B Level Audit of
Raw Meal Vertical Roller Mill Systems
HGRS /Mechanical Process Technology/OR
MPT 03/14918/E
PT-Dok. B8.1.1-6
Table of Content
1 What is a "Field" Audit? ............................................................................3
2 Gathering of the design and operating information ...................................4
2.1 Starting point for a Field Audit ...........................................................4
2.1.1 Definition of the raw meal mix to realize the field audit with
and identification of quality targets (fig. 2).................................................4
2.1.2 Conditions prior and during a Field Audit (fig. 3) .....................4
2.1.3 Logical realization order (fig. 3)...............................................5
2.2 Design information from main machines............................................6
2.3 Control Room: Mill Control System & Strategy, Operation Data &
Trends ..........................................................................................................7
2.4 Circuit Visual Inspection ....................................................................8
2.5 Energy Measurements.......................................................................9
2.5.1 Electrical energy consumption ................................................9
2.5.2 Fuel consumption....................................................................9
2.6 Circuit: Material Measurements & Sampling....................................10
2.6.1 Material throughput ...............................................................10
2.6.2 Liquids consumptions ...........................................................10
2.6.3 Material sampling..................................................................10
2.7 Circuit: Mill Ventilation Measurements.............................................11
2.8 Mill: Material Sampling.....................................................................12
2.9 Mill Visual Inspection .......................................................................12
2.10 Separator: Visual Inspection............................................................13
2.11 Fans: Visual Inspection....................................................................13
3 Data compilation .....................................................................................14
4 Raw meal grinding systems equipped with a ball mill .............................15
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1 What is a "Field" Audit?
The performance evolution with the time of a grinding system can be followed
through the process performance indicators. Regular in depth analysis of these
indicators is paramount to keep the efficiency of the grinding system at its top
through identification of optimisation actions or required additional studies and
investigations (fig 1).
The Field Audit consist of the following steps:
Gathering of the required information
Each cement type has a mill system operating point (throughput, mill
motor absorbed power, etc.) influenced, see limited, by the design values
of the different machines that compose the grinding system.
Determining the operating point and comparing it with the design values of
the main machines in the grinding circuit is the first step.
Standard representation of the operating conditions
The gathered raw operation data have to be further compiled in standard
performance document for future interpretation and comparison.
Circuit performance evaluation
Mill motor and system specific energy consumption related to product
fineness and composition
Hourly production related to mill feed characteristics and product fineness
Drying capacity (product temperature/residual moisture)
Mill control behavior and mill stability
Mechanical weak points list
Conclusions and proposals
Based on the weak points found and each case process particularities
conclusions can be drawn and proposals made.
The present document handles the "gathering of information" and its "standard
representation".
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2 Gathering of the design and operating information
2.1 Starting point for a Field Audit
2.1.1 Definition of the raw meal mix to realize the field audit with
and identification of quality targets (fig. 2)
In the case were more than one raw meal mix are produced is very important
to define the one to carry on the audit with. This definition depends on what
the audit targets are:
The one with the highest hourly throughput
The most produced
The one with the highest moisture content at the mill feed (when
evaluating the system drying capacity)
The above have to be completed with the quality targets and limits of the raw
meal mix: fineness on different sieves, residual moisture, etc. (see Annex I)
2.1.2 Conditions prior and during a Field Audit
Prior the audit
Calibration of the grinding system measuring devices as fresh feed
weight feeders, electrical counters, water and air flow meters, etc. is
necessary.
Conditions during the audit
The conclusions from an audit are based on the quality and representative
of the data collected.
It is a must to have a stable circuit operation during 6 - 8 hours (if
necessary the circuit will be operated manually).
Stable circuit operation means material flow stability (mill fresh feed and
external recirculated material).
