Factors Influencing The Grinding Efficiency

Slegten grinding course 1
Factors influencing the grinding efficiency

- Ventilation
- Moisture
- Water injection
- Coating
- Grinding Aid
- Product addition: limestone
slag
Purpose:
Fluidization / progress of the material
Removal of fine particles risk of coating
Cooling of the material coating / gypsum dehydration
Usual ranges of ventilation:
Air speed Amount of air:
Open circuit : 0.8 to 1.2 m/sec Open or closed circuit:
Closed circuit: 1.2 to 1.5 m/sec 0.3 to 0.45 Nm
3
/kg

Ventilation

0,10
0,20
0,30
0,40
0,50
0,60
0,70
1,0 1,8 2,0 3,0 4,0 5,0 6,0 7,0
Mill diameter in m
Q
u
a
n
t
i
t
y

i
n

N
m
3
/
k
g

0,45 Nm3/kg
0,3 Nm3/kg
0,7 m/sec
1,0 m/sec
1,2 m/sec
1,5 m/sec
Comparison between m/sec et Nm3/kg:
Ventilation
AIR FLOW

Open circuit
The filter product goes directly to the finished product.

Open or closed circuit
A high ventilation
can result in a transportation of uncrushed particles from Cpt 1 to Cpt 2
can have a bad influence on the material level in Cpt 1
is necessary if fresh feed is moist
In general, it is necessary:
. to limit to 20-25 m/sec at mill feed entrance
. to limit to 15 - 25 m/sec in the diaphragms
. to provide a feeding chute with air passage
. to provide an isolation device at mill discharge
Ventilation Limits
Inlet Chute
Ventilation
Influence of the moisture on the ginding efficiency
Moisture
Solutions to high moisture

- Use hot clinker
- Control rejects temperature (closed circuit)
- Work at high circulating load
- Dry the material
Moisture
Water injection
Purpose
Maintain the outlet temperature
< 105 C (115 C max)
coating

dehydration of gypsum

Dehydration of gypsum
. in the mill: short stay
not too bad effect
. In the silo: long stay
extremely serious

100
80
60
40
20
0
10 20 30 40 0
150C
140C
130C
120C
110C
EFFECT OF TEMPERATURE ON GYPSUM DEHYDRATION
TIME OF EXPOSURE (minutes)
D
E
H
Y
D
R
A
T
I
O
N

%

Water injection
Rules :

Cpt 1
If clinker temperature > 80 C at mill inlet ---> max 1 % H20 (on fresh feed)
The water has to be dropped on the fresh feed or at mill inlet
No spray, just drop

Cpt 2
The water has to be sprayed close to 2
nd
Cpt inlet
The water can be sprayed from intermediate or outlet diaphragm

A PID regulation and a security device has to be foreseen

Water injection
AIR
WATER
MATERIAL
AIR
WATER
FEED
Equilibrium: IN = OUT
KW
Shell
3 parameters:
. Mill outlet temperature
. Necessary amount of water
. Mill ventilation

Also take into account: thermal balance on the separator
Water injection Thermal balance
Example of calculation - Open Circuit
Basis 4m x 13m
2900 kW
97 t/h
Feed temp: 90 C
Air and water temp: 15 C
Air amount through mill: 26900 Nm
3
/h
Cement temperature: 105 C
IN Energy
Material
Air
Water
2900 kW x 0,85 x 860 Kcal/kW / 97000 kg cem =
0,19 kcal / kgC x 90C =
0,31 kcal / Nm
3
C x

26900 Nm
3
/h x 15C / 97000 kg cem =
1597 l/h x 15C / 97000 kg cem =
21,85 kcal/kg cem
17,10
1,29
0,25
40,49
OUT Shell
Cement
Air
Water
750 Kcal / m
2
h

x 188 m
2
/ 97000 kg cem =
0,19 kcal / kgC x 105C =
0,31 kcal / Nm
3
C x 26900 Nm
3
/h x 100C / 97000 kg cem =
1597 l/h x [ 537 kcal/kg + 100 kcal/kg + 0,44 kcal/kgC x(100C - 100C) ] / 97000 kg cem =
1,45
19,95
8,60
10,49
40,49
Feed: 102C
194 t/h recirculated air:
135 000 m3/h
18 980 m3/h at 86C
fresh air:
feed/air ratio: 15 000 m3/h
Process: dp f ilter: 1,29 kg/m3 78C at 15C
18 980 m3/h 150 mmWG
at 91C
300 mmWG A/F= 2
Fines: 91C 150 000 m3/h
Process: 97 t/h
f ilter product 155 858 m3/h
at 91C dp cycl: dp sep:
500 mmWG 100 mmWG 250 mmWG
Product:
97 t/h
3000 Blaine Tails: 92C
at 86C 97 t/h
dp f ilter:
impact 150 mmWG Design:
f lowmeter 47 000 m3/h
400 mmWG
at 90C
26 908 m3/h
at 15C 43 649 m3/h
at 91C
dp mill: 200 mmWG
air speed: 1,34 m/sec 15,0% false air
FRESH FEED: T/H: C: %H2O:
Clinker 92,15 90 0 2900kW
Gypse 4,85 18 15 105 C cement
0 0 0 0 water injection: f ilter product
0 0 0 0 0 l/h
tot fresh feed: 97 86,4 0,75 475 l/h
Company: Plant: Mill: Separator: SD 100
BAG FILTER
SEPARATOR
MILL
E
L
E
V
A
T
O
R
ch.1 ch.2
FAN
PROCESS AND THERMAL FLOW-SHEET
MILL FILTER FAN
CYCLONE
HD
FAN
clinker add.1 add.3 add.2
materialflow:
air flow:
air-materialflow:
Thermal balance Water injection
% of each component IN and OUT heat balance
according to mill (30 kWh/t - 1,2 m/s - clinker 100C)
1,8 2 2,2 2,4 2,6 2,8 3 3,2 3,4 3,6 3,8 4 4,2 4,4 4,6 4,8 5 5,2 5,4 5,6 5,8 6

