2007 08 27 KermanMomtazan KHD OFF ShoreTraining Program CementGrindingProcess

KHD Humboldt Wedag GmbH
Joerg Binner
Kerman Momtazan
KMCC Off-Shore Training Program
Cement Grinding Process
Germany, Wednesday, August 29th, 2007
CONTENT
 Power demand
 Grindability of the feed material
 Process description
 Design data of main equipment
 Ball mill
 Design
 Slide shoe bearings
 Lubrication
 Lining and diaphragm wall
 Water dosing system
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CONTENT
 Dynamic separator
 Drive and coarse discharge
 Function principle
 Classifying
process
Operation diagram
 Sealing between cage wheel and housing
 The cage wheel
 Separator features
 Lubrication of the drive and bearings
 Gear box
 Separator fan

CONTENT
 General layout
 Measuring points
 Control loops
 Starting procedure
 Shutting down of the grinding plant
 Blaine measurement according to EN 196 – 6
 Cement classification according to EN 197 – 1
 Early and final strengths of cement types

POWER DEMAND
 How much is the total electrical energy consumed by a complete

cement plant?
 How many percentage is used for raw material and clinker grinding?
 What is the percentage consumption for the cement grinding?

POWER DEMAND
 The total electrical power consumption of a complete cement plant

varies about 80 -100 kWh/t of cement.
 About 80 % of the total power consumption of a cement plant is

consumed by the grinding process of raw- and cement mills.
 The main motor of a ball mill consumes about 30-60 kWh per ton of
cement, depending on cement type.
 In average the motor of a ball mill consumes more than 50% of the
total electrical power of a cement plant.

GRINDABILITY OF THE FEED MATERIAL

Specific energy consumption / kWh/t .
closed circuit
open circuit
Cement fineness / m²/kg (Blaine)

PROCESS FLOW SHEET

Feed material: A)
d: 190,000 m³/h (90 °C) d: 90,000 m³/h (100°C) d: 605 t/h
1. Clinker 95.0%
2. Gypsum 5.0%
Feed size: 0 - 30 mm
5416AS2
350,000 m³/h ( 90°C)
5423FN1 5417FN1
165,000 m³/h ( 40°C)

2 1
5413DA11
5423CN1-4 5417BF1 5415BE1
5111WF2 5111WF1 5413SR1
5115BC1 5416AS3 5614AS4
A) 210 t/h
5416FM1 5417FN2 3,000 cm²/g (BL)

max. 90°C
5417BF2
Gehe zu
0
5411BM1
Water injection
d: 250 t/h d: 395 t/h chamber 1 and 2 4516AS1
d: Design
A) 210 t/h A) 315 t/h Altitude a.s.l.: 1710 m

PROCESS DESCRIPTION
The clinker grinding plant mainly consists of a ball mill and a dynamic separator.
The initial product is a mixture of clinker and gypsum.
All components are fed under control from the prebins via proportioning weigh feeder
and a belt conveyor into the ball mill.
The ball mill is divided into two grinding chambers.
The first grinding chamber is the coarse grinding chamber.
Lifting liners are installed in the first chamber to lift the balls for achieving a good
crushing- and comminuting result.
The two chambers are separated by an intermediate wall.
To ensure the grinding material transport from the first to the second chamber, the
transition wall is provided with slots.
The fine grinding takes place in the second chamber.
This chamber is equipped with a classifying lining to sort the different ball sizes.
The larger balls at the chamber inlet and the smaller balls at the outlet.
The material is discharged by a screw into the outlet housing.

DESIGN DATA OF MAIN EQUIPMENT
Ball mill Ø 5.0 x 16.0 m

motor: 1 x 6,700 kW

BALL MILL – WITH SLIDE SHOE BEARINGS

BALL MILL – FEATURES
 The two-shoe support for ball mills up to 4.6 meter diameter.
 The four-shoe support for larger mills.
 During the 1980’s ball mills became bigger and bigger, plants capacity
became larger and there was a need to change the mill design from trunnion
support to slide shoe support to meet this requirement.
 Change from trunnion to slide shoe support in 1988
 Today, our ball mills are generally equipped with slide shoes for a drive
power of 1,000 to more than 8,000 kilowatt.

