samples
Charge
Direction of rotation
C1 C2
1 2 3 4 5 6 1 2 3 4 5
- Sampling procedure
At each sampling location, dig, using a sampling scoop, a 10 to 15 cm deep transverse trench, over a half
diameter of the lifting side of the mill, in order to take material from the ball charge (the surface layer might
become polluted by the material deposit following the crash stop).
Take, over the entire length of the trench, between 0.5 and 1 L of material adapted to the material fineness. The
coarser the material the larger the sample (sample representativity).
In compartment 2 where ball size is smaller, it is recommended to use a sieve (10 to 15 mm mesh) to facilitate the
material / ball classification.
Caution: grains, eventually too coarse, retained on the sieve, must be added to the material and not discarded
with the balls.
Following the grading analysis of each sample, a curve should be plotted for each compartment showing the
percentage of retained particles as a function of the compartment length. This analysis makes it possible to see
the evolution of the particle-size distribution of the material in each compartment and adjust the size of the balls.
The sieve sizes depend on what is available.
As a basis:
10 mm
5 mm
Compartment 1 2.5 mm (important)
1 mm
500 µm
5 mm
2.5 mm (important)
1 mm
Compartment 2 500 µm
200 µm
100 µm
63 µm
40 µm
7
IV - 3 - Equipment analysis methods
IV - 3 - 1 - Typical dimensions for each compartment
☞ Measure the useful diameter and length.
The useful length means beyond inlet or outlet heads.

The useful diameter takes into account 1 out of 2 steps.
☞ Measure the rotating speed of the mill
When the mill is rotating, take as a reference point a door for example, record the time required for the shell to
make a given number of rotations. Calculate the rotating speed (V).
☞ Check the V/Vc ratio
42.3
Vc is obtained using the formula : Vc (rpm) =
useful Ø (m)
With the measured rotating speed (V in revolutions / minute) the percentage of the critical speed can be
determined (required value for the calculations of the mill power). This is the V/Vc ratio or % Vc.
Usually mills rotate at between 70 and 75% of the critical speed.
IV - 3 - 2 - Liners for each compartment
☞ Survey the types of liners (lifting, classifying, etc.) length and number of rows. For classifying liners,
note the number of plates in a given row (see picture p 8).
☞ Measure the steps (difference in height between 2 consecutive plates in a given row).
Make several measurements, identify the maximum and minimum step and estimate an average value.
Step
Lifting liners Combined lifting and classifying liners
8
Step
Classifying liners: 1 inclined plate Classifying liners: 1 flat plate + 1 inclined plate
☞ Take note of broken, tilted plates

A tilted plate is a plate that is no more in the same plan as the others be it on the vertical or horizontal axis, even
both. As a result the step liner is modified (vertical axis) as well as the slope (horizontal axis).
When there are too many tilted plates the charge efficiency may be reduced.
☞ Note the wear on the plates particularly scratches (specially in compartment 1)
☞ Note the possible presence of material coatings on the liners (hard material should be distinguished
from dust that might have settled during the crash stop).
IV - 3 - 3 - Diaphragms and outlet or inlet heads
- a - Inlet head
☞ Measure the diameter (beginning and end) of the mill shell inlet and its length.
☞ Note the possible presence of turns and their length, promoting the feed of material.
Turn height
Mill shell length
Mill shell diameter
Mill shell inlet turns
9
☞ Note how the material is fed (Toboggan, ladder)
Toboggan at the feed end Ladder at the feed end
☞ Take note of broken or tilted plates or both and wear conditions
Inlet head showing severe wear Intermediate diaphragm showing severe

(pronounced scratches and waving) wear (pronounced waving and irregular slots)
- b - Outlet head
☞ Take note of broken or tilted plates or both and wear conditions
☞ Measure the diameter of the ventilation ring and estimate its permeability
% of free surface
Permeability =
Total ring surface
10
Ventilation ring diameter
Measurement of the ventilation ring diameter
- c - Diaphragms
☞ Type of diaphragm (simple, double, double adjustable) and supplier (Slegten, Pfeiffer, Polysius, FLS...)
☞ Measure the diameter and assess the permeability of the ventilation ring.
☞ Note the number of sectors and possible staggering.
Staggered sectors generate a more or less large spacing that can be assimilated to a slot. If that spacing is large,
coarse grains are likely to enter compartment 2.
☞ Slot position (radial, tangential, circumferential).
Radial slots
11
Tangential slots
Circumferential slots
☞ Measure the slots (several measurements including estimated maximum, and average values).
Scrap
Slot width
Slot measurement (slots not peened but presence of scrap)
12
☞ Estimate the slot permeability and wear conditions (possible peening)
Slot permeability = % of opening remaining unclogged (estimate visually).
Peening is characterized by a partial closing of the slots and with the edges appearing notched.
Scrap and peening restrict the entrance of the material and the slots must be cleaned.
☞ Note the presence of scrap, check if it is hard (loss in permeability) or not.
It is normal to see material in the slots (crash stop) but in that case it loosens up.
peened slots - notched edges peened slots - opening variation
IV - 3 - 4 - Grinding charges
☞ Measure the length of the free space in 2 or 3 locations along the length of the compartment.
The height is measured on the mill diameter between the center of a step or liner plate and the ball charge.
Length measurements should be averaged in order to determine the filling rate.
It is estimated that the material increases the actual ball filling rate by about 2% in a compartment having a
suitable material rate.
13
Measure from 1/2 a step or plate

transversal center
Vertical
measurement
Middle axis
Measurement of the free space height (filling rate)
☞ To complete the free space measurement, measure the distance between the charge and the lower
part of the ventilation ring.
Distance between the charges and

the lower part of the ventilation ring.
☞ Estimate, for compartments equipped with classifying liners, the charge classification (very good, right,
poor, reverse) given that the large balls should be at the beginning of the compartment and then, in a regular
decreasing order, the small ones at the end of the compartment.
☞ Measure the diameter of the largest and smallest visible ball (gives an idea of the charge wear
compared to its original conditions).
14
☞ Note the possible presence of ball coatings. Ball coatings or liner coatings or both may be the cause
of charge declassification.
☞ Note the possible presence of foreign matters as well as their nature in the ball charge. These foreign
matters hinder the charge action and may get stuck in the slots (scrap).
15
IV - 4 - Interpretations of results
IV - 4 - 1 - Material levels
- Compartment 1
• The material should be essentially at the same level as the balls.
This level can be controlled to a constant output by means of adjustable scoops (on a double diaphragm only,
opening varying according to the inclination of the scoop) and by adjusting the grading of the grinding charge.
In operation the material level is controlled by means of an electronic listening device placed at about 1/3 of the
compartment length and 15˚ below the horizontal axis (where balls drop).
A charge that is too coarse, hence permeable, will let the material flow too rapidly and the compartment will
become relatively empty of material.
This will create inter ball and ball / liner shocks without grinding results and cause the deterioration of the
equipment.
A charge that is too fine will increase the material rate and when the balls fall back on a bed of material that is too
thick, they loose their grinding efficiency.
Scoop
Increased position
Scoops (intermediate diaphragm)
Compartment 2
The material level should be located :
3 to 4 cm above the charge at the beginning of the compartment
at the same level as the charge in the middle of the compartment
3 to 4 cm below the charge at the end of the compartment
The material rate, at constant flow, can be adjusted only by the grading of the charge.
Note: The grinding charge grading should be mainly determined according to the desired fineness of the
finished product and following the analysis of the curves showing the evolution of the particle-size distribution of
the material in each compartment.
16
IV - 4 - 2 - Evolution of the particle-size distribution of the material in the mill
Curves based on samples of material in the mill (for each compartment) should show a decreasing pattern over
the entire length of the compartment.
FINENESS EVOLUTION IN THE MILL

% Cumulative Rejects
100
90
80
70
60
50
40
30
20
10
0
1 2 3 4 5 6 7 8 9 10 11 12
Samples
40 µm 63 µm 100 µm 200 µm 500 µm

1 mm 2.5 mm 5 mm Diaphragm Diaphragm
Case 1 - Proper evolution of the particle-size distribution of the material

100
90
80
70
60
50
40
30
20
10
0
1 2 3 4 5 6 7 8 9 10 11 12
Samples
40 µm 63 µm 100 µm 200 µm 500 µm

Case 2 - Compartment 1: There is no more evolution between sample 4 and 5 at the end of the compartment.
Compartment 2: same, no evolution on the last 2 samples
The grinding charges in the 2 compartments should be reviewed
17

100
90
80
70
60
50
40
30
20
10
0
1 2 3 4 5 6 7 8 9 10 11 12
Samples
40 µm 63 µm 100 µm 200 µm 500 µm

Case 3 - Compartment 1: Curves are ascending at the end of the compartment, this is typical of an accumulation
of grains in the intermediate diaphragm. If the slots are clean and of proper size, the solution is to raise the
grinding power by increasing the charge grading.
Compartment 2: OK
The grinding charge of compartment 1 should be reviewed.
A good working criterion for compartment 1 charge is to have less than 5% retained on the 2.5 mm mesh
at the beginning of compartment 2 for a cement mill.
Caution: A mill is often used for several products and before changing a charge, the compatibility of the
charge with all the manufactured products (internal samplings and observations) should be insured.
Unfortunately, as seen before, the particle-size evolution curves are distorted by the circulating charge.
The greater the circulating charge, the shorter the material flow time and the flatter the curves.
To do away with the circulating charge, a mathematical treatment procedure is used (based on internal samples)
to plot a RFCS curve (Reduced Fineness Curve Slope).
The index is calculated only for compartment 2 (grinding).
The RFCS index characterizes a mill for its ability to reduce the size of the material.
The RFCS calculation is explained in the grinding stage section.
In practice, the corresponding calculation sheet is filled (see appendix) with the particle-size distribution analyses
of the samples taken in the mill.
18
A straight line is obtained that looks like this:
LOG RFCS(x) vs LOG x
3.0
2.5
2.0
1.5
1.0
0.5
0.0
-1.4 -1.2 -1.0 -0.8 -0.6 -0.4 -0.2 0.0
LOG x
Regression Line RFCS 10 3.5

a = 1.158
b = 2.866
R2 = 0.997
( )
Log RFCS (x) = a • log
x
1000
+b
RFCS 100 51.0
RFCS for a CEM Type 1 cement at a 45 µm mesh reference, has usual values at Lafarge Ciments ranging
between 11 and 83 with an average standing at 35.
The higher the RFCS the more efficient the grinding charge.
19
IV - 4 - 3 - Liners
- Compartment 1
Compartment 1 does the crushing, hence the need to lift the grinding charge with the lifting liners.
From a process standpoint, the step should not be worn out by more than 60% to maintain a lifting function.
In practice the original step usually measures 70 mm. When it wears down to less than 30 mm, assurance should
be given that this will not affect the performance of the mill.
Border line step

Suitable step
Case 1 - Lifting liners with a suitable step on the front plates and a border line step on the back liners
Case 2 - Lifting liners with completely worn out and heavily scratched steps
On this open-circuit mill, the mere replacement of the C1 liners resulted in a flow rate increase from 20% to 25%.
20
- Compartment 2
Compartment 2 works by attrition (grinding produced by the rubbing of balls against the material),
liners being usually of the classifying type.
They may consist of 1 to 3 plates depending on the mill diameter (see pictures p 8).
- 1 plate (25 cm): small diameter mill, short compartment
- 2 plates (50 cm): usual situation
- 3 plates: recommended for large diameter mills exceeding 4 m in diameter
The last plate of each group of 2 or 3 is inclined (which produces the classifying effect), the preceding ones can
be flat or inclined.
The original step measures about 12 cm, and given the small size of the balls (60 mm max.) in compartment 2,
the evolution is slow.
Wear usually takes place in the form of scratches perpendicular to the compartment axis.
☞ Pay attention to coating.
Wear - Heavy scratches and coating starting.
21
IV - 4 - 4 - Diaphragm
Note the type of intermediate diaphragm.
- a - Simple diaphragm
It won’t allow the adjustment of the material level in compartment 1.
Possible adjustments involve the permeability of the grinding charge and eventually the partial clogging of the
slots.
This type of diaphragm is not recommended.
- b - Double diaphragm
A front face provided with slots, a rear face provided with blind plates and between the two, lifters which control
the material flow.
Drawback: The lifts are fixed and non adjustable.
- c - Adjustable double diaphragm - Picture page 15
A diaphragm similar to a double diaphragm with a system that regulates the amount of material transferred from
C1 to C2. The lifting liners are replaced with scoops allowing, depending on the adjustment, more or less material
to be picked up.
☞ Note the “opening” range of the diaphragm in this case.
- Slegten: The number of scoops and their positions (opened at x%, closed, not used)
- Polysius: Lifting liner recess
- Pfeiffer: Slide opening
The adjustment can be performed only during a mill stop, which explains that in practice the scoop adjustment is
very seldom modified during product switching.
For a Slegten diaphragm, the optimum scoop adjustment can be determined for each product only through a
series of adjustments of the number of opened scoops and their opening positions (in general, there are 6 to 8
scoop positions).
After each adjustment, the material rate in compartment 1 should be measured. It is a time-consuming and
tedious job but which is important when switching from a straight product to a blended product for example. The
material rate of compartment 1 is one of the indicators of performance.
For the other types of diaphragms, the procedure is similar. The adjustment control designed by the
manufacturer should be used.
22
- d - Slots - Pictures page _____
Slots have an opening width depending on the type of products:
- 6 to 7 mm for a cement mill (intermediate diaphragm)
- 10 to 12 mm even up to 16 mm for a raw mill (intermediate diaphragm)
The following should be adhered to:
Slot opening width of the outlet diaphragm = opening width of the intermediate diaphragm slots + 2 mm.
The adherence to this rule allows the grains having reached the intermediate diaphragm, but too coarse to be
ground in compartment 2, to move out of the mill without interfering with the operation of compartment 2.
☞ Check the slot wear
Slots have a double inverted clearance.
The first one must insure that the grains do not get stuck, the second one facilitate the release of the material
either towards compartment 2 or mill discharge.
Manufacturers provide dimensions of the total slot surface with ratios in the range of:
10 to 20 cm2 per tonne/h of material passing through the diaphragm (= flow of fresh material + rejects)
Slot Side 2 Clearance

Side 1 Clearance
Width
Slot Diagram
23
wear zone
peening
Width of Width of C2 side clearance

C1 slide clearance worn out
original
becomes slot
slot
non-existant
peening
Worn out slot diagram
After excessive diaphragm wear, the slot width increases and the C1 side clearance disappears which will cause
the plugging of the slots with grains or scrap.
While waiting for the diaphragms to the replaced, frequent cleaning of the slots are required.
☞ Insure that the slots don’t get peened picture page 12
Peening is caused by the impact of the balls on the diaphragm resulting in the closing of the head slots of side 1
clearance; peening is characterized by slots of variable width and notched edges.
Peening may induce in the long term total plugging of the slots.
It is then necessary to clear the slots to allow a suitable flow of material through.
24
- e - Ventilation Ring
It must be as large (compatibility with the filling rate of the balls + material) and as permeable as possible to
promote mill ventilation.
However the grate must remain sufficiently rigid to prevent balls from moving from one compartment to another.
Case 1 - Good permeability Case 2 - Average permeability

