MUGHER CEMENT FACTORY

January 2019
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THE FINSH GRINDING UNIT

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The stations finish grinding consists of the
following partial stations
Proportioning plant and transport to the mill
Finish grinding plant with water injection
device
Cement transport to the cement silo

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 INTRODUCTION

Cement is a material which develops strength when it reacts

with water.
It is inorganic material which consists of calcium, silicon,
iron and aluminium.
Phase in cement
C3S (Alite)
C2S (Belite)
C3A
C4AF
C- Cao, S- Sio2, A- Al2O3 and F- Fe2O3
Type of cement
OPC- ordinary port land cement
Clinker+ gypsum
PPC- pozzolana Portland cement
Clinker +pumice+ gypsum

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Process over view in cement production

Mining
Raw mill Raw meal
and
grinding homogeni
crushing
zation
Pyro
processin
g or
Packing Final clinkeriza
grinding tion

Limestone + corrective Clinker

Clinker + gypsum + additive Cement
Cement + water cement paste
Cement+ water +sand mortar
Mortar + gravel Concrete
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 Why grinding?
The purpose of grinding is
to get a higher surface area
to make it easier to homogenize
 or to transport by air.

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Ball or tube mills are rotating steel cylinders
where size reduction of the mill feed is
performed by motion of the grinding media.
 Grinding is performed by impact and friction
between the grinding balls and mill internals
Two different processes occur inside the mill:
Crushing: Breaking up of the incoming particles
from a size of about 30 mm to a size of minus 2.5
mm diameter. This process takes place in the
first compartment of the mill.
Refining: Powdering of the particles until they
reach the required fineness. This process takes
place in the second or last compartment of the
mill.
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Grinding can be performed in
Open circuit
Closed circuit
.

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Open circuit size reduction the material
passes only once through the machine
Product sent to storage without returning
oversize to mill for further grinding.
Economic for low Blaine products (coarser
material).
The higher the feed rate the shorter the
retention time.
Inefficient for high Blaine

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 Open circuit
Feed

Finis
h
Mill Produ
ct

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 Closed circuit
Closed circuit size reduction the material
discharged from the machine is separated by
screening or classifying into fine and coarse
particles and the coarse particles return to
the machine for further reduction.

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 Closed circuit

Separator

Mill Feed
Fines
Rejects

 Mill

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Mill Product sent to separator and
oversize (rejects) returned to mill for
further grinding.
Fines taken off as finished product.
Over grinding minimized.
Options for adjustment greater on closed
circuits.
Quality and efficiency better. Especially
on products over 3300 Blaine.

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Important process parameters of cement mill
The operator is responsible for a stable process
during start up, operation and shut down of
production
He must realize every change in the system to bring
the process back to normal
These main parameters are:
 Feed rate to mill
You start a mill with lower feed rate.
 The temperature after mill
When mill is in operation, the mill outlet material
temperature is kept(90-115oc) constant by injection
of water at the mill inlet
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Cement discharge temperature is
maintained between 90-115;if too
cold ,gypsum is insufficiently dehydrated and
cement strength is lost, if too hot, excessive
dehydration of gypsum occurs resulting in
false set.

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Gypsum: often used as an umbrella term for calcium
sulfates, which are added as set retarders to cement
clinker
False set: the rapid development of rigidity in a mixed
Portland cement suspension. This rigidity can be
dispelled and fluidity regained by further mixing without
addition of water.(the result of higher temperature
cement)
Flash set: the rapid development of rigidity in a mixed
Portland cement paste, mortar or concrete usually with
the evolution of considerable heat. Rigidity cannot be
dispelled nor can the fluidity be regained by further
mixing without addition of water.
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 Circulation fan
The circulation fan is arranged after the
cyclone collector; it is rated for the required
gas volume flow of the grinding plant in
material separation process

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mill Ventilation(exhaust gas fan):

A major technological aspect to control the

grinding process is the mill ventilation. It is used
to
cooling the cement
 removing the heat generated during the
grinding process,
carrying part of the finished product out of the
grinding area.
ensures rapid removal of the fines which are
produced
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 The quality of the finished product
Cement blaine
Cement so3

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 separator

Separators are the main responsible for

controlling product fines(blaine)
1.Air-Swept Separator
2.Top Feeding Separator:

Air-Swept Separator:
This type of feed allows less space to be taken
up and use in vertical grinding mills or air
swept ball mills.

