en

Edition: 10.
2008
Operating instructions BA 841-6083 en

Page 1 of 22
Former edition:
Cement grinding plant

with ball mill and
Separator SKS-Z 3250
Humboldt Wedag GmbH
Colonia-Allee 3
Modifications in this edition:
51170 Köln
Deutschland
Phone. . . . . . . . . : + 49 (0) 221 6504-0
Telefax . . . . . . . . : +49 (0)221 6504-1569
E-Mail. . . . . . . . . : Info@KHD.de
BA 841-6083 en
Operating instructions
INDEX
1. General 3
2. Safety 4
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Use as directed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.3 General references. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.4 Safety regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.1 Explanation of symbols and references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.1.1 Safety symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.1.2 Attention reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.1.3 Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.2 Safety references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.4.2.1 General safety references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4.2.2 Person-related safety references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.4.2.3 General machine-related safety references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4.3 Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3. Process description 8
3.1 Control scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4. Transport 11
5. Assembly 11
6. Preparations for commissioning 12
6.1 Tests without material and checking works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

6.2 Interlocking tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3 Lubricating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.4 Water cooling systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7. Commissioning 14
7.1 Starting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

7.2 Shutting down the plant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
7.3 Optimisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8. Plant operation 18
8.1 Monitoring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.3 Elimination of failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.4 Flow diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Page 2 of 22
BA 841-6083 en
1. General
These operating instructions are meant for the operating staff of the clinker grinding plant. The
essential items for production operation, starting up and shutting down, recognising and
eliminating of operational failures and maintenance of the plant are dealt with here. By a
thorough observation of the indicated items and measures, production interruptions and damage
to the plant shall be avoided.
It is pointed out that the accident prevention regulations must absolutely be observed; the same
applies to the special operating instructions for the individual machines, which are filed in the
plant documentation.
The copyright to these operating instructions remains with the Humboldt Wedag GmbH. The
information contained must not be multiplied, distributed – neither completely, nor in part – or
used for purposes of competition without according authorisation or disclosed to third parties,
unless this has been expressly approved. The non-observance of the above will entail damages.
Page 3 of 22
BA 841-6083 en
2. Safety
2.1 Introduction
The safety regulations for the operation of Humboldt Wedag grinding plants are summarised in
this description.
The attention is drawn to possible risks which can occur in connection with the operation of
Humboldt Wedag grinding plants.
The mentioned behavioural instructions are meant to reduce the risk of hazards or help to largely
avoid accidents, provided that all activities are realised with the necessary care and caution.
The responsible operator must make available these safety regulations to all persons in charge
of commissioning, operation, maintenance and / or repair of Humboldt Wedag grinding plants or
their components.
It is urgently recommended to the responsible person to have the respective persons confirm in
writing their factual knowledge of these safety regulations.
Responsible in the sense of this description is the person charged by the buyer with the
management of and the responsibility for the operation of the overall plant.
For the operation and to ensure that maintenance- and / or repair works can be safely performed,
a responsible person must be indicated who then co-ordinates these works and determines the
competences between operation- and maintenance staff.
The grinding plant is only permitted to be operated, maintained and repaired by especially
trained and authorised staff.
The operation documentation includes additional machine-related safety regulations to be
observed as well.
2.2 Use as directed
All Humboldt Wedag grinding plants are operationally safe and built according to the approved
technical rules.
The Humboldt Wedag grinding plant serves for grinding clinker and the pertaining additives to a
fineness suitable for the intended use.
Starting up, operation and shutting down of the plant must be performed according to the
process-related instructions.
The special connecting and shutting down procedures must be observed, in particular the fuse
protection of all plant sections via the electrical interlockings and emergency disconnections
must be made sure. The checking and monitoring measures required here must be performed
with care.
2.3 General references
Modifications to Humboldt Wedag grinding plants are not admissible.

