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    Blaine Reference Blaine Required e K

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    Nael
    1. The document discusses cement grinding plants and describes formulas for calculating the Blaine fineness factor, expected mill output when adding limestone as an additive, and the absorbed power of a ball mill. 2. Details are provided on composite cement composition and properties, with an example of how limestone additive affects mill output. 3. Information is given on a high efficiency separator (SEPOL), the TROMP curve for analyzing separator performance, and typical ranges for separator efficiency and separation cutting diameter for ordinary Portland cement.

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    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd

    Blaine Reference Blaine Required e K

    Uploaded by

    Nael
    1K views4 pages
    1. The document discusses cement grinding plants and describes formulas for calculating the Blaine fineness factor, expected mill output when adding limestone as an additive, and the absorbed power of a ball mill. 2. Details are provided on composite cement composition and properties, with an example of how limestone additive affects mill output. 3. Information is given on a high efficiency separator (SEPOL), the TROMP curve for analyzing separator performance, and typical ranges for separator efficiency and separation cutting diameter for ordinary Portland cement.

    Original Title

    Cement Grinding

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    1. The document discusses cement grinding plants and describes formulas for calculating the Blaine fineness factor, expected mill output when adding limestone as an additive, and the absorbed power of a ball mill. 2. Details are provided on composite cement composition and properties, with an example of how limestone additive affects mill output. 3. Information is given on a high efficiency separator (SEPOL), the TROMP curve for analyzing separator performance, and typical ranges for separator efficiency and separation cutting diameter for ordinary Portland cement.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    1K views4 pages

    Blaine Reference Blaine Required e K

    Uploaded by

    Nael
    1. The document discusses cement grinding plants and describes formulas for calculating the Blaine fineness factor, expected mill output when adding limestone as an additive, and the absorbed power of a ball mill. 2. Details are provided on composite cement composition and properties, with an example of how limestone additive affects mill output. 3. Information is given on a high efficiency separator (SEPOL), the TROMP curve for analyzing separator performance, and typical ranges for separator efficiency and separation cutting diameter for ordinary Portland cement.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    The document discusses cement grinding plants and how different additives like limestone can affect mill output and fineness. It also covers concepts like the Polysius C factor, ball mill absorbed power, high efficiency separators, and the TROMP curve.

    The addition of 15% limestone to the cement composition results in a higher expected mill output of 111 t/h compared to 100 t/h for plain OPC cement, when both are ground to a fineness of 3200 cm^2/g. This is because limestone gives approximately twice the fineness compared to an equivalent amount of clinker.

    The Polysius C factor depends on parameters like the ball charge, material type, mill type, and process type. For a cement mill operating at different ball charge filling degrees, the C factor ranges from 9.8 to 9.1.

    1

    CEMENT GRINDING PLANT




    BLAINE FINENESS FACTOR
    POLYSIUS Coefficient

    49 , 0 *
    1000
    |
    .
    |

    \
    |

    =
    Blaine Reference Blaine Required
    e K


    Exemple



    Mill output : 100 t/h

    Fineness according to Blaine: 3000 cm/g



    New fineness required: 3500 cm/g

    K = exp ((3500-3000)/1000*0,49)

    K= 1,278

    Expected mill output = 78,3 t/h

    CEMENT GRINDING PLANT


    COMPOSITE CEMENT
    ____________________________________________________________________________________

    OPC (Ordinary Portland Cement)

    Composition

    96 % CLINKER
    4 % GYPSUM
    _____________________________________________________________________________________
    CPC (Composite Portland Cement)

    Type of additives:
    Limestone, pouzzolane, trass, slag, fly ash, .

    Properties:
    increase of fineness and output, decrease of initial and final strength, increase of concrete plasticity and workability, colour
    modification
    _____________________________________________________________________________________


    2

    CEMENT GRINDING PLANT
    Exemple of the additive influence on the mill output

    Production of cement with 15 % of limestone

    Composition
    81 % CLINKER
    4 % GYPSUM
    15% LIMESTONE

    Cement Mill
    Output = 100 t/h of OPC (96 % Clinker 4% Gypsum)
    Fineness = 3200 cm/g
    CPC cement (81% Clinker 4% Gypsum 15% Limestone))
    Fineness required 3200 cm/g according to blaine
    Calculation of equivalent clinker fineness
    We consider that the limestone gives 2 times more fineness.
    X = equivalent clinker fineness
    2.X = limestone fineness
    3200 = (0,81+0,04) X + 0,15 2.X
    X = 2783 cm/g
    Limestone fineness = 5565 cm/g
    CEMENT GRINDING PLANT
    Expected cement mill output with 15% limestone
    Fineness factor
    K = exp ((3000-2783)/1000*0,49)
    K=1,11
    Expected mill output = 111 t/h at 3200 cm/g with 15% limestone

    BALL MILL ABSORBED POWER

    Absorbed power at mill shaft / Polysius Formula
    P(kW) = G x C x Di x 0,736

    P = Mill power absorbed (kW)
    G = Ball charge weight (tons)
    C = POLYSIUS C Factor (-)
    Di = Internal mill diameter (m)
    Lu = Effective grinding length (m)
    F = Filling degree of ball charge (%) normal range : 24 32 %
    d = Bulk density of grinding balls (t/m
    3
    ) 4,5 4,6
    Ball charge weight

    G (tons)= ( x Di / 4) x Lu x F x d

    Absorbed power at mill motor shaft

    Pmotor(kW) = P(kW)/

    = Drive efficiency
    = Girth gear (0,98) x Combiflex (0,97) x motor coupling (0,99)
    = 0,94

    POLYSIUS C Factor
    Depends on different parameters: ball charge, kind of material, type of process, type of mill

    3


    Cement mill / closed circuit
    26 % C = 9,8 28 % C = 9,6
    30% = C = 9,4 32% = C = 9,1
    CEMENT GRINDING PLANT

    HIGH EFFICIENCY SEPARATOR SEPOL

    A












    F

    R

    Separator efficiency

    f r
    a r
    f
    a

    = .
    1
    1



    a = % passing cumulated in fresh feed
    f = % passing cumulated in finish product
    r = % passing cumulated in separator rejects
    CEMENT GRINDING PLANT

    TROMP Curve


    %
    100



    50



    by pass

    40

    Aa = % passing between 2 sieves in the fresh feed
    Ar = % passing between 2 sieves in the grits
    Af = % passing between 2 sieves in the finish product


    SEPOL

    4

    Sa = % passing sieve: 10 20 > 100
    Sr = % passing sieve: 10 20 > 100
    Sf = % passing sieve:: 10 20 > 100
    100 *

    =
    Sr Sf
    Sr Sa
    Vf



    100 *

    =
    Sr Sf
    Sa Sf
    Vg



    100 *
    . .
    .
    Vf f Vr r
    Vr r
    T
    A + A
    A
    =


    Tau = By pass %
    This percentage represents the % of fines which has been considered by the Separator as rejects.
    Normal range for a high efficiency separator SEPOL with OPC cement
    : 5 15%

    Separation cutting : diameter m
    This point gives where is the limit of accuracy of the SEPOL for the cement produced.
    Normal value for standard OPC: 10 20 m
    Imperfection
    Polysius formula
    kapa = d30/d70
    Lafarge formula
    I = (d75 d25 ) / 2 (d50)

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