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Top Feeding Separator:
 Material is fed on top of a rotating dispersion plate
where it is dispersed in to the classifying air stream
which is sucked from tangential inlet ducts through
fixed guide vanes.
 classifies between particles performed by
centrifugal force and the inward force(gravitational).
 the coarse fraction falls and is discharged from the
bottom of the vessel.
The material that is near the product size is picked up by
the rising airflow to the collecting cyclone
 Fiennes is controlled mainly by rotor speed;
Increasing speed increase fineness
Decreasing speed decrease fineness
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Principle of separation
The fan blades pull air from inside the inner cone and
push it into the outer cone. There are return nozzles
in the inner cone for the air to return so that most of
the air is recycled inside the separator housing.
Feed enters the top of the inner vessel and falls by
gravity through the hollow drive shaft onto a rotating
disc called the dispersion plate. It is flung (throw) off
the dispersion plate by centrifugal force and
distributed into the rising stream of air in the space
between the periphery of the dispersion plate and the
walls of the inner vessel. The material that is near the
product size is picked up by the rising airflow in the
inner cone and thus entrained and carried to the
separation zone.
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The fine product which shows the
required fineness is separated by means of
the separating wheel. The gas stream
carries the separated fine product out of
the classifier and into the dust collector
arranged afterit. The coarser particles
(coarse material) that do not yet show the
requiredfineness do not pass the
separating wheel and rejected to the mill.

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 AIR FLOW THROUGH
SEPARETOR
Air flow through the separator has an
influence on the finesse of the cement

Lower Air flow through Separator =

Finer Product
Higher Air flow through Separator =
Coarser Product

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Mechanism of size reduction in tube mills
 The grinding media and the feed material to be ground
are brought together in a rotating tubular or drum
shaped compartment.
 The media and the material are lifted to some distance at
the rising side of the mill in its rotational motion.
 After reaching a certain height ,come tumbling down.
The actual height to which they are lifted depends on a
number of factors
The speed of the mill
The type of lining at the wall of the mill
The composition and shape of the grinding media
The filling ratio
The properties of the feed material.
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Size reduction work is done both during
the rising movement and during the
tumbling down of the grinding media and
the feed material.
In the first cycle, the lifting stage the
material is reduced mainly by compressive
and shearing action.
In tumbling down the bottom of the mill it
is subjected mainly to impact and attrition.
The grinding media used in cement
manufacturing industry are steel balls or
short cylindrical steel media
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The mill is lined with plates, usually of steel
and commonly referred to as liners.

Liners serve to

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 Protect the mill shell against wear
 To assist the lifting of the feed material and
grinding media
 To classify the grinding media according to
size along the length of the mill by using
specially shaped liners

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 Steel ball quantity required for cement mill
for one time recharging in case o MCF is
cement mill first
1st compartment 60t/42(before modification)
2nd compartment 130t/112
Cement mill second
1st compartment 42t
2nd compartment 112t

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 Motion of grinding media
Rotation of the mill causes the charge consisting
of the grinding media and feed material to be lifted
some distance by friction between the media and
the lining.
The height to which the charge is lifted depends on
 Circumferential velocity of the mill
 Shape ,size and weight of the grinding
 Friction between the lining and the grinding media
which is governed by the design of the liner
 Friction with the mill charge which is governed by
the loading percentage and properties of the
material such as its moisture content and flow
ability of the material.
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 Consider a single ball
There are two forces acting on it
The centrifugal force: due to the rotation of
the mill given by Fc=mv²/r
 where V=circumferential velocity of the mill
 R=radius of the mill
Force of gravity=mgcosθ
 Where θ=the angle from the vertical that the
ball lifted
 g=gavitational constant=9.8m/sec2