BALL MILL – FEATURES
 The main features of slide shoe supported mills are

 lower stresses of the mill shell.
 Less weight, and the overall length is reduced.
 No cast parts are required, which makes manufacturing easier.
 KHD design is the easy alignment during the initial erection and a simple
foundation.
 We are building the slide shoe construction in steel, and do not leave it up to
the customer to make a relatively complicated foundation.

BALL MILL - DESIGN
 mill with slide shoe bearing

and integral drive
 mill with slide shoe

bearing and central drive
 mill with trunnion bearing

and central drive

BALL MILL - DRAWING
16.5 m
5.0 m

BALL MILL - DESIGN

 Speed
nmill = 73 – 76 % of the critical speed
ncrit = 42.3 / di
 Filling degree 28 – 32 %
 Type of main drive
 Girth gear Power factor = 1 (up to 4,500 kW)
 Central drive Power factor = 0.97 (5,000 to 10,000 kW)
 Integral drive Power factor = 0.95 (up to 6,500 kW)

BALL MILL - DESIGN
 from 3.0 to 6.0 meter shell diameter,

with slide shoe support
 mill length from 8.0 to 19.0 m
 design up to 10 000 kW, in operation:

up to 7700 kW

BALL MILL – TRANSPORT

BALL MILL – ERECTION
Slide shoes
pre-assembled
Slide ring
housing
axial bearing

BALL MILL – SLIDE SHOE SUPPORT
 1989: first application

 2006: more than 50 mills equipped with slide
shoes for 1000 to 8000 kW in operation
main features of slide shoe bearings:

- less weight of mill shell, reduced length, no cast parts
features of KHD design:

- easy alignement, simple foundation

BALL MILL – SLIDE SHOE BEARINGS

view before erection of slide
ring housing
4 - Shoe Support
swing-support for 2 shoes
each

BALL MILL – SLIDE SHOE BEARINGS
 oil cooling system for

slide ring and bearing
 high pressure start up system
 oil lubrication

BALL MILL – HOUSING OF SLIDE SHOE BEARINGS

BALL MILL – OIL LUBRICATION UNIT FOR MILL BEARINGS

BALL MILL - OIL LUBRICATION UNIT FOR MILL BEARINGS

BALL MILL – MILL INTERNALS

6 mm 8 mm

BALL MILL – INSIDE
Inlet chute

BALL MILL - INSIDE
Diaphragm
BALL MILL - LINING
Lifting liners Classifying liners

BALL MILL - LINING
FH
FH Mill outlet
FG FG
BALL MILL – WATER DOSING SYSTEM

PROCESS FLOW SHEET

Feed material: A)
d: 190,000 m³/h (90 °C) d: 90,000 m³/h (100°C) d: 605 t/h
1. Clinker 95.0%
2. Gypsum 5.0%
Feed size: 0 - 30 mm
5416AS2
350,000 m³/h ( 90°C)
5423FN1 5417FN1
165,000 m³/h ( 40°C)

2 1
5413DA11
5423CN1-4 5417BF1 5415BE1
5111WF2 5111WF1 5413SR1
5115BC1 5416AS3 5614AS4
A) 210 t/h
5416FM1 5417FN2
3,000 cm²/g (BL)
max. 90°C
5417BF2
5411BM1
Water injection
d: 250 t/h d: 395 t/h chamber 1 and 2 4516AS1
d: Design
A) 210 t/h A) 315 t/h Altitude a.s.l.: 1710 m

PROCESS DESCRIPTION
The air slide conveys the mill discharge and the material of the mill dedusting
filter to the bucket elevator.
From there, it‘s conveyed via airslide to the SKS-separator for classifying.
The fine classified by the rotating cage wheel is collected into cyclones.
The separated coarse fraction (rejects) is returned to the mill for further grinding.
The rejects volume is measured by a flow meter.
The SKS-separator is dedusted into a separate bag filter.
The discharge of the cyclones is transported to the Airlift via airslides.
The accruing filter dust from the separator is also fed into the airslides to the
Airlift.
The cement is transported to the silos via Airlift.
Before the Airlift, a sampling device is installed for taking samples from the
product for analysing fineness and quality.

