Vertical Ball Mill

Tanjung Jati B Training VERTICAL BALL MILL

REA GE REA GENT NT PREPA PREPARA RATI TION ON VERTICA L B A L L MIL L

Tanjung Jati B Training

PT Cen t r al J av a Po w er Tanju njung ng Ja J ati B Units 1 & 2 Flu lue e Ga Gas De Desu sulf lfur uriza izati tion on (F (FG GD) Sys ystem tem

Absorber Area

Dewatering Area

Reagent Preparation Area

Limestone Jetty And Conveyor


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l

THE INTENT OF THIS SECTION IS TO DISCUSS BASIC PROCEDURES FOR STARTING UP THE VERTICAL BALL SYSTEM. THIS SECTION, BY NO MEANS ESTABLISHES OPERATING PROCEDURES,, THEREFORE IT IS THE RESPONSIBILITY PROCEDURES OF THE OPERATORS TO FULLY UNDERSTAND THE OPERATING PROCEDURES PROVIDED IN THE OPERATION & MAINTENANCE MANUALS.



Prio riorr to t o sta st art rting ing the Ve Verti rtical cal Ball Ball Mil illl se s ecti ction, on, let’ let’s s firs fi rstt re r evi vie ew the t he Reagent Prepara Preparati tion on flo f low w paths and related rela ted components. comp onents.


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Limestone Silo

Bin Activator

Limestone Feeder

Mill Hydroclone

Limestone Pre-Crusher

Limestone Slurry Storage Tank

Mill Recirculation Sump Seawater

Vertical Ball Mill Mill Recycle Pump

Mill Outlet Sump Tanjung Jati B Training

Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l The fu func ncti tion on of o f Rea Reagent Prepa Preparatio ration n is i s to process raw raw limestone l imestone stored in the t he Limestone Sil ilos os into in to a limestone limestone “ slurry” whic which h is ultima ulti mate tely ly stored sto red in the Lime Li mesto stone ne Slur Slurry ry Stor tora age Ta Tank. Lim esto Lime stone ne Slur Slurry, ry, produc pro duce ed by the Ve Vert rtical ical Ball Mills and classif c lassified ied by the t he Hydr Hydrocl oclones, ones, wi will ll ha have ve a solids cont co nte ent of o f 30 30%. 95% of those th ose solids solid s will wi ll pa p ass thro t hrough ugh a 325 325 mesh mes h screen. screen .


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Limestone Silo 95% of solids through a 325 mesh screen Bin Activator

Limestone Feeder

Mill Hydroclone




30% SOLIDS Vertical Ball Mill Mill Recycle Pump


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l The Limeston Limest one e Slu lurr rry y prod pr oduc uce ed by th the e Reagent Prepa reparatio ration n System, by design, desig n, will wil l ha h ave a solids conte cont ent of 30%. 30%. Con ontr trol ol of th the e Re Reagent Prepara Preparati tion on Sys ystem tem is from the ma main in control contr ol room. The system is operated opera ted most eff ffici icie entl ntly y as as a batch batch pro process cess with wit h a constant con stant design f eed rate of limeston l imestone e to the t he verti vertica call ball mil ls. ls .



The Hydroclone is an int i nte egr gra al pa p art of th the e Reagent Prepa reparation ration sys system tem as as we w ell as being integra i ntegrall to t o the t he operatio opera tion n of the Ve Vert rtical ical Ball Mil Mill. l. Let’s fir f irst st ta t ake a lo look ok at the Vertic rt ica al Ball Mill Mil l components.



DRIVE MOTOR

GEAR REDUCER RAW MATERIAL INLET

BALL FILL

MILL RECIRCULATION SUMP

TO MILL OUTLET SUMP

SCREW TO MILL RECIRCULATION PUMP



LOW LEVEL SWITCH

SLURRY FEED

WASH CONNECTION BALL DISCHARGE

DRAIN


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l AIR VENT

CLAMP ASSY

AGITATOR MOTOR

SLURRY OUTLET

AGITATOR BLADES

MILL RECYCLE SUMP (PLAN VIEW)

AGITATOR (300 RPM)


