Best Practice Guidance Paper Evaluation Ball Mill Grinding Plants 2016 02 PDF

HeidelbergCement Group
Guidance Paper
Edition: 02
Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31
Process owner: EG Grinding
Guidance Paper on Process Evaluation of Ball

Mill Grinding Plants
Best_practice_guidance_paper_evaluation_ball_mill_grinding_plants_2016_02.docx Page 1 of 52
HeidelbergCement Group Guidance Paper Edition: 02
Contents
1 HEALTH AND SAFETY ........................................................................................................ 3
2 FUNDAMENTAL DATA ON THE TEST /TARGET ............................................................... 4

3 SCHEME OF A TYPICAL BALL MILL GRINDING PLANT................................................... 5
4 PLANT EXAMINATION – SITE INSPECTION ...................................................................... 6
5 RECORDING OF OPERATING DATA .................................................................................. 8
5.1 GENERAL OPERATING DATA ............................................................................................. 8

5.2 PRESSURE AND TEMPERATURE MEASUREMENTS .............................................................. 9
5.3 AIR/GAS QUANTITY MEASUREMENT .................................................................................. 9
5.4 TEMPERATURE OF THE MATERIAL ..................................................................................... 9
6 SAMPLING PROCEDURE .................................................................................................. 10
6.1 COMPLETE CIRCUIT SAMPLING ....................................................................................... 10

6.2 METER SAMPLING DURING INTERNAL BALL MILL INSPECTION ........................................... 13
7 ASSESSMENT OF PLANT DURING STOP CONDITION ................................................... 14
8 PROCESS EVALUATION ................................................................................................... 16

8.1 SEPARATOR ASSESSMENT ............................................................................................. 16
8.1.1 Separation curve: TROMP CURVE .......................................................................... 18
8.2 INTERNAL MILL INSPECTION............................................................................................ 25
8.2.1 Preparation of Grinding Diagram .............................................................................. 25
8.2.2 Determination of the Filling Degree .......................................................................... 26
8.2.3 Calculation of Grinding Media Quantity .................................................................... 28

8.2.4 Calculation of Power Consumption of Mill Tube ....................................................... 28
8.2.5 Determination of the Average Ball Diameter and Classifying Effect in Chamber 2 ... 29
9 ASSESSMENT OF MILL DRYING PLANTS ....................................................................... 30
9.1 BALANCE PREPARATION................................................................................................. 31

9.1.1 Air Quantity Balance ................................................................................................ 32
9.1.2 Heat balance ............................................................................................................ 34

10 LITERATURE, STANDARDS AND GUIDELINES .............................................................. 38
11 APPENDIX .......................................................................................................................... 38
1 Health and Safety
The auditing team (including all staff) should be familiar with normal cement manufacturing
hazards and special risks in the cement, raw and coal grinding departments.
All relevant local and Group safety guidelines and instructions should be followed. Each
plant is different and there may be plant specific safety regulations. They should be
requested before and to follow as well.
Lockout procedures must be in place and rechecked before any equipment internal
inspection. Individual risk assessments are necessary if existing plant procedures are not
sufficient enough.
Special attentions for all kind of ducts and roofs are needed for any kind of threat from
falling coatings or objects.
Some lockouts need special attention. In principle and as safe practice of good lockout
procedure, the lockout should be checked and tested. For example the lockout of auxiliary
drives should be checked before with the onsite switch AND in control room.
The reason for such double testing is that the control room operator might have given for
the test local control to the wrong motor. Then, the motor would not start by pressing the
start button at the onsite switch wrongly assuming that the test was successful.
All safety relevant issues should be followed up. But some locks need special attention
(only as example):
 Mill main drive
 Mill auxiliary drive
 All connected fans (mill fan, separator fan….)
 Separator rotor drive
 Tightness and lock of hot gas flaps at raw mills
 Hot gas generators
 Feed and reject belts, screw conveyors….
In general all drives, which might have an impact on the specific working area during the
audit has to be locked. For example a separator rotor drive might create huge hazard while
entering the separator but no hazard while entering the mill. In case of any doubts please
carry out a proper risk assessment of the situation.
All measurement and sampling points should be safely accessible and all measurement
and sampling procedures must be ensured for safe audits and inspection of plant.
2 Fundamental Data on the Test /Target
An examination for the assessment of a ball mill grinding plant should allow carrying 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,

 When the plant is new (to record the fundamental state) or a mill test has not been
carried out at the plant so far,
 If deviations from the expected grinding capacity occur,
 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 operations and is part of
current control. Furthermore, it helps to create the basis for optimization measures.
The following overview shows the details with the procedure of a mill test. If possible, the
test should be divided into the following periods:
 Site inspection At first, only a visual and audible control, partly as

well by recording visible plant settings on site
 Recording of the operating data Includes:

 Verification of the control room data
 Assessment of the actual setting
 Measurements at site  Pressure

 Temperature
 Special features
 Sampling All around samples
 Recording of the actual state Equipment revision at plant stop
Important: the control room protocol during the test period should be used. Additionally, all relevant
data is to be recorded in hourly intervals.
3 Scheme of a Typical Ball Mill Grinding Plant
 Feeding station for components (with scales)

 Roller press (optional)
 Ball mill
 Static separator; preliminary separator (optional)
 Mill filter
 Dynamic separator with filter (or cyclones + filter)
 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 installed equipment.
Picture 1: Scheme of a typical ball mill grinding plant with separator dedusting in filter
Picture 2: Scheme of a typical grinding plant with separator dedusting in cyclones (+filter)
4 Plant Examination – Site Inspection
Feeders area
 State of the weight equipment; when was the last calibration/control? Is a control
necessary?
 Material flow conditions; homogeneous discharge without segregation; if not, which
kind?
 Grinding aid addition; constant input; yes/no
 State of the conveying equipment
Roller press
 Regular running without unusual change of the grinding gap

