In the name of Allah, the Beneficent, the Merciful

Mill check up

Slegten grinding course

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 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

Mill check up
Check up Procedure
1. Technical 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 compartments are visited and examined
7. Samples are collected in the mill
8. Separator visit
Slegten grinding course

Survey before crash stop

Technical Data Sheet

Flow sheet
Ball charge history
Dailyproduction time
Sheet history
Auxiliary capacities
Control systems (if any)

Slegten grinding course

Survey before crash stop

Main parameters

C PJ 35

C PJ 45

3 0 tp h
( 2 8 .9 tp h )

( 2 7 .0 9 tp h )

61%
6%
33%

77 %
6 %
17 %

20 - 24 % R 40

15 - 20 % R 40

60 A m p
( 710 kW )
2 3 .6 k W h /t
( 2 4 .5 k W h /t)

60 Am p
( 710 kW )
(2 6 .2 k W h /t)

SEPARATOR
T ype
F re s h a ir d a m p e r
A ir f lo w
A ir r e c irc u la tio n d a m p e r
R e je c t o u tp u t
C a g e s p e e d ( 1 0 -4 0 r p m )

50 % o p en
3 6 0 0 0 m 3 /h
100 % open

50 % open
3 6 0 0 0 m 3 /h
100 % open

2 0 rp m

2 4 rp m

M IL L
D E D U ST IN G
A c tu a l a ir flo w
D a m p e r p o s itio n
D e p re s s io n a t m ill in le t
D e p re s s io n a t m ill o u tle t

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

yes
no
yes
6 0 - 1 3 -1 0 - 1 0

C IR C U IT F E E D IN G
O u tp u t ( d u rin g th e v is it )
A v e ra g e 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 im e s to n e
3 .5 %
a m b ie n t
F IN IS H P R O D U C T
F in e n e s s ( ta r g e t)
A BSO RBED PO W E R
M o to r a m p s
( A b s o rb e d p o w e r)
S p e c ific p o w e r

M IS C E L L A N E O U S
E ar
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

Slegten grinding course

Survey before crash stop

Sampling : separator & filter

0
1

9 mm 10 mm

Slegten grinding course

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

Slegten grinding course

Internal Visit of the Mill

Collecting of
samples

Slegten grinding course

Internal Visit of the Mill

Grinding balls
characteristics

Slegten grinding course

Internal Visit of the Mill

Filling
degree

Slegten grinding course

10

Internal Visit of the Mill

Filling
degree
ST = p x D2/4
H1 = H - D/2
A = 2ARCOS(2 x H1/D)

m2
ST

m
H

H1

A
S1 = D2/8 x (p x A/180 - sinA) m2
S1
R = S1/ST x 100

Slegten grinding course

11

Measured filling degree

Filling degree (%) / H/D

0.8

D
H

0.75

H/D

0.7

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 (%)

Slegten grinding course

12

Internal Visit of the Mill

Grates slots size

check up

Slegten grinding course

13

Internal Visit of the Mill

Cpt. length and
liner thickness

Slegten grinding course

14

Internal Visit of the Mill

Discovery of unground
particles &
untightened grates

Slegten grinding course

15

Internal Visit of the Mill

Material level and
filling degree in 2nd cpt.

Slegten grinding course

16

Internal Visit of the Mill

Other various
measurements

Slegten grinding course

17

Separator Inspection

Space between blades and external casing

Fan general condition
Seals and valves general condition
Holes in distribution plate
Coating
Wear follow up.
Slegten grinding course

18

Separator Inspection

Slegten grinding course

19

Theoretical curves
CUMULATIVE PERCENT RETAINED
35
1/2"