DESIGN DATA OF MAIN EQUIPMENT
Ball mill Ø 5.0 x 16.0 m

motor: 1 x 6,700 kW
Separator SEPMASTER® SKS – Z 3500

motor: 265 kW
Cyclone: 4 x Ø 3.2 m
System fan 384,000m³/h (inlet)

40 mbar
motor: 630 kW

SEPMASTER® - SKS
outlet head
fan cyclone
coarse
drive

SEPMASTER® - SKS
 First application: 1988

 in 2006: 250 Sepmaster sold
 rotor diameter: 400 to 4600 mm
 air volume: 2.000 to 760.000 m3/h
 different models: SKS-M, SKS-Z, SKS-L

SEPMASTER® - DRIVE AND COARSE DISCHARGE
Coarsedischarge
1 Coarse discharge
1 1
4 Drive
2 Drive
Gearbox
3 Gear box
Cagewheel
4 Cage wheelshaft
shaft
2
3

SEPMASTER® - PNEUMATIC COARSE DISCHARGE

SEPMASTER® - FUNCTION PRINCIPLE
1
2
1 Feed
Feed
2 Fine++air
Fine air
3 Reject
Reject
4
4 Air
Air

SEPMASTER® – CLASSIFYING PROCESS
classifying
zone

SEPMASTER® – OPERATION DIAGRAM
SKS - Z 3500
180
Air Flow
160
365,000 m³/h
140
cut point "d-95" / µm
100%
120
85%
100
70%
80
60
40
20
25 50 75 100
cage speed / %

SEPMASTER® - SEALING
air
Airgap
Air gap
rinsedby
rinsed by
self
self
gap
propelled
propelled
airflow
airflow

SEPMASTER® - CAGE WHEEL



SEPMASTER® - FEATURES
 Rotor shaft supported at both ends (stable run)

 Rotor bearings outside (cool, no dust ingress)
 Shaft ends are flanged on (easy maintenance)
 Drive below (easy access for maintenance)
 All wear parts exchangeable (quick action)
 Air rinsed rotor gap (good against wear, no OSP`s)
 excellent performance (high efficiency for plant)

SEPMASTER® – LUBRICATION
Temperature
Warning:90 °C
Stop: 100 °C
S = Lubrication point
T = Temperature sensor

SEPMASTER® – GEAR BOX
Flow controller Filter

Pump
4 – 13 l/min p = 2 bar ALARM
cleaning required
> 2.5 bar STOP
Oil cooler Temperature
> 75 °C ALARM
> 85 °C STOP

SEPARATOR FAN
Fan Impeller Guide vane controller
actuator

FAN – CHARACTERISTIC CURVE

GENERAL LAYOUT

GENERAL LAYOUT

GENERAL LAYOUT

GENERAL LAYOUT

Measuring points
GIC
PdI
GIC PIC GIC
PdS M
LSA GIC
2 1 LSA
IIA
WISA M
WISA
FIC
SIC TI
FIC
IIA
QIC
FI
PI PdS GIC
To silo
1st LETTER PROCESSING TIC

A ALARM M IIA
F FLOW Gehe zu M IIA
G GAUGING
I CURRENT
L LEVEL
M MOTOR
P PRESSURE
Q QUALITY GIC GIC
S SPEED SWITCHING
T TEMPERATURE FIC FIC
W WEIGHT

BALL MILL – SCREEN SHOT
BALL MILL

CONTROL LOOPS
Loop 1: Fresh feed

The feed rate to the ball mill inlet should be constant.
 Fresh feed + separator rejects = constant
Loop 2: Cement fineness

The cement fineness is controlled by the speed of the separator cage wheel.
The fineness is measured as specific surface acc. to Blaine
Loop 3: Temperature of mill discharge

The temperature is controlled by the quantity of water which is injected into the ball
mill.
 The water injection is starting first into chamber 2.
 The temperature should be maintained at 100 - 115°C.