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2.1.3 Logical realization order (fig. 3)
Define the raw meal type for the audit
Gathering of main machines design data (only first time and after
equipment modification)
Central Control Room visit
Circuit visual inspection
Field activities
Counters reading
Sampling
Measuring
Mill, separator and auxiliaries internal inspection
Data compilation, analysis and calculations
In Fig. 3a, an example of the distribution of activities for the 4 main teams is
made and an indication of the time allocation and order of activity is shown.
See Annex 16 and 17 for checklist and planning example.
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2.2 Design information from main machines
To know the design data from all the main machines in a grinding system is
very important because they are setting the frontiers of what can/could be done
with our grinding system. The data in annex 2 have to be completed with an
up to date grinding system flow sheet (typical example in fig. 4) and some
additional data as below indicated:
Feeding system
Process problems can have their source in the feed bin, for example
material segregation, the bin design & capacity must also be included in
the information package.
For the protection devices the nominal data are to be given (metal
detector: sensibility setting, and the magnetic separator: type (drum,
overband), installed power).
From the feeders the type and weighing range are required.
Hot gas generator
The heating capacity, the fuel type and gas temperature at the generator
outlet. A detailed flow sheet of the HGG installation.
Mill
Mill motor reducer nominal power
Mill body general drawing (see annex 3)
General drawings and wear profiles of the grinding tools, indicating
the type of material they are made off, achieved lifetime, initial weight
and final weight at then of lifetime, net & gross wear rates (annex 4).
Filters
For the main filters, mill and separator, indicate the design airflow
capacity, filtering surface, number and dimensions of bags, casing main
dimensions and a general drawing.
Fans
For each main fan (at least mill and separator fans) a characteristic curve
and wheel main dimensions as well as rotating speed and the flow
control device.
Transports
For each material transport in the flow sheet (fresh feed belt, mill outlet air
slide, separator feed air slide, etc.) the type and its transport design
capacity.
Control system
Short description of the control strategy used, the completed questionnaire
of annex 5 and short term trends, less than 6 [h] per screen, of the fresh
feed, mill and bucket elevator motor, mill differential pressure, mill inlet and
Page 6 of 16
outlet temperatures and mill vibrations covering 2 - 3 days of operation and
a start/stop sequence.
2.3 Control Room: Mill Control System & Strategy, Operation
Data & Trends
In modern factories the mill circuit's most important operating data are visible
on the control screens (see fig. 5). These systems allow e.g. the evaluation of
production parameters by statistics and trends. The following points have to be
checked:
Automatic Mill Control System
Which inputs does the control system use and are they reliable? (e.g: kW's
etc.).
Automatic Mill Control Strategy
What are the control loops used? (e.g. PID-control of fresh feed as a
function of mill motor power, etc.)? What are the set points for the
controlling parameters? Are the action times in accordance to the reaction
time of the mill?
Control Screens
With the data on the control screen it is possible to cross - check the field
measurements done during the performance test (specially temperature
and static pressures, annex 6).
Production parameter trends
A trend analysis of the production most important parameters (fresh feed
rate, mill motor power, mill pressure drop, mill vibrations, separator speed,
mill airflow, mill inlet and outlet temperatures, external recirculation rate) is
needed to establish if during the performance test the circuit was
stable.
Unstable operating conditions will make the test less representative or even
unusable.
If circuit instability is observed, which can be related to the performance of
the automatic mill control system, it is recommended to carry out the
performance test in manual operation.
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2.4 Circuit Visual Inspection
The first step of the fieldwork can be undertaken: a visual inspection of the
whole circuit (fig. 6). The visual inspection means looking at, listening to and
touching, to get a feeling on how the circuit is processing material, liquids
and gas.
Some points to pay attention to are:
Mill feed system
Can the bin design produce a material segregation that affects cyclically
mill performance? How full are the feeders? Is the material flow well
centered on the belt? Where and how will be the material samples taken?
Mill inlet chute
Are there material build ups? What type of feed device is used? Is it heated
up? How does the hot gas ducting layout looks like? Are all the sides
warm? Are they any sign of wear ? In case of a triple gate, what is the
opening/closing sequence?
