VALID PRACTICE

FOR THE

PRODUCTION PROCESS
#10 BALL CEMENT MILL
MONITORING, INSPECTION & EVALUATION

Athens, December 2007

Valid Practice #10

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Valid Practice #10

BALL CEMENT MILL

MONITORING, INSPECTION & EVALUATION

1.
SAFETY GUIDELINES FOR BALL CEMENT MILL INSPECTION...................................3
2.
BALL CEMENT MILL MONITORING................................................................................6
2.1.
Flow sheet.................................................................................................................... 6
2.2.
Performance................................................................................................................ 7
2.2.1. Material Sampling.................................................................................................. 11
2.2.2. Gas measurement.................................................................................................. 11
2.2.3. Radiation & Convection.......................................................................................... 11
2.2.4. Heat Balance......................................................................................................... 12
2.2.5. Process flow sheet.................................................................................................14
3.
BALL CEMENT MILL INSPECTION...............................................................................15
3.1.
Circuit efficiency......................................................................................................... 15
3.2.
Separator efficiency................................................................................................... 17
3.3.
Grinding efficiency...................................................................................................... 23
3.3.1. Guideline for Crash Stop........................................................................................ 24
3.3.2. Guideline for Empty Grinding Stop........................................................................29
4.
BALL CEMENT MILL EVALUATION...............................................................................31
4.1.
Relative mill speed calculation...................................................................................32
4.2.
Axial sampling............................................................................................................ 33
4.3.
Ball charge calculation............................................................................................... 35
4.4.
Ball charge Management........................................................................................... 37
4.4.1. Recommended Ball Charge Sorting Frequency.....................................................37
4.4.2. Ball Mill Loading..................................................................................................... 37
4.4.3. Ball charge record keeping....................................................................................38
4.4.4. Ball sorting............................................................................................................. 39
4.5.
Conclusions................................................................................................................ 40

Introduction
The purpose of the respective Valid Practice is to outline the parameters that
should be included in a Ball Cement Mill Evaluation as well as the appraisal of
the findings in order to identify the bottlenecks and suggest the necessary actions
that would result in the Ball Cement Mill Optimization.

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Valid Practice #10

1. SAFETY GUIDELINES
INSPECTION

FOR

BALL

CEMENT

MILL

Initially, it should be noted that each Plant is responsible for the implementation of
the own safety procedures and the following are suggestive general guidelines
that could be included.

SAFETY FIRST
The workers should be trained for the job, work always in pairs and should be
equipped with the following safety equipment (Personal Protection Equipment,
PPE):
Uniform
Safety Boots
Fireproof/heatproof Gloves
Helmet
Mask
Safety glasses
Body belt with rope
Portable scaffolding with barriers
Fork lift vehicle

Guideline for safe entry

Danger of unwanted mill start-up during the mill inspection. The power of the
main motor should be cut off from the main power supply and the fuses
should be removed.

Danger of unwanted material entry to the mill interior during the mill stoppage.
The power of the main raw material belt conveyors should be cut off from the
main power supply and the fuses should be removed. Also the respective
pipes should be blocked mechanically from the dampers or using steel
sheets. Given the dusty environment inside the mill, anyone entering the mill
must be wearing a face shield and goggles.

Danger of severe burning in case hot gases enter the mill. The safety damper
at the hot gases duct should be closed, its power should be cut off from the
main power supply and the fuses should be removed. Also the damper should
be blocked mechanically.
Prior to dismantling any doors and guards, make sure that the following
equipment has been stopped and interlocked to prevent starting:
Mill main motor

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Valid Practice #10

Mill and separator fan

All feeding equipment
Water spraying and grinding aid addition
Heat generator

The power supply for the above mentioned equipment must be effectively
locked by means of padlocks in the MCC (motor control center) room to
prevent accidental starting of the motors. The supervisors in charge of the
inspection team undertaking work inside the mill must keep the key for the
lock. The padlocks must remain fitted until all personnel have left the mill
and all doors and guards have been remounted.

Apart from the respective Plants safety procedure, everybody should keep in
mind:
Ensure Safe Isolation:
Mill drive, auxiliary drive, feed belts, etc
Physical barrier (locked closed/de-activated)
Comply with local Permit to Work procedure
Ensure Safe Access:
Consider fall hazard (e.g. access door on top of mill)
Confined space someone outside mill
Maintain ventilation to cool air space

In case of a ball mill inspection there is danger of speeding balls from the
pavement due to contact with the fork lift wheels. The pavement should be
properly cleaned.

