REPORT ON RAW MILL SECTION

BY

ONWUKWE JUSTUS C
 TABLE OF CONTENT
- Raw material mining
- Crusher
- Classification of raw material for cement production
- Composition of raw mix
- Starking or pilling method
- Starker operation
- Method of reclaiming material
- Reclaimer operation
- Machine control mode
- Pile estimation
- Interlocks
- Component of discharge chute
- Material transport
- Lube room
- Component of vertical roller mill
- Mill specification
- Basic operation parameters
 RAW MATERIAL MINING

All the raw material used for cement production in the O C P plant are gotten
from the mines except Gypsum which is imported from spain. Clay and latherite
are directly escavated from the top surface of the earth. Iimestone is mined by
blasting of the rock deposite

LIMESTONE MINING

- Scooping or removal of the overburden material to expose the limestone

-Make a hole of about 2 to 3 m deep
- Apply a explosive material into the hole . The explosive is a mixture of Ammonia
[6 part] to one part of diesel. The explosive is connected to a wire connection
which energises the explosive for it to blast the rock. Some of the material
gotten might be too big which are broken down further mechanically be the
crushers.
CRUSHERS
 Main Crusher ; for crushing of limestone
Additive Crusher; for crushing of clay and latherite
RAW MATERIAL FOR CEMENT PRODUCTION
Limestone
Clay
Latherite
Gypsum
CLASSIFICATION OF RAW MATERIAL FOR CEMENT PRODUCTION
1,Calcarus material ( High grade). They are basically limestone
2, Argilaceous Material. They are majorly the additives eg. Clay ,latherite and
schist. Schist are overburden material found on top of the soil. Sometimes
schist is used in place of clay.
ADVANTAGES OF CLAY OVER SHIRST
1, Clay material are free from donomite (Mgo) except those at it’s transition
to clay from schist. Donomite affect the calcination process. It also causes
blockage at the cyclone feed pipe leading to cyclone jam.
DISADVANTAGES OF CLAY
It has high moisture content especially during the raining season. It sticky in
nature especially when it contain high water content. This can as well
blockage at the cyclone feed pipe.
ADVANTAGES OF SHIRST OVER CLAY
1, Flacky in nature
2, Has lower water retention capacity over clay.
DIADVANTAGE OF SHIRST
It contain high percentage of donomite than clay.
REMOVAL OF DONOMITE (MgO) FROM THE SYSTEM
The can be removed from the system through alkaline By- pass by the use of
a chemical (iodine and fluorine vapour) to form magnesium iodine which is not
harmful to the system. When fluorine vapour is used, the compound form with
MgO help to form coating at the burning zone of the kiln thereby reducing the
effect of high temperature in the burning zone of the kiln to the system.
Accumulation of alkali in the system can as well be removed by the addition of
gypsum.
 COMPOSITION OF RAW MIX
Raw material composition Oxide present (Major)
Limestone Limestone (CaCO3) CaO
Clay Alumina(AL2O3), Silica Aluminum Oxide, Silicon
Oxide (SiO2)
Latherite Iron (ferrite) Fe2O3

APPROXIMATE ANALYSIS OF RAW MIX AND THEIR PERCENTAGE

COMPOSITION
OXIDES (MAJOR) % COMPOSTION IN RAW MIX
CaO 65 - 68
SiO2 20 - 23
AL2O3 4 - 6
Fe2O3 2 - 4

OXIDE (MINOR) % COMPOSITION

MgO 1 - 5
Mn2O3 0.1 - 3
TiO2 0.1 - 1
SiO2 0.1 - 2
K2O 0.1 - 1
Na2O 0.1 - 0.5

STARKING OR PILLING METHOD

1, Chevron : Stacking in layers along a single axis with the feed conveyor sweeping
and forward along the length of the pile
2, Windrow : Stacking in longitudinal strips side by side and then in a successive
layers. This avoids the segregation which characterizes chevron stacking. This
method of stacking requires a more complex and expensive stacking belt
arrangement
3, Cone: Stacking material at a particular point to form a full pile. It is a step wise
method of stacking of material to form a successive cone.

