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© Copyright 1990-2010, Lafarge SA. All rights reserved. BALL MILLING incl. SEPARATORS – Page 1/25
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CEMENT PROCESS ENGINEERING VADE-MECUM
CHAPTER 1-1 – BALL MILLING INCLUDING SEPARATORS
Table of Contents
1. Ball Mill General ............................................................................... 3
1.1. Comparison of Grinding Equipment ................................................................3
1.2. Mill Design .......................................................................................................3
1.3. Percent loading of mill .....................................................................................3
1.4. Mill Critical Speed ............................................................................................4
1.5. Retention Time ................................................................................................5
1.6. Mill Throughput ................................................................................................5
1.7. Required air velocities for mill ventilation ........................................................5
1.8. Optimum filling ratio: ........................................................................................5
7. Separator ........................................................................................ 17
7.1. Circulating Load (CL).....................................................................................17
7.2. Tromp Curve ..................................................................................................17
7.3. Indicators for Cement Milling and Typical Values .........................................19
7.4. Recommended Sizing for a HES...................................................................20
10. References...................................................................................... 24
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CHAPTER 1-1 – BALL MILLING INCLUDING SEPARATORS
* Integral grinding is not used for cement grinding due mainly to quality issues with the narrow particle
size distribution of the product. Hence semi-integral grinding using a closed circuit roller press and
closed circuit ball is more common with a circuit power consumption of around 30 kWh/t.
πr 2
0.7
where:
r is the radius 0.6
h is the free height
h−r 0.5 0
α (degrees) = arccos
10 20 30 40 50%
r % volume load
© Copyright 1990-2010, Lafarge SA. All rights reserved. BALL MILLING incl. SEPARATORS – Page 3/25
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Rules of thumb
• % vol. Load = 111.87 – 123.98 (h/d), 25 – 50%: error max 0.6%.
• It is estimated that material increases the actual ball filling ratio by about 2%.
• Another method (quick but not as accurate) consists in counting the number of visible shell liner
plates (n) and to divide by the total number of shell liner plates per circumference (N): Angle α =n
x 360 / N.
Values of angle h/d ratio in relation to the ball load (% filling degree)
Ball load (%) h/d n/N Ball load (%) h/d n/N
20 .7459 .667 31 .6516
21 .737 32 .6434 .590
22 .7281 .653 33 .6352
23 .7193 34 .627 .580
24 .7106 .639 35 .6189
25 .702 36 .6109 .569
26 .6926 .625 37 .6028
27 .685 38 .5948 .558
28 .6765 .611 39 .5868
29 .6682 40 .5789 .549
30 .6598 .601 41 .5709
42 .563 .539
60 2 g 42.3
• Mill critical speed: nc = = with D in meters
4 π2 r D
% Critical speed:
• Practically, mill speed between 68 and 82% of critical speed.
• % critical speed is the mill actual speed in RPM divided by nc.
Example:
3.98 meter mill with rotational speed of 15.6 rpm then nc = 21.2, % critical speed = 73.6 %.