Such intentions are only permitted to be realised after having consulted Humboldt Wedag
GmbH.
If nevertheless attachments or other modifications are made without the approval of the
Humboldt Wedag GmbH, the operator will take any risk and also the responsibility for the
operation of the entire grinding plant.
Safety and monitoring facilities must absolutely be installed prior to first starting up. By no
means, they are permitted to become or be put out of function.
Page 4 of 22
BA 841-6083 en
The removal or putting out of function of safety systems, e.g. for repair works, must only be made
upon a standstill of the grinding plant after having fuse protected the respective drive. After the
termination of the works, the safety systems must be mounted or put into function again.
2.4 Safety regulations
2.4.1 Explanation of symbols and references
2.4.1.1 Safety symbol
This symbol is found at all safety references in the operating

documentation indicating danger for life and limb of persons.
Observe these references and behave with particular care in
these cases. Make all safety references also known to other
users. Beyond the references given in the operating
documentation, the generally applicable safety- and accident
prevention regulations as well as the works- and operator-
specific safety regulations must be observed.
2.4.1.2 Attention reference
Attention!
This reference is found at items in the operating documentation

which must be particularly observed to ensure that the
regulations, directions, references and the correct course of the
works are observed and damage to or the destruction of
machines and / or other plant components is avoided.
2.4.1.3 Reference
Note!
This reference points out general information on the operation
which must be particularly observed.
2.4.2 Safety references
In the following sections, safety references are marked with the safety symbol.
Page 5 of 22
BA 841-6083 en
2.4.2.1 General safety references
– The grinding plant has been built according to the approved technical rules and is
operationally safe. However, the machines can entail risks, if they are improperly operated
by staff not accordingly trained or if used for purposes other than directed and
commissioned or operated not observing the relevant instructions.
– The competences for assembly, dismantling and mounting again, commissioning, operation
and maintenance must be clearly determined and observed to avoid that, under the aspect
of safety, unclear competences can occur.
– For all works regarding assembly, dismantling and mounting again, commissioning,
operation, conversion, adaptation and maintenance, the disconnection procedures
described in the technical machine documentation must be observed.
– Any kind of working must be refrained from affecting the safety in the grinding plant.
– By according instructions and checks, the operator’s works must ensure cleanliness and
clearness in the area of the machines.
– Unauthorised conversions and modifications influencing the safety of the grinding plant are
not permitted.
– All works in the grinding plant (except for those indicated in the individual sub-assembly
descriptions) must generally be performed only upon a plant standstill with fuse protected
drive.
– All works on hydraulic systems are only permitted to be performed with the oil pressure
relieved (system must be pressureless).
– In any case, for the operation of the grinding plant, the local safety- and accident prevention
regulations will apply.
– As far as provided, sound guards at the machines must be in protecting position during
operation.
– Wear specified personal ear protection.
– Wear protective clothing.
2.4.2.2 Person-related safety references
– The grinding plant is only permitted to be operated, maintained and repaired by authorised,
especially trained and familiarised staff. This staff must have been given a special training by
the respectively responsible persons regarding possible hazards.
– Every person in charge of assembly, dismantling and mounting again, commissioning,

operation and maintenance (inspection, servicing, repair) on the premises of the operator
must have read and understood the complete operating instructions and, in particular,
chapter „Safety and Health“.
Note!
It is recommended to the operator to have this confirmed in
writing in every individual case.
– The operator has to ensure that only authorised persons are working on the machines.
– The operating staff is obliged to immediately notify changes occurring in the grinding plant
affecting the safety.
– The operator must oblige himself to always keep the grinding plant in proper condition.
Page 6 of 22
BA 841-6083 en
2.4.2.3 General machine-related safety references
– Prior to starting the works, the drives and additional systems must be secured against
unintended connection. This is possible with a lockable local VDE-switch (safety
disconnection).
– Generally, for all works performed in and on plant sections, not only all main switches of the
motors must be set to „OFF“, but the main fuse must be isolated.
– The working instructions for isolating or closing the main fuse must be given in writing and
must be counter-signed by the responsible electrician after the completion of the works.
– Remove guards only upon a standstill of the secured drives.
– Prior to starting after repairs, check whether all guards have been mounted.
– With the plant running, it is prohibited to stay in the identified zones of hazard.
– The carrying capacity of lifting facilities must at least correspond to the weight of the heaviest
individual part (see section „Technical Machine Documentation“).
– Upon dismantling and mounting of the individual machine components, the slinging fixtures
indicated in the individual sub-assembly descriptions must be used.
– After an according electric installation or –repair, the applied protective measures must be
tested (e.g. earthing resistance).
– Regularly check warning paintings and renew them, if required.
– All warning references at machines must be kept in complete number and in legible
condition.
– Maintenance and inspection intervals („Maintenance / Maintenance- and inspection list“)

