Imagine an online classroom that takes you to learn at your own pace, allowing more choices with your learning opportunities. The Cement Institute is dedicated to providing the most dynamic and engaging programs available, as our enhanced online experience demonstrates an interactive and hands-on knowledge applicable directly to your plant.
The Ball Mill Maintenance course is designed to engage in the effective use of hands-on learning methodology as a unique combination of theory and practical work section applied to the ball mill systems maintenance inspection. This course offers an in-depth understanding of the maintenance activities, providing the precise tools to achieve optimal levels of personal performance and accomplishment, obtaining tangible and positive impact in the ball mill areas performance and reliability.
Grinding is one of the cement industrys fundamental processes: (for the preparation of raw materials, coal grinding, and cement grinding). Cement manufacturing is a continuous process industry with very high requirements and performance rates, requiring high reliability in both the process and maintenance.
In the open circuit system, the mill product has the fineness required for the next stage. In the closed-circuit system, the mill product is classified in a separator in a fine fraction that is then taken to the next step and a thick fraction that is returned to the mill for subsequent milling.
It is necessary to grind clinker, gypsum, and sometimes other additives in the proportions required at a predetermined fineness in any cement grinding circuit. The fineness is usually defined by the cements specific surface area measured in m/kg or cm/g. High-efficiency separators are normal to grind cement in a closed-circuit system due to energy consumption savings.
Safety hazards in ball mills involve numerous situations; anywhere, we can observe conditions related to process, operation, and maintenance. Ball mills can be hazardous machines if they are not operated properly. Therefore, operators should follow the essential safety and maintenance advice; as part of the course, we will cover all the safety precautions to ensure safe operation and maintenance. Operators must take certain precautions before beginning to operate a ball mill. Here is a list of the most critical safety maintenance steps that all operators must follow when using a ball mill:
Cleaning the machine after use: A ball mill must be cleaned after each operation or at the end of the working day. Major components like the grinding tool, grinding roller, and grinding ring are prone to wear. Because of that, each part or component should be regularly lubricated and checked for damage.
Ball mill is generally used to grind material 1/4 inch and finer, down to the particle size of 20 to 75 microns. To achieve reasonable efficiency with ball mills, they must be operated in a closed system.
There is a specific operating speed for the most efficient grinding. At a certain point, controlled by the mill speed, the load nearest the cylinders wall breaks free, and other sections so quickly follow it in the top curves to form a cascading, sliding stream containing several layers of balls separated by the material of varying thickness. The top layers in the stream travel faster than the lower layers, causing a grinding action between them. There is also some action caused by the spinning of individual balls or pebbles and secondary movements having the nature of rubbing or rolling contacts inside the main contact line.
The mechanical elements of a tube mill could be separated into components that directly function with the grinding process (i.e., grinding media, liners, diaphragms) and into parts that can be considered individual units connected to a specific tube mill. The latter group includes:
The mechanical elements of a tube mill can roughly be subdivided into internal and external parts. The mill internals directly functions concerning the grinding process and include the wear parts of a mill, such as mill liners, diaphragms, and grinding media principally. We will explain how to inspect the mill liners, diaphragm, water spray system, and components as well as physical mill inspection with our checklist instruction:
This module will detail a regular sequential physical inspection of conveyors by operators and mechanical maintenance personnel. It will detail what items require inspection and what possible issues and problems the inspecting personnel should be trying to identify and rectify. It will cover each of the major components that make up a conveyor system and include the variations within different conveyor designs. The topic will cover such components as:
The turbomachines used for gas compression are classified into radial, axial, or mixed flow types according to the impellers flow. In a radial or centrifugal machine, the increase in pressure due to centrifugal action is an essential factor in its operation. Energy is transferred by dynamic means from the impeller to the fluid. The fluid due to centrifugal action is continuously thrown outward, allowing fresh fluid to enter due to reduced local pressure.