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l RAW MATERIAL INLET

SLURRY OUTLET TO RECIRC SUMP

VERTICAL BALL MILL FLOW PATH RECYCLE SLURRY FROM RECIRC PUMP



VERTICAL BALL MILL INTERNALS @ TJ-B Tanjung Jati B Training


A n Oil Lubrica An Lubri cation tion Unit is re r equi quired red for the operation operation Ball Mil Mill’ l’s s Ge Gear Re Redu ducer. cer. Thi his s Lube Lub e Oil Unit requires requi res a coo cooli ling ng water water source sou rce and and has instrum inst rume entation for f or measuring oil flow, fl ow, temperature temperature and and differe di fferenti ntia al pressure. pressure. The sou source rce of cooli coo ling ng water water is Ser Ser vice vi ce Wat Wat er . The cooli coo ling ng wa w ater exit exiting ing the Lube Oil Unit goes to the th e dr dra ain (tre (tr enc nch). h).


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l DUPLEX FILTER

OIL INLET

OIL OUTLET

OIL PUMP

FLOW METER

MOTOR DIFFERENTIAL SWITCH

OIL COOLER

THERMOMETER (WITH SWITCH)


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Pri rior or to t o discus dis cussi sing ng the th e start-up of the th e Vert rtical ical Ball Ball Mil ill, l, let’ let’s s look lo ok at the Alarms Alarms… … • • • • • • • • • •

Mill Trip Recycle Pump Trip Recirculation Sump Agitator Trip Mill Liquid Level Low Mill & Mill Motor Bearing & Winding Temperatures Temperatures High Mill Motor Current (amps) High Gear Reducer Lube Oil Pump Trip Gear Reducer & Bearing Temperatures High Gear Reducer Lube Oil Flow Low Gear Reducer Lube Oil Temperature High


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l The Re Reagent Prepara Preparati tion on Sys ystem tem is i s started s tarted in i n the t he follow fol lowing ing sequence sequence.. Note, the Lim Lime esto stone ne Slur lurry ry Sto torage rage Tank mus m ustt be rea ready to t o receive sl slur urry ry… … 1. Mi Mill ll Out Outle lett Sump Sump,, Agit Agitat ator or & Pu Pump mp… … 2. Tower Mill System • • • • • •

Lube Oil System Mill Main Drive Mill Recycle Pump & Recirc Sump Agitator Limestone Pre-Crusher Limestone Weigh Feeder & Silo Gate Valve Limestone Bin Activator… Tanjung Jati B Training

Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l …The Re Reagent Preparatio Preparation n System Sys tem is i s st sta art rte ed in i n the t he followin foll owing g se seque quence nce… … 3. Limestone Slurry Storage System • Slurry Storage Tank (Level not Hi-Hi) • Tank Agitator • Limestone Slurry Feed Pumps


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l We have di disc scus ussed sed system sys tem alarms alarms and the t he st sta art rt--up sequence, seque nce, now lets look lo ok at the basic basic steps for fo r starting the th e Vertic rt ica al Mill and re r elate lated d equipm equi pme ent nt… … Plea lease se consul cons ultt the t he O&M Manual Manuals s for the t he de details tails for fo r starting starti ng and stopp st opping ing the Ve Vert rtical ical Mil Milll and related related equipment.


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Starting the Ball Ball Mil illl System (M (Mil illl Outle Outl et Sum Sump p )… • Open the Mill Outlet Sump Recycle Valve • Close Sump Pump Common Discharge Valve • Open manual Feed Valve to the Hydroclone • Verify that the manual Flushing Valve to the Hydroclone Overflow is closed • Verify that the manual seawater Flushing Valve is closed


Reag en t Preparatio Preparati o n SUMP VALVE ARRANGEMENT DURING START-UP

Vert rtic ica al Ball Mill Mil l FLUSH

FEED

To Vertical Mill Recirculating Sump

Mill Hydroclone

From Vertical Mill Recirculating Sump (Flush Water)

O C Seawater Flush

To Limestone Slurry Tank Seawater Fill

C

C C*

C

* Open Valve if sump level is low

O

Pump Pu mps s “A” “A” & “B” “B”


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Starting the Ball Ball Mil illl System (M (Mil illl Outle Outl et Sum Sump p )… • Place the Mill Outlet Sump Pump in Automatic • Place the Mill Outlet Sump Agitator in Automatic • Once Sump level is achieved, the Pump & Agitator will start. The Sump Pump disch di scha arge flow wil w illl remain remain in i n the th e Recyc cycle le Mode Mode until unti l the t he enti entire re mill sys system tem is in i n ope op eration.