30

1/4"
25

8M

20

16 M
30 M

15

50 M
10

100 M

200 M

0
1

10

Slegten grinding course

20

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

Partition

% Retained

55,0%
50,0%

#4
#8

45,0%

#16

40,0%

#30
#50

35,0%

#100

30,0%

#200

25,0%
20,0%
15,0%
10,0%
5,0%
0,0%
1

10

11

Position in Mill

Slegten grinding course

21

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
Partition

% Retained

50,0%
45,0%

#4
#8
#16

40,0%

#30

35,0%

#50

30,0%

#100
#200

25,0%
20,0%
15,0%
10,0%
5,0%
0,0%
1

10

11

Position in Mill

Slegten grinding course

22

Conclusions from findings

5.18 m x 10.36 m 4100 kW
65,0%

Partition

60,0%
55,0%
50,0%
45,0%
Percent Retained

1/2"
40,0%

1/4"
#8

35,0%

#16
#30

30,0%

#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

Slegten grinding course

23

Conclusions from findings

CUMULATIVE OVERSIZE DISTRIBUTION (%)

75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
CH1/1

10
2.36
1.18
0.6
0.3
0.09
0.044

CH1/2

CH1/3

CH1/4

CH2/1

CH2/2

CH2/3

CH2/4

CH2/5

CH2/6

Slegten grinding course

24

Conclusions from findings

Granulometric curves
40.00

35.00

% cumulative residue

30.00

25.00

18 mm

20.00
11,2 mm
8 mm

15.00

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

Slegten grinding course

25

Conclusions from findings

99
98
97
96
95

90
85
80

70
60
50
40

characteristics
30
20

d75..............: 78.90

15

d50..............: 60.58

10

d25..............: 46.52
Imperfection.....: 26.73 %

dl...............: 10.00

4
3
2

#N/A

10

100

1000

Slegten grinding course

26

Conclusions from findings

0.1

99.9

99

finish
Product

10
20

95
90
80

30

70
63.2

36.8

Filter

50

50

Separator
feeding

60
70
80

40
30
20

Fines

85

15

90
10

Rejects

95

5
96

97

98

99

99.5
0.1

0.5
1

10

100

1000

dimension

Slegten grinding course

27

Conclusions from findings

Granulometric curves
40.00

35.00

% cumulative residue

30.00

25.00

18 mm

20.00

11,2 mm
8 mm
15.00

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

Slegten grinding course

28

Filling degree

ST = p x D2/4

m2

H1 = H - D/2

A = 2ARCOS(2 x H1/D)

ST
H

H1

S1 = D2/8 x (p x A/180 - sinA) m2

S1
R = S1/ST x 100

Slegten grinding course

29

Conclusions from findings

PLANT :
SEPARATOR :

OBOURG
SD150

dim.

fines
%P

feed
%P
2
4
8
16
20
25
30
45
60
75
80
90
120
200
210

Blaine :

5.92
10.26
15.87
23.67
27.32
32.33
37.73
55.39
70.56
81.55
84.25
88.65
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
76.37
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

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 cm2/gr 3778 cm2/gr 715 cm2/gr

Circulating load : 2,81

correlation : 0,9681

vf : 0,356

vg : 0,644

Slegten grinding course

30

Conclusions from findings

100

d75
d50

dl
10

Characteristics

by-pass

tromp %

d25

d75...........: 36,32
d50...........: 26,45
d25............: 19,26
Imperfection : 32,25 %
dl................: 14,41
by-pass....: 11,28 %

1
1

10

100

1000

Slegten grinding course

31

Conclusions from findings

PLANT :

sep. inlet
Sieve ()
0.7
1.4
2
3.2
4
8
12
18
30
45
56
70
90
110
135
165
210
260
Blaine

Mill :
Date :

OBOURG

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 sep.
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. rejects Filter blaus.

3 diam. 5,2m
25/03/1994

finish product

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 cm2/gr 2841 cm2/gr 1324 cm2/gr 3216 cm2/gr 3187 cm2/gr
Slegten grinding course

32

Conclusions from findings

100.00

10.00
sep. inlet
Passing %

Fines sep.
sep. rejects

1.00

0.10
0.1

10

100

1000

10000

dimension

Slegten grinding course

33