---

I Comminution manual Contents .-- I Comminution manual Contents

A: Ball mill ..- C: Vertical Mills

Charge and power Layout,Alternatives C.1
Calculationof charge A.1 Verticalmillcalculations
Calculationof power A.2 Symbols C.2
Specificcharge
Torque factors
A.3
AA -' Power consumption
Grindingpressure
C.3
CA
Example A.5 Millinternals
Maxcharges, dryingcompartment A.6 ~ Nozzle ring C.5
Grindingmedia Dam ring C.6
Equilibriumcharges A.7 Heat balances, Example C.7
Charges - Large balls
Charges - Small balls
A.8
A.9
.- D: Closed circuit grinding
Charges - Cylpeps
Standard charge compositions I
A.10
A.11 .- Grindingtheory
Comminutionindex
Circulationfactor
D.1
Standard charge compositions II
Wear on grindingmedia
Piece weight and specificsurface
A.12
A.13
A.14
-' By sieve residues or weight
Separator efficiency
D.2

Sampling of grindingmedia
Grindingand fineness
Transport through mill
A.15

A.16
- Description
Power reduction
Maxpower reduction
D.3
DA
D.5
Normalfineness in mill
Heat balance, Example
A.16
A.17
.... Vs values
Tromp curve
D.6

Description D.7
B:
Closed Circuitgrinding,Layout
Roller press
A.18
.- Example
Factors of influence
D.8
D.9
Layout
Pre-grinding B.1 '- E: Various
Fans
Semi-finishgrinding
Finish grinding
B.2
B.3
- Fan calculations 1
Fan calculations II
E.1
E.2

-
Rollerpress calculations
Symbols B.4 Airand heat
Formulas B.5 Densities and Cp-values E.3
Typicalvalues B.6
- Variousformulas
Wet and dry temperature
Water vapour in air
EA
E.5
E.6

- Pitottube measurements 1
Pitottube measurements II
E.7
E.8

-
False air calculation E.9
Moisturecalculations E.10
Sieve to mesh conversions E.11

- Unittransformations E.12

-
~

~~

~I

~,

A: Ball mill
~_,.

:~~

--
~

~-
~-
.--
-~

~
:"~'

-~ ICharge and power Calculation of charge

~"

-
-- -
H

--
~=-:-
'~ -
-- D: Effective diameter of compartment em]
l: Effective length of compartment em]
-~
- -~ V: Volume of compartment
V= ,,14, D2. L [m3]
'-' h: Centre distance (hiD used in page A.3)
-- ~
h=H-DI2 em]
--~ hiD = HID - Yz [-I
H: Free height
H=(hID + Yz). D em]
-'=--'
q: Specific charge (from page A.3) [%]
w: Bulkweight (from page A.4) [Um3]
~--- F: Charge
F = q/100' w. V [t]
--
-"

-~

--,

--

--
-_I
--
-- Ball mill Page A.1
 ~-~

Charge and Power Calculation of power ~-~

ICharge and power Specific charge

hID a a hID a a
~-
0.000 0.425 50.0 0.200 0.647 25.2
0.005 0.430 49.4 0.205 0.653 24.6
~:C 0.010 0.435 48.7 0.210 0.659 24.1
0.015 0.441 48.1 0.215 0.665 23.5
0.020 0.446 47.5 0.220 0.670 22.9
~.- 0.025 0.452 46.8 0.225 0.676 22.4
0.030 0.457 46.2 0.230 0.682 21.8
0.035 0.462 45.6 0.235 0.688 21.2
~
0.040 0.468 44.9 0.240 0.693 20.7
0.045 0.473 44.3 0.245 0.699 20.1
Compartment power consumption: ~-'. 0.050 0.479 43.6 0.250 0.705 19.6
0.055 0.484 43.0 0.255 0.711 19.0
a: Arm of gravity in relation to mill diameter [-] 0.060 0.490 42.4 0.260 0.717 18.5
n: Rotational speed of the mill [rpm] ~~ 0.065 0.495 41.8 0.265 0.722 17.9
0.070 0.501 41.1 0.270 0.728 17.4
g: Acceleration of gravity [m/s'] 0.507 40.5 0.275 0.734 16.8
~~ 0.075
a: Angle of displacement [0] 0.080 0.512 39.9 0.280 0.740 16.3
N: Power consumption by compartment at mill shell 0.085 0.518 39.2 0.285 0.746 15.8
N = F . g . D . a . sin(a). 1t.n/60 [kW(net)j 0.090 0.523 38.6 0.290 0.751 15.3
0.095 0.529 38.0 0.295 0.757 14.8
sin(a) is the torque factor IJ.Standard values from page A.4. 0.100 0.534 37.4 0.300 0.763 14.2
!:-""
0.105 0.540 36.7 0.305 0.769 13.7
N = 0.514 . F . n . IJ . D . a [kW(net)]
0.110 0.546 36.1 0.310 0.775 13.2
~,. 0.115 0.551 35.5 0.315 0.781 12.7
Wherethe constant0.514is (g . 1t / 60) 0.120 0.557 34.9 0.320 0.786 12.2
0.125 0.562 34.3 0.325 0.792 11.8
Critical speed: 0.130 0.568 33.6 0.330 0.798 11.3
0.135 0.574 33.0 0.335 0.804 10.8
Thecriticalspeedncis the speed,wherethe centrifugalforceat the 0.140 0.579 32.4 0.340 0.810 10.3
mill liningis equalto the gravitationalforce: !.-'~
0.145 0.585 31.8 0.345 0.816 9.87
42.3 0.150 0.591 31.2 0.350 0.822 9.41
[rpm]
nc = JD -'
"- .... 0.155 0.596 30.6 0.355 0.828 8.95
0.160 0.602 30.0 0.360 0.833 8.51
Normal mill speeds are 70 - 80% of the critical speed. 0.165 0.608 29.4 0.365 0.839 8.07
.~ 0.170 0.613 28.8 0.370 0.845 7.64
0.175 0.619 28.2 0.375 0.851 7.22
.~ 0.180 0.625 27.6 0.380 0.857 6.80
0.185 0.630 27.0 0.385 0.863 6.39

