Guide Grind Plants 3rd Edition11 PDF

Guideline on plant and
process evaluation
for grinding plants
HeidelbergCement Group
3rd Edition
As of September 2002
Authors: HTC-PPE/PRC
Gerd Gudat
Melchior Buhendwa
Guideline on plant and process evaluation
for grinding plants
Edition: 3
Contents
1 Fundamental data on the test / target
2 Plant scheme
3 Plant examination – „control on site“
4 Recording of the operating mode

4.1 General operating data
4.2 Pressure and temperature
4.3 Air/gas quantity measurement
4.4 Material temperature curve
5 Sampling
5.1 Complete sampling/analysis
5.2 Meter sampling – ball mill
6 Ascertainment of the operating state during shut down

period
7 Evaluation
7.1 Separator assessment
7.1.1 Evaluation „Separation curve“
7.2 Assessment „Internal inspection of ball mill”
7.2.1 Mill filling ratio
7.2.2 Power consumption at mill tube
7.2.3 Average ball diameter
8 Assessment „Mill drying plants“

8.1 Balance preparation
8.1.1 Air quantity balance
8.1.2 Heat balance
9 Literature, standards, guidelines
10 Appendix
Guideline-Grinding-Plants-3rd-Edition1.doc 19.09.02 1/53

for grinding plants
Edition: 3
Plant register
1 Forms „Control on site“
2 Forms “Control room data”
3 Form “Pressure and temperature curve”
4 Form “Material temperature curve”
5 Form “Mill inspection and observations”
6 Form “Mill internals 1st & 2nd chamber”
7 Form “All around samples”

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1 Fundamental data on the test / target
An examination for the assessment of a grinding plant should allow to

carry out all measurements and samplings during a stable plant
operating state. A reliable test requires a period of at least 8 hours.
A grinding plant is to be examined,
Ø when the plant is new (to record the fundamental state) or a mill test
has not been carried out at the plant so far,
Ø if deviations from the expected grinding capacity occur,
Ø as routine controls, approx. once a year to assess the actual state of

the plant.
Target: the test is primarily to show the actual state of the plant and is
part of current control. Furthermore, it helps to create the basis for
optimization measures.
The following overview shows the deals with the procedure of a mil test.
If possible, the test should be divided into the following periods:
Control in site At first, only a visual and audible control,

partly by recording visible plant settings
on site
Recording of the operating Includes:

mode − Ascertainment of the control room
data
− Assessment of the actual setting
and
Recording of the operating − Pressure

data on site − Temperature
− Special features
Sampling Complete tests
Recording of the actual state Plant inspection during shut down period

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Important: the control room protocol during the test period should be
used. Additionally, all relevant data is to be recorded in hourly intervals.
2 Scheme of a typical plant
Ø Feeding station for components (with scales)

Ø Roller press (optional)
Ø Ball mill
Ø Static separator; preliminary separator (optional)
Ø Mill dedusting filter
Ø Dynamic separator with filter (or cyclones + filter)
Ø Auxiliary equipment for material transport
A device list of the plant equipment is generally to be prepared, which

includes the relevant data (dimensions, parameters) of the used parts.
Pic. 1: Scheme of a typical grinding plant with separator filter

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Pic. 2: Scheme of a typical grinding plant with cyclones + filter

for grinding plants
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3 Plant examination – “control on site”

(cf. form “Control on site” in the Appendix)
Tasks
Ø State of the weight equipment; when was the last calibration/control?

Is a control necessary?
Ø Material flow conditions; homogeneous discharge without
segregation; if not, which kind?
Ø Grinding aid addition; constant input; yes/no
Ø State of the conveying equipment
Roller press
Ø Regular running without unusual change of the grinding opening

Ø Unusual sound
Ø Unusual vibration
Ø Roller gap (right/left)
Ø Hydraulic pressure (right/left)
Ø leakage, e.g. hydraulic cylinder
Ball mill
Ø Audible control during running period over the mill length; protocol on
unusual sound with meter number (chamber 1 and chamber 2)
Ø Visual control
Ø Dust emission or similar
Ø Material output at the inlet
Ø Control of well running valves at the mill outlet (discharge valve!);
impermeability
Static separator
Ø Position of the guide vanes

Ø Control of discharge valve on well running and impermeability
Ø Leakages (dust/air)

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Edition: 3
Mill filter
Ø Leakage etc. (false air)

Ø Cleaning
Filter, fan
Ø Setting (inlet vane control system, valve or speed of rotation)

Ø Vibration
Dynamic separator
Ø Position and number of counter blades

Ø Position of the guide vanes
Ø Well running of discharge valves
Ø Sound/vibration
Ø Leakages
Separator/fan
Ø Setting (inlet vane control system, Flap)

Ø Vibration
Separator filter
Ø Leakage etc. (false air)

Ø Cleaning
Cyclones
Ø Well running of discharge valve

Ø Impermeability of discharge valve
Auxiliary equipment
Ø Bucket elevators
Ø Conveying equipment etc.
− Control on obvious damage; audible control as well
− Vibration etc.
− Leakage

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4 Recording of the operating mode
4.1 General operating data
Power consumption of:

Ø Roller press
Ø Ball mill
Ø Separator (including fan)
Ø Mill filter fan
Ø Auxiliary equipment
with kWh meter (locally)
Speed of rotation
Ø Separator (min.-1 or %)
− Rotor/ Counter blades
Ø Mill filter fan
− Speed of rotation (min.-1 or %)
− Valve position/inlet vane control system
Throughputs
Ø Feed components, continuously
Ø Grits, actual value
Ø Circulating load, actual value in the control room
In general: the control room protocol is to be considered during the test

period! All relevant data is to be recorded in hourly intervals!
4.2 Pressure and temperature measurements
Recording of the static pressure with an U-tube as well as of the gas

temperature at the following spots:
Ø before ball mill

Ø after ball mill/before static separator
Ø after static separator
Ø between filter and fan
Ø after fan
Ø dynamic separator; pressure difference of the fan

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Further pressure and temperature curve
Ø before separator filter

