Ball Mill Systems Grinding and Separating Efficiency

Grinding with ball mill systems
Separating
Separating
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Tikaria_Mill Workshop
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Separating process
Air
FR
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Separation in 3rd Generation Separator

Basic function:
Material enters the separator at
Feed
Centrifugal Forces
the top.
Air stream is generated by
external fan.
Material falls down between rotor
Air
Guide vanes
Air
Turning cage rotor
and guide vanes. Fines are

sucked in. Coarse particles are
accelerated by rotor and stopped
by guide vanes, where they slip
down and leave the casing at the
bottom.
Fine material exits with airflow at
the lower/upper part of the casing

Returns
Air with fines
the rotational speed of rotor.

7
Source: Chr. Pfeiffer QDK Separator
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Product fineness is adjustable by
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What is the separating efficiency dependent on?

Material:
fineness
- Feed (A)
- Fines (F)
Tromp curve
- Return (R)
Amount of feed
Feed distribution
Air:
V
F
Volume (V [m3/h])
Distribution
The fineness relationship mill
filter / separator fines
R
8
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Possible causes that limit the separating efficiency

The typical situations for 3rd generation separators are:
Uneven airflow and/or feed distribution to the rotor
Reduced separating airflow due to:
Separator fan damper (or speed) not at maximum

Fan nominal too low
Limited rotor speed due to mechanical problems or
insufficient nominal capacity of the motor and/or gear box
Contamination of the fines by coarse product

Separator fines much finer than final product
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Tromp curve key parameter

Tromp value [%]
Probability for a particle

to be in the return
100
Separator fines
Separator
return
Bypass
The BYPASS is one of

the best indicator of the
separator efficiency
[m]
10
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Tromp curve key parameter

Tromp value [%]
Coarse in fines
Agglomeration
100
Separator fines
Separator
return
Bypass
[m]
11
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Amount of material
Circulating load:
A, F & R en [t/h]
A= F +R
Circulating load factor:
u=
A
F
[-]
V
R
12
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Separator performance (1/2)

6.0
5.5
High
5.0
Circulating load factor u [-]
4.5
4.0
Normal
3.5
3.0
2.5
2.0
Low
1.5
1.0
2'500
3'000
3'500
4'000
4'500
5'000
5'500
6'000
Cement fineness [cm2/g]

13
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Separator performance (2/2)

50
45
40
High potential
By pass [%]
35
30
Medium potential
25
20
15
10
Low potential
5
0
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
Circulating load factor u [-]

14
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Air volume
Separator specific feed load
Asl =
X 1000 [kg/m3]
V
Asl < 2.5 [kg/m3]
Separator specific fines load
Fsl =
X 1000 [kg/m3]
Fsl < 0.7 [kg/m3]

F
R
15
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Air distribution
Air
FR
Lower air speed
Finer product
Higher airspeed
Coarser product
16
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Uneven airflow distribution

Uneven airflow distribution can
be identified from (1/2):

Observation of the ducting
configuration:
- General arrangement
- Relative position inlet / outlet
air ducts
Uneven wear of paintings or

steel along the guide vanes
height
steel along the rotor blades
height
Low separator efficiency
despite low material specific
loads
17
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How to determine the airflow profile

Uneven airflow distribution can
be identified and evaluated

from (2/2):
Airspeed mapping at the

inlet of the separator volute
Static pressure profile in
each duct ( )
Fineness comparison of the
fines at each cyclone (mass
balance for each cyclone)
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Solutions for even airflow profile

Even airflow distribution with
air guide plates

The positioning and length of
the air guide plates should be

done considering the air flow
distribution in the ducting (start
from where the air is already
evenly distributed)
Too short
Good
Laminar and even
flow across whole
duct section
19
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Feed distribution
< 50 [mm]
20
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Symptoms of uneven material distribution

steel of the impact ring

Uneven pressure loss and
fineness of the fines in a

cyclone air separator
Separator efficiency is low in
spite of low material specific

loads
Configuration of airslides from
separator discharge to the

separator feed point(s)
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Solutions evaluation
Even as much as possible
material load to all separator

feeding points:
Adjust / install splitters
Install mixing boxes
Change airslides
configuration
22
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The fineness relationship mill filter / separator fines
MF
F
If F finer than C check:
Send MF to the separator feed

