Content

Objectives

Standard measurements of ball mills

Explanation of the tasks and frequency
B level Audit
Pre-requisites
Realization steps: 111
Results Output
Standard measurement frequency

Key Messages

1
Objectives
Understand the importance of standard measurements
in the management of process performance
Know the expectations and requirements for standard
measurements and which tasks to perform for a BM
Comprehend the output and main objective of standard
measurements
Develop an action plan for process optimization

2
Standard Measurements
Standard Measurement = Health Check of your grinding
systems
Standard in terms of the measurement description & frequency
Regular measurements must be made to ensure continuity
and to build knowledge (and data) about the system
performance weak and strong points
Allows investigation of the root cause of problems

Displays trends in performance

Pro-active approach to process management

Quality of data and sampling is paramount to success

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 Standard Measurements Tasks & Frequency
one year
1. Circuit mat. granulometry
2. Mill longitudinal sieving
3. Ball charge filling degree
4. Mill material level
5. Mill ventilation
6. Separator Tromp curve
B-level audit
7. Separator ventilation
8. Mill internal conditions
9. Weigh feeder calibration
10. Instrument verification
11. Control loop verification
yearly stop 4
B-level audit pre-requisites
Define the raw meal/cement type for the audit
Gather the main machines design data
Material flow and temperature stability for at least 2 hours
Sampling and airflow measurements during 6-8 hours of stable
operation
Operation data recorded (minimum required):
Production [t/h], type, composition [%]
Fineness and fineness target
Specific energy consumption [kWh/t] of mill motor, separator fan and
rotor, bucket elevator, mill fan, separator filter fan, auxiliary equipment,
fuel consumption of HGG, etc.
See output sheet
Visual inspections of mill, separator and auxiliaries
Conclusions and report (actions for optimization)

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B-level audit
Realization 1. Circuit material granulometry
1.1 Sampling

Grinding SF CF
temperature aid MF
F C
R

SSR
K G L S

MO

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B-level audit
Realization 1. Circuit material granulometry
A Clinker 10 [kg] 1x per test 50, 25, 16, 8, 4, 2, 1, [mm], temperature

B Gypsum 10 [kg] 1x per test 50, 25, 16, 8, 4, 2, 1, [mm] + %H2O

C Limestone 10 [kg] 1x per test 50, 25, 16, 8, 4, 2, 1, [mm] + %H2O

S Slag 10 [kg] 1 x per test 50, 25, 16, 8, 4, 2, 1, [mm] + %H2O

MO Mill outlet

SSR Static. Sep. return

A Separator feed

CF Sep. cyclone fines 200 [m] Alpine Sieve pre-screening

1 x per 1/2 - ~1- 200 [m] Laser
0.5 [kg]
SF Sep. filter dust 1.0 h (6x) Blaine [cm2/g]
temperature (at least MO & R)
F Separator fines

R Separator returns

MF Mill filter dust

C Cement
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B-level audit
Realization 1. Circuit material granulometry - Example
N
F
Filter
Ex
am
pl
e
H
P
SKS
G Product
Vor-
prod.
I
VSKS Product
Filter
20t O Staub
D Gs
B C L
Klinker Gips Res.

Tr.
E A prod.
K Q

x Material Sampling R
point M

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B-level audit
Realization 2. Longitudinal sieving test
2.1 Longitudinal sampling
*Sample weight:
1-2 kg 1st compartment
0.5 kg 2nd compartment

20 cm
0.5 1m 1m 1m 0.5 0.5 1m 1m 1m 1m 1m 1m 0.5

1.1 1.2 1.3 1.4 2.1 2.2 2.3 2.4 2.5 2.6 2.7

20 cm
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B-level audit
Realization 2. Longitudinal sieving test
2.2 Sieves and guide values Guide values valid for 3000
Blaine and no pre-grinder
% residue
accumulated Sieve [mm] Blaine
Sample 16 8 4 2 1 0.5 0.2 0.12 0.09 0.063 0.045 cm2/g
1. Chamber 1.1 Guide values for sample 1.4:
1.2 R0.5mm: 15-25%
1.3 R2mm: <5%
1.4

2. Chamber 2.1
2.2
Guide values for sample 2.7:
2.3
R0.09mm: 15-25%
2.4
R0.2mm: <5%
2.5
2.6
2.7 10
B-level audit
Realization 3. Ball charge filling degree
1. Measure average internal diameter Di
2. Measure height h, in three different points along axis
3. Calculate h/Di and determine filling degree from diagram
h
Di

h/Di

0,75
h
Di = Mill diameter

Di 0,70 inside mill

1 9 liners

0,65

0,60 filling degr

20 25 30 35 f [%]

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B-level audit
Realization 4. Material level
4.1 - 1st Compartment

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B-level audit
Realization 4. Material level
4.2 - 2nd Compartment

>> 50 [mm] bad

~ 50 [mm] good

< 50 [mm] bad

<< 50 [mm] very bad

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B-level audit
Realization 5. Mill ventilation measurements
Static pressure, temperature
Airflow, static pressure & temperature
MFC

MFO

Allow nominal 10% false air when calculating

actual airflow through mill (minimum!)

MFI

MO
HGSA
HGFA MI
HGPA

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B-level audit
Realization 5. Mill ventilation measurements - Example
x Air Flow Measurement point: p, T 16
14
15
Ex
x Air Flow Measurement point:
17 Filter
8 7
am
p, T, V
pl
e
12

13 9
=17 4
6
5
SKS
Product 3

VSKS Vor-
prod. Sampler Product
Filter
20t 11 Staub
=17
Gs
2
Klinker Gips Res.
Tr.
prod.