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

 Control of discharge valve on well running and functioning
 Leakages (dust/air)
Mill filter
 Leakage etc. (false air)

 Cleaning
Filter, fan
 Setting (inlet vane control system, damper or speed of rotation)

 Vibration
Dynamic separator
 Position and number of counter blades

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

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

 Cleaning
Cyclones
 Well running of discharge valve

 Operation of discharge valve
Auxiliary equipment
 Bucket elevators
 Conveying equipment etc.
 Control on obvious damage; audible control as well
 Vibration etc.
 Leakage
5 Recording of Operating Data

5.1 General Operating Data
Power consumption of:

 Roller press
 Ball mill
 Separator (including fan)
 Mill filter fan
 Auxiliary equipment, with kWh meter (locally)
Speed of rotation
 Separator (min.-1 or %)
 Rotor/ Counter blades
 Mill filter fan
 Speed of rotation (min.-1 or %)
 Damper position/inlet vane control system
Throughputs
 Feed components, continuously
 Grits, actual value
 Circulating load, actual value from 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!
5.2 Pressure and Temperature Measurements
Recording of the static pressure with a U-tube as well as of the gas temperature at the
following spots:
 Before ball mill

 After ball mill/before static separator
 After static separator
 Between filter and fan
 After fan
 Dynamic separator; pressure difference of the fan
Further pressure and temperature curve
 Before separator filter/cyclone

 After separator filter/cyclone
 After separator filter fan.
5.3 Air/Gas Quantity Measurement
Measurement of:
 Mill exhaust gas quantity (before or after fan)
 Separating air quantity (example: air separator)
 Potential cooling fresh air quantity (separator inlet)
5.4 Temperature of the Material
Material temperature
 Feed material
 After mill
 Filter dust (mill filter)
 Separator feed material
 Separator grits
 Separator fine product
 Separator filter dust
 Finished material.
Important: It is necessary for all measurements (air quantities, pressure and
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.
6 Sampling Procedure
6.1 Complete Circuit 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 reliability
of the test, further samples can be taken. The additional staff, time and device expenditure
for the sampling procedure and analysis should, however, be considered.
The following Table 1 and Table 2 describe the sampling, location, quantity etc. and
suggest analysis plan. 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 – in no case
“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.
For each sampling point it is important to consider the number of samples as representative
for the sampled material flow! Appendix shows a table for recording of complete circuit
sample results.
Picture 3: Ball mill circuit sampling points
Table 1: Sampling Plan
Sl. Location Type Quantity Frequency Sampling

No.
1. Feed Bulk sample during Main components every 3 hours Material flow over the
test period complete width
 5-6 kg each
Others
 2-3 kg each
2. Roller press Bulk sample during  4-6 kg each every 3 hours cakes vehicle
test period
-cakes- of each roll section
 2 kg
3. Mill discharge Individual sample  1-2 kg each every 2 hours Over complete
material flow
4. Static separator Individual sample  1 kg each every 2 hours Over complete

material flow
-Grits-
5. Cyclone separator Individual sample  1 kg each every 2 hours Slot sampler
6. Mill filter Individual sample  1 kg each every 2 hours In short time intervals
Discharging 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 intervals
Discharging screw
9. Finished material Individual sample  1 kg each every 2 hours Over complete

material flow
Important:
Blending section of
sufficient length!
Table 2: Analysis Plan
Sl. Location Analysis Analyzing method Evaluation

No.
***
1. Feed Sieve analysis ISO 565 Particle size distribution
**
Grind ability Zeisel Grind ability in kWh/t
**
Mineralogy X-ray diffractometer
RFA
(Main component)
***
2. Roller press Sieve analysis ISO 565 Particle size distribution
Clarify cakes des-
agglomeration
****
3. Mill discharge Sieve analysis ISO 565 Particle size distribution
Laser particle seizer Laser particle seizer
Specific surface Blaine
****
4. Static separator Sieve analysis ISO 565 Particle size distribution
-Grits- Laser particle seizer Laser particle seizer
****
5. Cyclone separator Sieve analysis ISO 565 Particle size distribution
Laser particle seizer Laser particle seizer
6. Mill filter Laser particle seizer Laser particle seizer Particle size distribution
*
7 Separator feed each : Particle size distribution
****
 Feed material* Sieve analysis ISO 565 and
 Separator grits*
Laser particle seizer Laser particle seizer separation curve
 Fine separator grains*
calculation (Tromp curve)
8. Separator filter* Laser particle seizer Laser particle seizer Particle size distribution
9. Finished material* Laser particle seizer Laser particle seizer Particle size distribution
*
Measurement of the complete particle size distribution
**
Only if required!
***
Sieve analysis suggestion (or similar diameters): 32/16/8/4/2/1/0.5/0.2/0.09 mm
****
Sieve analysis suggestion (or similar diameters): 2/1/0.5/0.2/0.09/0.045/0.032 mm
6.2 Meter Sampling during Internal Ball Mill Inspection
The grinding progress along the ball mill axis will be evaluated by meter samples.
For this purpose, a material sample of 1 to 2 kg is taken in meter intervals, starting at the
inlet (0 m). The sample is not to take directly at the surface, but from the level of the 3rd or
4th ball layer. After the partition wall, it is started again at 0 m. The last sample position is
also directly 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
Picture 4: Positions for meter sampling
7 Assessment of Plant during Stop Condition
Table 3: Inspection List
Area Plant assessment during stop condition
Roller press  State of the roller surface