CONTROL LOOPS
PIC GIC
2 1 C5
FIC FIC GIC

M
C4 TI
SIC
C1 FI C2 QIC
PIC C6 GIC
1st LETTER PROCESSING To silo

A ALARM
F FLOW
G GAUGING Gehe zu M
I CURRENT
L LEVEL TIC
M MOTOR
P PRESSURE
Q QUALITY
S SPEED SWITCHING GIC GIC
T TEMPERATURE
W WEIGHT FIC FIC
C3

CONTROL LOOPS
Loop 4: Cement temperature

Cooling air into the separator is used for cooling of the cement.
The amount of cooling air is controlled by the damper position at the fresh air inlet
of the separator
Loop 5: Pressure at the separator fan outlet
Controlled by the damper position of the dedusting duct.
 Dedusting of the separator
Loop 6: Draught after the mill

Controlled by the damper position of the mill fan.
 Dedusting of the mill
 Transport of fines inside the mill
 Cooling of the cement

CONTROL LOOPS
PIC GIC
2 1 C5
FIC FIC GIC

M
C4 TI
SIC
C1 FI C2 QIC
PIC C6 GIC
1st LETTER PROCESSING To silo

A ALARM
F FLOW
G GAUGING Gehe zu M
I CURRENT
L LEVEL TIC
M MOTOR
P PRESSURE
Q QUALITY
S SPEED SWITCHING GIC GIC
T TEMPERATURE
W WEIGHT FIC FIC
C3

STARTING PROCEDURE
 Starting takes place according to the specified interlocking system.
 It is permitted only in interlocked condition.
 The grinding plant is sub-divided into groups and is also started by groups.

STARTING PROCEDURE – CEMENT TRANSPORT AND DEDUSTING
 Group 5417
Selection of silo 1
Airslide reversing system 5416 DG 1 to silo 1 5811 SO1
Filter control 5817BF1
Filter fan 5817FN1
Airslide blower 5416FN9
Selection of silo 2
Airslide reversing system 5416 DG 1 and 2 to silo 2 5821 SO1
Filter fan 5827FN1
Airslide blower 5416FN10 to 9
Selection of silo 3
Airslide reversing system 5416 DG 1 and 2to silo 3 5831 SO1
Filter fan 5837FN1
Airslide blower 5416FN11 to 9
PROCESS FLOW SHEET – SILO SYSTEM

Air lift bag filter and transport

Rotary lock 5417RF5
Rotary lock 5416RF1
Screw conveyor 5417SC5
Filter fan 5417FN
Air lift
Airlift blower 5416BL1
Bag filter and transport

Filter fan 5417FN4
Airslide blower 5416FN8 to 6 Rotary
lock 5417RF4

PROCESS FLOW SHEET – MILL SYSTEM
to silo

SKS bag filter and transport

Rotary lock 5417RF1
Rotary lock 5417RF2
Filter fan 5417FN1
Filter fan damper 5417LD1


STARTING PROCEDURE – SKS-SEPARATOR
 Group 5413
SKS-Separator
Separator gear lubrication 5413LQ1
Separator drive 5413SR1
Separator fan 5413FN1
Separator fan flap 5413LD1


STARTING PROCEDURE – MILL MATERIAL CIRCUIT
 Group 5416
Mill material circuit
Filter fan 5417FN3
Filter fan flap 5417LD3
Scavenging air fan 5419FN2
Scavenging air fan 5419FN1
Bucket elevator 5415BE1
Rotary lock 5417RF3


STARTING PROCEDURE – AUXILIARY BALL MILL DRIVES
 Group 5411
Auxiliary ball mill drives
Circulation pump 5411LQ1M02
Circulation pump 5411LQ2M02
High-pressure starting lubrication 5411LQ1M01+3
High-pressure starting lubrication 5411LQ2M01+3
Mill lubrication 5411LQ1M04
Mill lubrication 5411LQ2M04
Mill gear lubrication 5411LQ3M01
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- and control delays for pumps and monitoring instruments can
occur.


