Ball Mills (Pro’s and Con’s)
© Holcim Group Support Ltd 2008
Objective
See different operation mode of BM
Pro’s and Con’s
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© Holcim Group Support Ltd 2008 BM + / - RHT
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Tube Mill – Open Circuit
Cli Gyp
to silo
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© Holcim Group Support Ltd 2008 BM + / - RHT
Tube Mill – Separator 1st Generation
Cli Gyp
to silo
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© Holcim Group Support Ltd 2008 BM + / - RHT
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Tube Mill – Separator 3rd Generation
Cli Gyp
to silo
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© Holcim Group Support Ltd 2008 BM + / - RHT
Capacity Increase
Tube Mill Roller Press Roller Press Roller Mill
Finish Grinding Pre - Grinding Combi - Grinding Finish Grinding
85 % 125 % 200 % >200 %
1st Generation
90 %
3rd Generation
100 %
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Reduction Electrical Energy Consumption
Tube Mill Roller Press Roller Press Roller Mill
Finish Grinding Pre - Grinding Combi - Grinding Finish Grinding
110 % 90 % 70 %
80 %
1st Generation
105 %
3rd Generation
100 %
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© Holcim Group Support Ltd 2008 BM + / - RHT
Investment Costs
Tube Mill Roller Press Roller Press Roller Mill
Finish Grinding Pre - Grinding Combi - Grinding Finish Grinding
….% 135 % 150 % 215 %
+ new infrastructure
1st Generation
…..%
3rd Generation
100 %
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© Holcim Group Support Ltd 2008 BM + / - RHT
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Tube Mill – Open Circuit
+ Pros, - Cons, « Limits
+ Classical mill, first generation grinding system
+ Low CAPEX installation
+ Little amount of equipment involved
+ High availability
- Low flexibility in changes to fineness, cement types, etc.
- Low flexibility in blended cement grinding
- Wide PSD (particle size distribution), large particles not controllable
« Limited control possibilities
« Limited heating (drying), cooling possibilities
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© Holcim Group Support Ltd 2008 BM + / - RHT
Tube Mill – Separator 1st Generation
+ Pros, - Cons, « Limits
+ Classical mill system, all cement standards adapted to it
+ Easy to operate
- Separator (generation) and system draw backs e.g.:
Poor separation efficiency
Limited separator control (only one drive)
Tendency to over grind product (fine rejects reground)
- Old systems Æ separator often overloaded (under dimensioned)
- Considerable change over product in tube mills
- Over grinding of soft components
« Limited heating (drying) in mill and separator
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© Holcim Group Support Ltd 2008 BM + / - RHT
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Tube Mill – Separator 3rd Generation
+ Pros, - Cons, « Limits
+ Standard tube mill system
+ Good quality control, good mill control possible
+ Narrow (PSD) particle size distribution can be produced
+ Separator (generation) and system provides advantages e.g.:
3rd generation separator Æ particle size distribution
Single pass separator Æ possible air cooling of cement
Good uniformity of product
- Considerable change over product
- Over grinding of soft components
« Limited heating in mill, drying (gas speeds in mill)
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© Holcim Group Support Ltd 2008 BM + / - RHT
Summary
+ Pros, - Cons
+ Standard tube mill system and relatively easy to operate
+ Good quality control, good mill control possible Î stable operation Î
higher MTBF
- Limited heating in mill, drying (moisture up to 4%)
- High specific energy consumption (+30% to VRM)
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© Holcim Group Support Ltd 2008 BM + / - RHT