Cut finer at the static separator (if any)
Reduce mill ventilation
Consider a static separator (or cyclone)
23
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Separator operating point (1/2)

100
95
Rotor speed [%] of nominal
90
Iso - fineness line
85
80
3500 [cm2/g]
75
70
65
60
55
50
45
40
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Air [%] of nominal

24
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Separator operating point (2/2)

100
Bypass 3
95
Rotor speed [%] of nominal
90
Bypass 2
85
80
By pass 1
75
70
65
Bypass 1 > Bypass 2 > Bypass 3
60
55
50
CONCLUSION is to operate the fan at 100%
45
40
10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100
Air [%] of nominal

25
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Grinding with Ball Mill Systems
Separators
What is separating?
Splitting a given material by particle diameter
Balls with 2, 4 and 10 mm diameter
> 3 mm
Separation by cutpoint of
3mm (e.g. by sieving)
Problem: Efficiency
of separation is
never perfect
< 3 mm
27
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Separation efficiency
The efficiency of a separation device (e.g. mill
separator) is a measure of the proportion of unseparated material following the separation process. It
indicates how much fines is in the coarse fraction
remaining and how much coarse is in the fines.
The efficiency is very much dependent on the separator.
Modern cage rotor separators show a far better

efficiency than older static and dynamic separators.
28
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Basic working principles Separators

Particles are accelerated by a vortex or a
rotating device into the direction of the

separator wall (Fz).
The big particles hit the wall (in older
separators) or the guide vanes (in 3 rd gen.

Separators) and slip down because they
are too heavy for transport by the air
stream.
The small and light particles are carried out
by the separator air (FL) stream supplied

by an internal (older separators) or an
external fan. The centrifugal force is
smaller than the impulse of the air flow.
Changes of airflow or distributor (rotor)
speed (consequence higher centrifugal

forces) lead to different product fineness.
29
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Main Separators used in Cement works

Type
Main features
Static separators and cyclones

adjustment via mechanical
No moving parts / fineness

modification
Dynamic separators 1st Generation Counter blades, distributor plate

internal fan/Fineness control
by mechanical adjustment or
counter blade speed change
and
Dynamic separators 2nd Generation Features as 1st Gen. / but external fans
and cyclones
Dynamic separators 3rd Generation Cage rotor instead of
counter blades
and distributor plate (variable speed drive) /
external fan / fineness
control by
rotor speed change
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Cyclone
Basic function:
fines
Material enters the cyclone

immersion tube
in the air stream at the top.

A vortex is generated.
feed
A fine vortex with opposite

cylindrical part
conical part
view from top
turning direction is
generated at the bottom and
carries the fine material back
to the top.
Coarse material goes to the
walls because of centrifugal

forces, slips down and
leaves at the bottom.
Fine material exits at top via
the immersion tube.

31
tailings
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Cyclones of a
cement mill
separator
32
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Static separator and cyclones

fines
Grit separator
immersion tube
adjustable blades
adjusting device
Basic function:
Material enters the
separator in air stream at

the bottom.
A vortex is generated in the
top of the grit cone by the

blades.
housing cone
tailings cone

forces, slips down and
Fine material exits at the
rad.pos.
Product fineness is
tailings
adjustable by changing the

blade position.
feed
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top via the immersion tube.
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Grit separator
Adjusting device blades
34
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Basic function:
KHD V-separator
Material enters the
separator from the top
Air + Fines
Coarse material slips down

Air
from plate to plate and

Fine material leaves the
separator at top together

with the air.
Plates
Returns
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35
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Dynamic separators 1st Generation

6
12
Basic function:
5
11
9
16
separator at the top.

