Ball Mill Inspection Procedure
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Transcript of Ball Mill Inspection Procedure
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Ball mill inspection procedure
Ball Ball millmill inspectioninspection procedureprocedureGeneralGeneral
Material Material samplingsampling
pp pp
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurvepp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
I.E.E.E West CoastI.E.E.E West CoastConference 2009Conference 20098th 8th 9th 9th OctoberOctober
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Control loopControl loop
P
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r
Tim NowackTim NowackVictorvilleVictorville/ CA/ CAU.S.AU.S.A
The Green The Green TreeTreeConventionConvention CenterCenter
C
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r
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Christian Pfeiffer Maschinenfabrik GmbH
Senior Process EngineerSenior Process Engineer
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Ball mill inspection procedure
General:
GeneralGeneral
Material Material samplingsampling
The process engineer should be the doctor of the system
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
doctor of the system.
The doctor is required for:
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
1) implementation of Health checks Regular action
pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
2) urgent investigations of actual process problems Non-regular action
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Control loopControl loop
This presentation focuses on the regular Health check procedure.
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-
Ball mill inspection procedure
General:
GeneralGeneral
Material Material samplingsampling
The Health checksconsist of standard measurements on a frequent basis
Type of measurement: 12 months scheduleLongitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Type of measurement: 12 months scheduleCircuit mat. granulometry Q
Mill longitudinal sieving Q Q Q Q
Ball charge filling degree Q Q Q QInternals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
Ball charge filling degree Q Q Q Q
Mill material level Q Q Q Q
Mill internal conditions Q Q Q Q
Ball charge sampling QppVentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
Ball charge sampling Q
Separator Tromp curve Q
Separator ventilation Q
Mill til ti Q
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Control loopControl loop Mill ventilation Q
Weigh feeder calibration Q
Instrument verification Q Q Q QVictorvilleVictorville/ CA/ CAU.S.AU.S.A
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Control loop verification Q
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Ball mill inspection procedure
General:
GeneralGeneral
Material Material samplingsampling
Healths checks are important in order to:
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
build up a knowledge and data base about the system performance
record the data and display them in trends for fastInternals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
record the data and display them in trends for fast and easy diagnostic of problems
The main ad antageppVentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
The main advantage:
Knowledge basis allows to investigate the root
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Control loopControl loop cause of problems and to avoid problems by early reaction based on the trend results.
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Ball mill inspection procedure
General:
GeneralGeneral
Material Material samplingsampling
For each measurement make sure you have:
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
design data of the machines/equipment available.
constant/stable operation condition for at least 2 hours.
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
recorded the actual operation data like:
Production rate [t/h], Product type, composition [M-%]
A t l d t t fi f d t [Bl i R id ]pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
Actual and target fineness of product [Blaine or Residue]
Actual mass flow rate (e.g. separator grits, water demand, etc.)
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Control loopControl loop
Electrical power consumption of the main equipment
Actual operation parameter of the main equipmentVictorvilleVictorville/ CA/ CAU.S.AU.S.A
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(e.g. separator speed, damper positions)
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Ball mill inspection procedure
Circuit material granulometry:
GeneralGeneral
Material Material samplingsampling
g ySampling points
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurvepp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
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Control loopControl loop
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Ball mill inspection procedure
Circuit material granulometry:
GeneralGeneral
Material Material samplingsampling
Sampling point: r ProceduresClinker feed
1 x per
SievingGypsum feed H2O
g y
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
10 kg 1 x per TestGypsum feed H2O
50, 25, 16, 8, 4, 2, 1, [mm]
Additive No.1 feed H2OAdditive No. 2 feed H2OMill tl t t i l
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
Mill outlet material Pre-screening with 450 m sieveSeparator feed material
Separator grits material S fi l 1
pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
0.5 kg1 x
every hour
PSD from 1-450 m with Laser equipment (e.g. Cilas, Malvern,
Separator fines cyclone 1 Separator fines cyclone 2 Separator fines mix
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Control loopControl loop Sympatec)
Fineness acc. to Blaine [cm/g]
Filter dust 1 (weighfeeder) Filter dust 2 (circuit dedusting) Filter dust 3 (mill dedusting)
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Blaine [cm /g]Cement
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Ball mill inspection procedure
Longitudinal sampling:
GeneralGeneral
Material Material samplingsampling
g gSampling points at crash stop
1m 0.5 0.50.5 1m 1m 1m 1m 1m 0.51m 1m 1m
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
1.1 1.2 1.3 1.4 2.1 2.2 2.3 2.4 2.5 2.6 2.71.1 1.2 1.3 1.4
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
Sample weight:1st compartment: 1-2 kgpp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
1 compartment: 1-2 kg 2nd compartment: 0.5 kg
20 cm
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Control loopControl loop
20 cmVictorvilleVictorville/ CA/ CAU.S.AU.S.A
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20 cm
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Ball mill inspection procedure
Ball charge filling degree:
GeneralGeneral
Material Material samplingsampling
g g g
Measurement by free height
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
M
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve 1. Measure average internal diameter, DippVentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
g , i2. Measure height, h, in three different points along
axis for each grinding compartment
For best results the measurement takes place in an
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Control loopControl loop For best results the measurement takes place in an empty mill (mill feed stopped for approx. 10 min).
