“I n the th e na nam me of A ll ah , the B ene neff ic iceent, the th e M erc rcifif ul ”
Mill check up
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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 t o 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. Technica echnicall 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 Both compartments are visited and examined 7. Samples are collected in the mill 8. Separator visit
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Survey Surve y before crash stop
Technical Data Da ta Sheet Flow sheet Ball charge history Dailyproduction time Sheet history Auxiliary capacities Control systems (if any)
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Survey Surve y before crash stop Main parameters
C PJ 35
C PJ 45
3 0 tp h ( 2 8 .9 t p h )
( 2 7 .0 9 tp h )
61% 6% 33%
77 % 6 % 17 %
2 0 - 2 4 % R 4 0µ
1 5 - 2 0 % R 4 0µ
60 Amp ( 710 kW ) 2 3 .6 k W h / t ( 2 4 .5 k W h / t )
60 Amp ( 7 10 10 k W ) ( 2 6 .2 k W h / t )
50 % o p en 3 6 0 0 0 m 3 /h 1 0 0 % op en
50 % open 3 6 0 0 0 m 3 /h 1 0 0 % o pen
2 0 rp m
2 4 rp m
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
ye s no ye s 6 0 - 1 3 -1 0 - 1 0
CIRCUIT FEEDING
O u tp u t ( d u rin g t h e v is it ) A v era ge 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 i m e s to n e 3 .5 % a m b ie nt F I N IS IS H P R O D U C T
Fineness (target) A B S O R B ED P O W E R
M otor amps ( A b s o r b ed ed p o w e r ) S p ec ific p o w er
SEPARATOR
Type F res h air d a m p e r A i r f lo w A ir r e c irc u la tio n d a m p e r Reject output C a g e s p e e d ( 1 0 -4 0 r p m ) MILL DEDUSTING
A c tu a l air flo w D a m p er p o sitio n D e p r e s s i o n a t m i l l i n le le t D e p r e s s i o n a t m i l l o u t le le t MISCELLANEOUS
Ear 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 Surve y 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 D 2/4 H1 = H - D/2 A = 2ARCOS(2 x H 1/D)
m2 ST
m H °
H1
A S1 = D2/8 x ( p x A/1 A/180°80°- si sinA nA)) m2 S1 R = S1/ST x 100
%
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Measured filling degree Filling degree (%) / H/D
0.8
D H
0.75
0.7 D / H
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
• Spa Space ce betw betwee een n blade bladess and ext exter erna nall casi casing ng • Fa Fan n gen gener eral al co cond ndiiti tion on • Seals and valve vess ge gene nerral cond ndiition • Ho Hole less in di dist stri ribu buti tion on pl plat atee • Coating • Wear follow up.
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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
n o i t i t r a P
55,0% d 50,0% e n i a 45,0% t e R 40,0% %
#4 #8 #16 #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
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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 n o i t i t r a P
50,0% d e 45,0% n i a t e 40,0% R % 35,0%
#4 #8 #16 #30 #50 #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 5.18 m x 10.36 m 4100 kW 65,0% 60,0%
n o i t i t r a P
55,0% 50,0% 45,0%
1/2" 1/4"
d 40,0% e n i a t e 35,0% R t n e 30,0% c r e P
#8 #16 #30 #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 CUMULATIVE O VERSIZE DISTRIBUTION (%)
75 70 65
10 2.36 1.18
60 55
0.6 0.3
50 45
0.09
40 35 30 25
0.044
20 15 10 5 0 CH1/1
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 Granulometric curves 40.00
35.00
30.00
e u d i 25.00 s e r e v i t20.00 a l u m 15.00 u c %
18 mm 11,2 mm 8 mm 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
5
dl...............: 10.00 µ
4 3
#N/A
Imperfection.....: 26.73 %
2 1
1
10
10 0
1 000
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Conclusions from findings 0.1
99.
1
99
finish Product
5 10 20
95 90 80
30
70 63.
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
10 0
1000
dimension µ
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Conclusions from findings Granulometric curves 40.00
35.00
30.00
e u d i s25.00 e r e v i t20.00 a l u m u15.00 c %
18 mm 11,2 mm 8 mm 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 D 2/4
m2
H1 = H - D/2
m
A = 2ARCOS(2 x H 1/D)
°
ST H
A
H1
S1 = D2/8 x ( p x A/1 A/180°80°- si sinA nA)) 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
Blai Blaine ne :
5.92 10.26 15.87 23.67 27.32 32.33 37.73 55.39 70.56 81.55 84.25 88 8 8.65 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 7 6.37 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 1324 cm2/ cm2/gr gr 3778 3778 cm2/ cm2/gr gr 715 715 cm2/ cm2/gr gr Circulating load : 2,81
correlation : 0,9681
vf : 0,356
vg : 0,644
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Conclusions from findings 100
d75 d50 d25 dl
% p 10 m o r t
Characteristics
s s a p y b
d75...... d75...... .....: 36,32 36,32 µ d50...... d50...... .....: 26,45 26,45 µ d25...... d25...... ......: 19,26 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 :
OBOURG
sep. sep. inlet inlet Sieve (µ) 0.7 1.4 2 3.2 4 8 12 18 30 45 56 70 90 110 135 165 210 260
Blain Blaine e
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 Fines sep. ep. 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. ep. rejec rejects ts
Mill : Date :
3 diam. 5,2m 25/03/1994
Filte Filterr blaus blaus..
finis finish h prod produc uctt
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 1199 cm2/g cm2/grr 2841 2841 cm2/g cm2/grr 1324 1324 cm2/g cm2/grr 3216 3216 cm2/g cm2/grr 3187 3187 cm2/g cm2/grr Slegten grinding course
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Conclusions from findings 100.00
10.00 sep. inlet Fines sep.
% g n i s s a P
sep. rejects
1.00
0.10 0 .1
1
10
100
1 000
10 000
dimension µ
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