Mill body
Where are the mill vibration measuring devices positioned? Are they many
possibilities for false air inlet? Are the rollers moving up and down much?
Mill ventilation system
Are the kiln ID fan in overpressure? How many and where are the gas flow
control damper positioned? What type of damper are they? Is there any
recirculation duct to the mill inlet? How do look like the different duct
connections? How is the hot gas distributed to the mill body? In what state
are the expansion joints? Can false air leaks be perceived? Are all the
ducts properly insulated?
Are the measuring/sampling points in an optimal position? How is the mill
filter duct layout? Which is the mill fan damper position? Are any other
equipment dedusted through the mill filter? Fan casing design?
Transport, ducting, auxiliary dedusting & sampler
Air slide blowers and blowing points? Air slide angles? Is there any air slide
in overpressure? How flows the material in each air slide? Is there any
accumulation of coarse material?
Do the ducts have material deposition during the operation?
Where is the sampler for finished product positioned? Is there any
dedusting point nearby?
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Where are the sampling points for the audit positioned?
2.5 Energy Measurements
2.5.1 Electrical energy consumption
The electrical energy consumption has to be measured because:
Electrical power consumption highly contribute to the manufacturing
cost
In a cement plant up to 25 [%] of the electrical energy consumption can be
for raw meal grinding resulting in a specific electrical cost from 0.6 to
2.8 [USD/t] depending on the electricity cost.
The possible cuttings in this cost will help to justify the
implementation of the optimisation actions.
Installed power in one motor can be one of the limiting factors
It is possible that the whole grinding circuit performance is limited just
because one motor has not enough installed power. For example, when
the motor of the separator rotor, and/or its reducer, are too small and
separator cannot be operated with maximum air.
Calculation of specific electrical energy consumption
The specific energy consumption related to the product composition and
fineness is vital for the system performance evaluation.
The electrical power has to be measured at the available counters (see
annex 7) or calculated from current intensity measurement, whenever
possible; for the following equipments (fig. 7):
Mill motor
Mill fan motor
Separator rotor motor
Separator fan motor
Bucket elevator (for material recirculation) motor
The whole grinding system
Counters must be visually noted at the counter, not through software or other
potential error influences. Avoid any need for calculations, use kWh-meters
were possible. Confirm counter factors are correct. Analyse the Line Diagram
to make sure the measurements do not include other machinery
2.5.2 Fuel consumption
In case of very high mill feed moisture the kiln gas drying capacity in not
sufficient and the use of a hot gas generator is required resulting in
significant increase of the operating cost for the raw meal preparation.
Therefore, as for the electrical energy, the possible savings on fuel will
allow justifying the implementation of the optimisation actions.
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2.6 Circuit: Material Measurements & Sampling
The amount and type of material being processed, its fineness, temperature
and moisture content after each of the process steps are key information for
the grinding circuit performance evaluation.
2.6.1 Material throughput
The circuit hourly throughput is one of the key process performance indicator
(KPI). During a "Field audit" it is necessary to measure this KPI with the
indication of the weight feeders cross - checked with the readings from the
field totalizers for each raw meal mix component (see annex 6).
2.6.2 Liquids consumptions
The water injection into the hot gas conditioning tower and the mill have to
be measured (see annex 6 & 7).
2.6.3 Material sampling
Figure 8 presents a typical example of necessary sampling points for a
cement mill system.
Taking samples and analysis (fig 9)
In annex 8 some indications for sampling are given.
The following analyses are to be done with the taken samples:
Sample Sample Quantity Analysis
reference [kg]
Limestone A 10 Cumulated residue on the
sieves, for example:
Clay B
50, 25, 16, 8, 4, 2, 1 [mm]
Iron ore C
Temperature [°C]
Sand D
Moisture: [%] H2O
Mill reject MR
Cyclones fines CF (*) 0.5 [%] Residue on 90 & 200 [µm] (1)
Filter dust FD Laser 0 - 200 [µm] - at least for
Raw meal silo feed RM the samples marked with an (*)
Temperature [°C] (at least CF)
Residual moisture (at least CF)
(1) The sieves normally used for product quality control.