10
8
Material enters the
3
15
2
Sturtevant
13

forces generated by the
distributor plate and
counter blades, slips down
at the grit cone wall and
leaves at the bottom (13).
Fine material exits at the
bottom of the casing (14).

14
1 fines chamber
2
3
4
5
6
7
8
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tailings cone
air vane
inside drum
fineness control valve rod
gear reducer
main shaft and distributing hub
distributing plate
9 fan cone
10 counterblades
11 main fan blades
12 feed spout and intake cone
13 tailings outlet
14 fines outlet
15 air inlet
16 air outlet
Product fineness is
adjusted by counter blade

position and rods (5) (No
counter blade speed
adjustment is possible!)
36
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Dynamic separators 1st Generation (Sturtevant)

Internal Fan
Counter blades
External
adjustment of
fineness control
valve rods
37
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Polysius Turbopol
Air vanes Grit cone
Distributor plate
Counter blades
Internal Fan
38
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Dynamic separators 1st Generation (Example: Pfeiffer Heyd)

Basic function:
8
the top.
9
10
Air stream is generated by internal
fan (9).
because of centrifugal forces,

generated by the distributor plate
and counter blades, slips down at
the grit cone wall and leaves at
the bottom (11).
6
3
Airflow
Coarse material goes to the walls
Fine material is sucked into the

11
1 fines chamber
2
3
4
5
6
tailings cone
air vane
separation chamber
distributor + counterblades
distributor plate
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outside chamber (1) and exits at

the bottom of the casing (12).
12
7
8
9
10
11
12
fines
chamber
counter
blades
fan shaft
fan blades
feed spout
tailings outlet
fines outlet
Product fineness is adjustable
usually by rotational speed of the

plate and counter blades (6+7). 39
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Separator Type Heyd
Variable speed drive for

counter blades and
distributor plate
Fan Motor
Fan
Counter blades
Feed spout
Distributor plate
40
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Dynamic Separators of 2nd Generation

8
1 separation chamber
6
5
11
11
1
14
15
13
tailings cone
7
8
9
10
11
12
gearbox
air vanes
distributor plate
counterblades
feed spout
motor
fines outlet
tailings outlet
cyclones
air duct to fan
13 fan
14 dust collecting
2
3
4
5
6
pipe to filter
15 return air duct
Polysius Cyclopol
10
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Dynamic Separators of 2nd Generation (Wedag)
to filter
Air flow direction
fresh air
42
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Basic function:
Material enters the separator at the top.
Air stream is generated by the external fan and
is recirculated.
Coarse material is separated by fan suction into
the main casing and leaves at the bottom via a

pendulum flap.
Fine material exits at the top of the casing by
airflow and enters the cyclone via gas duct. The

material separated by the cyclones leaves at
the bottom and goes into air slides. A part of the
recirculated air together with the fine dust from
the cyclones goes to a filter.
Product fineness is adjustable usually by
rotational speed of the plate and counter

blades.
43
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Counter blades
Distributor plate
44
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Separators of 3rd Generation

Basic function:
Feed
Centrifugal Forces
the top.
external fan.
Material falls down between rotor
Air
Guide vanes
Air
Turning cage rotor
and guide vanes. Fines are

accelerated by rotor and stopped
by guide vanes, where they slip
down and leave the casing at the
bottom.
Fine material exits with airflow at
the lower/upper part of the casing

Returns
Air with fines
the rotational speed of rotor.

45
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Main parts cage rotor separator

Cage rotor
Bars
Guide vanes (in bad shape)
46
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11
Example: Polysius Sepol

5
10
1 guide vanes
2 rotor blades
3 distributor plate
4 rotor shaft
5 feed spouts
6 sealing
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7 air + fines outlet

8 tailings outlet
9 air inlet
10 gear box
11 motor
47
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Basic function:
Drive
Example: FLS O-Sepa

Air outlet
+ fines
Prim.
air
Sec.
air
Sealing
the top.
Airstream is generated by
external fan.
Feed
Material falls down between the
Distributor
Tert.
air
Guide
vanes
Rotor
Fines
Coarses
Coarses
Centrifugal force
rotor and guide vanes. Fines are

accelerated by the rotor and
stopped by guide vanes, where
they slip down and leave the
casing with the tailings outlet.
Fine material exits with the airflow
at the upper part of the casing .

