FINISH MILL PLANT 9/10

Mill Workshop
Presentation
2013
AGUSTA ALI AKBAR
1211641

Production Junior Engineer

PT Indocement Tunggal Prakarsa Tbk.
Plant 9/10 – Palimanan Plant

Mill 9C & 10B

Citeureup, 25/10/2013
1
OUTLINE

 Finish Mill 9C & 10B

 Benchmarking 9C v 10B

 Problem & Discuss

 Improvement

 Summary

2
 FINISH MILL 9C & 10B (TWIN MILL)

• Spesification Design
Type JIDONG center drive ball mill
Capacity 100 t/h (PCC)
Fineness Blaine 4000 cm²/gr
Dimensions 4,2 m internal diameter of shell, 14,5 m length
Net Length of grinding path 13,85 m
Compartment 2 compartment
Mill speed 16,1 rpm
Motor Capacity 4000 kW
Shell thickness 60 mm
Grinding media charge 250 tons
Supporting Methode Twin sliding shoe bearing

3
  FINISH MILL 9C

Steel Ball Composition

Design FM 9C Actual (7 Okt 2013)
Grinding Media Surface Surface
Compartement (Ton) Compartement (Ton)
(mm) Area (m 2 ) Area (m 2 )
1st 2nd 1st 2nd
90 Ø 21 - 179.4 16 - 134.4
80 Ø 33 - 317.1 24 - 226.8
70 Ø 24 - 263.8 18 - 201.8
60 Ø 14 - 179.5 9- 112.1
50 Ø - - 0.0 6- 94.1
Total 1st Compt 92 - 939.8 73 - 769.2
50 Ø - - 0.0 - 0 0.0
40 Ø - 1 19.2 - 2 43.5
30 Ø - 25 641.0 - 23 579.4
25 Ø - 46 1415.4 - 44 1367.5
20 Ø - 42 1615.3 - 38 1448.5
17 Ø - 84 2746.0 - 81 2659.5
Total 2nd Compt - 198 6437.0 - 188 6098.3
Feeling Degree (%) 35.66 32.50 28.2 30.9

4
 FINISH MILL 9C

Surface Area v Steel Ball Diameter FM 9C

3000.0

2500.0 FM 9C Design Actual FM 9C

Unit
Product PCC PCC
Capacity TPH 100 104.5
Surface Area (m2)

2000.0 Blaine kg/m2 400 366.47

Residue 45µ % max 5 4.10

1500.0
Design FM 9C
Actual FM 9C
1000.0

500.0

0.0
90 80 70 60 50 40 30 25 20 17
Steel Ball Diameter (mm)

5
 FINISH MILL 10B

Steel Ball Composition

Design FM 10B Actual (10 Sep 2013)
Grinding Media Surface Surface
Compartement (Ton) Compartement (Ton)
(mm) Area (m 2 ) Area (m 2 )
1st 2nd 1st 2nd
90 Ø 18 - 153.8 10 - 85.4
80 Ø 29 - 278.7 32 - 305.8
70 Ø 24 - 263.8 27 - 299.7
60 Ø 9- 115.4 14 - 174.8
50 Ø - - 0.0 4- 55.9
Total 1st Compt 80 - 83 - 921.6
50 Ø - 6 92.3 - 7 109.5
40 Ø - 0 0.0 - 10 195.7
30 Ø - 23 589.7 - 15 391.3
25 Ø - 19 584.6 - 13 407.0
20 Ø - 45 1730.7 - 135 5204.3
17 Ø - 117 3824.8 - 0 0
Total 2nd Compt - 210 6822.2 - 181 6307.8
Feeling Degree (%) 31.01 34.47 27.4 30.9

Convert 17 Ø
mm to 20 Ø mm
6
 FINISH MILL 10B

FM 10B Design Actual FM 10B

Unit
Product PCC PCC
Capacity TPH 100 101.6
Blaine kg/m2 400 378.27
Residue 45µ % max 5 4.98