(2) Only if used for product quality control.
The results from the sample sieving and laser analysis can be plotted on the
documents presented in annex 9 & 10. In special cases, to evaluate the
separator performance a sample of the separator returns can be taken with a
screw sampler that goes through the mill casing and the separator cone.
For raw meal grinding systems equipped with ball mills see chapter 4 in the
present document for possible sampling points.
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2.7 Circuit: Mill Ventilation Measurements
Air and/or hot gas in a grinding circuit are used for drying, cooling,
transporting and separating purposes. Disturbances of air/hot gas quantity
and/or distribution will have a negative influence on the circuit performance.
Measuring
Also here good measurements airflow, oxygen content, static pressure and
temperature are critical for the later evaluation (see annex 11, 12 & 13).
Mill circuit measuring points
As for the material sampling and measurements the air/gas measuring
points have to be adapted to the circuit particularities. An example is given
in fig. 10. Many values can be calculated (eg. HGG primary air)
Point Point Measure
reference
Hot gas generator (1):
Primary air fan HGPA Static pressure
Secondary air fan HGSA Temperature
Fresh air HGFA Volume flow rate
Preheating tower outlet or PHO / CTI Static pressure
conditioning tower inlet CTO Temperature
Conditioning tower outlet DO [%]O2
Direct operation duct MR Volume flow rate
Mill recirculation duct MI
Mill inlet MO
Mill outlet CO
Cyclones outlet MFO
Mill fan outlet FI
Filter inlet FO
Filter outlet FFO
Filter fan outlet PHO / CTO
Preheating tower outlet or KM
Conditioning tower inlet CO
Duct to coal mill system FA
Mill cyclones outlet MR
Fresh air (1) DO
Mill recirculation duct FFO
Direct operation duct
Filter fan outlet
(1) If in operation
The airflow measurements have to allow making an airflow balance that
completes the balance that can be done with the [%]O2 measurements.
It is not always possible to find an optimal point for airflow measurements.
In this case the air/gas volume can also be calculated based on the fan
characteristic curves using the fan motor absorbed power, the
temperature, the static pressures before/ after the fan.
For raw meal grinding systems equipped with ball mills see Chapter 4.
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2.8 Mill: Material Sampling
The sampling of material on the table is currently under investigation.
2.9 Mill Visual Inspection
The state of mill internals (table and roller liners, armour and nozzle ring,
housing liner plates, etc.), the material level and distribution on the grinding
table is important information for the mill grinding efficiency evaluation (fig. 11).
Mill internals
Grinding tools wear profile and state
The wear profile of the grinding tools is important information to
evaluate if the grinding tools material is optimal, it allows taking decision
on wear parts management, for example, planning the replacement or
the reversion of the rollers, etc.
Nozzle ring and armour rings
The wear pattern and inclination of the armour and the nozzle rings
allow estimation of the gas flow to the separator.
Also look for possible gaps between the nozzle ring and the mill table
that would allow material falling directly to the scrapers area.
Mill housing and separator grits
The wear pattern on these two internal parts gives additional
information on air and material path inside the mill. Additionally the
geometry of the separator grits cone and its design can have a great
influence on the separator efficiency.
Mill bottom area: scrapping and hot gas inlet
To avoid problems related with bad shape of the scrapers or reduction
of hot gas flow through the mill due to material build ups.
Dam ring height
The dam ring height influences de level of material on the grinding table.
Controlling its remaining height is important to ensure proper mill
performance.
Material level and distribution on the table
The material distribution on the table has to be looked at together with the
mill main organs geometry (feed chute, roller supports, etc.) aiming to
understand what the material flow pattern on the table is.