Case 1 - Grate offering a good permeability if the bar spacing is right (25 to 30 mm)
This is certainly one of the best types of ventilation ring combining permeability and sturdiness.
Caution: In case of cramming of compartment 1 there is a risk that coarse grains might enter into compartment 2.
To prevent this a grate can be installed on compartment 2 side.
Case 2 - Sturdy grate but less permeable than case 1. It is still acceptable to the extent that the holes with a
diameter larger than 25 mm are sufficiently numerous.
Case 3 - Low permeability Case 4 - Zero permeability

Case 3 - Sturdy grate but with lower permeability because of a lack of holes.
Not recommended in closed-circuit but acceptable in open-circuit where mill ventilation is lower.
Case 4 - Grate with an almost nil permeability. Very few holes of small diameter which will get plugged up with
material. The result is practically no mill ventilation left.
Ventilation rings of this type are stiff found in closed-circuit mills. This belongs more like to the handy-man world
(a few holes drilled on a blind plate) than to process technology.
This type of grate should be banned and replaced with bars with a spacing adapted to the grading of the grinding
charge of compartment 2 (mainly open-circuit where balls can be reduced to a 17 even 15 mm diameter and
liners not necessarily of the classifying type).
25
IV - 4 - 5 - Grinding charge
- a - Compartment 1
Filling rate of 30 to 35% which corresponds to a good compromise between flow rate and specify consumption.
The grinding charge is made up of large-diameter balls to crush the material.
In clinker mills, 4 sizes of balls: 90, 80, 70 and 60 mm are typically used:
90 mm 20.0% by mass
80 mm 38.4% by mass
70 mm 25.6% by mass
60 mm 16.0% by mass
Apparent density: about 4.5 t/m3. An average value for a typical charge as described above. This value may
vary ± 0.1 t/m3 depending on the installed charge.
The apparent density will be lower if the charge is coarser.
In raw mills the same mass proportions with an almost identical range of balls can be found The raw mix is easier
to grind (decrease in ball range), but the grading at the inlet is coarser (increase in ball range).
The ball sizes and proportions constitute a theoretical base that should be adjusted after an internal inspection
and on the basis of the fineness curves plotted from material sampling data.
If the charge does very little work at the end of the compartment and the 2.5 mm mesh reject < 5%, the charge
will have to be improved. Case 2 page 24. If on the contrary an accumulation of grains is found in the
intermediate diaphragms with 2.5 mm mesh rejects > 5%, the charge will have to be made coarser.
To maintain a good crushing performance an average mass of approximately 1.8 kg per ball should be
maintained.
- b - Compartment 2
Filling rate of 28 to 32%
Compartment 2 or finishing compartment must produce the fineness and the ball diameters are relatively small (in
a closed circuit) or very small (in an open-circuit since the material must have the required fineness at the mill
discharge).
The theoretical charge is divided into 2 zones: the first of transition (between compartment 1 and compartment 2)
and the second of finishing.
26
Transition zone consisting of 50 and 40 mm balls in numbers equal to that of the 60 mm balls of compartment 1.
Number 60 mm = Number 50 mm = Number 40 mm.
Finishing zone made up of balls < 40 mm and with a distribution following slegten equations.
Ø = 3.3 e-0.1x
Where: Ø = ball diameter
x = abscissa in compartment 2 (in meters) with origin at the diaphragm
Knowing for a given diameter the section length and on the basis of the filling rate and apparent density, the ball
mass of the section can be calculated (see the corresponding working sheet in the appendix).
Apparent density: roughly 4.7 t/m3. Average value for a typical charge as described above. This value may vary
±0.12/m3 depending on the installed charge.
The apparent density will be higher if the charge is finer. Here too reference is made to a theoretical base that will
require adjustment based on the internal samples but also the type of mill and the desired fineness.
It is clear that in open-circuit the charge has to be improved to obtain the desired fineness at the mill discharge;
the same applies for a very fine product.
The finer the charge, the finer the product, the greater the risk of coating that will have to be minimized with better
ventilation, failing that with a grinding aid.
A problem often encountered is the multiplicity of products for a given mill. In that case a grinding charge for both
compartments needs to be determined to reach a compromise between optimum charges for each product.
The finer the grinding charge the longer the material will be retained in the mill.
To give an idea of the differences the charge makes between an open and closed circuit, the retention time is:
3 to 5 min in closed circuit
15 to 20 min. in open circuit
27
IV - 4 - 6 - Retention time
Fluorescein
introduction
Compartment 1 Compartment 2
Sampling
location
The retention time is measured when the mill is in stable operation
The procedure consists of introducing a tracer and to take samples at regular intervals at the mill discharge
(fluorescein, impregnated on the product either with alcohol for clinker or water for raw mix, is used).
The suggested dosage is 2 g / t of feed. The introduction of fluorescein and the sampling must take place as
close as possible to the mill inlet and outlet.
In plotting a fluorescein concentration curve with time, the retention time at the maximum concentration peak is
obtained (graph hereafter).
From the retention time, the mass of material in the mill can be calculated and a C/M ratio that should be between
8 and 12 can be determined. The C/M ratio only puts a number on the average material level through the entire
mill. The material level should be determined visually during the internal inspection of each compartment.
C = Ball mass
M = Mass of material in the mill
In practice this gives reliable results for a compound mill but this is rarely the case for a birotator mill.
This phenomenon can be explained by the fact that the retention time is determined by the maximum intensity
peak, whereas it would be preferable perhaps to calculate it by surface integration.
28
The procedure doubles up the internal inspection, and given its mediocre precision, is almost never used to-day.
It can still be used relatively speaking to compare an operation with another (tests on circulating charges for
example) because it offers the advantage of not requiring the stoppage and opening of the mill gates.
Fluorescein intentisy (%)

100
90
80
70
Max. 4 min.
60
50
40
30
20
10
0
0 1 2 3 4 5 6 7 8
Time (min.)
29
V -SEPARATION BALANCE
V - 1 - Separation balance objectives
The separation balance is done on the separator and allows deduction to be made of its performance coordinates
as much from the standpoint of the characteristic values as for the various material flows.
It is produced from data obtained from material samples taken at both the separator inlet and outlet.
The sampling procedure is explained in the material balance section.
V - 2 -Analysis procedure - Distribution curve
From the particle size distribution analysis of the separator inflow and outflow, a distribution curve is plotted
(abscissa in logarithmic coordinates, ordinate in normal distribution coordinates).
From the curve the following characteristics are determined:

- acuity limit
- bypass
- imperfection
- fines cumulative yield
To allow the determination of the separator efficiency.
From at least one given flow, the separator inflows and outflows (taken from the average R/A calculation) are
calculated as well as the circulating charge.
V - 3 - Distribution curve calculation
Reminder: Additional details of this calculation can be found in the section “Finishing mill operation”.
Feed
Separator
Rejects
Fines
30
Note: The distribution curve should be calculated over the entire inflows and outflows. If the separator
is ventilated, the dust carried by the gases must be included.
It can be written: 1) A = R + F on a flow basis

2) A • ax = R • rx + F • fx for each size fraction
Where:
- A, R, F = feed, rejects and fines flows (t/h)
- “X” = index characterizing a size fraction
- ax, rx, fx = feed proportion (rejects and fines respectively) in the size fraction X
- A • ax is the material flow (t/h) in size fraction X at the feed end
R fx - ax
From these 2 equations : (x) = is obtained
A fx - rx
R R
(x) is the ratio predicted by the particle size distribution of size fraction x
A A
For the overall particle-size distribution, the average R/A ratio is the integration of all the size fractions and can be
summarized after simplification by the formula:
∑ (fx - ax) • (fx - rx)

Average R/A =
∑ (fx - rx)2
On the other hand the probability (Px) for an inflow grain of size x to end up with the rejects can be expressed:
Rrx
Px =
Aax
This equation can be transformed with equations 1) and 2) into:
Average R rx
A
Px =
R rx + (1 - Average R ) fx
Average
A A
The average sieve size of each size fraction can be calculated by the formula:
dx = (d1 • d2)
For example between 2 and 4 µm dx = (2 • 4) = 2.83
The separator distribution curve is drawn by plotting on the graph the function : px = f(dx)
31
2 straight lines are obtained, the first, slightly inclined (zone where the separator does not recognize the size of
the particles, if not globally) and the second, more inclined, called acuity line (zone where the separator
recognizes the size of the particles).
All the calculations are made in a spread sheet (see appendix).
Example of a calculation of the beginning of the distribution curve found in the appendix.
Laser gross result % Cumulative passing

Mesh (µm) Fines Feed Rejects
(1) 88.91 97.81 74.57 60.78
(2) 76.32 95.72 67.36 50.64
(3) 65.51 92.71 59.89 41.04
(4) 56.23 88.68 52.74 32.21
(5) 48.27 83.60 46.03 24.49
etc.
Mesh dx fx ax rx dx R/A mesh
(1) - (2) (88.91 • 76.32) ^ 0.5 = 82.4 97.81 - 95.72 = 74.54 - 67.36 = 60.78 - 50.64 = 89.9 0.636
2.09 7.18 10.14
(2) - (3) (76.32 • 65.51) ^ 0.5 = 70.7 95.72 - 92.71 = 67.36 - 59.89 = 50.64 - 41.04 = 85.4 0.677
3.01 7.47 9.60
(3) - (4) (65.51 • 56.23) ^ 0.5 = 60.7 92.71 - 88.68 = 59.89 - 52.74 = 41.04 - 32.21 = 80.1 0.650
4.03 7.15 8.83
(4) - (5) 56.23 • 48.27) ^ 0.5 = 52.1 88.68 - 83.60 = 52.74 - 46.03 = 32.21 - 24.49 = 73.6 0.617
5.08 6.71 7.72
etc.
Average 0.647
R/A
32
It is from the distribution curve that the separator operating parameters are determined.
99.9
99.8
99.5
99
98
95
90
Fines cumulated yield curve
80
70
60
50
40 Line slope =
30
imperfection
20
10
Bypass
reading
Intersection point of the 2 lines
2
1
0.5
0.2
0.1
1 10 Acuity limit reading 100
Fines cumulated Circulating charge 141% Imperfection Normalized Gross

yield 83.4 % Bypass 6.2% 0.38 0.40
Acuity limit 16 µm d 25 (µm) 28 µm 26 µm
Corr. bypass 10.6% d 50 (µm) 40 µm 38 µm
Normalized imperf. 0.37 d 75 (µm) 58 µm 56 µm
- a - Lafarge circulating charge
The Lafarge circulating charge is the ratio of the rejects flow over the fines flow, expressed as a percentage
R/A
Lafarge CC = R / F may be expressed in the form of CC =
1-R/A
Quite often suppliers use the ratio of the feed flow over the fines flow as a definition of the circulating charge or
call it the circulation rate.
Supplier CC = A/F
= 1 + Lafarge CC
33
- b - Flow calculation
The distribution curve has allowed the calculation of the average R/A, i.e. the rejects flow with respect to the feed
flow.
Assuming any given flow and with the equation: A = R + F, it is easy to recalculate the other 2 flows.
- c - Acuity limit
It is the minimum particle size that can be recognized by the separator. It is expressed in micrometers and is the
abscissa of the intersection point of the 2 lines.
The lower the acuity limit, the best the separation.
It varies with the type of separator.
- d - Bypass
It is the minimum probability for a particle to end up in the rejects. It is expressed as a percentage and is the
ordinate of the intersection point of the 2 lines.
The bypass should be as low as possible but is influenced by the circulating charge (the type of separator aside).
This is why a “corrected bypass” free of the circulating charge is calculated using the formula:
Bypass • (1 + circulating charge)

Corrected bypass =
circulating charge
rejects flow
The Lafarge circulating charge being defined by the ratio:
fines flow
34
- e - Imperfection
Slope of the acuity line using the formula:
d 75 - d 25
I =
2 • d 50
This is the “gross imperfection”.
d 25, d 50 and d 75 (µm) being the abscissa of the corresponding coordinates Px at 25, 50 and 75%.
The lower the imperfection (hence the steeper the slope) the better the separation.
The imperfection is also a function of the bypass. Therefore a “normalized imperfection” is calculated from the
Tromp curve, with no bypass, using the formula:
100 (Px - Actual bypass)

P’x =
100 - Actual bypass
The “normalized imperfection” is then calculated by the same formula as that of the gross imperfection. A
parameter which is the stripping dimension is also used. It is the sieve size for which a particle has as much
chance to end up in the rejects as in the fines.
- f - Fines cumulative yield
For each sieve size it is the ratio:
(1 - average R/A) = Fx / Ax
A curve showing the cumulative percentage of the feed particles going into the fines is obtained, the maximum
percentage being called fines cumulative yield.
This yield gives a better prediction of the separator efficiency than the bypass.
35
V - 4 - Rosin-Rammler Slope
It defines the range of the particle-size distribution of the separator fines and is calculated from the laser analysis.
Draw on a graph (abscissae in logarithmic coordinates, ordinates in decimal coordonates) the relationship: Ln Ln
(proportion of cumulative rejects) = f (Ln sieve size).
Rosin-Rammler adjustment
98.9
93.4
80.8
63.2
45.5
% passing
30.8
20.0
12.7
7.9
4.9
3.0
1.8
1 10 100
Sieve size (µm)
Rosin - Rammler line

Rosin-Rammler Slope = 0.81
Equation of the Ln Ln (100/R) line = 0.8130 Ln (x) + -2.9371
Correlation coefficient = 0.9972
In this example the Rosin-Rammler slope (n RR) is 0.81.
The more efficient the separator the higher the n RR.
The Rosin-Rammler slope can be calculated 3 ways:
- total slope: from 2 µm to x µm (x µm is the maximum sieve size that produces a very good correlation
coefficient)
- from 2 to 30 µm for a fine product
- from 2 to 20 µm for a very fine product
36
V - 5 - Separator inspection
The inspection report sheet shown in the appendix should be used.
V - 5 - 1 - Static separators
Static separators are connected to the mill ventilation and can be adjusted only one way: by tilting the blades.
The blades are tilted in such a way that be fineness of the filter dust is compatible with that of the finished product.
The more tangential the blades (the static is closed) the higher the fineness of the fines.
Fines
Adjustable blades
Fresh air bleed valve
Thimble
Inner cone
Outer cone
Rejects
Feed (mill sweep)

Static separator
☞ Check the internal mechanical condition: wear, material clogging.
37
V - 5 - 2 - 1st or 2nd generation separator or both
☞ Check the condition of the diaphragm.
☞ Check the condition of the ventilation blades. Record their quantity and dimensions.
☞ Check the condition of the distribution plate.
☞ Check the condition of the rejects and fines cone.
☞ Check the condition of the liners.
☞ Check the operation of the valves under the separator.
☞ Selector blades: Number of blades
Measure length and width
Tilt
Measure the distance to the casing (interior liners) and the diaphragm
diaphragm d
h
casing d
L
☞ Check the cleanliness of the return air vanes. Material clogging.
38
Motor shaft
Selector blades
Ventilating blades
Diaphragm
control
Casing
Return air vanes
Air flow
Rejects cone Fines cone
Rejects
1st Generation Internal-Ventilation Separator (Sturtevant)
39
Fresh air
Feed
Exhaust
Cyclone
Table
Recycling ventilator
Fines
Return air vanes
Rejects
2nd Generation External-Ventilation Separator
The ventilation and the fines recovery with external cyclone on the 2nd generation separators produce a better
fines recovery than the 1st generation separators.
Ventilation being important as it reduces the temperature of the finished product, these separators also produce
better raw mill drying results.
40
V - 5 - 3 - 3rd generation separator
☞ Check the condition of the cage bars.
☞ Check the condition of the fixed blades (O’SEPA) sometimes adjustable with other makes (SEPOL).
☞ Check the condition of the liners.
☞ Check the operation of the valves under the separator.
☞ Measure the dimensions of the cage.
Fines
Secondary air Feed
Cage
Primary air
Fixed blades
Rejects
rd
3 Generation Separator (O’SEPA)
It is the type of separator which right now produces the best separation performances.
It is easy to adjust for the desired fineness.
The strong ventilation allows the temperature of the product to be lowered.
On the other hand if the type of separator does not take as much space, i.e. requires a larger filter since all the
production goes through it, contrary to the 1st and 2nd generation separators where the filter only handles the dust.
41
V - 6 - Interpretation of the distribution curve results
V - 6 - 1 - Sieve size selection
It is always interesting to use as many sieve sizes as possible, however the smallest mesh should be less than 2
µm for the sake of analysis accuracy.
The largest selected sieve size should be that which corresponds, for the fines, to the percentage immediately
lower than the 100% passing.
V - 6 - 2 - Sampling locations for the calculation of the separator distribution curve
Instantaneously, a separator is not perfectly stable this is why it is better to smooth out these fluctuations by
taking samples of material several times.
At each location, take 4 to 6 samples of equal mass over a period of about 2 hours and place in a box These
samples after homogenization will be analyzed by laser.
It is also possible, with one person available at each sampling location, to take 4 to 5 samples over a period of 5
to 10 min.
This procedure is used when controlling the operation of the separator during regular tests. The distribution curve
calculation should be done from material samples taken from all the separator inlets and outlets (simple case p
29).
More complex cases are illustrated in the following diagrams.

