Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 1 / 16
Technical Report No.
Installation Commissioning EC&I Retrofit / Modification Service
Codeword : Ilara RM/Ilara CS Mill 1/ Mill 2
Code no. : P.11002/ P.12610
Client : BUA Cement Company
Reporting period : 15.09.2021 – 18.09.2021
Mill type : LM 56.4 RM with LDC/ LM 53.3+3 CS with LDC
Plant type : Raw Meal Grinding Plant/ Clinker Grinding Plants
Year of manufac. : 2017
Issued on : 17.09.2021
Reporter : Lukman Adeboye
Structure:
1. Introduction
2. Raw Material Information
3. Mill Behaviour
4. Mill and Classifier Internal Inspection
5. Identified Problems, Categorized
6. Conclusion
7. Recommendations
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 2 / 16
1. Introduction
This is a courtesy visit to review operational behaviour of the mills and also check the
actual physical conditions of the mill component parts. Furthermore, to introduce our
Pronamic parts and services. This technical report documents the mill parameters and
critical findings from stoppage inspection. The intervention period is between
15.09.2021 and 18.09.2021, including travel days. Contacts at site were Mr. Adeyinka
Adesola, Head of Quality, Process and Environment, Email:
[email protected], Tel: +234 8034889888, and Mr. Benjamin Odang,
Process Manager. Email: [email protected] , Tel: +234 8166078345.
2. Raw Mill
Data, LM56.4 RM
Machine type LM 56.4 RM
Motor Power 3400 kW
Mill Fan Motor Power 4000 kW
Mill Motor Current 215.6 A
Fan Motor Current 251.5 A
Table speed max. 24.08 rpm
Gearbox Type Renk KPBV 160, 3400 kW
Feed rate (guarantee) 465 t/h
Max feed size *(Guarantee) 125 mm
Feed moisture *(Guarantee) average 6 %
Product moisture ≤1.0 %
Residue 90μm ≤12 %
M-Roller (nos.) 4
Table Diameter 5600 mm
HSLM Cabinet (nos.) 2
Table 1: Mill Design
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 3 / 16
2.1 Raw Mill Behaviour
The mill was met in running condition, hence an opportunity to document the mill
running parameters. There was a plan to later stop the raw mill for stoppage
inspection, but this did not hold due to the need to continuously run the raw mill.
test date 18.03.2019 15.09.2021
feed (without reject) [t/h] 482 470
reject circulation [t/h] 90 75
total feed [t/h] 572 545
feed moisture [%-H2O] 2.04 2.1
product rate [t/h] 474 461
residue 90µm (mesh 170) [m-%] 12.2 16.5
product moisture at
105°C [%-H2O] 0.2 0.2
mill inlet draft left [mbar] -31 -8.9
mill inlet draft right [mbar] -34 -12
mill outlet draft [mbar] -84.5 -100
mill differential pressure [mbar] 54.3 91.1
mill inlet temperature left [°C] 128 190
mill inlet temperature right [°C] 126 189
mill outlet temperature [°C] 81 90
air flow cyclone outlet [m³/h] 932500 840500
working press. M-roller [bar] 97 75
mill vibration time
average [mm/s] 10 6
classifier rotor speed [%] 82 64
LM motor current [A] 183 135
fan motor current [A] 214 210
classifier motor current [A] 302 230
LM-Motor power [kW] 3329 2580
fan motor power [kW] 3917 3894
classifier motor power [kW] 121 62.5
Recirculation Damper [%] 96 55
Stack Damper [%] 60 94
Fresh Air Damper [%] 27 0
Hot Gas Damper [%] 25 97.2
Bypass Damper [%] 97 97
Fan Inlet Damper [%] 85 94
Table 2: Comparative Mill Operating Conditions
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 4 / 16
2.2 Raw Mill Observation
The mill feed rate has dropped by 11t/h while the residue on 90µm is now 16.5% as
against 12.2%. Operationally, the levers to achieve the prior throughput and product
quality still have sufficient margins, namely: grinding pressure, classifier speed and mill
motor power. Since stoppage inspection was not possible during this visit, there is no
information whether or not there is a mechanical constraint to reach better mill
performance.
The mill inlet pressures now indicate values in a good range (-8.9mbar) compared to the
high negative pressure value of -31mbar. This should be sustained. However, there in
increased pressure drop across the mill, evidenced by high mill outlet pressure and mill
differential pressure. This may have resulted from a number of factors such as false air
inleaks and/or modified louvre ring area.
