Download - Cement Mill
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PLANT : BINANI CEMENT - 09.06.2004
208.50 km3/hr False Air 5 mass%, w 47.31 km3/hr
172.64 tph 37.51 tph
Sepax Fan 106.0 deg.C 108.4 deg.C
ESP 355/38 kW/amps Sepax
Cyclones 16.71 tph
Elevator 19.12 %
146.32 tph, dry 10.14 1168 rpm 31.5 amps Stack
0.00 % H2O 5.00
Belt Conveyor
ESP Fan
50 amps
6.74 km3/hr Airslide
108.0 deg.C 62 amps
JPF
45.25 km3/hr
5.76 tph 35.64 tph 156.47 tph
Coarse Return 115.0 deg.C 17.68 %185.00 tph
83.78 %
157 tph, wet 110.0 deg.C Folaphone 69 %
100.00 %
Cement
28.77 km3/hr 341.47 tph
31.05 tph 46.91 %
34.5 deg.C 115.0 deg.C Silos
Cement Mill - 1
110.0 deg.C 324.76 tph
48.67 %2.18 m3/hr 1.87 m3/hr
Water Pump, I/L Water Pump, O/L Cement Silos
E.S.P.
ClinkerHopper
Gypsum Ho...
Separator
Ball MillUMS 46x16.5
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Cement Mill Basic Calculations : UMS 46 x 16.5 BM
Site Conditions Equipment Specifications
Plant Elevation mts +MSL 402 Mill Diameter mts 4.60
Barometric Pressure mmWG 9827 Mill Length mts 16.50
Barometric Pressure mmHG 723 Mill System open/closed closed
Ambient Air Temperature deg.C 34.5 Mill Speed rpm 15.20
Radiation Surface 271.18 Separator Type Sepax 400M-222
Pitot Constt. S-Type, L=1m S1 0.883 ESP Fields nos. 4
Pitot Constt. S-Type, L=2m S2 0.847 Cement Grade OPC grade 43
Pitot Constant - L Type L 1.000
Feed - Product - Water Mill Operation - CCR
Mill Feed Rate, wet tph 157.00 Mill Main Drive - I kW 2320
Mill Feed Rate, dry tph 156.47 Mill Main Drive - II kW 2207
Clinker Feed Rate tph 146.32 Total Main Drive Power kW 4527
Gypsum Feed Rate, wet tph 10.68 Total Installed Power kW 2600x2
Percent Gypsum % 6.80 rpm 1168
Percent Water, Gypsum % 5.00 Separator Load amps 144
Gypsum Feed Rate, dry tph 10.14 Folaphone % 69.0
Clinker Temperature deg.C 124.3 Sepax Elevator Load amps 32
Gypsum Temperature deg.C 31.0 Silo Elevator Load amps 62
Mill Output, dry tph 156.47 Sepax Fan Load kW/amps 355/38
Coarse Return, Calc. tph 124.04 ESP Fan Load amps 50
Coarse Return, CCR tph 185.00 Mill Sp. Power Consumption kWh/ton-Cem 33.38
Coarse Return Temp. deg.C 110.0 Cement Fineness (Blaine) 311
Water Injection, Inlet 2.182 Dampers / Speed
Water Injection, Outlet 1.874 Sepax Fan Damper % 100
Water Injection, Total tph 4.06 Sepax Fan Speed % 98.50
Diaphragm Temperature deg.C 110.0 Mill Inlet % 100
Cement Temperature deg.C 115.0 ESP Fan % 84
Water Temperature deg.C 35.0 Dedusting Fan deg. 108
Mat. Concn. at Sep. Outlet 1345 Water Vapor (ESP I/L) 0.1650
Sepax Dust Load kg-cem/kg-wg 1.62
Heat & Dust Parameters Miscellaneous Parameters
