RAW GRINDING BALL MILL - CONTROL LOOPS V0.
0 DATA TO BE FILLED BY PLANTS
Controlled Parameter
Total mill feed (Fresh feed + separator
rejects) or elevator power
Separator Gas Flow
Mill Outlet Gas Temperature
Mill Inlet static Pressure
Fineness Final Product
Raw Meal Chemistry
Hot Gas Generator Outlet Gas
Temperature
Actuator
Fresh Feed Weigh feeders
Raw Mill fan Variable Speed Drive or
adjustable Damper
Inlet damper, bypass damper, second
Adequate drying of raw material and to
compartment water injection or Hot
protect mill bearing and separator
gas generator damper/fan speed
Recirculation Damper
Separator Variable Speed Drive
Proportions of Raw Mill Feed and
corrective material
Fuel Amount
Target
Optimized production and power
consumption
Consistent particle size distribution
Optimization of pressure load on fan
Constant product fineness
Consistent quality results
To maintain the target HAG
Control Loop
Control Loop in
Comments Available in PCS Reason for run in Manual Mode Comments [if any]
Auto/Manual
(Y/N)
To provide constant material flow through the mill, target mill throughput is given
by operator in t/h
Constant gas flow through the separator ensures constant lift of material and
separator performance constant, gas flow measurement by venturi before mill fan,
pressure loss across the mill cyclones can also be used.
Excessively high temperatures affect bearings of mill & separator and
performance of a downstream electro-static precipitator (if fitted). Outlet
temperature should be controlled by hot gas/ recycle gas flow.
Air flow through the separator must be maintained constant to achieve constant
product fineness at the same speed
QMC can be used to control the proportions of corrective material according to
quality results
Outlet gas temperature is automatically controlled by controlling the fuel flow rate.
 RAW GRINDING BALL MILL - ESSENTIAL PROCESS INTERLOCKS V0.0 DATA TO BE FILLED BY PLANT
Interlock Available in Value of Start Value of Stop Values of Alarm Sensor Operating Range Sensor Operating Existing Delay for Stop Interlock Active
Process Group Source of condition Start Condition Stop Condition Delay for stop [seconds]* Comments Reason for Bypass Comments [if any]
PCS (Y/N) Condition Condition Limits Min Value Range Max Value [Seconds] /Bypass
Raw Meal Feed Bin Level <H > HH 3 Avoid overfilling
Corrective Material 1 Feed Bin Level <H > HH 3 Avoid overfilling
Corrective Material 2 Feed Bin Level <H > HH 3 Avoid overfilling
Raw Meal Feed Bin digital Level Sensor Not activated Activated 3 Avoid overfilling
Hoppers Feeding
Corrective Material 1 Feed Bin digital Level Sensor Not activated Activated 3 Avoid overfilling

Corrective Material 2 Feed Bin digital Level Sensor Not activated Activated 3 Avoid overfilling

Close damper for separator and mill bearing

Mill Inlet Damper Raw Mill Outlet Gas Temperature > HH 5*60
protection,
Raw Mill Outlet Gas Temperature >L N/A Mill must be heated up properly before giving feed
Raw Mill Sound Level < LL 3 Avoid overfilling of the mill.
Raw Mill Feed Raw Mill Power < LL 3 Avoid overfilling of the mill.
Homo Silo Level > HH 3 Avoid overfilling of homo silo
Hopper Level >L <LL 3
Elevator boot level <H > HH 3
Weigh Feeders OFF 5*60 Avoid empty running of mill and damage to liners
5% Deviation in weigh feeders. To avoid quality
Weigh Feeder's Deviation Deviation 5*60 deviations and empty run of mill. Need to to be set in
weigh feeder controller
Avoid overfilling of mill 1st chamber. (Raw mill main
Raw Mill Main Drive Mill Outlet Elevator power <H >HH 3
drive stops mill feeding stop)
Kiln Fan Outlet Pressure >HH 60 >10 mbar
Stopped or Minimum
Kiln ID Fan 3
Speed
Kiln ID fan Damper Closed 3
Kiln Filter Fan OFF 3
Raw Mill Outlet Gas Temperature >H <H 3 Open damper for separator protection
Inlet Fresh Air Damper
Raw Mill Inlet Gas Temperature >H <H 3 Open damper for protecting the mill bearing

Mill Filter Hopper Level Sensor Not activated Activated 5*60 Trip Mill Filter Fan. If the mill has its own filter

Mill Filter & Fan (Normally with Mill Filter DP/Filter Outlet Pressure >HH 3 Trip Mill Filter Fan. If the mill has its own filter
Pyro system)

Mill filter outlet pressure >HH 3 Trip Mill Filter Fan. If the mill has its own filter

Mill Second Compartment Water Mill feed ON OFF 3 Enabled

Spraying Mill Outlet Gas Temperature >L <H 3 Temperature Deadband to be fixed by plant
Silo Selection for Product ON 3 Ensure correct silo is selected
Raw Meal Transport/Others
Homo Silo Level > HH 3 Avoid overfilling of homo silo
Hot Gas Generator Outlet Gas Temperature <H > HH 3 For protecting the mill bearing and separator
Raw Mill Outlet Gas Temperature <H > HH 3
Hot Gas Generator Control Unit Raw Mill Inlet Gas Temperature <H > HH 3
Hot Gas Generator Outlet pressure Negative Positive 3 To avoid HGG backfiring

*Delay for stop:- 3 seconds is proposed in order to avoid stoppage due to signal perturbation (can be increased/reduced according to site conditions)
In general, delays can be adjusted according to site conditions/circuit configuration/OEM recommendation.

Some limit values mentioned in comments are for ultimate safety. Operational limits needs to be
Note:-
set based on supplier/OEM recommendation or circuit configuration.