Ø after separator filter
Ø after separator filter fan.
4.3 Air/gas quantity measurement
Measurement of:
Ø mill exhaust air quantity (before or after fan)
Ø separating air quantity (example: air separator)
Ø possible cooling air quantity (after separator filter)
4.4. Temperature of the material
Material temperature
Ø Feed material
Ø after mill
Ø Filter dust (mill filter)
Ø Separator feed material
Ø Separator grits
Ø Fine separator grains
Ø Separator filter dust
Ø Finished material.
Important: it is necessary for all measurements (air quantities,

pressure, temperature), that at least two measurements are carried out
during constant running. If deviations occur, further measurements have
to be carried out to receive a reliable result.

for grinding plants
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5 Sampling
5.1 Complete sampling
In a test period of around 8 hours, at least two samplings should be

carried out during constant operating state. Since the number of
complete samples strengthens the importance of the test, further
samples should be taken. The additional staff, time and device
expenditure for the sampling procedure and analysis should, however, be
considered.
One the one hand, the following tables describe the sampling, location,
quantity etc. and suggest analyzing types on the other. If “individual
sample” is stated, the sample is to be taken in short time intervals at the
sampling location over the complete material flow width – no “sampling
with the big bucket (put in and there we are!)”… In case of a large
number of samples, please use a sample divider in the laboratory.
It is important for each sampling to consider the number of samples as

representative for the sampled material flow!
Appendix 3 shows a table fro recording of complete sample results.

for grinding plants
Edition: 3
Sampling plan
Location Type Quantity Frequency Sampling

1. Feed Bulk sample during Main components every 3 hours Material flow over
test period ≥ 5-6 kg each the complete width
Others
≥ 2-3 kg each
2. Roller press Bulk sample during ≥ 4-6 kg each every 3 hours cakes vehicle
-cakes- test period of each roll section
≈ 2 kg
3. Mill discharge Individual sample ≥ 1-2 kg each every 2 hours Over complete
material flow
4. Static Individual sample ≥ 1 kg each every 2 hours Over complete

separator material flow
-Grits-
5. Cyclone Individual sample ≥ 1 kg each every 2 hours Slot sampler

separator
6. Mill filter Individual sample ≥ 1 kg each every 2 hours In short time

Discharging intervals
screw
7.1 Separator feed Individual sample ≥ 1-2 kg each every 2 hours Over complete
material flow
7.2 Separator grits Individual sample ≥ 1 kg each every 2 hours Over complete
material flow
7.3 Fine separator Individual sample ≥ 1 kg each every 2 hours Over complete
grains material flow
8. Separator filter Individual sample ≥ 1 kg each every 2 hours In short time

Discharging intervals
screw
9. Finished Individual sample ≥ 1 kg each every 2 hours Over complete

material material flow
Important:
Blending section of
sufficient length!

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Edition: 3
Analyzing plan
Location Analysis Analyzing method Evaluation

1. Feed Sieve analysis*** DIN 4188 Particle size distribution
Grindability** Zeisel Grindability in kWh/t
Mineralogy** X-ray diffractometer
RFA
(Main component)
2. Roller press Sieve analysis*** DIN 4188 Particle size distribution

Clarify cakes
desagglomeration
3. Mill discharge Sieve analysis**** DIN 4188 Particle size distribution

Laser granulometer Laser granulometer
Specific surface Blaine
4. Static separator Sieve analysis**** DIN 4188 Particle size distribution

-Grits- Laser granulometer Laser granulometer
5. Cyclone separator Sieve analysis**** DIN 4188 Particle size distribution

Laser granulometer Laser granulometer
6. Mill filter Laser granulometer Laser granulometer Particle size distribution

7 Separator feed each*: Particle size distribution

Ø Feed material* Sieve analysis**** DIN 4188 and
Ø Separator grits* Laser granulometer Laser granulometer separation curve
Ø Fine separator grains* Specific surface Blaine calculation (Tromp
curve)
8. Separator filter* Laser granulometer Laser granulometer Particle size distribution

9. Finished material* Laser granulometer Laser granulometer Particle size distribution

*
Measurement of the complete particle size distribution
**
Only if required!
***
Sieve analysis suggestion: 32/16/8/4/2/1/0.5/0.2/0.09 mm
****
Sieve analysis suggestion: 2/1/0.5/0.2/0.09/0.045/0,032 mm

for grinding plants
Edition: 3
5.2 Meter sampling during internal ball mill inspection
For assessment of the grinding process along the mill center, the meter
samples will be evaluated.
For this purpose, a material sample of 1 to 2 kg is taken in meter

intervals, starting at the inlet (0 m). The sampling is not to be carried out
directly at the surface, but from the level of the 3rd or 4th particle layer.
After the partition wall, it is started again at 0 m. The last sample is also
taken before the outlet wall.
Definition of the method

Three samples are taken in each sampling meter:
a. on the mill center
b. approx. 1 m right of the mill center
c. approx. 1 m left of the mill center
To get a representative sample, some balls should be removed and the

material taken from inside the ball charge.
Inlet Outlet Direction of rotation
1.0 m
Pic. 3: Positions for meter sampling

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Edition: 3
Analysis and evaluation of meter samples
General: - Sieves analysis for both chamber**

- In 2nd chamber also specific surface acc. Blaine
Evaluation: In a diagram: Residue (particle size) and Blaine as function

of mill length
** Grading curve suggestion:

32/16/8/4/2/1/0.5/0.2/0.09 mm for 1st chamber
4/2/1/0.5/0.2/0.09/0.045 mm for 2nd chamber

for grinding plants
Edition: 3
Mill No. CM 1 Mill: ø 3,4 x 13,6 m
Length ch. 1: 3,8 m Legth ch. II: 9m Separator: ZUB 38/4

Filling degree: 26% Filling degree: 26,80% Cement: CEM II A -S 32,5 R
Lining: Lifting Lining: Classifying with 30% slag
Diaphragm: Adjustable Fineness: 3300 cm²/g Blaine
R0,032 mm = 20%
100 3000
90 2800
80 2600
70 2400
spec. Surface Bleine [cm²/g]

60 2200
Residue [M-%]
50 2000
40 1800
30 1600
20 1400
10 1200
0 1000
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Length [m]
Diaphragm Diaphragm 32 µm 63 µm 90 µm 630 µm