PILES AT THE O C P MIX STORAGE AND COPMOSITION

PILE NO COMPOSITION STARKING QUANTITY HEIGHT (m)
METHOD (tones)
1 (A& B) Mix Grade Chevron 40,800 12.5
2 (A & B) Mix Grade Chevron 40,800 12.5
3 Mix Grade Chevron 20,700 12.5
4 Mix Grade Chevron 20,700 12.5
5 Clay Cone 5,000 6.5
6 Latherite Cone 5,000 6.5
7 High Grade Cone 5,000 6.5
8 High Grade Cone 5,000 6.5
9 Gypsum Cone 5,000 6.5
10 Gypsum Cone 5,000 6.5

STACKER
This the machine used in pilling the raw material at the mix storage
TYPES OF STACKER
1, Boom stacker
2, Wheel bucket stacker
3, Bridge stacker
4, chain bucket stacker
5, slewing and luffing stacker

PILES IN THE MIX STORAGE AND THEIR TAG NO

Stacker tag no Stacker belt Pile no
131 ST 100 131 BC 100 1 to 8
232 ST 200 232 BC 200 9 to 10

STACKER OPERATION
M11 = Belt conveyor running
M12 = Slewing movement of the stacker jib from one side to another. Example
From pile 2 to pile 4. Clockwise and anticlockwise
M17 = Hydraulic unite. Help to adjust the height of the stacker jib. Jip raise and jip
Down
M31 and M32 :Bogie drive, forward and backward
M51 and M35 : Cable drum

NOTE
The name of the material left at the edge of the pile in which the reclaimer could
not reclaim is called DEAD EDGE. The edge of the pile that can be reclaimed is
called the SLOPE EDGE.
MAGNETIC POLE : It indicate to the stacker the end of a pile. And to stop the
stacker. It shows the beginning and the end of a pile.
MECHANICAL STOPPER: Help to stop the stacker should in any case the magnetic
fails.
MECHANICAL READER : It is fixed at the stacker and as well as on the magnetic
pole .It works in conjunction with the magnetic pole to restrict the movement of
the stacker from one pile to another.

STACKING A NEW PILE

Jib height : Max = 12%
Minimum = 8%
The piling is stopped at 85% to prevent the stacker from kissing the pile. Standard
length to width ratio of a pile is 5 : 1

METHOD OF RECLAIMING MATERIAL

1, End Reclaim : this is the a method of reclaiming a pile by taking an entire end
face with a transfer scraper at floor level moving material to a discharge
conveyor. It involves reclaiming from the side down to the dead edge.
2, Side Reclaim : A boom mounted scraper working end to end along the side of
the pile. This gives less effective blending and recovery flow rate is not constant .
RECLAIMER BELT RECLAIMING TO PILE RECLAIMING FROM
131 R 300 131BC 400 1 and 2
132 R 300 132 BC 400 3 and 4
133 R 300 133 BC 500 5–8
232 R 300 232 BC 100 9 – 10

RECLAIMER OPERATION ( 131 AND 132 R 300)

M17 = Tensioning the bucket
M11 = Running the bucket
M21 = Raking device, forward and reverse movement . maximum speed 80%
M31 + M32 = shunting device
M14 = Lubrication system for the bucket
M31 = cable drum

133 R 300 AND 232 R 300

M11 = running bucket
M14 + M14 = lubricating the chain
M25 + M26 = Hoist. Jip raise and jip down
PREECAUTION :Do not reclaim above 2%. This is the maximum cut. Above this,
will cause material jam and the reclaimer will trip. The reclaimer jip should be
raised to 100% position before the machine can be on shaunting. This is to enable
the machine to move to different position within the mix storage. It will enable
interlock to be broken.
M31 + M32 = Bogie drive, forward and backward
RECLAIMER CHAIN LUBRICATION
The lubrication of the chain is done when the reclaimer chain is dried.
Signs of Dried Rollers

