Grinding with Ball Mill Systems

Mill Ventilation

Heating & Cooling - Possibilities

Cooling in Separator

Mill Ventilation

Heating

HGRS

Cement
Coolers

Water
Injection
Tikaria_Mill
Workshop

2
SEPT-07

Heating and Cooling Units

Mill Ventilation
Water Injection
Heating

HGRS

Tikaria_Mill
Workshop

3
SEPT-07

Mill Ventilation - Objectives

Avoid the consequences of too high grinding

temperatures inside the mill (115 130 [C]):

HGRS

Material coating on balls and liners resulting in a

performance loss of 5 10 [%]
Cement false setting gypsum dehydration
Lump formation in the silos

Tikaria_Mill
Workshop

4
SEPT-07

Mill Ventilation - Guidelines

False air

Filter dimensioned for 1.5 [m/s]

airspeed above the ball charge

Optimum mill ventilation is a
compromise between :

Fan

Material level in the first chamber

Mill outlet temperature
Filter dew point (T >25 30 [C])
Product fineness at the filter

Mill fresh air

False air
False air reduces the cooling

capacity of the mill tube

HGRS

Tikaria_Mill
Workshop

5
SEPT-07

Additional ventilation cooling possibilities

False air

Separator fresh air

Fan

Clinker

Mill fresh air

False air

Water
HGRS

Tikaria_Mill
Workshop

Cooler
6
SEPT-07

Separator fresh air

Separator fresh air

A single pass separator with 0.7 [m3/kg cement] can cool down

the cement at the mill outlet 30 40 [C].

The mill tube is cooled down through the lower temperature

separator rejects

A cyclone air separator only achieves marginal cooling of the

cement (5 10 [C])

HGRS

Tikaria_Mill
Workshop

7
SEPT-07

Heating and Cooling - Units

Mill Ventilation
Water Injection
Heating

HGRS

Tikaria_Mill
Workshop

8
SEPT-07

Water injection - Guidelines

1 [m3/h] water = 15000 30000 [m3/h] air in heat dissipation
Water acts like a grinding aid (mill capacity increase)
Water increases the air dew point (watch out starts & stops) must

maintain air temperature 25 to 30 oC higher than dew point in filter

Not more than 1.0 1.5 [%] water injection on total mill feed basis

Water
HGRS

Tikaria_Mill
Workshop

9
SEPT-07

Water injection - Systems

Water in 1st chamber only if mill feed > 100 [C] and oriented towards

the ball charge

If water is required in both chambers: 1/3 in the 1st chamber & 2/3 in

the 2nd chamber, starting in 2nd

HGRS

Tikaria_Mill
Workshop

10
SEPT-07

Water injection - Devices

HGRS

Tikaria_Mill
Workshop

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SEPT-07

Standard Installation

HGRS

Tikaria_Mill
Workshop

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SEPT-07

Water injection Control scheme

HGRS

Tikaria_Mill
Workshop

13
SEPT-07

Heating and Cooling - Units

Mill Ventilation
Water Injection
Heating

HGRS

Tikaria_Mill
Workshop

14
SEPT-07

Fresh feed moisture and mill performance

[t/h] dry

Clinker temperature &

proportion

Hot gas generator

maximum capacity

100

90

[%] H2O in fresh feed

HGRS

Tikaria_Mill
Workshop

15
SEPT-07

Dying wet components without hot gas

+/-

+/-

> 90 - 95 [C]

+
HGRS

Tikaria_Mill
Workshop

16
SEPT-07

Drying wet components with hot gas

+/-

+/-

+
> 90 - 95 [C]

+
HGRS

Tikaria_Mill
Workshop

17
SEPT-07

Drying wet components with hot gas

False air

Hot gas
+

Water steam
False air

Fan gas

= Fan gas

False air

Water
steam

Hot gas
False air

HGRS

Tikaria_Mill
Workshop

18
SEPT-07

Hot gas generator

Fuel type
Nozzle adapted to the

operating range
Control
Hot gas generator type

(start/stop sequences)

HGRS

Tikaria_Mill
Workshop

19
SEPT-07

Drying wet components in a drying chamber

Parameters to play with in a drying chamber:

HGRS

Gas flow path

Material trajectory
Material retention time

Tikaria_Mill
Workshop

20
SEPT-07