must be observed and be performed and documented by skilled staff only.
– Only genuine spare parts are permitted to be used, as these meet the technical
requirements of the manufacturer. When using other spare parts, there is no right to liability
claims.
Note!
As a supplement, the safety references in the individual sub-
assembly descriptions must be observed.
2.4.3 Use as directed
The grinding plant is designed exclusively for comminuting … (see Technical Machine
Documentation “Customer-specific characteristic and technical data / Field of application”). Any
use beyond this is considered not as directed. The manufacturer will not be liable for resulting
damage, the risk will be borne by the operator.
The use as directed also includes the observation of the conditions for assembly, dismantling
and mounting again, commissioning, operation and maintenance specified by the manufacturer
as well as further regulations laid down in the technical machine documentation.
Page 7 of 22
BA 841-6083 en
3. Process description
The clinker grinding plant essentially comprises ball mill and SKS-separator for finishing and fine
grinding of the end product.
The fresh material is a mixture of clinker, gypsum, limestone and flyash. The components clinker,
gypsum and limestone are fed under control from the prebins into the ball mill via proportioning
belt weightmeters, a belt conveyor and a bucket elevator. The flyash is withdrawn under control
from the prebin via an airslide with the aid of a dosing roller and a flowmeter and fed onto a
further airslide of the ball mill via a vertical emptying device. The flyash can optionally also be
admixed to the grinding material at the ball mill outlet.
The ball mill is sub-divided into two grinding chambers. Normally, the entire length of the grinding
path is sub-divided into portions of one third for the first chamber and of two thirds for the second
chamber. The first grinding chamber is the coarse grinding chamber. Lifting plates are installed in
the chamber as liner plates to lift the large filled in balls for achieving a good crushing- and
comminuting result.
The first and second chamber are separated by an intermediate wall – transition wall - to ensure
that the large balls of the first chamber do not get mixed with the smaller balls of the second
chamber.
To ensure the grinding material transport from the first to the second chamber, the transition wall
is provided with slots through which the pre-ground material enters the second grinding
chamber. In the centre of the transition wall, an opening closed with a screen is provided for to
ensure the desired air draught and the desired dedusting of the mill, respectively.
In the second grinding chamber, fine grinding takes place. It is provided with a classifying lining
to sort the different small ball sizes in the chamber, the larger balls at the chamber inlet and the
smallest balls at the outlet of the chamber. The surface of the classifying lining is corrugated to
achieve a better friction and movement between the lining and the grinding balls. At the same
time, the balls are further lifted as in the first chamber to increase the grinding effect.
The discharge wall at the end of the second grinding chamber differs from the transition wall only
by somewhat larger slots to maintain a good material discharge.
The mill discharge material is directed through discharge wall and discharge screw into the outlet
housing. An air slide conveys the material into a bucket elevator and from there, via a further
airslide, to the separator where the fine separation of the ground material takes place.
The mill is dedusted via bag filters in which the material is separated from the air. The filter
material is fed to the separator together with the mill discharge material
In the separator, fines and coarse material are separated. The fines are drawn into the following
hose filter by the air jet generated by the separator fan via the rotating cage wheel. There, the
fines are separated from the separating air. Via the fan, the separating air is returned to the
separator.
The separated coarse material (rejects) falls into the rejects duct thereby passing the cage
wheel. Via a circular airslide and a pendulum flap, the material falls into further airslides and is
returned to the mill for being ground again.
The rejects volume from the separator is measured behind the last airslide with the aid of a
flowmeter.
The separated product is fed into airslides via screw conveyors and rotary locks, the airslides
conveying the material to the cement silos
Page 8 of 22
BA 841-6083 en
3.1 Control scheme
To achieve a uniform plant operation at constantly high production rate, an optimal utilisation of
the grinding plant is indispensable. Above all, this means to avoid strong deviations in the
material- and gas flows.
Therefore, it is of high importance for the ball mill circuit to keep the feed volume constant.
The feed volume into the ball mill comprises the fresh material components, clinker, gypsum,
limestone and flyash, fed at dosed volumes, as well as the rejects from the separator.
Fresh material + rejects = constant
To ensure a constant feed to the ball mill, the rejects reaching the ball mill from the separator are
measured with a flowmeter. The feed volume of raw material to the ball mill is controlled via the
measured rejects volume.
If e.g. a smaller volume of rejects comes from the separator, the overall feed to the ball mill is
reduced. On that basis, via the automatic control, a larger fresh material volume is required from
the proportioning belt weightmeters. By the increased fresh material requirement, the mill feed
material volume is increased, until the rated value rejects plus raw material is reached again. The
other way round, the raw material is reduced, if more rejects are determined behind the
separator via the flowmeter.
The fineness of the product is, above all, controlled via the separator speed. With the aid of
sample analyses, the product fineness is measured and the speed of the separator matched to
the fineness. In case of a too fine product, the separator speed is reduced, with a too coarse
product, the speed must be increased. Accordingly, also the rejects volume to the ball mill is
changed and is then balanced again via the regulation of the fresh material feed.
For controlling the air flows, the following factors must be considered.
To achieve a safe material transport in the separator and to the product filter as well as to reach
a high efficiency of the separator and the bag filter, during operation, the swirl regulator for the
separator circulating air must be opened by 80 to 100 %.
For cooling the cement during the grinding process, the fresh air flap at the inlet of the ball mill
can be used. Normally, the fresh air flap is open. The air draught required for dedusting and for
the transport of the fines in the mill is set via the swirl regulator of the mill filter fan.
Furthermore, for cooling the cement during grinding, also water can be injected into the mill.
Generally, the water injection is activated as soon as the temperature in the mill discharge
reaches the defined set point. The control regulates the water volume to be injected such that a
set rated value for the mill discharge is maintained. If the temperature decreases to a minimal
value, the water injection is disconnected.
Using a common installation, the water lance is blown out with compressed air to avoid that the
residual water together with the cement dust can clog the nozzle. To keep the water nozzle free
from cement dust, the water pipe is enclosed by a protective pipe. Air is blown into the protective
pipe to keep the water nozzle dust-free.
Attention!
In any case, the protection air fan must be in operation prior to