1, Dragging of the chain

2, Unusual noise

Lubrication Procedure

M11
M14 = Lubricate ( 5 minute)
Stop lubrication after 5 minutes. Over lubrication can cause chain derail

LIMIT FORWARD ;Indicate machine forward stoppage

LIMIT REVERSE ; Indicate machine stoppage at reverse motion

COLLISION FORWARD; Indicate machine stoppage when it hit a hard material. It
makes use of sensor attached to a plate

COLLISION REVERSE; Shows that there is too much material beside the bucket or
high material cut.

CONTROL MODE

Central Control : control of the machine the CCR operator

Advantage of CCR mode: Reduces labour

Disadvantage: Cannot stop the machine when a strange object is found on
the pile

Local Control ; it is also known as automatic control

Advantage of local control : Stop the machine immediately the belt stops.
Resist interlock.
Disadvantages of local control: slower than local test. Does not allow the
operator to take a cut as desired. Not convenient for reclaiming material from
small pile

Local Test; It is also called manual control. In this case the site operator has total
control of the machine.
Advantages of Local Test : it is faster than local control. The machine can be
stopped when strange object is found on the pile
Disadvantages of local Test : machine will not stop when the belt stopped
except manually. This can lead to material jam and spillages.

PILE ESTIMATION

In – between beams in pile 1 to 4 is estimated to be between 3000 to 3500 tones.

In – between beams in pile 5 to 10 is estimated to be 1000 tones.

INTERLOCKS

1, Two machine cannot be on the same pile except the machines is on local
control mode.
2, Reclaimer 133 R 300 and 232 R 300 must be on shaunting position before
they can be move from one pile to another.
3, Stacker can only be slew only when it is inside pile

COMPONENT OF DISCHARGE CHUT

Deflector Plate : Channel the material to the next transport system (belt).
Reduces the speed at which the material falls on the next belt thereby reducing
tears and wears.

Baffle Plate : Channel material directly to the next belt and as well protect the
discharge chut plate from material wears

Side Scrapper : removes material that stick to the belt

MATERIAL TRANSPORT
Additive Line

133 R 300

133 BC 500

143 BC 100

143BC 150
145 DG 170

REJECT 143 BC 200 145 DG 240

LINE 2
143 BC 350

143 BC 250

143 BC 300
 LATHERITE BIN 311BIN 400 CLAY BIN 311 BI 200 HIGH GRADE BIN

311 WF 450 311 WF 250 31 BI300,311WF350

MIX GRADE LINE

RECLAIMER 131 BC 400 141DG360

REJECT
141 BC 100

142 BC 300
141 BC 300

MIX GRADE BIN MIX GRADE BIN

 TRANSPORT SYSTEM FROM WEIGH BIN TO THE MILL

WEIGH FEEDER

311 BC 600

311 BC 660
DG

REJECT BIN

321RF090

RAW MILL

321 BC 270 321BC220

REJECT

WEIGH FEEDER BIN

Weigh feeder is also called variable set point feeders because it feeds according to the variable
set point.

MATERIAL CODE QUANTITY (TONES)

MIX GRADE 311 WF 150 900
HIGH GRADE 311 WF 350 250
CLAY 311 WF 250 200
LATTHERITE 311 WF 450 300

The mix grade , high grade and latherite are made of lamella plate conveyor while the clay
weigh feeders is made of belt conveyor. PIN GATE is use to stop the flow of material at the
weigh feeder bin during maintenance. The mix grade bin has 49 pin gate

RAW MILL ID FAN FN400

Draft hot gas from raw mill through the high efficiency cyclone through SD415 and LD420.
SD415 is manually opened. The flow is controlled at the CCR using LD420. The hot gas from the
preheater into the raw mill is controlled using SD425 and LD430. SD425 is manually opened
while LD430 is actually used to control the flow of hot gas into the mill.