3. Clinker Mills
Data, LM53.3+3 CS
Machine type LM 53.3+3 CS
Motor Power 4200 kW
Mill Fan Motor Power 2500 kW
Mill Motor Current 264.4 A
Fan Motor Current 261.8 A
Table speed max. 22.77 rpm
Gearbox Type Renk KPBV 160, 4200 kW
Feed rate (guarantee) OPC: 200 t/h @3200cm2/g; cem II: 200 t/h@3400cm2/g
Max feed size *(Guarantee) 115 mm
Feed moisture *(Guarantee) (Average)OPC: 0.64%; cem II: 1.73%
Product moisture 0.2 %
M-roller (nos.) 3
Table Diameter 5300 mm
HSLM Cabinet (nos.) 1
Table 3: Mill Design
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 5 / 16
3.1 Clinker Mill 1 Behaviour
The mill was met in running condition, hence an opportunity to document the mill
running parameters. There was a plan to later stop the clinker mill 1 for stoppage
inspection, but this did not hold due to the need to continuously run the clinker mill 1.
test date 10.04.2019 15.09.2021
clinker/gyp/l.stone [%] 90.8/4.2/5 85.5/2.5/12
feed (without reject) [t/h] 172 112
reject circulation [t/h] 14 18
total feed [t/h] 186 130
[%-
feed moisture H2O] 0.02 0.04
product rate [t/h] 172.3 112.2
residue 90µm (mesh
170) [m-%] 4.1 4.3
Blaine [cm2/g] 3891 4450
product moisture at [%-
105°C H2O] 0.2 0.2
mill inlet draft [mbar] -5.6 -2.8
mill outlet draft [mbar] -42.2 -25.9
mill differential pressure [mbar] 36.6 23.1
mill inlet temperature [°C] 98.7 112.5
mill outlet temperature [°C] 94 90
filter outlet temperature [°C] 92 89
air flow cyclone outlet [m³/h] 679800 4441000
working press. M-roller [bar] 107 115
counter press. M-roller [bar] 19 22
mill vibration time
average [mm/s] 3.9 3.3
classifier rotor speed [%] 90 77
LM motor current [A] 189 153
fan motor current [A] 102 77
classifier motor current [A] 384 259
LM-Motor power [kW] 3529 2780
fan motor power [kW] 1924 1440
classifier motor power [kW] 175 87
recirculation damper [%] 65 51
stack damper [%] 99 97
fresh air damper [%] 98 0
hot gas damper [%] 100 100
fan inlet damper [%] 85 58.4
Table 4: Comparative Mill Operating Conditions
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 6 / 16
3.2 Clinker Mill 1 Observation
The product finess target has changed from the previous 3800cm2/g to 4500cm2/g. The
more stringent the product fineness becomes, the less the mill throughput becomes. The
mill feed rate has obviously dropped from 171t/h to 112t/h. The optimum value has to be
trialied keeping in mind the available margins. Furthermore, water injection has increased
from 42.5l/ton to 50l/ton, again, the optimum value has to be trialed.
3.3 Clinker Mill 2 Behaviour
Clinker mill 2 operation data was not recorded.
3.4 Clinker Mill 2 Stoppage Inspection
The mill internals as well as the classifier internals and ring duct were inspected. The
below report will focus on areas that require attention to be given.
3.4.1 The grinding parts
The grinding roller tires are of Ni-Hard type which has been recently rewelded by the
welding company Castolin on 14th February 2021. The latest wear measurement taken by
the customer would be shared when made available.
Figure 1: Condition of grinding rollers
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 7 / 16
The grinding plates have also been rewelded with minimal wear as shown in the the
picture below.
Figure 2: Condition of grinding plate
The dam ring has been further increased by the customer to 450mm from 436mm. There is
significant wear on the support ring. There is advanced wear on the working surface of all
4 rollers. Refer attached picture of one roller as an example.
Figure 3: Condition of the dam ring and support ring
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 8 / 16
The sealing bars of the lever sealing have advanced wear on them.
Figure 4: Condition of the sealing bars of the lever sealing
3.4.2 Other component Parts
The seal air hose for M-Roller 2 is loose at the roller connection point as shown below.
Figure 5: Loose sealing hose connection
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 9 / 16
The leak oil collection container for all HSSW hydraulic cylinders are missing
Figure 6: Missing leakmoil container
Wear on the feed chute.