starting the mill dedusting system.
Page 9 of 22
BA 841-6083 en
To improve the grinding results, a dosing system for grinding aid is installed. The grinding aid is
fed into the chute to the ball mill. Normally, dosing of the grinding aid is interlocked with the
proportioning weightmeters and the material feed volume and can only be connected, when also
the fresh material feed is started.
Page 10 of 22
BA 841-6083 en
4. Transport
(see separate machine documentation)
5. Assembly
(see separate machine documentation)
Page 11 of 22
BA 841-6083 en
6. Preparations for commissioning
6.1 Tests without material and checking works
After the completion of the mechanical and electrical assembly, filling the gears and bearings
with the specified lubricants and lubricating of the machines and additional sets as per lubricating
list, checking works are performed, unless these have already been performed during the
assembly.
Functioning and tightness of the lubricating systems were checked.
Assembly materials and foreign matter must be removed from all material- and gas paths.
Still existing transport guards, if any, mounted to machines and sets must be removed.
After the completion of these works, tests without material must be performed. Pre-condition for
the tests without material is that, after the completion of the mechanical and electrical assembly,
the drives coming into question are notified as ready for connection by the competent supplier
and the sense-of-rotation tests have been made. Here, machines where a wrong sense of
rotation can cause defects (e.g. return locks, rapping mechanisms) must be uncoupled.
Tests without material means starting of individual machines and facilities (without material) via
the local switches/control stand to get an evidence of their proper condition and correct
functioning.
The tests without material are terminated when all re-adjusting works possibly required and
having become necessary are completed and when it is made sure that the mechanical sets can
be operated without further supervision during the time of the interlocking tests.
The notification of readiness for commissioning of the ball mill, the separator etc. by the expert
commissioning staff has been given, i.e. all mechanical/electrical drives and all auxiliary systems
in the grinding plant were previously checked and adjusted according to the commissioning
instructions personally by the expert commissioning staff.
For plants or plant sections not supplied or provided by Humboldt Wedag, the notifications of
readiness must be obtained by the staff respectively responsible in this respect.
Pendulum flaps must be checked for unhindered movement.
All controllable and non-controllable gates, flaps or swirl regulators must be set such that the
entire movement path is passed to ensure that a closed and a 100 % „Open“ position can be set.
It is expressly pointed out that the linkage between the servo drives and the shafts of the flaps or
swirl regulators must be mounted such that it is made sure that the greatest possible torque is
transmitted onto the adjusting mechanism. As far as possible, after the setting procedures, the
flaps and swirl regulators must be moved again with connected blower, the maximal current
consumption of the blower motors to be observed. The flap position should be externally
identified.
The correct sense of rotation of all flaps or swirl regulators must be ensured. If necessary, they
must be displaced by 180° including the drives. A displacement of the stop strips in case of a
wrong installation of the flaps or the swirl regulators is not recommended.
All V-belt drives must be checked for correct alignment and tension.
Certain temperature measuring points must respond to a cable rupture; immediately disconnect
the pertaining drives. The warning and disconnection alarms must be accordingly set and
integrated into the interlocking.
For the monitoring of bearing temperatures, it must be made sure that the resistance
thermometers are in contact with the bearings or bearing shells. Important temperature
monitoring systems must be checked for proper indication with hot oil or water. Pressure
measuring points and pressure measuring lines to the measuring transducers must absolutely be
tight.
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BA 841-6083 en
All water cooling systems are checked and adjusted. A sufficient lighting and the specified
guards must be available.
6.2 Interlocking tests
After the completion of the tests without material, the persons responsible for the electrical and
mechanical assembly will give the release for the interlocking tests.
Pre-condition is the general check of the electrical control system to be made locally or from the
control stand.
Attention!
During the interlocking tests, no mechanical and electrical works