- 0.190
0.195
0.636
0.642
26.4
25.8
0.390
0.395
0.869
0.875
5.99
5.59
a can also be calculated as:
~~ a = 0.009' (96.7 - q) [-j

Ball mill .~ Ball mill Page A.3

Page A.2
I Charge and power Torque factors --- Charge and power Example

Internal Media - Examole:

Material Grinding Lining w Torque
fittings Type 1.1

Coarse
None Balls
rtlm>]
4.3 0.73 -- In a UMS42 x 13 millrunningwith16.0 rpm. the followingwas
measured:
FirstcomQ,aJ1ment:
None Rods 6.0 0.55
and Steel
Danula Balls 4.3 0.75 ~.- D 4.01 m = L =3.89 m H =2.75 m
medium Second compartment:

Cement
Sonex
None
Balls
Balls
4.3
4.5
0.66
0.69
-- D=4.13m L = 8.38 m H = 2.81 m

and None Cylpebs 4.7 0.73

Calculations for first compartment:
raw meal None Minipebs 4.7 0.64
Fine Steel =
V 1t 14 . (4.01 m)2 . 3.89 m =49.1 m'
(dry) Danula Balls 4.5 0.71
Danula 4.7 0.75
~:: hID = 2.75/4.01 - Yo= 0.186
Cylpebs From page A.3: q = 27.0%; from page A.4: w = 4.3 tlm3
Danula Minipebs 4.7 0.66 F = 27 0/100. 4 311m3. 491m3 = 57 0 I
Steel None Ceramic 1.9 0.75
All
Silex None Stone 1.5 0.75 Calculations for second compartment:

Coarse
None Balls 4.3 0.66 =
V 1t/4. (4.13 m)2 . 8.38 m = 112.3 m3
None Rods 6.0 0.50 hID = 2.81/4.13 - Yo= 0.180
and Steel
Danula Balls 4.3 0.67 From page A.3: q = 27.6%; from page A.4: w = 4.5 tlm3
medium
Sonex Balls 4.3 0.59 F = 27 6/100.45 11m3.1123 m3 1394 I =
Slurry None Balls 4.5 0.66
~'/'" Power calculations:
(wet) None Cylpebs 4.7 0.66
Fine Steel N =0.514 . F. n . J.1. D '8
Danula Balls 4.5 0.67 (kW(netJ]
.......-
Danula Cylpebs 4.7 0.67
First compartment:
None Ceramic 1.9 0.85
Steel None Stone 1.5 0.85
_.- From page A.3: a =0.630; =
from page A.4: 1.1 0.73
All N =0.514' 57.0 t . 16.0 rpm . 0.73 . 4.01 m . 0.630
Wash Silex
Lifters Stone 1.5 0.85 - N = 865 kW(net)
drum
Coarse
Medium
None Balls 4.3 0.69 -' Second compartment:
None Balls 4.5 0.69 =
FrompageA.3:a 0.625; from page A.4: 1.1 0.69 =
Coal
Medium
Medium
Steel
None Cylpebs 4.7 0.69 -- N =0.514' 139.4 t. 16.0 rpm' 0.69' 4.13 m. 0.625
= 2042
Danula Cylpebs 4.7 0.71
'- N kW(net)

Page A.4 Ball mill -- Ball mill

Page A.S
Charge and power Max charges
Drying compartment
IGrinding media Equilibrium charges
-
Mill Maximum Eauilibrium charae. definition
soecific charae r%1 An equilibrium charge is the distribution of ball sizes that will be
Balls Cylpebs realised when operating a ball mill for a long time, compensating the
36 33 wear by adding balls of one specific size, and removing the balls,
Dry which are smaller than half the diameter of the ball size used for
UM Wet> 5 kWh/t 34 31
28 26 compensation.
Wet < 5 kWh/t
TUM 2-compartments 32 29 The equilibrium charge is characterised by the diameter of the ball
1-comoartments 28 size used for compensation.
TM 2-compartments 28 26 Equilibrium charges may be mixed to adjust the required piece
Rod 35 ~ weight and surface area. Two or more ball sizes are then used for
Silex Ceram. 38 compensation.
Wash Drum 34 The average piece weight and the specific surface of an equilibrium
~~
Duodan 28 32 charge with normal steel balls can be calculated according to:
34 32.7
'--' ;=0.001913Dc3 [g]
38 31.5
UMSall 42 30.4
compartments 46 29.4 ~:- 0= 1018 [m2/t]
50 28.6 Dc
54 28.6 where Dcis the diameter in mm of the ball size used for
34 34.9 ~~ compensation.
Second 38 33.5
compartment
UMS w. Stanex
42
46
32.3
31.3
-- --
Diaphragm. 50 30.4
54 30.4 ,---

-'-
Power consumDtion of drvinQ comDartment:
Doe Nominal diameter of drying compartment [m]
--
Loe Nominal length of drying compartment [m]
Noe Power consumption of drying compartment [kW(net)] -
- ..
The power consumption of a drying compartment can be calculated
as follows:
For raw and cement mills
=
Noe 1.5.00/.5. (Loc - 0.4) [kW(net)]
For coal mills -'
Noc= 0.8 . 00/"5. (Loc- 0.4) [kW(net)]
._-