Evaporation Heat kcal/kg 594.6 Gas Velocity a/c Ch.I m/s 0.46
Grinding Heat kcal/kW 860 Gas Velocity a/c Ch.II m/s 0.53
Mill Surf. Radiation Heat 393 False Air a/c ESP w.r.t. Mix, vol.% dry% 5.00
Mill Surf. Convection Heat 293 False Air a/c ESP Fan (Norms) % 0.50
Cyclone Dust (FLS Norms) 30.0 Avg. Surface Temp. of Mill deg.C 97.0
ESP Dust 369.2 Wind Speed m/s 3.0
ESP+Aux. Heat Emissions Mcal/hr 21.81 Junction Draft mmWG 101
PLANT : BINANI CEMENT - 09.06.2004
Cem. Mill No. 1 < < E R R O R S > >
Error1 0.0000
Error2 0.0000
m2
Separator Speed ( Max. 1500 )
m2/kg
m3/hr
m3/hr
gm/m3-wg
kcal/m2/hr
kcal/m2/hr
gm/m3-wg
gm/m3-wg
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Cement Mill Power & Separator Calculations : UMS 46 x 16.5 BM
BALL MILL POWER CALCULATION
Description Comp. I Comp. II Combined
Effective Length, L m 4.330 11.410 15.740
Lining Thickness, t mm 95.0 40.0 -
Effective Diameter, D m 4.410 4.520 -
Charge Density 7.854 7.854 -
Charge Amount Comp.I Comp.II
Hichrome Balls 90 mm 25 mm t 15.770 41.920 -
Hichrome Balls 80 mm 20 mm t 22.480 83.850 -
Hichrome Balls 70 mm 15 mm t 14.710 83.850 -
Hichrome Balls 60 mm t 15.960 - -
Total Charge (booked), F t 68.920 209.620 278.54
Total Charge (calc.), F t 68.229 213.263 281.49
Specific Surface 10.33 41.76 -
Mean Piece Weight gms/ball 1554.59 22.68 -
Total Surface 712 8754 -
Relative Efficiency 5.30 14.30 12.06
Torque Factor (B4), u - 0.73 0.73 0.73
Media Bulk Weight, g 4.30 4.50 4.45
Arm of Gravity, a m 0.665 0.644 -
Segment Width, W m 4.010 4.170 -
Free Height, H m 3.123 3.132 -
Centre Distance, h m 0.918 0.872 -
Compartment Volume, V 66.14 183.08 249.22
Filling Degree, q % 23.99 25.89 25.38
% 20.14 19.90 20.02
Mill Speed, n rpm 15.20 15.20 15.20
1155 3485 4640
1224 3694 4919
SEPARATOR PERFORMANCE & EFFICIENCY
Parameters % Residue Used for Blaine
212µm 90µm 45µm Calculation
Feed, Ro % 100.00 100.00 100.00 100.00 -
Coarse, Rg % - - 83.78 83.78 95
Mill Discharge, Rd % - - 48.67 48.67 219
Separator Feed, Rm % - - 46.91 46.91 236
ESP Dust, Re % - - 19.12 19.12 265
Fines, Rf % - - 17.68 17.68 311
Circ. Factor, Calc. - - - 1.79 1.79 -
Circ. Factor, CCR - - - 2.18 2.18 -
Sep. Efficiency, Vs % - - 80.72 80.72 -
Fines Efficiency, Vf % - - 86.49 86.49 -
Coarse Effciency, Vc % - - 78.98 78.98 -
yes/no - - yes yes -
Dust from ESP tph - - 16.71 16.71 265
t/m3
m2/t
m2
t/kWhnet
t/m3
m3
Critical Speed, nc
Calculated Power, Nnet kWnet
Calculated Power, Ngr kWgr
m2/kg
Rg > 44 * Rf0.2
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Volume, m3/ball
0.0003817
0.0002681
0.0001796
0.0001131
Balls, nos.