1 mm 2 mm 4 mm Blaine
Pic. 4: Grinding diagram

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Edition: 3
6 Ascertainment of the operating state during shut

down period
Aggregate area Ascertainment of the operating state during shut down

period
Roller press Ø State of the roller surface
Ø Fractures, Wear
Ø Spalling
Ø Gap width between roller and side plate
Ø State of the internal primary seal:
o Grease collar visible: good
o No grease collar: plant maintenance
Ø Zero gap
Ball mill Condition:

Mill has to be shut down during operation (incl. mill fan) –
otherwise risk of fine material output!!
Internal inspection:
Ø Meter sampling along the total length of the mill (cf. 5.2)
Ø Filling volume determination
Ø Ball charge determination (cf. 7.2.1)
Ø Control mill internals:
o Breaks / Wear
o Inlet / outlet wall thickness
o Control of diaphragm on:
o Slot width
o Obstructions (clogging) of the slot wall
o Material thickness
o Adjustment of diaphragm control system
(if adjustable)
Ø Evaluation of classifying effect
Ø Random sampling from ball grading (cf. 7.2.3)
Static air separator Position of louvers or blades

for grinding plants
Edition: 3
Aggregate area Ascertainment of the operating state during shut down

period
Cyclone separator Wear
Mill filter Ø Condition of filter bags

Ø Wear
Mill fan Ø Wear of inlet vane control system
Dynamic separator A) Turbo air separator

Ø Wear of
o Upper/internal fan blades
o Distributor plate
o Counter blades
o Material feed cone
o Grit cone/lining
Ø Position and number of blades
B) Cyclone air separator

Ø Wear of
o External fan
o Internal louver
o Distributing plate
o Counter blades /rotor
Ref. to rotor: sealing between rotating and fixed part
Ø Ascertain louver setting
Ø Position and number of counter blades
Ø Material deposit in cyclone inlet?
Ø Separator lining
C) Cage separator
Ø Wear on
o rotor
o Guide vane
o Distributing plate
o Sealing of rotor between fixed and rotating part
o Separator lining
Ø Sealing of rotor: Adjustment of gap between fixed and rotating
part
Separator fan Ø Wear
Auxiliary equipment Ø Wear, holes, leakage

e.g. bucket elevator

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7 Evaluation
7.1 Separator assessment
Definitions
M = Fresh material [t/h]

A = Separator feed [t/h]
F = Separator fines [t/h]
G = Separator grits [t/h]
a = Passing of A [%]
f = Passing of F [%]
g = Passing of G [%]
“Passing” means the weight share of a material as percentage, which

particle size is smaller than or equal to the standard particle size;
Passing (D) + residue (R) = 100%.
∆a = Weight share of a particle class of A [%]

∆f = Weight share of a particle class of F [%]
∆g = Weight share of a particle class of G [%]
“Particle class” means the range between two particle sizes (xi); the sum
of the weight shares of all particle classes of a material comes up to
100%.
For the calculation of the “Passing” (D) of a particle class must be

applied:
Dx=x(min) = 0%
and
Dx=x(max) = 100%
Additionally, these fundamental equations are applicable:
A=F+G (1)
A⋅a=F⋅f+G⋅g (1.1)
A ⋅ a = F ⋅ ∆f + G ⋅ ∆g (1.2)

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The following sub items are classified in the system of naming below:
VF = Take out of fines [%]

VG = Take out of grits [%]
u = Separator circulating load [%]
η = Separation efficiency [%]
t = Separation degree [%]
dt = Cut size [µm]
Take out of fines and grits
F Σa − Σg
vF = = (2)
A Σf − Σg
G
vG = (3)
A
vG = 1 − vF (4)
with:
VF = Take out of fines [-]

VG = Take out of grits [-]
Separator circulating load
The circulating load (u) defines the relation between feed quantity and
fine material amount:
A 1
u = = (5)
F vF
or related to particular particle classes:
f −g
u = (5.1)
a−g

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Separation efficiency
The separation efficiency (η) is related to a particular particle class; it

means the share of the separator feed material below this particle class,
which reaches the fine separator grains.
F⋅ f
η = ⋅ 100 [%] (6)
A⋅a
f
η = vF ⋅ ⋅ 100 [%] (6.1)
a
f
η = ⋅ 100 [%] (6.2)
a⋅u
with:
VF = Take out of fines [-]

η = Separator efficiency [%]
7.1.1 Evaluation “Separation curve: TROMP CURVE
Definition of Cut size

The cut size is that particle size, for which is applied, that the number of
coarse particles in the fine material is equal to the quantity of fine
particles in the grits.
Cut point d50: Size of grain which has equal probability of passing to
either coarse or fine streams.
Definition of separation degree

Separation degree means the ratio between the quantity of a definite
particle size, which has reached the grits, and the quantity existing in the
feed material.

for grinding plants
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Calculation example “Separation curve”
The following particle size distribution has been determined:
Particle size Total of mass distribution

µm a (%) f (%) g (%) v(F) v(G)
1 0 6.3 0.8 0.230 0.770
2 4.2 10.7 3 0.230 0.770
4 7.6 19.2 5.3 0.230 0.770
7 12.1 29 7.8 0.230 0.770
10 15 36.5 9.1 0.230 0.770
20 23.9 57.6 13.3 0.230 0.770
40 43.2 88 27.6 0.230 0.770
50 52.4 94.9 37.3 0.230 0.770
75 68.5 99.5 57.9 0.230 0.770
90 74.9 99.9 66.6 0.230 0.770
150 87.3 100 82.5 0.230 0.770
175 89 100 85.2 0.230 0.770
200 90 100 87.1 0.230 0.770
250 91.3 100 89.8 0.230 0.770
315 93.3 100 92.4 0.230 0.770
400 96.2 100 95.6 0.230 0.770
500 98.9 100 98.7 0.230 0.770
560 99.8 100 99.7 0.230 0.770
600 100 100 100 0.230 0.770
Σ 1147,6 1441,6 1059,7
Table 1: example of particle size distribution
For a reasonable evaluation of these results in process-technical respect,

the model of the separation curve calculation according to the VDZ
(Association of German Cement Producers) Guideline MT 28 was slightly
modified. Each particle class is calculated with a failure ratio typical for
the class (caused by analysis inaccuracy, rounding errors etc.). The
subsequent calculation procedure then follows MT 28 again. Right of each
formula is a numerical example, which is related to tables 1 or 2.