STARTING PROCEDURE – BALL MILL
 Group 5315
Material transport, clinker, additives transport and dedusting
Filter fan 5117FN3
Belt conveyor 5115BC1
Rotary lock 5117RF3
Proportioning belt weightmeter 5111WF1
Proportioning belt weightmeter 5111WF2
 Group 5411
Ball mill
Ball mill drive 5411BM1
For heating up, all heating systems shall already have been connected a long time before.
if possible, it should be permanently running.

PROCESS FLOW SHEET – FEEDING AND DOSING

SHUTTING DOWN OF THE GRINDING PLANT
 The grinding plant is shut down approximately in reverse sequence

than when 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.

 Group 5111 The fresh feed system is stopped first.
 Group 5315 The material transport runs empty for a sufficient time.
 Group 5411 The ball mill can be stopped when the rejects volume is
sufficiently reduced, the ball.
 Group 5411 The ball 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.

 Group 5416/17/19 The ball mill material circuit can be disconnected if

no rejects are measured any more.
 Group 5413 Separator and separator fan are disconnected.
 Group 5416 The material transport should be run empty for a

sufficient time prior to shutting down.
 Group 5817/27/37 The silo dedusting system is only shut down, if nothing is
withdrawn from the respective silo.

BLAINE MEASUREMENT ACC. TO EN 196 - 6

socket
piston
cell stop cock
manometer
compacted
cement bed
filter paper
bulb
perforated disc

BLAINE MEASUREMENT ACC. TO EN 196 - 6

CEMENT CLASSIFICATION ACC. TO EN 197-1

EARLY AND FINAL COMPRESSIVE STRENGTHS OF

CEMENT TYPES


Joerg Binner
Kerman Momtazan
KMCC Off-Shore Training Program
Cement Grinding Process
Germany, Wednesday, August 29th, 2007

2007 08 27 KermanMomtazan KHD OFF ShoreTraining Program CementGrindingProcess

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Wednesday, March 25, 2020 3

Wednesday, March 25, 2020 4

Wednesday, March 25, 2020 5

 How much is the total electrical energy consumed by a complete

 What is the percentage consumption for the cement grinding?

Wednesday, March 25, 2020 6

 The total electrical power consumption of a complete cement plant

 About 80 % of the total power consumption of a cement plant is

Wednesday, March 25, 2020 7

GRINDABILITY OF THE FEED MATERIAL

Cement fineness / m²/kg (Blaine)

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PROCESS FLOW SHEET

165,000 m³/h ( 40°C)

5115BC1 5416AS3 5614AS4

5416FM1 5417FN2 3,000 cm²/g (BL)

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DESIGN DATA OF MAIN EQUIPMENT

Ball mill Ø 5.0 x 16.0 m

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BALL MILL – WITH SLIDE SHOE BEARINGS

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BALL MILL – FEATURES

 The two-shoe support for ball mills up to 4.6 meter diameter.

 The four-shoe support for larger mills.

 Change from trunnion to slide shoe support in 1988

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BALL MILL – FEATURES

 The main features of slide shoe supported mills are

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BALL MILL - DESIGN

 mill with slide shoe bearing

 mill with slide shoe

 mill with trunnion bearing

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BALL MILL - DRAWING

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BALL MILL - DESIGN

 Type of main drive

 Girth gear Power factor = 1 (up to 4,500 kW)

 Central drive Power factor = 0.97 (5,000 to 10,000 kW)

 Integral drive Power factor = 0.95 (up to 6,500 kW)

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BALL MILL - DESIGN

 from 3.0 to 6.0 meter shell diameter,

 mill length from 8.0 to 19.0 m

 design up to 10 000 kW, in operation:

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BALL MILL – TRANSPORT

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BALL MILL – ERECTION

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BALL MILL – SLIDE SHOE SUPPORT

 1989: first application

main features of slide shoe bearings:

features of KHD design:

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BALL MILL – SLIDE SHOE BEARINGS

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BALL MILL – SLIDE SHOE BEARINGS

 oil cooling system for

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