Professional Documents
Culture Documents
laws.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 2
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 3
GRINDING PROCESS
CATARACTING ACTION
Crushing by Impact
Ball Mill 1st Compartment
Breaking of particles by
balls impact due to falling
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 4
GRINDING PROCESS
CASCADING ACTION
Grinding by Attrition
Ball Mill 2nd Compartment
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 5
GRINDING PROCESS
Rotation
Rotation
Release points
Re le ase Points
3
2
1 1 2 3
Lift
Lift Zo ne
Zone
Grinding
Grinding
Zone
Zone
1 - Cascading (tumbling)
1 - Cascading (tumbling) Liners digs into charge.
Liners digs into charge.
2 - Cataracting (free fall - max impact)
2 - Cataracting (free fall
3 - Excessive Lift - max.
(impact impact)
on liner) Some
Some slipslip occurs
occurs.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 6
GRINDING PROCESS
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 7
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 8
BALL MILL COMPONENTS
Gas + dust
outlet
Intermediate diaphragm
Outlet diaphragm
Reject return Inlet head C2 liners Discharge box
chute C1 liners
Fresh feed
Outlet seal
Material discharge
Shell
Central or ventilation ring
Fresh air inlet
Central Ventilation ring grate
Supports
Trunnion
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 9
BALL MILL COMPONENTS
2
5
4
7
6
8
1. Mill inlet
2. Mill shell w. welded on slide rings & gear flange
3. Slide shoe bearing
4. Stanex diaphragm with adjustable lifters
5. Outlet diaphragm with adjustable lifters
6. Lining of coarse grinding compartment
7. Lining of fine grinding compartment
8. Cast gear with guard
TYPICAL FLS BALL MILL
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
10
22 March 2019
BALL MILL COMPONENTS
MILL INLET
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
11
22 March 2019
BALL MILL COMPONENTS
DRIVE TYPES
CENTRAL DRIVE
SIDE DRIVE
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
12
22 March 2019
BALL MILL COMPONENTS
BEARINGS - TRUNNION
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
13
22 March 2019
BALL MILL COMPONENTS
BEARINGS – SLIDE SHOE
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
14
22 March 2019
BALL MILL COMPONENTS
LINER TYPES
2ND COMPARTMENT
1ST COMPARTMENT
CLASSIFYING /
STEP LINER
CORRUGATED LINER
Rotation
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
15
22 March 2019
BALL MILL COMPONENTS
CENTRAL DIAPHRAGM
1) Diaphragm Slots – 10 to 12 mm
2) Ventilation Ring
3) Scoops
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
16
22 March 2019
BALL MILL COMPONENTS
HOW A PARTITION WALL WORKS
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
17
22 March 2019
BALL MILL COMPONENTS
OUTLET GRATE
2) Ventilation Ring
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
18
22 March 2019
BALL MILL COMPONENTS
STUFFING BOX ARRANGEMENT FOR
WATER SPRAY IN CENTRAL DRIVE
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
19
22 March 2019
BALL MILL COMPONENTS
GRINDING MEDIA
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
20
22 March 2019
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
21
22 March 2019
TYPES OF CIRCUIT
OPEN CIRCUIT
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22
22 March 2019
TYPES OF CIRCUIT
CLOSED CIRCUIT
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
23
22 March 2019
TYPES OF CIRCUIT
CLOSED CIRCUIT
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
24
22 March 2019
TYPES OF CIRCUIT
CLOSED CIRCUIT – 2 FAN SYSTEM
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
25
22 March 2019
TYPES OF CIRCUIT
CLOSED CIRCUIT – 3 FAN SYSTEM
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
26
22 March 2019
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
27
22 March 2019
BALL MILL POWER CONSUMPTION
POWER DRAW FORMULA
N=CxFxnxμxD xa
N = Mill Power Draw (kW)
C = Mill Constant (0.514) = g x π / 60
g = Acceleration of gravity
F = Ball Charge (MT)
n = Mill Rotational Speed (rpm)
µ = Torque Factor
D = Mill Effective Diameter (m)
a = Arm of Gravity in relation to mill diameter
= Distance between center of the mill and center
gravity of charge The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 28
BALL MILL POWER CONSUMPTION
MILL SPEED
The operating speed of a mill may be expressed as a percentage of its critical
speed.