Page A.6 Ball mill -- Ball mill Page A.7

"tI (j')
I»
cc
Recommended initial charges for equilibrium Large balls ~.
(I) 120 110 100 90 90 80 70 ~
> Compensationsize(s) * mm 110 100 90 80 70 Q.
00
110 100 90 80 70 70 60 ~
max. 120 110 110 100 100 90 90 90 80 80 70 70 cc
Ballsizes in chamber 3
min. 50 50 50 50 50 40 40 40 40 40 30 30 (I)
120 mm 7085 9 6.4 m2't 9 Q.
110 mm 5457 9 7.0 m2't 23
;-
19 10 .
100 mm 4100 9 7.7 m2't 24 28 24 21 10
90mm 2989 9 8.5 m2't 18 21 26 31 27 23 12 12
80mm 2099 9 9.6 m2't 12 14 18 22 27 32 29 16 26 13
70mm 1406 9 11.0 m2't 8 10 12 14 18 21 28 25 36 32 29 15
60mm 886 9 12.8 m2't 5 6 7 9 11 14 18 25 22 31 37 36
50mm 513 9 15.4 m2't 1 2 3 3 7 8 10 15 13 17 21 30
40mm 262g 19.2 m2't 2 3 7 3 7 11 16 o
::r-
I»
30mm 111 9 25.6 m2't 2 3 ..
cc
Piece weight initial 9 2750 2393 2116 1925 1582 1300 1123 880 1004 808 612 505 (I)
1/1
Piece weight equil. 9 2877 2546 2185 1913 1613 1395 1151 892 979 786 656 507
Specificsurfaceinitial m2't 8.4 8.8 9.2 9.5 10.1 10.8 11.3 12.2 11.8 12.7 13.8 14.7 r-
I»
..
Specificsurfaceequil. m2't 8.9 9.3 9.7 10.2 10.7 11.3 12.0 12.9 12.7 13.6 14.5 15.8 cc
(I)
DJ *: Where two sizes for compensation are stated, they are introduced in equal amounts by weight. g-
~ I»
iii
§

IIIIIIIDIII~IIIII
DJ Small balls (j')
Recommended initial charges for equilibrium ~.
~ 60 50 40 30 25 20 ~
Compensation size(s) * mm 60 50 50 40 40 30 25 20 15 Q.
§ 30 25 20 15 ~
cc
max. 60 60 50 50 40 40 3 30 25 25 20 20 15
Ballsizes in chamber 3
min. 50 30 25 25 20 20 15 15 10 10 10 10 5 (I)
60 mrr Q.
886 9 12.8 m2't 35 18
I»
50 mrr 513 9 15.4 m2't 40 41 42 21
40 mrr 262g 19.2 m2't 20 32 42 47 51 26
30 mrr 111 9 26 m2't 5 9 13 24 33 35 35 18
25 mrr 64g 31 m2't 3 8 13 27 40 40 40 20
20mm 33g 38 m2't 3 12 21 31 41 46 51 26
15mm 14 9 51 m2't 4 11 17 30 43 53 62
10mm 4g 77 m2't 2 4 6 21 36
5mm o
0.5g 154 m2't 2 ::r-
I»
Piece weight initial 9 418 329 246 178 127 83 53 40 28 21 16 10 5.8 ..
cc
Piece weight equil. 9 413 303 239 162 122 73 52 38 30 20 15 9.1 6.5 (I)
1/1
Specific surface initial m2't 15.8 17.1 18.8 21 23 27 31 34 38 42 46 53 63
Specific surface equil. m2't 17.0 18.7 20.4 23 25 30 34 37 41 46 51 59 68 en
3
*: Where two sizes for compensation are stated, they are introduced in equal amounts by weight. !.
"tI
I» g-
cc I»
(I)
> iii
io
"'U Ci)
DI
CQ
Recommended initial charges for equilibrium Cylpeps :!.
ell 35 30 25 22 19 16 12 :I
» Compensationsize(s) * mm 35
30
30
25
25
22
22
19
19
16
16
12
12
10
0.
:.. :I
Q max. 35 35 30 30 25 25 22 22 19 19 16 16 12 12 CQ
Cylpeps inchamber min. 16 12 12 12 12 12 10 10 8 8 8 3
8 6 6 ell
35x35 mm 263g 22.0 m2/t 29 14 0.
DI
30x30 mm 165g 25.6 m2/t 37 35 34 17
25x25 mm 96g 30.8 m2/t 17 24 31 28 25 12
22x22 mm 65g 35 m2/t 9 13 16 25 34 31 28 14
19x19 mm 42g 40 m2/t 6 8 10 16 22 30 36 35 32 16
16x16 mm 25g 48 m2/t 2 5 7 11 15 20 25 35 44 48 52 26
12x12 mm 11 g 64 m2/t 1 2 3 4 7 9 12 16 24 33 35 35 17
10x10 mm 6g 77 m2/t 2 4 6 9 12 27 40 42
8x8 mrr 3g 96 m2/t 2 3 3 12 21 34
6x6 mrr 1.3 9 128 m2/t 4 7 o
::r
Piece weight initial 9 115 83 68 53 44 36 29 24 18 14 12 8 5.1 4.1 DI
..
Piece weight equil. 9 123 95 78 57 45 36 31 24 20 15 12 7 5 3.6 CQ
ell
Specific surface initial m2/t 28 30 33 35 38 41 44 47 51 55 58 67 79 85 1/1

Specific surface equil. m2/t 29 32 34 37 41 43 46 50 54 59 64 74 85 93 o

OJ *: Where two sizes (or compensation are stated, they are introduced in equal amounts by weight. ~
'a
~ ell
'a
1/1
§

IIIIIDIDIIIDDDIDDDDI
OJ
~
§
m5"()

t i-~
§'~~
::!. Cir:J
,f>.(J1
NO
3
-:::::5'
::T_
... tD
~3
(') CD
m5"()
.c -. 0
5. 5f-3
-C' -0--0<1> N(J1
(J10
3
()
o
!!!.

~
m5"()
t i-~
§'~~
:Joffi°:J
NO

o
<0
3
3
()

3 ~
CD

CD
~ o
n
-
"'1'1 Ci)
:!.
:I
0.
:I
c: (') en o 3 00. 2" ~.~ o 3 c: (') en s«>3 CQ
3CD!!!. 3- 3<1>!!!.
-oa 3<1>!!!.
3
"2.::E g' -'- Q) tD
"2.::E g' "2. :;: g'
jjJ'g
::E ~ tD
~ !!!...
<1>CQ
::!.n
30 ~ !!!... ~ !!!... co 3 3 0.
::T
:;::-!"
<1> ,f>.
N
to CD3
~'a
3D1
CDcg.
:;::-!"
CD
,f>. to
,f>.0
0
<1>cg.
:;::-!"
<1>
wo
N
0 3
:::
:':' -S'
CD
:I DI

cO'
'#- 3 en _.~ cO' '#- 3 en cO'
3tO ;::;:
Ff
'-I-
N'
3 <1>
~~
.. :I -
S-
o:;:
~
--
3 N' CD ~