5260
10677
10429
17968
44333
Arm of Gravity
a
h/D
a
04/18/2023 06:51:03 document.xls Mill-Calc LU000111-CMP#Ver.1.4***
Volume, m3/ball Weight, gms/ball Surface, m2/ball
0.0000082 2997.90 64.26 0.02545 0.00196
0.0000042 2105.52 32.90 0.02011 0.00126
0.0000018 1410.53 13.88 0.01539 0.00071
888.27 0.01131
Balls, nos. Mean Piece Wt., gms/ball Sp. Surface, m2/t
652397 15770000 41920000 133.86 1280.98
2548728 22480000 83850000 214.67 3202.83
6041430 14710000 83850000 160.54 4270.44
15960000 203.21
9242555 68920000 209620000 712.27 8754.24
1554.59 22.68 10.33 41.76
Arm of Gravity
Comp-I Comp-I
4.010 4.170
15.275 16.046
1.466 1.455
0.665 0.644
0.208 0.193
0.657 0.639
24.29 26.06
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Cement Mill Heat & Mass Balance Calculations : UMS 46 x 16.5 BM
S. Constraints Amount Temp. Cp Heat
No. tph kNm3/hr deg.C kcal/kg/deg.C kcal/hr x 103 kcal/kg-Cem
I N P U T
1 Clinker, dry 146.32 - 124.3 0.190 3453 22.07
2 Gypsum, dry 10.14 - 31.0 0.211 66 0.42
3 Water, gyp 0.53 - 31.0 1.000 17 0.11
4 Water Spray, Inlet 2.18 - 35.0 1.000 76 0.49
5 Water Spray, Outlet 1.87 - 35.0 1.000 66 0.42
6 Inlet Air, dry 30.59 24.22 34.5 0.242 256 1.63
7 Water, air 0.46 - 34.5 1.000 16 0.10
8 Coarse Return 124.04 - 110.0 0.188 2569 16.42
9 Grinding Heat - - - - 3699 23.64
TOTAL INPUT 10217 65.30
O U T P U T
1 Cement 263.80 - 115.0 0.189 5729 36.61
2 Total Air, dry 30.59 23.65 115.0 0.270 950 6.07
3 ESP Dust 16.71 - 115.0 0.189 363 2.32
4 Water Vapour 5.05 - 115.0 0.449 260 1.66
5 Evaporation 4.59 - - - 2729 17.44
6 Surface Heat Losses - - 97.0 - 186 1.19
7 Balance / Losses - - - - 0 0.00
TOTAL OUTPUT 10217 65.30
PLANT : BINANI CEMENT - 09.06.2004
04/18/2023 06:51:03 document.xls HMB LU000111-CMP#Ver.1.4***
Heat Cap - Coefficients
Gas/Mat *T^0 *T^1 *T^2 *T^3 *T^4
0.2485 -3.340E-06 4.440E-08 -2.797E-11 5.597E-15 Not used in calc.
0.1244 0.000E+00 0.000E+00 0.000E+00 0.000E+00 Not used in calc.
O2 0.2130 7.796E-05 -7.563E-08 4.074E-11 -8.183E-15
CO2 0.1906 1.771E-04 -1.733E-07 9.315E-11 -1.894E-14
N2+Ar 0.2465 -3.284E-06 4.366E-08 -2.750E-11 5.504E-15
H2O,steam 0.4445 2.910E-05 6.887E-08 -3.726E-11 6.472E-15
H2O, liq. 1.0000
Rawmeal 0.2060 1.014E-04 -3.673E-08
Clinker 0.1742 1.414E-04 -1.283E-07 5.074E-11
Cement 0.1742 1.414E-04 -1.283E-07 5.074E-11
Gypsum 0.2070 1.414E-04 -1.283E-07 5.074E-11
04/18/2023 06:51:03 document.xls Air-Flow LU000111-CMP#Ver.1.4***
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Cement Mill Air Flow Calculations : UMS 46 x 16.5 BM
Flow Analysis Mill Mill ESP False Air Sepax Fan Sepax
Inlet Outlet Outlet ESP Inlet Vent
Dry Bulb Temp. deg.C 34.5 115.0 108.4 34.5 106.0 108.0
Wet Bulb Temp. deg.C 22.0 - 65.0 22.0 39.0 39.0
Dew Point (F4) deg.C 19.5 - 62.7 19.5 25.0 35.0
Dew Point, calc. deg.C 19.6 62.1 62.7 19.6 25.1 35.2
Water Vapor kg/kg-dg 0.015 0.165 0.170 0.015 0.021 0.038
Avg. Ps mmWG -25.00 -110 -190 -110 -524 -93
RMS Pd mmWG - 3.33 7 - 20.00 5.08
Duct Diameter mts 0.80 1.00 1.20 - 2.00 0.50
vol % 21.00 21.00 21.00 21.00 21.00 21.00
vol % 0.00 0.00 0.00 0.00 0.00 0.00