are permitted to be performed on the plant.
The interlocking tests are meant for testing first individual plant groups among them as well as
thereafter in combination to make sure that, upon a failure of a drive, the drives connected in
front in the interlocking chain are immediately disconnected or after specified periods of time. It is
absolutely required that all drives are interlocked in the correct sequence and that the control
system is properly functioning. During the interlocking test, all motors must be running. To
ensure this, it may become necessary to disengage couplings.
Attention!
A simulation of running drives with removed fuses or electrical

slide-in units must not be made in the interest of the later
commissioning.
For variable-speed drives, the notification of readiness for operation also applies to the control.
The pertaining indication instruments must be checked for proper functioning.
6.3 Lubricating systems
All lubricating- and oil pumps are interlocked with the corresponding machine, i.e. upon a failure
of a lubricating system, the respective set and the interlocking chain including all plant sections
connected in front are disconnected.
Other lubricating points and their lubricating intervals may be taken from the lists of lubricating
points in the machine documentation.
6.4 Water cooling systems
The following plant sections are equipped with a water cooling:

1. Mill bearing
2. Mill gear
3. Oil lubrication of the separator gears
Page 13 of 22
BA 841-6083 en
7. Commissioning
7.1 Starting procedure
Prior to starting the grinding plant, the prepared grinding bodies are filled in (with central drive,
abt. 75-80 %). Further filling to 100 % depends on the running-in instructions for the gear and on
the grinding progress in the mill (longitudinal screening).
The prebins are filled with material.
Prior to starting the plant, the dosing- and weighing systems are roughly calibrated with material.
The precise calibration is done after the first trial operation with material.
Starting now takes place according to the specified interlocking system and is permitted only in
interlocked condition.
If possible, for the first trial run, material dosing should be made by hand and should not
immediately be run at full capacity.
During this first trial run, all plant sections must be checked for abnormal noise, leakages and
other problems.
The grinding plant is sub-divided into groups and is also started by groups. Below, the
connection sequence is given in the form of a table.
Note!
Changes in the connection sequence becoming necessary during
commissioning cannot be excluded.
Starting by groups
Group 543/1 Dedusting cement transport
Group 543/2 Cement transport
Group 544/1 System fan SKS separator
Group 544/2 SKS-separator
Group 543/3 Material circuit ball mill
Group 543/4 Ball mill lubrication
Group 543/5 Ball mill main drive
Group 542/3 Material feed flyash
Group 541/2 Dedusting material feed
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BA 841-6083 en
Group 542/1 Material feed

Sampler
Airslide blower 543.81

Rotary lock 543.87
Filter control 543.85
Filter fan 543.86
Rotary lock 543.84
Screw conveyor 543.88
Rotary lock 543.76
Rotary lock 543.83
Rotary lock 543.77
Fresh-air flap 544.44
Circulating-air flap 543.80
Swirl regulator 543.73
Filter fan 543.70
Flowmeter 544.46
SKS gear lubrication 544.43
SKS drive 544.40
Bucket elevator 543.52
Locking-air fan 543.41
Rotary lock 543.65
Swirl regulator 543.63
Filter fan 543.62
Group 543/4 Ball mill lubrication

Feeding pump 543.02
Feeding pump 543.12
High-pressure pump 543.01
Page 15 of 22
BA 841-6083 en
Circulation pump 543.04