© Copyright 1990-2010, Lafarge SA. All rights reserved. BALL MILLING incl. SEPARATORS – Page 4/25
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CEMENT PROCESS ENGINEERING VADE-MECUM
CHAPTER 1-1 – BALL MILLING INCLUDING SEPARATORS
© Copyright 1990-2010, Lafarge SA. All rights reserved. BALL MILLING incl. SEPARATORS – Page 5/25
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CHAPTER 1-1 – BALL MILLING INCLUDING SEPARATORS
Quick calculation:
• Ball diameter (mm) = 3 250 P (P = weight in g)
785 2
• Specific surface of balls of diameter = m / mt (d = diameter in mm)
d
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CHAPTER 1-1 – BALL MILLING INCLUDING SEPARATORS
Wear rates:
In the 1st compartment the wear rate is correlated with the average ball weight (positive correlation),
whereas in the 2nd compartment it is correlated with the ball charge surface area (positive correlation as
well). Below are general guidelines for raw as well as cement grinding wear rates:
Raw grinding
• Raw mix with free silica (quartz) content <5%: 30-60 g/t
• Raw mix with free silica (quartz) content >5%: 50-100 g/t
Cement
• CEM I, clinker >90%, 300 m2/kg : 30-60 g/t
• CEM I, clinker >90%, 450 m2/kg: 60-100 g/t
• CEM III, slag 70%, 300 m2/kg: 60-120 g/t
• CEM III, slag 70%, 450 m2/kg: 120-200 g/t
• Suppliers would typically guarantee <40 g/t for CEM I
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3.2. Ball charge design for new mill without pre-existing experience
Closed circuit finish mill
Chamber 1 Chamber 2
Coarse charge Fine charge Coarse charge Fine charge
Ball size (mm) Ball size (mm)
% % % %
40 (transition
90 40 21 10
zone)
80 29 38 30 25 15
70 19 25 25 25 15
60 12 16 20 20 30
17 20 40
Average ball Average ball
1.83 1.63 47 34
weight (kg/ball) weight (g/ball)
Specific surface
32 37
(m2/t)
Note: With high circulating loads, as with oversized separators the coarser grading in the 2nd chamber is
more suitable to help maintain charge permeability
1
The recommended volume loading for minimum kWh/t is based on an acceptable compromise with production. For
minimum kWh/t the volume loading can be as low as 22% in the second compartment. Due to risk of breakage the
minimum volume loading in first compartment shall not underpass 25%.
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Chamber 1 Chamber 2
Coarse charge Fine charge
Ball size (mm) Ball size (mm) %
% %
90 40 21 30 10
80 29 38 25 10
70 19 25 20 20
60 12 16 17 60
Average ball Average ball
1.83 1.63 30
weight (kg/ball) weight (g/ball)
Specific surface
39
(m2/t)
Raw mills
Chamber 1 Chamber 2
Coarse charge
Ball size (mm) % Ball size (mm) Fine charge %
%
90 40 60 20
80 29 50 30 30
70 19 40 30 30
60 12 30 20 40
Average ball Average ball
1.83 260 186
weight (kg/ball) weight (g/ball)
Specific surface
18 21
(m2/t)
Note: Up to 50% 90 mm are used in some mills
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Slegten Model
• Compatible mostly with classifying linings in the second compartment.
Transition Zone
• This is the start of the second compartment and its job is to crush any oversize that penetrated the
diaphragm
• The design for this area is to use "n" balls of 50 and 40 mm.
Ø Ball (mm) Number/ 10 t of Charge
50 1820
40 1820
• The largest ball size used in this transition zone can be identical to the smallest ball size used in the
first compartment.
Second Compartment – Fine Grinding
• The envelope curve for the balls smaller than 40 mm follows the following formula:
• D = 3.3e −010.x
where:
- D = Ø ball (cm)
- x = distance from transition zone finish (m)
• The 30 mm balls start at the completion of the transition zone and the exponential curve follows.
Rule of thumb:
• The smallest ball size should, as a minimum, be at least twice the width of the slots in the grates (ex.
≥16 mm balls if slots are ≤8 mm wide). For this reason, it is generally recommended to use ¾” (19
mm) balls as the smallest size in Finish mills. 5/8” balls are fine when the grates are new but often
become problematic as the grate slots enlarge.
1st compartment useful length = 3.81 m, 2nd compartment useful length = 7.66 m
Using an average ball weight of 1.65 kg per ball and 3 ball sizes in the first compartment for
the Slegten model.
Ball size and % Polysius Slegten
compartment load design design
1st compartment 3 ½” 31.0% 32.1%
3” 31.2% 43.1%
2 ½” 37.8% 24.8 %
2nd compartment 2” 2.31% 7.67% Transition zone
1 ½” 23.73% 2.94%
1 ¼” 34.05% 10.08%
1” 2.57% 48.18%
¾” 37.34% 31.13%
5/8” - (Some)1
A limited amount of 5/8” balls should theoretically be added but the designer decided to
use ¾” as the smallest ball size.