The critical speed nc is the speed, where the centrifugal force at the mill
lining is equal to the gravitational force.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
29
22 March 2019
BALL MILL POWER CONSUMPTION
MOVEMENT OF GRINDING MEDIA
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
30
22 March 2019
BALL MILL POWER CONSUMPTION
MILL CHARGE
The mill charge is defined as amount of grinding media in the mill compartment.
Where,
q = Percentage media filling
W = Bulk Density of media (Based on media shape, size and proportion)
V = Effective Volume of the compartment
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
31
22 March 2019
BALL MILL POWER CONSUMPTION
PERCENTAGE FILLING
The percentage filling is the percent volume occupied by media in the mill
compartment. It can be found from the mathematical cylindrical segment
concept.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
32
22 March 2019
BALL MILL POWER CONSUMPTION
PERCENTAGE FILLING
or
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
33
22 March 2019
BALL MILL POWER CONSUMPTION
MEDIA BULK DENSITY & TORQUE FACTOR
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
34
22 March 2019
BALL MILL POWER CONSUMPTION
POWER CALCULATION - EXAMPLE
Compartment 1st 2nd
Gross Diameter, m 4.6 4.6
Gross Length, m 6.1 9.9
Liner Thickness, mm 95 42
Eff. Length, m 5.9 9.4
Mill RPM 15.33 15.33
Eff. Dia, m 4.4 4.5
Eff. Volume, m3 89.9 150.2
35
22 March 2019
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
36
22 March 2019
GRINDING MEDIA SIZE DISTRIBUTION
BALL CHARGE – COMPARTMENT 01
Emphasis on crushing and less on grinding
Typical top size:
80 mm Ø if easy to crush, small feed size
90 mm Ø is the most common
100 mm Ø in rare cases; very hard, coarse feed
Coarser ball charges, gives good crushing capability but:
Too porous - shorter retention
Less surface, less grinding
Can result in poor preparation for second chamber if you overfeed
Extra wear
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
37
22 March 2019
GRINDING MEDIA SIZE DISTRIBUTION
FEED SIZE Vs BALL SIZE
1000
B= Max Ball Size (mm)
100
90
15
10
1
0.1
0,5
1 10 15 100
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22 March 2019
GRINDING MEDIA SIZE DISTRIBUTION
BALL CHARGE PROPORTION – COMPARTMENT 01
40 %
40 % 25 %
20 %
30 %
15 %
20 %
10 %
Size Size
Ø 90 / 80 / 70 / 60 mm Ø 90 / 80 / 70 / 60 mm
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22 March 2019
GRINDING MEDIA SIZE DISTRIBUTION
BALL CHARGE – COMPARTMENT 02
Top size depends on how much preparation is done in the first chamber.