Circulation pump 543.14
Low-pressure pump 543.03
Low-pressure pump 543.13
To avoid delays upon starting the mill, the lubrication systems of the ball mill and of the separator
must be started during or prior to the other connection processes.
In particular with cold oil, starting or control delays for pumps and monitoring instruments can
occur.
Group 543/5 Ball mill main drive
Ball mill main drive 543.21

Water injection 543.42
Vertical emptying device 542.41

Filter fan 541.10
Flowmeter 542.39
Dosing roller 542.37
Shut-off gate 542.36
Belt conveyor 542.08
Y-chute 542.09
Bucket elevator 542.06
Belt conveyor 542.05
Proportioning belt weightmeter 542.01

Filter fan 541.20
For heating up, all heating systems shall already have been connected a long time before,
if possible, they should be permanently running.
Page 16 of 22
BA 841-6083 en
7.2 Shutting down the plant
The plant is shut down by disconnecting the proportioning belt weightmeters, the dosing roller for
flyash and the ball mill.
For a short standstill of up to one or two hours, only the swirl regulators in front of the SKS-Z-
separator fan and the mill dedusting system must be closed at their minimal position.
For an extended period of time, the grinding plant must be shut down as described below.
Shutting down the grinding plant

The grinding plant is shut down approximately in reverse sequence than upon being started. If
possible, the circuits should always be run empty to permit the performance of repair-, setting-
and maintenance works without any problem.
The automatic disconnection of the drives takes place at stop intervals with respective delay
times to run empty all sets and transport paths.
In particular dedusting systems must be run empty for a sufficient time.
The material feed (proportioning belt weightmeter, dosing roller) is disconnected first.
Run empty transport elements for a sufficient period of time.
When the rejects volume is sufficiently reduced, the ball mill can be disconnected.
Attention!
It must not be operated for more than 15 minutes without feed

material.
The mill lubrication is disconnected after the mill has come to a standstill, abt. 2 minutes after the
mill stop.
The high-pressure lubrication automatically starts upon stopping of the mill. During interval
turning of the mill, the high-pressure lubrication remains connected.
If the mill is operated at a high process temperature (>105 °C), the mill circulation lubrication
must continue to run (also after the mill stop!) for 2 – 3 hours.
When no rejects can be measured any more, the ball mill circuit can be disconnected.
Separator and separator fan are disconnected.
The material off-transport should be run empty for a sufficient time prior to shutting down.
The silo dedusting system is only shut down, if no material is withdrawn from the respective silo.
7.3 Optimisation
After first starting-up of the grinding plant, the optimisation phase follows for the mechanical as
well as for the electrical scope.
Operating parameters are now finally determined and specifications, if any, matched to the plant.
Due to a change of the grinding material, this can still become necessary at a later date.
The quality of the separating process is determined by taking and analysing random samples.
Page 17 of 22
BA 841-6083 en
8. Plant operation
8.1 Monitoring
During plant operation, the most important operating parameters must be permanently
monitored. Indications in the control stand must be regularly checked for correctness by local
measurements.
To determine changes in the plant (wear, clinker quality etc.), it is necessary to keep plant
journals.
8.2 Maintenance
Maintenance intervals may be taken from the machine documentations. To avoid operational
failures, these intervals must be strictly observed.
To prevent failures and standstills, all filters for water and oil should be cleaned on a weekly
basis. The intervals for the oil- or grease changes may be taken from the lubricating instructions.
Particularly observe oil- and grease specifications.
To make sure that the product transport systems do not cause problems, the airslides should be
checked at intervals of abt. 1 month. If deposits are found in the air boxes, the fabric of the
airslide must be checked.
The V-belts of the individual drives must be permanently checked for proper tension. Wrongly
tensioned V-belts cause damage and plant standstills.
To ensure a good course of operation, wear and defects must be particularly observed as
described in the separate instructions.
Dedusting systems must be checked for tightness and a good dust separation.
Page 18 of 22
BA 841-6083 en
8.3 Elimination of failures
Failure sources ball mill & SKS-separator

Due to
Observations /
Possible causes Measures / checks
Machine
changes Material
Product
Product too coarse
x Feed material too large Matching again feed material
Sample taking mill/ longitudinal

x Changed material composition
screening
x Changed grindability Matching ball filling

