Ball Mill Checking [Compatibility Mode]

Slegten grinding course 1

Mill check up“In the name of Allah, the Beneficent, the Merciful”


Preparation of the visit1. 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 foreseeCircuit : thermometer / anemometer

plastic bags

Cpt 1 : buckets of 5 to 10 L / scoop / light

Cpt 2 : buckets of 1 L / plastic bags / sieve, scoop

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

Mill check up


Survey before crash stop

Technical Data Sheet

Flow sheet

Ball charge history

Dailyproduction time

Sheet history

Auxiliary capacities

Control systems (if any)


C P J 3 5 C P J 4 5

C IR C U IT F E E D IN GO u tp u t ( d u rin g th e v is i t ) 3 0 tp hA v era g e in J u n e ( 2 8 .9 tp h ) ( 2 7 .0 9 tp h ) % H 2 0 T °CC lin k e r a m b ie n t 6 1 % 7 7 %G yp su m 2 .5 % a m b ie n t 6 % 6 %L im es to n e 3 .5 % a m b ie n t 3 3 % 1 7 %

F IN IS H P R O D U C TF in e n e ss ( ta rg e t) 2 0 - 2 4 % R 4 0 µ 1 5 - 2 0 % R 4 0 µ

A B S O R B E D P O W E RM o to r a m p s(A b so rb ed p o w e r)

6 0 A m p( 7 1 0 k W )

6 0 A m p( 7 1 0 k W )

S p ec ific p o w er 2 3 .6 k W h /t(2 4 .5 k W h /t) (2 6 .2 k W h /t)

S E P A R A T O RT y p eF res h a ir d a m p e r 5 0 % o p en 5 0 % o p e nA ir f lo w 3 6 0 0 0 m 3 /h 3 6 0 0 0 m 3 /hA ir r ec irc u la t io n d am p e r 1 0 0 % o p e n 1 0 0 % o p e nR e je c t o u tp u tC a g e sp e ed (1 0 -4 0 rp m ) 2 0 rp m 2 4 rp m

M IL LD E D U S T I N GA c tu a l a ir f lo w 2 5 0 0 0 m 3 /h 2 5 0 0 0 m 3 /hD a m p er p o s i t io n 1 0 0 % 1 0 0 %D e p re ss io n a t m il l in le tD e p re ss io n a t m il l o u t le t

M IS C E L L A N E O U SE a r yes ye sW a te r in je c tio n n o n oG rin d in g a id yes ye sC 3 S -C 2 S -C 3 A -C 4 A F 6 0 -1 3 -1 0 -1 0 6 0 -1 3 -1 0 -1 0


Main parameters


09 mm 10 mm1

2

3 4

Sampling : separator & filter

5 67



Internal Visit of the MillSampling in the mill

To excavate !

3x on the width

4x on the length Cpt 1

6x on the length Cpt 2


Collecting ofsamples

Internal Visit of the Mill


Grinding ballscharacteristics



Fillingdegree



A H1

ST

H

ST = p x D2/4 m2

H1 = H - D/2 m

A = 2ARCOS(2 x H1/D) °

S1 = D2/8 x (p x A/180° - sinA)

R = S1/ST x 100

m2

%S1

Fillingdegree



Measured filling degree

Filling degree (%) / H/D

0.55

0.6

0.65

0.7

0.75

0.8

20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

Remplissage (%)

H/D

DH


Grates slots sizecheck up



Cpt. length andliner thickness



Discovery of ungroundparticles &

untightened grates



Material level andfilling degree in 2nd cpt.



Other variousmeasurements



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

Separator Inspection


Separator Inspection


Theoretical curves

CUMULATIVE PERCENT RETAINED

0

5

10

15

20

25

30

35

1 2 3 4 5 6 7 8 9 10

1/2"

1/4"

8 M

16 M

30 M

50 M

100 M

200 M


0,0%

5,0%

10,0%

15,0%

20,0%

25,0%

30,0%

35,0%

40,0%

45,0%

50,0%

55,0%

60,0%

65,0%

70,0%

75,0%

80,0%

85,0%

1 2 3 4 5 6 7 8 9 10 11

Position in Mill

% R

etai

ned

1/2#4#8#16#30#50#100#200

Part

ition

3.66 m x 10.97 m 2162 kW

Conclusions from findings


0,0%

5,0%

10,0%

15,0%

20,0%

25,0%

30,0%

35,0%

40,0%

45,0%

50,0%

55,0%

60,0%

65,0%

70,0%

75,0%

80,0%

1 2 3 4 5 6 7 8 9 10 11

Position in Mill

% R

etai

ned

1/2#4#8#16#30#50#100#200

Part

ition

3.66 m x 10.97 m 2162 kW



0,0%

5,0%

10,0%

15,0%

20,0%

25,0%

30,0%

35,0%

40,0%

45,0%

50,0%

55,0%

60,0%

65,0%

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

Perc

ent R

etai

ned

1/2"1/4"#8#16#30

#50#100#200

Part

ition

5.18 m x 10.36 m 4100 kWConclusions from findings


CUMULATIVE OVERSIZE DISTRIBUTION (%)