Another characteristic feature of the centrifugal impeller is that the angular momentum of the fluid flowing through the impeller increases because the impellers outer diameter is significantly larger than the inlet diameter. In axial flow machines, the rotating impeller sets in motion a large mass of gas and is advanced by the blades aerodynamic action.
Dust collection systems are the most widely used engineering control technique by cement processing plants to control dust and decrease workers exposure to respirable dust. A well-integrated ball mill dust collection system has multiple benefits, resulting in a dust-free environment that increases productivity and process operation. The most common dust control techniques in cement plants use local exhaust ventilation systems.
This course is primarily geared to all maintenance staff personnel with a focus on the preventive maintenance area. Future managerial persons, whether from maintenance or production, may also benefit significantly by participating.
Those with little or no prior experience with ball mill maintenance will learn to understand, interpret, and use the core concepts of equipment design and their limitations. Gain valuable skills that can be used immediately to analyze and implement preventive maintenance.
A unique combination of theoretical and practical skills throughout this course will be learned, which will help you develop and execute the concepts and technical knowledge acquired in the daily maintenance activities. The following downloadable materials are part of the course to enhance and facilitate the participants learning experiences.
Work section book: Provide learning activities and hands-on practice case study and exercises. Solutions are included after each training is completed. Certification is achieved by completing a satisfactory level of exercises, quizzes, and final exams for each module.
The course is conducted online, allowing students flexibility (within four weeks) to complete all modules. Students should expect to spend more than 10 hours per week and some additional time for private reading/study. A computer with Internet access (broadband recommended) and email will be required.
Applications: it can be used in the materials such as limestone, clinker, concrete, activated carbon, etc. in the fields such as silicate products, glass ceramics, beneficiation of ferrous and non-ferrous metal.
The cement mill is the most commonly used grinding equipment in cement plants. General cement refers to the cement used in civil engineering construction, such as Portland cement, ordinary Portland cement, slag Portland cement, portland-pozzolana cement, Portland fly-ash cement and composite Portland cement.
The main shaft of the cement mill produced by Fote Heavy Machinery adopts self-aligning to ensure the normal operation of the rotary part. It is lubricated by oil spoon, oil ring or automatic oil station. The three lubricating forms can guarantee the cement to be well lubricated.
A cement mill is the key equipment for re-crushing the materials after they are primarily crushed. It is widely used for the dry type or wet type grinding of all kinds of ores and other grindable materials in cement, silicate product, new building material, refractory, fertilizer, black and non-ferrous metals and glass ceramic industry.
This machine is a mill with the structure of a horizontal cylinder and two bins, and its outside runs along with gear. The material enters the first bin of the cement mill uniformly through the hollow shaft spiral from the feeding equipment. And there is a ladder lining plate or corrugated lining plate in the bin, which is filled with steel balls of different specifications.
The rotation of the cylinder generates centrifugal force to bring the steel balls to a certain height and then the balls fall down, causing a heavy impact on the materials and grinding them coarsely.
After the materials are grinding coarsely, it is conveyed into the second bin through the single-wall partition. There is lined with a flat lining with steel balls to further grind the material. The powder is discharged through the discharge raft to complete the grinding operation.
To ensure the high efficiency of the cement mill, customers should be careful to purchase on the basis of the above points. We introduce a cement mill machine manufacturer with professional production technology and a good reputation here--Fote Heavy Machinery (FTM). It produces cement grinding machines that are very popular among users:
Rich limestone resources provide huge resources for the production of cement, while the Indonesian Ministry of Industry encourages domestic cement companies to increase investment and expand the cement plant on a large scale.
When receiving the message, our engineers contacted Mr. Adijaya for the first time. After communicating with him in detail, we recommended our 3.513 cement mill for him. After giving Mr. Adijaya the detailed data of the machine, he was very satisfied with the specifications. After a short visit to the factory, Mr. Adijaya reached cooperation with us.
Last month, we received feedback from Adijaya, who said that the equipment has been running smoothly and productively during the past several months and he is looking forward to cooperating with us again.