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Under the action of these forces the ball will
travel in a circular path,I.e in contact with the
rising wall of the mill so long as the
centrifugal force is greater than the
gravitational force.
At the point of the circumference where the
gravitational force is larger than the
centrifugal force, the ball detaches itself from
the wall and falls back into the mill. In doing
so it travels a parabolic path
On the assumption that the ball cannot slide
or roll on the mill lining Fg=Fc and the angle
of detachment can be determined.
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Speed of the Mill:
The operating speed of the mill can be expressed
in percent of the mill critical speed. The optimal
operating speed depends mainly on filling
degree, grinding media size and type of liners.
 Cement mills speed is at 74-90% of its critical
speed

Critical Speed:
The critical speed of a tube mill is that speed of
rotation at which the centrifugal power
neutralizes the force of gravity which influences
the grinding balls, the grinding balls don’t fall
and therefore don't perform grinding work.
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 Motion of the material
In tube mills the raw material is fed and the
product is discharged in a continuous flow
In the course of size reduction the material
moves from the inlet to the outlet of the mill.
This motion is due to several factors
Increase in bulk volume of the material
accordingly as it is ground to finer particle
size
Increasing flow ability of the material as it is
more finely reduced
Displacement of the fine material with better
flow properties by the courser feed material
with poor flow ability. 34
 GRINDING CHARGE VOLUME
Besides proper adjustment of grinding media to
suit the feed material; the proportion of the
material in relation to the grinding media in the
mills is a major factor governing the effectiveness
of the grinding process.
If the proportion of material is too low a high
percentage of direct impacts between grinding
media will occur, so that no material is crushed
between them and no comminution work is done
and also it damages the mill shell lining.
On the other hand, if there is too much material in
the mill, too much of the energy of the falling will
be displaced the particles from between the
impacting grinding media and will thus be wasted. 35
Grinding charge volume percentage(loading
percentage or filling ratio): is the ratio of the
bulk volume of the grinding media to the total
internal volume of the grinding compartment
ENERGY IN CEMENT MATERIAL
GRINDING
 Grinding of materials in the tube mill involves
considerable loss of energy.
 The actual energy input required for reducing
a given material to a certain particle size far
exceeds the energy theoretically needed for
breaking down the particles thus increasing
the surface area of the material.

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The energy required for the commuinution or
size reduction of a material to a certain
required fineness(characterized by the
specific surface of the product obtained)will
depend on
 The hardness of the material
 Its compressive strength
 Its temperature
 Its moisture content
 Nature of the comminuting action exerted by
the grinding process employed.
 The size and shape of the particles
 Its brittleness(elasticity or plasticity)
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The best grinding results are generally
obtained when ,with the mill at rest, the top
level of the material coincides with the top
level of the grinding media charge along the
whole effective length of the mill.
In order to get such conditions it is necessary
that, with increasing bulk volume of the
material with progressively finer size
reduction along the mill, the speed at which
the material is transported longitudinally
through the mill should proportionally
increase. this is achieved with better
flowability of the material as it gets finer.
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Only between 2 and 20% of the energy supplied to
the grinding system is utilized for producing new
surface. the remainder i.e. between 98 and 80% is
lost energy largely going to waste as heat and
vibration.
more particularly these energy losses are due to
 Friction between the particles of the material
themselves and between them and the grinding
elements(grinding media, liner plates,, etc).it is
higher in ball mills
 Wear of the grinding elements; elastic and plastic
deformation of the elements
 Elastic deformation of the material to be
comminuted until the fracture stress is attained at
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 Mill internals
 Mill liners
 Diaphragms
Mill liners Purpose
To prevent wear and associated damage to
the structure members of the mill(mill shell
protection)
To transfer energy to the charge
To facilitate the grinding action of the mill
Based on their use as grinding facilitators,
mill linings classified as
Lifting liners
Classifying liners
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 Lifting liners
Responsible for facilitating coarse grinding
and mainly installed at the inlet of the mill
Lifting action of liner is particularly
important to transmit enough energy to the
grinding media for the coarse materials to be
crushed.
Lifter liners with different dimensions and
shapes are used based on the requirements of
 Energy consumption reduction
 Improving throughput
 Increasing lifetime
 Solving breakage problems
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Purpose
 To avoid the falling of the grinding media on
the liners instead of the material
The selection of individual type of lifting
liner plate based on
Type of ball mill
The material to be ground
The filling degree of the balls in the mill
Type of the circuit
The characteristic of the ball charge
The rotating speed and diameter of the mill

