WEL COME

TO
FAUJI
CEMENT
 Ball Mill
Vs
Vertical Roller Mill
 Preamble
 To educate the participant about the suitable
grinding units in cement industry.
 To create a discussion forum and healthy
environment for sharing knowledge.
 To provide a plate forum for the selection of
grinding technology for future.
 Introduction
 Cement manufacturing is highly energy
intensive consuming process. It consumes
approximately 3,100 ~ 3,400 MJ of fuel and
80~120 kwh of electricity to produce a ton of
cement.
 Electricity is a major cost factor in cement
manufacturing and grinding process consume
38% of electricity in cement plant.
 Grinding Technologies

 There are two basic options for cement

grinding
 Ball Mill Grinding
 Vertical Roller Mill Grinding
 Ball Mill
 Ball mill is better option for cement grinding
due to its simplicity and proven reliability.
 It remains predominant today, representing
more than 80% of all cement mills in operation
globally.
 We will favour Ball mill over Vertical Roller Mill
for cement grinding due to the following.
 Merits Of Ball Mill

 Investment Cost
 As per FLSmidth, Ball mill price is 35% less than
Vertical Roller Mill.
 26% less erection price than Vertical Roller Mill.
 Civil work price is 27% higher than Vertical Roller
Mill.
 Resultantly, price of Ball Mill comparing all the cost
is 30% less than Vertical Roller Mill.
 Merits Of Ball Mill
 Process/Operational Superiority:
 Due to simplicity, it has easy operation than
Vertical Roller Mill.
 Ball Mill has higher Cement finess range when
compare with Vertical Roller Mill(~6000 cm2/gm).
 Uniform partical size distribution (residue) which is
not affected by the variation in clinker size.
 Safe operation than Vertical Roller Mill when it
comes to the metallic pieces in the feed.
 Merits Of Ball Mill
 Process/Operational Superiority:
 During operation, hot air requirement is lower as
compare to the Vertical Roller Mill.
 It is far more flexible than Vertical roller Mills
considering feed size.
 Design and operation of Ball Mill is suitable for
Blended Cement production.
 There is no such problem of reject clinker in Ball
Mill which usually occurs in Vertical Roller Mill.
 Merits Of Ball Mill
 Maintenance/Mechanical Supremacy:
 Ball Mill VRM
Investment Cost [%] 100 130
Annual plant availability 97-99 88-90
[%]
Operating 100 107
Cost(energy/maintenance)
[%]
Spares holding cost [%] 100 115-125
Cement quality/pricing General May require
acceptance discounting for more
advanced user
 Ball Mill VRM
Investment Cost [%] 100 130
Annual plant availability 97-99 88-90
[%]
Operating 100 107
Cost(energy/maintenance)
[%]
Spares holding cost [%] 100 115-125
Cement quality/pricing General May require
acceptance discounting for more
advanced user
 Christian Pfeiffer in CPB-Seminar held on
November 2015 compared two grinding
options according to overall cost.
 Case A is two grinding unit consisting of ball
mill dia 4.6mx14.25m with QDK220-Z
seperator and cyclone discharge.
 Case B is 1xgrinding unit consit of vertical
mill V-MILL 63/4 with DSM 800-Z seperator
and filter discharge.
System Ball Mill VRM
Circuit description 2x Grinding unit 1x Grinding unit
consisting of ball mill consisting of a vertical
Ø4.6m x 14.25m with mill V-MILL 63/4 with
QDK220-Z separator DSM 800-Z separator
and cyclone discharge and filter discharge

Maintenance Cost:-
Production(6400h/a) 1728000 1728000
Material specific value 0.20 € 0.70€
€/t
Personal specific value 0.40 € 0.55 €
€/t
Maintenance cost €/a 1.036.800 € 2.160.000 €

Savings €/a -1.123.200 € -€

System Ball Mill VRM
Circuit description 2x Grinding unit 1x Grinding unit
consisting of ball mill consisting of a vertical
Ø4.6m x 14.25m with mill V-MILL 63/4 with
QDK220-Z separator DSM 800-Z separator
and cyclone discharge and filter discharge

Annual operational 4.332.800 € 4.838.400 €

Cost
Savings €/a -505.600 € -€

Total Circuit 14.000.000 € 18.000.000 €

investment
Plant Availability > 95 % 75%
based on long term
experience
 Improving grinding energy conversion with
activator lining.
 Diaphragm replacement
 Mill internals upgrade
 Separator upgrade
 The rolled-steel slotted plates free from
peening assure proper particle size control
into the 2nd compartment throughout useful
life.
 Large central opening and free slot area
assure maximum ventilation.
The END