Ball mill inspection procedure

Ball mill inspection p procedure p

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation Conference 2009 8th 9th October Victorville/ Victorville / CA U.S.A The Green Tree Convention Center

Tim Nowack
Senior Process Engineer Christian Pfeiffer Maschinenfabrik GmbH

Christian Pfeiffer

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Ball mill inspection procedure

General:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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The process engineer should be the doctor of the system. system

The doctor is required for: 1) implementation of Health checks Regular action 2) urgent investigations of actual process problems Non-regular action This presentation focuses on the regular Health check procedure.

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Ball mill inspection procedure

General:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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The Health checksconsist of standard measurements on a frequent basis Type of measurement:

Circuit mat. granulometry Mill longitudinal sieving Ball charge filling degree Mill material level Mill internal conditions Ball charge sampling Separator Tromp curve Separator ventilation Mill ventilation til ti Weigh feeder calibration Instrument verification Control loop verification
Q Q Q Q Q

12 months schedule
Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q

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Main annual audit

Ball mill inspection procedure

General:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Healths checks are important in order to: build up a knowledge and data base about the system performance record the data and display them in trends for fast and easy diagnostic of problems The main advantage: ad antage Knowledge basis allows to investigate the root cause of problems and to avoid problems by early reaction based on the trend results.

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Ball mill inspection procedure

General:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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For each measurement make sure you have:

design data of the machines/equipment available.

constant/stable operation condition for at least 2 hours. recorded the actual operation data like: Production rate [t/h], Product type, composition [M-%] Actual A t l and dt target t fineness fi of f product d t [Blaine [Bl i or Residue] R id ] Actual mass flow rate (e.g. separator grits, water demand, etc.) Electrical power consumption of the main equipment Actual operation parameter of the main equipment (e.g. separator speed, damper positions)

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Ball mill inspection procedure

Circuit material g granulometry: y

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Sampling points

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Ball mill inspection procedure

Circuit material g granulometry: y

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Sampling point:
Clinker feed Gypsum feed Additive No.1 feed Additive No. 2 feed Mill outlet tl t material t i l Separator feed material Separator grits material S Separator fi fines cyclone l 1 Separator fines cyclone 2 Separator fines mix Filter dust 1 (weighfeeder) Filter dust 2 (circuit dedusting) Filter dust 3 (mill dedusting) Cement

r
1 x per Test H 2O H 2O H 2O 1x every hour

Procedures
Sieving 50, 25, 16, 8, 4, 2, 1, [mm]

10 kg

Pre-screening with 450 m sieve PSD from 1-450 m with Laser equipment (e.g. Cilas, Malvern, Sympatec) Fineness acc. to Blaine [cm [cm/g] /g]

0.5 kg

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Ball mill inspection procedure

Longitudinal g sampling: g
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Sampling points at crash stop

0.5 1m 1m 1m 0.5 0.5 1m 1m 1m 1m 1m 1m 0.5

1.1 1.1

1.2 1.2

1.3 1.3

1.4 1.4

2.1

2.2

2.3

2.4

2.5

2.6

2.7

Sample weight: 1st compartment: 2nd compartment: 20 cm 1-2 kg 0.5 kg

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20 cm

Ball mill inspection procedure

Ball charge g filling g degree: g

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Measurement by free height

1. Measure average g internal diameter, , Di 2. Measure height, h, in three different points along axis for each grinding compartment For best results the measurement takes place in an empty mill (mill feed stopped for approx. 10 min).

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Ball mill inspection procedure

Mill material level:

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Inspection only at crash stop

Record the material level approx. each meter along axis

Too high = above charge Good = below charge Too low = >1 1 below charge
Good material level for 1st compartment

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Ball mill inspection procedure

Mill material level:

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation

Inspection only at crash stop

Record the material level approx. each meter along axis

Too high = > 50mm above charge Good = approx. pp 20 mm above charge Moderate = equal with ball charge Too low = >> 50 mm below charge
Good material level for 2nd compartment

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Ball mill inspection procedure

Mill material level:

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Inspection only at crash stop

Record the material level before and after transfer points

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Ball mill inspection procedure

Mill internals condition:

General Material sampling Longitudinal sampling Filling degree Material level
1-4 1-2

Crash stop information:

Type of product:
T o t a l m ill f e e d: F re s h f e e d: C o a rs e re t urn:

M a in m ill driv e :

OPC n.a. [t/h] n.a. [t/h] n.a. [t/h]

Finish mill No. 2

3,5 m x 9,6 m
2nd comp. 3rd compartment

power installed power absorbed mill speed critical speed

1495 n.a. 16,72 72,67

[kWh] [kWh] [r.p.m.] [%]

Free heightcalculation: Pabs= 1247 kW

1st compartment

Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation
2,115 mm 1,290

1-8

M
+

5,380 mm

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Ball mill inspection procedure

Mill internals condition:

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation

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Ball mill inspection procedure

Mill internals condition:

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation

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Ball mill inspection procedure

Ball charge g sampling: g

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Solution 1) Total sorting of ball charge

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18 20 25 30 40 50 60 Scrap

Ball mill inspection procedure

Ball charge g sampling: g

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
891.80 g
Cu stom e r D ata:
Project-No.: Project: Customer: Plant: Installation: Compartment:
3 3.4 2 0

Solution 2) Analysing the actual grinding media composition by spot samples.