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 Classifying liners
Classifies the grinding media according to the
size in decreasing way from the inlet of the
grinding chamber up to the outlet.
Classification carried out in a continuous,
quick and efficient way.
Principle
The shape of the lining causes a
classification of the grinding media resulting
in a decrease in size along the grinding path.

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Generally classifying liners
Counter the tendency of the grinding media
to declassify during mill rotation
Classify the grinding media even under
difficult or momentarily disrupted operating
conditions
Keep the different ball sizes in position along
the chamber or the length of the mill
Contribute to a smooth flow of the material
and allow the use of fine grinding balls.

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 Factors to be considered for the
selection of mill liners
Mill capacity
Moisture content of the feed material
The coarse particle size distribution
Uniformity of hardness of the coarse feed
If the material movement through the
grinding ball charge is not effective, the
material accumulates between the balls and
expands the charge volume.
The accumulation reduces the impact energy
imparted to the uncrushed material, resulting
in a drop in the crushing performance of the
mill 46
 Diaphragms
Purpose
 The purpose of the diaphragms with their slotted
plates is to act as screen which allow feed material
which has been sufficiently reduce in size to pass to
the next grinding compartment or to the mill outlet,
while grinding media and oversize particles are
retained.
 The effective cross-sectional area of the openings in
the diaphragms should be sufficiently large to enable
the fine particles as well as the air or hot gas to pass
at the required rate.
 Fragments from fractured grinding media, heavily
worn media or the feed material itself-especially if it is
too moist and/or the air flow through the mill is
inadequate-may cause choking of the slots in the
diaphragms and thus obstruct transfer or discharge of 47
 Factors to be considered for selection of
grinding media for grinding in ball mill
 Wear cost
 Performance over a long period of operation
 Breakage rate
 Shape stability
 Minimum effort for cleaning and sorting a
grinding media charge.
The use of highly wear resistant grinding
media made of chrome-cast iron for cement
and raw meal grinding in the cement industry
has become the common standard to achieve
minimum wear and low breakage rates.

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 Grinding media wear
Ball mill operators monitor grinding media wear
from the points of
 Operational
 Process technology
 Economic view
Reasons to evaluate wear
Evaluation of wear rate
Determination of grinding media recharge
Control of grinding media performance during
the time of operation
Development of quality criteria for grinding
media for the specific plant application. 49
 Methods to determine the wear rate
1.Mass balance of the complete ball
charge
It involves
Emptying and de-dusting the ball charge
Weighing the ball charge
Recharging the mill
Advantage
When carefully and properly performed
show best results
Disadvantage
Length of time to accomplish the task
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2.Comparison of wear related values
Basics
A couple of easily determined measuring
values are influenced by the loss of the
weight of the ball charge
For example,
wear related parameter for absorbed
power of the mill at constant operating
conditions
During mill operation, the mass of a
grinding media charge is reduced due to
wear and therefore, the power consumption
is increased with long term data on the
specific grinding plant, a wear rate related to
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 wear related parameter for production rate of
the mill or measurement of the free height above
the ball charge inside the mill
With increasing loss of weight due to wear, the
production rate of the mill is reduced and also
the free height above the charge increases.
Advantage
Simple and quick procedure
Disadvantage
Only applicable
if the wear rate is high
if the production rate and operating conditions
are very stable
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 Thank
you
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