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Ball mill inspection procedure
Mill material level:
GeneralGeneral
Material Material samplingsampling
Inspection only at crash stopRecord the material level approx. each meter along axis
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial levelM
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
M
pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
Too high = above charge
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Control loopControl loop
Good material level
Good = below charge
Too low = >1 VictorvilleVictorville/ CA/ CAU.S.AU.S.A
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Good material level for 1st compartment
Too low 1 below charge
-
Ball mill inspection procedure
Mill material level:
GeneralGeneral
Material Material samplingsampling
Inspection only at crash stopRecord the material level approx. each meter along axis
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial levelM
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
M
pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
Too high = > 50mm above chargeGood = approx. 20 mm
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Control loopControl loop
Good material level
ppabove chargeModerate = equal with ball charge
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for 2nd compartmentToo low = >> 50 mm below charge
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Ball mill inspection procedure
Mill material level:
GeneralGeneral
Material Material samplingsampling
Inspection only at crash stopRecord the material level before and after transfer points
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial levelM
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
M
pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
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Control loopControl loop
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Ball mill inspection procedure
Mill internals condition:
GeneralGeneral
Material Material samplingsampling
M ain mill drive:
1495 [kWh]n.a. [kWh]
Type of product: 16,72 [r.p.m.]72,67 [%]
T o tal mill feed: n.a. [t/h]
mill speedcritical speed
Crash stop information: power installedpower absorbed
OPC
Finish mill No. 2Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
T o tal mill feed: n.a. [t/h]F resh feed: n.a. [t/h]C o arse return: n.a. [t/h] 3,5 m x 9,6 m
3rd compartment1st compartment2nd
comp.
Free heightcalculation:Pabs= 1247 kW
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
M
+
1 - 4 1 - 2 1 - 8
pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
2,115 mm 1,290 5,380 mm -
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Control loopControl loop
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Ball mill inspection procedure
Mill internals condition:
GeneralGeneral
Material Material samplingsampling
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurvepp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
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Control loopControl loop
VictorvilleVictorville/ CA/ CAU.S.AU.S.A
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Ball mill inspection procedure
Mill internals condition:
GeneralGeneral
Material Material samplingsampling
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurvepp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
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Control loopControl loop
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Ball mill inspection procedure
Ball charge sampling:
GeneralGeneral
Material Material samplingsampling
g gSolution 1) Total sorting of ball charge
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurvepp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
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18 20 25 30 40 50 60 Scrap
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Ball mill inspection procedure
Ball charge sampling:
GeneralGeneral
Material Material samplingsampling
g gSolution 2) Analysing the actual grinding media
composition by spot samples.1st t tLongitudinal Longitudinal
samplingsampling
Filling degreeFilling degree
Material levelMaterial levelM
1st compartment:
50 balls per sample
2nd compartment:Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
p
200 balls per sampleDate: 23.02.2006Prepared by: Now
Avg. Piece weightInput Table
Customer Data:Grinding ballspp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
Project-No.: 33.420
Customer:
Plant:
Installation:
Compartment:
Ball - 60 50 40 30 25 20
-
-
Monochamber (1/3 lifter - 2/3 class.)
Project:
2.4m x 5.0m w ith QDK 8,5-F
-
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Control loopControl loop891.80 g
Std. 886 g 513 g 262 g 111 g 64 g 33 gMax 1400,0 g 681,0 g 374,0 g 176,0 g 80,0 g 44,0 gMin 682,0 g 375,0 g 177,0 g 81,0 g 45,0 g 14,0 g
Piece Mass1 891,8 g 891,8 g2 886,2 g 886,2 g3 879,6 g 879,6 g4 878,0 g 878,0 g5 873,5 g 873,5 g6 873 3 g 873 3 g
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6 873,3 g 873,3 g7 861,0 g 861,0 g8 860,6 g 860,6 g9 858,2 g 858,2 g
-
Ball mill inspection procedure
Ball charge sampling:
GeneralGeneral
Material Material samplingsampling
g gSolution 2) Analysing the actual grinding media
composition by spot samples.