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  BENCMARKING FINISH MILL 9C & 10B
Changing steel
2010 2011 2012 2013
ball compotition
Finish Mill (Apr-Dec 9C) Jan-Dec Jan-Dec Jan-Oct at 1st
First Compartment
Commisioning
(Aug-Dec 10B)
FM 9C & 10B Production (Tonnes)
FM 9C 203,240 643,401 690,046 638,553
FM 10B 195,047 609,373 699,725 582,207
Running Hours Changing
steel ball
FM 9C 2,193.6 6,182.4 6,475.2 6,110.4 compotition at
FM 10B 2,112.0 6,076.8 7,735.2 5,731.2 1st & 2nd
Compartment
Capacity (TPH)
FM 9C 92.7 104.1 106.6 104.5
FM 10B 92.4 100.3 90.4 101.6
Spesific Power Consumption (kWh/Ton cement)
FM 9C 50.0 43.2 41.1 40.8 Uses Dryer
for additve
FM 10B 43.6 41.6 39.7 40.3 trass
Additive Moisture Content (%)
FM 9C 6.61 6.26 7.38 3.98
FM 10B 10.56 10.24 11.35 11.50

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  BENCMARKING FINISH MILL 9C & 10B Feeding less
than std due to
using water at
Finish Mill 9C Finish Mill 10B
Parameter Unit clinker extract
(1-24 Okt 2013)
Feeding TPH 107.07 99.89
Tailing TPH 120.34 232.49
Mill Sound % 73.18 96.4
Mill Power kW 3376.26 3577.52
BE Cement kW 24 21.95
o
Temp Outlet Material C 105.91 107.22 Worn out
o
Temp Outlet Gas C 88.11 93.33 of linners
ch1 have
Pressure Inlet Mill mmH2O -0.41 -0.46 a lot of
inluence
Pressure Outlet Mill mmH2O -104.04 -118.93
o
Temp Shoe Bearing 56C C 63.58
o
Temp Shoe Bearing 58C C 70.05
o High outlet shoe
Temp Shoe Bearing TIA621 C 70.65
bearing temp due to
o
Temp Shoe Bearing TIA622 C high clinker temp 72.95
Spesific Power Consume kWh/ton cmt 38.90 43.21
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  BENCMARKING FINISH MILL 9C & 10B
Quality Parameter
2011 2012 2013
Parameter Unit STD
FM 9C FM 10B FM 9C FM 10B FM 9C FM 10B
Clinker Ratio % 75 75.21 76.22 72.99 73.01 73.31 74.16
Blaine cm2/gr 3700-3800 3875 3769 3750 3741 3708 3839
Residue 45µ % max 6 6.17 4.72 7.29 5.30 4.87 4.53
SO 3 Content % 1.5 - 1.7 1.58 1.58 1.59 1.57 1.59 1.60
IL max 5 4.62 4.84 3.82 3.86 3.55 3.54
IR max 12 13.35 12.54 17.06 16.91 17.45 16.39
H 2 O Cement % max 0.35 0.36 0.35 0.42 0.43 0.41 0.41
Setting Time
Initial Set Minutes min 45 137 142 132 145 139 141
Final Set Minutes max 375 259 263 242 255 247 251
Compressive Strength
1 Day kg/m2 90 107 96 95 88 102 102
3 Days kg/m2 180 230 223 209 201 209 207
7 Days kg/m2 260 308 299 284 275 278 279
28 Days kg/m2 360 396 396 374 369 365 369
Already used
water for
cooling down
clinker temp
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  BENCMARKING FINISH MILL 9C & 10B

Shell Linner 1st Compartment Condition..

Last Measurement (March 6th, 2013)
MEASURMNT MEASURE ITEM Act Meas ORIGINAL
NO REMARKS
POSITION (1st Compartment) (mm) SIZE
1 03:00 1st Shell Liner AI-42 48.23 60 AI-42 already worn out 38 % (remain 36.77 mm)

2 03:00 6th Shell Liner AI-42 - 60

3 03:00 12th Shell Liner AI-42 - 60

4 03:00 18th Shell Liner AI-42 24.66 60

5 09:00 1st Shell Liner AI-42 47.76 60

6 09:00 6th Shell Liner AI-42 26.35 60

7 09:00 12th Shell Liner AI-42 26.85 60

8 09:00 18th Shell Liner AI-42 46.77 60

Shell Linner 1st

Compartment already
worn out until avg 38%
but capacity still good
enough

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 PROBLEM AND DISCUSS

What about FM 10B??