 Fractures, Wear
 Spilling
 Gap width between roller and side plate
 State of the internal primary seal:
o Grease collar visible: good
o No grease collar: plant maintenance
 Zero gap
Ball mill Condition: Mill has to be shut down by emergency stop (incl. mill fan) – to prevent
fine material losses!!
Internal inspection:
 Meter sampling along the total length of the mill (cf. 5.2)
 Filling volume determination
 Ball charge determination (cf. 7.2.1)
 Control mill internals:
o Breakages / Wear
o Inlet / outlet wall thickness
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)
 Evaluation of classifying effect
 Balls sampling (cf. 7.2.3)
Static air separator Position of louvers or blades
Cyclone separator Wear
Mill filter  Condition of filter bags

 Wear
Mill fan  Wear of inlet vane control system
Separator fan  Wear
Auxiliary equipment  Wear, holes, leakage e.g. bucket elevator
Area Plant assessment during stop condition
Dynamic separator A) Turbo air separator

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

 Wear of
o External fan
o Internal louver
o Distributing plate
o Counter blades /rotor Ref. to rotor: sealing between rotating and fixed
part
 Ascertain louver setting
 Position and number of counter blades
 Material deposit in cyclone inlet?
 Separator lining
C) Cage separator
 Wear on
o Rotor
o Guide vane
o Distributing plate
o Sealing of rotor between fixed and rotating part
o Separator lining
 Sealing of rotor: Adjustment of gap between fixed and rotating part
8 Process Evaluation
8.1 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%.
∑a = Sum of all particle class results of A [%]

∑f = Sum of all particle class results of F [%]
∑g = Sum of all particle class results G [%]
All weight share results over all particle classes are to summarize (Example: see bottom
sum line in “Table 1”)
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)
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 factor [%]
 = Separation efficiency [%]
t = Separation degree [%]
dt = Cut size [µm]
Take out of fines and grits

𝐹 Σ𝑎− Σ𝑔
𝑉𝐹 = = (2)
𝐴 Σ𝑓− Σ𝑔
𝐺 Σ𝑓− Σ𝑎
𝑉𝐺 = = (3)
𝐴 Σ𝑓− Σ𝑔
𝑉𝐺 = 1 − 𝑉𝐹 (4)
with:
𝑉𝐹 = Take out of fines [-]
𝑉𝐺 = Take out of grits [-]
Separator circulation factor and circulation load
The circulation factor (u) defines the relation between feed and separator fines quantity:
𝐴 1 Σ𝑓− Σ𝑔
𝑢= = = (5)
𝐹 𝑉𝐹 Σ𝑎− Σ𝑔
or related to particular particle class:

𝑓−𝑔
𝑢= (5.1)
𝑎−𝑔
The circulation load (CL) defines the relation between rejects and separator fines quantity.
It differs from circulation factor (u) by 1.
𝐺 Σ𝑓− Σ𝑎 𝑓−𝑎
𝐶𝐿 = = 𝑢−1= or related to particular particle class: 𝐶𝐿 =
𝐹 Σ𝑓− Σ𝑔 𝑓−𝑔
Separation efficiency
Separation efficiency got as well different other names in literature. It is as well called:
separator efficiency; recovery of fine particles; separation degree and some others.
The separation efficiency () is related to a particular particle class. It means the share of
the separator feed material below this particle class, which reaches the separator fine
product.
The result of the separation efficiency is changing with dedicated particle class.
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 [-]

 = Separation efficiency [%]
8.1.1 Separation curve: TROMP CURVE
Example calculation “Separation curve”
The following particle size distribution has been considered:
Table 4: Example of Particle Size Distribution