NO
en
N'
"-1<1>
iii'
-n
::r
DI
en
_
DI
:I
NN(J1 (J1 <0 ca 0.
wO'>o ......w ~ 0'> <DO
WW W010 3 .,tD ..DI
<D°3 0'>0 n NWs«> 010 ~~3 o 3 0.
c.cc.c3 3 ::T c.c c.c ,f>. 3 c.cc.c3 n
o 3 DI o o 3 ::r
...
CQ
-- DI
tD 3 ..
I I IJ 3 W-J 0'> CQ
ell
NO
3 n
o
o 3 3
'a
o
"'U
1/1
DI ~
CQ o
ell :I
'1>
1/1
...
...
 -~-...-

IGrinding media Standard charge compositions II IGrinding media Wear on grinding media
Fine grinding compartment initial charge:
Non-classifyinglining: Cast
Media
Ball size Chrome alloy
Mill system 25mm 20mm 15mm
%C 1.2- 28
Open 20% 40% 40%
Closed 40% %Mn 1.0 -1.2
40% 20% Analysis
ODen Closed
%Cr 12- 28
Compensation: 20 & 25 mm 25mm %Mo 0.2- 0.5
Initial piece weight: 23 g 30 g Hardness HRC 50 - 56
Equilibrium piece weight: 20 g 30g
Wear in g/kWh taken up by compartment
Classifying lining:
Large balls 10 - 20
50mm 15mm Wet Small balls 15 - 30
10% 15% Cylpebs 15 - 30
~- 2-5
25% Large balls
Compensation:
75% Raw Small balls 1-3
Cylpebs 1- 3
Large balls 2-5
Cement Small balls 1-3
Cylpebs 1- 3
90mm 20mm ~-
14% 10%

Compensation: 60%
40%

50mm 15mm
11% 10%

Compensation: 50mm: 22.5%

40mm: 22.5%
30mm: 55%
Initial piece weight: 70 g
Equilibrium piece weight: 75 g
......

Page A.12 Ball mill - Ball mill Page A.13

 --
Grinding media Piece weight and specific surface
-='" [Grinding media Sampling of grinding media

d: Diameter of ball [mm] Example 1: Ball charge Compartment 1 - compensated for

wear with 90 mm balls.
p: Specific weight of material [g/cm3]
i: Piece weight -=-"" Fraction Weight % No.
i 0
(m2/t)
00
(m2)
(mm) (kg) (gram)
90 - 85 70.52 25.0 24 2938 8.58 0.605
i = !!... d3 . p
6 [g] ~ 85 - 75 81.87 29.0 38 2154 9.52 0.779
75 - 65 60.08 21.3 44 1365 11.08 0.666
Ifp=7.8 g/cm3(normal steel): 65-55 40.34 14.3 40 1009 12.26 0.495
-::--
;=0.0041 d3 [g] 55-45 23.88 8.5 49 487 15.63 0.373
0: Specific surface:
6000 [m2/t]
- < 45
Broken
Total
2.91
3.02
282.62
1.0
1.1
13
7
215
224
431
20.25
16.28
2.918
0=-
p.d - Main fraction >45 mm: 276.69 kg
media
- 0.27669ton- 97.9%- 195
If p=7.8 g/cm3(normal steel):
o
769 - Piece weight .' 276690 1419
. / = ---:;gs- = g

o
d

123
~
[m2/t] - Specific surface : 0 = 2.9180
0.27669
-10.5 m2 It
It
For examination of a grinding media charge, take out not less than
200 pieces from each sampling spot in compartment 1, and no less
~ Example 2: Cylpebs charge
for wear with 25 x 25 mm cylpebs.
Compartment 2 compensated -
than 2000 from compartment 2. Extract from under the centreline
and dig as deeply as possible. Broken media is sorted out.
- Fraction
(mm)
Weight
(kg)
% No.
I
(gram)
0
(m2/t)
00
(m2)
Separate in fractions as shown in examples on page A.15.
Calculation of surface is based on the average piece weight and on
the assumption that all the media are of spherical shape. This
- 25 - 23.5
23.5 - 20.5
20.5 - 17.5
2.23
3.65
2.10
22.2
36.4
20.9
26
58
48
85.7
63.0
43.8
27.89
30.90
34.88
0.062
0.113
0.073
assumption also applies to cylindrical cylpebs.
Piece weight and specific surface of the charge is calculated from
-' 17.5 - 14.0
14.0 - 12.5
1.49
0.38
14.8
3.8
56
30
26.6
12.7
41.19
52.70
0.061
0.020
the main fraction by disregarding media less than half the diameter
of the largest size used for compensation for wear. -' < 12.5
Broken
Total
0.104
0.09
10.04
1.0
0.9
16
7
241
6.5
12.6
65.88
52.84
0.330
In compartments with classifying lining the charge normally consist
of two equilibrium charges constituting a coarse-grinding and a fine- ..- Main fraction >12.5 mm: 9.85 kg - 0.00985 ton - 98.1 % - 218
media
grinding charge, their proportions being determined during the
dimensioning and adjusted during running in.
..-- .
Plecewelg ht
. . 9853
The classifying effect is most clearly expressed in the proportion
: /=-=
218
. g
452
between the piece weights in the inlet end and outlet end of the
compartment. .... Specific surface :0 = 0.330 =33.5 m2I
0.00985 It
~

Page A.14 Ball mill -- Ball mill Page A.15

. .
 0:::- -

Grinding and fineness Transport through mill

Normal fineness in mill
~-
[Heat balance Example I
~- Ane xample of a heat balance for a ball mill (ball mill tube only).
Transport capacity of material through grates: Flow Heat
Temp Cp
Width of slots Open circuit
Closed circuit
6mm
-
8 12 mm
~- -
IN
Fee I. dry
tfh
85.0
°c
95.9
kcalfkgrC
0.186
Mcalfh
1516
1sl. partition
Dry 2nd. partition approx. 5 V(dm2.h) ~- Wat !r in feed 0.2 20.0 1.000 4
Outlet qrate Return mal. 102.0 114.0 0.186 2163
Width of slot Normally 6 mm Grin jing heat 2498
~-
Wet 1sl. partition 8 m3f(dm2.h) !Air 22.8 25.0 0.244 139
2nd. partition 9 m3f(dm2.h)
10 ~ Fals 3 air.inlet 0.0 25.0 0.244 0
Outlet grate m3f(dm2.h}
Wash 3.0 Fals 3 air. outlet 2.2 25.0 0.244 13
Peripheral Grate
drum Inclined outlet grate 2.5
m3f(dm2.h)
m3f(dm2.h} -
Wat Jr inj.
TOT 'AL IN
1.8 0.0 1.000 0
6334
Transport capacity of material through mill body:
.
20 30 t/h/m2
-~
-
OUT