15
B-level audit
Realization 6. Separator Tromp curve
6.1 Sampling A

Separator
Required samples:
R F
Separator feed (A)

Separator fines (F)

Rejects (R) Fresh feed
Mill
Sampling according to step 1 material sampling
Sample particle size distribution is measured by a laser particle size
analyzer
Residue on 200 [m] depends on lens used

If residue on 200 [m] > 0 correct the laser results prior to Tromp calculations

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B-level audit
Realization 6. Separator Tromp Curve
Bypass
6.2 Graphical Presentation Separator
Circulation load
efficiency
100 Slope
90
SEPARATION / EFFICIENCY [%]

80
70
60
50
40
30
20
10 Bypass
0
1.0 10.0 100.0 1000.0
PARTICLE SIZE [m]
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B-level audit
Realization 7. Separator airflow
Static pressure, temperature
Airflow, static pressure & temperature SVI

CO
SVI
SFO

SFI SO

Airflow measurement at the volute inlet

Airflow in single pass separator to

be measured at the separator filter
exhaust stack
Airflow in Cyclone air separator to SVI
be measured as indicated
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B-level audit
Realization 8. Mill visual inspection (& measurements)
Ball filling Slot width, gaps, Ball filling
degree plugging, thickness degree

Slot width, gaps,

Slot width, flow plugging,
setting thickness

State &
thickness
State, position
Liner residual
lifting height Extreme ball Extreme ball size, Liner type, state &
size, state classification, state main dimensions

Liner type, state

& rotation sense
Material level & coating Material level & coating
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B-level audit
Realization 8. Mill visual inspection

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B-level audit
Realization 8. Mill visual inspection
Separator visual inspection
1

2
6
3
5
4

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B-level audit
Realization 9. Weigh feeder calibration
9.1 Static calibration - feeder not in operation
Zero-point - adjustment (local control box, no load)

Span adjustment with calibration weight (local control box)

9.2 Calibration with feeder in operation (preferred if possible)

operate weigh feeder with defined setpoint and load
material into truck for e.g. 10 minutes, while mill is
shut down

weigh truck empty and loaded, calculate throughput

and adjust controller if necessary
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B-level audit
Realization 10. Instrument verification
10.1 Electronically

Check and adjust zero-point and span with e.g. mA

transmitter

10. 2 Operation check: manual measurements vs. CR indications

Compare control room indication with local manual

measurement of temperature, pressure and flow

Adjust transmitters

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B-level audit
Realization 11. Control loop verification
11.1 Operation check
record process parameters with control loop in
operation over period of e.g. 6-8 h with constant production

Get information on:

Available information at the CR
Control system
Control strategy
First impression on operation
Circuit stability
Operator actions
Operation procedures

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B-level audit
Realization B-level Audit - Output
Ball Mill Performance (Cement)
Plant: Date: 24.01.2003
Mill Nr.: Cement mill 3 Visa:
Production Mill production 202.3 [t/h] Mill dimensions
Cement type Type I-II Diameter 5.0 [m]
Fineness 3660 [cm/g] Blaine Length 15.8 [m]
1.8 [%] R 45 [m] Motor 6000 [kW]inst.
Feed moisture 0.240 [%] wet base

Cement Material type Composit.[%] Product Moisture [%] H2O (wet base)
Composition Clinker 94.7 [%] [%]
Gypsum 4.3 [%] 5 [%]
Limesone 1 [%] 2.5 [%]
.... [%] [%]
Total 100 [%] Feed moisture average 0.240 [%]

Energy Mill motors 5'358 [kW]abs. 26.5 [kWh/t] counter

Consumption Separator rotor 222 [kW] 1.1 [kWh/t]
Separator fan Sepol 575 [kW] 2.8 [kWh/t]
Separator fan Stat. 584 [kW] 2.9 [kWh/t]
Press motor 1 802 [kW] 4.0 [kWh/t]
Press motor 2 810 [kW] 4.0 [kWh/t]
Mill fan 98 [kW] 0.5 [kWh/t]
Bucket elevators 229 [kW] 1.1 [kWh/t]
Auxiliaries 671 [kW] 3.3 [kWh/t]
Total mill system 9'349 [kW] 46.2 [kWh/t]

Separator Circulating factor 2.5 [ - ] calc System

Separator load
- product / air ratio 0.57 [kg/m] Rotor diameter 3.50 [m]
- feed / air ratio 1.44 [kg/m] height 2.33 [m]
By-Pass 7 [%] area 25.6 [m]
Cut point 17.5 [m] speed 133.2 [min-1]
Air flow rate 352000 [m/h] Radial air speed 3.8 [m/s]
Separator fan flap 100 [%] Circumf. speed rotor 24.4 [m/s]
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 Standard Measurements Tasks & Frequency
one year
1. Circuit mat. granulometry
2. Mill longitudinal sieving
3. Ball charge filling degree
4. Mill material level
5. Mill ventilation
6. Separator Tromp curve
B-level audit
7. Separator ventilation
8. Mill internal conditions
9. Weigh feeder calibration
10. Instrument verification
11. Control loop verification
yearly stop 26
Key messages
Standard measurements give valuable information
on grinding system performance
on grinding system weak points
B-level audit is the base-line of all medium-long term
actions in process optimization
Detailed & accurate interpretation of the results are the
key success factors of a B-level audit

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