vol % 79.00 79.00 79.00 79.00 79.00 79.00
Density, dry - O2 1.203 0.945 0.954 1.193 0.927 0.964
Density, dry - CO2 1.665 1.308 1.319 1.650 1.282 1.334
Density, dry - N2 1.058 0.832 0.839 1.049 0.815 0.848
Density - H2O 0.677 0.532 0.537 0.671 0.521 0.543
kg 25.27 19.85 20.03 25.05 19.46 20.25
kg 0.00 0.00 0.00 0.00 0.00 0.00
kg 83.61 65.69 66.28 82.89 64.38 67.01
kg 1.63 14.12 14.67 1.62 1.76 3.32
mass % 22.86 19.92 19.83 22.86 22.73 22.36
mass % 0.00 0.00 0.00 0.00 0.00 0.00
mass % 75.66 65.92 65.64 75.66 75.21 73.98
mass % 1.48 14.17 14.53 1.48 2.06 3.66
Gas Density, dry 1.293 1.293 1.293 1.293 1.293 1.293
Gas Density, wet 1.282 1.191 1.188 1.282 1.277 1.265
Gas Density, dry 1.089 0.855 0.863 1.079 0.838 0.873
Gas Density, wet 1.079 0.788 0.793 1.070 0.828 0.854
Pitot Tube S1/S2/L - - S1 - S2 S1
Gas Velocity m/s 15.90 16.00 11.62 - 18.44 9.54
Duct C.S. Area 0.503 0.785 1.131 - 3.142 0.196
Gas Flow Rate, wet tph 31.05 35.64 37.51 1.88 172.64 5.76
Gas Flow Rate, wet 24.22 29.93 31.57 1.46 135.18 4.55
Gas Flow Rate, wet 28.77 45.25 47.31 1.75 208.50 6.74
Gas Flow Rate, wet 480 754 788 29 3475 112
Moisture, by diff. tph 0.46 5.05 5.45 0.03 3.55 0.21
Gas Flow Rate, dry tph 30.59 30.59 32.06 1.85 169.09 5.55
Gas Flow Rate, dry 23.65 23.65 24.79 1.43 130.76 4.29
Gas Flow Rate, dry 28.09 35.76 37.15 1.71 201.68 6.35
Gas Flow Rate, dry 468 596 619 29 3361 106
Sp. Heat, gas kcal/kg/C 0.242 0.270 0.271 0.242 0.245 0.248
Heat Content, gas Mcal/hr 259.54 1107.10 1100.98 15.68 4479.80 154.28
Dust, gas tph - 16.71 0.00 - 6.25 0.20
Sp. Heat, Dust kcal/kg/C - 0.189 0.188 - 0.188 0.188
Heat Content, Dust Mcal/hr - 362.83 0.00 - 124.52 4.11
Heat Content, total Mcal/hr 259.54 1469.93 1100.98 15.68 4604.32 158.38
O2, dry
CO2, dry
N2, dry
kg/m3
kg/m3
kg/m3
kg/m3
Mass - O2, dry
Mass - CO2, dry
Mass - N2, dry
Mass - H2O
O2, wet
CO2, wet
N2, wet
H2O
kg/Nm3
kg/Nm3
kg/m3
kg/m3
m2
kNm3/hr
km3/hr
m3/min
kNm3/hr
km3/hr
m3/min
04/18/2023 06:51:03 document.xls Air-Flow LU000111-CMP#Ver.1.4***
MILL VELOCITY Heat Cap - Coefficients
Mill I/L Diaph. Gas/Mat *T^0 *T^1 *T^2 *T^3 *T^4
Diaph. Mill O/L 0.2485 -3.340E-06 4.440E-08 -2.797E-11 5.597E-15
72.3 112.5 0.1244 0.000E+00 0.000E+00 0.000E+00 0.000E+00
- - O2 0.2130 7.796E-05 -7.563E-08 4.074E-11 -8.183E-15
- - CO2 0.1906 1.771E-04 -1.733E-07 9.315E-11 -1.894E-14
N2+Ar 0.2465 -3.284E-06 4.366E-08 -2.750E-11 5.504E-15
0.053 0.128 H2O,steam 0.4445 2.910E-05 6.887E-08 -3.726E-11 6.472E-15
-25 -110 H2O, liq. 1.0000
- 3.33 Rawmeal 0.2060 1.014E-04 -3.673E-08
0.80 1.00 Clinker 0.1742 1.414E-04 -1.283E-07 5.074E-11
21.00 21.00 Cement 0.1742 1.414E-04 -1.283E-07 5.074E-11
0.00 0.00 Gypsum 0.1742 1.414E-04 -1.283E-07 5.074E-11
79.00 79.00
1.072 0.951
1.483 1.316
0.943 0.837 A 23.5771
0.603 0.535 B -4042.90
22.50 19.98 C -37.58
0.00 0.00 0.804
74.47 66.12
5.09 10.98 23
22.05 20.58
0.00 0.00
72.96 68.11
4.99 11.31
1.293 1.293
1.255 1.210
0.970 0.861
0.941 0.806
10.63 7.95
0.503 0.785
18.1 18.1
14.4 15.0
19.2 22.5
321 375
0.90 2.05
17.2 16.1
13.3 12.4
17.7 18.7
296 311
0.250 0.264
327.39 538.14
- #REF!