Non-matched grinding media
x filling
screening
Matching ball filling
Checking transition walls

x Too strong mill ventilation Checking pressure behind mill
Checking mill filter
x Speed SKS-separator too low Matching speed SKS-separator
Matching SKS separating-air

volume
Sample taking SKS-separator –
x SKS-separator worn down
checking efficiency
Checking SKS-separator
Repairing SKS-separator
Pressure measurements
x Cyclone clogged Checking fan and swirl regulator
Checking cyclones
Product too fine

x Changed material composition Inspection mill

screening
x Grindability material composition
Checking material paths
Non-matched grinding media

x filling
Matching ball filling
Matching speed SKS-separator

Matching SKS separating-air
volume
x Speed SKS-separator too high Sample taking SKS-separator –
checking efficiency
Pressure measurements
Checking fan and swirl regulator
Page 19 of 22
BA 841-6083 en

Due to
Observations /
Machine
Material
changes
Product temperature too high

x Feed material too hot Water injection not in order

x Insufficient mill ventilation Checking pressure behind mill
Checking mill filter
SKS-separator flap setting not

x correct
Matching flap setting
High material circulation

x Feed material size too large Reducing lump size
x Product finenesses too high Reducing SKS-separator speed
Product too hot

x Grinding media cushionings
Water injection not functioning
x Balls worn down Measuring mill filling degree
Inspecting separator
x Separator efficiency
Sample taking separator
Rated value raw material + Reducing rated value

x rejects portion too high (ball mill Checking belt weightmeters and
circuit) dosing rollers
Energy requirement mill

Energy requirement too high
x Ball filling too high Measuring mill filling degree
Grindability of the material 

x worse
Checking grindability
Reducing rated value for material

x Material circulation too high
circulation
Overall energy requirement

Energy requirement too high
x Grindability is worse Checking grindability
Checking preliminary
x Feed material too large
comminution
x Grinding media worn down Checking for wear
x Lining worn down Checking for wear
Page 20 of 22
BA 841-6083 en

Due to
Observations /
Machine
Material
changes
x Separator worn down Checking for wear
Page 21 of 22
BA 841-6083 en
8.4 Flow diagram
Page 22 of 22

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Edition: 10.

Operating instructions BA 841-6083 en

Cement grinding plant

Humboldt Wedag GmbH

Phone. . . . . . . . . : + 49 (0) 221 6504-0

Telefax . . . . . . . . : +49 (0)221 6504-1569

3.1 Control scheme . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6. Preparations for commissioning 12

6.1 Tests without material and checking works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

7.1 Starting procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2 Use as directed

2.3 General references

Modifications to Humboldt Wedag grinding plants are not admissible.

2.4 Safety regulations

2.4.1 Explanation of symbols and references

2.4.1.1 Safety symbol

This symbol is found at all safety references in the operating

2.4.1.2 Attention reference

This reference is found at items in the operating documentation

2.4.2 Safety references

2.4.2.1 General safety references

– Wear specified personal ear protection.

– Wear protective clothing.

2.4.2.2 Person-related safety references

– Every person in charge of assembly, dismantling and mounting again, commissioning,

2.4.2.3 General machine-related safety references

– Remove guards only upon a standstill of the secured drives.

– Regularly check warning paintings and renew them, if required.

– Maintenance and inspection intervals („Maintenance / Maintenance- and inspection list“)

2.4.3 Use as directed

3.1 Control scheme

In any case, the protection air fan must be in operation prior to

(see separate machine documentation)

(see separate machine documentation)

6. Preparations for commissioning

6.1 Tests without material and checking works

6.2 Interlocking tests

During the interlocking tests, no mechanical and electrical works

A simulation of running drives with removed fuses or electrical

6.3 Lubricating systems

6.4 Water cooling systems

The following plant sections are equipped with a water cooling:

3. Oil lubrication of the separator gears

7.1 Starting procedure

Group 543/2 Cement transport

Group 544/1 System fan SKS separator

Group 544/2 SKS-separator

Group 543/3 Material circuit ball mill

Group 543/4 Ball mill lubrication

Group 543/5 Ball mill main drive

Group 542/3 Material feed flyash

Group 541/2 Dedusting material feed

Group 542/1 Material feed

Airslide blower 543.81

Group 543/4 Ball mill lubrication

Circulation pump 543.04

Group 543/5 Ball mill main drive

Ball mill main drive 543.21

Vertical emptying device 542.41

Filter control 541.19

7.2 Shutting down the plant

Shutting down the grinding plant

It must not be operated for more than 15 minutes without feed