Evolution of Technology

Ball Mill VRM Roller Press Horrow Mill Ball mill has concept of impact, friction & compression (Alteration)

WHAT IS GRINDING ?

We Grind materials for homonising it. Grinding depends upon grain size of material & Mineral phase of clinker like Tricalcium Silicate (Alite)-C3S Dicalcium silicate- C2S Tricalcium Aluminate-C3A Tetra calcium alumino ferrite- C4AF Free lime Etc

PROCESS PARAMETERS

Performance & energy efficiency of tubular grinding mill depends upon number of variables related to its design, operation & maintenance. The important factors are:

Operating speed Grinding media characteristics Size and their distribution Percentage loading Compartment lengths Diaphrams Mill users Wear of media and liners

ROLLER PRESS

HIGH PRESSURE GRINDING ROLLS MAIN FEATURES First application 1984 Today worldwide more than 600 mills in operation. Throughput rates up to 1300 t/h. Grinding force from 2 to 20 Mega Newton. Efficiency 1.8 to 3.5 times higher than ball mill 1.1 to 1.4 times higher than vertical roller mill Cement finish grinding limited by PSD.

DEFINITION: ROLLER PRESS

Roller press is a highly efficient communication system where the feed material is exposed under a very high grinding pressure between two solid rollers [ one fixed and one moving ] for a short time due to compression. The high pressure causes formation of micro cracks in the feed material and generates a substantial amount of the fine material.

SELECTION CRITERIA FOR RP

Energy efficient grinding solution. Flexible grinding solution for new as well as existing project. Higher productivity in combination with ball mill. Low operation & maintenance cost. Long life for wear parts comparison to VRM. Minimum downtime for wear parts replenishment.

ADVANTAGES -RP
Flexibility of operation. Lower specific energy consumption. Extremely low wear rate in raw grinding application.

DISADVANTAGES - RP
Low drying capability. Higher wear in case of abrasive material

OPTIMIZATION OF MILLS
Lower feed size to the mill. No frequent feed cuts to the mill. Reduce Start / Stops

MILL LINERS

Generally, mill liners are of two types, namely, LIFTERS & CLASSIFIERS. The lifting type raises the balls to a certain height above the horizontal central line of the mill, from where they fall onto the balls and the balls spin or rotate against each other in the bottom of the mill, thereby, grinding the material by attrition. Mills often have first compartment with lifting liners and second compartment with classifying liners.

High Eff. Separator

High eff. Separator, separate the mill product in to two fraction, one contains finish product of desired fineness and other contains coarse material recycled to the mill for further grinding. High eff. Separator produce uniform size of cement with narrow size range and hence has the ability to have better control of cement strength.

ENERGY SAVING MEASURES IN GRINDING MILLS

Reduction of false air and excess air. Optimizations of operation. Fine tuning of parameters. Reduction of material size input. Increase in the residue of product. Reduction in air volume , removal of fan inlet damper in sepax fan. Reduction idle running.

Parameter effect

LSF (0.88-0.95) A high LSF make it difficult to burn raw mix Trend to produce unsoundness cement High Cao) Increase C3S Contents Reduce C2S

High Silica Modulus

Range (2.2-2.6) Result in hard burning and high fuel consumption Cause difficulty in coating formation , affect radiation loss Deteriorates kiln ling Result in slow setting and hardening cement

High AM

Range (1.3-1.6) Impact hard burning Increase C3A & Reduce C4AF Reduce liquid phase & Kiln output Tends to render quick setting and strength at early ages

Parameter affect mill efficiency

Bond index Grain size High % of free Quartz

Thanks