If you don't know how to choose a cement mill, the author suggests you come to Fote Heavy Machinery to have a visit. Please click on the consultation button on the right to learn more about FTM cement mill models.
As a leading mining machinery manufacturer and exporter in China, we are always here to provide you with high quality products and better services. Welcome to contact us through one of the following ways or visit our company and factories.
Based on the high quality and complete after-sales service, our products have been exported to more than 120 countries and regions. Fote Machinery has been the choice of more than 200,000 customers.
The cement plants and process engineer (due to training and job title) is frequently asked to examine the big picture in a production/operations environment. This can be a formal request for a diagnostic review or a vague request from top management to see whats wrong or what kind of improvements can be done with production/operations. Operations audit is a procedure that helps the industrial and process engineer determine not only what is wrong, but more importantly, what is right in an operations activity.
Operations audit is the first step in conducting a general and objective assessment of a production/operations area. It is called by many other names, such as diagnostic review, general survey, operations exam, etc. It can be done as a stand-alone project, but is often part of a larger project, such as reducing costs or improving productivity. The technique is based on a logical evaluation of the current factors that control the operating environment.
The audit can be performed by a person or by a team, depending on the complexity of the operation under examination and the need for skills outside the training of the industrial and process engineer. The audit can range from two days to several weeks, depending on the size and complexity of the operation under review.
The audit should result in a concise written statement of the operations strengths and weaknesses and support functions. It should also contain diagrams of the interactive features that contribute to the product or service being provided and any comments on areas for improvement and any specific areas for further analysis. The audit will be based on data, numerous interviews, field visits, and the objectivity and past experience of the systems.
An operations audit should be carried out whenever important changes of a general nature are considered. Some important changes may include: a plant-wide cost reduction effort, the installation of a productivity program, thermal energy efficiency program, electrical energy efficiency program, chemistry and operations strategy, the introduction of new products, changes in the management information system, new plant acquisitions, prior to relocations of plants, etc.
An audit is usually the first step by a management consultant who has been given a broad objective by senior management to improve the profitability of an operation. The consultant may conduct a portion of the audit before the formal proposal is submitted, to ensure that the correct issues are addressed in their proposed work plan. Likewise, the plants process engineer or internal consultant will often find that the audit is a necessary first step in ensuring that they address control issues and not just some of the symptoms.
A variety of tools are used during the conduct of the operations audit and the emphasis will vary based on the complexity of the audit and the time available. One of the most important tools will be the industrial and process engineers ability to conduct the audit as a project, with a written objective, defined tasks, expected deliverables, listing of work steps, and a schedule. If other team members are used, then their efforts will be directed and coordinated as well.
Other important tools are the ability of the industrial and process engineer to conduct meaningful interviews at all levels of the organization, and to document findings and draw clear, concise, conclusions. The handling and gathering of data necessary for the conduct of the audit is a particularly important task, since the time usually allotted to the audit will require not only care in analyzing data, but in making realistic data requests of key departments.
The operations tour and related field trips can be an important source of general information, and the tour can be augmented with product flow charts, equipment location drawings, and facility expansion plans. The observations and answers to key questions during operation tours and related visits can become a useful part of the data gathering stage of the operation audit for confirmation and verification at a later date.
Organization charts, job descriptions, budget plans, financial statements, operations records, and written operating procedures can be useful information to be obtained during the conduct of the audit.
Plant operating and shutdown data need to be collected for the past two or more years. The reasons, duration and frequency to identify the causes in order of severity of the stops are analyzed and their classification:
Plant performance is also analyzed by department. Often, the best performance of a department does not occur at the same time as the best performance of the plant as a whole. If we choose the best throughput times for each department and make them occur at the same time, the throughput of the plant will show a significantly higher level of efficiency. Attempts are being made to make them happen at the same time, which is not an unrealistic goal, as the departments had indeed done so at that level in the past.