Mill door opening

Danger of load displacement during the mill door opening. Ensure that the
ball charge is leveled horizontally using the auxiliary mill drive, the mill door is
at the correct location for opening and finally before opening the door ensure
that the mill is not linked to the auxiliary drive.

Danger of mill door falling in case of hoist malfunction. After lifting the mill
door it should be placed on the mill shell.

Danger due to high dust concentration as well as high level of hot material.
After opening the door the leveling of the ball charge as well as the level of
hot material is checked with a flash light.

Case 1: Ball Mill entry through the top of the mill

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Scaffolding and protective barrier placement: Danger of fall during

getting in or out of the mill. Ensure that the scaffolding and the
protective barriers are safely placed at the top of the mil shell and that
they are firmly attached at least to two different points.

Ladder placement: Danger of fall during getting in or out of the mill.

Ensure that the ladder is safely placed at the top of the ball charge
and that it is tightly connected to the mill shell or the protective
barriers.

Case 2: Ball Mill entry through the side of the mill

Installation of false-door: Danger of ball charge falling. A false-door

(temporary for easy in/out) is installed and the loading displacement is
taken into consideration.

False door removal: Danger of load displacement during the mill door
opening. Ensure that the mill door is at the correct location and
remove the false-door.

During Inspection

Danger of faint. In case somebody faints, he should be wearing the body-belt

in order to facilitate easier taking out.

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Valid Practice #10

2. BALL CEMENT MILL MONITORING

2.1. Flow sheet

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2.2. Performance
Monitoring the Cement Mill (CM) performance is considered the most critical
aspect of a CM evaluation. The performance monitoring procedure for each
cement type produced should include:
i.

Checking the weigh feeders on regular basis.

ii.

Operating the mill at the recommended fineness (Blaine) target set by

quality control.

iii.

Collecting representative spot sample of each raw material used (~30 Kg)
after any change at the feeding of raw materials. All samples should be
safely kept for further analysis (Moisture, XRF, wet chemical analyses &
LOI).

iv.

Collecting samples of the cement produced, as well as from certain

locations of the grinding circuit (mill outlet, filter outlet, separator inlet,
separator rejects and separator fines). All samples should be safely kept
for further analysis (Moisture, fineness (Blaine & sieves), XRF/wet
chemical analysis, LOI, strength analysis, Water Demand, Setting time
(early & late), and Granulometry (laser) analysis)

v.

Perform gas measurements (flows & temperatures). Repeat the

measurements after every permanent change at the process parameters.

vi.

Perform temperature measurements at the mill shell in order to calculate

the heat loss due to radiation & convection. In case there is necessity to
implement heat balance with boundaries that include the separator,
include the separator to the shell temperature measurements for losses
calculation.

vii. Record the operating parameters.

vii i. Record the specific electrical energy consumption.
The following table is submitted as template in case of a mill inspection, while
part of it could be also used in daily operation logging, for the recording of the
CM operating parameters, specific electrical energy consumption data, gas
measurements data as well as quality parameters.

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Technical Details
Plant
Mill
Mill Supplier
Mill Type
Operating hours since installation
Operating hours since last ball charge refill
Operating hours since last inspection
Operating Parameter
Cement Type
Date
Time
Production rate (wet)
Composition (wet)

Unit
dd/mm/yy
hh:mm
t/h
Clinker
Natural Gypsum
Limestone
Pozzolana
Other
Water content

Water injection
Grinding aid
Iron Sulfate Heptahydrate (FeSO4.7H2O)
Production rate (dry)
Composition (dry)
Clinker
Natural Gypsum
Limestone
Pozzolana
Other
Grinding aid
Iron Sulfate Heptahydrate (FeSO4.7H2O)
Temperature
Mill inlet temperature
Mill outlet temperature
Mill filter outlet temperature
Pressure
Mill inlet pressure
Mill outlet pressure
Mill delta P
Mill filter delta P
Separator filter delta P
Gas Measurement
Flow at mill filter stack (wet)
Flow after mill (wet)
Flow at separator filter stack (wet)
Flow after separator (wet)
Flow fresh air (wet)
Flow hot gas (wet)
Operational Parameters
Folafon
Separator speed
Mill fan speed
Separator fan speed
Recirculation elevator
Mill fan damper
Recirculation damper
Fresh air damper
Energy Consumption
Mill motor
Mill separator
Mill fan
Separator fan
Mill bucket elevator
Specific Electrical Energy Consumption (SEEC)
Mill motor
Mill classifier
Mill fan
Separator fan
Mill bucket elevator
Mill motor, separator, mill fan & separator fan
Total