Reag en t Preparatio Preparati o n

SUMP PUMP AND AGITATOR TO AUTO (SHORT RECYCLE)


FEED


Mill Hydroclone


O C Seawater Flush


C

C C

C O



Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Starting the Ball Ball Mil illl System (Hydroclone (Hydroclone)… )… • Verify that 4 of 5 Cyclone Isolation Valves are open • Mill Hydroclone Recycle Valve to manual and open • Open Sump Pump Common Discharge Valve • Close Mill Outlet Sump Pump Recycle Valve • Mill Hydroclone Recycle Valve to automatic



MILL HYDROCLONE IN THE RECYCLE MODE


FEED


Mill Hydroclone


O C Seawater Flush


C

O C

O O




4 of 5 Cyclones open for normal operation

CYCLONES CYCLONE

MILL HYDROCLONE (PLAN VIEW)

MILL HYDROCLONE



OVERFLOW

INLET

MILL HYDROCLONE UNDERFLOW



CYCLONES

Vert rtic ica al Ball Mill Mil l

MILL HYDROCLONE or “CLASSIFIER”

UPPER LAUNDER

LOWER LAUNDER

KREBS U.S.A. Tanjung Jati B Training

Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Starting the Ball Ball Mil illl System (Lu (Lube be Oil Oil Uni nitt )… • Verify Lube Oil Shutoff Valves are Open • Verify Cooling Water Shutoff Valve is Open (Observe cooling water discharging into trench) • Start the Lube Oil Pump • Verify Lube Oil Flow is above minimum, temperature below maximum and differential pressure below maximum


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l DUPLEX FILTER

OIL INLET

OIL OUTLET

OIL PUMP

FLOW METER

MOTOR DIFFERENTIAL SWITCH

OIL COOLER

THERMOMETER (WITH SWITCH)


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Starting the Ball Ball Mil illl System (V (Vert rtic ica al Mill)… Mill )… • Verify Mill Flush & Drain Valves are closed • Seawater Seawater Flow Flow Control Control Valve Valve to manual manual and open open fully fully • Open Seawater Make-Up Isolation Valve • If Mill is empty, open seawater isolation valve. Fill Mill until water is seen overflowing into the Mill Outlet Sump • Verify Seawater Valve to Mill Hydroclone Hydroclone Underflow is open Tanjung Jati B Training


MILL HYDROCLONE

O

O

O

SEAWATER MAKE-UP

O VERTICAL MILL

MILL OUTLET SUMP Tanjung Jati B Training

Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Starting the Ball Ball Mil illl System (V (Vert rtic ica al Mill)… Mill )… • Once water from the Mill Recirculating Sump is seen discharging into the Mill Outlet Sump, the Mill can be started (manually). • If the Mill is in Automatic, Automatic, the Mill will start when the level in the Mill Recirculating Sump is above the low level (switch).



MILL HYDROCLONE

O

O

O

SEAWATER MAKE-UP

O VERTICAL MILL

MILL OUTLET SUMP Tanjung Jati B Training

Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Starting the Ball Ball Mil illl System (R (Recy cycl cle e Pum Pump p & Sum ump p Ag A g i t at ato o r )… )… • Verify Mill Flush and Drain Valves are closed. • Verify Mill Recycle Pump Isolation Valves are open • Verify Mill Recycle Feed Valve is open • Place Pump & Agitator in automatic. Both will start if the level within the Recirculating Sump is above the minimum (low level switch)


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l TO MILL OUTLET SUMP MILL RECIRCULATING SUMP

O

O

O

MILL RECYCLE PUMP Tanjung Jati B Training

Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Starting the Ball Ball Mil illl System (S (Syst yste em Dust Coll olle ecto ctor r )… )… • Verify Instrument Air Isolation Valve is open • Verify Isolation Valves at the Mill and Limestone Feeder are open • Start the Dust Collector • Verify Differential Pressure is not excessive



