MIDES® BALL MILL SORTING AND LOADING SYSTEMmidesus.com/catalogos_2016_en/07_Presentation MIDES Ball...
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MIDES® BALL MILL SORTING AND LOADING SYSTEM Objective: To increase efficiency , reduce energy consumption and therefore reduce the production cost of ball mill grinding processes.
Transcript of MIDES® BALL MILL SORTING AND LOADING SYSTEMmidesus.com/catalogos_2016_en/07_Presentation MIDES Ball...
MIDES® BALL MILL SORTING
AND LOADING SYSTEM
Objective: To increase efficiency, reduce energy consumption and therefore reduce the production cost of ball mill grinding processes.
Ideal grinding process The balls geometry has to be as perfect as possible
Spherical
• Maximum process efficiency • Minimum energy consumption
Minimum production cost
BALL MILL GRINDING PROCESS DYNAMICS
During the grinding process the friction and collision between
the balls and the material
Erosion and deformation of the balls
• Efficiency Decreases
• Energy consumption Increases
• Production cost Increases!
BALL MILL GRINDING PROCESS DYNAMICS
A ball mill with a: • Production of 100 ton/h; • 250 ton1 (balls).
25% of defective balls (scrap)
Defective balls = 62,5 ton1
Energy to move the load is changed into heat and not in grinding; efficiency decrease
• 15% loss of the mills production capacity;
• Energy consumption increase; • Acceleration of the balls erosion
process.
BALL MILL GRINDING PROCESS DYNAMICS
Example (real case):
1 – Metric Ton
The Cement Group Votorantim
Before Sorting with MIDES® Ball Mill Sorter
has in the Ball Mills 40% of scrap
Loss of the mills production capacity; Enourmous energy consumption; Acceleration of the balls erosion
process.
BALL MILL GRINDING PROCESS DYNAMICS
Example (real case):
After Sorting with MIDES® Ball Mill Sorter has a
maximum contamination of 2%
Increase of Production more than 25%; The return of the investment in the
Service of Classification was in 3 to 4 days;
MIDES Service Evaluation by Brazil customers
99% of customers approval
Over 91 customers
Huge decreases in Cost of Production
Less than 2% contamination inside of the Ball Mill
Increase Production
MIDES® BALL MILL SORTING SYSTEM
Cleaning the load
Removal of scrap and defective balls
Separation of the good balls by size
Size (Diameter): Rank of Separation (Diameter):
Scrap ≤ 13 mm
15 mm > 13 ≤ 17 mm
20 mm > 17 ≤ 22 mm
25 mm > 22 ≤ 27 mm
30 mm > 27 ≤ 32 mm
35 mm > 32 ≤ 37 mm
40 mm > 37 ≤ 45 mm
50 mm > 45 ≤ 55 mm
60 mm > 55 ≤ 65 mm
70 mm > 65 ≤ 75 mm
80 mm > 75 ≤ 85 mm
90 mm > 85 mm
Separation of the good balls by size
ADVANTAGES:
Elimination of the scrap and defective balls that are in the ball mill: • Maximum efficiency of the ball mill grinding
process;
• Minimum energy consumption;
• Lowest possible production cost.
Perfect control of the ball load that is inside the ball mill:
• Accurate knowledge of the quantity of balls of different
sizes that are inside the mill.
MIDES® BALL MILL SORTING SYSTEM
Sorting and Loading Service cost +
Replacement cost of new balls
Represents 4 to 8% of the cost of the balls
that are inside the mill
ADVANTAGES:
Final cost RETURNS IN A SHORT TERM with the increase of production
(from HOURS to A FEW DAYS)
MIDES® BALL MILL SORTING SYSTEM
Considering that all the variables of the Grinding process are constant and the limit of the Grinding is
related to the power of the Mill. Numbers in reference of the Brazilian market.
Ideal condition of the Grinding: » Energy consuption- 40kw/Ton finished
» Production: 100Ton/Hour » Contamination in the Mill: 2%
ADVANTAGES WITH NUMBERS:
Conditions of the Ball that are in the Mill after 1 year of work
» Contamination in the Mill: 12% » Loss in production: 4%
» Operating factor for grinding: Minimun 93%
• Loss 32.587 ton1 of finished product; • Energy wasted 1.303.488 kw
1 – Metric Ton
MIDES® BALL MILL SORTING SYSTEM
Considering that all the variables of the Grinding process are constant and the limit of the Grinding is
related to the power of the Mill. Numbers in reference of the Brazilian market.