Water injection
Position, orientation and state of the water injectors has to be verified to
make sure that the water injection flow meet at the right place with the
material flow that will go underneath the rollers.
Documention of the mill inspection with photos is good practice (fig 12).
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2.10 Separator: Visual Inspection
The separator optimal operation depends, among others, on adequate air and
material distribution at the different phases of the separation process. Attention
has to be paid to the following points (fig 13):
Guide vanes
The wear pattern indicates the separator feed and gas flow path. If wear is
less, the guide vanes can be painted to observe the resulting pattern.
Rotor cage plates
Wear pattern, state of fixation
Separator dynamic seal
A dynamic seal in a good state is of paramount importance to avoid
contamination of the separator fines by coarse particle from the feed.
2.11 Fans: Visual Inspection
Air is one of the main actors participating in optimal grinding circuit
performance. The state of fans, especially ones for separator and mill, has to
be checked to be sure they are performing according to nominal capacity.
The points to be checked on a fan are the following (fig. 14):
Inlet connection (1)
Sketch the layout of the fan inlet connection and the measure the
dimensions to calculate the air inlet speed.
Venturi (2)
Check the surface state and the presence of holes due to wear. Measure
the gap between the venturi and the fan wheel all along the circumference
and establish the relative position between both. Sketch the venturi to allow
airspeed calculation.
Rotor
Rotation sense: Verify the rotation sense according to stator design
Geometry: Verify that the installed fan wheel has geometry similar to
the original design given by the fan manufacturer.
Wear pattern: Sketch the wear pattern of the fan wheel
Material build ups: Look for and sketch any material build ups
Outlet connection
Sketch the layout of the fan inlet connection and the measure the
dimensions to calculate the air outlet speed.
The information above, together with the fan operation point (pressures,
rotation speed, vibrations level, etc.) is useful when identifying why a fan could
be performing below its nominal capacity.
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3 Data compilation
All the gathered data have to be compiled in such a way that they summarise in
a little number of sheets. These documents are:
Performance test sheet (fig. 15 and annex 15)
This sheet is a data summary that represents the grinding circuit operating
conditions during the "Performance test".
Circuit layout (fig. 4)
Fresh feed particle size distribution (annex 9)
Grinding tools wear profiles (annex 4)
Mill internal inspection (fig. 11)
Circuit samples particle size distribution (annex 10)
Mill control questionnaire (annex 5)
Mill data sheet (annex 2)
Additional main machines data
Raw mix requirement data sheet (annex 1)
With these documents it can be considered that there are enough data for the
evaluation of the grinding system.
Page 14 of 16
4 Raw meal grinding systems equipped with a ball
mill
Within the Holcim Group, even if the vertical roller mill is the preferred
machine for raw meal grinding, there are other grinding systems.
The sampling and the measuring points for each of these systems are
given in the figures 16 to 21.
These systems are equipped with an end discharge, a centre discharge or
an air - swept mill.
The sampling and measuring points of the whole raw meal system can be
completed replacing the vertical roller mill system in figures 7 & 8 by one
of the mentioned mill system.
As these systems are equipped with a ball mill, see "Field audit for
cement ball mill system for the points to be checked, mill inspection,
separator, etc., and the required annex.
Page 15 of 16
Bibliography
Roller mills (VA 94/4167/E)
Raw grinding systems (VA 93/4031/E)
Annex:
1. Product and production data sheet
2. Mill data sheet
3. Mill general drawing
4. Grinding tools
5. Mill control questionnaire
6. CCR measurements and readings
7. Field measurements
8. Taking samples
9. Feed granulometry and moisture
10. Circuit samples granulometry
11. Airflow measurements
12. Prandtl sheet
13. False air calculation
14. Gas flows calculation
15. Performance test data sheet
16. B-Level Audit Pre-start Checklist
17. B-Level Audit Planner
Page 16 of 16