for grinding plants
Edition: 3
Mode of procedure
1 Calculation of the material output (cf. 7.1.1)
1147,6 − 1059,7
vF −Fines(Gl.2) vF = = 0,23
1441,6 − 1059,7
vG −Grits(Gl.3) vG = 1 − v F = 0,77
2 Determination of the specific particle fraction failure S(X)
S( x ) = a ( x ) − [v F ⋅ f ( x ) + vG ⋅ g ( x ) ]
S( l ) = 0 − [0,23 ⋅ 6,3 − 0,77 ⋅ 0,8] = − 2,066 (7)
3 Correction of each particle fraction of the calculated failure S(X)

according to the following formula:
S( x ) −2,066
a(*x ) = a ( x ) − a(*1) = 0 − = 13 (8)
1+ v + v
2
F
2
G (1 + 0,232 + 0,77 2 )
S( x) ⋅ v F −2,066 ⋅ 0,23
f (*x ) = f ( x ) + f (*1) = 6,3 + = 6,0 (9)
1+ v + v
2
F
2
G (1 + 0,232 + 0,77 2 )
S( x ) ⋅ vG −2,066 ⋅ 0,77
g(*x ) = f ( x ) + g(*1) = 0,8 + = − 0,17 (10)
1+ v + v
2
F
2
G (1 + 0,232 + 0,77 2 )
4 Supplementation of the table by the corrected mass distribution totals

and the derived sizes derived according to MT 28
Calculation of the mass distribution of each particle class:
∆g1* = g(*x2 ) − g(*x )1 ∆g1 = 2,7 − ( −0,2) = 2,9 (11)

∆g2* = g(*x3 ) − g(*x2 ) ∆g2 = 4,9 − 2,7 = 2,2
∆f i * and ∆ai* are to be calculated respectively.

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Following MT 28, the separator feed share should be calculated according

to the following formula:
∆a (*x ) errechnet = ∆f * ⋅ v F + ∆g * ⋅ vG
(12)
∆a (*1) errechnet = 4,6 ⋅ 0,23 + 2,9 ⋅ 0,77 = 3,293
The rated value only slightly differs from the analytical one.
The separation degree (t) is calculated as follows:
∆g(*x ) ⋅ vG ⋅ 100 2,9 ⋅ 0,77 ⋅ 100

t( x) = +
t (1) = = 67,9 (13)
∆a ( x ) errechnet 3,291
The following table shows the re-calculated values:
Particle Failure Corrected fraction values Separation

size- degree
S(x) a* f* g* ∆a* ∆ f* ∆g* ∆a* acc. to MT
28
µm (%) (%) (%) (%) (%) (%) (%) calculated (%)
1 -2,066 1,3 6,0 -0,2 3,3 4,6 2,9 3,293 67,9
2 -0,571 4,5 10,6 2,7 3,6 8,5 2,1 3,598 46,0
4 -0,897 8,1 19,1 4,9 4,3 9,8 2,7 4,305 47,4
7 -0,576 12,4 28,9 7,5 2,8 7,5 1,4 2,794 38,1
10 -0,402 15,2 36,4 8,9 8,4 21,2 4,6 8,406 42,0
20 0,411 23,7 57,7 13,5 18,5 30,6 14,9 18,512 62,0
40 1,708 42,2 88,2 28,4 9,1 6,9 9,8 9,113 82,5
50 1,852 51,3 95,2 38,2 16,6 4,5 20,2 16,598 93,8
75 1,032 67,9 99,6 58,4 6,6 0,3 8,5 6,638 98,8
90 0,641 74,5 100,0 66,9 12,3 0,1 16,0 12,319 99,8
150 0,775 86,8 100,1 82,9 1,9 -0,1 2,5 1,930 100,6
115 0,396 88,8 100,1 85,4 1,3 -0,1 1,7 1,281 101,2
200 -0,067 90,0 100,0 87,1 1,8 -0,1 2,3 1,773 101,4
250 -0,846 91,8 99,9 89,4 2,0 -0,0 2,6 2,001 100,0
315 -0,848 93,8 99,9 92,0 2,6 0,1 3,4 2,635 99,5
400 -0,412 96,5 99,9 95,4 2,5 0,0 3,2 2,510 99,6
500 -0,099 99,0 100,0 98,7 0,8 0,0 1,1 0,821 99,5
560 0,031 99,8 100,0 99,7 0,2 -0,0 0,3 0,219 100,5
600 -0,000 100,0 100,0 100,0 0,0 0,0 0,0 0,000 100,0
Σ 1147,6 1441,6 1059,7
Table 2: Corrected particle distribution

for grinding plants
Edition: 3
Evaluation of the separation curve (=Tromp curve)
The separating effect is generally characterized through the relation of

two particle classes, which are classified with particular separation
degrees. The dimension X35:X65 (particle size with a separation degree of
35% or 65%) or X25:X75 is frequently used as assessment criterion.
During the process of cement separation, this is, however, not always
possible to be put into practice, since an intersection with a X25 or X35
line is not available in every case (for example: by using separators of 1st
generation)
The following features are used for the evaluation of the Tromp
curve:
1. Separator By-Pass (τ)
The shortest distance (τ) between separation curve and abscisses

(particle size) determines, which part of the total feed material
enters the grits without separation.
The separator by-pass (τ) corresponds to the minimum of the

curve, it is the lowest Tromp coefficient.
The old generation of separators is characterized by a high by-pass

around 50%. With the same energy supply, a reduction of the τ
value does usually lead to an increase in throughput.
The by-pass level depends of the circulating load, for low fineness
cement (3.000 cm²/g acc. to Blaine) the by-pass is low, it
increases with the cement fineness.
2. Cut point d50:
It corresponds to 50% of the feed passing to the coarse stream.

It is that size of grain which has equal probability of passing to
either coarse or fine streams.

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3. Imperfection I:
It is calculated as follows
D75 - D25
I=
2 D50
If the separation is perfect, the Tromp curve is a step curve.
In this case, D75 = D25 and I = 0
More I (Imperfection) is high, worse is the separator.
4. Sharpness k:
It is defined as ratio between the particle size at the

separating degree of 75% and the particle size at the separating
degree of 25%.
d 75
k =⋅
d 25
For an ideal separation k would be 1.