Considering that: > Cement in Brazil is 160 USD/Ton1; > Energy in Brazil is 0,14 USD/Kwhr
ADVANTAGES WITH NUMBERS:
Loss in Production 160 USD X 32.587 Ton1 =
Total lost 5.213.952,00 USD
Loss in energy transform in to heat 0,14 USD X 1.303.488 kw =
Total lost 182.488,32 USD
1 – Metric Ton
MIDES® BALL MILL SORTING SYSTEM
» Average Production of MIDES® Ball Mill Sorter = 70 to 110ton1/shift of 10 hours - depends of the contamination in the Mill
» Loading of the Mill with the MIDES® Loading System = 30ton1/hour » Time spent to do Classification of the Mill = 35hours
» Time spent to Load the Mill = 8hours » Total time of stopage of the Mill = 48hours – considering losses of time
ADVANTAGES WITH NUMBERS:
Average cost with a Service of Classification with MIDES® Ball Mill Sorter:
Production of 100ton1/hour = 240ton1 of Ball in the Mill
Loss of production = 4.800ton1 x 160 USD = 768.000,00 USD » This cost
normally is not considered due to the regular stopage of the Mills
1 – Metric Ton
MIDES® BALL MILL SORTING SYSTEM
ADVANTAGES WITH NUMBERS:
Average Cost of Service made by MIDES® Ball Mill Sorter(with average dislocation of 1000miles):
> 130 USD/Ton1 of Ball Classified and Loaded
Total cost of 130 USD X 240 Ton1 =
Total Cost 31.200,00 USD
RUN YOUR NUMBERS TO
FIND THE ADVANTAGES
In the Brazilian Market the companies, due to huge savings and increases in production, are
Sorting the Cement Mills in periods of 8 months and the Raw Mills in period of 1 year
1 – Metric Ton
MIDES® BALL MILL SORTING SYSTEM
Factories currently with signed contract to sorting and loading with MIDES® System in Brazil
HOLCIM
LAFARGE
LIZ
VOTORANTIM
VALE
ANGLO
FERROUS
2 year contract to all the Ball Mill in each plant
3 year contract to all the Ball Mill in each plant
3 year contract to all the Ball Mill in each plant
3 year contract to all the Ball Mill in
each plant
2 year contract to all the Ball Mill in each plant
1 year contract to all the Ball Mill in
each plant
MIDES® BALL MILL SORTING SYSTEM
MIDES® SORTER (Sorting machine)
Mobile Unit: • Truck + "Container“ = Sorter and all the Necessary Equipment.
Execution Speed: • From 6 up to 12 ton1/h of classified balls (classification speed depends on the contamination level of the load to be classified).
Process Quality: • Elimination of the scrap and defective balls; • The classified balls are left with a 2% maximum contamination.
Main Features
1 – Metric Ton
Safety: • All work performed outside the "Container“; • No contact man / machine.
The Classified Load is Accommodated in "Bags": • Increased security and reliability; • Easy handling and storage of the balls; • Increased productivity of the classification and loading of the mills.
2 Operators for the Service Execution: • Only 2 workers needed to operate the machine; • Educated and trained workers to operate the machine.
Main Features
MIDES® SORTER (Sorting machine)
Main Features
Positioning, Assemblage and Preparation of the MIDES® Sorter in Local Defined by the Customer • The local area must be large enough for the skid steer loader handling and storage of the “bags”.
MIDES® SORTER (Sorting machine)
Automatic Weighing of the Classified Balls: • Weighing is made by different balls size.
Electrical Power of the MIDES® Sorter: • The customer must have available a power source (220, 380 or 440 V); • The customer is responsible to ensure the electrical power during
operation; • The source shall be within 55 yards from MIDES® Classifier.
Main Features
MIDES® SORTER (Sorting machine)
MIDES® LOADING SERVICE
MIDES® Vertical System MIDES® Belt System
MIDES® Vertical System
MIDES® LOADING SERVICE
Safety: • No contact man / ball.
Production Rate: • 25 ton1 / h
Linked with the MIDES® Classifier
Effective Height of Work: • Min. 2,5 m / Max. 6,5 m
1 – Metric Ton
Safety: • No contact man / ball.
Production Rate: • 25 to 40 ton1 / h
MIDES® LOADING SERVICE
MIDES® Belt System
Linked with the MIDES® Classifier
Effective Height of Work: • Min. 3,0 m / Max. 8,5 m
1 – Metric Ton
587 E Sample Road Suite 246 - Pompano
Beach, FL 33064
Website: www.midesus.com
Email: [email protected]
Phone: (786) 245 – 5231
Fax: (954) 788 – 6765