- 0.000
- #REF!
327.39 #REF!
Sp. Gravity, dry - O2 kg/Nm3
Sp. Gravity, dry - CO2 kg/Nm3
Sp. Gravity, dry - N2 kg/Nm3
Rho H2O-Steam, kg/Nm3 Sp. Gravity - H2O kg/Nm3
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Heat Cap - Coefficients
Not used in calc.
Not used in calc.
1.429
1.977
1.257
0.804
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sheet 1 of 2
Process, Efficiency & Performance Monitoring
Section : CEMENT MILL - UMS 4.6x16.5 BMMILL No. 1 / 2 Time : Date :
Site Conditions & Constants :
Plant Elevation : mts +MSL
Ambient Air Temperature : deg.C
Pitot Constant (S-Type : L=01m) : 0.883 (P.S. No. 601)
Pitot Constant (S-Type : L=02m) : 0.847 (P.S. No. V422)
Pitot Constant (L-Type : L=01/02m) : 1.000 -
Process Parameter Requirement :
Mill Feed Rate-Wet, tph : Coarse Temp., deg.C :
Gypsum, % : Cement Temp., deg.C :
: :
Clinker Temp., deg.C : :
Gypsum Temp., deg.C : Water Temp., deg.C :
Wind Speed, m/s : Mill Surf. Temp. deg.C :
Sepax Inlet, S : ESP Dust, D :
Fines, F : ESP Drop-test, tph :
Coarse, G :
Mill Inside Dimensions :
Chmb.I/II Dia., mts : GM Type, Bal/Cpb/Dpb :
Chmb.I/II Length, mts : GM Const. Mat. :
Chmb.I/II Lin. Thick., mm : Chmb.I Ball Dia., mm :
Chmb.I/II Loading, % : Chmb.II Ball Dia., mm :
Chmb.I/II Seg. Width, mts : Chmb.I/II Free Ht., mts :
Other Parameters in CCR :
Folaphone, % : Main Drive Load, kW :
Coarse Return (CCR), tph : Spx. Sep. Load, amps :
Diaphragm Temp., deg.C : Spx. Sep. Speed, rpm :
Spx. Elev. Load, amps : ESP Fan Load, amps :
Silo Elev. Load, amps : ESP Fan Damper, % :
Spx. Fan Load, kW/amps : Mill Sp. Power, kWh/t :
Spx. Fan Spd./Dmp., %/% : Ded. Fan Damper, % :
Free H2O in Gypsum, % Water Inj. I/L, m3/m
Water Inj. O/L, m3/m
Residue (+45/+90/+212 mm) / Blaine analysis :
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sheet 2 of 2Flow Measurement & Gas Analysis :
Flow/Gas Analysis Tapping Location
Mill Mill ESP Spx. JPF Sepax
Inlet Outlet Outlet Inlet Duct
Dry Bulb Temperature deg.C
Wet Bulb Temperature deg.C
Static Pressure "WG
Dynamic Pressure "WG
Time Period hh.mm - hh.mm
SignatureProcess Engineer (Monitoring)
04/18/2023 06:51:03 document.xls Tromp
Cement Mill Tromp Curve - Sepax Separator 400M-222
Sieve % Residue Cir. Factor Vs Sieve Tromp
mm Rf Rm Rg C
