Maintenance costs high for vrm and low for ball mill process controlprocess technology ball is operation friendlt and simple in operation but vrm requires some pid or control technology. Operations and maintenance training for ball mills flsmidth. Optimising your ball mill productivity through operations and maintenance training from flsmidth institute. The modification includes raw material handling and storage, kiln feed preparation with an inline raw mill, a dry process rotary kiln coupled with preheater and calciner, a clinker cooler, a coalpet coke mill, a finish mill, and cement storage, packaging and shipping operations. The first unit was built for a 2000 kw power rating and was delivered to holcim belgium in obourg. Ball mill cyclones weight feeders recycling elevator sep. Since then, numerous gmds for ball mills and sag mills have been installed in the. Cement is a finely ground, nonmetallic, inorganic powder when mixed. For constructional purposes, the meaning of the term cement is restricted to the bonding materials used with stones, sand, bricks, building stones, etc. Manufacture of portland cement university of technology. There are three types of grinding media that are commonly used in ball mills. Ball mill maintenance manual the purpose of this manual is to assist you in the proper installation and to acquaint you a bit further with the assembly and care of this equipment.
In new combigrinding systems, seriesconnected ball mills can have correspondingly smaller sizes than usual. Energy efficiency of cement finish grinding in a dry batch. The mechanism of breakage is illustrated in 23 by a diagram shown in fig. In taking visible emission observations, extreme care should be taken to ensure that the emission point is correctly identified at the time of observation. European cement research european cement research academy. Mill inspection via the inlet is possible, thus increasing personnel safety less wear and simpler form of wear lining on straight end walls short inlet cone less bearing clearance and thus less mill shell deflection polysius ball mill with direct drive there are two types of gear unit available for the mill drive unit. Slide shoe bearing pdf the drive cement ball mill shoe bearing operation 16 sep 20 ball mill slide shoe bearing pdf ball mill operation and maintainance slidemills with circumferential and sliding shoe bearing assemblies provide the following. The development was first realised in 1970 for grinding mills in the cement industry. Titan florida cement pennsuco plant 2040 avenue c 1 nw 121st way bethlehem, pa 18017 medley, fl 33178. For the cement industry the ball mill was really an epochmaking breakthrough as for almost 80 years it was the predominant mill for grinding of raw materials and coal, and still today is the most used mill for cement grinding.
Modern processing techniques to minimize cost in cement. These are the two observations made prior to entering the plant. Thus, b1j, b2j, bnj are the mass fractions of particles in size classes 1, 2, n after a breakage of particles in size class j. The twocompartment ball mill operating in a closed circuit with a high efficiency separator is thus still the most preferred arrangement for new cement grinding installations although the vertical roller mill now has emerged as a viable alternative to the ball mill system and has increased its share of the market for cement mills over. Cement ball mill maintenance infinity for cement equipment. Industrial spp partner teaming profile serviceproduct provider industrial partner flsmidth inc. On an overall basis, vrm consumes about 20 % lower specific energy than conventional closed circuit ball. This number of rollers also enables operation with only one pair.
Energy efficiency of cement finish grinding in a dry batch ball mill article in cement and concrete research 363. Plantsystem auxiliaries less auxillaries in ball mill and hydraulic circuit to be maintained for vrm. Cement grinding vertical roller mills versus ball mills. Ball mill technical specifications crusher mills, cone. The present handy manual on cement kiln operator s manual binq mining. Loesche developed the 4roller coal grinding mill with four tried and tested modules for throughputs over 150 th.
Interface for drives in cement plants semantic scholar. Ball mills and vertical roller mills are used for many grinding applications in cement production. Manufacture of portland cement university of technology, iraq. In 2014 the european cement research academy ecra has started the cross sectorial future grinding technologies research project in order to optimize and develop comminu tion technology for the cement industry but also for other related sectors. Ball mill improvements case example 1 diaphragm replacement 2011 plant name country lafarge austria cement mill type 2 compartment closed circuit mill, o 4,6 x 14,4 m scope of modifications installation of new flow control intermediate diaphragm results before after difference cement type cem ii amsl 42,5n. Planning for expansion is therefore a consideration in all but the shortestlived operations. Ball mill s mainly used to grind materials in minera, cement, refractory, chemical industry, etc. Polysiuss double drive combiflex two compartment tube mill 5. Typically, the motor of the ball mill consumes about 14 15 kwh ton of raw mix whereas the vrm motor uses 7 8 kwh ton. We are also a key supplier for the first fill of main industrial oems. Operation and maintenance of ball mill in cement manufacture.