Figure 7: Wear on the feed chute
The louvre ring area is an important area of the mill internals which should not be altered
at will. This area has been modified without Loesche`s consent as you will find below.
The alteration has consequences.
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 10 / 16
Figure 8: Louvre ring area modified by customer (unauthorised)
Figure 9: Louvre ring covering during commissioning period
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 11 / 16
Figure 10: Current louvre ring covering
Louvre ring area
At commissioning time At the moment
Fully Covered 15 28
With Insert Plates 6 3
Fully Opened 33 23
Total 54 54
Table 5: Comparative study of louvre ring area at commissioning time and at the moment
The mean area which was approximately 4.02m2 has now been effectively reduced to
approx. 2.80m2. By this action, the mill differential pressure and the velocity at the louvre
ring area will increase, air volume will decrease. This will impact negatively on the mill
throughput and accelerate wear problems of the mill internal components.
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 12 / 16
The densit wear protection for the inner part of the classifier upper housing is failing in
some parts.
Figures 11 & 12: Failing densit wear protection at the classifier upper housing
There is a sign oil lubrication oil leakage at the pump seal of the classifier gearbox
lubrication pump and lubrication pipeline.
Figures 13 & 14: Classifier gearbox lube oil leakage from pipeline and pump seal
The distance dimensions behind the M-rollers when rested on the buffer to the dam – and
support rings were recorded and found to be within acceptable limit.
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 13 / 16
Distance Recommended
Distance "C"
"D"
Distance "C"
Roller 1 20 80
Roller 2 20 80 15 ±5
Roller 3 20 80
Table 6: Distance from roller to dam and support ring
Pooled hydraulic oil on the HSLM cabinet to be cleaned and always kept dry in order to
monitor new leakage from the fittings of the HLSM cabinet.
Figures 15: condition of the HSLM cabinet
Pooled M-roller lubrication oil at the base of the HSMS cabinet to be cleaned for the same
reason mentioned above for the HSLM cabinet
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 14 / 16
Figures 16: condition of the HSMS cabinet
Oversized mill feed additive material found. Mazimum allowable mill material size is
115mm.
Figures 17: Oversized limestone – mill feed material
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 15 / 16
Figures 18: Typical values of N2 charge in bladder accumulator
4.0 Recommendations
1. The increased product fineness (Blaine) from 3800cm2/g to 4500cm2/g will reduce the
mill throughput. The optimum mill throughput has to be trialed to determine the new
base value
2. Restore the louvre ring area to the as-built condition to cover the lost air volume and
mill throughput and reduce wear associated with increased air velocity
3. M-rollers speed sensors to be replaced, if broken as these sensors give roller bearing
information as well
4. Repair wear on mill feed chute
5. Secure M-roller 2 seal air hose to protect the roller bearings
6. Average N2 charge of bladder accumulators to be restored to 40bar from 35bar
7. Optimise mill water injection, current value is 50 l/ton
8. Loesche offers upgradation projects such as dynamic S-roller modification as well as
smart drives (LM drive and mill fan drive). Up to 15% additional capacity boost can be
obtained from the clinker mills. Contact our Loesche Germany office for additional
information ([email protected]).
9. Regular wear measurement with Loesche`s supplied profile gauge in order to retain the
tire profile at all times. Loesche offers Pronamic wear parts and services to continuously
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
Codeword: Ilara RM/CS
Code no.: P.11002/P.12610
Date: 17.09.2021 Technical Report
Name: Lukman Adeboye
Pages: 16 / 16
assure the reliability of your mills. Our pronamic services offer complementary audit and
optimisation to restore your mills to their full potentials. Contact our Loesche Middle East
office for additional information ([email protected]).
10. Restore the support ring to its previous dimension
5.0 Recommended Spares
Part List Number Parts
1. 10283446 2 nos. hydraulic cylinders/mill
2. 2 nos. H2 multi-layer promanic tires for M-roller tyres for
the clinker mills and 2 nos. for the raw mill
3. 10195786 6 nos. proximity switch for M-roller position monitoring
4. Filters for HSLM and HSMS cabinets
5. 10229827 12 nos. Lever sealing bars (pos. 7) drawing number 069079-
00-0
Ilara RM_CS P.11002_P.12610 - 15092021 - 18092021 - Technichal Report 15092021 – 18092021 Rev. 0 / 31.08.2013 / FR
