CRCM

Research Center
Cement & Minerals Industries

Grinding Plants
Optimization and Modelling
(CEMTECH 93 , St Petersburg)

Alain Cordonnier - Christophe Obry

1. Introduction
For the last few years, FCB has conducted extensive research works in the grinding field and particularly
in the digital simulation of the ball mill. A portion of these works performed in that time in cooperation with
Société des Ciments Français has been presented during the "study days on new grinding techniques and energy
savings" on October 25 and 26, 1989 in Paris and was published by the review "World Cement" in August and
September 1991. This publication exposes the underlying theoretic principles for the modelling and simulation
of any grinding circuit equipped with a ball mill.
After completion of these works, FCB was endowed with two new tools :
A precise, accurate and reliable grindability test (FCB Index) fully representative of the comminution
process as it occurs in an industrial ball mill. This test permits to define the relative efficiency, called
σ (sigma) of a grinding plant with respect to the FCB Index :

FCB Index Specific Energy

σ=
IndustrialSpecific Energy

A computation program for the simulation of grinding plant with ball mill, including a new
formulation of the grinding functions. This programme takes into account all configurations and
operating conditions of an industrial plant (classifier, ball charge and classifying, ventilation, etc..).

Today we are able to bring a number of complementary improvements concerning the last theoretical
developments as well as the results obtained on the field.
Finally, the success achieved in all cases where we applied the modelling has enabled us to define two
investigation methods now routinely used.

2. Theoretical Advances

2.1. Blaine Model

2.1.1. Objective

Digital simulation is based on the computation and the evolution of the different particle size distributions
in a circuit, but ignores the concept of the Blaine specific surface area which is the most generally used criterion
in ciment grinding. It was therefore important to be able to compute the Blaine value directly from the complete
size distribution. In fact, simple correlations (Blaine vs. R8µ and other) are insufficient because they do not take
into account the size grading homogeneity (Rosin Rammler slope, for instance) which depends on the plant
(classifier, circulating load, etc.).

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 2.1.2. Means

A systematic study of the correlations between the Blaine specific surface area and the size distribution
for different products has shown that it was impossible to achieve a model independent of the material being
investigated. The solution requires a complement of calculation in addition to the grindability test (FCB Index)
and to the determination of the S and B function (see figure 1).

The Blaine Model in the FCB's Modelisation Method

FBS Mill Simulator

FCB index SIZE
Distributions MODELISATION
Calculated
Size Grinding Plant
BLAINE Distributions Simulation

Without Blaine Model

With Blaine Model Blaine
Model

Figure 1 : The Blaine model in the modelling method

In fact, the FCB Index gives, for standard conditions, a set of measured values (grainsize distribution and
Blaine surface area) covering the considered range (cement of approx. 2000 to 4000 Blaine). These data are then
consolidated (FCB Index examination and calculation of the size distribution by FBS: first modelling step). This
permits to secure both parameters of the Blaine model on consistent data.

2.1.3. Conclusions

• The Blaine model completes the characterization of the investigated material.

• Entered in our ball mill simulator, it enables us to associate the corresponding Blaine value to all
calculated size distributions.
• We can now impose on the simulator to search for a circuit solution which permits to produce a given
Blaine value. For instance, if the Blaine value and the circulating load are first selected, the simulator
shall determine the classifier setting and the end product throughput, as the operator of an industrial
circuit would do.

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 2.2. Partition Curve Model of size classifiers
FCB has developed, tested and now validated a mathematic universal formulation of the partition curve
of a classifier (see figure 1). This funtion gives the efficiency value Ri for the mesh Xi. It consists in the
combination of two sigmoids (S-shaped curves): one curve describes the size while the other describes the fines
bypassing.
The parameters of this function
have a physical meaning : Str
1−
Mc : separation mesh of the classifier Pts
Xi
Pt : slope 1+
Str Ms
Ms : separation mesh of the fines Ri = Stg + (1 − Stg ) ⋅ Pts
+ Pt
bypassing Xi Mc
Pts : fines bypassing slope 1+ 1+
St : maximum fines bypassing
Ms Xi
Stg : global fines bypassing
Their meaning is shown on the St − Stg
Avec:Str =
figure 2. The figure 3 shows us to which 1 − Stg
extent the parameters enable us to simulate
any classifier type.
Figure 1 : Universal FCB's formula for efficiency calculation.

First Second Third

Generation Generation Generation
mc 20 20 20
pt 2.5 3.5 6
Ms 6 5 6
Pts 1.5 2 2.5
St 0.7 0.5 0.2
Stg 0.4 0.3 -0.05

Modelised Partition Curve

T ypical Partition Curves
1.0

0.9

0.8
β 0.7

0.6
Efficiency

(1-Stg)/2
0.5
0.5 First
Generation
0.4 S econd
Generation
St 0.3 Third
Generation

0.2
(St+Stg)/2

0.1
βs
0.0 0
Stg Size
1 10 100
Ms Mc
M = ln(10)=2.3
tgß=Pt.M/4 Size
tgßs=Pts.M/4

Figure 2 : Parameters Meaning Figure 3 : Modelling of the three classifiers generation

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 Two practical cases of partition curve modelling from industrial size distributions are summarized in the
figure below. The curve for the Sturtevant classifier is an example of a first generation classifier, while the other
curve (TSV) shows the third generation FCB classifier.