05

1015202530354045505560657075

CH1/1 CH1/2 CH1/3 CH1/4 CH2/1 CH2/2 CH2/3 CH2/4 CH2/5 CH2/6

102.361.180.60.30.090.044



Granulometric curves

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

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

% c

umul

ativ

e re

sidu

e

18 mm

11,2 mm

8 mm

4 mm

2,8 mm

1 mm

0,5 mm

0,25 mm

0,15 mm

0,1 mm



1 10 100 1000

1

99

98

979695

90

85

80

70

60

50

40

30

20

15

10

5

32

4

characteristics

d75..............: 78.90 µ

d50..............: 60.58 µ

d25..............: 46.52 µ

Imperfection.....: 26.73 %

dl...............: 10.00 µ

#N/A



99.9

99

95

90

80

7063.2

50

40

30

20

15

10

54

3

2

1

0.50.1 1 10 100 1000

dimension µ

0.1

1

5

10

20

30

36.8

50

60

7080

85

90

95

9697

98

99

99.5

Filter

Rejects

Separatorfeeding

finishProduct

Fines



Granulometric curves

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.00

40.00

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

% c

umul

ativ

e re

sidu

e

18 mm

11,2 mm

8 mm

4 mm

2,8 mm

1 mm

0,5 mm

0,25 mm

0,15 mm

0,1 mm



A H1

ST

H

ST = p x D2/4 m2

H1 = H - D/2 m

A = 2ARCOS(2 x H1/D) °

S1 = D2/8 x (p x A/180° - sinA)

R = S1/ST x 100

m2

%S1

Filling degree


PLANT : OBOURG SAMPLE : cementSEPARATOR : SD150 DATE : 24/03/1994

dim. feed fines rejects efficiency dim effic. (i) trompµ % P % P % P % µ % %

2 5.92 12.93 3.03 77.83 1 63.77 29.744 10.26 22.95 4.78 79.71 3 72.2 24.048 15.87 36.26 6.13 81.41 6 84.58 15.43

16 23.67 55.23 7.69 83.15 12 87.12 12.9720 27.32 63.23 8.72 82.47 18 82.5 18.7925 32.33 72.6 11.03 80.02 22.5 71.44 30.8730 37.73 80.74 14.64 76.25 27.5 59.74 44.4245 55.39 95.67 33.21 61.55 37.5 21.27 69.2160 70.56 99.99 52.25 50.49 52.5 7.49 88.8375 81.55 100 66.6 43.7 67.5 0.01 99.9880 84.25 100 70.13 42.3 77.5 10090 88.65 100 76.37 40.2 85 100

120 94.83 100 85.95 37.57 105 100200 96.6 100 94.51 36.89 160 100210 96.6 100 95.01 36.89 205 100

Blaine : 1324 cm2/gr 3778 cm2/gr 715 cm2/gr

Circulating load : 2,81 correlation : 0,9681 vf : 0,356 vg : 0,644



1

10

100

1 10 100 1000

µ

trom

p %

Characteristics

d75...........: 36,32 µd50...........: 26,45 µd25............: 19,26 µ

Imperfection : 32,25 %dl................: 14,41 µby-pass....: 11,28 %

d75d50

d25

dl

by-p

ass



PLANT : OBOURG Mill : 3 diam. 5,2mDate : 25/03/1994

% passingsep. inlet Fines sep. sep. rejects Filter blaus. finish product

Sieve (µ)0.7 1.90 4.46 0.901.4 4.69 10.03 2.482 5.92 12.93 3.03

3.2 8.62 19.19 4.194 10.26 22.95 4.788 15.87 36.26 6.1312 20.06 46.56 7.0018 25.39 59.15 8.0630 37.73 80.74 14.6445 55.39 95.67 33.2156 66.86 99.13 47.7570 78.47 100.00 62.7990 88.65 100.00 76.37110 93.76 100.00 83.64135 96.08 100.00 88.80165 96.60 100.00 92.27210 96.60 100.00 95.01260 96.60 100.00 96.20

Blaine 1199 cm2/gr 2841 cm2/gr 1324 cm2/gr 3216 cm2/gr 3187 cm2/gr



0.10

1.00

10.00

100.00

0.1 1 10 100 1000 10000

dimension µ

Pass

ing

%

sep. inletFines sep.sep. rejects


Ball Mill Checking [Compatibility Mode]

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