Air force
Prim.air
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Gravity force
the rotational speed of the rotor.

48
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Example: O&K cross-flow separator
feed spout
gearbox
motor
the top.
distributor plate
Airstream is generated by an
air inlet
external fan.
air guide
vanes
rotor
blades
separating
zone
fines
coarses
air + fines
outlet
tailings outlet
rotor and guide vanes. Fines

are sucked in. Coarse particles
are accelerated by the rotor and
stopped by the guide vanes,
where they slip down and leave
the casing via the tailings outlet.
Fine material exits with the
airflow at the lower part of the

casing .
Product fineness is adjustable

shaft
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Basic function:
by the rotational speed of the

rotor.
49
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Separators of 3rd Generation (FLS SEPAX)
50
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Separators of 3rd Generation (FLS SEPAX)

Basic function of the compact version:
Material enters the separator at the bottom with the air stream. The air
stream is generated by an external fan.

Material enters the rotor in the air stream via guide vanes. Fines are
sucked in. Coarse particles are accelerated by the rotor and stopped by
guide vanes, where they slip down and leave the casing on the side.
Fine material exits with the airflow at the top of the casing .
Product fineness is adjustable by the rotational speed of the rotor.
Additional functions roller press version:

Roller Press slabs enter desagglomerator under the compact separator
where they are crushed

Fines go up in the air stream to the separator
Coarses fall down and pass through the grit separator, where additional
fines are separated und go up in the air stream. Rejects go back to the
press
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Separators of 3rd Generation (Polysius Sepol SM)

Basic function:
Rotor drive
the bottom with the air stream

(e.g. air swept mill)
Fines with air
Air stream is generated by an
external fan.
Rotor
Material enters the rotor in the air
stream via guide vanes. Fines are

casing at the bottom.
Guide vanes
Inspection doors
Returns
at the top of the casing .

Airflow with material from mill

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Separators of 3rd Generation (KHD Sepmaster)

Sepmaster SKS-D (for RP* circuits)
feed material
Sepmaster SKS-LS (for ASM**)
feed material
desagglomerator
rotor
air+fines
air+fines
impact ring
air and fine

product
coarse fraction 2
coarse fraction 1
feed material+air
* Roller Press
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coarse product
** Air Swept Mill 53

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Sepmaster SKS
5
4
7
guide vanes
rotor blades
distributor plate
rotor shaft
feed spout
sealing
air + fines outlet
tailings outlet
air inlet
10 gear box
11 motor
11
10
8
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Basic function:
Material enters the separator at the top.
Air stream is generated by external fan.
Material falls down between the rotor and guide vanes. Fines are
sucked into the rotor. Coarse particles are accelerated by the rotor and
stopped by guide vanes, where they slip down and leave the casing at
the bottom.
Fine material exits the separator with the airflow at the top of the casing
.
Product fineness is adjustable by the rotational speed of the rotor.
Special features SKS-D: Additionally equipped with slab
desagglomerator at the top (use in roller press circuits)

Special features SKS-LS: Used for air swept mills. Function is very
similar to Polysius Sepol SM.

55
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Separators of 3rd Generation (Pfeiffer QDK)

Rotor drive
Basic function:
the top.
external fan.
rotor and guide vanes. Fines are

casing at the bottom.
Air inlet
Air +Fines Fine material exits with the airflow

at the lower part of the casing .
Rotor
Returns
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56
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Separators of 3rd Generation (vertical roller mill ; Loesche)

Basic function:
Feed

Separator drive
the bottom with the air stream.
Air
Air
external fan.
Cage rotor

Guide vanes
Returns flow
Conical casing
Grit cone
Airflow with material from grinding table
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they slip down, leave the grit cone
at the bottom and fall back on to
the grinding table.
at the top of the casing .

