cement mill

04/18/2023 06:51:03 document.xls Pic LU001016-CMP#Ver.2.3D***

Page-1/5

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

04/18/2023 06:51:03 document.xls Mill-Calc LU000111-CMP#Ver.1.4***

Page-2/5

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


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


Page-3/5

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 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


HMB Simulation


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


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

04/18/2023 06:51:03 document.xls HMB LU000111-CMP#Ver.1.4***

Page-4/5

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


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***

Page-5/5

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


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


Heat Cap - Coefficients

Not used in calc.

Not used in calc.

1.429

1.977

1.257

0.804

04/18/2023 06:51:03 document.xls Mon-Form

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 :

04/18/2023 06:51:03 document.xls Mon-Form

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


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,

%


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


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


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

cement mill

Documents