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t/h
t/h
t/h
t/h
t/h
%
lt / min
g/t
g/t
t/h
%
%
%
%
%
%
%
C
C
C
mbar
mbar
mbar
mbar
mbar
Nm3/h
Nm3/h
Nm3/h
Nm3/h
Nm3/h
Nm3/h
%
%
%
%
%
%
%
%
KW
KW
KW
kW
KW
kWh / t
kWh / t
kWh / t
kWh / t
kWh / t
kWh / t
kWh / t

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Valid Practice #10

Quality Parameters
Gypsum moisture
Limestone moisture
Pozzolana moisture
Other moisture
Blaine

Unit
%
%
%
%

Mill outlet
CM Filter outlet
Separator Filter outlet
Separator inlet
Separator rejects
Separator fines
Final product
Corrected Final product Blaine (w/o effect of additives)
Fineness (Residue at 90m)
Fineness (Residue at 45m)
Water Demand (WD)
Setting Time (initial)
Setting Time (Final)
Strength (N/mm)
LOI
IR
SO3
Free CaO
SiO2
Al2O3
Fe2O3
CaO
MgO
K2O
Na2O

cm / gr
cm / gr
cm / gr
cm / gr
cm / gr
cm / gr
cm / gr
cm / gr
%
%
%
min
min
1day
2days
7days
28days
%
%
%
%
%
%
%
%
%
%
%

Granulometry Analysis, Sieve

Cumulative Passing, %
1
1,5
2
3
4
6
8
12
16
24
32
48
64
96
128
192

%
%
%
%
%
%
%
%
%
%
%
%
%
%
%
%

Rosin - Rammler
Slope, n
#
d
m
Production between 3 - 32 m
%
Tromp curve
Separator efficiency as recovery of fines, Uf
%
Circulation load based on laser
#
d50
%
d75
%
Kappa (k), slope of the curve in the interval 50%-75%
#
Cut size, particle size corresponding to the Tromp value 50%
%
By-pass, Tromp value at the lowest point of curve
%
Separator efficiency as reduction in power consumption, Vs (32 m sieve)
Circulation load
#
As reduction in power consumption, Vs
%

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Valid Practice #10

Apart from the above, on monthly basis the following tables should be completed:

regarding operation:
Mills Stoppages
Available hours
Actual operating hours
Duration of Annual Maintenance

h
h
h

Duration of Strategic stoppages

(for example Saturation etc.)

Duration of stoppages because of Other external reasons

(for example Power failure etc.)
Downtime
Downtime because of Operational reasons
Downtime because of Mechanical reasons
Downtime because of Electrical reasons
Downtime because of Planned maintenance
(excluding annual maintenance)
Total Downtime
Grinding media consumption
(including refilling and new load)
5 year history
1 year history

h
h
h
h
h
h

g/tCement produced
g/tCement produced

regarding quality:
Quality Parameters
CEMENT TYPE
Composition (dry)

Unit

Clinker
Natural Gypsum
Limestone
Pozzolana
Other
Grinding aid
Iron Sulfate Heptahydrate (FeSO4.7H2O)
Blaine
Fineness (Residue at 90m)
Fineness (Residue at 45m)
Water Demand (WD)
Setting Time (initial)
Setting Time (Final)
Strength (N/mm)

LOI
IR
SO3
Free CaO
SiO2
Al2O3
Fe2O3
CaO
MgO
K2O
Na2O

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MONTHLY AVERAGE

%
%
%
%
%
%
%
%
%
%
min
min
1day
2days
7days
28days
%
%
%
%
%
%
%
%
%
%
%

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Valid Practice #10

regarding ball charge management:

Ball charge
1st compartment
Amount
Specific weight
Composition

2nd compartment

t
t/m3
90
80
70
60
50
40
30
20

mm
mm
mm
mm
mm
mm
mm
mm

Ball charge compensation

Last date
Amount

regarding maintenance cost:

The maintenance cost (including spare parts and man-hours cost) should be
calculated and attributed per mill.