Modern dry-process cement plants with an efficient grinding and pyro processing system, typically consume less than 700 kcal/kg-cl of thermal energy and 100 kWh/mt of electrical energy. Older plants with inefficient systems, combined with operational and maintenance failure, tend to have much higher energy consumption. Based on the specific plant conditions and requirements, a general benchmarking is conducted to set goals. Plant audits evaluate the performance of a cement plant against the appropriate benchmark. After a detailed evaluation, recommendations are made for optimizing the plant at three levels of capital investment:
A successful thermal energy management program requires energy auditing as its one of the important procedures. The possible approaches of heat recovery from some major heat loss sources by making a detailed analysis of kiln, raw mill, coal mill and grate cooler. To improve the production process, increase the productivity, decrease energy consumption of the plant.
The main aim of the energy audit is to provide an accurate account of energy consumption and energy use analysis of different components and to reveal the detailed information needed for determining the possible opportunities for energy conservation.
Mills: In the case of ball mills, optimizing the mill load and maintaining the internal parts of the mill will minimize energy consumption. As for the vertical roller mills, the inspection of the internal parts of the mill and the separator, and the adjustments in the operation will bring improvements, both in energy consumption and in increased production.
The evaluation of the process will include chemical data on the input and output streams for the efficiency of the mixture, an annual record of the moisture content and the granulometry of the feed material.
The operations audit can be a beneficial first step in aiding the industrial and process engineer in assessing the appropriate focus for later problem-solving efforts and can be used in a variety of circumstances in most production and operations environments.
US: Phoenix Industrial will install the raw mill for Denmark-based FLSmidths raw mill upgrade of CalPortlands integrated Mojave cement plant in California. The company said that it will conduct civil, concrete, structural steel, mechanical and electrical work on the project. Mobilisation of crews to the site is due to begin in March 2021 with commissioning scheduled for December 2021. Saxum Engineering is also working on the upgrade.
India: Germany-based Gebr. Pfeiffer has received an order from Aditya Birla subsidiary UltraTech Cement for nine vertical roller mills. The producer plans to install the mills across three newly-built clinker lines. The supplier said, The cooperation between UltraTech Cement and Gebr. Pfeiffer is based on the understanding of not only being a customer or supplier, but to achieve common goals in partnership.
Austria: Germany-based Loesche has received an order to supply a new raw materials grinding plant to LafargeHolcim subsidiary Lafarge Zements Mannersdorf cement plant. The plant will consist of a type LM 45.4 mill, a LSKS type classifier, a rotary feeder, a magnetic separator, a conveyor, a pair of Hurriclons, a mill fan and the Digital Ready 4.0! digital package. Loseches subsidiaries Kingsblue and AixProcess are responsible for the digital products and A-Tec for the Hurriclons. Commissioning is scheduled by the end of February 2022.
Cement and ore head of sales Stefan Baaken said, "Many cement plants in Europe are facing similar challenges to our customer in Mannersdorf. For us as an original equipment manufacturer and also for the customer, the new grinding plant is an important signpost towards more energy-efficient and sustainable cement production.
Latvia: Schwenk Building Materials Group subsidiary Schwenk Latvija plans to invest Euro34m in installing a new 170t/day grinding mill and 12,500t silo at its Broceni cement plant. The Baltic Business Daily newspaper has reported that the company aims to reduce energy consumption with the new mill.
Turkey: Denmark-based FLSmidth has won a contract to provide a grey-to-white cement line conversion at imko imentos cement plant in Adiyaman. The company will supply equipment suited to the production of white cement including its DuoFlex burner, rotary cooler and OK raw mill. It said that it will begin work in 2021 and the producer will commission the renovated line in early 2022.
The supplier said, Once completed, the upgraded line will offer imko imento new opportunities to expand its product range and enter new markets. White cement is especially sought-after in countries with relatively hot climates, as it tends to keep buildings cooler with its reflective characteristics. In addition, as a high-quality, value-added product, white cement is often used in the construction of innovative buildings and important landmarks. FLSmidth brings significant experience and know-how to the project, having conducted several similar grey-to-white conversions in recent years, including projects with Turkey-based Adana Cement and Eskisehir Cement, as well as Alsafwa Cement Company and Riyadh Cement Company in Saudi Arabia.