Last Measurement (March, 26th 2013)
MEASURMNT MEASURE ITEM Act Meas ORIGINAL
NO REMARKS
POSITION (1st Compartment) (mm) SIZE
1 03:00 1st Shell Liner AI-42 39.5 60 AI-42 already worn out 46.63 % (remain 32.02 mm)
Prepare Spare part,because worn out already
2 03:00 6th Shell Liner AI-42 22.56 60
more than 45 %
3 03:00 12th Shell Liner AI-42 23.78 60

4 03:00 18th Shell Liner AI-42 24.23 60

5 09:00 1st Shell Liner AI-42 47.03 60

6 09:00 6th Shell Liner AI-42 26.33 60

7 09:00 12th Shell Liner AI-42 26.77 60

8 09:00 18th Shell Liner AI-42 45.98 60

Shell Linner 1st

Compartment
already worn out
until 45%

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 PROBLEM AND DISCUSS
Hot clinker from P-10

Hot clinker affects high

temp shoe bearing outlet

13
  PROBLEM AND DISCUSS

Adding Water for Cooling Down Clinker Temp:

Advantage:
 Control shoe bearing temp that can stop mill when
goes high
Disavantage:
 Unstable process due to blocked inside mill (mill
sound go high > 98 %)
 Decreasing cement quality due to clinker already
reacted with water so cement strenght lower than Adding water for
standard cooling down
 Sometimes adding more water can make shoe clinker temp
bearing temp high too because excess water
evaporated inside mill and makes chamber heater
so shoe bearing influnced
 Steam from evaporated water usually make bag
filter lifetime be faster due to hydrolisis with steam,
so using acrylic bag (more expensive) that water
resistant

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 Spesific Steel Ball Consumption year to month 2013
Finish Mill 9C Finish Mill 10B
Month 2013 Steel ball Production Spes. St Ball Con. Steel ball Production Spes. St Ball Con.
ton ton kg st. ball/ton cmt ton ton kg st. ball/ton cmt
January 0 59449 0 0 57409 0
February 6 55600 107.91 0 53554 0
March 0 64853 0 0 55080 0
April 17 50554 336.27 16 44471 359.79
May 16 28764 556.25 0 36326 0
June 5 71030 70.39 4 59663 67.04
July 14 72423 193.31 98 64401 1521.72
August 0 59499 0 90 34805 2585.84
September 6 72762 82.46 11 63757 172.53
October 0 70690 0 0 72671 0
Average 134.66 470.69
Dumping steel ball 2nd
Dumping steel ball 1st Compartment due to
Compartment due to a lot of blocked at slot diafragma
steel ball broken and found big
size add trass inside mill 15
 IMPROVEMENT
Finish Mill 9C had 18 times stopped in 2012 due to high
outlet shoe bearing temperature
Oil cooler modification
OLD new

 Upgrade oil pump from 125 L/min to 135 L/min

After modification until end of Oktober 2013, FM 9C has improved only

2 times stopped by high outlet shoe bearing temperature.

16
 IMPROVEMENT

Modification oil distibution for shoe bearing 10B

Old Pipe New Pipe

Better oil distribution after

modification

17
 SUMARRY

 Shell linner FM 10B worn out faster than 9C, must be replaced
immidiately (Planning Jan, 2014)
 Hot clinker not acceptable for FM 10B operational due to be affected
high shoe bearing outlet temp that can stop mill
 High temp clinker can be reduce by control cooling process at cooler
area, with increase grate 2# to max speed that makes thin bed
material, so get the best heat transfer
 Adding water to cooling down clinker temp not good enough, using
outside clinker will be better

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THANK YOU……
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