The product fineness is adjustable
by rotational speed of the rotor.57

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Separators of 3rd Generation (Vertical roller mill)

Reject cone
Cage rotor
Guide vane system

58
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Separators of 3rd Generation (coal grinding) in VRM

Basic function:
Coal from the grinding table enters the
separator at the bottom with the air

stream. (Used in vertical roller mills)
Air stream is generated by external fan.

accelerated by the rotor and stopped by
guide vanes, where they slip down and
leave the casing at the bottom.
Fine material exits with the airflow at the
top of the casing .

Product fineness is adjustable by the
rotational speed of the rotor.

Pfeiffer RTKM Separator for coal mills
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Separator arrangements in grinding circuits

Single Pass design
Fresh-Air
Mainly used where

high cooling is
required
3
Product
4
2
Feed bins
Mill with water injection
Separator with filter
Mill dedusting filter
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Standard Arrangement 1st Generation Separator
4a
1
3
5
Product
2
Feed bins
Separator with filter
4a
Grit separator
Optional cement cooler
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Cyclone Air Separator
1
3
Product
4
2
Feed bins
Separator with cyclone and dedusting filter
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Potential Problems
Wear /
Clogging
Wear
Sealing not tight
Wear
Wear
Blades too short
63
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Potential Problems
Wear,clogging
uneven feed distribution
Wear
Wear
64
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Potential Problems
Wear
Sealing not tight
Wear
Guide vanes not
correctly adjusted
Wear
Breakouts
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Potential Problems / clogging

Cage rotor separator casing
partly clogged
guide vane
system
Material deposits
due to insufficient
airflow or airflow
distribution
66
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Reduced separation efficiency 1st and 2nd generation dynamic separators
Gap between internal fan

and separating chamber
bigger than 5 [mm]
Reduced number of
counter blades
Gap between counter

blades and wall of
separating chamber bigger
than 10 [mm]
Possible consequence: Desired

fineness can not be achieved anymore
67
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Ball Mill Systems Grinding and Separating Efficiency

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Ball Mill Systems Grinding and Separating Efficiency

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Drepturi de autor:

Formate disponibile

Grinding with ball mill systems

Separation in 3rd Generation Separator

Turning cage rotor

and guide vanes. Fines are

the lower/upper part of the casing

Air with fines

the rotational speed of rotor.

Source: Chr. Pfeiffer QDK Separator

Product fineness is adjustable by

What is the separating efficiency dependent on?

Possible causes that limit the separating efficiency

Separator fan damper (or speed) not at maximum

Contamination of the fines by coarse product

Tromp curve key parameter

Probability for a particle

The BYPASS is one of

Tromp curve key parameter

Separator performance (1/2)

Cement fineness [cm2/g]

Separator performance (2/2)

Circulating load factor u [-]

Fsl < 0.7 [kg/m3]

Lower air speed

Uneven airflow distribution

be identified from (1/2):

Uneven wear of paintings or

How to determine the airflow profile

be identified and evaluated

Airspeed mapping at the

Solutions for even airflow profile

air guide plates

the air guide plates should be

Symptoms of uneven material distribution

steel of the impact ring

fineness of the fines in a

spite of low material specific

separator discharge to the

material load to all separator

The fineness relationship mill filter / separator fines

If F finer than C check:

Send MF to the separator feed

Separator operating point (1/2)

Rotor speed [%] of nominal

Iso - fineness line

Air [%] of nominal

Separator operating point (2/2)

Rotor speed [%] of nominal

Bypass 1 > Bypass 2 > Bypass 3

CONCLUSION is to operate the fan at 100%

Air [%] of nominal

Grinding with Ball Mill Systems

The efficiency is very much dependent on the separator.

Modern cage rotor separators show a far better

Basic working principles Separators

rotating device into the direction of the

The big particles hit the wall (in older

separators) or the guide vanes (in 3 rd gen.

The small and light particles are carried out

by the separator air (FL) stream supplied

Changes of airflow or distributor (rotor)

speed (consequence higher centrifugal

Main Separators used in Cement works