1.0 93.40 95.50 97.00 2.40 10.72 - -
2.0 89.20 92.50 95.10 2.27 12.02 1.5 39.86
4.0 81.80 87.30 91.50 2.31 11.44 3.0 41.61
8.0 71.50 80.90 88.10 2.31 24.44 6.0 32.59
12.0 63.20 76.40 86.60 2.29 37.46 10.0 20.93
16.0 53.70 71.40 85.30 2.27 49.27 14.0 16.70
24.0 38.30 65.80 85.25 2.41 67.76 20.0 0.47
32.0 23.60 55.60 76.90 2.50 65.50 28.0 45.42
48.0 8.50 36.00 52.60 2.66 50.75 40.0 70.21
64.0 5.70 25.90 38.20 2.64 33.91 56.0 88.28
96.0 2.40 14.00 21.00 2.66 12.28 80.0 88.42
128.0 1.20 8.80 12.90 2.85 -4.12 112.0 90.82
12 - - - 2.46 - - -
CUT SIZE 30.22 KAPPA 0.55 DELTA 0.47
PLANT : BINANI CEMENT - 09.06.2004
Cement Mill : 2
1 10 100 1000
0
10
20
30
40
50
60
70
80
90
100
Tromp Curve
Particle , mm
Wt.
% i
n C
oa
rse
, %
1 10 100 1000
0
10
20
30
40
50
60
70
80
90
100
Separator Efficiencies
Vs Vf Vc Vf*Vc
Particle Size, mm
Eff
icie
nc
y,
%
04/18/2023 06:51:03 document.xls Tromp
Tromp
39.8641.61 0 0.0032.59 0 0.0020.93 0 0.0016.70 0 0.000.47 0 0.0045.42 20 0.4770.21 0 45.4288.28 0 70.2188.42 0 88.2890.82 0 88.42
0 90.8220 -
45.42 28.00 50
70.21 40.00
CUT SIZE 30.22
KAPPA 0.55
DELTA 0.47
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Sieve Ro 100.00
0.00 0.001.50 0.00 0.003.00 0.00 0.00 Tromp Rg Corr. Vs Vf
6.00 0.00 0.00 Corr. Rm Tromp Rm
10.00 0.00 0.00 95.54 1.5 61.11 14.00 0.47 20.00 92.71 2.83 1.90 11.37 3.0 63.46 20.00 45.42 28.00 87.56 5.14 3.60 11.73 6.0 62.05 28.00 70.21 40.00 81.37 6.20 3.40 17.94 10.0 64.72 40.00 88.28 56.00 77.11 4.26 1.50 30.95 14.0 67.97 56.00 88.42 80.00 72.48 4.63 1.30 43.36 20.0 71.21 80.00 90.82 112.00 66.20 6.28 0.05 58.52 28.0 74.74 112.00 55.28 10.93 8.35 66.63 40.0 68.76
34.71 20.57 24.30 58.13 56.0 53.82 25.01 9.69 14.40 42.33 80.0 48.16
0.47 20.00 25 13.45 11.56 17.20 23.09 112.0 42.71 45.42 28.00 8.15 5.30 8.10 4.08 37.96
X25 24.37
70.21 40.00 75
88.28 56.00
X75 44.24
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Corr. Vf Vc Corr. Vc Vf*Vc Corr.
Vf*Vc
59.25 36.21 62.28 57.50 58.38 36.49 36.35 62.75 59.43 58.47 36.88 36.68 63.39 61.67 60.55 39.91 38.39 66.35 63.94 62.80 43.46 41.69 69.59 66.92 65.43 47.65 45.56 72.97 75.89 71.40 56.72 52.18 71.75 83.04 79.46 57.10 56.91 61.29 91.11 87.07 49.03 53.07 50.99 91.67 91.39 44.15 46.59 45.44 93.55 92.61 39.96 42.05 40.34 95.22 94.38 36.15 38.05