grinding with tube mill
TRANSCRIPT
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Institut Semen dan Beton Indonesia Cement Mill Operation
Bab 2 Penggilingan Semen dg Tube Mill
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Institut Semen dan Beton Indonesia Cement Mill Operation
Departemen Penggilingan Semen
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Institut Semen dan Beton Indonesia Cement Mill Operation
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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Institut Semen dan Beton Indonesia Cement Mill Operation
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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Institut Semen dan Beton Indonesia Cement Mill Operation
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