Part.-Size [D%] Part.-Size [D%]
[mm] Fines (f) Feed (a) Grits (g) [mm] Fines (f) Feed (a) Grits (g)
1.0 5.13 2.20 1.04 32.0 84.51 34.97 16.02
1.2 6.79 2.90 1.44 36.0 88.48 39.15 20.27
1.4 8.38 3.56 1.78 40.0 91.57 43.26 24.76
1.6 9.87 4.17 2.09 45.0 94.46 48.16 30.46
1.8 11.28 4.74 2.36 50.0 96.52 52.71 36.00
2.0 12.61 5.27 2.60 56.0 98.19 57.65 42.22
2.2 13.86 5.76 2.82 63.0 99.40 62.67 48.74
2.6 16.15 6.65 3.20 75.0 100.00 69.63 57.98
3.0 18.23 7.43 3.51 90.0 100.00 75.96 66.50
3.5 20.57 8.30 3.85 106.0 100.00 80.68 72.83
4.0 22.70 9.08 4.14 125.0 100.00 84.51 77.91
4.5 24.67 9.80 4.41 150.0 100.00 87.79 82.17
5.0 26.50 10.47 4.65 175.0 100.00 89.94 84.92
5.5 28.24 11.10 4.87 200.0 100.00 91.46 86.87
6.3 30.86 12.04 5.19 225.0 100.00 92.62 88.37
7.0 33.04 12.80 5.43 250.0 100.00 93.56 89.61
8.0 36.01 13.80 5.71 280.0 100.00 94.51 90.88
9.0 38.87 14.72 5.91 315.0 100.00 95.45 92.17
10.0 41.65 15.58 6.04 355.0 100.00 96.37 93.47
12.0 47.00 17.15 6.17 400.0 100.00 97.26 94.73
15.0 54.57 19.37 6.30 450.0 100.00 98.08 95.93
16.0 56.96 20.12 6.39 500.0 100.00 98.73 96.92
18.0 61.53 21.66 6.73 560.0 100.00 99.30 97.87
20.0 65.78 23.31 7.32 600.0 100.00 99.58 98.37
22.0 69.70 25.05 8.17 800.0 100.00 100.00 99.67
25.0 74.96 27.85 9.96 1000.0 100.00 100.00 99.97
28.0 79.50 30.83 12.28 Sum 3,468.54 2,429.68 2,019.97
VF = 0.283 VG = 0.717
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. On the right hand side of each
formula is a numerical example shown, which is related to table 3 or 4.
Procedure
1 Calculation of the material output (cf. 7.1.1)
2,429.68 − 2,019.97
𝑉𝐹 − 𝐹𝑖𝑛𝑒𝑠 (𝐹𝑜𝑟𝑚𝑢𝑙𝑎𝑟 2) 𝑉𝐹 = = 0.283
3,468.54 − 2,019.97
𝑉𝐺 − 𝐺𝑟𝑖𝑡𝑠 (𝐹𝑜𝑟𝑚𝑢𝑙𝑎𝑟 3) 𝑉𝐺 = 1 − 𝑉𝐹 = 0.717
2 Determination of the specific particle fraction failure S(X)
𝑆(𝑋) = 𝑎(𝑋) − [ 𝑉𝐹 ∗ 𝑓(𝑋) + 𝑉𝐺 ∗ 𝑔(𝑋) ]
𝑆(1) = 2.20 − [ 0.283 ∗ 5.13 + 0.717 ∗ 1.04 ] = 0.0009529 (7)
3 Correction of each particle fraction of the calculated failure S(X) according to the
following formula:
∗ 𝑆(𝑋) ∗ 0.0009529
𝑎(𝑋) = 𝑎(𝑋) − 𝑎(2) = 2,9 − = 2.93 (8)
1 + 𝑉𝐹2 + 𝑉𝐺2 1 + 0.2712 + 0.7292
∗ 𝑆(𝑋) ∗ 𝑉𝐹 ∗ 0.0009529 ∗ 0.271

𝑓(𝑋) = 𝑓(𝑋) + 𝑓(2) = 6,79 + = 6.78 (9)
1 + 𝑉𝐹2 + 𝑉𝐺2 1 + 0.2712 + 0.7292
∗ 𝑆(𝑋) ∗ 𝑉𝐺 ∗ 0.0009529 ∗ 0.729

𝑔(𝑋) = 𝑔(𝑋) + 𝑔(2) = 1,44 + = 1.41 (10)
1 + 𝑉𝐹2 + 𝑉𝐺2 1 + 0.2712 + 0.7292
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:
∗ ∗ ∗ ∗
∆𝑔(1) = 𝑔(2) − 𝑔(1) ∆𝑔(1) = 1.41 − 1.04 = 0.372 (11)
∗ ∗ ∗ ∗
∆𝑔(2) = 𝑔(3) − 𝑔(2) ∆𝑔(2) = 1.74 − 1.41 = 0.329
fi * and ai* are to be calculated respectively.
Following MT 28, the separator feed share should be calculated according to the following
formula:
∗
∆𝑎(𝑥)𝑀𝑇28 = ∆𝑓 ∗ ∗ 𝑉𝐹 + ∆𝑔∗ ∗ 𝑉𝐺
∗
∆𝑎(1)𝑀𝑇28 = 1.653 ∗ 0.283 + 0.372 ∗ 0.717 = 0.734 (12)
The rated value only slightly differs from the analytical one.
The separation degree () is calculated as follows:

∗
∆𝑔(𝑥) ∗ 𝑉𝐺 ∗ 100 0.372 ∗ 0.717 ∗ 100
𝜏(𝑥) = ∗ 𝜏(1) = = 36.3 (13)
∆𝑎(𝑥)𝑀𝑇28 0.734
The following table shows the recalculated values:
Table 5: Corrected particle distribution