Australia: Adbri subsidiary Cockburn Cement has approved a US$152m upgrade to its Kwinana grinding plant in Western Australia. It says the investment will consolidate the cement operations at its Kwinana site. At present clinker is transported by truck from the Kwinana Bulk Terminal to cement mills at both the Kwinana grinding plant and the companys integrated plant at Munster. It will increase its production capacity to 1.5Mt/yr from 1.1Mt/yr at present. The project is expected to save the company US$15m/yr due to better energy, transport and maintenance efficiency when the plant is commissioned by mid-2023. The producer will fund the investment through existing debt facilities.
The upgrade project includes: a bulk materials conveyor linking the Kwinana Bulk Terminal (KBT) facility to a new 110,000t clinker storage shed, incorporating an automated reclaim system, to eliminate road transport and minimise clinker handling using mobile equipment; a slag feed system that will handle granulated blast furnace slag and additives such as gypsum and limestone; a ball mill circuit with the installation of two new cement mills capable of grinding slag and clinker; and a new 21,000t finished product storage, truck loading and weighbridge infrastructure for storage and despatch.
Kuwait: Spain-based Cemengal says that it has received a second order from ACICO Cement for a 1Mt/yr ball mill with a XP4i-130 type Magotteaux classifier for a new grinding plant. The company said that the project, which it expects to commission in the first quarter of 2021, encompasses full engineering and complete supply of mechanical, process, electrical and automation equipment, as well as steel manufacturing from the raw materials handling areas up to the silos cement discharge. In addition to the delivery of technology, the site supervision, training and commissioning activities.
Belgium: Magotteaux has launched Expand, a vertical roller mill (WRM) wear parts product line for the cement industry. The equipment supplier says that the range offers high resistance, consistent production, energy efficiency and lower maintenance and replacement frequency. It also uses a scrap buy-back program to consider product lifecycle concerns. The wear parts line comes in two variants: Expand One, the standard metal matrix composite (MMC) product; and the higher performance Expand+.
India: Shree Cement has ordered two vertical roller (VR) mills from Germany-based Gebr. Pfeiffer for the upcoming clinker line at its Raipur cement plant in Chhattisgarh. The supplier says that one of the mills will grind raw materials and the other will grind coal.
A MVR 6000 R-6 type raw mill will grind 800t/hr of raw material and have a drive power of 8700kW. Gebr. Pfeiffer said, The grinding rollers of this mill can be equipped with roller tires for raw meal grinding as well as for cement grinding, provided that they have been designed according to the same force module. This saves money, because the identical components of rollers, tensioning system, roller arms, etc. mean that customers can reduce their spare parts inventory, since the same spare parts can be used for a raw meal mill and for a cement mill. The mill will be equipped with an SLS 6000 VR high-efficiency classifier.
A MPS 2800 BK type mill will be used to grind coal with a capacity of 28t/hr, a drive power of 720kW and be equipped with the latest design of the integrated SLS 2900 BK high-efficiency classifier optimised for MPS mills.
The supplier said, While the core components of the mills as well as the drive units will be supplied by Gebr. Pfeiffer from Europe, the Indian subsidiary Gebr. Pfeiffer (India) will provide components such as the mill and classifier housings, the steel foundation parts as well as internal parts of the classifiers.
UK: Welding Alloys says that it has carried out maintenance on a vertical roller mill at HeidelbergCement subsidiary Hansons 1.0Mt/yr Purfleet slag plant in Essex, repairing the mills Loesche 46 2+2S grinding table and rollers. The company said that the mill, which had ground 3500t of granulated blast furnace slag (GBFS), was in urgent need of refurbishment. Following a wear audit, Welding Alloys took the grinding components back to the profile template using its Integra Wire Mill products.