Recommendation : 30 ... 40 mm
Smallest size depends on the discharge grate slot size
Practical rule of thumb; smallest Ø = 2 X slot width
E.g. slot width = 8-10 mm; smallest Ø = 16-20 mm
Non-classifying liners limits compartment 02 to 3 sizes
Classifying liners allow a large variety of sizes
Best Practice “Ball Charge Optimization”
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
40
22 March 2019
GRINDING MEDIA SIZE DISTRIBUTION
BALL CHARGE POROSITY
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 41
GRINDING MEDIA SIZE DISTRIBUTION
MEDIA MANAGEMENT
Volume Load vs. Specific Power
25
Specific Grinding Energy
20
[kWh/t]
15
10
5
15 20 25 30 35
Volume load [%]
42
22 March 2019
GRINDING MEDIA SIZE DISTRIBUTION
EQUILIBRIUM CHARGE
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
43
22 March 2019
GRINDING MEDIA SIZE DISTRIBUTION
EQUILIBRIUM CHARGE – COMPARTMENT 01
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
44
22 March 2019
GRINDING MEDIA SIZE DISTRIBUTION
EQUILIBRIUM CHARGE – COMPARTMENT 02
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
45
22 March 2019
GRINDING MEDIA SIZE DISTRIBUTION
MEDIA PATTERN
BALL SIZE – 1ST COMPARTMENT
90 mm 80 mm 70 mm 60 mm
23% 32% 21% 24%
Compensation 90 mm
Initial Piece Weight 1533 g
BALL SIZE – 2ND COMPARTMENT
Equilibrium Piece Weight 1295 g
Mill System 25 mm 20 mm 15 mm
Open 20% 40% 40%
Closed 40% 40% 20%
Mill System Open Closed
Compensation 20 & 25 mm 25 mm
Initial Piece Weight 23 g 30 g
Equilibrium Piece Weight 21 g 28 g
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 46
GRINDING MEDIA SIZE DISTRIBUTION
BALL SAMPLING
Where,
d = Diameter of the ball
ρ = Specific Weight of ball = 7.8 g/cm3 (Normal Steel)
These parameters are determined on the basis of ball sampling
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 47
GRINDING MEDIA SIZE DISTRIBUTION
BALL SAMPLING PROCEDURE
Compartment 01 - min 200 Pieces
Compartment 02 - min 50 kg
Extract from under the centreline and dig as deeply as possible
Sort out the broken media
Separate in fractions as shown in the table
Weigh each separated fractions
Count the number of pieces in each fraction
Difference between Initial charge weight and weight during ball
sampling gives the wear rate The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 48
GRINDING MEDIA SIZE DISTRIBUTION
BALL SAMPLING
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 49
GRINDING MEDIA SIZE DISTRIBUTION
BALL SAMPLING
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
50
22 March 2019
GRINDING MEDIA SIZE DISTRIBUTION
KEY NUMBERS
Wear in g/kWh
Large Balls 2 to 5
Small Balls 1 to 3
22 March 2019 51
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
52
22 March 2019
MILL GRINDING PERFORMANCE
MATERIAL SAMPLING
The mill grinding performance can be evaluated by material sampling over the
length of each compartment.
Mill performance is evaluated based on analyzing the PSD of sampled material.
Sampling shall be made near the beginning and end of each compartment.
Compartment 01 – Sampling at equal distance with about 50 cm spacing.
Compartment 02 – Sampling at equal distance with about 0.75 – 1 m spacing.
Minimum of 4 to 5 locations per compartment.
Using a sampling scoop dig deeply over a half diameter of the lifting side.
In Compartment 02 use 10 mm sieve to facilitate material & ball classification.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 53
MILL GRINDING PERFORMANCE
MATERIAL SAMPLING
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 54
MILL GRINDING PERFORMANCE
MATERIAL SAMPLING
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 55
MILL GRINDING PERFORMANCE
MATERIAL SAMPLING
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 56
MILL GRINDING PERFORMANCE
SAMPLE ANALYSIS
10 mm
5 mm
2 mm
COMPARTMENT 01
1 mm
500 μm
200 μm
5 mm
2 mm
1 mm
COMPARTMENT 02 500 μm
200 μm
90 μm
45 μm
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 57
MILL GRINDING PERFORMANCE
NORMAL FINENESS
25 – 40% + 0.2 mm
At Partition in Two 8 – 16% + 0.5 mm
Compartment Mill 2.5 – 4% + 1.0 mm
Max 0.5% + 2.0 mm
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 58
MILL GRINDING PERFORMANCE
22 March 2019 59
MILL GRINDING PERFORMANCE
22 March 2019 60
MILL GRINDING PERFORMANCE
Compartment 01 – Curves are ascending at the end of the compartment. If the slots
are clean and of proper size, the solution is to upgrade the grinding media
Compartment 02 – Found OK
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 61
MILL GRINDING PERFORMANCE
OTHER FACTORS AFFECTING GRINDING PERFORMANCE
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 62
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
63
22 March 2019
SEPARATOR PERFORMANCE
SEPARATOR CONCEPTS
It decreases the retention time in the mill reducing coating and excessive
temperatures
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 64
SEPARATOR PERFORMANCE
SEPARATOR CONCEPTS
[Qf /Qa] & [Qp /Qa] is an important parameter for all separators specifications
Feed to Air Ratio is the ratio of separator feed (kg) to the total internal airflow
(m3) used.