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Edition: 3
Picture 5: TROMP CURVE
Cement quality: CEM I 42,5 R
SEPARATION VALUES TROMP CURVE VALUES
Circulating load: 2.78 Bypass: 4,75 % at 11 µm

Take out of fines Vf: 35,97 % D25: 20,23 µm
Take out of grits Vg: 64,03 % D50: 23,22 µm
Efficiency at 30 µm: 73,28 % D75: 29,39 µm
Efficiency at 45 µm: 63,23 % Imperfection: 0,20
Efficiency at 90 µm: 76,48 %
100
80
60
40
20
0
1 10 100 1000
Particle size [µm]

for grinding plants
Edition: 3
7.2 Assessment “Internal mill inspection”
The analysis of the mill inspection refers to:
Ø Preparation of a grinding diagram over the grinding path length

Ø Determination of the filling degree
Ø Calculation of the grinding media quantity
Ø Calculation of the consumed power at the mill tube
7.2.1 Determination of the filling degree
Following the example below, the filling ratio (f) can be graphically
determined from the grinding level and the clear grinding chamber
diameter. The concept of this example also supports the internal
inspection of a ball mill and its result is to be considered in connection
with the grinding diagram of the meter samples.
In the grinding diagram, the residue in [%] should be laid off as first
ordinate and the grinding fineness (acc. to Blaine in cm2/g) as the
second. The absciss is the length of the grinding path. The residue values
of various particle classes are laid off.
As cutout of the form sheet, the following picture shows the graphical
determination of the filling ratio.
It is to be determined:
Ø Grinding level (h)
Ø Clear grinding chamber diameter (Dli).

for grinding plants
Edition: 3
0,75
0,74
0,73
0,72 y = -0,0086x + 0,9192
0,71
0,7
0,69
h/Dli
0,68
0,67
Dli
0,66
0,65
0,64
0,63
0,62
0,61
0,6
20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
Filling ratio f %
Picture 6: graphical determination of the mill filling ratio
The filling degree f can be calculated correctly with the following formulas
(MT22):
α sin 2α
f = −
180° 2π
α sin α cos α h
f = − with cos α = 2 −1
180° π Dli
h
For the range 065 < < 0.75 resp. filling degree within 0.2 < f < 0.31, the
Dli
following formula can be used:
h
f = 1,0678 − 1,164
Dli

for grinding plants
Edition: 3
7.2.2 Calculation of the power consumption at the mill tube
From the filling ratio calculated under 7.2.1 the weight of the grinding
media filling (in t) can be derived:
1 Grinding media filling
π
G= ⋅ Dli2 ⋅ Lli ⋅ f ⋅ γMK
4
Dli = Inside liner diameter of grinding chamber in m

Lli = effective length of the grinding chamber in m
f = grinding media filling degree
γMK = bulk density grinding media in t/m3
reference coarse ball charge (1st chamber): approx. 4.5
value:
fine ball charge (2nd chamber): approx. 4.6
The filling ratios determined by measuring the grinding level are to be

reduced by 1 to 3 % depending on the level of the mill charge with
material.
From the weight of the grinding media, the power consumption at the
mill tube is then to be calculated.
The nomogram in the following allows determination of the entrainment

factor “c” depending on the filling ratio, which is necessary to calculate
the power consumption at the mill tube. Thereby, the ball mill is to be
stopped from full operation.

for grinding plants
Edition: 3
0,26
0,25
uncovered grinding balls
Entrainment factor C
0,24
grinding balls and material on
0,23 the same level
0,22
0,21
covered grinding balls
0,2
19 21 23 25 27 29 31 33 35
Filling ratio f [ % ]
Picture 7: Entrainment factor c
From these values power consumption at the mill tube can be

determined:
2 Power consumption at the tube
Pw = c ⋅ G ⋅ Dli ⋅ nR (kW)
c = entrainment factor ( - )
G = weight of grinding media (t)
Dli = Inside liner diameter of grinding chamber (m)
nR = revolutions of the tube (rpm)
PZ = 1
Pw ⋅ (kW counter)
ηA
ηA = Total efficiency

for grinding plants
Edition: 3
The total efficiency η A = ηmech * ηel
Following values can be used:
For girth gear drive: η A = ηmech * η = 0.92
For central drive: η A = ηmech * η = 0.94
7.2.3 Determination of the average ball diameter respectively

classifying effect
The first chamber of a ball mill is normally emptied every 1 to 2 years,

the second chamber approximately every 3 to 5 years. Thus, the ball
grading becomes obvious via sorting of the removed ball charge.
Important: Empty grinding is only necessary in the second chamber;

here screening can be done in one step together with the meter sampling
of the mill charge! The first chamber does not give sound results!
Sampling in the fine grinding chamber
Ø Ball sampling each meter as in the case of material meter sampling.

The utilization of a corresponding punched screen is recommended to
separate still in the mill the amount of ball samples from the material.
Ø The amount of taken samples should approximately correspond to the
volume of a 10-l bucket.
Ø Sampling device: robust shovel or similar
To evaluate the condition of the ball charge and define the ball charge
with regard to grinding performance, the average ball diameter is to be
determined and examined in connection with the results from the meter
sampling.

for grinding plants
Edition: 3
Per meter sample, only the number of balls and the total weight of the
taken sample are to be determined. Out of this determination, the
average ball diameter at the sampling point can be calculated when
knowing the density of the ball material.
Proceeding for evaluation:
To be determined: Ø total amount of balls per meter sample

(number of balls)
Ø total weight of the meter sample
(sample weight in t)
Given: Ø material density (ρ) of the grinding media

(usually 7.85 t/m3)
Calculation of the average ball diameter of a meter sample:
1/ 3
é sample weight 1 1 ù
D m =2⋅ê ⋅ ⋅ ú [m]
ë number of balls ρ 4 / 3⋅π û
The result should then be converted into mm.

for grinding plants
Edition: 3
8 Assessment of „Mill drying plants“
In addition to the procedures and methods described in items 1 to 7, the

following issues must be examined, when evaluating mill drying plants:
Ø Moisture of the material (sampling within the complete sampling):

o feed material
o finished product
Ø Gas/air quantity within the mill system
Ø Temperature (moist and dry) of the mill exhaust air for calculation
of the dew point
Ø Gas/air temperatures in the mill system
Ø With additional firing: o fuel consumption

o conveying and combustion air
o (can usually be neglected)
Ø Gas analysis for determination of false air (at least