Particle Failure Corrected fraction values
τ MT28
Size [D%] S(X) a* f* g* ∆a* ∆f* ∆g* ∆a* MT28
[mm] Fines (f) Feed (a) Grits (g) [%] [%] [%] [%] [%] [%] [%] [%] [%]
1.0 5.13 2.20 1.04 0.001 2.20 5.129 1.040 0.734 1.653 0.372 0.734 36.3
1.2 6.79 2.90 1.44 -0.054 2.93 6.78 1.41 0.683 1.579 0.329 0.683 34.6
1.4 8.38 3.56 1.78 -0.092 3.61 8.36 1.74 0.631 1.492 0.292 0.631 33.2
1.6 9.87 4.17 2.09 -0.119 4.24 9.85 2.03 0.584 1.404 0.260 0.584 32.0
1.8 11.28 4.74 2.36 -0.142 4.83 11.26 2.29 0.541 1.322 0.233 0.541 30.9
2.0 12.61 5.27 2.60 -0.161 5.37 12.58 2.53 0.503 1.245 0.210 0.503 29.9
2.2 13.86 5.76 2.82 -0.180 5.87 13.82 2.74 0.908 2.291 0.362 0.908 28.6
2.6 16.15 6.65 3.20 -0.215 6.78 16.11 3.10 0.802 2.067 0.303 0.802 27.1
3.0 18.23 7.43 3.51 -0.247 7.58 18.18 3.40 0.892 2.338 0.322 0.892 25.9
3.5 20.57 8.30 3.85 -0.282 8.47 20.52 3.72 0.802 2.125 0.280 0.802 25.0
4.0 22.70 9.08 4.14 -0.313 9.28 22.64 4.00 0.735 1.961 0.252 0.735 24.6
4.5 24.67 9.80 4.41 -0.341 10.01 24.60 4.26 0.685 1.834 0.231 0.685 24.2
5.0 26.50 10.47 4.65 -0.365 10.70 26.44 4.49 0.643 1.734 0.213 0.643 23.8
5.5 28.24 11.10 4.87 -0.387 11.34 28.17 4.70 0.959 2.617 0.305 0.959 22.8
6.3 30.86 12.04 5.19 -0.419 12.30 30.79 5.01 0.778 2.171 0.228 0.778 21.0
7.0 33.04 12.80 5.43 -0.445 13.08 32.96 5.23 1.026 2.967 0.260 1.026 18.2
8.0 36.01 13.80 5.71 -0.478 14.10 35.93 5.49 0.940 2.854 0.186 0.940 14.2
9.0 38.87 14.72 5.91 -0.507 15.04 38.78 5.68 0.870 2.770 0.121 0.870 10.0
10.0 41.65 15.58 6.04 -0.531 15.91 41.55 5.80 1.593 5.349 0.112 1.593 5.0
12.0 47.00 17.15 6.17 -0.565 17.51 46.90 5.91 2.230 7.567 0.125 2.230 4.0
15.0 54.57 19.37 6.30 -0.582 19.74 54.47 6.04 0.746 2.393 0.097 0.746 9.3
16.0 56.96 20.12 6.39 -0.580 20.48 56.86 6.13 1.539 4.565 0.345 1.539 16.1
18.0 61.53 21.66 6.73 -0.567 22.02 61.43 6.48 1.629 4.254 0.593 1.629 26.1
20.0 65.78 23.31 7.32 -0.547 23.65 65.68 7.07 1.731 3.927 0.864 1.731 35.8
22.0 69.70 25.05 8.17 -0.524 25.38 69.61 7.94 2.781 5.270 1.800 2.781 46.4
25.0 74.96 27.85 9.96 -0.488 28.16 74.88 9.74 2.959 4.544 2.335 2.959 56.6
28.0 79.50 30.83 12.28 -0.457 31.12 79.42 12.07 4.115 5.014 3.760 4.115 65.5
32.0 84.51 34.97 16.02 -0.427 35.23 84.44 15.83 4.172 3.967 4.253 4.172 73.1
36.0 88.48 39.15 20.27 -0.410 39.41 88.40 20.08 4.102 3.098 4.498 4.102 78.6
40.0 91.57 43.26 24.76 -0.404 43.51 91.50 24.58 4.903 2.890 5.698 4.903 83.3
45.0 94.46 48.16 30.46 -0.406 48.41 94.39 30.28 4.553 2.061 5.536 4.553 87.2
50.0 96.52 52.71 36.00 -0.410 52.97 96.45 35.82 4.935 1.668 6.224 4.935 90.4
56.0 98.19 57.65 42.22 -0.408 57.90 98.12 42.04 5.021 1.207 6.525 5.021 93.2
63.0 99.40 62.67 48.74 -0.395 62.92 99.33 48.57 6.853 0.633 9.306 6.853 97.4
75.0 100.00 69.63 57.98 -0.233 69.77 99.96 57.87 6.194 0.039 8.621 6.194 99.8
90.0 100.00 75.96 66.50 -0.011 75.97 100.00 66.49 4.606 0.031 6.410 4.606 99.8
106.0 100.00 80.68 72.83 0.164 80.57 100.03 72.90 3.712 0.034 5.163 3.712 99.7
125.0 100.00 84.51 77.91 0.355 84.29 100.06 78.07 3.141 0.040 4.364 3.141 99.6
150.0 100.00 87.79 82.17 0.580 87.43 100.10 82.43 2.039 0.031 2.831 2.039 99.6
175.0 100.00 89.94 84.92 0.756 89.47 100.13 85.26 1.444 0.022 2.004 1.444 99.6
200.0 100.00 91.46 86.87 0.882 90.91 100.16 87.26 1.107 0.015 1.538 1.107 99.6
225.0 100.00 92.62 88.37 0.964 92.02 100.17 88.80 0.907 0.009 1.261 0.907 99.7
250.0 100.00 93.56 89.61 1.016 92.93 100.18 90.06 0.925 0.006 1.288 0.925 99.8
280.0 100.00 94.51 90.88 1.049 93.85 100.19 91.35 0.932 0.003 1.299 0.932 99.9
315.0 100.00 95.45 92.17 1.063 94.78 100.19 92.65 0.927 -0.001 1.293 0.927 100.0
355.0 100.00 96.37 93.47 1.060 95.71 100.19 93.94 0.900 -0.004 1.256 0.900 100.1
400.0 100.00 97.26 94.73 1.037 96.61 100.18 95.20 0.842 -0.008 1.177 0.842 100.3
450.0 100.00 98.08 95.93 0.995 97.45 100.18 96.38 0.688 -0.011 0.964 0.688 100.4
500.0 100.00 98.73 96.92 0.934 98.14 100.17 97.34 0.640 -0.018 0.899 0.640 100.8
560.0 100.00 99.30 97.87 0.830 98.78 100.15 98.24 0.329 -0.014 0.465 0.329 101.2
600.0 100.00 99.58 98.37 0.753 99.11 100.13 98.70 0.743 -0.092 1.073 0.743 103.5
800.0 100.00 100.00 99.67 0.235 99.85 100.04 99.78 0.136 -0.038 0.204 0.136 108.0
1000.0 100.00 100.00 99.97 0.019 99.99 100.00 99.98 0 0 0 0 100.0
Sum 3,468.54 2,429.68 2,019.97 2,429.68 3,468.54 2,019.97
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 Bypass ()
The shortest distance () between separation curve and abscises (particle size)
determines, which part of the total feed material enters the grits without separation.
The separator bypass () corresponds to the minimum of the curve, it is the lowest
Tromp coefficient.
The old generation of separators is characterized by a high bypass around 50%.

