Improvements

in New &
Existing Cement
Grinding Mills

Agen
da

1 Introduction
.
Types of
mills in use
2 cement
today
.
Factors
ball mill
3 affecting
performance
. Ball mill improvements exampl
es
4 & case
. Conclusi &questi tim
ons
on
e
5
.

1 Introduct
. ion

Cement
manufacture is
energy intensive
o Cement manufacture consumes typically 3,100 - 3,400
MJ of fuel/t

clinker & 90 -130 kWh / t cement in a modern

plant, & more for older
or less efficient plants;
o Generally 2/3 of the electricity consumed is
used in the grinding of raw materials, fuels &
finished cement;
use pla desi &
o Finished grinding may consume
50gn
kWh/t
d,25 nt
cement, depending

Cement grinding is the single biggest

consumer of electricity in the manufacturing
process.
4

1.
Introductio
n
Whiche the

mill
ver
grindi i types,
inheren ineffici
ng
s tly
ent
Grindi
ng

Absorb
ed

Product
ion
Finenes
s

Driv
e
Pow
er

Loss
es

He
at

Friction
Sound
We
Nois
ar

Vibrati
on

o < 20% of energy absorbed is reckoned to be converted to useful grinding:

the bulk is lost as heat, noise, equipment wear & vibration;
o For ball mills, only 3 - 6% of absorbed energy is utilized in surface
production, the heat generated can increase mill temperature to > 120 C &
causes excessive gypsum dehydration & media coating if mill ventilation is

poor.
5

2. Types of
cement mills

There are basically 5

types of
cement mills in use
today:
1 Ball Mill (BM): predominant despite higher
. energy consumption
partly because of historical reason but partly
offers
considerable
over other mills, opera wit
also because
it still
advantages
h
roll pres fo pregrind o i often
combin grindin te
er s
r ing
r n ed
g;

Open
circuit

Clos circ
ed uit
6

2. Types of
cement mills

There are basically 5

types of
cement mills in use
today:
2 Vertical Roller Mill (VRM): gained popularity in
. last
decade
due to &high capaci relativ fe plan i
lower
consumpt
energy ion
er ty,
ely
w ts n
service;

2. Types of
cement mills

There are basically 5

types of
cement mills in use
today:
2 E- Mill : gained popularity in last decade due to
. lower
consumpt &high capaci relativ fe plan i
energy ion
er ty,
ely
w ts n
service;

2. Types of
cement mills

There are basically 5

types of
cement mills in use
today:
3 Roller Press (RP): also a more recent choice
. especially
after
the
advent of the
V-separator
& improved th lowe
roller
life, offers bu eve fe plan i servic e st
ener consumpt
gy

ion

t n

w ts

n e;

Fee
d

Fine
s

Ball Mill with Roller in combined

Press
grinding

2. Types of
cement mills

There are basically 5

types of
cement mills in use
today:
4 Horizontal Mill (HM): also very few in
. service
found
to the mill
compan&relat
ies
ed developer.
Material speed control
system
Scrap
ers

main i
ly
n

Extraction
zone

Inl
et

Scrap
ers
Outl
et

Centrifugation
zone

4-6
grinding
acti
ons

Example: fives FCB

Horomill
9

2. Types of
cement mills

Comparison of
specific
ener consumpt
gy

ion

Basis: 3200 g/cm OPC

Mill machinery
Main power absorbed
[kW]
Output
[t/h]
Spec. Mill Power
absorbed
[kWh/t]
Spec. Power absorbed
relative to ball mill
[%]
Ancillaries
[kWh/t]
Plant total
[kWh/t]
Total power relative to ball
mill installation
[%]

Ball
Mill
4.6x14.2
5m
4,350
1
5
0
2
9
,
0
1
0
0
5
,
30
4
,
1
0
0
0

BM + RP
(combined
grinding)
4.0x8
.75 m
+RP
16/1
3
0
,
41
05
00
2
2
,
77

V
R
M
Type
46
2,900
1
5
0
1
9
,
36

8
,
30
0
,
79
0

1
1
3,
0
6
,
99
1
1
0

2. Types of
cement mills

Factors
TC o a
affecting
ne ceme mi O f
w nt

ll
Ball
mill in
closed
circuit

Ball MillBM

RP

(combined
(comb.

grinding)
Investment cost

[
%
]

Annual plant
availability

[
%
]

Operating cost
(energy +
maintenance)
Spares holding cost

Cement quality
acceptance

1
0
0
97 - 99

V
R
M

+
BM + RP

1
2
5
8
5
9
01
1
6

[
%
]

1
0
0

[
%
]

1
0
0

115-125

Non
issue

Non issue

g
r
i
n
d
i
n
g
)

1
3
0
88 - 90

1
0
7
115125

May
have
issu
es
1
1

2. Types of
cement mills

Consider all
investment
aspects!

ke
y
Ball mill in closed circuit
has the
lowest investment

Ener
gy

Investment

Maintenan
ce
Spare
parts
Stock
holding

Availability
Quality

lowest operating cost

lowest maintenance
cost
highest availability
highest cement
quality
acceptance!

