TUBE MILL AUDIT

Information required before hand.

Data to be collected from site.

Mill inspection.
Technical services
Tube mill audit
Process flow sheet of the milling system with gas and material flow.

Auxiliary equipment characteristics as per following table.




Tube mill general dimensional data and historical data of mill
internals retrofitting.

Major difficulties limiting performance of system. (Mill is consuming
higher power, mill is not achieving its rated capacity etc.)
Equipment Type Make Power (KW) Critical
dimensions
Output (TPH)
Rated Actual Rated Actual
Suction fan ABB 40 35 60,000 cum/hr
Bucket elevator Chain BHA 30 40 25m hight 100 80
INFORMATION REQUIRED BEFORE HAND
Technical services
Tube mill audit
DATA TO BE COLLECTED
FROM SITE
Manual check at site :

Mill RPM - Matching with design value.
Sound level of the mill. - Matching with control room
value.
Ventilation at inlet of the mill. - High,Medium,Less,No
Damper position of all the fans. - Matching with control room
value.
Leakages from the mill, circuit. - High, Less and where, No
leakages.
Feed condition. - Matching with design value.
Mill motor power meter. - Matching with control room
value.
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Tube mill audits
Collect the trend data of circuit parameters:
FM#6 log sheet of last 24 hrs.
0.00
50.00
100.00
150.00
200.00
250.00
8/20/2003 19:12 8/21/2003 0:00 8/21/2003 4:48 8/21/2003 9:36 8/21/2003 14:24 8/21/2003 19:12 8/22/2003 0:00
Parameters
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4000.00
4100.00
4200.00
4300.00
4400.00
4500.00
4600.00
4700.00
4800.00
4900.00
Sep power BE Kw Sep Speed Mill o/l draft Out temp Mill fan Kw S Fan X 10
Sep damper Mill damper D dust fan D dust damper Rej TPH Feed TPH Mill motor
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Tube mill audits
DATA TO BE COLLECTED
FROM SITE
A
B
C
D
E
F
G
H
A,B,C : Feed sample :10 kg 1 test
D-H : Circuit sample : 0.5kg
3 times every 2 hours

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Tube mill audits
DATA TO BE COLLECTED
FROM SITE CIRCUIT SAMPLE
Sample Quantity Particle size analysis, sieves, moisture
A Clinker 10 [kg] 50, 25, 16, 8, 4, 2, 1, [mm]
B Gypsum 10 [kg] 50, 25, 16, 8, 4, 2, 1, [mm] + %H2O
C Other add. 10 [kg] 50, 25, 16, 8, 4, 2, 1, [mm] + %H2O
D Mill outlet
E Separator reject
F Separator product
0.5 [kg]
212m,90m,45m, Blaine manual
~1- 200 [m] Laser
G Filter product
H Finish product
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Tube mill audits
DATA TO BE COLLECTED
FROM SITE ANALYSIS OF SAMPLES
MILL INSPECTION
Crash stop.

Chamber sampling.

Internal dimensions.

Internal inspection.
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Tube mill audits
The crash stop must be made on stable operation of the mill and
circuit.
Crash stop means simulateneous stappage of:
Mill feed
Mill
Mill fan

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Tube mill audits
MILL INSPECTION CRASH STOP
Chamber I Chamber II
1 2 3 4 5 1 2 3 4 5 6
Dig around deep transverse
trench inside the grinding media
at each sample location.

1-2 Kg sample at each point
Get samples from the level of
grinding media.

0.5 Kg sample at each point
50
cm 100 cm 150 cm
50
cm
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Tube mill audits
MILL INSPECTION CHAMBER SAMPLES
MILL INSPECTION - SIEVES IN
CHAMBER SAMPLE ANALYSIS
% residue
accumulated Sieve [mm] Blaine
Sample 16 10 5 2.5 1 0.5 0.2 0.12 0.09 0.045 cm2/g
1. Chamber 1
2
3
4
2. Chamber 5
6
7
8
9
10
11
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Tube mill audits
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Tube mill audits
MILL INSPECTION
INTERNAL DIMENSIONS
Empty running condition Material lacking condition
Optimum material level Higher material level
Technical services
Tube mill audits
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MILL INSPECTION MATERIAL LEVEL
Head liner :
Remaining thickness min. 40mm for HiCr
Preferential wear check
1
st
chamber liner :
Breakage, Lost plate, Coating on liner
Residual lifting height : 50%
Bolt breakage
Grinding media both chamber :
Breakage, Wear, De-shaping
Maximum and minimum size of GM
Coating on grinding media
2
nd
chamber liner :
Breakage, Lost plate, Coating on liner
Residual thickness : 50%
Bolt breakage
Diaphragm slot and blind plate :
Remaining thickness minimum 25mm.
Slot chocking,
Breakage or crack,
Preferential Wear,
Coating on Liner
Diaphragm structure:
Gaps between structure,
Bolt breakage,
Crack on structure,
Flexibility,
Level controlling device
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MILL INSPECTION WEAR CONDITION