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4. Grinding Laws
4.1. Absorbed Power of a Mill
• Only 5-10 % of the energy is used for grinding, 90% is wasted into heat, wear, noise…
• With similar ball charge gradation and similar liners' lifting effect, the absorbed power is related to:
- Tonnage of balls
- Mill rpm
- % volume load
- Mill diameter
Slegten formula
1.27
⎛ rpm ⎞ π
• P = W * ⎜⎜ ⎟
⎟ * K j * K Fr and W= * Fr 2 * L * J * d
⎝ Vcr ⎠ 4
where:
- P : the motor absorbed power (kW) - J : the ratio between the apparent ball
- W : the weight of the load (T) volume and the internal volume
- Fr : internal diameter (inside liners) (m) - rpm: is mill speed (rpm)
- d is the apparent density of load (t/m3)
#1 comp : d = 4.5
#2 comp : d = 4.65, if fine ball size distribution (average ball weight < 40 g)
d = 4.6, if coarser ball size distribution (average ball weight > 40 g)
Average : d = 4.6
⎛ 42.3 ⎞
- Vcr is the critical speed inside liners= ⎜ ⎟ , L : the useful length of mill (m)
⎜ F ⎟
⎝ r ⎠
K j = 1.36 − 1.2 J , K Fr = C.Fr
0.379
-
- K Fr is the influence of the location of the center of gravity for the moving ball charge vs. the mill
center (C is a constant depending on the material and the liners).
- C= 11.262 for Clinker mill closed circuit with Slegten equipment
10.7 for clinker + slag, 12.16 for raw mix, 10.1 for slurry
1.27
⎛ rpm ⎞ π
• P = L * ⎜⎜ ⎟
⎟ * J* K j * * Fr2.379 * d * C
⎝ cr ⎠
V 4
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Simplified formula
⎡ RPM ⎤ 100 Fr
• P =T *⎢ ⎥* *Kj * * 9.5
⎣ Vcr ⎦ 75 1.366
Kj Function of Volume Load
Volume load Kj
40% 0.9
30% 1
20% 1.1
Rules of Thumb
• One metric tonne of balls increases the mill power draw by 10 kW.
• Usually, 8 to 12 kWh/t is absorbed in the first compartment for clinker grinding (approximately 1/3 of
the mill power)
Rules of thumb
• Raw material: 10-16 kWh/t (mill motor) target fineness: passing 200µm>99%, passing 90µm>88%
depending upon burnability of raw mix)
• Clinker: 45 ± 15 kWh/t at 350 m2/kg (mill motor). For a pure cement (95% clinker) at <400 m2/kg, the
mill motor consumption should be <40 kWh/t.
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5. Grindability Measurement
Lafarge Data
• 60 clinkers. Typical results are 48-60 kWh/t 3500 m2/kg.
BB10 for 250 m2/kg for 300 m2/kg for 350 m2/kg for 400 m2/kg
kWh/t kWh/t kWh/t kWh/t kWh/t
Minimum 21 30 39 49
Average 29.2 39.8 51.8 65.3
Maximum 43 56 68 83
Remark: An average CEM I 32,5 at 300 m²/t can be ground with 28kWh/t related to the mill main drive.
The additional energy for finer grinding should not exceed the Normalized Blaine fineness equation
described in chapter 4.2.
Formula
44.5 dp100 is the sieve with 100% passing feed material
Wi = dp80 80% feed material
⎛ 10 ⎞
d p 100 0.23 • P 0.82 * ⎜⎜ ⎟
10
− ⎟⎟
df80 80% finish material
⎜ d p 80 d f 80 P is the production (g/rev of mill) of product at the level the
⎝ ⎠
circulating load is requested.
Wi is the Bond work index kWh/short ton.
• Developed to predict energy requirements of 2.44m diameter, wet, closed circuit, ball mill at a
fineness of either 65 mesh (220 µm) or 100 mesh(150 µm).
• Pre-crush feed to #6 (3.35 mm). Maintain 700g sample in test mill. Turn mill 100-150 rev.
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• Remove undersize (dp100 – 65 or 100 mesh) and replace with fresh feed (300 – 400 g). 1st cycle is
now completed. Repeat procedure until steady state is reached. Typically 6-8 cycles so that 200 g
are removed at each cycle, which equals 250% circulating load or 30% of “P”.