3 measurements / tests), when kiln exhaust air is used:
o sampling before and after the mill
o sampling after the separator and / or
filter
Ø Operating conditions (to be monitored every hour):

o cooler fan outlet:
position of the inlet vane control
system or
flap position or revolutions per
minute
o clinker output (control room)
o amount of cooling air (control room)
o additional firing:
fuel amount
fan adjustment

for grinding plants
Edition: 3
8.1 Balance preparation
Air quantity balance
air to
mill
air from auxiliary burner exhaust air from mill

(mostly to neglect) after filter
Mill system
steam from moist material
quench / false air

(mostly rest of balance)
Heat balance
air to mill enthalpy power of

exhaust air from mill
air from auxiliary burner radiation and

mill system convection losses
driving force conversion into heat heating up of the raw mill
quench / false air

(mostly rest of balance) enthalpy of steam

for grinding plants
Edition: 3
The false air volume flow is calculated on the basis of the air quantity
balance respectively of the Orsat analyses, e.g. of the kiln exhaust gas.
8.1.1 Air quantity balance
Balance
additional air (+ V
V conveying air/combustion) + V
false air + V
steam = V
exhaust air
Measured variables: additional air

V [m3(i.N.)/h]
conveying air
V [m3(i.N.)/h]
exhaust air
V [m3(i.N.)/h]
steam
m [m3(i.N.)/h]
Operand: false air

V [m3(i.N.)/h]
Water amount to be vaporized
f A− fR f −f
water =
m ⋅M meal − resid .moist = A R ⋅M feed − moist [kg/h ]
100− f A 100− f R
with: fA Ø initial moisture in %

vR Ø residual moisture in %
M meal-resid.moist Ø meal incl. residual moisture in kg/h
M feed - moist Ø feed material - moist in kg/h
Resulting steam volume
steam = mw ⋅ TN
V water / 0.804 = R ⋅
m [m3(i.N.)/h]
PN ⋅100
with: R Ø general gas constant: r = 461 J/kg K

TN Ø reference temperature 273 K
PN Ø 1013 mbar

for grinding plants
Edition: 3
Balance for false air calculation
false air = V
V exhaust air - V
additional air - V
steam (- V
conveying air/combustion)
Example for false air determination via gas analysis
Orsat analysis
CO2 O2 CO N2 n
Before mill (1) 30.75 4.15 - 65.1 1.315
After filter (2) 21.50 9.10 - 69.4 1.974
Share of false air (in %) related to gas after mill:
n 2 − n1
VF [%] = ⋅ 100
n2
Calculation:
VF [%] = 33.4 %
Gas amounts: before mill: 75,500 m3(i.N.,tr.)/h

steam: 9,100 m3/h
after mill: 121,300 m3/h
From air quantity balance:
false
V = 121,300 – 75,500 – 9,100
= 36,700 m3(i.N.)/h
From gas analysis:
false
V = 33.4
(121,300 – 9,100) ⋅
100
= 37,475 m3(i.N.)/h

for grinding plants
Edition: 3
The error is 2% related to the balance result. It can be explained by the

measuring inaccuracy connected to the measuring method. The error in
the Orsat analyses is up to 0.3 vol.-%.
8.1.2 Heat balance
Reference temperature should be 25°C, as the cp-diagrams (pictures 7

and 8) refer to this temperature.
Balance input = Q
Q loss
input:
Q
additional air + Q
Q additional firing + Q
combustion air + Pmech + Q
feed material + Q
fresh air
+ Q false air
loss:
Q
exhaust air + Q
Q water vaporizing + Q
finished product + Q
heat losses
Input
additional air
Q = additional air ⋅ cp ⋅ (ϑadditional air - 25°C)
V [kJ/h]
additional firing
Q = fuel ⋅ hu(fuel)
m [kJ/h]
combustion air
Q = combustion air ⋅ cp ⋅ (ϑcombustion air - 25°C)
V [kJ/h]
fresh air
Q = fresh air ⋅ cp ⋅ (ϑfresh air - 25°C)
V [kJ/h]
false air
Q = false air ⋅ cp ⋅ (ϑfalse air - 25°C)
V [kJ/h]
feed material
Q = feed material ⋅ cm ⋅ (ϑfeed material - 25°C)
m [kJ/h]
Pmech = Pdrives ⋅ η ⋅ 3600 s/h (0.9 < η < 0.96 ≈ efficiency) [kJ/h]
with Pdrives = performance counter of the drives over test
period [kJ/h]
and η = 0.92 for ball mill with girth gear drive
η = 0.94 for ball mill with central drive

for grinding plants
Edition: 3
Loss
Q exhaust air exhaust air ⋅ cp ⋅ (ηexhaust air - 25°C)
= V [kJ/h]
vaporizing water = m
Q water ⋅ 2446 kJ/kg [kJ/h]
finished product =
Q finished product ⋅ cp ⋅ (ϑfinished product - 25°C)
m [kJ/h]
losses
Q = balance deviation
(accounts for approximately 5 % of thermal input)
General issues as to the theory of radiation and convection in ball mill

systems
The item „thermal losses“ mainly includes losses due to radiation and
convection, which relate to the whole system. A detailed calculation of
the single losses is possible, but involves considerable effort and
expenses, since the whole grinding system within the balance scope
includes very different heat transfer mechanisms, which would have to
be considered. Normally, a loss should be seen from the balance and only
be checked in case of discrepancies.
A rough check of the radiation and convection losses is possible on the

basis of the following approximate values:
Q rad.-con. = αgas ⋅ Acomponent ⋅ (Tsurface – Tambience) ⋅ 3600 s kJ [kJ/h]

h 1000 J
with αtotal = αrad + αcon
4'
Tsurface
αrad = ε ⋅ δ ⋅ [W/m2 K]
Tsurface
with: δ = 5.67 ⋅ 10-8 W/m2 K4

ε ≈ 0.3 galvanized sheet metal
ε ≈ 0.4 iron with silver coating
ε ≈ 0.65 rusty surface (iron)
ε ≈ 0.9 heavily rusted iron, rust protection coating

for grinding plants
Edition: 3
The calculation of αcon is far more difficult, as, in this case, different heat
transfer mechanisms overlap. Taking into account the following limits,
the approximate values below can be used:
40°C < ϑmill tube < 110°C