Product to Air Ratio is the ratio of separator product (kg) to the total internal
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 65
SEPARATOR PERFORMANCE
SEPARATOR CONCEPTS
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 66
SEPARATOR PERFORMANCE
SEPARATOR CONCEPTS
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 67
SEPARATOR PERFORMANCE
SEPARATOR CONCEPTS
Bypass / Delta:
The minimum probability for the fines to be sent back to the mill
Cut Size :
The limit beyond which the separator cannot see a difference between
particle size
Kappa :
It varies like the inverse of the slope, the lower the kappa, the better the
separation
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
68
22 March 2019
SEPARATOR PERFORMANCE
SEPARATOR EFFICIENCY
Operating in closed circuit with a separator results in specific power reduction.
The size of reduction results on the separator efficiency, fineness level and CF
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
69
22 March 2019
SEPARATOR PERFORMANCE
FIRST GENERATION SEPARATORS
Bypass : 30 – 60 %
Efficiency : 25 – 40 %
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
70
22 March 2019
SEPARATOR PERFORMANCE
SECOND GENERATION SEPARATORS
Feed
Bypass : 15 – 30 % Exhaust
Efficiency : 40 – 60 %
Fresh air
Fines
Rejects
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 71
SEPARATOR PERFORMANCE
THIRD GENERATION SEPARATORS
Fines
Material Feed
Secondary
Air
Bypass : 5 – 15 %
Efficiency : 75 – 85 %
Primary
Air
Rejects
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22 March 2019 72
SEPARATOR PERFORMANCE
THIRD GENERATION SEPARATORS
Feed
Cage rotation
Primary
Air Uniform
Inlet Flow distribution
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
73
22 March 2019
SEPARATOR PERFORMANCE
THIRD GENERATION SEPARATORS
ROTOR SPEED
AIR FLOW
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
74
22 March 2019
SEPARATOR PERFORMANCE
TROMP CURVE
Describes the % of the feed material of any grain size in the return material
T D
Amount _ of _ size _ D _ in _ returns
* 100
Amount _ of _ size _ D _ in _ separator _ feed
D
Amount _ of _ size _ D _ in _ fines
* 100
Amount _ of _ size _ D _ in _ separator _ feed
T ( D) ( D) 100
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
75
22 March 2019
SEPARATOR PERFORMANCE
TROMP CURVE
Where,
C - Circulation Factor
△Rg - % of return material in the fraction in the interval representing
the particle size
△Rm - % of material leaving the mill in the interval representing the
particle size
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
76
22 March 2019
SEPARATOR PERFORMANCE
TROMP CURVE
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
77
22 March 2019
SEPARATOR PERFORMANCE
TROMP CURVE
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
78
22 March 2019
SEPARATOR PERFORMANCE
TROMP CURVE
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
79
22 March 2019
SEPARATOR PERFORMANCE
TROMP CURVE
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
80
22 March 2019
SEPARATOR PERFORMANCE
TROMP CURVE
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
81
22 March 2019
SEPARATOR PERFORMANCE
PLOTTING TROMP CURVE
1) Collect sieve residue data for separator feed, reject and product.