Industrial and modelised Classifier Partition Curves

100

90

80

70
LASER
Selectivity Values

60
Alpine Sieve
50
Sturtevant First Generation

40 LASER

TSV Third Generation

30

20

10

0
1 10 100 1000
Size

2.3. Residence time distribution

The operation balances of different existing industrial plants achieved during the simulator validation
period showed that the material flow in a mill is a very complex process closely dependent on the mill design.
In fact, in an industrial mill, the flow is not at all of the "plug flow" type, but presents an important
mixing ratio; in practice, the mill can be assimilated to a succession of perfect mixers with each a length-to-
diameter ratio of about 0.5.
This approach is however complicated by other phenomena :
Air sweep in the mill which causes a differential advance of the fines with respect to the coarser
sizes.
Ball coating tendency with slowing down and overgrinding of a fines portion.
Mill overfilling which shows itself in a portion of the material passing through the mill without
being ground.
Partition effect which not only locally increases the gas velocity and the quantity of air entrained
material, but also screens the material.
These different phenomena are simulated as follows :
• The mill is split into several elementary sections.
• Each elementary section is equipped with two virtual classifiers which permit to simulate the
different points above mentionned.

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 Elementary Theoretical Tube Part
Part n

V
D
Part n-1 Part n+1

V : Simulation of ventilation and/or bypass (overfilling)

D : Simulation of a grate and/or coating
M : Elementary mill section assimilated to a perfect mixer.

This sectional mill approach has permitted a simple and modular programming of the simulator and gives
a high flexibility of use.

3. Modelling on the field

3.1. Ball Charge Recommendation

For a Belgian cement producer who want to optimize the operation of his grinding plant for a cement of
3700 Blaine with 48.5 % slag, we have achieved a complete modelling including a balance of the industrial
operation, a simulation of the existing plant and several theoretic simulations whose purpose was to find
solutions for production increase. These simulations have lead to two concrete proposals :
• Recommendation of a new ball charge
• Installation of a TSV classifier instead of the two first generation Sturtevant classifiers.
We had predicted a potential gain of 7.2 % with the new ball charge. The operator has modified the
charge in compliance with our recommendations. Today, statistics for more than 6 months of operation show an
average gain of 7 % with this new charge of grinding balls !
For the classifier, we can predict and ensure an additional gain of 10 %. We have no feedback from
industrial operation yet because the change of classifier is still in the project stage.

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 Balls charge and Separator Influence

1.1

TSV and Optimized Balls Charge

1

TSV and Initial Balls Charge

0.9
Initial Industrial Production 17/12/91
σ Initial Modelisation
0.8 Modelisation

Modelisation

Modelisation 01/93
0.7
NEW Industrial Production after
01/93

0.6
1.0 1.5 2.0 2.5 3.0
Recirculating Load (Rejects / Fines)

3.2. Grinding with "overfilling"

When modelling a classical grinding plant for the production of portland cement in Canada, we identified
and quantified overfilling in the second compartment. This has been achieved with theoretical "V" type
classifiers (see figure of par. 2.3) of the elementary sections of the second compartment. With a very high
accuracy, we have then retrieved not only the grainsize distributions in the circuit but also in the mill.

Modelisation w ith Overfilling

Portland Cement - 3600 cm²/g - 80 t/h

100.0
Norm al RTD (Fine s)

90.0 Norm al RTD (Reje cts)

80.0 Ove rfilling (Fine s)

Ove rfilling (Re je cts)

70.0
Cumulative Residue

Industrial Fine s (Alpine )

60.0
Industrial Fine s (LASER)

50.0 Industrial Reje cts (Alpine )

40.0 Industrial Reje cts (LASER)

30.0

20.0

10.0

0.0
1 µm 10 µm 100 µm 1000 µm
Size

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 Grainsize distribution along the Mill

70
First Compartment

60 Diaphragm

Second Compartment
50
63 µm
Cumulative Residue

40

100 µm
30

20

250 µm
10
630 µm

0
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Position along the Mill (m)

3.3. Grinding with balls coating

A grinding plant for Portland Cement with 20 % limestone has enabled us to go still further in the
simulation of malfunctions. There was an important overfilling in the second compartment, but in spite of the
integration of this parameter (as for the above mentioned grinding plant in Canada), the simulation was not fully
satisfactory. The simulation was correct only after integrating in the model the problem of ball coating which
had been shown by the plant operation balance. In this case, the theoretical classifiers used in the simulation are
of the "D" type.