• The Work index expresses the specific net energy needed to grind a material from indefinite feed size
to dp80 =100 µm
• Wi for Raw materials for cement plants are usually in the range of 8 – 16 kWh/st
*Clearlythe Wi can vary significantly from these figures depending upon the nature of the materials and material testing is
necessary for each particular case when assessing a mill.
Bond gave the following equation to convert HGI into a Bond Wi:
435
Wi =
HGI 0.91
Other similar relationships can be found in the literature. Ranges of HGI found in cement plant raw
materials are given below:
Material HGI*
Clay 130 – 160
Coal 35 – 90
Limestone 60 – 120
Shale 60 - 170
Silica Sand 30 - 100
*Clearlythe HGI can vary significantly from these figures depending upon the nature of the materials and material testing is
necessary for each particular case when assessing a mill.
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PA Where:
PIFMA = PA – actual specific power consumption mill drive
PT PT – quasi theoretical specific power consumption,
calculated from standard grindability figures
The theoretical power consumption at a standard surface of 300 m2/kg calculated by:
P
T 300
=
1
MF
(
• X C • SPC C + X G • SPC G + X S • SPC S + X A • SPC A + X P • SPC P + X L • SPC L + X O • SPC O )
Where:
XC, XG, XS, XA, XP, XL and XO are the weight fractions of clinker, gypsum, slag, flay ash, pozzolan,
limestone and other components in the product.
MF is the mill type factor = 1 for a ball mill, =1.6 for a Horomill, = 1.7 for Vertical mill and 1.8 for a roller
press
SPC refers to the standard grindability kWh/t of the components at 300 m2/kg. The standard figures
used are:
Note the low figure used for fly ash is to adjust for it’s initial surface
The theorectical specific power consumption at 300 m2/kg is then corrected to the actual product
surface area SA, by the following equation:
fs
⎛ SA • (1 − 0.1 * ( X G + X A + X P + X L )) ⎞
P = P •⎜ ⎟
T T 300
⎝ 300 ⎠
Where:
fs = Factor Separator (1.6 for open circuit, 1.5 for first, 1.4 for second, 1.3 for third generation separator, 1.0
for roller press, 1.10 for vertical mill & 1.05 for Horomill)
Subtraction of the term 0.1*(XG+XA+XP+XL) from the surface area is meant to correct for over-grinding of
the softer components.
The resulting PIFMA will be influenced by the mill efficiency and by the grindability of the cement.
Therefore especially in cases of high PIFMA (>1.15) the grindability of the components and the condition
of the milling system will need to be investigated to find improvement potential.
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Calculate the theoretical power consumption at a standard surface of 300 m2/kg by:
P
T 300
=
1
MF
(
• X C • SPC C + X G • SPC G + X S • SPC S + X A • SPC A + X P • SPC P + X L • SPC L + X O • SPC O )
P
T 300
1
( )
= • 0.8829 • 28 + 0.0347 • 10 + 0.0168 • 43 + 0.0656 • 10 = 26.4 kWh / t
1
Next calculate the theoretical power consumption at the actual product surface area using:
fs
⎛ SA • (1 − 0.1 * ( X G + X A + X P + X L )) ⎞
P = P •⎜ ⎟
T T 300
⎝ 300 ⎠
1.3
⎛ 369 • (1 − 0.1 * ( 0.0347 + 0.0656)) ⎞
P = 26.4 • ⎜ ⎟ = 34.2 kWh / t
T ⎝ 300 ⎠
Finally calculate the PIFMA
P
PIFMA = A = 35.6 = 1.04
P 34.2
T
The power consumption for a new mill can be estimated from the Bond Equation:
⎛ 10 10 ⎞⎟
Where:
Ws = FB • 1.102 • Wi • ⎜ − Ws – calculated industrial mill shaft power kWh/t
⎜ P 80 F80 ⎟⎠ P80 – Product 80% passing size µm
⎝ F80 – Feed 80% passing size µm
FB - Bond Factor for dry grinding normally 1.3
⎛ 10.3 + P80 ⎞
FP = ⎜⎜ ⎟⎟
⎝ 1.145 • P80 ⎠
The Bond equation can also be used for benchmarking existing mills in conjunction with actual mill shaft
power consumption (WSA kWh/t) to compute the Bond factor:
WSA
FB =
⎛ 10 10 ⎞⎟
1.102 • Wi • ⎜ − •F
⎜ P 80 F ⎟ P
⎝ 80 ⎠
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The Bond equation is also useful to assess the potential impact of changes to mill feed or product size.