10°C < ϑambience ≤ 30°C
2m ≤ Dmill tube ≤ 4m
15 min-1 ≤ nmill ≤ 26 min-1
As approximate value for the heat transfer coefficients at the rotating mill
tube the following can be assumed:
αcon ≈ 8 - 9 W/m2 K for 2 m ≤ D ≤ 3 m

αcon ≈ 9 - 10 W/m2 K for 3 m < D ≤ m
Accuracy is about ± 15 %.
To stationary components, which are not exposed to flows (tubes,

housings etc.), the following considerably simplified relation applies, if
the following boundary conditions are met:
20°C < ϑsurface < 70°C und 10°C < ϑambience ≤ 30°C
αcon ≈ 1,6 (ϑsurface - ϑambience) 1/3 [W/m2 K]
Accuracy is about ± 10 %.
The cp-values for air, furnace gas and raw meal can be taken from the
corresponding sheets.
The specific thermal capacity of non-air is composed of:
cp(gas) = Σ xi ⋅ cp(i)
with xi = share of component i in the total gas volume
cp(i) = specific thermal capacity of component xi

for grinding plants
Edition: 3
Units
V = [m3(standard)/h] or [m3(standard,tr.)/h]
m = [kg/h]
H = [kJ/h]
cp = [kJ/kg ⋅ K] or [kJ/m3 ⋅ K]
T = [K]
α = [W/m2 ⋅ K]
A = [m2]
hu = [kJ/kg]
P drives = [kW]

for grinding plants
Edition: 3
9 Literature, standards and guidelines
[1] Leaflet MT 22 „Rohrmühlen und Mahltechnik“

(= „Tube mills and grinding technology“); VDZ, 9/61; Düsseldorf
[2] Leaflet MT 28 „Rohrmühlen und Mahltechnik“
(= „Tube mills and grinding technology“); VDZ, 2/65; Düsseldorf
[3] Duda, H.W.: Cement-data-book; 3rd edition; 1985, Bauverlag
Wiesbaden
[4] Labahn, O., Kohlhaas, B.: „Ratgeber für Zementingenieure“
(= „Guidebook for cement engineers“), 6. edition, 1982, Bauverlag
Wiesbaden
[5] Guideline „Gasanalyse“ (= „Gas analysis“)
10 Appendix
1 Forms „Control on site“
2 Forms “Control room data”
3 Form “Pressure and temperature curve”
4 Form “Material temperature curve”
5 Form “Mill inspection and observations”
6 Form “Mill internals 1st & 2nd chamber”
7 Form “All around samples”

for grinding plants
Edition: 3
Page 1/3: Control on site Date:

Plant:
Plant type:
A B
Time:
Scales discharge behaviour A:
of components B:
C:
D:
homogeneous +
segregated -
grinding aid
where?
distribution on material
bed
grinding aid flow +/-
+/-
last control weighing date
last calibration date

condition belt
selection +, o, - weigher
Roller press zero gap [mm]
grinding gap approx. right
[mm] left
hydraulic pressure right
[Mpa] left
vibration yes/no
Ball mill grinding sound
chamber 1
mill sound along
grinding path
chamber 1
description with m
grinding sound
chamber 2
mill sound along
grinding path
chamber 2
description with m
= homogeneous; good
o = medium; normal
- = inhomogeneous; bad

for grinding plants
Edition: 3

Plant:
Plant type:
A B
Time:
Ball mill mill discharge normal
well running of valves bad
Material discharge at
mill inlet
dust discharge - where
Static separator setting of blades
coarse – medium – fine
discharge valve normal
well running bad
leakage yes / no
Cyclone(s) discharge valve normal
well running bad
leakage yes/no
Mill filter fan setting
inlet vane control %
system/valve
leakage yes / no
Separator no. 1 discharge valves
well running
example: no. 1+, no.
2+, no. 3+
discharge valves
frequency min ^-1
example: no. 1 (3), no.
2 (5)
cooling air valves
setting %
separator settings
main rotor %/min ^-1
Counter blades %/min ^-1
= homogeneous; good
o = medium; normal

for grinding plants
Edition: 3

Plant:
Plant type:
A B
Time:
Separator no. 2 discharge valves
well running
example: no. 1+, no.
2+, no. 3+
discharge valves
frequency min ^-1
example: no. 1 (3), no.
2 (5)
cooling air valves
setting %
separator settings
main rotor %/min ^-1
Counter blades %/min ^-1
Separator filter fan setting
inlet vane control %
system/valve
leakage yes / no
Auxiliary unusual occurrences
equipment aggregate
aggregate
aggregate
= homogeneous; good
o = medium; normal

for grinding plants
Edition: 3
Page 1/2: Recording of control room values Date:

Plant:
Plant type:
A B
Time:
components in t/h A:
B:
C:
D:
fresh material t/h
fresh material Counter
separator feed t/h
grinding aid l/min
material temperature °C
discharge
mill exhaust air °C
temperature
Separator no. 1 speed of rotation
rotor %/min^-1
Type: counter blades %/min^-1
finenesse
R (0.03) %
specific surface cm^2/g
(Blaine)
Separator fan
setting %/min^-1
Filter fan
setting %/min^-1
Separator no. 2 speed of rotation
rotor %/min^-1
Type: counter blades %/min^-1
fineness
R (0.03) %
specific surface cm^2/g
(Blaine)
Separator fan
setting %/min^-1
Filter fan
setting %/min^-1

for grinding plants
Edition: 3
Page 2/2: Recording of control room values Date:

Plant:
Plant type:
A B
Time:
Mill filter fan
setting %/min ^-1
Power roller press
consumption indication kW
kWh-meter kWh
ball mill
indication kW
kWh-meter kWh
separator drives
indication kW
kWh-meter kWh
bucket elevator kW
electric ear %

for grinding plants
Edition: 3
Pressure/temperature development Date:
Plant:
Plant type:
Test periods: A B
Time:
mbar °C mbar °C
Static before ball mill
pressure after ball mill
before static
separator
(= after ball mill)
before cyclone
(= after static
Air/gas separator)
temperature before mill filter fan
[°C] (= after filter)
after mill filter fan
separator 1
before fan
after fan
separator filter
before filter
after filter
after fan

for grinding plants
Edition: 3
Pressure/temperature development Date:
Plant:
Plant type:
Test periods: A B
Time:
feed component A:
B:
C:
D:
ball mill outlet:

cyclone fines:
Material (after static
temperature [°C] separator)
mill filter
temperature of filtered
material:
separator 1
fines:
grits:
separator filter
temperature of filtered
material:
finished product:
A: clinker
B: gypsum
C: slag

for grinding plants
Edition: 3
MILL INSPECTION AND OBSERVATIONS
Plant: Date:
Mill: Time:
Important: Measurements and observations after mill crash stop
Material distribution (above or below ball charge) (taken at three different locations)
in mm
Inlet Middle Outlet
1st chamber:
2nd chamber:
Material level measurements (h: taken from the material surface to the highest
in mm point on the midpoint of the mill shell liners)
Inlet Middle Outlet