The logging of the parameters as well as the data warehouse management

should be automated and implemented in the Plant everyday procedures.
2.2.1. Material Sampling
As far as the sampling procedure is concerned it is vital to know the Sampling
Points before sampling is needed. The samples are being collected only be those
assigned by plant personnel in order to know the locations (e.g. product, circuit
samples).
Before starting the sampling procedure the access for sufficient size (and
sampler) should be verified. There safety for access (heights, steps, guard rails,
etc) should be assessed whereas the exposure risk to pressure/suction, heat,
dust, etc should be checked.
Finally, all participants should have suitable equipment (PPE, containers, sample
devices, etc) and be aware of moving parts (e.g. rotary valves, screw conveyors).
Note that when in Doubt ASK!
2.2.2. Gas measurement
In order to calculate the flows at the grinding circuit, the temperature and the
pressure has to be measured. Temperature is being measured using
thermocouples while the pressure (differential and static) is being measured
using Pitot tube. The flows should be depicted at the relevant process flowchart.
2.2.3. Radiation & Convection
In order to evaluate the heat transfer, the heat losses which are being attributed
to radiation and convection has to be verified. In order to calculate the heat loss,
the temperature at the surface of interest is being measured and following the
heat loss is being calculated.

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2.2.4. Heat Balance

A heat balance is being conducted in order to evaluate the heat transfer and
calculate the dew point. The mill should operate under steady conditions
throughout the test. The following steps are being followed:
Define system boundaries to evaluate heat inputs and outputs.
Define test duration.
Define mill operating conditions.
Define type of measurements to be carried out (e.g. temperature, air
flows, etc).
Define parameters to be measured.
Define position and frequency of measurements.
Define inputs from panel to be recorded.
Define material sampling methodology.
Prior to testing, make sure that everyone involved has fully understood the
test procedure (what, when and how). Prepare logsheets.
Make sure that the electronic data recording systems are operating.
Calibrate and check the proper operation of all instruments (portable and
stationary).
Reference Temperature: i.e. 20 C.

The dew point can be calculated using either the wet bulb temperature
method or gas measurement and applying the respective chart from the
bibliography (i.e. FLS manual).

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A typical is example is presented hereafter:

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2.2.5. Process flow sheet

It is suggested to present the process data in flowcharts per CM and per cement
type in order to have better control compared to the every day operation, as
following:

Based on the above information, it is possible to provide a clear picture of the CM

performance and evaluate it compared to the typical values in terms of:

Throughput and Specific Electrical Energy Consumption (SEEC). The

production rate and the SEEC per cement type produced compared to the
design values and the typical references (benchmarks, other mills).

Cement quality. The contribution of the additives at the Blaine value, the
relationship between the separator and the mill fan speed and the RosinRammler (RR) slope as well as the effect to the water demand and the
strength profile.

Mass & Energy (heat) Balance. Based on the results, the weighing feeder
accuracy as well as the heat demand and the amount and location of false air.

Utilization & reliability. Even though, utilization is subject to the sales demand
(quantity) and scheme (peak and saturation), reliability is judged by the
reliability (run) factor which should lie above 90%.

Ball charge (composition) and wear profile (g/t).

It should be noted that even though the monthly performance (utilization,

reliability, wear) is judged based on average values, the monitoring of the hourly
performance (throughput, SEEC) as well as any additional measurements and
evaluation should be done during stable conditions.

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3. BALL CEMENT MILL INSPECTION

3.1. Circuit efficiency
The evaluation of the circuit efficiency involves sampling at specific locations of
the circuit. In particular, the necessary samples include:
1.

Mill outlet

2.

CM filter outlet

3.

Separator inlet

4.

Separator rejects

5.

Separator fines

6.

Separator filter outlet

7.

Final product

The above locations should be sampled under stable operating conditions and at
least three times per location. Also is should be noted that ideally all sampling of
the above locations should be done at the same time.
Based on the sieve and Blaine values of the mill outlet and the filter outlet we
calculate the percentage of the separator feed that comes from the mill outlet.
Also, using the same principle we can calculate the amount of the separator filter
returns to the final product.

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Based on the sieve and Blaine values of the mill outlet and the filter outlet we
calculate the percentage of the separator feed that comes from the mill outlet.
Also, using a mass balance we can calculate the amount of the separator filter
returns to the final product.
As far as the circulation loading is concerned, it is a function of:
Product fineness.
Chamber I ability to prepare the feed for chamber II.
In-mill fineness (mill exit Blaine) and hence the degree of particle
agglomeration and coating.
Separator loading and hence separation efficiency.
Grinding efficiency.
Each mill has its optimum circulation loading which is determined from operation
at different total feed set-points and will be higher for large diameter mill, large
separator and use of additive.