1st compartment: t t 50 balls per sample
M

2nd compartment: p 200 balls per sample

Avg. Piece weight
Input Table
Date: 23.02.2006 Prepared by: Now

Grinding balls
2.4m x 5.0m w ith QDK 8,5-F Monochamber (1/3 lifter - 2/3 class.)

Ball -
Std. Max Min Piece 1 2 3 4 5 6 7 8 9 Mass 891,8 g 886,2 g 879,6 g 878,0 g 873,5 g 873 3 g 873,3 861,0 g 860,6 g 858,2 g

60
886 g 1400,0 g 682,0 g 891,8 g 886,2 g 879,6 g 878,0 g 873,5 g 873 3 g 873,3 861,0 g 860,6 g 858,2 g

50
513 g 681,0 g 375,0 g

40
262 g 374,0 g 177,0 g

30
111 g 176,0 g 81,0 g

25
64 g 80,0 g 45,0 g

20
33 g 44,0 g 14,0 g

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Conference 2009 8th 9th October Victorville/ Victorville / CA U.S.A The Green Tree Convention Center

Ball mill inspection procedure

Ball charge g sampling: g

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation

Solution 2) Analysing the actual grinding media composition by spot samples.

Results of grinding media sampling
Ball 60 50 40 30 25 20 Total pc.
24 23 18 13 8 0 86

1 weight mass-%
19920 11112 4293 1384 481 0 37190 53,56% 29,88% 11,54% 3,72% 1,29% 0,00% 100,00%

pc.
3 20 35 28 14 3 103

2 weight mass-%
2552 9269 8468 2997 835 93 24215 10,54% 38,28% 34,97% 12,38% 3,45% 0,39% 100,00%

Sampling Point 3 pc. weight mass-%

3 10 19 59 73 66 230 2353 4651 4592 6328 4369 2025 24316 9,68% 19,13% 18,88% 26,02% 17,97% 8,33% 100,00%

pc.
0 0 5 28 66 76 175

4 weight mass-%
0 0 1209 2943 3923 2366 10441 0,00% 0,00% 11,58% 28,19% 37,57% 22,66% 100,00%

pc.
0 0 4 63 144 98 309

5 weight mass-%
0 0 952 6617 8576 3056 19200 0,00% 0,00% 4,96% 34,46% 44,67% 15,91% 100,00%

60,0%

50,0%

40,0%

30,0%

20,0%

10,0%

0,0% 0,5 1 1,5 60 mm 2 50 mm 2,5 3 40 mm 3,5 30 mm 4 4,5 25 mm 5 20 mm 5,5

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N ame

Now
D ate

Avg P iece Weight Avg.

P ro je c t . N o . C o unt ry

Ins t a lla t io n M ill dim e ns io ns C us t o m e r P la nt

23.02.2006

33.420 -

Ball mill inspection procedure

Separator tromp curve:

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Define the sampling points

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Ball mill inspection procedure

Separator tromp curve:

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation

Define the sampling points

Separator feed material before splitter Separator rejects material

Separator fines material from each cyclone

and
Check the stable condition of the circuit Record all main operation parameters

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Ball mill inspection procedure

Separator tromp curve:

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
Navigation

Define the sampling points

Sampling point: Separator feed material Separator grits material Separator fines cyclone 1 Separator fines cyclone 2
0.5 kg

Procedures
Pre-screening with 450

m sieve PSD from 1-450 m with 1x Laser equipment (e.g. every hour Cilas, Malvern, Sympatec) Fineness acc acc. to Blaine [cm/g]

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Ball mill inspection procedure

Separator Ventilation:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Basics: Air flow measurement

Select your equipment

Prandtl-Pitot Tube S-Type Tube

No correction factor needed Easy to operate within 15 angle Only in low vortex channel Not for high dust loaded channels

C ti f factor t required i d( (~0.84) 0 84) Correction Misalignment results in mistakes Preferred for high dust loaded h l channels

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Ball mill inspection procedure

Separator Ventilation:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Measurement points:
Separator circuit with cyclones Separator circuit with filter

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= Air flow, Static pressure, Temperature = Static pressure, Temperature

Ball mill inspection procedure

Mill Ventilation:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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= Air flow, Static pressure, Temperature = Static pressure, Temperature

Remark: Consider minimum 10% false air intake after mill.

Ball mill inspection procedure

Weigh g Feeder Calibration:

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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a) Static calibration - feeder not in operation

Zero-point - adjustment (local control box, no load) Span adjustment with calibration weight (local control box)

b) Calibration with feeder in operation (preferred if possible)

operate weigh feeder with defined setpoint and load material into truck for e.g. 10 minutes, while mill is shut down weigh truck empty and loaded, calculate throughput and adjust controller if necessary

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Ball mill inspection procedure

Instrument Verification:
General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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1) Electronically
Check and adjust zero-point and span with e.g. mA-transmitter

2) Operation check
Compare control room indication with local manual measurement of temperature, pressure and flow Adjust transmitters

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Ball mill inspection procedure

Control loop Verification:

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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1) Operation check
record process parameters with control t ll loop i in operation ti over period of e.g. 6-8 hours with constant production record mill p power consumption p at counter (kWh)

Adjust control loop

parameters t if necessary Information on: Available information at the CCR Control system Control strategy First impression on operation Circuit stability

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Ball mill inspection procedure

Thank you for your attention

General Material sampling Longitudinal sampling Filling degree Material level Internals condition Ball charge Trompcurve p Ventilation Weighfeeder Instrument C t ll Control loop
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Questions?

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