Mate rial total 187.0 119.7 0.186 4163

Wat, Ir in product 0.0 116.0 1.000 0
Normal fineness of grinding material in the mill . Wal Ir evap 2.0 116.0 0.453 1295
Two comcartment mill:
Tota air 23.9 116.0 0.244 676
25 -40 %

--
+ 0.2 mm
At partition
-
8 16 % + 0.5 mm ~ Surf; Ice loss
TOT AL OUT
199
6334
2.5- 4 % + 1.0 mm
max. 0.5 % + 2.0 mm Wate ter
injectl ,oC:
Three comg,artment mill:
15 - 25 % + 0.5 mm ~-.:.
10 - 20 % + 0.6 mm
First partition 7 - 14 % + 1.0 mm -~ The a r
, The
max. 4 % + 2.0 mm evap
20 - 30 % + 0.2 mm air am a of
Second partition max. 5 % + 0.5 mm --~ 9.70m 5 thus
0.80

The samples are taken inside or immediately in front of the For Cp values see page E.3 For grinding heat calculation and
partitions. surface heat loss. see page E.4.
~

~-

Page A.16 Ball mill --~ Ball mill Page A.17

.J
IClosed Circuit grinding Layout
~

Typical layout of closed circuit grinding: -~'

Separator with product collection in cyclones:
Offers maximum heat preservation for maximum drying in the mill, ~.
smallest possible filter and pressure drop over separator system.

,~-

"
.- -
~~-

--
~-
B: Roller press
Separator with product collection in filter. Offers maximum cooling
of the product:
~-

~-

~.

-~
1-1-
--
~t[J~. )
1 bj-IJ.
..-
~-
Both systems may be designed to offer partly recycling of the
separator air for the best compromise between the two solutions.
~.-

Page A.18 Ball mill p--'-

---
-- I Layout Pre-grinding

-
- Feed
...- bin

---
-
--
Feed

Recycled
Flow
splitter
device
pressed
material
...- Pressed
material to

- Pre-arindlna lavout
ball mill

- · Flowsplitter controls ratio between material recycled to roller

press and pressed material to ball mill.

-- . Roller press specific power consumption:

-2 to -5 kWh/t material to ball mill

-- . Roller press circulation factor =

Roller press throughput/new feed:
-- 2.1
- 1

...-
...-
ooc-
.--- Roller press Page B.1
 -
.-~

ILayout
-
~ I Layout Semi-finish grinding Finish grinding

-
--
~

Fine
-"
Finished
Feed
material to
ball mill -" product

-"-
Recycled
coarse
-" Recycled
Magnet coarse
material
-" material

Semi.finish
·
arlndina lavout -- Finish arindina lavout

·
Separator controls ratio between material recycled to roller
press and pressed material to ball mill.
Deagglomeration and separation may be combined in one
- .
.
Separator controls ratio between material recycled to roller
press and pressed material to ball mill.
machine Deagglomeration and separation may be combined in one

· Roller press specific power consumption: .

machine
Separator may be divided into a grit separator and separator

.
-6 to -14 kWh!t material to ball mill
Roller press circulation factor =
-- .
working in series
Roller press specific power consumption (cement grinding):
Roller press throughput/new feed:
- -14 to -30 kWh!t finished product
-2,5 6
. Roller press circulation factor =
Roller press throughput/new feed :
-6 to 14

Page 8.2 Roller press Roller press Page8.3

I Roller press calculations Symbols I
.-
.- IRoller press calculations Formulas

.:II

. .-
JI:I
Total roller force T is calculated from the hydraulic pressure and
the number and area of the hydraulic cylinders:
T =c . A . B . 102
SDecific roller Dressure kTis the total force divided by the
projected roller area:
[kN]

.
Moveable
roller F. W Fixed roller
-- kT= T/(D W) [kN/m')

PeriDheral velocltv v of the rollers is calculated from the roller

v
-=- speed and the roller diameter:
. D . (n/60)
--
v = It [m/s]

Power consumDtion N of the roller press is calculated from the

applied total force, the peripheral velocity and the rolling torque
factor between material and roller surface:
N = II . T . v
JJ:I [kW]
D:
W:
n:
v:
Rollerdiameter
Rollerwidth
Rollerspeed
Rollerperipheralvelocity
[m]
[m]
[rpm]
[m/s]
-- or when using the specific roller pressure:
N = II . kT . D . W . v [kW]
ThrouahDut caDacitv M of the roller press is calculated from the
thickness of the grinding bed, the density of the pressed material,
--=-
s:
F:
B:
A:
Grindingbedthickness
Rollerforce
Hydraulicpressure
Pistonarea
[m]
[kN]
[bar]
-- the width of the rollers and the peripheral velocity:
M = 3.6 . s . 5 . W . v

SDecific Dower consumDtion E1 applied to the material at each

[Uh]

pass through the roller press is the power consumption divided by

[m')
--=-
--
c: [-] the throughput capacity:
Numberof hydrauliccylinders E1 = N/M [kWh/t]
------------------------
5:

--
Densityof pressedmaterial [kg/m3] Roller Dress circulation factor C is the throughput capacity
IJ: Torquefactor [-I divided by the new feed rate:
kT: H
--
Specificrollerpressure [kN/m') C=M~
M: Rollerpresscapacity [Uh]
SDecific Dower consumDtion E applied to the product from the

--
N: Powerconsumption [kW] roller press system (finished product or product to ball mill) is the
E: Specificpowerconsumption [kWh/t] specific power consumption applied to the material at each pass
E1: through the roller press multiplied by the circulation factor:

--
Specificpowerconsumptionper pass [kWh/t]
E = C . E1 [kWh/t]
c: Rollerpresscirculationfactor [-]
P:

--
Newfeedto rollerpress [Uh]

Page8.4 Rollerpress -- Roller press Page 8.5

 ~~

IRoller ~-
press calculations

Typical roller press parameters

Typical values

-
Roller press velocity [m/s] 1.3 - 1.6
-
-
6000 (Cement and slag)
Specific roller pressure [kN/m2J
4500 (Raw materials)
Torque factor [-] 0.07 - 0.1
Grinding bed [%ofD] 1.8 - 2.3
Density of pressed material [t/m3] .2.2-2.7 ~~

-
~

P:-
c: VerticalMills
-
-
-
-
-
-
~.

r:-

PageB.6 Roller press ...-.