4) Recalculate the mill product residue for each fraction using the average
circulation factor value (RM, corr)
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22 March 2019
SEPARATOR PERFORMANCE
PLOTTING TROMP CURVE
Ro R C 1* Rg
log C * log o
Rf R f C 1* Rg
Vs
Ro C 1*100
*100
Ro
log C * log
Rf R f C 1*100
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
83
22 March 2019
SEPARATOR PERFORMANCE
PLOTTING TROMP CURVE
Sieve (d) Residues C RM, corr Vs Sieve(dm) Tromp
µm RF, % RM, % RG, % - % % μm %
2 88,9 92,0 95,4 1,93 91,88 19,4
4 79,1 85,1 91,4 1,96 84,75 23,2 3 25,97
8 69,0 78,3 88,2 1,94 77,86 32,2 6 21,52
12 57,5 70,9 85,9 1,89 70,63 45,1 10 14,71
18 46,8 64,2 84,3 1,86 64,18 55,3 15 11,13
21 41,7 60,9 83,7 1,85 61,12 59,6 19,5 9,85
25 35,6 57,1 82,9 1,83 57,50 64,3 23 9,58
30 28,9 52,7 81,9 1,82 53,45 68,6 27,5 11,54
36 22,1 48,0 80,2 1,80 49,00 71,8 33 17,90
45 15,8 42,9 77,0 1,80 44,12 73,3 40,5 29,88
63 5,9 31,7 64,0 1,80 32,78 71,8 54 53,40
90 1,1 21,2 44,6 1,86 21,26 69,9 76,5 77,72
C-average 1,86
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
84
22 March 2019
SEPARATOR PERFORMANCE
PLOTTING TROMP CURVE
Delta 9.58
Cut-size 52.1
Kappa 0.51
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
85
22 March 2019
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
86
22 March 2019
OPTIMISATION OF MILL OPERATION
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
87
22 March 2019
OPTIMISATION OF MILL OPERATION
GRINDABILITY
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
88
22 March 2019
OPTIMISATION OF MILL OPERATION
GRINDABILITY - EXAMPLE
Assume,
Grindability of a OPC feed component = 28 kWh/t @ 3000 Blaine @ Shaft
Maximum available mill power** = 4598 kWh @ shaft
Maximum production can be achieved = 4598 ÷ 28 = 164 TPH
Mill can give best specific power consumption @ 164 TPH OPC with 3000 Blaine.
However the above production is the minimum to be achieved, higher the
production more the savings in power consumption.
** Maximum available power can be arrived from the mill power calculation using
optimum media charging.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
89
22 March 2019
OPTIMISATION OF MILL OPERATION
FACTORS INFLUENCING GRINDABILITY
Feed Chemistry
Product Fineness
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
90
22 March 2019
OPTIMISATION OF MILL OPERATION
OPTIMISATION TO ACHIEVE THE TARGET
Ball Mill
Separator
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
91
22 March 2019
OPTIMISATION OF MILL OPERATION
BALL MILL OPTIMISATION
The following are the areas in Ball Mill for optimisation,
Fresh Feed
Mill Performance
Mill Ventilation
Separator Rejects
Fresh Feed
Ventilation
Flow Rate
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
92
22 March 2019
OPTIMISATION OF MILL OPERATION
BALL MILL OPTIMISATION
Fresh Feed
• Constant Feed Rate
• Low Moisture additives
• HAG in case of high moisture
• Less variation in feed chemistry
• Constant size and Granulometry
• Avoid frequent change in feed recipe
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
93
22 March 2019
OPTIMISATION OF MILL OPERATION
BALL MILL OPTIMISATION
Mill Performance
• Media Management by chamber sampling
• Good liners
• Proper slots in diaphragm
• Scoop adjustment based material distribution
• Fine atomised water spray
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
94
22 March 2019
OPTIMISATION OF MILL OPERATION
BALL MILL OPTIMISATION
95
22 March 2019
OPTIMISATION OF MILL OPERATION
BALL MILL OPTIMISATION
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
96
22 March 2019
OPTIMISATION OF MILL OPERATION
BALL MILL OPTIMISATION
Mill Ventilation
• Insure the removal of fines
• Insuring heat removal
• Helps for material movement