7. Separator
7.1. Circulating Load (CL)
Junction with Three Streams
A • A, R, F are the feed, rejects and fines of the separator
- ai , ri , f i are the cumulated % passing at a defined sieve(i).
- da, dr, df are the % retained corresponding to the sieve interval dx.
- A=R+F
- A da = Rdr + Fdf
R F
R df − da F dr − da
With: da = a i + 1 − ai , = , =
A df − dr A dr − df
Drawing CL calculation
• Plot ( f i − a ) vs ( f i − ri ) • Using the least square line calculations,
If the mill circuit is steady, the graph has to with α = 0
be a straight line:
( f − a) = α + β( f − r ) Quick CL calculation
- α should be close to 0 • With one set of results of sieving:
R R f −a
- β is the most probable value of =
A F a−r
- The circulating load is defined as:
R β
=
F 1− β
• On the Gauss-logarithmic paper, let's plot the probability for a given particle of a certain size entering
dr( x )* R
the separator to go to the rejects = with:
da( x )* A
n
∑
( f i − ai )( f i − ri )
R i =0
=
A n
∑
( f i − ri ) 2
i =0
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• The Tromp curve can be divided into Tromp Curve Representation OSEPA N1500
two straight lines
• The higher sieve fractions have a 99.8
99.5
slope which is representative of the 99
98
separator efficiency (a perfect one
95
would be vertical).
% Probability of Rejection
90
80
70
60
50
40
30
20
10
5
b) Imperfection
• d 75 − d 25 where:
I= - d25 is the size of the particle which has 25 % chance of going to
2 * d 50 rejects
- d50 is the size of the particle which has 50 % chance of going to
rejects
- d75 is the size of the particle which has 75 % chance of going to
rejects
0.42
0.40
0.38
0.36
0 100 200 300 400
Circ. load (%)
c) Acuity Limit
• AL is the abscissa of the intersection of the two Tromp curve lines.
• It’s the size at which selection is initiated
d) Bypass
Definition:
• By-pass is the ordinate of the intersection of the two Tromp curve lines.
• The bypass is the lowest percentage of feed that will go to the separator rejects.
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Bypass vs. feed rate – Sturtevant Bypass vs. feed rate O’Sepa/Sturtevant
• The following graph shows the Bypass of an
18’Sturtevant versus its feed rate. 80
100
70
Sturtevant
60
80
Bypass (%)
50
Bypass (%)
60 40
30
40
20
O-Sepa
10
20
0
1.0 1.5 2.0 2.5 3.0 3.5
0 Qf/Qa (kg feed/m3 separator sweep)
50 100 150 200 250 300
Feedrate to Separator (t/h)
40
QF/Qa vs. bypass
• If Qf is the separator feed rate (kg/h) and Qa 30
the separator ventilation (m3/h),
Bypass (%)
• Qf/Qa is an important ratio for the separator 20
efficiency.
⎛ Qf ⎞ 10
⎜⎜ − f1 ⎟
Qa ⎟⎠
• Bypass = 1 + e ⎝
0
- f1: coefficient for the separator 0 1 2 3 4
Qf/Qa (kg/m3)
7.3. Rosin Rammler Number (RR#) RRnumber vs. Feed to Air Ratio
•
1.20
The steeper the particle size distribution (RR#
high) the more efficient the grinding and
Rosin-Ramler Number (n)
1.15
separating process.
1.10
• Raw mix RR# are usually lower than those for cement 1.05
grinding
1.00
1.0 1.5 2.0 2.5 3.0 3.5 4.0
Qf/Qa (kg/m3)
Separator Performance
• Rate of recuperation in the fines of particles smaller than a given dimension.