LUBE ROOM

MAAG GEAR LUBRICATION SYSTEM LQ145 . The maag gear lubrication unit supply oil for
cooling the gear box and for reducing wear. The gear box drives the table. It made up of two
pumps, the high pressure and low pressure pump. The high pressure pump supplies oil to the
high pressure line and the low pressure pump supplies oil to the low pressure line. The low
pressure have 4 small motor while the high pressure is made of 2 bigger motors. The low
pressure pump supply oil for the lubrication of the maag gear box. The high pressure pump hold
the table to the grinding piston with the aid 15 hoses called trust pad. The hot oil coming back
from the maag gear is cooled using a heat exchanger to about 20C. the maag gear is a three
stage input reducer. The viscosity of the used is 320.

HYDRAULIC UNIT HY110: viscosity = 46 , capacity of 1200 litres

It is responsible for the grinding pressure of the rollers. It has a pump that can pump oil to the
rollers through a cylindrical shaft. There is a spring action as a result nitrogen action in the
cylinder for the grinding action. The Nitrogen accumulators has a valve that supply pressure to
the piston. The unit is consist of a filter which filters the oil before they are returned to the tank
for recirculation. It consist of system 1 and 2 with each valve block. System 1 = for roller 1 and 3
, system 2 = for 2 and 4.
NB; Bladder and Piston accumulator acts as shock absorbers. The piston accumulator allows to
be lifted up while the bladder accumulator allows to be pressed down on the table.

Piston Accumulators: Transmit the force through the rocker arm through the rollers against the
material on the table. The oil in the piston and bladder accumulator returns back to the
reservoir tank when the mill is not running.

ROLLER LUBRICATION UNIT LQ120: It sends pressurized oil into the rollers. It consists of suction
and supply line. Each roller has separate supply line. The major function of the lubrication is to
cool and prevent wear in the moving parts of the rollers. It has a heat exchanger which help to
cool the oil with the aid of water before pumped back to be used again. The lubrication is
majorly for the roller bearing.

COMPOSITION OF VERTICAL ROLLER MILL

SEPERATOR ; Seperation of the fine particles from coarse type. It consists of 68 vanes. 45mm
allowance with each other.

FEED INLET CHUTS : this is the opening through which raw mix enters the mill.

GAS AND MATERIAL OUTLET DUCT : This is the opening through which fine particles and hot
gas leaves the mill to the high efficiency cyclone for separation.

GAS INLET : This is the two opening through which hot gas enters the mill.

REJECT CONE : This is the opening through which coarse material returns to the mill for further
grinding

GRINDING ROLLERS : This is where the mill tyre is attached to.

ROCKER ARM : Link the roller shaft to the piston cylinder

ROLLER FORK : it is made of chromium carbide alloy. Directly In contact with the material during
grinding operation

SEPERATOR DRIVE SHAFT ; Link the separator with the drive

DAM RING : Help to retain the material on the mill table for proper grinding.

LOVOUR OR NOZZLE RING ; This the point where the hot gas get in contact with the grinded raw
mix for separation at the high efficiency cyclone

SCRPPER : Scrap the coarse material in the ring canal into the vibro conveyor.
 MILL SPECIFICATION

Mill Type : Fuller Roller Mill

Mill Size : 52 /400

Capacity : 450tph

Guaranteed Fineness : 10% residue on 90u and 20% residue on 200u

Table Diameter : 5.2m

Table Speed : 25.4rpm

Roller Width : 0.68m

No of Rollers : 4

Mean Track Diameter : 4.45mn

Roller Diameter : 2.55m

Maximum Feed Lump Size: 0% > 100m and 2% > 75%

Nozzle Ring Area : 6.1m2

Mill Main Drive : 4000KW ( 999rpm)

Classifier Type : RAR – LVT 50.0

Classifier Motor : 204 KW

Feed moisture : 8%

Dumy : 6ft

Dam Ring Height : 140mm to 150mm.