Feed
(A)
Separator
Dust (P)
Dust collector
Rejects (R)
Finished
Product (F) Fines (Fs)
In this case A = R + Fs + P
The distribution curve must be plotted considering: F = Fs + P
42
☞ All that is required is to take samples of material at locations: A, R and F for the calculation of the
distribution curve.
This is a case particularly encountered with 2nd generation separators.

Feed
(A)
Dust (P)
(QPb)
Separator
(QB) (QBb)
Dust
grinding (QBa) (QPa)
mill (B)
Dust collector
Dust collector separator + Dust collector
grinding mill grinding mill separator
Finished (Ba) (Bb + Pb) (Pa) Rejects

Product (PF) Fines (R)
(Fs)
This is certainly the most complex case encountered in finishing mills where a filter handles at the same time
grinding mill dust and separator dust.
To plot the distribution curve, determine the separator outlet dust and fines flows, then recalculate a particle-size
distribution of these 2 flows in proportion to the outputs.
In practice this requires the elaboration of the material balance and part of the finishing mill air flow balance.
Sample: ☞ Separator feed (A)
☞ Separator fines (Fs)
☞ Separator rejects (R)
☞ Fines from the grinding mill dust collector (Ba)
☞ Fines from the grinding mill + separator dust collector (Bb + Pb)
☞ Fines from the separator dust collector (Pa)
☞ Finished product (PF)
43
Measure: ☞ Grinding mill outlet air flow (QB)
☞ Grinding mill outlet air flow towards mill filter (Qba)
☞ Grinding mill outlet air flow towards mill + separator (Qbb)
☞ Separator outlet air flow towards separator filter (Qpa)
☞ Separator outlet air flow towards mill + separator filter (Qpb)
☞ Additionally a first hypothesis must be made on the dust concentration at the mill outlet
As a general rule, it is estimated based on the gas velocity in the conduit.
It ranges between 200 and 600 g / m3. (Average values since concentrations in excess of 1000 g/m3 have been
encountered under high ventilation in a small diameter duct.
☞ The 2nd hypothesis consists of considering, in terms of particle-size distribution and BSS, that: P = Pa +
Pb and B = Ba = Bb.
44
Calculation method
Based on the estimated dust concentration and grinding mill outlet air flow, the mill outlet total dust tonnage is
calculated.
The distribution between mill filter and mill + separator filter branches is done in proportion to the air flows of each
branch.
The equation is written:

BSS (Pa) • x + BSS (Ba) • y = BSS (Bb + Pb) • (x + y)
Where: x = separator dust flow to separator + mill filter
y = mill dust flow to separator + mill filter
x+y = total separator + mill filter flow
This equation is resolved given that y is known (hypothesis of the mill outlet dust concentration in proportion to the
air flows) as well as the BSS.
At this stage of the calculation the following is therefore known:

- mill filter flow
- separator + mill filter flow
- separator dust flow towards separator + mill filter
- mill dust flow towards separator + mill filter
- finished product flow (= feed flow)
The dust flow to the separator filter is calculated in proportion to the air flows of the branches coming out the
separator and the calculated separator dust flow to the separator + mill filter.
The material flow of the 3 filters being therefore known, the separator fines flow (Fs) remains to be deduced.
For the calculation of the distribution curve, calculate a reconstituted particle-size distribution (size by size) of the
total fines (F) based on the grading of the fines (Fs) and dust (P) in proportion to their respective flows.
☞ Verify the assumed hypotheses, insuring that:
The separator feed flow (A), calculated from the distribution curve, corresponds to that calculated by the elevator
power (knowledge of the elevator characteristics required).
The measured Blaine fineness of the finished product with that obtained by the addition of the Blaine fineness of
the 3 filters + separator fines (Fs) in proportion to their respective flows.
45
V - 6 - 3 - Average values of the separator distribution curve
The values of the distribution curve parameters depend highly on the circulating charge. Here is what is usually
obtained with properly controlled finishing mills.
Parameters 1st generation 2nd generation 3rd generation

Circulating charge 200 to 350% 100 to 250% 100 to 250%
Acuity limit > 20 µm 15 to 25 µm < 15 µm
Bypass 20 to 50% 10 to 35% 5 to 10 %
Gross imperfection > 0.45 0.30 to 0.35 < 0.30 to 0.35
Rosin-Rammler n 0.75 to 0.85 0.85 to 1 >1
- a - The acuity limit testifies of the ability of a separator to strip a finished product.
- b - The bypass corresponds to the minimum probability of a particle to end up with the rejects. The higher it is,
greater is the amount of fine product returning to the mill, which is inefficient.
- c - The imperfection gives an idea of the separation difficulty. The higher it is, the less sharp is the stripping
and the higher the amount of coarse particles in the finished product.
V - 6 - 4 - 3rd generation separators
For the 3rd generation separators, a ventilation criterion characterized by the following ratios is determined:
- Qf / Qa, kg / m3
- Qp / Qa, kg / m3
Where: Qf = material flow at the separator feed end

Qa = flow of air entering the separator (it is the actual volume (m3) and not n/m3)
Qp = flow of material fines leaving the separator
In general the following should occur: Qf/Qa = 2 kg/m3
Qp/Qa < 0.8 kg/m3
Notes: In Qf, f means feed

In Qa, a means air, not to be confused with the separator feed (alimentation) material flow
In Qp, p means product
46
VI - MATERIAL BALANCE
VI - 1 - Material balance objectives
The material balance gives the flow of material in each circuit branch.
The most important point lies, without a doubt, with the separator and its circulating charge which was discussed
in the previous section.
It also quantifies the filter fines flow. A filter overloaded with material will give a poor performance and create air
flow problems.
For electrostatic filters, manufacturers use a dimension ratio of: 10 to 50 m2 / 1000 m3 / h to obtain stack dust in
the order of 30 to 40 mg 1 m3.
(Surface area of collecting electrodes with respect to the gas flow through the filter).
If the volume of the filter inlet dust is too large, it is more than likely that the concentration of the filter outlet dust
will increase.
For bag-house filters, the dimension ratio varies between 60 and 140 m3 / h / m2 (filtration velocity or working rate)
which corresponds to velocities ranging from 1 to 2.3 m / min. It defines, based on the gas flow, the surface area
of the filtering medias.
With this kind of filters, if there is sequential unclogging, a material overload will translate into an increase of filter
loss of charge causing air flow problems.
If there is unclogging by a loss of charge, an increase in the energy required for the cleaning of the bags will
become apparent.
VI - 2 - Calculation principle
The flow of the finished product in a dry state is equal to the feed flow. This is known.
On certain installations provided with mass measurements of rejects, this flow is also known. It is used as a basis
of calculation but more currently used for checking the dynamic separator distribution curve and the different
computations resulting from the junction calculation method.
The calculation of the flow traveling in the elevator (under its own power) is also more of a checking mean than a
basis of calculation.
47
It is very difficult to know the power efficiency of the motor and in practice the verification consists of confirming
the suitable efficiency of the motor (about 0.9).
Using an installation diagram as shown in section VI-4, the calculation principle can be described as follows:
☞ Starting from the finished product flow, the separator feed and rejects flows are determined from the
separator distribution curve.
The separator feed flow that will be used as a basis for the evaluation of the elevator is now known.
☞ For the elevator, the filter and mill outlet flows are determined using the junction calculation method.
Verification of the separator feed flow based on the elevator power.
☞ On this simple installation, 2 distribution curves were sufficient to establish the material balance.
☞ If additional junctions are encountered, the same method is applied as often as necessary.
VI - 3 - Junction calculation method
VI - 3 - 1 - Using the distribution curve
The distribution curve calculation has been discussed previously.
The same procedure is used to determine the material flow in the installation. This is what is called the junction
calculation method. The principle is that of a distribution curve but only the average R/A ratio is retained. Given
one flow the other 2 can be calculated knowing that: A = R + F.
VI - 3 - 2 - Using Blaine and temperature
The distribution curve works very well with a separator.
As a matter of fact, in separators there is particle sorting and the particle-size distribution of the various flows are
very different.
The junction calculation method derived from the distribution curve is more random precisely because the
particle-size distribution of the different material flows are too close.
48
This could translate into an average R/A > 1, which is impossible since to meet: A = R + F, F would have to be
negative.
In this instance, except when weighing trucks, an attempt can be made to calculate the different flows using the
global fineness (BSS).
Q(A) • BSS(A) = Q(R) • BSS(R) + Q(F) • BSS (F)
By the same principle, a reduced simplified heat balance of the 3 points can be established.
In this perspective, at least one temperature reading at each material sampling location should be made during
the sampling process. Actually this temperature procedure is used more to confirm the Blaine method than to
determine the various material flows.
Wall losses cannot be taken into account. Moreover, the thermocouple reaction time allows time for the material
to cool down slightly. (The thinnest possible thermocouple, although mechanically weak, should be selected to
obtain a better reaction time). Another alternative for a filter is to assume a dust concentration of the gas flows
entering the filter and calculate the material flow with respect to the gas flows. (Case of the mill + separator filter -
pp 41 & 42).
VI - 3 - 3 - Other methods
Certain installations are now equipped with separator rejects scale providing a way to verify part of the material
balance.
Another verification is possible by calculating the elevator flow based on its power (and its characteristics).
(Pc - Pv) • ρ • 3600

Q= h•g
Where: Q = Flow (t/h)

Pc = Power draw of elevator when loaded (kW)
Pv = Power draw of elevator when running empty (kW)
ρ = Elevator motor electrical output
h = Elevator height (m)
g = 9.81
49
VI - 4 - Selection of sampling locations
☞ Take material samples on the 3 branches each time 2 material flows intersect to form a third one, or
when a flow splits in two.
3
E
L
Separator Separator E
Filter Mill Separator
V
A
5 T 2
O
Finished Product R
4
Mill
Feed 1
Case of a finishing mill equipped with a 3rd generation separator. The mill filter dust is returned to the separator
by the elevator.
☞ In the above case, take samples at locations 3, 4 and 5 needed for the distribution curve.
☞ The separator feed being made up of mill outlet + mill filter material flows, samples should be taken at
locations 3 (already done for the distribution curve), 1 and 2.
The number of samples and sampling frequencies are the same as for those used for the determination of the
distribution curve. Samples taken around the separator form an integral part of the material balance. After
homogenization of each sample, the particle-size distribution should be determined (laser) as well as fineness
(BSS).
For drying mills, it is preferable to express the material balance on a dry basis.
50
VI - 5 - Numerical example
The following data will be considered:

- Feed = 100 t / h
- The separator distribution curve is that given on p 32
- Mill discharge BSS = 1800 cm2 / g
- Mill filter BSS = 3400 cm2 / g
- Separator feed BSS = 2000 cm2 / g
- Elevator power draw when running empty = 5 kW
power draw when loaded = 23 kW
height = 25 m
- The junction calculation method applied to the elevator gives R/A = 0.85
(R = mill discharge, A = separator feed)
- a - Separator flow
Feed flow = finished product flow (location 5) = 100 t/h (dry basis)
The distribution curve gives a circulating charge of 141% (R/F)

A= Location 3
R= Location 4
F= Location 5
F= 100 t/h
Given R/F and F, it is easy to calculate R

R= 1.41 • 100 = 141 t/h
A= R+F
A= 141 + 100 = 241 t/h
- b - Elevator flow
The elevator flows (locations 1, 2 and 3) must now be calculated.
☞ Choose: A = Elevator discharge = mill feed (location 3)

R = Mill discharge (location 1)
F = Mill filter dust (location 2)
The choice of R and F may be reversed, all that is needed is to know what they represent.
But A must always be chosen as being the resultant of the 2 other flows.
Mill Filter Mill Discharge
(location 2) (location 1)
Separator Feed
(location 3)
51
The only known flow is the separator feed. Using the junction calculation method (simplified distribution curve)
the mill discharge (location 1) and mill filter dust (location 2) flows are then calculated.
The junction calculation method gives an average R/A = 0.85

A = 241 t/h
R = 0.85 • 241 = 204.85 t/h (mill discharge)
A= R+F
F= A-R
F = 241 - 204.85 = 36.15 t/h (mill filter)
The material balance has therefore been established for the installation. However it is necessary to check the
calculated flows mainly around the elevator.
- Verification by fineness
On the basis of the flows and the fineness of the materials entering the elevator, the elevator discharge fineness
should be close to 20000 cm2/g.
(204.85 • 1800) + (36.15 • 3400)

= 2040 cm2/g
241
Given the precision of the Blaine test, a 100 to 200 points variation is deemed acceptable.
In the present case, the Blaine 40 points variation confirms the validity of the flows calculated by the junction
calculation method.
- Verification by the elevator power draw
Flow • Height • 9.81 241 • 25 • 9.81