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3.2. Separator efficiency

Major part of the cement mill evaluation regarding a ball mill circuit is the
evaluation of the separator efficiency.
Based on sieves analysis:
Separator efficiency as recovery of fines
Separator efficiency measured as Recovery of fines is calculated according to
the expression:
Uf=100*(100-Rf)/(100-Rm)/C [%]
The method can be used for comparison between separators operating at the
same circulation factor.
Separator efficiency as reduction in power consumption
The separator efficiency as reduction in power consumption (Vs) is calculated
according to the expression:

Typical values for efficiency, Vs, relating to residues in the interval 32m-45m:

1st generation separators:

CV, Heyd, Sturtevant

2nd generation separators:

REC, Wedag, ZUB

Vs:=40%-60%

rd

3 generation separators:

Sepax, O-Sepa, Sepol

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Vs:=25%-40%

Vs:=75%-85%

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Based on CILAS (laser) analysis of the above samples the Rosin Rammler
Curve as well as, the Tromp Curve are constructed:
The Rosin Rammler Curve is the logarithmic chart of the particle size
distribution where the critical parameters are:

Slope (usually varying from 0.8-1.2; increases with the technology

applied)

Limiting grain size / characteristic diameter, d [m] for the RR value of

36.8% (typically 10-30m)

Fraction of material between 3mm and 32mm

Rosin Rammler

The Tromp curve values are calculated according to the expression:

T=100*(C-1)/C*Rg/Rm
where, for the interval representing the particle size:

Rg is the percentage of return material

Rm is the percentage of material leaving the mill

The Tromp curve resulting from the Tromp curve values shows for each
individual particle size of the separator feed the percentage which gets into
the fine fraction.

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Tromp Curve

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The main parameters of the Tromp Curve, are depicted hereafter:

i.

Cut size:

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ii.

Kappa (Imperfection) slope:

iii.

By-pass:

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The above are being compared to the reference values:

Product Blaine
Mill Outlet Blaine
Filter outlet Blaine
Separator rejects Blaine

Reference Values
3.800
<2.000
~2.200
<900
1-2 for dynamic separator
2-3 for high efficiency separator
25%-40% for 1st generation
40%-60% for 2nd generation
75%-85% for 3rd generation
0,8-0,9 for Ball mill (open circuit)
0,9-1,0 for Ball mill (closed circuit)
1,0-1,1 for Ball mill (high efficiency separator)
1,1-1,2 for Vertical mill/roller press
10 - 30 m

5-15

depends on rotor speed and fineness level

cm2/g
cm2/g
cm2/g
cm2/g

Circulation load

Vs,
Separator efficiency as reduction in power consumption

Rosin Rammler slope

Rosin Rammler characteristic diameter, d'

By-pass,
Tromp value at the lowest point of curve
Cut size,
particle size corresponding to the Tromp value 50%
Kappa (k),
slope of the curve in the interval 25%-75%
Separator Load

0,5-0,6

Kg/Am3

max 0,85kgproduct/Amair3
max 2.5kgfeed/Amair3

It should be noted that we should not compare separator performance at different

circulation values, as well as the results of the laser analysis from different
instruments.

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3.3. Grinding efficiency

Inlet
Trunnion

Step
Linin
g
Plates

Mill End
Wall

First
Chamber

Intermediate
Diaphragm

Coarse
Grinding Media

Second
Chamber

Classifying
Outlet
Lining
Trunnion
Plates

Fine
Grinding
Media

Outlet
Diaphragm

Maintaining the condition and effectiveness of the equipment relies on regular site
inspections and measurements around the system. Internal inspection of the mill
should take place on regular basis to assess the condition of the charge and the
liners. Periodically axial samples need to be taken in the mill to assess the
progression of fineness development along the grinding path. From this the
appropriateness of the media size grading for the fineness of the predominant
cement produced on the mill can be assessed. Samples also need to be taken
around the milling circuit to assess the recirculation load and the characteristics
and efficiency of the separator. Temperatures and pressures around the milling
system need to be measured to calculate air velocities and a mass and energy
balance. In combination this information will provide a comprehensive
assessment of the condition of the milling equipment. Periodic gathering of this
information is useful for detecting changes in the condition and the performance
of the mill.
Each ball mill should be inspected at minimum every month. Along with the
internal mill inspections, the ball charge should be monitored according to the mill
kilowatts. The mill should be inspected as soon as mill kW drops by 5% from the
targeted mill kW. During each inspection, a Monthly mill ball charge inspection
sheet should be filled out.

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3.3.1. Guideline for Crash Stop

The CM should be crash stopped and visually inspected internally.
i.

All associated departments should be informed at least 24hours prior to crash

stopping the mill. The departments involved include Production, Maintenance,
Process and the Quality Control.

ii.