 ~

-.::--e
I Layout Alternatives

'~
There are two basic layouts of the VRM system; product collection
in cyclone(s) or product collection in filter,
Below only the ducting used with the mill in operation is shown.
--
- Product collection in cvclone(s):

To dedusting
........
....-
--
-
-..:- Heat source

'-'
'-
'- Product collection in filter:

.~
--
-
-~
-- Heat source

--
-- Vertical mills Page C.1
 --
IVertical mill calculations Symbols 1 -=- I Vertical mill calculations Poy,
wer consumption

-=:II The theoretical power consumption of aver cal roller mill is

A Rollerprojected area. one roller [m2] expressed by the formula:
N =Kr . A . z, v . J1
A.,orzJeNozzle ringarea [m2] -=- For the Atox mill following applies:
[kW(net)]

Do Grindingtable diameter [m]

Kr: Typically500- 700 [kN/m2]
DcyI Hydrauliccylinderdiameter
Dm Grinding track diameter
[m]
[m]
-=:II A = Droller. W roller [m2]
Droller= 0.6 . Dc [m]
Dpiston Hydraulic piston diameter [m] 8::1
Wroffe,= 0.2 . Do [m]
Drone, Rollerdiameter [m]
Dc= Millsize/10
F
FH:
Grindingforce
Hydraulicgrindingforce
[kN]
[kN]
.:II z=3
[m]
[-I
8::1 v =n . 1/60 . Om . tr [m/s]
FR: Rollergrindingforce [kN]
Om =0.8' Dc [m]
KT Specificgrindingpressure [kN/m2]
MR
1.1
Rollerassemblyweight,oneroller
Torque factor
[kg]
[-I
.:II For the OK mill following applies:
Kr: Typically 700 - 1000 [kN/m2]
N Mill power uptake [kW] 8::1
A = Drolle,' Wrolle, [m2]
n Grinding table speed [rpm]
DroI/e,=0.59' Dc (OK 25-3: 0.69' Do. [m]
Phyd
v
Hydraulicgrindingpressure
Grinding track speed
[Bar]
[m/s]
.:II WroIIe,= 0.24' Do [m]
00.= Mill size/ 10 [m]
WroJler Roller width [m] 8=iI z=30r4 [-]
z Numberof rollers [-I v = n . 1/60. Om . tr [m/s]
8:1 Dm=1.17'Dc [m]

8:;1 will normally be in the f ange

The torque factor, 1.1.

... Mill
Atox
Atox
Application
Rawmat.grinding
Coalgrinding
1.1-ran ge
0.09- 0.11
0.07- 0.09
IRI OK Cementgrinding 0.08- 0.10
11:I OK Slaggrinding 0.09- 0.11

JJ::I
AI
Verticalmills Verticalmills
Page C.2 IJ:;I Page C.3

I .....
 ~,
~-

I Vertical mill calculations Grinding pressure ~.

IMill internals Nozzle ring

Formulas apply for Atox and OK mills only. ~J The nozzle ring area is the free area, perpendicular to the direction
of the gas flow, as measured at the shortest distance between the
table and the air guide cone:
~~
Piston rod
-- Anozzle

Shock
~-
absorber

----
Air guide cone
Hydraulic !-
cylinder

---- Q)
VJ
:J
o
.c
Dam ring
~\~/
Grinding table
The grinding pressure, F, consists of:
--'
-::; - -
F = FR + FH [kN]
where
.
FR = MR 9.81/1000 [kN]
and
.
FH = Phyd ((Dcyt)2- (Dpiston)2) .1t/4 . 100 [kN]
Gas flow direction
The specific grinding pressure will then be:
Kr = F I A [kN/m"] ~ The gas velocity in the nozzle ring will normally be in the range:
The mechanical instruction will most often enclose a graph giving -
35 50 m/s.
the correlation between Phyd and Kr. The higher the velocity, the less material falls through the nozzle
ring.

Page C.4 Vertical mills ~--- Vertical mills Page C.5

 --~

IMill Internals Dam ring -.......

[Heat balances Example

The dam ring height is the height measured from the grinding table ~- An example of a heat balance for a vertical mill
segment to the top of the dam ring Case: 200 Uh, 8 kWh/t (net), drying from 8% to 0.5% moisture
For Atox mills: ---
Flow Temp. Cp Heat
-~ Uh °C kcallkg/OC Mcal/h

>--- In
200 20 0.218 872
Table segment
Grinding table - Feed, dry
Water in feed 17.4 20 1.000 348
Recirc. mat (1)
',- Grinding heat (2) 1376
Gas 302 252 0.242 18417
>- False air (3) 30 20 0.244 146
For Atox mills the dam ring height is often referred to as n%of table 0
Water injection
diameter". The optimum height is normally in the range 2.5 - 4% of
table diameter.
"- Total in 21160
Example:
A dam ring of 120 mm in an Atox 32.5 will give a relative height of:
'- Out
mm =3.7% 0.218 3706
120 mm 13250
-- Product
Water in product
200
1.0
85
20 1.000 20
For OK mills: Water evap. (4) 16.4 85 0.453 10406
"-" Gas, total 332 85 0.242 6829
200
"- Surface loss
Recirc mat. (1)

-- Total out 21160

-- (1): Recirculated material is not included in the heat balance since

the inlet and outlet temperatU/"eof this is virtually the same.
.' Table segment I

Grinding table - (2): 1600 kW .3600 s/h 1 4.186 J/Cal = 1376 MCal/h

-
(3): False air from mill inlet to mill outlet is calculated based upon
C02 and O2measurements. Standard value is 10%
For OK mills the dam ring height is given in mm only. (4): Water evap. is calculated as evaporation at O°C(596 kcal/kg)

'- plus heat in vapor

Page C.G Vertical mills '- Vertical mills Page C.7

-:---

--
-"
-"
-'
-
-"

-"
- D: Closed circuit grinding

~~

~.