Efficiency = Efficiency = = 0.91
(Ploaded - Pempty) • (23 - 5) • 3600
3600
An efficiency of 0.91 is a suitable value confirming also the flow entering the elevator.
The material balance is therefore validated.
The flows can also be verified by the material temperature using the same principle as for fineness.
This method is however less accurate since abstraction is made of wall losses. It is used when the 3 flow
finesses are almost identical.
Mass measurements offer the best verification or starting base.
- Weighing of rejects. It is increasingly more common to have a scale installed to weight the separator
rejects and to serve as a mill operation parameter.
- Weighing of trucks. Difficult to put in practice but more reliable.
52
VI - 6 - Interpretations of results
Notwithstanding the difficulty in reconstituting the particle-size distribution of the total fines (see distribution curve
section), there is generally no or very few problems with the distribution curve of dry dynamic separators.
On the other hand, difficulties are encountered when establishing the static separator inflows and outflows.
The other problems stem mainly from the calculations by the junction calculation method and are of 2 types:
- sample representativity
- too close a particle-size distribution of the materials making up the flows.
VI - 6 - 1 - Static separator
Right now nobody seems to know how to take samples of gas-suspended materials. This is why materials are
sampled strictly where only materials circulate (airslides, chutes, belt conveyors, ...).
It is practically impossible, for this reason, to produce a distribution curve with a static separator (no sampling of
materials at the static separator inlet).
Consequently, if the fines flow can be calculated, the static separator rejects and feed flows cannot. The only
solution is to estimate a rejects flow. Another solution would be truck weighing which could be useful for filter dust
for instance.
This is rarely done for practical reason and also because too risky for the quality of the finished product.
For a filter with a small flow, weighing would have to be done over one or several hours to be suitable but then
what would happen to the fineness of the finished product without filter dust?
VI - 6 - 2 - Sample representativity
With bag-house filters in particular, fineness is not always uniform in relation to unclogging cycles and the material
flow is sequential.
Quite often filters unload in airslides which do not have blending capability.
Material sampling resulting from the sum of a filter + separator fines for example, in an airslide, will become
hampered.
At times only separator fines will be sampled, at other times, a filter blend having a higher flow compared to the
average will be sampled.
53
Hence the need to increase the number of samples to smooth out this phenomenon.
A second source of error is due to the existing depression (caused by dusting). It is a depression which, when the
scoop is withdrawn from the duct, will lose a portion of the surface layer of the material and as a result may distort
the particle-size distribution.
The best way to counteract this phenomenon is to use a scoop that can be closed before being pulled out of the
duct in order to eliminate the depression inside the sampler.
Simple samplers
Closed position before pulling out of

the duct
Open position in the duct
“Anti-depression” samplers
54
VII - AIR FLOW BALANCE
VII - 1 - Air flow balance objectives
The balance determines the ventilation of each equipment, chiefly the mill and dynamic separator.
Initial air inleakage can also be located and quantified by a drop in output and energy increase of the draft
ventilator.
For drying mills, this also serves as a basis for the drying balance.
VII - 2 - Selection of measurement locations
An air flow measurement must be made at the inlet and outlet of each equipment (repeat the measurements to
make sure of the result). In ducts, the gas streams must be as stable as possible, and not subjected to
turbulences. Turbulences are generated by elbows, guide vanes, a change in section - - - -.
The measurement should preferably be made over 3/4 of a long and straight portion (8 to 10 times the diameter of
the duct). Unfortunately it is not always possible and to minimize the error, testing is done on 2 diameters at 90˚.
5 Ø and 3 Ø adhered to 5 Ø and 3 Ø not adhered to
5Ø 3Ø 2 Measurement Axis
Gas Direction
2 Ø exploration at 90°
Measurement Axis
55
VII - 3 - Air flow measurements
VII - 3 - 1 - Anemometer measurements
Propellor
Propellor
Reader
Length
dial
Timer
Maxant Type Anenometer Electronic Anemometer
They are made on so-called “open” sections such as ventilator horn, mill fresh air inlet...
An integrating anemometer is used that cumulates length with time during the measurements.
Sweep the entire open surface with a motion as regular as possible.
The “maxant” anemometer is equipped with 2 dials. The first one gives length (m), the second, time (s).
By dividing length by time, velocity (m/s) is obtained. Nowadays electronic anemometers give directly the velocity
measurement. By multiplying the acceleration by the cross section, the flow in m3/s is obtained.
To obtain flow at 0° C (normal: Nm3) a temperature correction must be made:
m3 • 273
NM3 =
273 + Ø
Where Ø: temperature, °C.
To take a flow measurement using an anemometer it is necessary to:
☞ measure the cross-section

☞ measure the temperature at the measuring location
☞ measure the velocity (anemometer)
Note:
Rectangular ducts: It is considered that in corners there is none or very little flow. Hence a 0.96 coefficient is
used in the calculation of the cross-section: S + L • 1 • 0.96
This cross-section is called air flow cross-section.
56
VII - 3 - 2 - Pitot, Strauscheib, Type R pitot tube measurements
They are made on so-called “closed” sections such as ducts.
Either a pitot tube (clean gas flows), or a type R pitot tube, or a Strauscheib tube (dust-laden gas flows) is used.
Strauscheib
Pitot
Dynamic
pressure
Static
pressure
Total
pressure
Pressure
meter
The formula used is drawn for Bernoulli’s law and applies to clean gases.
V= 2•g•h
ρ
Where V = Velocity ( m/s)
g = 9.81
h = Measured dynamic pressure average (mmCE)
p = Gas unit mass (kg/m3)
By multiplying the velocity by the cross-section the flow is obtained.
But it is necessary beforehand to calculate the unit mass of the gases taking into account first their composition
and then apply a temperature and pressure correction.
273 10336 + Pst

ρ = ρ0 • 273 + Ø • 10336
Where: P = Standard unit mass (kg/m3)

Pst = Static pressure (mmCE)
Ø = Temperature (°C)
57
In general for clinker mills, the unit mass of the dry air gases (P0 = 1.293 kg/m3) is used if the additions are in
small quantity and the moisture is low. If not, it must be recalculated based on the gas analysis.
A flow in m3 is obtained that will require a temperature and pressure correction to obtain a flow in NM3/h.
Q (Nm3 / h) = Q (m3 / h) 273 • 10336 + Pst

• 273 + Ø 10336
Where: Ø = Temperature (°C)

Pst = Static pressure (mmCE)
To measure the flow using a Pitot or Strauscheib tube, it is necessary to:
☞ measure the cross section
☞ measure the temperature at the measuring location
☞ measure the static pressure at the measuring location
☞ measure the dynamic pressures on the testing duct axis
The dynamic pressure is read directly on the meter by connecting the total and static pressures. Dynamic
pressure = total pressure = static pressure.
Notes: Rectangular ducts: it is considered that in corners there is none or little flow. Hence a 0.96 coefficient
is applied for the calculation of the cross-section: S = L • 1 • 0.96.
- Strauscheib or Pitot type R tube: The static pressure is measured opposite the total pressure (Pitot
tube at 90°) and therefore a correction coefficient (k) must be determined in the laboratory (or supplied by the
manufacturer) and applied directly to the calculated velocity. For a Pitot tube k = 1.
Additionally, the Strauscheib tube is used in dust-laden atmospheres.
Nonetheless the Bernoulli formula is applied (no other means are known today) by correcting the unit mass of the
gases from the dust concentration.
Calculate the unit mass of the gases with the temperature and static pressure correction, then add to it the dust
concentration (kg/m3).
ρ total (kg / m3) = (ρ0 gas • temperature correction • pressure correction) + dust
The dust concentration is determined after doing the material balance (the hourly amount of material moving in
the duct is then known).
58
3
Proceed by iteration until the gas flow (m /n) • dust concentration equals the material flow transported in the duct.
Strauscheib tube measurements are subject to criticism and this should be remembered when completing the air
flow balance.
The general formula is:
2•g•h
V=k•
ρ + dust Q m3 / s = V • cross section
Where: V = gas acceleration, m/s

g = 9.81
h = dynamic pressure average, mmCE
Numerical example
In the configuration of the finishing mill (p 49), the material balance gives a mill filter material flow of 36.15 t / h.
An air flow measurement was done with the Strauscheib tube in the mill discharge duct leading to the mill filter.
A first analysis, omitting the dust, reveals a flow of 108 000 m3 / h with a ρ for gases of 0.928.
The dust concentration is calculated to be 36.15 • 106 / 108 000 = 335 g / m3 of dust.
Now proceed by iteration, since by including the ρ dust corrections, the flow will change.
The new ρ will then become 0.928 + 0.335 = 1.263. This will give a flow of 92 700 m3 / h.
The dust flow will then become 335 • 106 • 92,700 = 31 t/h instead of 36.15 as desired.
The new dust concentration is 36.15 x 106 / 92,000 = 390 g / m3. Repeat the calculations by iteration until the
obtention of : dust concentration • flow = 36.15 t/h.
A concentration of 400 g / m3 for a flow of 92,400 m3 / h will be found.
On the Pitot calculation sheet, use the target value function which will immediately give the correct dust
concentration value.
Caution: Dust concentrations are expressed in g / m3.
59
VII-3-3 - Gas analyses
They are used to recalculate the gas unit mass but will also serve when doing the drying balance (moisture).
They must be done at the same locations as the air flow measurements if the composition of the gases varies (air
inleakage, material drying).
The O2 and CO2 analyses are done by pumping the gases out of the duct and the test gases are dried before
going through the various analyzers. The actual analysis should be recalculated taking moisture in the duct into
account.
In a cement plant, the essential analyses involve O2, CO2, N2 and H2O.
O2 and CO2 are determined dry, H2O as is. N2 = 100% - (% actual O2 + actual CO2 + % H2O) • % actual gas =
% dry gas • (1 - proportion of H2O)
H2O is analyzed either by pumping, or by measuring the dry and humid temperatures.
O2 Analyser
Test gas
CO/CO2 analyser
Gas analyzers
60
VII - 4 - Interpretations of results
VII - 4 - 1 - Anemometric Measurements
Except when using the technique consisting of sweeping the surface with a regular motion, there are no particular
problems with small and large dimensions.
On the other hand, with big horns (> 1 m) at times the sweeping may not give good results (case of the separator
fresh air intake - Martres BK4 where the separator air flow closure was not good).
A point by point measurement on 2 axis at 90° has allowed the closure of the separator air flow balance and
meeting the plant annubars.
VII - 4 - 2 - Pitot, Strauscheib, Type R Pitot Tubes
- a - Exploration
Most of the time, a regular depth exploration is used instead of taking an equivalent surface ring measurement
which requires a depth recording for each duct.
In the case of regular depths, instead of calculating the arithmetical mean of the dynamic pressures, the root
mean is determined.
This method gives good results provided the gas flows are not too irregular. If the gas flows are too irregular, the
equivalent surface ring exploration should be done.
In this case the mean of the dynamic pressures is determined arithmetically.
61
The diagram and table below provide the depths based on the number of measurement points for a 1 m diameter
duct.
Positioning of the measurement points of the equivalent surface rings
D 1m
Table for D = 1 m
d1
Distance from
d2 Number of points Point designation
the edge
d3 6 a1 0.044
a2 0.146
a3 0.296
B A
a4 0.704
a5 0.854
a6 0.956
a1 0.032
8
a2 0.105
a3 0.194
a4 0.323
a5 0.677
a6 0.806
6 5 4 3 2 1
a7 0.895
a8 0.968
10 a1 0.026
a2 0.082
a3 0.146
a4 0.226
a1 a5 0.342
a6 0.685
a2 a7 0.774
a3 B a8 0.854
A
a4 a9 0.918
a 10 0.974
a5 a1 0.021
12
a6 a2 0.067
a3 0.118
a4 0.177
a5 0.250
a6 0.356
The indicated values in the Table apply
a7 0.644
only for D = 1 m a8 0.750
a9 0.823
a 10 0.882
For D = x, multiply the values by x a 11 0.933
a 12 0.979
- b- Dust-Laden Atmospheres
In case of dust-laden atmospheres, the standard Pitot tube gets plugged up too rapidly and the flow cannot be
measured.
Hence, either a Straucheib or Type P Pitot tube is used. Their main feature is that they are provided with a total
pressure - taking opening that is bigger than that of the standard Pitot Tube. It will get plugged up also but less
rapidly allowing a measurement to be made.
☞ Pull out and clean the tube after each measurement.
62
The rapidity with which plugging takes place is not in itself an indication of the dust concentration in the duct.
Other phenomena such as the nature and fineness of the dust come into play.
Contrary to what may be thought, when plugging occurs, the observed dynamic pressure suddenly increases.
Note the difference in the diameter of the openings

Total
Pressure
Static
Pressure
Left : Strauscheib — Right : Pitot
- c - Dirty Conduits
It occurs sometime that a conduit in an almost level position and carrying dust, becomes dirty.
This can be the case of a conduit where dust-laden gases circulate between the tower and a drying mill. Also,
tower gases are moist and humidity promotes sticking at the base of the conduit (during stoppage, this
phenomenon is amplified by condensation) The gas circulation cross section becomes artificially reduced and the
effective cross-section must be calculated.
h
initial Ø
accumulated
material
The easiest way in that case to calculate the effective cross-section for gas circulation of is to use the mill filling
rate procedure.
☞ calculate the initial cross-section from the initial diameter

☞ measure h (comparable to the free height of a mill)
63
☞ calculate the “filling rate”
Effective Cross-section = initial cross-section • (1 - “filling rate”)
VII - 4 - 3 - Gas analyses
O2 and CO2 analyses are done by pumping over a very short time (1 to 2 min.) and should be confirmed once or
twice.
The moisture analysis by pumping takes much longer (30 min. to 2 hours depending on the moisture level) and
can be checked in case of doubt, being understood that testing must be conducted during stable mill operation.
The moisture analysis under dry humid temperatures is spotty and should be checked one or twice.
How to choose between the two types of moisture analysis?
- by pumping: it covers everything (particularly dust-laden gases) and integrate with time.
Its main drawback is the set-up (electrical pump, meter, silicagel, sampling lance).
☞ Make sure you place a glasswool pad at the end of the lance to filter the dust.
☞ Make sure you limit condensation between the lance outlet and the silicagel (the shortest possible
distance). Incline the lance towards the silicagel to capture any possible condensation.
Moisture calculation:
volume of absorbed water

% moisture by volume = 100 •
volume of absorbed water + volume of pumped gas (at 0°
C)
The volume of absorbed water is in fact a mass of water to be translated into volume.
mass of water (kg) • 22.4

Volume of water (Nm3) =
18
22.4 l = volume occupied by a mole of gas. The correspondence of the units gives Nm3.
18 g = molar mass of water. The correspondence of the units gives kg.
- by dry humid temperatures: spot measurements must be limited specially to the exhaust gases.
Drawbacks: there can be no dust (it will stick to the damp cotton and distort the measurement).
The dry temperature should not exceed 110 to 120 ° C otherwise the cotton dries very rapidly and the
measurement becomes impossible.
64
Use very thin thermocouples to get a quick answer.
Watch the humid temperature because it will progressively increase to a certain level; read it and switch over to
the dry temperature; read it immediately. Humidity readings are done using humid air Tables.
VII - 4 - 4 - Air inleakage calculation by gas analyses
In drying mill circuits, air inleakage can be calculated with the O2 or CO2 elements or both which are influential
elements.
But it is necessary for reasonable accuracy to have different analyses of the ambient air. This is why these
calculations cannot be made unless the hot drying gases originate from a tower or a grate.
Air inleakage calculated with O2:
outlet O2 - intake O2
% air inleakage / intake = 100
20.94 - outlet O2
•
20.94 = O2 of ambient air
Air inleakage calculated with CO2:
intake CO2 - outlet CO2