The CM must be crash stopped while the mill is at maximum production and
has been running stable for at least 4hours to give consistent representative
samples.

iii.

The control room operators will crash stop the mill by stopping the mill and all
related equipment including all fans and bucket elevators. If possible, the mill
is stopped so that it can be entered without any further turning. It must be
ensured that material feeding is not stopped previously and that also the mill
fan stops simultaneously to prevent that fines are discharged with the air flow.
The product conveying equipment should remain running to convey the
remaining product from the lines and hoppers.

iv.

The mill will be prepared for inspection according to the respective safety
procedure. Estimated time for preparations is 2hours. It should be noted that
at all time the fuses should be removed from the respective motors and that
nobody should enter without clearance from the Production manager and the
Maintenance Manager.

v.

The mill is allowed to cool down. Estimated time for cooling is 5hours.

vi.

To check the grinding progress (grinding efficiency over the compartment

length), axial sampling is performed.

The procedure is as following:

Take samples from below surface, below level of balls, along the mill axis.

Assess presence of nibs (e.g. coarse material, ~5mm) especially near the
outlet of the 2nd compartment.

The most important (Key) samples are those on either side of intermediate
diaphragm as well as at mill outlet.

Usually 3 samples in chamber 1 and 5 samples in chamber 2 are collected,

whereas in theory we should collect axial samples after every 1m from the
mill inlet to the intermediate diaphragm as well as from the intermediate
diaphragm to the mill outlet and at each point we take a set of three samples
along the mill chord.

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The result shows whether or not the grinding progress in the mill is good.
Furthermore, axial sampling can provide indications of possible causes in case of
disturbances.
A typical example of axial sampling is presented hereafter:

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vii. The grinding progress is not only influenced by the ball charge but also by the
material load.

viii. Parallel to the axial sampling and the material load evaluation, the mill internal
is being inspected for coating (on ball charge, liners and diaphragms) The
grading is presented hereafter:
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None: Appearance of metal as surface

Light: Appearance of cement as surface. Readily cleaned by hand to

reveal metal surface.

Moderate: Appearance of heavier cement as surface. Partially cleaned

by hand to reveal cement/metal surface.

Heavy: Appearance of thick cement as surface. Difficult to see metal

surface, even after cleaning by hand.

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liners condition (cracks, wear):

adjustment and condition of the intermediate wall (slope opening):

ix.

Finally the mill dimensions are checked by measuring the compartment length
and diameter.

x.

After internal mill inspection and material (axial) sampling the maintenance
department will close the doors and turn the mill over to the production
department for restart.

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3.3.2. Guideline for Empty Grinding Stop

When the mill inspection is finished, after the crash stop, the mill should run for
~30minutes without fresh feed and following should be stopped again (empty
grinding stop). Visual inspection of mill interior along with measurements (free
height, ball charge distribution, etc.) will be carried out. Visual inspection of static
& dynamic separator is also necessary.
i.

All associated departments should be informed at least 24hours prior to crash

stopping the mill. The departments involved include Production, Maintenance,
Process and the Quality Control.

ii.

The CM must be stopped after running for ~30minutes without fresh feed so
that all material to be ground between the grinding media is discharged from
the mill.

iii.

The grinding plant is then stopped with EMERGENCY STOP, while the mill
fan should continue operating in order to cool the mill interior.

iv.

The mill will be prepared for inspection according to the respective safety
procedure. Estimated time for preparations is 2hours. It should be noted that
at all time the fuses should be removed from the respective motors and that
nobody should enter without clearance from the Production manager and the
Maintenance Manager.

v.

The mill is allowed to cool down. Estimated time for cooling is 3 hours.

vi.

In order to calculate the filling degree:

a. the height should be measured along the centerline of the mill from the
top of the balls to the top of mill (minimum 3 locations in 1st compartment
and 4 locations in 2nd compartment).

b. the chord length should be measured on top of the ball charge level
(minimum 3 locations in 1st compartment and 4 locations in 2nd
compartment).
c. the number of free liner plates should be measured (minimum 3
locations in 1st compartment and 4 locations in 2 nd compartment). Make
sure that the first and last plates (% plate) are estimated with as much
accuracy as possible.

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vii. To check the ball charge quality and composition, ball charge sampling is
performed at the same principle as material axial sampling. Cement bags are
filled with balls after every 1m from the mill inlet to the mill outlet.
viii. After internal mill inspection and material (axial) sampling the maintenance
department will close the doors and turn the mill over to the production
department for restart.