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
pc. weight mass-% pc. weight mass-% pc. weight mass-% pc. weight mass-% pc. weight mass-%60 24 19920 53,56% 3 2552 10,54% 3 2353 9,68% 0 0 0,00% 0 0 0,00%50 23 11112 29,88% 20 9269 38,28% 10 4651 19,13% 0 0 0,00% 0 0 0,00%40 18 4293 11,54% 35 8468 34,97% 19 4592 18,88% 5 1209 11,58% 4 952 4,96%30 13 1384 3,72% 28 2997 12,38% 59 6328 26,02% 28 2943 28,19% 63 6617 34,46%25 8 481 1,29% 14 835 3,45% 73 4369 17,97% 66 3923 37,57% 144 8576 44,67%
Results of grinding media sampling5
Ball
Sampling Point1 2 3 4
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
20 0 0 0,00% 3 93 0,39% 66 2025 8,33% 76 2366 22,66% 98 3056 15,91%Total 86 37190 100,00% 103 24215 100,00% 230 24316 100,00% 175 10441 100,00% 309 19200 100,00%
50,0%
60,0%
pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l20,0%
30,0%
40,0%
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Control loopControl loop
N ameAvg Piece Weight
Installat io n -
0,0%
10,0%
0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 60 mm 50 mm 40 mm 30 mm 25 mm 20 mm
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D ate P ro ject . N o . 33.420C o untry -
Now
23.02.2006 -P lant
Avg. Piece Weight
-C usto merM ill dimensio ns -
-
Ball mill inspection procedure
Separator tromp curve:
GeneralGeneral
Material Material samplingsampling
Define the sampling points
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurvepp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
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Control loopControl loop
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Ball mill inspection procedure
Separator tromp curve:
GeneralGeneral
Material Material samplingsampling
Define the sampling points
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
Separator feed material Separator feed material before splitterbefore splitter
Separator fines Separator fines material from material from each cycloneeach cyclone
pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
Separator rejects Separator rejects materialmaterial
Check the stableCheck the stableand
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Control loopControl loop
Record all main operation Record all main operation parametersparameters
Check the stable Check the stable condition of the circuitcondition of the circuit
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parametersparameters
-
Ball mill inspection procedure
Separator tromp curve:
GeneralGeneral
Material Material samplingsampling
Define the sampling pointsSampling point: r Procedures
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Separator feed material
1 x
Pre-screening with 450 m sievePSD from 1-450 m with Separator grits
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
0.5 kg 1 x every hour
Laser equipment (e.g. Cilas, Malvern, Sympatec)Fineness acc to Blaine
material
Separator fines cyclone 1
pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
Fineness acc. to Blaine [cm/g]
Separator fines cyclone 2
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Control loopControl loop
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Ball mill inspection procedure
Separator Ventilation:
GeneralGeneral
Material Material samplingsampling
Basics: Air flow measurementSelect your equipment
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Prandtl-Pitot Tube S-Type Tube
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurvepp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l C ti f t i d ( 0 84)
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Control loopControl loop No correction factor needed
Easy to operate within 15 angle
Only in low vortex channel
Correction factor required (~0.84)
Misalignment results in mistakes
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Not for high dust loaded channels channels
-
Ball mill inspection procedure
Separator Ventilation:
GeneralGeneral
Material Material samplingsampling
Measurement points:
Separator circuit with cyclones Separator circuit with filterLongitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Separator circuit with cyclones Separator circuit with filter
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurvepp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
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Control loopControl loop
= Air flow, Static pressure,VictorvilleVictorville/ CA/ CAU.S.AU.S.A
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Temperature= Static pressure, Temperature
-
Ball mill inspection procedure
Mill Ventilation:
GeneralGeneral
Material Material samplingsampling
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurvepp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
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Control loopControl loop
= Air flow, Static pressure,Remark: Consider minimum 10% false air intake after mill.
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Temperature= Static pressure, Temperature
-
Ball mill inspection procedure
Weigh Feeder Calibration:
GeneralGeneral
Material Material samplingsampling
ga) Static calibration - feeder not in operation
Zero-point - adjustment (localLongitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
control box, no load) Span adjustment with calibrationweight (local control box)
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve operate weigh feeder with defined
b) Calibration with feeder in operation (preferred if possible)
pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
operate weigh feeder with definedsetpoint and load material into truckfor e.g. 10 minutes, while mill is shutdown
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Control loopControl loop weigh truck empty and loaded,calculate throughput and adjust controller if necessary
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Ball mill inspection procedure
Instrument Verification:
GeneralGeneral
Material Material samplingsampling
1) ElectronicallyLongitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Check and adjust zero-point and span with e.g. mA-transmitter
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
2) Operation checkpp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
Compare control room indication with local manualmeasurement of temperature, pressure and flow
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Control loopControl loop
Adjust transmitters
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Ball mill inspection procedure
Control loop Verification:
GeneralGeneral
Material Material samplingsampling
1) Operation check record process parameters with
t l l i tiLongitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
control loop in operation overperiod of e.g. 6-8 hours withconstant production
record mill power consumptionInternals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
p pat counter (kWh)
Adjust control loopt ifpp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
parameters if necessary
Information on:
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Control loopControl loop Available information at the CCR Control system Control strategy
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First impression on operation Circuit stability
-
Ball mill inspection procedure
Thank you for your attentionThank you for your attentionGeneralGeneral
Material Material samplingsampling
Longitudinal Longitudinal samplingsampling
Filling degreeFilling degree
Material levelMaterial level
Internals Internals conditioncondition
Ball chargeBall charge
TrompcurveTrompcurve
Questions?Questions?pp
VentilationVentilation
WeighfeederWeighfeeder
InstrumentInstrument
C t l lC t l l
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Control loopControl loop
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The Green The Green TreeTreeConventionConvention CenterCenter