% air inleakage / intake = 100
intake CO2
•
Caution: The analyses being run on a dry basis, the air inleakage percentage is expressed on a dry basis.
Example:
Intake Outlet
O2 = 8% (as measured) O2 = 11.5 % (as measured)
CO2 = 25% (as measured) CO2 = 15.5 % (as measured)
H2O = 8% (as measured) H2O = 18.2 % (as measured)
10,000 Nm3/h (as measured) 15,000 Nm3/h (as measured
MILL
Vaporisation : 2,000 Nm3 / h
With O2: With CO2:
(11.5 - 8) (25 - 15.5)

% air inleakage / intake = 100 • (20.94 - 11.5) = 37% % air inleakage / intake = 100 • 25 = 38%
65
The moist measured intake flow is 10,000 Nm3 / h at 8% H2O = 9,200 Nm3 / h dry and 800 Nm3 / h water.
The calculated air inleakage averages 37.5%.
The dry flow at the outlet will be 9,200 • (1 + 0.375) = 12,650 Nm3 / h representing an air inleakage of 3,450 Nm3
/h.
Let’s assume that the ambient air contains 2% moisture.
The water carried by the air inleakage will be : 12,650 + 800 + 2,00 + 70 = 15,520 Nm3 (to be compared with the
measurement taken).
800 = volume of water contained in the intake gases.
2,000 = volume of the material evaporable water in the mill (drying).
79 = volume of water carried by the air linkeage.
The outlet moisture will be : (800 + 2,000 + 90) / 15,520 = 18.5% (to be compared with the measurement taken).
Gas outlet Gas intake
“Moist”
silicagel Thermometer
Sampling
“Dry” lance
silicagel
Reservoir
Pump Meter
Gas moisture by pumping
Dry / humid
switch
Readers
Dry
thermocouple
Humid thermocouple
Thermocouples - Standard above - Dry / humid below

66
VII - 4 - 5 - Mill ventilation ratios
An important aspect of the air flow balance is the determination of the mill ventilation.
It is expressed as a fictitious gas velocity in the mill in empty tube equivalent. All that is needed is to divide the
actual gas volume by the internal cross-section of the mill.
As a general rule, the actual volume is calculated at 100° C which is an average temperature in a mill
It is very difficult to measure the volume of gas crossing the mill, although 2 possibilities exist.
1st by measuring the tube outlet flow but in this case it is distorted (by excess) by the air inleakage, namely at the
trommel outlet. This is what can be qualified as an optimistic hypothesis.
2nd by measuring the tube inlet flow, but in this case it is distorted (by default) by the impossibility of measuring
the air entering with the material. This is what can be qualified as a pessimistic hypothesis. The actual value
stands between these 2 hypotheses.
The ventilation ratio for a mill is: in open circuit, from 0.6 to 0.8 m/s
in closed circuit, from 1 to 1.5 m/s
If the finishing mill is equipped with a static separator, the ventilation can be increased up to 2 m/s provided the
static fines are compatible with the finished product.
Also:
- gas velocity at 100° C over the charge (varies according to filling rate)
in open circuit from 0.8 to 1.2 m/s
in closed circuit from 1.4 to 2.1 m/s
- specific ventilation in Nm3 / kg of finished product (varies according to mill output, and gives an
evaluation of the cooling / drying potential.
The ratio ranges from 0.3 to 1 Nm3 / h of finished product depending on the installation.
Currently, in finishing mills equipped with 3rd generation high-efficiency dynamic separator, it is preferable to
return the dust-collected fines at the base of the elevator. This allows a strong ventilation of the tube and
furthermore it is an assurance of quality of the finished product.
67
VIII - DRYING / HEAT BALANCE
VIII - Drying / Heat Balance Objectives
The balance allows material drying optimization and the quantification of the drying energy required.
The recirculation of the exhaust gases can be also adjusted.
Therefore it is possible to give priority to the optimization of the energy supplied by the heat source especially if
the latter is generated by a furnace (saving on the purchase of fuel).
This type of balance can be done on raw or fuel mill circuits.
It is sometimes possible to give consideration to a drying balance on a clinker mill when a cementitious addition is
very damp and used in large proportion.
In this case the question is to find out if it is useful to add hot gases to the mill or if the heat produced by the mill is
sufficient.
VII - 2 - Drying and Heat Balances
The drying balance is in fact combined with a heat balance because besides knowing where the water in the
material is eliminated and in what amount, 2 ratios are determined that are related to the energies involved.
The first ratio is the theoretical drying efficiency which is the total energy provided at the inlet per kg of
evaporation water.
Total energy means the energy supplied by the heat source but also by the sensible heat from the inlet gases and
materials (the reference used is 0° C).
This ratio may also be expressed as a percentage of the theoretical vaporization (596 kcal / kg of water) to the
total supplied energy.
The second ratio is the useful drying efficiency which is the pure energy provided at the inlet per kg of
evaporation water. The pure energy is strictly coming from the heat source(s).
☞ Measure (flow, temperature) and analyze(H2O) the gas flows coming in and out of the installation and for
each equipment if it is desired to find out more precisely when water evaporation takes place.
☞ Sample (flow, temperature) and analyze (H2O) the materials coming in and out of the installation and for
each equipment if it is desired to find out more precisely when water evaporation takes place.
☞ In the case of a furnace the fuel analysis and flow (pure energy) should be obtained but also all the
amount of air entering the furnace (primary and diluted).
It is essential for the calculation of the volume of the combustion smokes and their analysis. It is frequently
difficult to measure the gas flow at the mill inlet (very short duct).
68
VIII - 2 - 1 - Drying Balance
The drying balance may be expressed in kg of water / h or in Nm3 / h of vapor.
However it is preferable to use kg/h on account of the ratios.
Determination of the water flow in and out of the circuit or for each equipment or both.
- Material
Volume of water (Nm3/h) = material flow (kg/h) • H2O proportion • 22.4 / 18
Mass of water (kg/h) = actual gas flow (Nm3/h) • H2O proportion
- Gas
Volume of water (Nm3/h) = actual gas flow (Nm3/h) • H2O proportion
Mass of water (kg/h) = actual gas flow (Nm3/h) • H2O proportion • 18 / 22.4
- Air inleakage
Don’t forget that ambient air carries water
The loss of water in the material in an equipment is called vaporization and is often expressed in
Nm3/h)
VIII - 2 - 2 - Heat Balance
It is expressed in kcal / h (or kJ / h) and covers, except in special cases, the entire circuit. It is expressed by
reference to 0° C.
- Material
Sensible heat (kcal / h) = material flow (kg/h) • temperature • average specific heat at the
temperature (kcal / kg).
- Gas
Sensible heat (kcal / h) = material flow (Nm3/h) • temperature • average specific heat at the
temperature (kcal / Nm3/h).
- Fuel
Sensible heat (kcal / h) = fuel flow (kg/h) • temperature • average specific heat at the temperature
(kcal / kg).
Combustion energy (kcal / h) = fuel flow (kg / h) • inferior heat capacity (kcal / kg).
- Mill
Part of the mill energy is transformed into heat and is included in the heat balance.
Heat supplied (kcal / h) = mill power (kW) • 1 h • proportion of transformed energy • 860.
860 : 1 kWh = 860 kcal.
69
In general - 90% of the electrical energy is transformed into mechanical energy

- 95% of the mechanical energy is transformed into heat
- overall, 85% of the electrical energy is transformed into heat
Note:
I HP = 0.735 kW 1 kW = 1.36 HP
1 J = 0.239 cal 1 cal = 4.186 J
1W=1J/s 1 kW = 1 kJ / s
1 kWh = 3,600 kJ = 860 kcal 1 thermie = 1000 kcal
- wall losses
They are not measured but estimated
A percentage of the sum of the intakes is used (kcal / h)
- vaporization
Do not forget, in the outlets, that the vaporization of water at 0° C uses 596 kcal / kg of evaporated water.
A vaporization value at 0° C is taken since the balance is expressed by reference to 0° C.
70
VIII -3 - Interpretations of Results
VIII - 3 - 1 - Drying Balance
For economical reasons, the contribution of hot gases should be minimized (specially if there is a furnace), but at
the same time a certain outlet temperature must be maintained to avoid water condensation in the filter (risk of
bag plugging and possible corrosion).
It is considered that an outlet temperature in excess of 25 to 30° C above the dew point should be
maintained.
In general, on standard installations, the heat source is controlled so as to maintain a mill outlet temperature at
around 80 to 85° C which is sufficient to prevent condensation in the filter.
The ambient air humidity varies with the climate, so the easiest way is to contact the local weather bureau.
For information:
Temperature (° C) Relative humidity (%) Humidity (% by volume)

25 100 3.1
20 100 2.3
15 100 1.7
10 100 1.2
5 100 0.9
25 80 2.5
20 80 1.8
15 80 1.4
10 80 1.0
5 80 0.7
25 60 1.9
20 60 1.4
15 60 1.0
10 60 0.7
5 60 0.5
It can be seen that as a first attempt, only a very small error can be make on the drying balance by considering
the ambient air humidity to be between 1 and 3% based on the temperature.
71
VII - 3 - 2 - Heat Balance
The lower the theoretical and useful drying efficiencies the better the drying optimization.
On very efficient installations the theoretical efficiency ranges from 1,100 to 1,200 kcal / kg of evaporation water.
An efficient installation requires: high inlet gas temperature (400° C).

low outlet gas temperature, between 80 and 90° C (this minimizes heat
losses).
recirculation of a portion of the exhaust gases (heat recovery)
large amount of evaporation water (material H2O >5%)
It is usual to see theoretical efficiencies between 1,400 and 1,500 kcal / kg of evaporated water, in particular,
even when the material moisture is low when the installation operates under favorable conditions.
- mill
The electric power of motors is recorded and do not forget the electric motor performance when
calculating the actual power transmitted to the mill.
It is estimated that 80 to 90% of the electrical energy of a ball mill is transformed into heat.
- wall losses
They are not measured because they represent only a small fraction of the heat balance.
The analysis and site measurement of wall losses are very time concerning.
It is estimated that wall losses range between 5 and 10% of the total energy input.
72
IX - ENERGY BALANCE
IX - 1 - Energy balance objectives
This balance, contrary to others, does not allow the detection of a precise area of operation problem.
This is above all a global indicator of the operation of an installation that is expressed in kWh / t of finished
product.
It is possible however to quantify the energy required for each equipment and the total energy required to produce
one tonne of finished product.
By regularly following up this ratio for each product, any possible drifting along the way can be detected. Any
such drifting will be an incentive for finding what causes it by reviewing the other balances.
An increase in kWh / t is often the result of a drop in production (same energy consumption but a lower divider).
IX - 2 - Energy balance
☞ Record the electric power of each piece of “process” equipment
- mill motor
- elevator
- dynamic separator motor(s)
- exhaust ventilator(s)
- dynamic separator fresh air ventilator
The other pieces of equipment such as auxiliary dust collectors, air slides, pneumex, are not included in the
“process” energy balance. They are normally integrated in the overall circuit total.
☞ Record the finished product output.
☞ Sample on the conveyor belts (once is enough) all the ingredients entering the mill.
☞ Have a BB10 grindability test done.
The BB10 mill is a calibrated laboratory mill which gives the theoretical “process” energy required to grind a
material at a desired fineness.
The test is conducted on the reconstituted finished product (ingredients sampled from the conveyor belts).
A curve is plotted with the kWh / t in ordinate and the corresponding finenesses in abscissa.
For cement the fineness is expressed in BSS.
For raw mixes, the fineness is expressed in amount retained on the 100 µm mesh.
The kWh / t of the circuit corresponds to the fineness of the finished product.
73
If the mill operates under good conditions, the same fineness should correspond fairly well to the same BB10
kWh/t.
Production energy (kWh / t)

70
BB10 Cement grindability

60
50
40
30
20
BSS fineness (cm2/g)

10
1000 1500 2000 2500 3000 3500 4000 4500
Production energy (kWh / t)

