Ball Mill Checking [Compatibility Mode]

“In the name of Allah, the Beneficent, the Merciful”

Mill check up

Slegten grinding course

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Mill check up Preparation of the visit 1. mill must be running steadily (4h) 2. mill must be crash stopped 3. ask for the coarsest cement to be produced (generally highest mill output)

Equipment to foresee Circuit : thermometer / anemometer plastic bags Cpt 1 : buckets of 5 to 10 L / scoop / light Cpt 2 : buckets of 1 L / plastic bags / sieve, scoop Slegten grinding course

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Mill check up Check up Procedure 1. Technical data sheet 2. 2 to 3 hours survey when mill steady 3. Parameters are collected every hour 4. Samples are collected every hour and before crash stop. The installation is visited at work. 5. Mill must be crash stopped 6. Both compartments are visited and examined 7. Samples are collected in the mill 8. Separator visit Slegten grinding course

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Survey before crash stop

Technical Data Sheet Flow sheet Ball charge history Dailyproduction time Sheet history Auxiliary capacities Control systems (if any)

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Survey before crash stop Main parameters

C PJ 35

C PJ 45

3 0 tp h ( 2 8 .9 tp h )

( 2 7 .0 9 tp h )

61% 6% 33%

77 % 6 % 17 %

20 - 24 % R 40µ

15 - 20 % R 40µ

60 A m p ( 710 kW ) 2 3 .6 k W h /t ( 2 4 .5 k W h /t)

60 Am p ( 710 kW ) (2 6 .2 k W h /t)

SEPARATOR T ype F re s h a ir d a m p e r A ir f lo w A ir r e c irc u la tio n d a m p e r R e je c t o u tp u t C a g e s p e e d ( 1 0 -4 0 r p m )

50 % o p en 3 6 0 0 0 m 3 /h 100 % open

50 % open 3 6 0 0 0 m 3 /h 100 % open

2 0 rp m

2 4 rp m

M IL L D E D U ST IN G A c tu a l a ir flo w D a m p e r p o s itio n D e p re s s io n a t m ill in le t D e p re s s io n a t m ill o u tle t

2 5 0 0 0 m 3 /h 100 %

2 5 0 0 0 m 3 /h 100 %

yes no yes 6 0 -1 3 -1 0 - 1 0

yes no yes 6 0 - 1 3 -1 0 - 1 0

C IR C U IT F E E D IN G O u tp u t ( d u rin g th e v is it ) A v e ra g e in J u n e % H20 T °C C lin k e r a m b ie n t G yp su m 2 .5 % a m b ie n t L im e s to n e 3 .5 % a m b ie n t F IN IS H P R O D U C T F in e n e s s ( ta r g e t) A BSO RBED PO W E R M o to r a m p s ( A b s o rb e d p o w e r) S p e c ific p o w e r

M IS C E L L A N E O U S E ar W a te r in je c tio n G rin d in g a id C 3 S -C 2 S -C 3 A -C 4 A F

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Survey before crash stop Sampling : separator & filter

2

3

4

5

6

7

0 1

9 mm 10 mm

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Internal Visit of the Mill Sampling in the mill

To excavate ! 3x on the width 4x on the length Cpt 1 6x on the length Cpt 2

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Internal Visit of the Mill Collecting of samples

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Internal Visit of the Mill Grinding balls characteristics

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Internal Visit of the Mill Filling degree

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Internal Visit of the Mill Filling degree ST = p x D2/4 H1 = H - D/2 A = 2ARCOS(2 x H1/D)

m2 ST

m H °

H1

A S1 = D2/8 x (p x A/180° - sinA) m2 S1 R = S1/ST x 100

%

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Measured filling degree Filling degree (%) / H/D

0.8

D H

0.75

H/D

0.7

0.65

0.6

0.55 20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

Remplissage (%)

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Internal Visit of the Mill

Grates slots size check up

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Internal Visit of the Mill Cpt. length and liner thickness

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Internal Visit of the Mill Discovery of unground particles & untightened grates

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Internal Visit of the Mill Material level and filling degree in 2nd cpt.

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Internal Visit of the Mill Other various measurements

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Separator Inspection

• • • • • •

Space between blades and external casing Fan general condition Seals and valves general condition Holes in distribution plate Coating Wear follow up. Slegten grinding course

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Separator Inspection

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Theoretical curves CUMULATIVE PERCENT RETAINED 35 1/2"

30

1/4" 25

8M

20

16 M 30 M

15

50 M 10

100 M

5

200 M

0 1

2

3

4

5

6

7

8

9

10

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Conclusions from findings 3.66 m x 10.97 m 2162 kW 85,0% 80,0% 75,0% 70,0% 65,0% 60,0% 1/2

Partition

% Retained

55,0% 50,0%

#4 #8

45,0%

#16

40,0%

#30 #50

35,0%

#100

30,0%

#200

25,0% 20,0% 15,0% 10,0% 5,0% 0,0% 1

2

3

4

5

6

7

8

9

10

11

Position in Mill

Slegten grinding course

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Conclusions from findings 3.66 m x 10.97 m 2162 kW 80,0% 75,0% 70,0% 65,0% 60,0% 55,0% 1/2 Partition

% Retained

50,0% 45,0%

#4 #8 #16

40,0%

#30

35,0%

#50

30,0%

#100 #200

25,0% 20,0% 15,0% 10,0% 5,0% 0,0% 1

2

3

4

5

6

7

8

9

10

11

Position in Mill

Slegten grinding course

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Conclusions from findings 5.18 m x 10.36 m 4100 kW 65,0%