1
2

3. Factors affecting
ball mills

Basically 6 key
factors
affecting mill
performance:
o Feed characteristic

psd,
etc.
moisture, );

(grindability,

o Cement fineness;
o Equipment design & plant
engineering;

o Operations & maintenance;

o clinker extenders
o
f (Additives);
Use

o
Use

o grinding aids
f (Admixtures).

1
3

3. Factors affecting
ball mills

Effect of moisture
feed
on
grindabili
ty
t/
h

kWh
/t

Empirical rule-ofthumb:
o Every 1% increase in
moisture content
above 0.5%
increases energy
consumption by
>10%, especially at
higher product
fineness
o At moisture above 3 4%, a

ball mill without

drying
chamber may not be
Use of synthetic / waste gypsum or additives can
operable
Feed
moisture

increase the total feed moisture & adversely affect

the mill performance if not properly managed.

1
4

3. Factors affecting
ball mills

Cement
vs
fineness
.
grindability
6
0

Grindability of a 95/5
OPC at
various Blaine
fineness:

5
5
5
0
4
5

o 27- kWh a 3,00 cm/

4
0

/t

3
5

t 0

32

o 39- kWh a 4,00 cm/

3
0

/t

2
5

47

2
0 250
0

300
0

350
0

Open circuit
kWh/t

400
0

450
0

Closed circuit
kWh/t

500
0

o 58-

t 0

kWh a 5,00 cm/

/t
t 0
g

69

Every 100 cm/g increase in cement fineness

increases the mill power consumption by 1-2 kWh/t
for a closed circuit mill & 2-3 kWh/t for an open circuit
mill, a sheer waste if this is not required by the
market!

1
5

3. Factors
affecting ball

mill
s

Equipm desig
ent
n:
Ba mi &mi
ll

ll

ll interna
ls

o Ball mill (L/D,

drives
&

speed,

reducers, etc.)
o Ventilation
o Liners
o Diaphragms
o

composit &fil rati

ion
l o

Media

Ball mill typically accounts for 85% of the total energy

consumed in the grinding plant & should be the focus of
improvements.
1
6

3. Factors
affecting ball

mill
s

Equipm desig
ent
n:
Separator
s
o Material
dispersion

o Air distribution
o Principle of
separation
S
ep
ar
at
or
with
cyclo
nes

o Adjustability
o Regularity
o Efficiency

CPB QDK Next Generation high efficiency separator has a

very low by-pass &
can improve mill output / energy consumption by 20 25%!
1
7

3. Factors
affecting ball

mill
s

Equipm desig
ent
n:
Separator
s
Generation

Bypass [%]

s
t

n
d

r
d

30 - 60

Min. Cut size [m]

>

Imperfection [-]

>2 0.50
0

Sharpness of cut
Max. Blaine
[cm/g]

Not
e:

3,800

Imperfecti I

on:

10 - 35

8 - 20

15 - 20

<

<

1
<
5
0
>. 0.45
4

<1 0.35
5

0.35 0.50
<
0
.
4,500
5

( x75
x225 )
x50

QDK Next
Generati
on
4 - 10

5,500

>
0
.6,000
5

Sharpness of x x25
cut:
x7
5

CPB QDK Next Generation high efficiency separator has a

very low by-pass &
can improve mill output / energy consumption by 20 25%!
1
8

3. Factors affecting
ball mills

Pla layo &engineer

nt ut
ing

o Plant lay-out has an

important

impact on efficient
operations &
maintenance, as well
as energy
consumption;
o Choice of ancillary
equipment such
as material transport &
electrical
control systems including
dampers,
Minimum Design Approach coupled with process
feed rates, etc, also
expertise & good
affect
the mill by 10 15%!
engineering can reduce energy
consumption
efficiency
&
energy
consumption