F f
r= *
A a
7.4. Indicators for Cement Milling and Typical Values
Slope Rosin Rammler 1.1 – 1.4 for HES
fines: 0.85 – 1.0 for 1st generation separators (Sturtevant, Raymond)
1.2 for second generation separators
% recovery, 45 μm: 45 to 55% for Sturtevant and >65% for HES
Acuity: 20 – 30μm for Sturtevant and <0.30μm for HES
Imperfection: <0.35 for HES
0.45 – 0.6 for Raymond separators
0.6 –0.7 for Sturtevant separators
Bypass: 5 – 10% range for HES
Circulating load: 150 –200 % with HES
HES Qf/Qa: 1.5 – 2.0 range
% Passing 45 μm: 93% minimum (45 μm = 325 mesh)
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1,0 m/min
less than 1,2 m/min
Filtration Velocity Pulse jet H.P.
0,8-1,3 m/min
or Air to cloth ratio 1,1 m/min
less than 1,2 m/min
Pulse jet L.P.
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8. Grinding Aid
Type of Products
• Surface active agents tend to saturate the free valence and inhibit the pack-set. Typical surface-
active agents are:
- ligno-sulphonates
- polyoils
- amines
- organic acids
• Polar compounds (water, ammonia) are known to have some action on such bonds through their
polar moment. However, their practical use as surface agents is limited by their other impacts on the
cement properties.
• Other agents, particularly coal dust, have been used in the past.
• Commercial products available as grinding aids are essentially (60-800 g/t ck):
- Triethanolamine
- Polypropylene glycols and polyethylene
• HEA2, DDA& and other products cause a definite reduction of pack-set but do not prevent
agglomeration or lump-formation problems that are caused by:
- Alkalis ( K 2 SO4 )
- Moisture
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9. Other Data
9.1. Sieve Sizes
Sieve Screen Micron Iso alter Screen Micron Iso alter
#400 37 38 #14 1400
#325 44 45 #12 1700
#270 53 53 #10 2000 2000
#230 63 63 #8 2360
#200 74 75 #7 2800
#170 88 90 #6 3350
#140 105 106 #5 4000
#120 125 125 #4 4750
#100 149 150 #3.5 5600
#80 177 180 1/4" 6350 6300
#70 210 212 5/16" 8000 8000
#60 250 250 3/8" 9510 9500
#50 297 300 7/16" 11200 11200
#45 354 355 1/2" 12700 12500
#40 420 425 5/8" 16000 16000
#35 500 500 3/4" 19000 19000
#30 595 600 7/8" 22600 22400
#25 707 710 1" 25400 25000
#20 850 1"1/4 32000 31500
#18 1000 1000 1"1/2 38100 38100
#16 1180 2" 50800 50000
© Copyright 1990-2010, Lafarge SA. All rights reserved. BALL MILLING incl. SEPARATORS – Page 22/25
INTERNAL USE ONLY Version September 2010
CEMENT PROCESS ENGINEERING VADE-MECUM
CHAPTER 1-1 – BALL MILLING INCLUDING SEPARATORS
CONVERSION OF
% residue at 90μm
SIEVE RESIDUES
70
50
40
30
355 μm
20
250 μm
12.0%
10
200 μm
180 μm
7
5
150 μm
4
3
125 μm
106 μm
0.7
0.5 90 μm
0.4
80 μm
0.3
14.22%
63 μm
0.2
75 μm
56 μm
% residue
12.0%
50 μm
45 μm 25 μm
0.1 0.7 1 2 3 4 5 7 10 20 30 40 50
© Copyright 1990-2010, Lafarge SA. All rights reserved. BALL MILLING incl. SEPARATORS – Page 23/25
INTERNAL USE ONLY Version September 2010
CEMENT PROCESS ENGINEERING VADE-MECUM
CHAPTER 1-1 – BALL MILLING INCLUDING SEPARATORS
10. References
© Copyright 1990-2010, Lafarge SA. All rights reserved. BALL MILLING incl. SEPARATORS – Page 24/25
INTERNAL USE ONLY Version September 2010
CEMENT PROCESS ENGINEERING VADE-MECUM
CHAPTER 1-1 – BALL MILLING INCLUDING SEPARATORS
My notes:
© Copyright 1990-2010, Lafarge SA. All rights reserved. BALL MILLING incl. SEPARATORS – Page 25/25
INTERNAL USE ONLY Version September 2010