With the same energy supply, a reduction of the  value does usually lead to an
increase in throughput.
The bypass level depends of the circulating factor, for low fineness cement (3.000
cm²/g acc. to Blaine) the bypass is low; it increases with the cement fineness.
Separator bypass means the ratio between the quantity of a definite particle size
(fines), which has reached the grits, and the quantity existing in the feed material.
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.
3. Imperfection I:
It is calculated as follows
𝐷75 − 𝐷25
𝐼=
2𝐷50
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%.
𝐷75
𝑘=
𝐷25
For an ideal separation k would be 1.
Further information on separator assessment please find under:

https://teamnet.grouphc.net/group/WOK/cemop/copgrinding/Pages/Documents_en-
US.aspx
Main category: Separator
Guidance Paper for Separator Inspection and Optimization
Cement quality: CEM I 42,5 R (sp)
SEPARATION VALUES TROMP CURVE VALUES
Circulating load: 3.54 Bypass : 4% at 12 µm

Take out of fines VF: 28.3% D25: 19 µm
Take out of grits VG: 17.7% D50: 23 µm
Efficiency at 32 µm : 68.2% D75: 33 µm
Efficiency at 45 µm : 55.4% Imperfection: 0.3
Efficiency at 90 µm : 37.2% Sharpness: 1.74
TROMP- Curve
100%
95%
90%
85%
80%
75% D75 = 33 μm
70%
65%
TROMP value T(x)
60%
55%
50% D50 = 23 μm
45%
40%
35%
30%
25% D25 = 19 μm
20%
15%
10%
5% τ = 4%; X=12 μm
0%
1 10 100
Particle size [µm]
Picture 5: Tromp Curve
8.2 Internal Mill Inspection
The analysis of the mill inspection refers to:
 Preparation of a grinding diagram over the grinding path length

 Determination of the filling degree
 Calculation of the grinding media quantity
 Calculation of the consumed power at the mill tube
 Determination of average ball diameter
8.2.1 Preparation of Grinding Diagram

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 abscissa is the length of the
grinding path. The residue values of various particle classes are laid off on the curve.
Analysis and evaluation of meter samples
General: - Sieves analysis for both chamber**

- In 2nd chamber also specific surface acc. Blaine from material < 0.5 mm
Evaluation: In a diagram: residue (particle size) and Blaine (chamber 2 only) as

function of mill length.
A good grinding is at steep sieve lines without big disturbances. The corn fraction of 2.3 mm
shall be less than 5 % in front of the intermediate diaphragm. The corn fraction of 1 mm
shall disappear in the second chamber within the first third of the chamber length.
Just in front of the intermediate diaphragm or of the outlet diaphragm there can be strange
results of the sieve curve. One or some curves may incline sharply instead of the expected
further decline. This is because of air segregation of fine particles and off influence of the
grinding performance.
Picture 6: Ball Mill Grinding Diagram
8.2.2 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.
As cutout of the form sheet, the following picture shows the graphical determination of the
filling ratio.
It is to be determined:
 Grinding level (h)
 Clear grinding chamber diameter (Dli).
0,75
0,74
0,73
y = -0,0086x + 0,9192
0,72
0,71
0,7
0,69
h/Dli
0,68 Dli
0,67
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 %
Usual filling degree numbers: 25 – 28 %, optimized on power consumption.

~35 %, optimized on throughput.
Picture 7: graphical determination of the mill filling ratio
The filling degree f can be calculated correctly with the following formulas (MT22):
𝛼 sin 2 𝛼
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 following
𝐷𝑙𝑖
formula can be used:
ℎ
𝑓 = 1.0678 − 1.164
𝐷𝑙𝑖
8.2.3 Calculation of Grinding Media Quantity

From the filling ratio calculated under 7.2.2 the weight of the grinding media filling (in t) can
be derived:
Grinding media quantity
𝜋
𝐺 = ∗ 𝐷𝑙𝑖2 ∗ 𝐿𝑙𝑖 ∗ 𝑓 ∗ 𝛾𝑀𝐾 [t]
4
Dli = Inside liner diameter of grinding chamber in m

Lli = effective length of the grinding chamber in m
f = grinding media filling degree
MK = bulk density grinding media in t/m3
reference value: coarse ball charge (1st chamber): approx. 4.4-4.5 t/m³
nd
fine ball charge (2 chamber): approx. 4.6-4.7 t/m³
The filling ratios determined by measuring the grinding level are to be reduced by 1 to 3 %
depending on the material cover over the ball charge. OR the mill has to be emptied out to
measure the degree of filling of the media.
8.2.4 Calculation of Power Consumption of Mill Tube
Power consumption of mill tube
Pw = G * 0.1026 * DLi ^ 1.014 * nR ^1.27 * f * (1.36 – 1.2 * f) [kW]
G = weight of grinding media [t]