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4. BALL CEMENT MILL EVALUATION

Sizing of the existing mill equipment is usually are not a factor which can be
optimized. In order to improve mill performance the target should be to follow the
benchmark regarding the production rate and the SEEC. Output and energy
consumption of a cement mill are interdependent and are combined in the kWh/t
of cement produced performance benchmark. The power drawn by the mill main
motor is dependent on the grinding media charge level in the mill rather than the
amount of material being ground in the mill. There is no opportunity to vary this
power drawn during operation of the mill. Whether the productivity is as high as it
could be for the type and fineness of cement being produced is a difficult question
to answer. Comparing performance between milling systems involves complex
peer group analysis.

The first consideration is the type of cement being produced. Blended

cements have a higher throughput than when grinding pure Portland
cement due to the lower grindability or inherent fineness of the
extender. A cement mill grinding blended cement with granulated slag
additions will have a lower throughput than when grinding pure
Portland cement due to the hardness of the slag.

The second consideration must be the fineness of the cement

produced on the mill. The kW hours consumed per ton of cement
produced are related to the surface area (cm2/g).

The third factor that must be taken into consideration is the complexity
of the grinding circuit as well as the respective mill and separator type.

Recognize the overriding importance of quality and focus the process control on
the whole process of cement grinding rather than simply the fineness.
The results of the mill inspection measurements need to be compared with
accepted norms and benchmarks from within the Group or elsewhere in the
cement industry. Certain benchmarks, or rules of thumb, are well established:

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length to diameter ratio should be close to 3.5 for a closed circuit mill

modern mills operate at 70%-75% of critical speed

1.5m/s-2.0m/s air velocity through the mill is normal for closed circuit
mill

1.0m/s-1.5m/s for an open circuit mill

1st chamber performance

o chamber one occupies 30%-35% of the length of a two chamber
mill
o High volume loading (>30%). 28-30% media volume loading is
normal for a closed circuit mill, exceptionally up to 33%
o Not excessively large feed sizes
o Chamber specific electrical energy consumption 8kWh/t-12kWh/t
o Good Media Grading, 60mm-90mm (all >55mm) , mean size of
75mm-78mm
o Good Liner Step (compared to mill speed), >40mm
o Good diaphragm condition, ~6mm slot width, no gaps, no
blockages
o Select % of 90mm media, usually between 15 and 40% which is
based on feed sizes and crushability (or axial testing).
Automatically calculate remaining charge as equal numbers of
80mm, 70mm and 60mm.
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4.1.

2nd chamber performance

o Absence of nibs of clinker or other feed
o Moderate volume loading (25%-35%). Second chamber media
volume loading should be lower than the first chamber
o Mean ball size of 18mm-30mm
o Good Media Classification, if media is up to 60mm
o Minimal Coating on liners and grinding media
o Good diaphragm condition, ~8mm slot width, no gaps, no
blockages

Relative mill speed calculation

The mill speed should typically range from 70% to 75% of the critical speed.

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4.2.

Axial sampling

At first, any metal parts (balls or ball scrap) must be removed from the
sampled material. The samples are then divided and thus reduced to suitable
quantities for analysis.
It should be noted that:

The axial sampling results must always be evaluated taking into account
the loading of the mill with material to be ground. Evaluation of the axial
sampling is done according to the following scheme:

The curves of the coarse particles (above 7mm) in compartment 1

should drop steeply and reach 0 after approx. 50% to 60% of the
effective grinding length of compartment 1. If this is not the case, the ball
charge may be too fine, i.e. the quantity of large balls is not high
enough.

In a two-compartment mill for cement grinding, the total of the residue

values before the intermediate wall should be between 15% and 25% on
the 0.5mm screen and not more than 5% on the 2mm screen. If this is
not the case, the share of large grinding media is too small and/or the
first grinding compartment contains too much material to be ground. In
that case, a relatively high amount of material is found above the
grinding media and between the grinding media after the emergency
stop.

For the evaluation of a grinding diagram, it is always necessary to

consider the material load of the mill.

In the 2nd grinding compartment, the residue values should drop steadily
and the specific surface of the samples should constantly increase.

With a two-compartment separator mill and a cement fineness (Blaine)

of 3.200cm/g, the following values should be attained before the
discharge wall:
o Residue on 90m approximately 15% to 25%
o Residue on 200m maximally 5%
o Blaine approximately 1.800cm/g

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4.3.

Ball charge calculation

The ball charge is being calculated according to the following formulas, using
the measurements performed during the empty grinding stop. The calculated
ball charge should be compared to the one given by the Plant and should be
confirmed with the power consumption measurements.

