Cement Mill Control DB MS

BLUE CIRCLE TECHNICAL CENTRE
CEMENT MILL CONTROL

DAVID BAIRD + MARK STOERKER DAVID BAIRD + MARK STOERKER
CEMENT MILL CONTROL
AIMS OF THIS PRESENTATION
To describe the various Control Loops available for
automatically controlling Cement Mills.
To identify the benefits to be gained.
To establish Where we are at present .
To ask the ?-Where do we go from here ?
To help you to develop an Action Plan to improve mill
control within HBM.
OPEN CIRCUIT
CEMENT MILL
CONTROL LOOPS
Open Circuit Mill Controls
Clinker
Gypsum
Other
Feed TPH
Mill sonic
Chamber 1 exit
temperature
Cement SSA m
2
/kg
and temperature
Water injection
Mill outlet
temperature
CLOSED CIRCUIT
CEMENT MILL
CONTROL LOOPS
CLOSED CIRCUIT CEMENT
MILL CONTROL LOOPS
AUTOMATIC LOOPS
Constant Feed Rate-( tph )
Ratio control of Feed Components-( % Clinker.Gypsum,MAC)
Total Feed Control (Rejects and fresh feed).
Sonic control (Folaphone)- Chamber 1 noise level.
Separator (H.E.S.) -airflow control.
Milling temperature control-( water injection % -C1+2)
Power -Mill Motor and Bucket Elevator KW.
ABERTHAW CM 10 ABERTHAW CM 10 - - AUTO AUTO + + MANUAL MANUAL CONTROL LOOPS CONTROL LOOPS
MILL FAN DAMPER
LIMESTONE RATIO CONTROL
CEMENT MILL CONTROL
LOOPS 1
CONSTANT FEEDRATE AND RATIO
CONTROL OF FEED COMPONENTS
Accurate weight and Ratio control of the clinker /
gypsum / Limestone / MAC / Pozzolan is essential if we
are to avoid.
STEP changes/variability in cement quality.
STEP changes in mill performance / stability due to
feed grindability changes.
Effect of Gypsum, Limestone + Pozzolan
Effect of Gypsum, Limestone + Pozzolan
on Cement mill performance
on Cement mill performance
G 1% SO3 = + 30 m2/kg Surface Area
G 1% Gypsum = + 5% Production
G 1% Gypsum = + 12 m2/kg Surface Area
G 1% Limestone = -2.5% B.C.I Grindability
G 1% Limestone = +2%Production at constant SSA.
G 1% Pozzolan = -0.4 to -0.67 % B.C.I.Grindability
CLINKER CHEMISTRY VARIATIONS CLINKER CHEMISTRY VARIATIONS- -AFFECT ON MILL AFFECT ON MILL
PERFORMANCE PERFORMANCE
consumption and Chemistry for two closed circuit mills
No 2 Mill SRC
N1 Mill (OPC)
N1 Mill (OPC)
N2 Mill (SRC)
Mill Only Kwh/t
L.S.F.
L
S
F
C
2
S
C
3
S
32.5 33.0 33.5
C
2
S
C
3
S
Mills under
Automatic
Total Feed
Control
LSF
+5% C2S =+ 1 kWh/tonne
BLUE CIRCLE TECHNICAL CENTRE
ESTIMATING THE COSTS OF
POOR MILL CONTROL
C em ent S S A V ariations
300
340
380
420
460
Tim e
S
S
A
-