1
9

3. Factors affecting
ball mills

Operations &
maintenance

Training: over-grinding / under-feeding is wasteful

of energy, hence
skills & motivation of plant operatives can impact
performance;

Mill ventilation: high mill temperature causes

media coating &
o excessive gypsum dehydration & can affect both
output & quality;
Maintenance: frequency & quality of planned
o maintenance can improve plant availability &
mill performance;
Feed variability: early detection of changes in
o quarry, kiln or cooler
affecting clinker grindability ensures early corrective
actions;
Difference between good & poor mill operation &
Technical can
audit:
regular
axial & circuit
analysis,
maintenance
results
in performance
variation
of +/including
adjustment
of media composition & filling
10%,
or more
in some cases!

ratio ensures optimum operation.

2
0

3. Factors affecting
ball mills

Use of
clinker

extende
rs:

Additives
Additives such as
limestone,
slag, fly-ash &
pozzolana for clinker
substitution can
reduce the total
energy consumption
of cement
manufacture by
o 50%;
o

However,
excessively wet
additives, or difficult
to grind materials
can impact the mill
Additives are highly effective in reducing the overall
performance
energy consumption & CO2 emission of cement
negatively.
production due to clinker substitution!
2
1

3. Factors affecting
ball mills

Use of
grinding

aid
s:

Admixtures

TE
A

DE
G

PC
E

Amine, glycol & increasingly

polycarboxylate polymer
(PCE) based grinding aids
can improve grinding
efficiency at low dosage
rate of 0.02
0.05% by neutralizing the
electrical charges formed
on the surfaces & cracks of
particles to reduce
agglomeration and coating
formation on media & liners
At higher dosage (> 0.2%
by weight), early strength
may be affected.

Output may increase by 5 10% for normal OPC, or more

for finer cement.
2
2

4. Ball mill
improvements

Plant & equipment

design

State-of-the-art

mi
ll

ball

o
Mill
linings
Mill

diaphragms
o

Grinding

media

Separator

2
3

4. Ball mill
improvements

State-ofthe-art

ba mi
ll ll

o Lateral drive & self-aligning

slide

shoe bearings;
o Integrated lubrication
cooling;
o Large, standard size
man-hole;
o Activator & classifying
liners;
o Monobloc low pressure
drop flow
control intermediate
diaphragm;
o High efficiency
separator;
Europes largest ball mill supplied
by CPB layout
for Heidelberger
o Efficient
Cement in Poland
& system
protection.

24

4. Ball mill
improvements

Mill
shell
optim
um

lining
design
for
grindi actio
ng

ns
1s compartment:
t
Cataracting
Media optimally lifted to achieve
maximize impact
compressive forces for coarse
grinding without causing liners
breakage.

2n compartment:
d
Cascading
Media sufficiently activated to
maximize shearing &
compressive forces for fine grinding,
good material
distribution & flowability.

2
5

4. Ball mill
improvements

Maintaining grinding
efficiency
ov liner servi lif
er s

ce

Tim
e

Conventional step
liner

CPB progressive
activator

Liner wear-rates are governed by the profile, incorrect

design can reduce the effective lifting height over time &
grinding efficiency in the 1st compartment.
2
6

4. Ball mill
improvements

Low P flowcontrol
diaphrag t impro grindi
ms
o ve
ng

o CPB monobloc diaphragm is highly robust & has a

long service life;
o Large central opening & low P maximizes mill
ventilation;
o Flow control optimizes material levels to maximize
grinding efficiency;
o Heat-treated, rolled steel slotted plates do not peen
over & require almost no maintenance;
o Output/power can be improved by 5-7% & cement
quality more consistent.
2
7

4. Ball mill
improvements

Media filling ratio

according
t requir producti
o ed

on
tph

kWh/t

1
5

2
2
3
0
5
0
Ball charge filling
ratio in %

3
5

Lowest grinding energy is achieved at a filling

ratio of 24-26%; hence opportunity to reduce
energy consumption if output is not needed.
2
8

4. Ball mill
improvements

High efficiency
separator
minimi overze

t
o

grinding

Latest QDK high efficiency separators from CPB can

achieve a bypass of
<10% & improve an existing mill performance by
20% or more, as well as producing greater cement
consistency.