"-

-
--
....
-...

--
 -~-

I Grinding theory Comminution index

Ro: Sieve residue of feed to mill system [%j

R,: Sieve residue of product [%j
~ Rg: Sieve residue of separator reject [%j
Rm: Sieve residue of separator feed [%j
W: Comminution index [kWh/t)
E: Specific power consumption for ball mill [kWh/tj
~.- C: Circulation factor [-j
The specific power consumption for a ball mill, grinding from sieve
~'
residue R1to R2' can be described by the following equation:

'-~- E = W x Log (- =: ) [kWh/t(nt)j

W is the comminution index specific for the particular mill operating
--'I with the particular materials, and states the specific energy
consumption in kWhIt required for reduction of the sieve residue to
one tenth.
:~~
The specific power consumption plotted against the sieve residue
will form a straight line, when the residue values are plotted using a
logarithmic scale.
For open circuit grinding the equation is:
-~
Eo = W x Log (:~) [kWh/t(nt)]

For closed circuit grinding, with a circulation factor C:

Ro + R x (C - 1)
Ec = W x C x Log R,+Rgxg ('C-1 [kWhIt(nt)j

The comminution index, being a measure for the grinding efficiency,

can be useful when making comparisons between two mills, or
products with different fineness.

~-
~~-, Closed circuit grinding Page D.1
 .-:......---

I Circulation factor By sieve residues or weight ,- ISeparator efficiency Description

From sieve residues: SeDarator efficiencv as reduction in Dower consumDtion:

-~---
Operating in closed circuit with a separator, normally results in a
reduction in the specific power consumption.
.-
The size of the reduction depends on the efficiency of the separator,
the fineness level of the product and of the circulation factor.
~~::. By applying the formulas for Vs and Bmax,the saving in kWh/t
obtained by using a separator can be determined. The calculations
c_ are based on the residues found in the samples R" Rm,Rg.
Typical values for efficiency, Vs, relating to residues in the interval
32 - 45 micron:
.~--~
1.st generation separators:
-- CV, Heyd, Sturtevant -
Vs = 25 40 %
2.nd generation separators:

~~ REC, Wedag, ZUB Vs = 40 60 % -

3.rd generation separators:
Material balance: Cx Rm = 1xR, +(C-1)xRg -- Sepax, O-Sepa, Sepol Vs =75 -85 %
R -R,
Circulation factor: C = 9
Rg - Rm -~-:
SeDarator efficiency as recovery of fines
Bv weiaht: Uf: Separator efficiency as recovery of fines [%J
Pltlh -~-.:..
Separator efficiency measured as Recovery of Fines is calculated
------- according to the expression:

u,=.!
-\-- -
x 100-R, x100 [%J
C 100 -Rm
The method can be used for comparison between separators
""!"'"8'- operating at the same circulation factor.
F(dry) =P (tIh) The method does not quantify the power reduction.
--
~_I-

'

Circulation factor: C =G+P --"

P
Page D.2 Closed circuit grinding Closed circuit grinding Page D.3
,,=~I
 ~,

ISeparator efficiency Power reduction ~.............

Separator efficiency Max power reduction

Vs: Separator efficiency as reduction in power consumption [%j

'~
B: Obtained power reduction [%j
Bmax: Maximum possible power reduction [%j Max power reduction, B(max)
<: ,

The separator efficiency (Vs), is defined as the reduction in specific 90

power consumption in the mill, obtained with the separator in -= '
question (B), in relation to the reduction which could have been
obtained if the separator were ideal Bmax.
,- 80
Vs =~.100 [%j
Bmax
~
hence the saving (B) can be expressed as:
B =BmaxxVs/100 [%j -- 70

The significance of an ideal separator is a residue in the returns, Rg

= 100 %.
..- 60

The value of Bmaxcan be calculated using the expression:

--
50
C x Log Ro+100x(C-1)
~, ~
B
max
= 1
1- Rf+100x(C-1)
R I
x
100 [o/.j
0
i
e
Log i!.. iD
Rf 40

The separator efficiency Vs is calculated according to the

expression: 30
Ro Ro+ Rg x(C-1)
Log--CxLog
Vs = Rf Rf+Rgx(C-1)
x100 [%j
L Ro C L Ro+100x(C-1) 20
og-- x og
Rf Rf+100x(C-1)

The specific energy consumption for closed circuit operation is

calculated from the expression:
~~.
Ro B .VS
E = WxLog-x
c
1- max
Rf ( 10000 )[kWh/t(nt)j

Circulation factor t C

Page D.4 Closed circuit grinding :-- Closed circuit grinding Page D.S
 -~-~

ISeparator efficiency Vs values --,-

ITromp curve Description

.-- T: Tromp curve value [%J

Separator efficiency, approximate values The tromp curve is used to evaluate the performance of a
Valid for C = 1.5 5. .-- separator.
The curve describes the percentage of the feed material, of any
100 ,- grain size, which is found in the return material.
The construction of a Tromp curve requires particle size distribution
curves for the material streams going into and leaving the
separator.
The particle size distribution curves, representing Rf, Rm, Rg, are
--- divided into particle size intervals, where each interval represents a
particle size.
85 The Tromp values are calculated according to the expression:

T= C -1 xl!1Rgx 100 [%J

80
~- C I!1Rm
where:
75
.~ I!1Rg = the percentage of return material in the interval representing
70 the particle size.
I!1Rm = the percentage of material leaving the mill, in the interval
:;t
representing the particle size.
t 65

80 Cut-size:
Particle size corresponding to the Tromp-value 50 %
55 Depends on rotor speed and fineness level

50 KaDDa:
Slope of the curve in the interval 25 - 75 %, Eg.: x25/ x75
45 Normal range: 0.5 - 0.6

Delta = BVDass:
40
Tromp value at lowest point on curve.
35
Nonnal range: 5 - 15 %

25 35 45 55 65 75 85
Rg,%
.:.-

Page D.6 Closed circuit grinding ~- Closed circuit grinding Page D.7
 -;~~

I Tromp curve Example ~~

ITromp curve Factors of influence

~ The shape of the Tromp curve is influenced by the following factors:

100
SeDarator desian.
Later generation separators designed with more favourable
90 geometry, resulting in higher values for Kappa and low By-pass
~ value.