• Normal gas velocity across the mill is 1.0 – 1.5 m/s
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
97
22 March 2019
OPTIMISATION OF MILL OPERATION
SEPARATOR OPTIMISATION
The following are the areas in Ball Mill for optimisation,
Optimum Separator Seals (Horizontal & Vertical)
Maintain Constant Air Flow Ventilation
Separator Ventilation - flow rate
- temperature
Sep. fines
Constant 1
Mill throughput
Mill ventilation
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
98
22 March 2019
OPTIMISATION OF MILL OPERATION
KEY OPERATING PARAMETERS
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
99
22 March 2019
OPTIMISATION OF MILL OPERATION
MILL START-UP
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
100
22 March 2019
OPTIMISATION OF MILL OPERATION
IRREGULARITIES ON MILL OPERATION
INDICATION REASON
Unsuitable ball charge composition
Badly worn balls
Mill output too low Diaphragm unsuitable or clogged
Unsuitable worn liners
Change in material grindability
Mill overfilled
Mill output too coarse Separator clogged
Feed size too large
Feed rate too low
Mill output too fine Feed size too small
Separator not adjusted
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
101
22 March 2019
OPTIMISATION OF MILL OPERATION
IRREGULARITIES ON MILL OPERATION
INDICATION REASON
Feed rate too high
Mill sound dull
Diaphragm clogged
Feed rate too low
Mill sound high
Inlet clogged
Mill inlet clogged
Diaphragm blocked
Inlet pressure low
Too low air draught through mill
Too much false air at mill outlet
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
102
22 March 2019
OPTIMISATION OF MILL OPERATION
IRREGULARITIES ON MILL OPERATION
INDICATION REASON
False air at mill outlet
Outlet pressure low Too little material in mill
Diaphragm broken
Mill inlet clogged
Outlet pressure high Diaphragm clogged
Too high feed rate
Material too wet
Outlet temperature low
Hot gas amount too low
Material temperature too high
Venting air flow too low
Outlet temperature high
Mill overfilled
Ball coating
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
103
22 March 2019
OPTIMISATION OF MILL OPERATION
IRREGULARITIES ON MILL OPERATION
INDICATION REASON
Mill feed high
Change in grindability
Separator Reject High
Poor mill performance
Low air flow
Mill Outlet above the limit
Product Temp High Less fresh air to separator
Problem in water flow
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
104
22 March 2019
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
105
22 March 2019
INSTRUMENTATION AND INTERLOCKING
CONTROL LOOPS
Diaphragm temp increase above 105 deg C inlet water pump will ON
Mill outlet temp increase above 110 deg C outlet water pump will ON
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
106
22 March 2019
INSTRUMENTATION AND INTERLOCKING
CONTROL LOOPS
Mill inlet pressure decreases then mill vent fan speed will increase
Separator fan outlet draft decreases then mill vent fan speed will increase
Mill fan power decreases then mill fan speed will increase
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
107
22 March 2019
INSTRUMENTATION AND INTERLOCKING
CONTROL LOOPS
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
108
22 March 2019
INSTRUMENTATION AND INTERLOCKING
INTERLOCKS
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
109
22 March 2019
INSTRUMENTATION AND INTERLOCKING
INTERLOCKS
Group Starting Interlock Start Sequence Operating Interlock
Mill Feed All Groups On Mill Feed weigh Feeders All downstream groups
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
110
22 March 2019
INSTRUMENTATION AND INTERLOCKING
INTERLOCKS
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
111
22 March 2019
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
112
22 March 2019