m
2
/
k
g
T arg et G ood C on trol P oor C on trol
Control +/- m
2
/kg Range kWh/tonne Avg. kWh/t
Poor 40 340 420 37.0 50.8 43.9
Good 10 340 360 37.0 40.3 38.6
Savings 5.3 kWh/t
Overgrinding
Overgrinding
-
-
Power Penalty
Power Penalty
m
2
/ kg
Variability
Max
m
2
/ kg
Chamber 1
kWh/tonne
Penalty
kWh/tonne
0 340 9.0 0
+/- 10 350 9.4 0.4
+/- 40 380 10.6 1.6
When we overgrind, we waste power in Chamber 1:
When we overgrind, we waste power in Chamber 1:
CEMENT MILL CONTROL LOOPS 2
SOUND CONTROL-CHAMBER 1
Can act as protection against overfilling Chamber 1
by cutting feed if noise level drops due to other factors
ie blockages within the mill or at the mill discharge.
Feed cuts off at fixed sound level.
A modification used at Aberthaw is to use Sonic to
input to the Total Feed Control Loop. This forward
feeds the effects of gradual build up in filling level.
Folaphone (Mill Sonic) Location
Sensor 25 mm
from shell
Rigid stand
0.5 m from end of
mill Chamber 1
Mill
centerline or
below
This bloody
thing will
never work!
Direction of Mill
MILLING TEMPERATURE CONTROL
Essential for Cement quality control and to avoid Mill
internal coating problems.
Control of Chamber 1 water injection should be
based upon material temperature at Intermediate
Diaphragm
Mill outlet temperature control should be based upon
the material temperature not gas temperature due to
the effects of inleaking air.
MILLING TEMPERATURE CONTROL (2)
With a High Efficiency Separator-install a gas recycle
system with 2 damper controls (fresh air and recycle)
to control milling temperatures.
Control of mill airflow is normally manual. Check mill
exit gas dew point temperature and increase mill airflow
if high water injection is used.
Mill outlet material temperature control should be
typically 110 - 115 C to avoid Flash/False set .
Mill Temperature Control
Thermocouple in
diaphragm Pickup
transmitter
Water injection
chambers 1and 2
Thermocouple 140
o
C
Inleak 15
o
C
Thermocouple 90
o
C
TOTAL FEED CONTROL
Essential for maintaining a constant mill filling level to
achieve optimum grinding efficiency (optimum voids
filling/powder loading-see C.T.C notes).
The separator characteristics remain more constant
with constant feedrate thus avoid large variations in Cut
size and Recirculating load.
Typical relationship:-
.
PLUS 1.4
PLUS 1.4
tph
tph
Rejects = minus 0.6
Rejects = minus 0.6
tph
tph
Fresh
Fresh
Feed Flow
Feed Flow
Overfilled / Underfilled Mills
OVERFILLED
Poor Grinding Efficiency
High Voidage Filling
Noise Level Low
Coating problems
UNDERFILLED
Poor Grinding Efficiency
Low Voidage Filling
Noise Level High
Risk of high wear and
media/liner breakages
CLOSED CIRCUIT
CEMENT MILL CONTROL
SOME PROBLEM AREAS
POTENTIAL CONTROL PROBLEMS
Inaccurate weigh feeders. Rejects flow spiking.
Undersized Separators with non linear characteristics.
Undersized Separator fan.
Excessive inleaking air over mill (>30%) and
Separator (>10%) dust filter plants.
Undersized Bucket Elevator limiting circulating load.
Poor airslide design causing uneven feed+rejects
flow.
Hold up inside mill due to nibs/poor internals causing
surging.
Cement
Separator/Fan
Weigh
feeders
Mill Internals
Mill Fan Mill Dust filter
To storage
Elevator/Airslides
POTENTIAL PROBLEM AREAS
POTENTIAL PROBLEM AREAS
Main filter
A VIEW INSIDE- WHAT CAN COMPLICATE
AUTOMATIC CONTROL
Material Surges
Chamber 1
Chamber 2
Material Surges
Build up of Nibs
at diaphragm
WORN/BROKEN SLOTS ALLOW NIBS TO ENTER CHAMBER 2 WORN/BROKEN SLOTS ALLOW NIBS TO ENTER CHAMBER 2
WORN WORN
LINERS LINERS
GAPS GAPS
IN IN
SECTIONS SECTIONS
PROBLEM AREAS PROBLEM AREAS- -MILL INTERNALS MILL INTERNALS
THE FUTURE-
WHERE DO WE GO FROM
HERE?
POSSIBLE OPTIONS FOR MILL CONTROL
POSSIBLE OPTIONS FOR MILL CONTROL
G ABB LINKMAN
-
-
NORTHFLEET
NORTHFLEET
G MAGOTTEAUX GO CONTROL
-
-
COOKSTOWN
COOKSTOWN
G POLYSIUS / FLS MILL EXPERT SYSTEMS
G ARTIFICIAL NEURAL NETWORK SYSTEMS,PANTEK
ETC.
-
-
BOWMANVILLE ?
BOWMANVILLE ?
G IMPROVE ON LINE ANALYSIS-SSA/PSD
-
-
MALVERN
MALVERN ,
SO3,
-
-
ITECA, FLS LAB X 3000.
ITECA, FLS LAB X 3000. 45 um ,ETC
WHAT NEW / OLD PROBLEM AREAS WILL WE FACE
WHAT NEW / OLD PROBLEM AREAS WILL WE FACE
WITH THESE NEW SYSTEMS?
WITH THESE NEW SYSTEMS?
G Level of reliability e.g. on line P.S.D. Analysers and
Sampling systems.
G Needs a Works Champion.
G Needs commitment and capital to have the best
chance of success.
G Expert system must be able to control process-e.g.
avoid artificial limitations imposed by
airslide/elevator/separator speed/mill internal
limitations etc.
YOUR TASK
YOUR TASK
DEVELOP AN ACTION PLAN TO
DEVELOP AN ACTION PLAN TO
IMPROVE AUTOMATIC CEMENT
IMPROVE AUTOMATIC CEMENT
MILL CONTROL WITHIN H.B.M.
MILL CONTROL WITHIN H.B.M.
BASE YOUR PLAN ON A CLOSED
BASE YOUR PLAN ON A CLOSED
CIRCUIT MILLING SYSTEM.
CIRCUIT MILLING SYSTEM.
HOW MUCH DOES THE LEVEL OF CONTROL
AFFECT MILL PERFORMANCE?

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BLUE CIRCLE TECHNICAL CENTRE

CEMENT MILL CONTROL

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