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The ball charge should be confirmed (both periodically i.e. monthly or after every mill
inspection) by the power measurement using the FLS formula:

N=F*D**a*n*g*/60= F*D**a*n*0,514
a= the arm of gravity in relation to the mill diameter=0.009*(96.7-specific ball charge%*100)
N=power consumption [kW]
F=charge [t]
n=rotational speed of the mill
=torque factor
D= effective diameter
Wherever it is necessary, the following tables are used for finding the specific charge & torque
factor:

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4.4.

Ball charge Management

The objective of this manufacturing best practice is to optimize production in a soldout market and to reduce the overall kWh/t consumption in a non sold-out market, by
maintaining the optimum ball charges level in all operational mills.
The ideal volume loading is dependent upon the individual plant priorities. The plant
must decide whether their main goal is either to reduce mill power consumption
(kWh/t), or to maximize production (t/h). The recommended volume loading are as
follows:
Minimum kWh/t
Maximum Production

Recommended Volume Loading

1st Compartment 2nd Compartment
26 28%
28 30%
32 34 %
34 36%

It is important to realize that there is higher power consumption (kWh/t) when the
maximum production rate is the first priority.
Some mills will be limited to lower volume loading due to mill motor power, stress
on mill shell or stress on the gearing.
Mill inlet trunion size is another possible limiting factor. Ball level in the trunion
should not be higher than 2 to 3 inches.
With a volume loading above 34% classifying liners often lose their beneficial
effect.
4.4.1. Recommended Ball Charge Sorting Frequency

The minimum frequency for ball charge sorting for mills is recommended as follows:
Raw and Coal Mills
Finish Mills

Ball Sorting
1st Compartment 2nd Compartment
Every year
Every year
Every year
Every two years

This is the recommended minimum ball charge sorting. Some plants may require
sorting more often. For mills with very low utilization, the ball sorting may be less
frequent.
4.4.2. Ball Mill Loading

After sorting add 85 to 90% of ball charge initially. Run ~100 hours before
topping up the ball charge, this allows addition of larger or smaller balls according
to mill inspection and fineness obtained at the partition for the 1st compartment.

After monthly mill inspection

o Balls should be added to get back to the original ball charge design.
o The average size of added balls will be larger than the average size of the
ball charge design, unless the ball charge design is changed.
o A ball charge sampling should be done if the current ball charge is uncertain,
in order to determine what ball sizes to add.
o An important rule of thumb is that one metric ton of balls will increase the mill
power draw by 10kW. The required mill kilowatts must be available before
adding the balls to the mill.

Do not mix different types and metallurgical compositions of balls together, i.e.:
o forged steel and chromium
o low chrome and high chrome balls in the 1st compartment
o balls from different supplier, unless proven effective by extensive testing and
quality control
Exception: Used first compartment balls could be recycled in the second
compartment, if they have the appropriate size (Not mandatory)

Do not add balls that are wet or snow covered to cement mills.

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Add a layer of material to the first compartment only before adding balls to an
empty mill, in order to protect the shell liners.

Never exceed mill motor power.

4.4.3. Ball charge record keeping

The following items should be kept as records in plants for proper ball charge
management:
Monthly mill ball charge inspection sheet.
Ball additions.
Ball charge sorting results.
Ball charge design.
Any unusual occurrence or problem that affected mill performance.
Dates of liner and partition changes

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4.4.4. Ball sorting

It is usual, that after some time the ball charge has to be sorted in order to replace
the worn parts and establish ball charge composition according to the axial sampling
results as well as the granulometry. This can be done either manually or using
specific equipment as following:

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4.5.

Conclusions

Depending on the findings, the most possible actions may include:

Once per month, the chambers should be charged with the required grinding
media. The required grinding media can be calculated by 3 ways:
Mill motor kW trend
Monthly production combined with the statistical grinding media
consumption (g/t)
Check of the grinding media level at the two chambers
Increase the ball charge according to the Plant policy (either for minimum
energy consumption or for the maximum production capacity), based on the
installed motor power and the typical reference values.
Sorting the ball charge of the both chambers. Once per year, sorting of the
ball charge is required.
Based on axial sampling the ball charge composition or the location of the
intermediate diaphragm could be changed.
The specific electrical energy consumption is compared to the typical
references.
The separator performance could imply the presence of a mechanical failure.
The gas measurements should be used for identifying the source of false air
induction.
The impact flow-meter of separator rejects needs to be calibrated periodically.
The folafon indication should be calibrated periodically.
Based on the main reason for stoppages the run factor is being evaluated and
justified.

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