1st chamber:
2nd chamber:
Mill inside liner diameter Dli 1st chamber: Dli = Lli =

Effective grinding length Lli 2nd chamber: Dli = Lli =
in mm
Calculation of mill filling degree f
1st chamber: h/Dli: f:

2nd chamber: h/Dli: f:
Coarse particle in front of diaphragms
1st chamber: Yes, mm: No

2nd chamber: Yes, mm: No
Slotted plates Openings free or clogged (clogging grade percentage %)
1st chamber:
2nd chamber:
Ball charge classification (2nd chamber) O good O bad

O No classification
Condition of mill shell liners
1st chamber:
2nd chamber:

for grinding plants
Edition: 3
MILL INTERNALS
Plant: Date:
Mill:
1st CHAMBER
HEAD LINERS
Lining Nos. Plates Orig. thickness Rem. thickness
Row 1 (outer) mm mm
Row 2 mm mm
Row 3 mm mm
Row 4 (inner) mm mm
Conditions:
SHELL LINERS
1st chamber Lining Nos. Rings Plates/Ring Shape Type
Lifter height (mm)
o bolted
o semi-bolted
Conditions:
GRINDING BALLS
Conditions
Diaphragm
Slotted plates Nos. Plates Orig. thickness Rem. thickness slots width
Row 1 (outer) mm mm mm
Row 2 mm mm mm
Row 3 mm mm mm
Row 4 (inner) mm mm mm
Conditions:

for grinding plants
Edition: 3
MILL INTERNALS
Plant: Date:
Mill:
2nd CHAMBER
Diaphragm
Backside plates Nos. Plates Orig. thickness Rem. thickness
Row 1 (outer) mm mm
Row 2 mm mm
Row 3 mm mm
Row 4 (inner) mm mm
Conditions:
SHELL LINERS
2nd chamber Lining Nos. Rings Plates/Ring Shape Type
Lifter height (mm)
o bolted
o semi-bolted
Conditions:
GRINDING BALLS
Conditions
Outlet Diaphragm
Slotted plates Nos. Plates Orig. thickness Rem. thickness slots width
Row 1 (outer) mm mm mm
Row 2 mm mm mm
Row 3 mm mm mm
Row 4 (inner) mm mm mm
Conditions:

for grinding plants
Edition: 3
ALL AROUND SAMPLES
Plant: Date:
Mill: Time:
Cement quality:
Particle size: 0.2 0.09 0.045 0.032 Blaine
[mm] R% P% R% P% R% P% R% P% cm²/g
Separator Feed
Separator rejects
Separator fines
Mill filter product
Stat. Separator
Finish product

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Guideline on plant and

1 Fundamental data on the test / target

3 Plant examination – „control on site“

4 Recording of the operating mode

6 Ascertainment of the operating state during shut down

8 Assessment „Mill drying plants“

9 Literature, standards, guidelines

Guideline-Grinding-Plants-3rd-Edition1.doc 19.09.02 1/53

1 Forms „Control on site“

2 Forms “Control room data”

3 Form “Pressure and temperature curve”

4 Form “Material temperature curve”

5 Form “Mill inspection and observations”

6 Form “Mill internals 1st & 2nd chamber”

7 Form “All around samples”

Guideline-Grinding-Plants-3rd-Edition1.doc 19.09.02 2/53

1 Fundamental data on the test / target

An examination for the assessment of a grinding plant should allow to

A grinding plant is to be examined,

Ø if deviations from the expected grinding capacity occur,

Ø as routine controls, approx. once a year to assess the actual state of

Control in site At first, only a visual and audible control,

Recording of the operating Includes:

Recording of the operating − Pressure

Sampling Complete tests

Guideline-Grinding-Plants-3rd-Edition1.doc 19.09.02 3/53

2 Scheme of a typical plant

Ø Feeding station for components (with scales)

A device list of the plant equipment is generally to be prepared, which

Pic. 1: Scheme of a typical grinding plant with separator filter

Guideline-Grinding-Plants-3rd-Edition1.doc 19.09.02 4/53

Pic. 2: Scheme of a typical grinding plant with cyclones + filter

Guideline-Grinding-Plants-3rd-Edition1.doc 19.09.02 5/53

3 Plant examination – “control on site”

Ø State of the weight equipment; when was the last calibration/control?

Ø Regular running without unusual change of the grinding opening

Ø Position of the guide vanes

Guideline-Grinding-Plants-3rd-Edition1.doc 19.09.02 6/53

Ø Leakage etc. (false air)

Ø Setting (inlet vane control system, valve or speed of rotation)

Ø Position and number of counter blades

Ø Setting (inlet vane control system, Flap)

Ø Leakage etc. (false air)

Ø Well running of discharge valve

Guideline-Grinding-Plants-3rd-Edition1.doc 19.09.02 7/53

4 Recording of the operating mode

4.1 General operating data

Power consumption of:

In general: the control room protocol is to be considered during the test

4.2 Pressure and temperature measurements

Recording of the static pressure with an U-tube as well as of the gas

Ø before ball mill

Guideline-Grinding-Plants-3rd-Edition1.doc 19.09.02 8/53

Further pressure and temperature curve

Ø before separator filter

4.3 Air/gas quantity measurement

4.4. Temperature of the material

Important: it is necessary for all measurements (air quantities,

Guideline-Grinding-Plants-3rd-Edition1.doc 19.09.02 9/53

5.1 Complete sampling

In a test period of around 8 hours, at least two samplings should be

It is important for each sampling to consider the number of samples as

Appendix 3 shows a table fro recording of complete sample results.