Dli = Inside liner diameter of grinding chamber [m]
nR = revolutions of the tube [ rpm ]
f = grinding media filling degree
1
PZ = Pw [ kW counter ]
A
A = Total efficiency
The total efficiency  A = mech * el
Following values can be used: For girth gear drive:  A = mech *  = 0.92
For central drive:  A = mech *  = 0.94
8.2.5 Determination of the Average Ball Diameter and Classifying Effect in Chamber 2
The first chamber of a ball mill is normally emptied every 1 to 2 years, the second chamber
approximately every 3 to 5 years. The ball grading becomes obvious after balls sorting.
Important: Balls and material are sampled together, at meter sampling.
 Ball sampling each meter in the same way as at material meter sampling. Balls and
material will be taken at once. Dividing of balls and material can be done already in the
mill or later, outside.
 The samples amount should approximately correspond to the volume of a 10-l bucket.
 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.
Per meter sample, only the number of balls and the total weight of the ball sample are to be
determined. Out of this, 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:  total amount of balls per meter sample (number of balls)
 total weight of the balls in meter sample (sample weight in t)
Given:  material density () of the grinding media (usually 7.85 t/m3)
Calculation of the average ball diameter of a meter sample:
3 sample weight 1 3
Dm = 2 ∗ √ ∗ ∗ [m]
number of balls ρ 4∗π
The result should then be converted into mm.
9 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 combined drying and grinding units:
 Moisture of the material (complete sampling and analysis plan):

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

o conveying and combustion air (can usually be
neglected), fan adjustment
 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
 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)
9.1 Balance Preparation
Air quantity balance
Air to mill
Air from auxiliary burner

(mostly to neglect)
Exhaust air from mill after

Steam from material moisture Mill system filter
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 convection
losses
Drive power heat conversion Mill system
Heating up of
the raw meal
Quench / false air
(mostly rest of balance)
Enthalpy of steam
The false air volume flow is calculated on the basis of the air quantity balance or out of gas
analyses, e.g. of the kiln exhaust gas.
9.1.1 Air Quantity Balance
Balance
𝑉̇ additional air (+𝑉̇ conveying air/combustion) + 𝑉̇ false air + 𝑉̇ steam = 𝑉̇ exhaust air
Measured variables: 𝑉̇ additional air [m3(s.c.)/h]
𝑉̇ conveying air [m3(s.c.)/h]
𝑉̇ exhaust air [m3(s.c.)/h]
𝑚̇steam [m3(s.c.)/h]
Operant: 𝑉̇ false air [m3(s.c.)/h]
Water amount to be vaporized
𝑓𝐴 − 𝑓𝑅 𝑓𝐴 − 𝑓𝑅
𝑚̇𝑤𝑎𝑡𝑒𝑟 = ∗ 𝑀̇𝑚𝑒𝑎𝑙−𝑟𝑒𝑠𝑖𝑑.𝑚𝑜𝑖𝑠𝑡 = ∗ 𝑀̇𝑓𝑒𝑒𝑑−𝑤𝑒𝑡 [kg/h]
100 − 𝑓𝐴 100 − 𝑓𝑅
With: fA initial moisture in %

F residual moisture in %
𝑀̇meal-resid.moist meal incl. residual moisture in kg/h
𝑀̇feed-wet feed material with moisture in kg/h
Resulting steam volume
𝑚̇𝑤𝑎𝑡𝑒𝑟 ∗ 𝑇𝑁
𝑉̇ steam = 𝑚̇water / 0.804 = 𝑅 ∗ [m3(s.c.)/h]
𝑃𝑁 ∗ 100
With: R general gas constant: R = 461 J/kg K

TN reference temperature 273 K
PN 1013 mbar
Balance for false air calculation
𝑉̇ false air = 𝑉̇ exhaust air - 𝑉̇ additional air - 𝑉̇ steam (-𝑉̇ 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:
𝑛2 − 𝑛1
VF [%] =  100
𝑛2
Calculation:
VF [%] = 33,4 %
Gas amounts: before mill: 75.500 m3(s.c., dry)/h

steam: 9.100 m3/h
after mill: 121.300 m3/h
From air quantity balance:
𝑉̇ false = 121.300 – 75.500 – 9.100

= 36.700 m3(s.c.)/h
From gas analysis:
33,4
𝑉̇ false = (121.300 – 9.100) ∗
100
= 37.475 m3(s.c.)/h
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.-percent.
9.1.2 Heat balance
Reference temperature should be 25°C, as the cp-diagrams (pictures 7 and 8) refer to this
temperature.
Balance 𝑄̇input = 𝑄̇loss
𝑄̇input:
𝑄̇additional air + 𝑄̇additional firing + 𝑄̇combustion air + Pmech + 𝑄̇feed material + 𝑄̇fresh air + 𝑄̇false air
𝑄̇loss:
𝑄̇exhaust air + 𝑄̇water vaporizing + 𝑄̇finished product + 𝑄̇heat losses
Input
𝑄̇additional air = 𝑉̇ additional air * cp * (additional air - 25°C) [kJ/h]
𝑄̇additional firing = 𝑚̇fuel * hu(fuel) [kJ/h]
𝑄̇combustion air = 𝑉̇ combustion air * cp * (combustion air - 25°C) [kJ/h]
𝑄̇fresh air = 𝑉̇ fresh air * cp * (fresh air - 25°C) [kJ/h]
𝑄̇false air = 𝑉̇ false air * cp * (false air - 25°C) [kJ/h]
𝑄̇feed material = 𝑚̇feed material * cm * (feed material - 25°C) [kJ/h]

Pmech = Pdrives *  * 3,600 s/h (0.9 <  < 0.96  efficiency) [kJ/h]
with Pdrives = performance counter of the drives over test period [kJ/h]
and  = 0.92 for ball mill with girth gear drive