18
16 BB10 raw mix grindability
14
12
10
2
% retained on 100 µm mesh
0
0 5 10 15 20 25 30 35 40
Typical examples of grindability results
74
IX - 3 - Interpretations of results
IX-3-1 - Energy balance
Very often an average is made of the different equipment powers taken from the record of the installation
operating data.
Assurance must be given that the computer data are right.
Hence it is good to have an electrician make a control measurement of the electric power of the motor of each
equipment.
The energy balance is calculated from the actual power consumptions (without taking into account the electrical
efficiency of the equipments).
A “process” consumption (kWh/t) is determined as well as a consumption of the mill itself which by far is the
equipment that utilizes the largest amount of energy in a finishing mill (80 to 95% in general).
IX - 3 -2 BB10 Test
The BB10 mill is a closed-circuit mill without ventilation.
The BB10 test was designed for clinker. The practical correlation giving the energy consumption vs the number
of revolutions has been done with finishing mills producing Portland cement or straight products (slag, ...).
It is estimated that for Type CEM I cement, the BB10 test is reliable within about 5%.
For Type CEM II cement and when the addition is limestone, there is a different behaviour of the addition fines
between production (ventilation sweeps the fines) and the test (no ventilation).
The same type of problem is encountered on pure products when high finenesses are obtained (BSS fineness >
4,000 cm2 / kg).
The phenomenon is the same with blended cement, i.e. an overgrinding of the fines that forms coating & thereby
reduced grinding efficiency.
In these 2 foregoing cases the curve is normal in the lower part but distorted in the high fineness range. It
becomes very steep.
When during production a grinding aid is used, it is difficult to maintain the same dosage in the BB10 because of
the small amount of material (1 kg).
The result is an offset on the overall grindability curve.
For all these reasons, the grindability test error is about 10% with blended cement (with or without admixture) and
also for BSS finenesses below 3,000 - 3,500 cm2/g. Beyond that the interpretation is very uncertain.
With blended cement it is a good practice to run a BB10 test on the pure clinker.
By comparing with previous tests, it is possible to find out if the increase of the finishing mill kWh/t is due to a
change in clinker grindability (major ingredient).
75
X - CONCLUSION
The mill follow-up is very important because it helps in spotting a progressive drifting of the installation in terms of
flow or total electrical power.
The progressive drifting should be an incentive to try and determine the cause of a problem by means of airflow,
drying balances, etc.
The evolution of the grinding charges and the internal conditions of the equipment as well as any eventual
modifications should be analyzed.
In that perspective the follow-up becomes very important from an historical standpoint and help in determining the
causes of operation problems.
Grinding aids promote the disposal of the fines from the mill by preventing agglomeration.
Also, they have a beneficial effect on the material flow and in general will slightly increase the Blaine fineness for
equal strength.
☞ It is recommended, for each product, to look for the optimum dynamic separator recirculation
rate.
(This should be done when the grinding charge is suitable after sorting out the charge for example)
This consists of varying either the rejects and feed or elevator power requirements and identifying the requirement
at which maximum feed is obtained.
Plot a curve of feed flow vs requirements.
Caution: The rejects are the dynamic separator rejects.
The feed is the fresh feed from the finishing mill and not the separator feed.
76
For satisfactory mill operations, follow-up and targeted actions are required without having to produce exhaustive
balances (refer to mill follow-up manual).
☞ Do a charge sorting out every 8000 h for compartment 1, 10000 h for compartments 2 and 3.
☞ Do a regular internal inspection of the mill (observations and if possible sampling of material to check
the evolution of the fineness). The grinding medium filling rate should be readjusted by adding balls.
☞ “Chase air inleakage” to insure a good mill ventilation (critical with drying mills).
☞ Check the operation of the dynamic separator (distribution curve).
☞ Check the operation of the valves.
77
LIST OF ANALYSIS COMPUTER PROGRAMS
- Pitot
- Distribution
- Rosin - Rammler
- RFCS (PCFR in French)
- Moisture (silicagel cartridges)
- Moisture (dry / humid) Available under excel 4 or 5 in Macintosh or
- Elevator flow Window version
- Drying / heat balance
- Charge characteristics
- Compartment 1 charge calculation
- Compartment 2 charge calculation
- Filling rate
- Smoke calculation
- Gas characteristics
- Pitot : Airflow calculation.
- Distribution curve : Calculation and plotting of the distribution curve (can be used also for the junction calculation
method).
- Rosin - Rammler: Calculation and plotting of the Rosin - Rammler curve.
- RFCS: Calculation and plotting of the RFCS curve.
- Moisture (silicagel cartridges): Calculation of gas moisture by pumping.
- Moisture (dry / humid): Calculation of gas moisture by dry and humid temperature measurements.
- Elevator flow: Calculation of the material flow from the elevator power draw and its characteristics.
- Drying / heat balance: Calculation of the drying and heat balances (several possible configurations. Maximum: 2
heat sources + furnace + 1 recirculation + 1 water spray).
- Charge characteristics: Calculation of the charge characteristics for each compartment with graphs and power
drawn by each compartment..
- Compartment 1 charge calculation: Calculation of compartment 1 charge plus large ball selected on the basis of
the material and mill characteristics.
- Compartment 2 charge calculation: Calculation of compartment 2 charge.
- Filling rate: Calculation of the compartment filling rate based on the measured height of the free space.
- Smoke calculation: Calculation of the combustion smokes and their analysis based on the solid fuel elementary
analysis.
- Gas characteristics: Calculations of the combustion smokes and their analysis based on the gas fuel elementary
analysis.
An outline, for all these calculation sheets, is given in the appendix.
A list (not complete) of equipment suppliers with price estimate is also given in the appendix together with the
characteristics of the balls and cylpebs vs their sizes.
78
LIST OF APPENDICES
Separator inspection report
Mill (2 compartments) inspection report
Ball and cylpeb characteristics
Testing equipment suppliers
Calculation sheets Pitot
Distribution curve
Rosin - Rammler
RFCS
Moisture (silicagel cartridges)
Moisture (dry / humid)
Elevator flow
Drying and heat balances
Charge characteristics
Compartment 1 charge calculation
Filling rate
Smoke calculation
Gas characteristics
79
MILL FOLLOW-UP SEPARATOR INSPECTION REPORT
Type of separator : STURTEVANT
Plant : Mill :
Date : Type of cement :
MEASUREMENTS, RECORDS, OBSERVATIONS COMMENTS

Good Average Poor
Diaphragm condition
Good Average Poor

Ventilation blades condition
Good Average Poor

Distribution plate condition
Selector blades (1) Number

1st Length mm
Width mm
and Inclination °
Distance from casing mm
2nd
Selector blades (2) Number
G Length mm
E Width mm
N Inclination °
E Distance from casing mm
R
A Good Average Poor
T Rejects cone condition
I
O Yes No
N Plugged return air vanes
Good Average Poor

Liner wear condition
Rejects valve in order

out of order
Fines valve in order

out of order
3rd
Good Average Poor
G Cage bars condition
E Fixed blades condition
N
E Good Average Poor
R Liner wear condition
A
T
I Rejects valve in order
O out of order
N
80
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
81
MILL FOLLOW-UP
MILL (2 COMPARTMENTS) INSPECTION REPORT
Plant : Mill :
MEASUREMENTS COMMENTS
Material level C1 Above* mm
Material Under*
C2 Above* mm
Under*
C1 Useful length M
Dimensions Useful diameter M
C2 Useful length M
Useful diameter M
Height of free space C1 M

C2 M
Filling rate C1 % to be calculated

C2 % to be calculated
Largest ball Smallest ball
C1 mm mm
C2 mm mm
Grinding Pollution from Liners

Charge External elements
Ball classification Good Null Inverse
C1
C2
Liners Type Step
C1 mm
C2 mm
Mill shell inlet Ø M
Intermediate diaphragm Slot width mm

Equipment % plugging %
Parts Ventilation ring Ø M
Permeability %
Outlet diaphragm Slot width mm

% plugging %
Ventilation ring Ø M
Permeability %
Coating Coating Balls Liners

C1 yes / no * yes / no *
* Strike out the non applicable mention
82
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
83
MILL FOLLOW-UP
MILL (3 COMPARTMENTS) INSPECTION REPORT
Plant : Mill :
MEASUREMENTS COMMENTS
Material level C1 Above* mm
Material Under*
C2 Above* mm
Under*
C3 Above* mm
Under*
C1 Useful length M
Dimensions Useful diameter M
C2 Useful length M
Useful diameter M
C3 Useful length M
Useful diameter M
Height of free space C1 M

C2 M
C3 M
Filling rate C1 % to be calculated
Largest ball Smallest ball
C1 mm mm
C2 mm mm
C3 mm mm
Grinding Pollution from Liners
Charge External elements
Ball classification Good Null Inverse
C1
C2
C3
Liners Type Step
C1 mm
C2 mm
C3 mm
Mill shell inlet Ø M

Intermediate diaphragm 1 & Slot width mm
2
Equipment % plugging %
Parts Ventilation ring Ø M
Permeability %
Intermediate diaphragm 2 & Slot width mm
3
% plugging %
Permeability %
Outlet diaphragm Slot width mm
% plugging %
Permeability %
Coating Coating Balls Liners
84
* Strike out the non applicable mention
85
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
86
BALL & CYLPEB CHARACTERISTICS

BALLS CYLPEBS
Ø Unit mass Developed surface Ø L Unit mass Developed surface
(mm) (g) (m2/t) (mm) (mm) (g) (m2/t)
90 2977 8.55 25 50 191 25.64
85 2508 9.05 25 32 123 28.53
80 2091 9.62 22 28 83 32.47
75 1723 10.26 19 24 53 37.67
70 1401 10.99 16 22 35 43.71
65 1122 11.83 12 15 13 59.83
60 882 12.82
59 839 13.04 25 25 96 30.77
58 797 13.26 22 22 65 34.97
57 756 13.50 19 19 42 40.49
56 717 13.74 16 16 25 48.08
55 679 13.99 12 12 11 64.10
54 643 14.25
53 608 14.51
52 574 14.79
51 542 15.08
50 511 15.38
49 480 15.70
48 452 16.03
47 424 16.37
46 398 16.72
45 372 17.09
44 348 17.48
43 325 17.89
42 303 18.32
41 281 18.76
40 261 19.23
39 242 19.72
38 224 20.24
37 207 20.79
36 191 21.37
35 175 21.98
34 161 22.62
33 147 23.31
32 134 24.04
31 122 24.81
30 110 25.64
29 100 26.53
28 90 27.47
27 80 28.49
26 72 29.59
25 64 30.77
24 56 32.05 Balls
23 50 33.44
22 43 34.97 P = V • 7.8
21 38 36.63 V = 4/3 • PI • R ^ 3
20 33 38.46 S = 4 • PI • R ^2
19 28 40.49 SD = S/P = 3 • 1000 / (R • 7.8)
18 24 42.74
17 20 45.25
16 17 48.08 Cylpebs Legend
15 14 51.28 P = mass
14 11 54.95 P = V • 7.8 V = volume
13 9 59.17 V = PI • D ^ 2/4 • L PI = 3.1416
12 7 64.10 S = PI • D ^ 2/2 + D • L S = surface
11 5 69.93 SD = S/P SD = developed surface
10 4 76.92
87
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
88
TESTING EQUIPMENT FOR MILL BALANCES
TESTING EQUIPMENT TYPE MEASURING RANGE SUPPLIER (1996) PRICE (T.E.)

Mini Air 2 Macro Mesureur
ANEMOMETER SCHILTKNECHT 0.1 - 40 m/s 72-76 rue du Château des Rentiers Casing 5 000 F
Macro probe 80 mm Ø 75013 PARIS
Ref. 648 / 24 Tel (1) 45 83 66 41 Probe : 8 000 F
PDM 208 ±1999 mm CE
PRESSURE GAUGE Neotronics Solomat ± 400 cm CE Neotronics Solomat 4 000 F
EDM Pressures Neotronics Solomat

PRESSURE GAUGE 0.00 to 99.99 mm H2O 16 rue Jacques TATI - B.P. 187
Ref: Zephir - SM 100 to 999.9 mm H2O 91006 Evry Cedex 12 000 F
1000 to 1224 mm H2O Tel.: (1) 60 77 89 90
Air - Neotronics Limited Velocity 1.5 to 141 m/s Fax: (1) 60 77 93 73
For clean gases us to 800°
PITOT TUBE Type S C Neotronics Solomat 1 990 F
Air Flow Developments Length 0.48 m 2 350 F
Length 1.00 m 3 200 F
Length 1.52 m 4 990 F
Length 2.74 m
S.F. 2 l. Length : (2 • 1.5 m) = 2 910 F
PITOT TUBE Strauscheib Tube For gas with high dust Zone artizanale - Ile du Moulin
concentration 07400 Le Teil Fabrication: CLV design
Tel. : 75.52.18.75
Fax : 75 52.25.25
Kurt Neuberger - 4 Bd d’Alsace
GAS PUMP N 010 KN 18 12 l/mm 68300 Village Neuf 1 440 F
Tel. : 89.70.35.00
Fax : 89.69.92.52
Q max. : 6 m3 / h Schlumberger
GAS METER Galus 2000 P max. : 0.5 b ZAC Val de Murigny 700 F
for dry and clean gases BP 227 51061 Reims
Tel. : 26.05.65.72
89
TESTING EQUIPMENT FOR MILL BALANCES
TESTING EQUIPMENT TYPE MEASURING RANGE SUPPLIER (1996) PRICE (T.E.)

For Type K Thermocouple A.I.S. Casing: 1700 F
THERMOCOUPLE Long Standard probe SI 1300 Range 1 = -200° C to +200° C Le Divin 69620 Bagnols
Short Standard probe SI 1300 Range 2 = 200° C to 1370° C Tel.: 74.71.70.61 L SI 1300 : 810 F
Fax: 74.71.77.05 C SI 1300 : 550 F
PROLABO - BP 369
GAS BAG Volume : 10 Litres 75526 Paris Cedex 11 200 F
(gold beater’s skin) Tel.: (1) 49.23.15.00
SILICAGEL For drying test gases Prolabo

Herrmann - Moritz Digital display 0 to 100% Pekly - 5 rue du Théâtre 25 300 F
O2 Oxymeter HM 100 Outlet 0-1V or 0-10V 91884 Massy
ANALYZER Paramagnetic Elec. outlet 4 - 20 mA Tel: (1) 69.53.73.00
Fax: (1) 69.53.73.01
Herrman - Moritz Digital display PEKLY 51 200 F
O2 - CO - CO2 Trigaz 123 PX O2: 0 to 100%
ANALYZER O2 Paramagnetic CO: 0 - 2000 or 0 - 10000 ppm CO Cell Ref. AL75 = 1750 F
CO Electrochemical Cell CO2: 0 - 20 or 0 - 30 or 0 -
CO2 Infrared Detector 100%
SIEMENS Digital display Siemens S.A.
Ultramat 22 CO Dept. instrumentation industrielle
CO - CO2 Infrared transmitter 0 - 5000 ppm (recommended) 39 - 47 Bd Ornano
ANALYZER 93527 Saint Denis Cedex 2 47 910 F
CO2 Tel.: (1) 49.22.38.51
0-5% Fax.: (1) 49.22.30.62
90
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
91
PITOT ANALYSIS Input

PLANT: MILL: Results
PRODUCT: DATE:
MEASUREMENT
POINT:
DYNAMIC PRESSURES CONDUIT CROSS-SECTION 0.79 m2
CONDUIT 25.00 AVERAGE DYN. PRESS. 23.29 mm CE
DIAMETER 1.00 m 22.00 RHO without dust 0.928 kg/m3
LENGTH m 23.00 RHO with dust 1.228 kg/m3
WIDTH m 25.00
25.00
TEMPERATURE 100 °C 20.00
STATIC PRESSURE -150 mm CE
PITOT COEFF. 0.84

VELOCITY 16.21 m/s
3
DUST 300 g/m FLOW 12.73 m3/s
9.18 Nm3/s
GAS COMPOSITION 45824 M3/H
if dry air is not involved 33052 Nm3/H
%H2O 15.00
% dry CO 0.00
% dry CO2 15.00 DUST (t/h) 13.75
% dry O2 8.00 Number of values: 6
The gas composition analysis is done on the H2O %. If H2O > 0 → takes the analysis into account. If H2O = 0 → gas = dry air.
92
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
93
DISTRIBUTION CURVE Page 1

The sieve sizes shall be classified in decreasing order Input
PLANT: PLN DATE: 95 / 5 / 16

MILL: CLINKER PRODUCT TYPE: CPA 52.5 CP2
SEPARATOR: SEPOL LASER TYPE : MALVERN VIVIERS
Mesh % cumulative passing
(µm) Fines Feed Rejects dx P (x) % R/A
1 88.91 99.82 76.93 61.80 fraction
2 76.32 98.64 70.97 52.73 82.4 µm 91.5 0.606
3 65.51 96.45 64.32 43.23 70.7 µm 85.9 0.610
4 56.23 93.02 57.65 33.89 60.7 µm 79.3 0.549
5 48.27 88.26 51.14 25.54 52.1 µm 71.2 0.485
6 41.43 82.30 45.01 18.77 44.7 µm 61.5 0.217
7 35.56 75.47 39.48 13.81 38.4 µm 50.5 0.695
8 30.53 68.25 34.68 10.46 32.9 µm 39.5 0.625
9 26.20 61.11 30.62 8.33 28.3 µm 29.6 0.614
10 22.49 54.60 27.23 7.06 24.3 µm 21.6 0.597
11 19.31 48.72 24.39 6.31 20.8 µm 15.1 0.592
12 16.57 43.46 21.98 5.91 17.9 µm 9.8 0.587
13 14.22 38.78 19.88 5.69 15.4 µm 6.1 0.578
14 12.21 34.59 17.98 5.51 13.2 µm 5.6 0.570
15 10.48 30.80 16.21 5.32 11.3 µm 6.5 0.563
16 9.00 27.34 14.55 5.07 9.7 µm 9.15 0.559
17 7.72 24.15 12.97 4.77 8.3 µm 11.92 0.557
18 6.63 21.21 11.48 4.42 7.2 µm 14.23 0.561
19 5.69 18.52 10.12 4.06 6.1 µm 15.72 0.568
20 4.88 16.09 8.87 3.72 5.3 µm 16.71 0.569
21 4.19 13.96 7.78 3.40 4.5 µm 17.31 0.571
22 3.60 12.14 6.84 3.12 3.9 µm 17.65 0.573
23 3.09 10.63 6.05 2.87 3.3 µm 18.74 0.565
24 2.65 9.39 5.38 2.65 2.9 µm 20.54 0.566
25 2.28 8.36 4.81 2.43 2.5 µm 22.93 0.569
26 1.95 7.48 4.30 2.22 2.1 µm 24.95 0.554
27
28
29
AVERAGE R/A = 0.584
100.00
90.00 Fines
% cumulative passing
80.00 Feed
70.00 Rejects
60.00
50.00
40.00
30.00
20.00
10.00
0.00
1.00 10.00 100.00
Mesh (µm)
94
DISTRIBUTION CURVE Page 2
PLANT: PLN DATE: 95 / 5 / 16

