pricast mill scan dsp lnvt
DESCRIPTION
Replace Mill Sound level Instrument by this Pricast Mill ScanTRANSCRIPT
29 de Julio de 2008
MillScanMillScanUsing vibration to measure the fill level of Ball MillsUsing vibration to measure the fill level of Ball Mills
K V ANJANI KUMAR
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Presentation sequence
1. MillScan – Introduction and advantages
2. Installation and calibration
3. Operational examples
4. Case studies
5. Conclusion
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MillScan IntroductionMillScan Introduction and Advantagesand Advantages
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•MillScan is a field instrument that measure the mill fill level using the vibration signal of the Mill bearing housing or table.
•MillScan can be used in Ball Mills.
MillScan - Introduction
•Due its technology, MillScan yields a highly accurate and instantaneous mill fill level signal that can be used to run the mill under automated loop control or greatly assist control room operators under manual control.
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MillScan Advantages
Higher resolution (more than two times) compared with traditional sound bases instruments;
Is not affected by other equipments or services in the area (system 100% digital);
Easy installation, setup and calibration (DON’T need to stop the mill for installation and calibration);
Option for customize the equipment for different products;
No additional equipment in the existent plant control system is needed (communication via a 4-20mA output).
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System Components
Main Unit
Sensor
USB Adapter
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System Configuration in a ball mill
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Installation in a ball mill
Sliding shoe bearing mill
Standard bearing housing
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Easy calibration (only 3 steps)
System calibration
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System calibration
Eliminating interferences from other equipments and mechanical problems.
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Signal ExamplesSignal ExamplesLooking into the “future”Looking into the “future”
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20:30 21:00 21:30 22:00 22:30
63.833
68.833
73.833
78.833
83.833
88.833
93.833
58.833
99.779
8.0227
13.606
8.0227
13.606
80.227
136.06
80.227
136.06
1560.5
1672.1
29.4164
49.8895
Looking into the “future”
Total FeedMill kWMILLSCAN
MillScan – Signal example
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Motor power
MILLSCAN
Elevator
Returns
Looking into the “future”
Aprox. 15min
MillScan – Signal example
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MillScan DSPMillScan DSPCase StudiesCase Studies
The real benefits of using MillScanThe real benefits of using MillScan
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Mill characteristics
Cement Mill 2 single compartment finish mills
Dimensions: 4,0m diameter; 6,4m long; 2.000HP
First generation separators;
Blaine: 5500-4000;
4 Different cements produced.
MillScan – Case Study I
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12:00 14:00 16:00 18:00 20:00 22:00 0:00 2:00
20
40
60
80
100
0
120
0
15
0
15
0
150
0
150
1400
1700
0
55
Bucket El 2 kW
Bucket El 1 kW
Total Feed
Mill kW
Separator 2 kW
Separator 1 kW
Step 1: Mill under Manual control
MillScan – Case Study I
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0:00 1:00 2:00 3:00 4:00 5:00 6:00 7:00 8:00 9:00 10:00 11:00 12:00 13:00
20
40
60
80
100
0
120
0
15
0
15
0
150
0
150
1400
1700
0
55
Bucket El 2 kW
Bucket El 1 kW
Total Feed
Mill kW
Separator 2 kW
Separator 1 kW
Step 2: Mill under kW control
MillScan – Case Study I
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15:00 17:00 19:00 21:00 23:00 1:00 3:00 5:00
20
40
60
80
100
0
120
0
15
0
15
0
150
0
150
1400
1700
0
55
Bucket El 2 kW
Bucket El 1 kW
Total Feed
Mill kW
Separator 2 kW
MILLSCAN
Step 3: Mill under MillScan control
MillScan – Case Study I
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Reduction In kWh/ton (Overall Cements) : 6%
Some Results (after MillScan installation)
MillScan – Case Study I
Cement Type A
Reduced Ave Blaine 4,6%
Increased Ave 325 Mesh Passing
0,25%
Reduced St Dev at 28 day strength
37%
Cement Type B
Reduced Ave Blaine 5,4%
Increased Ave 325 Mesh Passing
0,7%
Reduced St Dev at 28 day strength
28%
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MillScan – Case Study II
Mill Characteristics
Cement Mill (nominal 80 ton/h) 2 single compartment finish mills
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MillScan – Case Study II
Ajuste em tempo real dos parâmetros do PID, ganhos e BM
Indicação de enchimento – Mill Scan
Alimentação total, controlada somente pelo nível de enchimento
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MillScan – Case Study II
MillScan Signal(fill level in %)
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MillScan – Case Study II
Fresh feed to the mill(in ton/h) – Mill in auto control
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MillScan – Case Study II
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MillScan – Case Study II
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Manual Control
Production average
73,88 ton/h
Finesses (0,044mm)
12,3
Auto Control with MillScan
Production average
77,80 ton/h
Finesses (0,044mm)
12,2
Results
Production increase 5,01 %
Production costs decrease
4,77 %
Cement finesses decrease
1,00 %
MillScan – Case Study II
Comparing before and after MillScan
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Mill Characteristics
Cement Mill (nominal 20 ton/h) 2 single compartment finish mills
MillScan – Case Study III
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MillScan – Case Study III
Comparing before and after MillScan
Motor Power control MillScan Control
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MillScan – Case Study III
Production average
Normal control 20,60 ton/h
MillScan control
21,75 ton/h
Results
Increase production in 5,5%Decrease specific consumption in 5,3%
Pay-back in 2 months !!!