Partition

60,0% 55,0% 50,0% 45,0% Percent Retained

1/2" 40,0%

1/4" #8

35,0%

#16 #30

30,0%

#50 #100

25,0%

#200 20,0% 15,0% 10,0% 5,0% 0,0% C1-1

C1-2

C1-3

C2-1

C2-2

C2-3

C2-4

C2-5

C2-6

C2-7

C2-8

C2-9

C2-10

Position in Mill

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Conclusions from findings CUMULATIVE OVERSIZE DISTRIBUTION (%)

75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 CH1/1

10 2.36 1.18 0.6 0.3 0.09 0.044

CH1/2

CH1/3

CH1/4

CH2/1

CH2/2

CH2/3

CH2/4

CH2/5

CH2/6

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Conclusions from findings Granulometric curves 40.00

35.00

% cumulative residue

30.00

25.00

18 mm

20.00 11,2 mm 8 mm

15.00

4 mm 2,8 mm

10.00

1 mm 0,5 mm 0,25 mm

5.00

0,15 mm 0,1 mm 0.00 1/1

2/1

3/1

4/1

5/1

1/2

2/2

3/2

4/2

5/2

6/2

7/2

8/2

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Conclusions from findings 99 98 97 96 95

90 85 80

70 60 50 40

characteristics 30 20

d75..............: 78.90 µ

15

d50..............: 60.58 µ

10

d25..............: 46.52 µ Imperfection.....: 26.73 %

5

dl...............: 10.00 µ

4 3 2

#N/A

1

1

10

100

1000

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Conclusions from findings 0.1

99.9

1

99

5

finish Product

10 20

95 90 80

30

70 63.2

36.8

Filter

50

50

Separator feeding

60 70 80

40 30 20

Fines

85

15

90 10

Rejects

95

5 96

4

97

3

98

2

99

1

99.5 0.1

0.5 1

10

100

1000

dimension µ

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Conclusions from findings Granulometric curves 40.00

35.00

% cumulative residue

30.00

25.00

18 mm

20.00

11,2 mm 8 mm 15.00

4 mm 2,8 mm 1 mm

10.00

0,5 mm 0,25 mm

5.00

0,15 mm 0,1 mm 0.00 1/1

2/1

3/1

4/1

5/1

1/2

2/2

3/2

4/2

5/2

6/2

7/2

8/2

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Filling degree

ST = p x D2/4

m2

H1 = H - D/2

m

A = 2ARCOS(2 x H1/D)

°

ST H

A

H1

S1 = D2/8 x (p x A/180° - sinA) m2 S1 R = S1/ST x 100

%

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Conclusions from findings PLANT : SEPARATOR :

OBOURG SD150

dim. µ

fines %P

feed %P 2 4 8 16 20 25 30 45 60 75 80 90 120 200 210

Blaine :

5.92 10.26 15.87 23.67 27.32 32.33 37.73 55.39 70.56 81.55 84.25 88.65 94.83 96.6 96.6

SAMPLE : DATE : rejects %P

12.93 22.95 36.26 55.23 63.23 72.6 80.74 95.67 99.99 100 100 100 100 100 100

3.03 4.78 6.13 7.69 8.72 11.03 14.64 33.21 52.25 66.6 70.13 76.37 85.95 94.51 95.01

efficiency % 77.83 79.71 81.41 83.15 82.47 80.02 76.25 61.55 50.49 43.7 42.3 40.2 37.57 36.89 36.89

dim µ

cement 24/03/1994 effic. (i) %

1 3 6 12 18 22.5 27.5 37.5 52.5 67.5 77.5 85 105 160 205

tromp % 63.77 72.2 84.58 87.12 82.5 71.44 59.74 21.27 7.49 0.01

29.74 24.04 15.43 12.97 18.79 30.87 44.42 69.21 88.83 99.98 100 100 100 100 100

1324 cm2/gr 3778 cm2/gr 715 cm2/gr Circulating load : 2,81

correlation : 0,9681

vf : 0,356

vg : 0,644

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Conclusions from findings 100

d75 d50

dl 10

Characteristics

by-pass

tromp %

d25

d75...........: 36,32 µ d50...........: 26,45 µ d25............: 19,26 µ Imperfection : 32,25 % dl................: 14,41 µ by-pass....: 11,28 %

1 1

10

100

1000

µ Slegten grinding course

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Conclusions from findings PLANT :

sep. inlet Sieve (µ) 0.7 1.4 2 3.2 4 8 12 18 30 45 56 70 90 110 135 165 210 260 Blaine

Mill : Date :

OBOURG

1.90 4.69 5.92 8.62 10.26 15.87 20.06 25.39 37.73 55.39 66.86 78.47 88.65 93.76 96.08 96.60 96.60 96.60

Fines sep. 4.46 10.03 12.93 19.19 22.95 36.26 46.56 59.15 80.74 95.67 99.13 100.00 100.00 100.00 100.00 100.00 100.00 100.00

% passing sep. rejects Filter blaus.

3 diam. 5,2m 25/03/1994

finish product

0.90 2.48 3.03 4.19 4.78 6.13 7.00 8.06 14.64 33.21 47.75 62.79 76.37 83.64 88.80 92.27 95.01 96.20

1199 cm2/gr 2841 cm2/gr 1324 cm2/gr 3216 cm2/gr 3187 cm2/gr Slegten grinding course

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Conclusions from findings 100.00

10.00 sep. inlet Passing %

Fines sep. sep. rejects

1.00

0.10 0.1

1

10

100

1000

10000

dimension µ

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