MILL: CLINKER PRODUCT TYPE: CPA 52.5 CP2
SEPARATOR: SEPOL LASER TYPE: MALVERN VIVIERS
FINES CUMULATIVE CIRCUL. CHARGE 141% IMPERFECTION NORMALIZE RAW

D
YIELD 83.3% BY PASS 6.2% 0.38 0.40
ACUITY LIMIT 16 µm d 25 (µm) 28 µm 26 µm
CORRECTED BY PASS 10.6% d 50 (µm) 40 µm 38 µm
NORM. IMPERFECTION 0.38 d 75 (µm) 58 µm 56 µm
99.9
99.8
99.5
95
90
80
70
60
50
40
30
20
10
2
1
0.5
0.2
0.1
1 10 100 1000
Number of points on the left side of the curve (optional):
95
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
96
ROSIN - RAMMLER CURVE

PARTICLE-SIZE DISTRIBUTION
Rosin - Rammler Adjustment
mesh % cumulative % cumulative
µm passing retained
1 1.95 8.87 91.13 98.9
2 2.28 10.34 89.66
3 2.65 11.95 88.05 93.4
4 3.09 13.74 86.26
5 3.60 15.75 84.25 80.8
6 4.19 18.01 81.99
7 4.88 20.55 79.45 63.2
8 5.69 23.40 76.60
9 6.63 26.56 73.44 45.5
% passing
10 7.72 30.06 69.94
11 9.00 33.91 66.09 30.8
12 10.48 38.11 61.89
13 12.21 42.66 57.32 20
14 14.22 47.59 52.41
15 16.57 52.82 47.18 12.7
16 19.31 58.32 41.68
17 22.49 64.03 35.97 7.9
18 26.20 69.92 30.08
19 30.53 75.66 24.34 4.9
20 35.56 81.05 18.95
21 41.43 85.90 14.10 3
22 48.27 90.06 9.94
23 56.23 93.44 6.56 1.8
24 65.61 96.03 3.97
25 76.32 97.87 2.13 1.00 10.00 100.00
26 88.91 99.06 0.94 mesh (µm)
27 103.58 99.72 0.28
28
29
30
Number of usable points 27
ROSIN - RAMMLER STRAIGHT LINE STANDARD MESH RECALCULATION (D90 - D10) /

D50
Using regression line Dimension for x % passing
Calculated between points 1 and 27 mesh % cumulative passing D 10 actual 2.2 µm
2.0 µm 103.6 µm 2 8.8 D10 recalculated 2.3 µm
8.9 % pass 99.7 % pass 4 17.0 D50 actual 15.3 µm
8 31.3 D 50 recalculated 14.6 µm
12 43.3 D 90 actual 48.2 µm
16 53.3 D 90 47.5 µm
recalculated
ROSIN - RAMMLER SLOPE 1.02 24 68.3
32 78.6
LINE EQUATION LnLn (100/R) = 1.0173 Ln(x) + -3.0933 45 88.7 Designation
97
64 95.6 Designation
Correlation coefficient 0.9987 Designation
Designation
98
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
99
RFCS CALCULATION
Plant: Product:
Mill: Date:
Sampling data Input
Sieves used 0.043 Sampling at 0.00 Mill flow: 36.6 T/h

(mm) 0.061 (m) 0.50 C2 power: 421 kW
0.087 1.46 C2 length: 7.67 m
0.103 2.42
0.160 3.38
0.400 4.34
5.30
6.26 Compartment power 11.50 kWh/t
7.67 Metric power 1.50 kWh/t.m
Fineness curves results
% cumulative retained on mesh

Sampling 0.043 0.061 0.087 0.103 0.160 0.400
0.00 m 74.02 56.47 37.69 30.63 22.17 7.20
0.50 m 73.01 54.85 35.46 28.37 20.43 5.71
1.46 m 71.66 53.43 34.00 26.97 19.79 4.12
2.42 m 67.90 49.25 29.20 21.97 15.42 1.99
3.38 m 62.80 43.48 24.11 17.30 10.85 0.75
4.34 m 59.95 40.73 21.38 14.57 8.67 0.41
5.30 m 56.57 37.24 18.22 11.59 5.92 0.18
6.26 m 55.82 35.20 14.90 8.31 3.61 0.08
7.67 m 52.53 32.11 12.80 6.66 2.48 0.06
RFCS 14.0 22.7 42.8 60.1 86.0 199.8
RFCS Curve
LOG RFCS(x) vs LOG x
3
LOG RFCS (x)
2.5
2
1.5
1
0.5
0
-1.4 -1.2 -1.0 -0.8 -0.6 -0.4 -0.2 -0.0
LOG x
Regression line
RFCS 10 2.9
a=
b=
R2 =
1.190
2.845
0.967
LOG RFCS = a • Log
( ) x
1000
+b RFCS 45
RFCS 100
17.5
45.3
100
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
101
MOISTURE MEASUREMENT (PUMPING)
PLANT :
MILL CIRCUIT:
MEASUREMENT POINT:
DATE :
TIME :
Input
TARE (g) FINAL MASS (g)

NO 1 CARTRIDGE 400.0 426.0
NO 2 CARTRIDGE 450.0 451.0
NO 3 CARTRIDGE
FLOW (litres)
INITIAL METER READING 5000
FINAL METER READING 5550
METER TEMPERATURE (°C) 20.0
H2O volume : 6.15%
102
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
103
MOISTURE CALCULATION Program by

PLANT: DATE : Hans Schrama June 92
MEASUREMENT POINT: MILL CIRCUIT Input
Case #1: Given dry and humid temperatures
Results: Relative humidity and dew point
T Dry (°C) 70 H2O Properties
T Humid (°C) 50
T Dry (°F) 158 617.67 deg R crit P, mmH 166818
T Humid (°F) 122 581.67 deg R crit T, R 1165.67
Press, mmHg 760 kg/kg mol
PM 28.97 Dry air molecular weight
Kd 3.22 Dimensionless parameter
Kw 3.24 Dimensionless parameter
Pd 233.54 mm Hg Dry temperature saturated vapor pressure
Pw 92.47 mm Hg Humid temperature saturated vapor pressure
Pm 9.32 mm Hg Portion of vapor pressure due to depression
Pa 83.14 mm Hg Partial vapor pressure
35.6 % Relative humidity
Humidity 0.0764 kg H2O / kg dry air

0.0710 kg H2O / kg humid air
10.94% H2O (humid volume)
Dew Point 577.84 deg R
47.9 deg C
Case #2: Given absolute dry and humid temperatures
Results: Dew point
T Dry (°C) 100
T Dry (°F) 212 617.67 deg R
Humidity 0.0615 kg H2O/kg dry air
Press, mmHg 745
PM 28.97 kg/kg mol
Pa 67.03 mm Hg Partial vapor pressure

9.00% H2O (humid volume)
Dew Point 570.26 deg R
43.7 deg C
104
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
105
ELEVATOR POWER CALCULATION
Input
PLANT:
MILL:
DATE:
Data Calculated value
FLOW t/h 250.80
POWER DRAW WHEN LOADED 24.50 kW
POWER DRAW WHEN RUNNING EMPTY 5.00 kW
HEIGHT BETWEEN AXIS 26.25 m
ELEVATOR EFFICIENCY 0.92
Insert in the “data” column the known values.

The program calculates the sought value using the equation:
9.81 x Flow x Height

Ploaded - Pempty =
3600 x Efficiency
106
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
107
HEAT AND DRYING BALANCES

Make a calculation list but start the calculation only when all the data are in.
Subject: La Malle, Coal Mill - 95/12/13
Input Input Retained values
Grinding or drying mill (G/D) G Grinding mill
Raw mix cement or coal (R/C/CO) CO Coal
Furnace (Y/N) Y With furnace
Heat source No 1 (Y/N) N Without HTS No1
Heat source No 2 (Y/N) N Without HTS No2
Recirculation (Y/N) Y With recirc
Water spray (Y/N) N Without water spray
Listing of data
General
Ambient air temperature 4 4
Ambient air relative humidity 80 80
% wall losses 8 8
Mill outlet gas temperature 80 80
% air inleakage in mill outlet gas flow 14.2 14.2
Coal
% of trapped total dust 0 0
Milloutlet dry flow 19 19
Mill inlet temperature 12 12
Mill outlet temperature 56 56
% mill inlet water 9.4 9.4
% mill outlet water 0 0
Grindability (KWH/T) 42.9 42.9
% grinding energy transformed in cal 95 95
% volatile materials 25
Move to line 37
You can enter the detailed composition or indicate the kind of heat source
Air, fuel kiln gas (A/F/C/D)
Coal kiln gas or detail O2
N2 99
H2O
CO2
SO2
3
Flow (Nm /H)
Temperature
Source 1 dust - flow (kg / h dry)
- temperature
Move to line 53
You can enter the detailed composition or indicate the kind of heat source
Air, fuel kiln gas (A/F/C/D)
Coal kiln gas or detail O2
N2 99
H2O
CO2
SO2
3
Flow (Nm /H)
Temperature
Source 2 dust - flow (kg / h dry)
- temperature
Furnace
You can enter the detailed composition or simply indicate the kind of fuel
Normal NO2 LSC, FOD, Detail or gas (N/L/F/D/G) G Gas
IHC 11856 Cal/g 11856
Specific heat 99 0.3
Caution: % by mass H 24.6 24.6
C 74.9 74.9
S 0.0
O 0.0
N 0.5 0.5
H2O 0.0
Fuel flow 141.3 141
Furnace inlet fuel temperature 15 15
% furnace air excess 1013 1013
Aeraulic ratio
3
Nm of gas per kg of dry material 2.82 2.82
% gas flow for a 40% material flow 70 70
108
HEAT BALANCE FOR A COAL MILL WITH FURNACE AND RECIRCULATION

Page 1 (results)
La Malle - Coal Mill - 95 / 12 / 13
General
Ambient air relative humidity 80% Ambient air temperature 4° C
Ambient air moisture (for 1 Nm3) 0.00620 Nm3 Ambient air N2 0.786 Nm3
Ambient air O2 (for 1 Nm3) 0.208 Nm3 Mass of 1 Nm3 of humid air 1.290 kg
% wall losses 8% Basic aeraulic ratio 2.8237 Nm3 / kg
% air inleakage in mill outlet gas flow 14.242 % Mill outlet gas temperature 80° C
Coal
Inlet dry dust flow 0.00 t/h Trapped dry dust flow 0.00 t/h
% mill inlet water 9.4% % mill outlet water 0%
Inlet flow 20.97 t/h Mill outlet dry flow 19.00 t/h
Inlet water 1.97 t/h Residual water 0.00 t/h
Vaporization water 1.97 t/h Mill outlet humid flow 19.00 t/h
Inlet temperature 12° C Outlet temperature 56° C
Coal grindability 42.9 kwh/t % of electrical energy transformed into heat 95%
Furnace Fuel : gas
Fuel flow 141 Kg/h Furnace inlet temperature 15° C
Fuel ihc 11,856 kcal/kg Furnace excess air 1,013%
Fuel consuming capacity 13.30 Nm3/kg Combustion neutral smokes 14.74 Nm3/kg
Neutral smokes 2,083 Nm3/h
COMPOSITION: N2 10.51 Nm3 H2O 2.84 Nm3
CO2 1.40 Nm3 SO2 Nm3
Total smokes 21,206 Nm3/h
COMPOSITION : smoke producing capacity 150.08 Nm3 O2 28.12 Nm3
N2 116.88 Nm3 (per kg of fuel) H2O 3.68 Nm3
CO2 1.40 Nm3 SO2 Nm3
No 1 Heat Source # N/A
Flow Nm3/h Temperature °C
% O2 (dry) % O2 % % N2 %
% CO2 (dry) % CO2 % % SO2 %
% H2O % Dew point °C
No 2 Heat Source # N/A
Flow Nm3/h Temperature °C
% O2 (dry) % O2 % % N2 %
% CO2 (dry) % CO2 % % SO2 %
% H2O % Dew point °C
109
HEAT BALANCE FOR A COAL MILL WITH FURNACE AND RECIRCULATION

Page 2 (results)
Mill Inlet
Mill inlet temperature 165° C Temperature before recirculation 256° C
Mill Outlet
Outlet total gas flow (humid) 53,650 Nm3/h Recirculated gas flow (humid) 22,350 Nm3/h
Circuit Outlet
Outlet total gas flow (humid) 31,300 Nm3/h Effective aeraulic ratio 2.82 Nm3/kg
Max. H2O concentration (w/o condensation) 0.37 kg/Nm3 H2O effective concentration 0.078 kf/Nm3
Condensation ratio 20.75% Dew point 45.6° C
% outlet N2 71.95% % outlet CO2 0.63% 0.70% dry
% outlet water 9.65% % outlet SO2 0.00%
% outlet dry gas O2 19.66% % outlet humid gas O2 17.77% 19.66% dry
Items Input flows °C kcal/h Items Output flows °C kcal/h

No 1 heat source (Nm3/h) 0 0 0 Vaporization (Kg/h) 1971 - 1174896
Source 1 dust (Kg/h) 0 0 0 Exhaust dust (Kg/h) 0 0 0
No2 heat source (Nm3/h) 0 0 0 Coal (Kg/h) 19,000 56 291047
Source 2 dust (Kg/h) 0 0 0 Trapped dust 0 0 0
Furnace (Kg/h) 141 - 1701922 Residual water 0 56 0
Air inleakage (NM3/h) 7641 4 8785 Dry gases (kg/h) 28280 80 686744
Coal (kg/h) 19000 12 58956 Water vapor (Nm3/h) 3020 80 86693
Coal moisture (t/h) 1.971 12 23656 Wall losses - - 196746
Sprayed water 0 4 0
Mill motor _______ - - 665937
Input total 2459323 Output total 2436125
Theoretical drying efficiency (total inlet calories / kg of evaporation water) 1248 kcal/kg
useful drying efficiency (pure inlet calories / kg of evaporation water) 863 kcal/kg ∆ E - S/E = 0.94%
110
Heat balance of a coal mill with furnace and recirculation