Heat Source : Preheater exhaust gas, Air heater or Hot Gas Generator

Main Dust Collector : Electrostatic precipitator

No of High Efficiency Cyclone : 4

Cyclone Diameter : 6.3m

BASIC OPERATING PARAMETERS

1, Inlet temperature of the raw mill before taking feed : 100 to 130 degree centigrade .

2, Outlet temperature less than 100 degree centigrade. It should be between ,70 to 85 degree
centigrade. Above 85 degree centigrade material becomes very light which can cause vibration in the
system.

3, Maximum mill inlet temperature = 250 degree centigrade.

Correction to high mill inlet temperature

Open LD430 more and close SD425

Spray more table water
Reduce the separator speed to pull less material thereby retaining more material in the system

4, The silo level should not be allow go below 30% unless the mill will trip

5, Mill differential pressure : 78 – 80hpa

6,Seperator bearing Temperature: H = 100C, HH = 120C

7, Grinding Pressure: Top pressure; 118 bar 115bar

Bottom Pressure ;23bar 24bar

8, Main Drive power (operating) : 2700 – 3400 KW

9, Vibration (mm/s): L = 2, H = 15, HH = 18. Running limit = 12mm/s. 18 – 21 mm/s the mill will trip

10, Mill inlet Temperature : 170 – 220 degree centigrade

11, Target Residue Content : 200um = 3%, 90um = 20%

12, Mill outlet Temperature : 72.2 degree centigrade. Out temperature should not to exceed 115
degree centigrade, above this the mill will trip

13, Gas Inlet pressure ; LL = o.oohpa, L =2.5hpa, H = 40hpa, HH = 100hpa . Running = 2.6hpa

14, Bed Height : Mini = 20mm, Max = 70mm

15, Mill differential pressure : 75.5hpa

16, cyclone differential pressure ( hpa) :L = 6.9, HH = 23. Running = 72%

17, Seperator Power : 240KW, Running = 143KW

18, Raw mill fan power = 4000KW, Running = 3256KW

19, Raw mill inlet damper = 69%

20, Recirculation damper = 95 %

21, EP fan speed = 86%

22, EP fan I/L Damper = 97%

INTERLOCK

1, Weigh feeders (WF 150) has interlock with the mill. Ones it goes off the mill will trip.

2, If BC660 trips the mill will trip and BE220 as well

3,When FN400 trips the mill main drive will trip

4, Transport system to the elevators (air slide and rotary feeders ) are in interlock with the mill fan

5, If BE050 is not running , the mill will not run

6, If HY100 ( hydraulic system ) fails the mill will trip.

7, If the hydraulic or the oil filter is blocked the mill will trip

8,If RF090 trips the mill will trip because their will not be material in the mill.

9, The reject bin trips when it contains material of about 100tones and also BE 220 and BC660 will also
trip

10, The mill lubrication unite will not run unless the temperature of the oil is 28 to 32 degree centigrade

11, The reclaimer stops when the mix grade bin is 700tones

MILL START – UP PROCEDURE

- Elevator group should start (BE050)

- Transport to elevator (AS, DG, FANS)
- Sealing air fan
- Oil heating group
- Roller lubrication
- Gear lubrication
- (grp 7) hydraulic unit. (would be ready in 15minutes). Group 7 is not an
interlock for group 8
- (8) mill fan and separator
- Mill feed (RF 090,BC660,DG680
- Material circulation (BE120, DG 280)
- Mill motor (rollers must be up for drive to work)
- Group 11 (feed start)
- DP 80 hpa

STOP PROCEDURE

- Stop the feed

- Raise the rollers
- 0% table water
- LD430 0% close
- LD420 should be opened fully
- LD 390 fully pon
- Separator rotor (50%) to allow material leave the mill
- De select group 11 and give quick stop
- Select to reject