REAGENT PREPARATION AREA DUST COLLECTOR

LIMESTONE SLURRY TANK (UNDER CONSTRUCTION) Tanjung Jati B Training


INSTRUMENT AIR

O

O FROM TOWER MILL “A” C FROM TOWER MILL “B”

O FROM LIMESTONE FEEDER “A” C FROM LIMESTONE FEEDER “B”

REAGENT PREPARATION SYSTEM DUST COLLECTOR Tanjung Jati B Training

Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Starting the Ball Ball Mil illl System (Cru (Crush sher, er, Fee Feeder der and Bin Activa Activator tor )… )… • Pre-Crusher will start after a short time delay after the Mill is started (automatic) (automatic) • Verify Silo Discharge Gate Valve is open • Limestone Feeder Feeder will start after a short time delay after the Pre-Crusher is started (automatic) • Bin Activator will start (if in automatic) when Feeder is running and Gate Valve is open.


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Limestone Silo

Bin Activator Slide Gate Limestone Feeder

Mill Hydroclone




Vertical Ball Mill Mill Recycle Pump


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l When the th e Lime Lim est ston one e Slu Slurr rry y Sto torage rage Ta Tank Leve Levell reach rea che es the th e hi high gh le l evel set point poi nt,, th the e Mill il l Outle Outl et Sump um p Pump will stop. When the Sump Pump Stop Stops, s, thi this s will wi ll stop s top the t he followin foll owing g equipm equipme ent if i f in automatic mode… Pre-Crusher

→

Limestone Feeder

→

Bin Activator

The Vert rtical ical Mil Milll will wi ll rema remain in in i n service servic e for fl flush ushing ing and prop p rope er shut s hutdow down n (appr (approxi oximate mately ly 60 min minutes) utes)..


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l SHUTDOWN ORDER Limestone Silo

Bin Activator (4)

Limestone Feeder (3)

Limestone Pre-Crusher (2)

Mill Hydroclone


Mill Recirculation Sump

High Level Set Point

Seawater

Vertical Ball Mill (5) Mill Recycle Pump

Mill Outlet Sump Pump (1) Tanjung Jati B Training

Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l The Ve Vert rtical ical Mill is required to opera operate te or run r un for 60 minut min ute es aft fte er the t he Mil Milll Outle Outl et Sump Pump ha h as stopped. This is re r equir quire ed so tha thatt the t he slur slurry ry withi w ithin n the th e Mill willl be wil becom come e finer (smaller) (smaller) and not se s ettle tt le rapidly if the Mil Milll we w ere shutdown shutd own earl rlier. ier. The Mil Milll wil w illl shutdown shutd own automatically utomatically aft fte er 60 minut min ute es if the th e Mill is in i n Automa Autom atic.


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l The Mil Milll Recy Recycl cle e Pum ump p and Mil Milll Reci Recirc rcul ula ati ting ng Sump Ag A g i t at ato o r will continue conti nue to ope op erate rate and slurry will be recycled back to the Ve Vert rtical ical Mill. It is i s re r ecom comme mended nded that the th e Vert rtical ical Mil Milll be b e run for a 5-minu mi nute te peri period od every every 4 hour s . This will preve prevent nt the compacting of ground gr ound lime l imestone stone within the t he Mill ill..


Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l TO MILL OUTLET SUMP MILL RECIRCULATING SUMP

MILL RECYCLE PUMP Tanjung Jati B Training

Reag en t Preparatio Preparati o n Vert rtic ica al Ball Mill Mil l Emerge mergency ncy Shut hutdow down n of o f the t he Ve Verti rtica call Ba B all Mil ill… l… In ca c ase of emergency mergency stop s top due to electri electrical cal fail failure ure or oth o the er ca c aus use e, th the e Mil illl is i s to t o be drained and and wa w ash she ed of all all slurry to preve prevent nt the “ ce ceme menta ntation” tion” of the ha hard rd particles. For next next start-up, start-up , the Ve Verti rtical cal Mil Milll must m ust be fille fill ed wit w ith h water wa ter until unti l the th e wate waterr is se see en overflowi overfl owing ng into i nto the Mil Milll Out utlet let Sump. Sump .


REA GE REA GENT NT PREPA PREPARA RATI TION ON VERTICA L B A L L MIL L (END)


Vertical Ball Mill

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