Total has achieved an expertise in the cement industry by supplying major international companies on all continents. Metallurgical contentball mill maintenance manualon mill installation and maintenanceball mill concrete foundationsgrinding mill foundationgroutingball mill. Again to quote shoemaker and gould, increased production of the final product is often more easily and economically attained through expansion than by increased recovery. Preventive maintenance checklist for ball mills pdf files. Gulin provide the cement mill technical data pdf files solution case for you how to make project report on grinding unit of cement plant ball mills for cement. Large ball mills for iron mines, cement plants and compressors are few examples of. Flsmidth delivers sustainable productivity to the global mining and cement industries. General ball mill maintenance after the mill is erected, in order to avoid overlooking both obvious and obscure installation details, we recommend the use of a check list. Power plant preventive maintenance refers to set of planned daily maintenance checklist of cement mill.
Ball mill maintenance manual pdf page 1 this f document is bookmarked operating instructions and parts manual variable speed turret mill model jtm vs shown with optional accessories x axis table powerfeed and dro walter meier manufacturing inc27 new sanford road lavergne tennes part no ph 6848 revision h. Table 21 cement industry economic statistics california u. Ball mill operation and maintenance pdf essay depot 26 nov 20. Improving knowledge of grinding technology and mill operations to operate, optimise and troubleshoot ball mill and vertical roller mill grinding installations.
Specific energy consumption of ball mill, production capacity and factors affecting ball mill. Ppt cement industry powerpoint presentation free to. In existing plants, the throughput can be increased by over 100 %. Field supervisory services for alignment of gear and pinion of a raw ball mill. Permit summary addition of a kiln and related operations. The grinding unit most commonly used for grinding brittle materials, such as cement, is still the ballfilled ball mill. Virtual cement and concrete testing laboratory vcctl 7. Also removes substances that adsorb to the dust particles, such as dioxins and metals.
Cirkan and carter ranges a comprehensive range of gearbox oils gears heavy loaded gears gears with high temperature of operation worm gears, ball mills gear boxes gears with possible. The ball mill is used to grind many kinds of mine and other materials, or to select the mine. The european cement research academy ecra has decided to broaden its research ac. Improvement in performance of ball mill in cement grinding. Table 21 presents economic statistics for the california cement industry, as compared to u. A free powerpoint ppt presentation displayed as a flash slide show on id. I n 1967, maag zurich switzerland invented a heavy duty gearbox design for the cement industry, namely, planetary gearboxes for cement ball mill grinding. A new ball mill circuit from cpb is not old fashion. Maintenance checklists for ball mills pdf exodus mining machine. This provides fullyautomatic control and realtime optimisation of the mill process through precise control of mill behaviour according to defined objectives of throughput, energy efficiency and mill availability. Flsmidths support of titans production facilities through the years has fostered a strong relationship that facilitates making equipment upgrades. This is particularly recommended for multiple mill installations where it is difficult to control the different phases of installation for each and every mill. As the marketleading supplier of engineering, equipment and service solutions, flsmidth improves performance, drives down costs, and reduces the environmental impact of operations.
Effects of grinding media shapes on ball mill performance niyoshaka nistlaba stanley lameck a dissertation submitted to the faculty of engineering and the built environment, university of the witwatersrand, johannesburg, in fulfilment of the requirements for the degree of master of science in engineering johannesburg, october 2005. Present in more than 50 countries and headquartered in copenhagen, denmark. Inspection checklist for nonmetallic mineral processing equipment 1. Modern processing techniques to minimize cost in cement industry.
The grinding unit most commonly used for grinding brittle materials, such as cement, is still the ball filled ball mill. Cement industry since 1955, total lubricants has developed innovative highperformance products and solutions. Jun 11, 20 polysiuss double drive combiflex two compartment tube mill 5. Conclusion ball mill closed circuit rollerpress with ball mill vertical mill case a case b case c lowest operational cost lowest investment cost highest availability higher flexibility by 2 grinding units easiest maintenance.
On an overall basis, vrm consumes about 20 % lower specific energy than conventional closed circuit ball mills and is being. Ball mill maintenance installation procedure20191125 metallurgical. Preinspection checklist for nonmetallic mineral processing. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext.
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