Page 3 (results)
58%
Circuit outlet
Flow 31300 Nm3/h
Flow 8.7 Nm3/s
Flow 11.2 m3/s
100% Filter Temperature 80 °C
or cyclones % O2 (dry) 19.7 %
or both H2O amount 0.078 kg/Nm3
% H2O by volume 9.6 %
Cond. ratio 21 %
Mill outlet gas Dew point 46 °C
Flow 53650 Nm3/h Circuit outlet coal
Flow 14.9 Nm3/s Coal flow 19.0 t/h dry 42% Recirculation
Flow 19.3 m3/s Dust flow 0.0 t/h dry Flow 22350 Nm3/h
Temperature 80 °C Total flow 19.0 t/h dry Flow 6.2 Nm3/s
Aeraulic ratio 2.82 Nm3/kg Total flow 19.0 t/h humid Flow 8.0 m3/s
Temperature 56° C Temperature 8.0 °C
% H2O 0%
Coal No 1 Heat Source: none
Flow 21.0 t/h Exhaust dust flow 0.0 t/h dry Flow 0 Nm3/h
% H2O 9.4 % Flow Nm3/s
Dust 0.0 t/h Water spray Flow m3/s
Flow 0 l/h Temperature °C
Dew point °C
% O2 (dry) %
Coal
Mill Furnace : Gas
Comb. flow 141 Kg/h
Air excess 1013 %
Gas flow 21206 Nm3/h
Mill Gas flow 5.9 Nm3/s
Power draw 815 kw Mill Inlet Gas flow 11.4 m3/s
% wall losses 8 % Flow 43556 Nm3/h Temperature 256 °C
Flow 12.1 Nm3/s
Flow 19.4 m3/s No 2 Heat Source: none
Air inleakage Temperature 165 °C Flow 0 Nm3/h
Percentage 14 % outlets Flow Nm3/s
Percentage 18 % inlets Before Recirculation Flow m3/s
Flow 7641 Nm3/h Flow 21206 Nm3/h Temperature °C
Relative humidity 80 % Flow 5.9 Nm3/s Dew point °C
Temperature 4 °C Flow 11.4 m3/s % O2 (dry) %
Temperature 256 °C
Origin of Exhaust Gas Water

Ambient Air 38 kg/h → 47 Nm3/h
Furnace 417 kg/h → 519 Nm3/h
111
No 1 Heat Source 0 kg/h → 0 Nm3/h
No 2 Heat Source 0 kg/h → 0 Nm3/h
Material 1971 kg/h → 2453 Nm3/h
Spray 0 kg/h → 0 Nm3/h
Total 2427 kg/h → 3020 Nm3/h
112
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
113
GRINDING CHARGE
Plant
Mill
Charge 1993 / 94 Date
Rotating speed 20.0 tr/min
Compartment 1 Useful length 4.90 m Compartment 2 Useful length 6.04 m
Useful diameter 2.52 m Useful diameter 2.48 m
Apparent unit mass C1 4.5 t/m3 Usual value for a typical

charge
C2 4.7 t/m3 Usual value for a typical
charge
Input
C1 Charge
Ball Ø Tonnage % by mass
% by mass vs diameter
90.0 mm 11.50 t 32.4 %
80.0 mm 11.00 t 31.0 % 35.0 %
70.0 mm 8.00 t 22.5 % 30.0 %
60.0 mm 5.00 t 14.1 % 25.0 %
20.0 %
35.50 t 15.0 %
10.0 %
Filling rate 32.3 % 5.0 %
Average mass per ball 1.732 kg 0.0 %
Number of balls 20,502 90.0 mm 80.0 mm 70.0 mm 60.0 mm
Developed surface 10.03 m2/t
C2 Charge
Ball Ø Tonnage % by mass
50.0 mm 5.90 t 14.0 % % by mass vs diameter
40.0 mm 6.50 t 15.5 %
30.0 mm 6.50 t 15.5 % 60.0 %
25.0 mm 23.10 t 55.0 % 50.0 %
40.0 %
30.0 %
42.00 t
20.0 %
Filling rate 30.6 % 10.0 %
Average mass per ball 92 g 0.0 %
Number of balls 457,363 50.0 mm 40.0 mm 30.0 mm 25.0 mm
Developed surface 26.03 m2/t
Developed surface at end of charge 30.77 m2/t
Mill Power (Slegten)
C1 381 kW
C2 453 kW Perfect classification distribution
Total 834 kW axle mechanical 50.0 %
power
40.0 %
0.93
Efficiency 897 kW motor electrical 30.0 %
power 20.0 %
10.0 %
0.0 %
1 2 3 4 5
Powers for each compartment are calculated on the basis of the characteristics and filling rate of the compartment and the
rotating speed of the mill. Ref. formulae in grinding section.
114
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
115
FIRST COMPARTMENT CHARGE CALCULATION
Plant
Mill Input
Date
Bond Formula
Standard values
Feed grading, 20% retained 15,000 µm 18,000 µm 20,000 µm Clinker Raw Coal
Bond work index (W) 13.9 kWh/t 10.6 kWh/t 11.4 kWh/t Bond index 13.49 10.57 11.37
Useful mill diameter 3.65 m 3.65 m 3.65 m
Rotating speed 15.8 tr/min 15.8 tr/min 15.8 tr/min Standard values
% of critical speed 71.4 % 71.4 % 71.4 % Clinker Raw Coal
Material unit mass 3.09 t/m3 2.67 t/m3 1.63 t/m3 Unit mass 3.09 2.67 1.63
Largest calculated ball 89.8 mm 85.6 mm 78.4 mm

Largest selected ball 90 mm 90 mm 80 mm
Bond Formula
Useful length of first compartment 4.25 m 4.25 m 4.25 m

Selected filling rate 32 % 31.5 % 31.5 %
Charge apparent density (4.5) 4.5 t/m3 4.5 t/m3 4.5 t/m3
Charge mass 63.04 t 63.04 t 63.04 t
Mass percentage of the

largest ball size 20 % 20 % 20 %
Number of corresponding balls 11,529 balls 11,529 balls 18,052 balls
Charge distribution in 4 sizes Ø t % Ø t % Ø t %
90 12.61 20% 90 12.61 20% 80 12.61 20%

80 24.11 38% 80 24.11 38% 70 25.29 40%
70 16.15 26% 70 16.15 26% 60 15.92 25%
60 10.17 16% 60 10.17 16% 50 9.22 15%
116
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
117
SECOND COMPARTMENT CHARGE CALCULATION

SLEGTEN DISTRIBUTION
Input Plant Val D’Azergues

Mill BK2
Date 94/04/25
Density = 7.8 t/m3
C2 useful length 7.75 C1 charge (T) 56.0

C2 Useful diameter 3.60 60 mm balls (T) 9.0
Filling rate 33 Number of 60 mm balls 10,157
Ball charge 125.0
Available sizes % T Number

50 mm 4.1 5.2 10,157
40 mm 2.1 2.7 10,157
30 mm 12.0 15.1 136,519
25 mm 35.0 43.7 685,401
20 mm 46.7 58.3 1,785,055
100% 125.0 2,627,289
Average mass / ball (g) 47.6
Developed surface (m2/t) 32.86
Developed surface at
end of compartment (m2/t) 35.17
(Balls < 25 mm)
118
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
119
MILL FILLING RATE
PLANT:
MILL:
DATE:
INPUT
COMPARTMENT 1
Useful diameter (m) 3.21

Height of free space (m) 2.10
Filling rate (%) 30.7
COMPARTMENT 2

COMPARTMENT 3

120
MILL FILLING RATE
0.90
0.85 H
0.80
0.75
H/D
0.70
0.65
0.60
0.55
0.50
0 5 10 15 20 25 30 35 40 45 50
Filling rate (%)
121
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
122
SMOKE CALCULATIONS
Fuel No2 Fuel 2 Fuel 3
Carbon 85.90 % Neutral air 10.55546 Nm3/Kg of fuel Analysis of neutral smokes
3
Hydrogen 10.50 % Dry neutral S. 9.97154 Nm /Kg of fuel of fuel alone
3
Sulfur 3.00 % Humid neutral S. 11.14827 Nm /Kg of fuel % Dry Humid
Oxygen 0.36 % CO2 16.09 % 14.39 %
3
Nitrogen 0.24 % Tot. dry neut. S. 4,986 Nm /h SO2 0.21 % 0.19 %
Water Excess air 134.23 % N2 83.70 % 74.86 %
Ashes Total dry S. 11,678 Nm3/h H2O 0.00 % 10.56 %
3
Analysis 100 % Total humid S. 12,423 Nm /h Total 100.00 % 100.00 %
total
Fuel Q 0.50 T/H
% fuel 100.00 % 0.00 % 0.00 %
O2, Outlet 12.00 %

Input
Water, Outlet 6.00 %
123
LIST OF APPENDICES
Distribution curve
Rosin - Rammler
RFCS
Elevator flow
Filling rate
Smoke calculation
Gas characteristics
124
GAS CHARACTERISTICS
Gas Source Content Fuel consuming Total Total Density Heat capacity
La Malle 95/12 - Type “H” gas in capacity carbonic gas water vapor with respect superior inferior
to air SHC in kWh/m3 IHC in kWh/m3
Gas fuel composition m3/m3 Vair m3/m3 VCO2 m3/m3 VH2O m3/m3
Type of gas % A B A•B C A•C D A•D E A E F A•F G A•G
Hydrogen H2 0.000 2.36 0.000 0 0.000 1 0.000 0.0695 0.000 3.52 0.000 2.96 0.000
Carbon oxide CO 0.000 2.38 0.000 1 0.000 0 0.000 0.968 0.000 3.51 0.000 3.51 0.000
Methane CH4 97.30 0.973 9.54 9.282 1 0.973 2 1.946 0.555 0.540 11.08 10.781 9.97 9.701
Ethylene C2H4 0.000 14.4 0.000 2 0.000 2 0.000 0.976 0.000 17.65 0.000 16.53 0.000
Ethane C2H6 2.10 0.021 16.84 0.354 2 0.042 3 0.063 1.048 0.022 19.58 0.411 17.88 0.375
Propylene C3H6 0.000 21.84 0.000 3 0.000 3 0.000 1.480 0.000 26.06 0.000 24.34 0.000
Propane C3H8 0.20 0.002 24.37 0.049 3 0.006 4 0.008 1.557 0.003 28.22 0.056 25.94 0.052
Butylene C4H8 0.000 29.64 0.000 4 0.000 4 0.000 2.007 0.000 34.99 0.000 32.68 0.000
Butane C4H10 0.10 0.001 32.41 0.032 4 0.004 5 0.005 2.096 0.002 37.41 0.037 34.49 0.034
Pentane C5H12 0.000 40.87 0.000 5 0.000 6 0.000 2.671 0.000 47.11 0.000 43.52 0.000
Carbon dioxide CO2 0.000 0 0.000 1 0.000 0 0.000 1.529 0.000 0 0.000 0 0.000
Nitrogen N2 0.30 0.003 0 0.000 0 0.000 0 0.000 0.968 0.003 0 0.000 0 0.000
Oxygen O2 0.000 -4.77 0.000 0 0.000 0 0.000 1.105 0.000 0 0.000 0 0.000
100.00 1.000 9.717 1.025 2.022 0.570 11.286 10.163
Input
Smoke capacity 0.79 Vair 7.677 m3/m3 Calculated heat capacity Vent mass
+ gas nitrogen 0.003 m3/m3 SHC 9706 kcal/Nm3 0.737 kg/Nm3
+ VCO2 1.025 m3/m3 IHC 8740 kcal/Nm3 Density / Air
Dry = V ds 8.70 m3/m3 IHC 11856 kcal/kg 0.570
+ VH2O 2.022 m3/m3 Proposed Heat capacity
Humid = V hs 10.73 m3/m3 SHC kcal/m3 at 15°C Note: m3/m3
Equals kcal/Nm3 is equivalent to
Smoke analysis Dry CO2 11.78 % Nm3/Nm3
(% volume) N2 88.22 %
Humid CO2 9.56 % Elementary weighted analysis
N2 71.59 % C H N O
H2O 18.85 % 74.44 24.47 0.51 0.00

Audit of Ball Mill Circuits PDF

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Audit of Ball Mill Circuits PDF

Hochgeladen von

Copyright:

Verfügbare Formate

Viviers Center

THE AUDIT OF BALL MILL CIRCUITS

II- Finishing mill follow-up p2

III- Operating problems and their analyses p3

IV- Internal mill inspection p4

1- Internal inspection objectives p4

2- Material analysis methods p5

3- Equipment analysis methods p7

2- Method of analysis - Distribution curve p 29

3- Distribution curve calculation p 29

VI- Material balance p 46

3- Junction calculation method p 47

4- Selection of sampling locations p 49

2- Selection of measuring locations p 54

3- Air flow measurements p 55

VIII- Drying / Heat balance p 67

2- Drying and heat balances p 67

IX- Energy balance p 72

List of computer analysis programs p 77

Various types of grinding will be covered:

A typical finishing mill generally consists of: grinding mill

All the analyses must be conducted on stable operation.

II - FINISHING MILL FOLLOW-UP

☞ A diagram of the finishing mill - material and gas circuits

☞ Equipment characteristics (type, make, power, dimensions, typical outputs, etc.)

☞ Grinding charges (charge classification, reloading sequences and dates)

☞ Background of process modifications (liner replacements, separator modifications)

☞ Accounts of installation problems (output, power, etc.)

pressures, composition, fineness, etc.)

III - OPERATING PROBLEMS AND THEIR ANALYSES

Causes Main effects produced Analyses to be given priority

IV - INTERNAL GRINDING MILL INSPECTION

IV - 1 - Internal Inspection Objectives

This can be done through:

- observations and material sampling

- observations of the parts: liners, grinding charge, ventilation ring, etc.

The results can be recorded in a typical form (see appendix).

Safety instructions must be kept in mind before making any move.

For example: - General view of each compartment in both directions

IV - 2 - Material Analysis Methods

☞ Evaluate the material level of each compartment

Suitable material level

quantify it (no grains, a few grains, large accumulation).

- Determination of the sampling locations (see diagram hereafter)

The sieve sizes depend on what is available.

IV - 3 - Equipment analysis methods

IV - 3 - 1 - Typical dimensions for each compartment

☞ Measure the useful diameter and length.

The useful length means beyond inlet or outlet heads.

☞ Measure the rotating speed of the mill

☞ Check the V/Vc ratio

Usually mills rotate at between 70 and 75% of the critical speed.

IV - 3 - 2 - Liners for each compartment

Lifting liners Combined lifting and classifying liners

☞ Take note of broken, tilted plates

☞ Note the wear on the plates particularly scratches (specially in compartment 1)

IV - 3 - 3 - Diaphragms and outlet or inlet heads

Mill shell length

Mill shell diameter

Mill shell inlet turns

☞ Note how the material is fed (Toboggan, ladder)

Toboggan at the feed end Ladder at the feed end

☞ Take note of broken or tilted plates or both and wear conditions