Specific Consumption
Normal control 38,03 kWh/ton
MillScan control
36,02 kWh/ton
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MillScan – Case Study IV
Cement Mill-02 (170 -185 TPH) Single compartment finish mills
Blaine: 3200-3500;
2 Different cements produced.
- OPC - PPC
Jk Lakshmi Sirohi -Mill Characteristics
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Cement Mill-02 Circuit
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45 Micron residue with Sound level and Millscan
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Rejects with Sound level and Millscan
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Mill power with Sound level and Millscan
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Production with Sound level and Millscan
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Separator Speed with Sound level and Millscan
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MillScan – Case Study V
Cement Mill-05 (75 -84 TPH) 2 Compartment finish mills
Dimensions: 3.8 m diameter; 12.5 m long; 2700 Kw
Blaine: 3200-3500;
OPC 53 is produced.
Jk Lakshmi Sirohi -Mill Characteristics
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Cement Mill-05 Circuit
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Production Report
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Separator Speed (Rpm) Before Vs After
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Separator Reject (TPH) Before vs After
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Product Residue on 45 mic Before vs After
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Mill Main Drive Power (KW) Before vs After
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Mill Feed Rate (TPH) Before vs After
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Mill Outlet Bucket Elevator (KW) Before vs After
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MillScan – Case Study VI
Cement Mill-01 (125 -130 TPH) 2 compartment finish mill
Blaine: 3300-3500;
Two Different cements produced.
- OPC - PPC
Madras Cement R R Nagar -Mill Characteristics
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Cement Mill-01 Operating Curves
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CEMENT MILL NO.1 MILL SCAN AUTO OPERATION DATE : 24.09.09
DESCRIPTION TIME 11 12 13 14 15 18 19 20 21 22 23 24 1 2 3 4 5 6 AVG1 - FEED UOMCLINKER FEED - 1 MT/HR 27 47 45 45 45 41 36 39 39 42 65 77 61 43 39 43 42 64 39CLINKER FEED - 2 MT/HR 47 30 29 29 30 40 36 39 38 42 12 0 12 36 33 37 35 10 36TOTAL CLINKER FEED MT/HR 74 77 74 74 75 81 72 78 77 84 77 77 73 79 72 80 77 74 76GYPSUM FEED MT/HR 8 9 9 8 11 12 10 11 11 9 10 9 9 10 11 8 10 10 9F.ASH FEED MT/HR 27 28 24 21 25 26 23 24 24 21 22 19 22 26 27 29 28 26 25TOTAL FEED (PPC) MT/HR 109 114 107 103 111 119 105 113 112 114 109 105 104 115 110 117 115 110 109BLAINE 320 341 345 341 338 334 341 331 327 341 320 324 341 345 338 345 327 335
Production(TPH) MILL SCAN OPERATION :-Minimum 103Maximum 119 START STOP Average 111 10.00 15.35Std Deviation 4.593 17.40 CONTI.
Blaine(m2/kg)) VRPM FINES ADDITION :-Minimum 320Maximum 345 STOP STARTAverage 335 13.05 13.45Std Deviation 8.707 15.40 16.05
21.00 22.05Clinker (TPH)Minimum 72Maximum 84Average 76Std Deviation 3.238
Fly Ash (TPH)Minimum 19Maximum 29Average 25Std Deviation 2.812
* Grinding Aid : ON
TIME (hrs)
TIME(hrs)
MILL SCAN AUTIO OPERATION
0
50
100
150
200
250
300
350
400
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
RUNNING HOURS
TP
H/B
LA
INE
PRODUCTION (TPH)
BLAINE (M2/KG)
Operating Conditions
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Operating Curves
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MillScan References
TOTAL OF 210 UNITS AROUND THE WORLD
Buzzi UnicemCal Portland
CementirCementos Portland
CemexCimpor
ColacemGCC
Hanson
HeidelbergHolcim
ItalcimentiLafargeLehigh
MitsubishiNuh Beton
SecilVotorantim
and others ...
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MillScan Conclusions
MillScan
Optimum operation point
Limits
P1
P2
OperatorBetter information
Repetitibility
Stable processBetter control
…
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MillScan high sensibility detects variations in the Mill Fill Level almost instantaneously when other typical signals used for Mill control are not affected or delay to accuse variations.
Acting with more precision and earlier gives the operator the possibility to improve operation.
MillScan – Conclusions
Pricast Equipamientos Industriales S.L.Calle Paris, 71, 1/4 - 08029 – Barcelona, SpainTel: (+34)93.444.31.23 Fax:(+34)93.419.87.71
[email protected]/millscan
Visit us at:www.pricast.es/millscan