Modelisation with Overfilling and Coating

Portland Cement - 4000 cm²/g - 60 t/h

100.0
Normal RTD (Fines)
90.0 Normal RTD (Rejects)

80.0 Overfilling & Coating (Rejects)

Overfilling & Coating (Fines)

70.0
Cumulative Residue

Industrial Fines (Alpine)

60.0
Industrial Fines (LASER)

50.0 Industrial Rejects (Alpine)

Industrial Rejects (LASER)

40.0

30.0

20.0

10.0

0.0
1 µm 10 µm 100 µm 1000 µm
Size

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 The modelling of these malfunctions (coating and overfilling) of course permits to get a better
understanding of the operation of the investigated plant, but also to quantify the effects on the throughput and
the finished product, and therefore to objectively assess the benefit of a considered modification.

3.4. Quantifying the influence of a classifier

3.4.1. Case of a raw meal double rotator

For the projected installation of a TSV classifier in a raw meal grinding plant in Great Britain, we were
lead to model a more complicate circuit equipped with a double rotator. The simulation of the existing circuit
was in all respects consistent with the industrial operation balance. The simulation permitted to quantify the
possible production increases to be achieved by the installation of a TSV classifier and the optimization of the
ball charge.

Double-Rotator Mill on Raw Meal

Specific Energy = f(Sieve Residue at 90 µm)

15

13

S
E
11
Industrial Production
k
Modelised Industrial Production
W
h 9 Mod. with TSV - RL 2.5
/
t FCB Index

5
1 10
Sieve Residue at 90 µm

3.4.2. Case of a coal grinding plant.

The simulation of two coal grinding plants in the steel industry has been performed to investigate and
quantify the advantages of dynamic TSV classifiers instead of existing static classifiers. They were air-swept
FCB ball mills with pneumatic extraction of the finished product at outlet.
The model proves to be quite able to simulate this type of mill with a very high ventilation (3 to 4 m/s in
the tube) which modifies the residence time distribution strongly. A perfect consistency is obtained with the
grainsize distributions in the circuit as well as with the throughput.
The simulation permitted to quantify the impact of a TSV classifier on the throughput of the grinding
plant and on the size distribution curve of the finished product. Thus for the same d80 of 80µ and a constant
circulating load, the TSV classifier brings a 25 % throughput increase and gives a finished product with a closer
size distribution; 40 µ oversize has gone up from 48 % to 54 % while 160 µ oversize has gone down from 4.3 %
to 0.7 %.

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 Air swept coal mill with static separator (41t/h)

100
c
u 90
m
u
80
l industrial partition curve
a
t 70 modelised partition curve
e
i
f industrial rejects
v
f 60
e
i modelised rejects
c
r 50
i industrial fines
e
e
s modelised fines
n 40
i
c
d
y
u 30
e
rejects/fines=1.56
20
%

10

0
10µ 100µ 1000µ
Size

Air swept coal mill MODELISATION

Influence of separator on fines product
100

90
c
u
m 80
u
l
70
a
t
i 60 with TSV Separator 17 kWh/t
v
e with Static Separator 21.2kWh/t
50
r
e 40
s
rejects/fines = 1.5
i
30
d
u
e 20

%
10

0
10 µm 100 µm 1000 µm
Size

The installation of both TSV classifiers was carried out on the end of 1992 and has confirmed the
calculations.

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4. FCB investigation methods
Two methods are presently routinely used. The first is related to the audits of existing plants for
equipment optimization or replacement. The second permits to precisely define a new plant in the project and
construction stages.

FCB's Milling Plant Audit Method

First Step

FCB Index
Milling Plant CRCM
Comparing
Industrial Data Base
Specific
Energy

Abnormal Energetic Consumption Normal Energetic Consumption

Second (optional) Step

Malfunction
FBS + Milling Plant
Identification
Mill Simulator Check-Up
and
Quantification

Balls
Separator
...

FCB's Milling Plant Design Method

First Step (Project Level)
FCB Index Milling Plant
CRCM
Data Base
Projected Basics Guarantees &
Generals
Milling Plant
Modelisation
Design
Results

Second Step (Realisation Level)

Ball Charge
FBS + Diaphragms
Mill Simulator Complete Milling Plant Specifications Separator Characteristics
Installed power
Internal Liners
...

It is very important to note that all grindability data of the material are determined by the grindability test
(FCB Index) and that the simulator is able to determine the throughput without any required "securing" of the
model by means of an industrial operation balance.
The industrial operation data are only used in order to take into account the specific features of the circuit
:
• Separation curve of the classifier
• Possible troubles such as overfilling and coating
• Ventilation in the mill.

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5. Conclusions
The model is reliable for any configurations encountered in the grinding plants for cement or other
materials.
The model allows for the simulation of plants with malfunctions. We do not simulate perfect
standard grinding plants only ! We can also simulate and QUANTIFY such complex phenomena as
mill overfilling, ball coating or also high air flows.
The model can be applied to and is today applied to many materials such as clinker, of course, but
also coal, raw mix, limestone, slag, coke, phosphate rock, etc.
Stimulated by these results obtained with the classical grinding process in ball mill, FCB will
pursue their efforts in the modelling field, in order to extend its scope of application to the bed
grinding process. This should give rise to a complementary model which will enable us to
integrate not only roll presses to our digital grinding plants, but also new machines based on
similar principles. Certain of these machines are in the final development stage at FCB and will be
brought to light by the end of this year.

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