grinding with tube mill

8/12/2019 Grinding With Tube Mill

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Institut Semen dan Beton Indonesia Cement Mill Operation

Bab 2 Penggilingan Semen dg Tube Mill


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Departemen Penggilingan Semen


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Feed

Drying

Grinding

Separating

Ventilation

and cooling

Quality

Control

Grinding

aids

Sistem Penggilingan Semen


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Feed

Maximum size: < 50 [mm]

Umpan Tube Mill


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Intermediate diaphragm

Mill feed arrangement

1stCompartment

(Coarse Grinding)

2stCompartment

(Fine Grinding)

Mill discharge

Air outlet

Air inlet

Elemen-Elemen Tube Mill


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Contoh Spesifikasi Semen Mill

2 Type : 13 x 441/2 (41 EGL)

Compeb mill

Drive system : Single, side drive

Inside shell dia. : 4,000 mm

Shell length, flange : 13,650 mm

to flange

Mill speed : 16.4 rpm

Number of : 2

Compartment

2 GIRT GEAR : ALLIS CHALMERS

Size 13 X 44 1/2

2 Motor output : 2,900kW, 6, 6 KV, 750 Rpm 50 HZSHINKO ELECTRIC

2 GEAR REDUCER : SEISA, OSOKA CHAIN &

MACHINARY LTD.Type : SHN- 1180

Speed ratio : 1/5. 304

Transmitting power : 2,900 kW

Speed of input shaft : 735 rpm

Speed out Put : 138,56 rpm

2 INCHING DEVICE, : Type(name plate loose)

Transmitting power : 22 kw

Speed ratio : 1/213.3

Inching speed : 0.1 rpm


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Proses Grinding

Power

Efficiency

Grinding


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Prinsip Kerja Grinding dg Tube Mill


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Tahapan Proses Grinding

Coarse

grinding

Medium

grinding

Fine

grinding


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Kompartemen 1 (Coarse grinding)

Coarse

grinding

Medium

grinding

Fine

grinding 90 60 [mm] balls


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Bagaimana Evaluasi Efisiensi Grinding Komp. 1 ?

Kehalusan Material di Kompartemen 1

[%] Residue on 2.38 [mm]

0

5

10

15

20

1.1 1.2 1.3 1.4

Very Bad

Bad

good

too good

Sampling point


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Contoh Komposisi Bola di Kompartemen 1

1.Co m p artm ent Ball [mm] Weight [ t ] Percent [%]

90 25.0 25.0

80 35.0 35.0

70 25.0 25.0

60 15.0 15.0

Total 100.0 100

Average ball weight [ g ] 1667

Spec. media surface [m2 / t ] 10.2


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Material level

Efisiensi Grinding Kompartemen 1 ?


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Power parameters

Filling degree

Liner

Speed Mill

Efficiency parameters

Ball charge (filling degree &composition)

Liner Ventilasi Mill

Parameter yang bisa kita atur


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Ball filling degree (f [%])

20 [%]

30 [%]

38 [%]


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Lifting Liners Effects

Liner-Lifting : low high


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Material transport capacity

Slots opening 68 [mm]

Central screen opening

Control gaps

Intermediate diaphragm


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[%] Residue on 2.38 [mm]

0

5

10

15

20

1.1 1.2 1.3 1.4

Very Bad

Bad

Situasi Kompartemen 1


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[%] Residuo en 2.38 [mm]

0

5

10

15

20

1.1 1.2 1.3 1.4

too good

Get a finer ball charge

Lower ball filling degree

Shorten the chamber

Situasi Kompartemen 1


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Penggilingan Halus (Kompartemen 2)

Coarse

grinding

Medium

grinding

Fine

grinding

30 - 17 [mm] balls 50 - 40 [mm] balls


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Material level

>> 50 [mm]: bad

~ 50 [mm] good

< 50 [mm] bad


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1

10

100

2.1 2.2 2.3 2.4 2.5 2.6

Parameter yang bisa kita mainkan ?

Komposisi bola

Ball filling degree

Liner


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1

10

100

2.1 2.2 2.3 2.4 2.5 2.6

50Ball size 40 30 25 20

% 126

22 20 40

Adjustment komposisi isian bola


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1

10

100

2.1 2.2 2.3 2.4 2.5 2.6

Example

20

17

Ball size

%

17

23

40

18

Adjustment komposisi isian bola


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OPC > 3200 [cm2/g] in closed circuit

2.Compar tment

Ball [mm] Weight [ t ] Percent [%]

50 20.0 10.0

40 20.0 10.0

30 32.0 16.0

25 32.0 16.0

20 42.0 21.0

17 54.0 27.0

15

Total 200.0 100

Average ball weight [ g ] 41

Spec. media surface [m2 / t] 32.8

Contoh Isian Bola Kompartemen 2


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Ball filling degree

> > 50 [mm]: bad

~ 50 [mm] good

< 50 [mm] bad

>> 0 [mm] very bad

Lower ball filling degree

Increase ball filling degree


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Liner design

Classifying liner

Klasifikasi bola yang baik dapat menurunkan konsumsienergi mill motor spesifik 510 [%]

Material flow

Millrotation


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Transport Material Dari Komp. 1 ke Komp. 2

desired


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Manajemen Bola (Ball Management)

Ball charge


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P k i B l


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Ketika bola berukuran 90 [mm] menjadi 80 [mm]

dan bola yang berukuran 80 [mm] menjadi 70 [mm]dan seterusnya

70 [mm]

80 [mm]

90 [mm]

Pemakaian Bola


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Kl ifik i B l


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100.00

Scraps Total

Ba lls in bucket t 7.2 11.1 25.2 30.7 89.8 6.0 170.0

Balls sampled -- 200 200 200 200 200 0 0 200

Sample weight kg 85.3 38.5 18.2 9.5 4.5 0.0 0.0 2.9

Diam. Equival. mm 47 36 28 23 18 0 0 15

Composition % 4 7 15 18 53 0 0 4 31 [g]

Number of balls -- 16'882 57'662 276'923 646'316 3'991'111 0 0 413'793 37.1 [m2/t]

200 balls per sample in the second chamber

Deformed & broken

balls sorted out

mechanically/manually

Klasifikasi Bola

50 balls per sample in the first chamber

Kl ifik i b l


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Good

Bad

Klasifikasi bola

Visual criteria for ball form classification

(deformed/broken)


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Mill ventilation and cooling


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Mill ventilation and cooling

Cooling

Tujuan ventilasi dan pendinginan pada sistem mill


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Tujuan ventilasi dan pendinginan pada sistem mill

Menghindari suhu operasi yang terlalu tinggi di dalam

mill (115130 [C]):

Coating material pada bola dan liner menghasilkan

turunnya kinerja mill sekitar of 510 [%] Resiko false set pada semen

Block di dalam silo

Cooling


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Cooler

False air

Mill fresh air

Water injection

Separator fresh air

False air

Mill fan

Clinker

g

Injeksi Air


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j

Pengaturan suhu ini juga penting untuk kondisi operasi ElectrostaticPrecipitator(EP) dimana EP tersebut akan bekerja dengan baik

pada suhu di atas 100oC.

Water injection pada (a) inlet mill dan (b) outlet mill

Injeksi Air


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Injeksi Air

Water injection

Memberikan efek pendinginan lebih besar dibandingkan udara

Air dapat meningkatkan kapasitas mill jika diinjeksi padakompartemen 2

Air meningkatkan dew point

Injeksi air harus memperhatikan :

Dilakukan jika temperatur outlet mill (> 100 [C]) Berefek pada kuat tekan awal semen jika klinker amat reaktif

grinding with tube mill

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