 = 0.94 for ball mill with central drive
Loss
𝑄̇exhaust air = 𝑉̇ exhaust air * cp * (exhaust air - 25°C) [kJ/h]
𝑄̇vaporizing water = 𝑚̇water * 2,446 kJ/kg [kJ/h]
𝑄̇finished product = 𝑚̇finished product * cp * (finished product - 25°C) [kJ/h]
𝑄̇losses = balance deviation (accounts for appr. 5 % of thermal input)
General issues 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:
3,600 𝑠 𝑘𝐽
𝑄̇rad.-con. = total * Acomponent * (Tsurface – Tambient) * [kJ/h]
ℎ 1,000 𝐽
with total = rad + con
𝑇𝑠𝑢𝑟𝑓𝑎𝑐𝑒 4 − 𝑇𝑎𝑚𝑏𝑖𝑒𝑛𝑡 4
rad =  *  * [W/(m2 K)]
𝑇𝑠𝑢𝑟𝑓𝑎𝑐𝑒 − 𝑇𝑎𝑚𝑏𝑖𝑒𝑛𝑡
with:  = 5.67 * 10-8 W/(m2 * K4)
Emission factor  ≈ 0.3 galvanized sheet metal
 ≈ 0.4 iron with silver coating
 ≈ 0.65 rusty surface (iron)
 ≈ 0.9 heavily rusted iron, rust protection coating
The calculation of con 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 < mill tube < 110°C
10°C < ambience  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:
con  8 - 9 W/(m2 * K) for 2 m  D  3 m
con  9 - 10 W/(m2 * K) for 3 m < D  4 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 < surface < 70°C and 10°C < ambience  30°C
con  1.6 (surface - ambience) 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) =  xi * cp(i)
with xi = share of component i in the total gas volume
cp(i) = specific thermal capacity of component xi
Units
V = [m3(s.c.)/h] or [m3(s.c., dry)/h]

m = [kg/h]
H = [kJ/h]
cp = [kJ/(kg * K)] or [kJ/(m3 * K)]
T = [K]
 = [W/(m2 * K)]
A = [m2]
hu = [kJ/kg]
P drives = [kW]
(s.c. = at standard conditions)
10 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“)
11 Appendix
1 Forms “Site inspection”
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”
Page 1/3: Site inspection Date:
Plant:
Plant type:
A B
Time:
Scales discharge behavior 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 weight
feeder
selection +, o, -
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
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
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 equipment unusual occurrences

aggregate
aggregate
aggregate
= homogeneous; good
o = medium; normal
Page 1/2: Recording of control room data 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 temperature °C
Separator no. 1 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
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
Page 2/2: Recording of control room data Date:
Plant:
Plant type:
A B
Time:
Mill filter fan

setting %/min ^-1
Power consumption roller press

indication kW
kWh-meter kWh
ball mill
indication kW
kWh-meter kWh
separator drives
indication kW
kWh-meter kWh
bucket elevator kW
electric ear %
Pressure/temperature profile Date:
Plant:
Plant type:
Test periods: A B
Time: mbar °C mbar °C
Static pressure before ball mill
after ball mill
before static separator

(= after ball mill)
before cyclone
Air/gas (= after static separator)
temperature
[°C] before mill filter fan
(= after filter)
after mill filter fan
separator 1
before fan
after fan
separator filter
before filter
after filter
after fan
Pressure/temperature profile Date:
Plant:
Plant type:
Test periods: A B
Time:
feed component A:
B:
C:
D:
Material temperature ball mill outlet:

[°C]
cyclone fines:
(after static
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
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:
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:
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:
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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HeidelbergCement Group

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

Process owner: EG Grinding

Guidance Paper on Process Evaluation of Ball

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

2 FUNDAMENTAL DATA ON THE TEST /TARGET ............................................................... 4

5 RECORDING OF OPERATING DATA .................................................................................. 8

5.1 GENERAL OPERATING DATA ............................................................................................. 8

6.1 COMPLETE CIRCUIT SAMPLING ....................................................................................... 10

8 PROCESS EVALUATION ................................................................................................... 16

8.2.3 Calculation of Grinding Media Quantity .................................................................... 28

9.1 BALANCE PREPARATION................................................................................................. 31

9.1.2 Heat balance ............................................................................................................ 34

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

1 Health and Safety

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

2 Fundamental Data on the Test /Target

A grinding plant is to be examined,

 Site inspection At first, only a visual and audible control, partly as

 Recording of the operating data Includes:

 Measurements at site  Pressure

 Sampling All around samples

 Recording of the actual state Equipment revision at plant stop

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

3 Scheme of a Typical Ball Mill Grinding Plant

 Feeding station for components (with scales)

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

4 Plant Examination – Site Inspection

 Regular running without unusual change of the grinding gap

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

 Position of the guide vanes

 Leakage etc. (false air)

 Setting (inlet vane control system, damper or speed of rotation)

 Position and number of counter blades

 Setting (inlet vane control system, Flap)

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

 Leakage etc. (false air)

 Well running of discharge valve

5 Recording of Operating Data

Power consumption of:

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

5.2 Pressure and Temperature Measurements

 Before ball mill

Further pressure and temperature curve

 Before separator filter/cyclone

5.3 Air/Gas Quantity Measurement

5.4 Temperature of the Material

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

6.1 Complete Circuit Sampling

Picture 3: Ball mill circuit sampling points

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

Table 1: Sampling Plan

Sl. Location Type Quantity Frequency Sampling

4. Static separator Individual sample  1 kg each every 2 hours Over complete

5. Cyclone separator Individual sample  1 kg each every 2 hours Slot sampler

9. Finished material Individual sample  1 kg each every 2 hours Over complete

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

Table 2: Analysis Plan

Sl. Location Analysis Analyzing method Evaluation

Process Evaluation of Ball Mill Grinding Plants Valid as of: 2016-03-31

6.2 Meter Sampling during Internal Ball Mill Inspection

Definition of the method

Inlet Outlet Direction of rotation