Diameter (m)
0%
10%
20%
30%
40%
50%
60%
IN : % energy
IN : % material
IN : % air
IN : % water
OUT : % shell
OUT : % cement
OUT : % air
OUT : % water
Water requested in % according to mill
for different air speeds - 30 kWh/t - clinker 100 C
Thermal balance Water injection
1,8 2 2,2 2,4 2,6 2,8 3 3,2 3,4 3,6 3,8 4 4,2 4,4 4,6 4,8 5 5,2 5,4 5,6 5,8 6
Diameter (m)
0,0%
0,5%
1,0%
1,5%
2,0%
2,5%
3,0%
0.7 m/sec
1 m/sec
1.2 m/sec
1.5 m/sec
Definition:
Agglomeration of fine particles (on lining and/or on grinding media)
grinding efficiency decrease
Reasons:
* Overgrinding (often in O.C., fine cement grinding and limestone addition)
* Too high outlet temperature in Cpt 2 ( > 110 C at mill outlet)
* Fresh feed moisture
Solutions:
* limit the fines - good mill ventilation
- good separator
* Avoid outlet temperatures > 105 C (ventilation, water injection, separator)
* Use grinding aids
* If coating is due to moisture, dry by hot clinker, hot rejects or hot gas

Coating
Rittinger
With
G.A.
Without
G.A.
Mill outlet fineness SSB (m
2
/kg)
Purpose : fight coating

Rittinger Law :
produced Blaine is directly
proportional to grinding efficiency
in theory, grinding efficiency
(cm
2
/j) constant
in reality, not constant because of
agglomeration negative
effects

Grinding Aids
Grinding Aids
Function principles:
Coating : due to static electricity on the generated areas
make them stick together
G.A.: contain components which neutralize cement grain
superficial charges
decrease these electrostatic forces

better grinding efficiency
production gain 5 - 30 %

Disadvantage: high price
Grinding Aids
Grinding Aids
Other advantages:
. Improve cement flow . One can use finer ball charge
. Easier cement transport to silos
. Silo build up elimination

. Allow a higher amount of additional components other than clinker
. Improve product quality
* Optimize cement particle size distribution
* Improve cement strengths 1, 2 and 28 days
Way of use:
GA sprinkled on fresh feed (diluted with water)
In general .01 % to .08% are added (250 gr/t)
Quantity (and efficiency) increase with Blaine fineness
Thionvilloise (100 %
laitier)
Thyssen (100 % laitier)
Sidmar (100 % laitier)
Atlantic (100 % laitier)
Ssang Yong (100 %
laitier)
Nittetsu (100 % laitier)

Slag grindability
Slag
Surface spcifique Blaine Surface spcifique Blaine
C
o
n
s
o
m
m
a
t
i
o
n

s
p
c
i
f
i
q
u
e

(
k
W
h
/
t
)

C
o
n
s
o
m
m
a
t
i
o
n

s
p
c
i
f
i
q
u
e

(
k
W
h
/
t
)

Slag grindability Clinker grindability
Slag
Slag Vs Clinker: Grindability
Slag
Properties of slag grinding:

- Beneficial on kWh/t if slag < 15 %

- Moisture problems (if slag not dried)

- Higher wear (balls / liners)
Slag
slag influence - increase of the spec.grinding energy vrs slag
content and blaine
0
10
20
30
40
50
60
70
80
90
100
2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200 4400 4600 4800 5000 5200 5400 5600
blaine
%
20%
40%
100%
Log. (100%)
Log. (40%)
Log. (20%)
Slag
Limestone
- prone to coating

- increase artificially the Blaine value

- mind slot sizes and moisture
Influence of the pozzolana on the specific grinding energy
Source Holderbank
0
10
20
30
40
50
60
70
80
2000 2500 3000 3500 4000 4500
blaine
k
W
h
/
t

(
m
i
l
l

s
h
a
f
t
)
100% clinker
95% cl + 5 % gypsum
85%cl.+ 5% gyp.+ 15% poz.
75%cl.+ 5%gyp.+ 20% poz.
65%cl.+5%gyp.+30% poz
Limestone

Factors Influencing The Grinding Efficiency

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Slegten grinding course 1

Factors influencing the grinding efficiency

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