2
9

4. Ball mill
improvements

Case Example
1

Diaphragm replacement (2011)

Plant name

2 compartment closed circuit mill,

4,6 x 14,4
m

(Country)
Cement
Sco of mill
pe modification
type
s
Results
Cement type
Fineness acc
Blaine
Output

Lafarge (Austria)

Installatio ne Flo Contr Intermedi

n of
w w ol
ate
Diaphrag
m
Before
A
Differen
ft
ce
e
CEM II AM-SL
r
42,5N
cm2/
g
t/
h

122
130

Power
consumption

kWh
/t

35,1
33,0

Mill exit
temperature

115
110

4
.
0
0
0

+ 6,6%
- 6,0%
5
3
0

4. Ball mill
improvements

Case Example
2

Complete mill internals upgrade

(2012)

Plant name

Heidelberg Cement (Romania)

(Country)

2 compartment closed circuit mill,

4,2 x 10,77 m
1st& com linin + flow
intermedi
nd
2
ate
diaphrap. g control

Cement
Sco of mill
pe modification
type
s

gm

Results

Before

A
ft
e
CEM II A-Sr
32,5R

Cement type
Fineness acc
Blaine
Output
Power
consumption

cm2/
g
t/
h
kWh
/t

69
81
34,6
29,6

3
.
2
0
0

Differen
ce

+
17,4%
- 14,4%

3
1

4. Ball mill
improvements

Case Example
3

Separator upgrade (2010)

Plant name

2 compartment closed circuit mill,

3,8 x 12,08

(Country)
Cement
Sco of mill
pe modification
type
s
Results
Cement type
Fineness acc
Blaine
Residue 63 m
Output
Power
consumption
Cement quality
2D
Cement quality
28 D

Phoenix Cement (Germany)

m

Replaceme 1s ge separa by
hig
t
nt
of QD 143n. tor
CPB h
efficien
cy

K Z
Befor
A
e
ft
CEM II A-LL
e
32,5R
r
2
cm
4.100
3.450
/g
%
6,5 8,0
2
4,5
t
68
/
84
kWh
37
h/t
30,4
N/m
24
25
m2
N/m
48
49
m2

Differen
ce

+
23,5%
- 17,8%
+
+
1
1

3
2

4. Ball mill
improvements

Case
Example 4

Biggest ball mill in Europe

(2012)

Plant name

Heidelberg Cement (Poland)

(Country)

2 compartment closed circuit mill,

5,2 x 16,75 m

Cement mill type

Scope of

Complete grinding plant on EP basis

modifications

Results

Achieved

Cement type

CEM I
42,5R

Fineness acc Blaine

cm2
/g

Output

t/h

Power consumption (mill only)

kW
h/t

Power consumption (complete

circuit)

kW
h/t

3
.
4
2
0
3
0
6
3
0
,
3
5
4
,
2

3
3

4. Ball mill
improvements

CPB ball mill system

versus
typical ball mill
an
systems
vertic roll mill
al
er s

d
Ball
mill
syste
m

10
0
9
0

Ball mill
with
CPB
compone
nts
VRM
syste
m

Power consumption (kWh/t)

8
0
7
0
6
0
5
0
4
0

3300
00
2
0

350
0

4
0
0
0

450
0

500
0

Data of typical ball mill system and VRM system from Cement International article
about Loesche, page 65, 2/2013
Fineness

acc. to
Blaine
(cm2/g)
3
4

5 Conclusi
. ons

1 Of the 4 main mill systems in use for cement

. grinding, ball mills are
by far the predominant, despite a higher
energy consumption compared with a standalone Vertical Roller Mill or Roller Press;
2
. Beside historical reason, ball mills are
generally more reliable, simpler to operate &
maintain, the wear parts readily available &
stocking
cost lower,
the
cost lower,
quality more
accept
b investment
th mark especi
fo th
and
the cemented
widely
y e et,
ally
r e
industrial
users;

3
5

5 Conclusi
. ons

3 For decision on new cement mill, it is essential to

. consider not only
energy but also equipment reliability, maintenance
requirements, plant availability, operational
flexibility, cement quality, and of course also the
investment cost, in order to arrive at the best Total
Cost of Ownership;
4 For existing ball mills, production cost can be
. significantly reduced by changing to well designed
& proven equipment such as the CPB activator
linings, low pressure drop monobloc flow control
diaphragm, and QDK high efficiency separator to
improve the plant efficiency.

3
6

5 Conclusi
. ons

5 More
grindi als mea alow carb foot. efficient ng
o ns
er on print
industry.

fo th
r e

3
7

Thank you for attenti

your
on,
an questio
y ns?
You will find us at
our booth:

Boot no 5 / 5
h
. 2 3

3
8