80 Material load.
-------------------------- Excessive material loading results in increased by-pass and lower
Kappa value.
Normal ranges: Product load: 0.85 kg/m3
CD Feed load: 2 - 2.5 kg/m3
1/1
~ ~
ns Airflow.
o
CJ Insufficient airflow results in higher by-pass value and lower Kappa
o
.... 50..~-~---~-
~I value
....
c ~, Circulation factor.
CD
~ 40-1-- --+- ~ -
Increasein circulationfactorleadsto increasein the by-passvalue.
CD
/1.
Grindina ald.
30+-- ~ ~ -
---------------------- Theuse ofgrindingaidmaycounteractagglomeration,resultingin
~
reducedby-passvalueandincreasedsharpnessof separation.
20 -, ,
I ' I Analvsis method.
I I I
I I I Different laser analysis methods may give different results.
10 ~I~
Delta I I I =-"'" Comparison of Tromp curves should be done using the same
I I I measuring method.
I I I
o
1 10 100
. . .
SleveSIZe, micron
x25
Cut size
x75
--
De~a=6%
Cut-size =31 my Kappa = 0.56
-=-
~

..:..--.

Page D.S Closed circuit grinding .;-- Closed circuit grinding Page D.9
 ~

~~

~:'"

E: Various
~

~~

:-'w

--...

.~

~~

:...~
':.~...:'!

~--::!
IFans Fan calculations I

--~ n: Fan speed [rpm]

Pt Total pressure difference over fan
P,=Pd + ps [mmWG]
N: Fan power consumption [kW]
Q: Volumeflowat inlet [m3/s]
~
1'): Fan efficiency [-]
D: Diameteroffan impeller [mm]
p: Densityof clean gas [kg/m3]
s: Dust content in gas [kg/m3]
Withchanging fan speed and/or density:
_ n
Q- Qref'-
nref

n
- P, = P,.ref.( nrel)
2

3
~
Prel

N= N rei . ~ .~
( nrel ) Prel +Srel

~ where the subscript "ref refers to the values the fan curve is based
upon.
;-a The fan power consumption can be calculated from the flow and the
pressure difference over the fan:
.::-
N= Q,P, .~. 9.81 pa/mmWG [kW]
1] P 1000 W / kW
=-
1')can vary from 0.60 for old type open blade impeller types to 0.85
for a modern closed impeller with curved blades.
::---

..:.-

=-
-=--
..-..-

-- Various Page E.1

1"----

...;--

IFans Fan calculations II --- I Air and heat Densities and Cp-values

The characteristics of a fan can be changed by changing the

diameter a given impeller:
-' Gases:

Gas Po Cp average>
0= Oref E
Dref
[m3/s] [kg/Nm3] [kcallkgrC]
H20 (steam) 0.804 0.453
2
~ Air 1.285 0.244
[Pa]
Pt = Pt,ref .(D~f J Kiln gas. 1.436 0.242

5
1:Air with 75% reI. humidity at 20 'C at sea level.
[kW]
N=Nrof {~f J ~. 2: Kiln gas: 02,vol:4.0%; CO2.vol:
32.0% and moisture content of 0.05
kg H20/kg dry gas.
3: Cp-average for the gases are the average values in the interval
Changing the diameter of the fan impeller causes the same o - 400'C
changes as changing the fan speed.

Materials:
~
Cp average1
Material
[kcal/kgrC]
Raw materials 0.218
Clinker 0.186
~
Coal, high volatile 0.321
Coal, low volatile 0.271
Slag 0.197
Puzolana 0.218
=--"
Fly ash 0.218
H20 (water) 1.000

~ 1:Cp-average for the materials are the average values in the

- 200 'C
interval 0

-
Page E.2 Various --
..; Various Page E.3
 .'--

I Air and heat Various formulas IAir and heat Wet and dry temperature
'"
0)
Po: Specific density of a gas [kg/Nm3] ~
P: Density of a gas [kg/m3] ~ ==---=-==-
+ 0
T: Temperature [.C] 0)

b: Barometric pressure as bo
bo: Barometric pressure at sea level ~ :e
bo=760mmHG, 1013 mBar or 10333 mmWG.
Height: Height above sea level [m] =-~ R
p: Relative pressure [mmWG]
t: Temperature ["C] '"
'"
Yo: Gas amount at normal conditions [Nm3]
V: Gas amount at actual conditions [m] ~-~
Barometric Dressure: ! ...
.E GI
b = bo . e(-O,0001255' Height)
E
., '" Gi
a. '" E 0
Densitv: E
.. E
l- ...
GI
273 b/bo: 10333 + p e o'" .c
..
P = Po' 273 +t' 10333
[kg/m3]
'0 ..GI
Do :!:
Volume: 3: '"
GI ...
Q
V =~ . 273+ t . 10333 [m3]
o 273 b/bo '10333 + p 0
...
A gas volume V 1 with temperature t1and pressure P1will change to
V2 when temperature and/or pressure changes to t2 and P2 '"
<')

V2 = V1. 273 + t2 . b/bo' 10333 + P1 [m3]

273 + t1 b/bo .10333 + P2
g
Heat of evaDoration of water:
595kcal/kgat O.C 539kcal/kgat 100.C.
Electrical enerav to heat:
1 kWh equals 860 kcal
Heat transmission from a surface: 0'"
0'"
8 kcal/h/.C/m2 for free convection. ~
10 -12 kcal/h/.C/m2 from forced convection. Dry thermometer
1000 kcal/h/m2from a cement mill surface.

Page E.4 Various ~ Various Page E.5

Air and heat Water vapour in air I Air and heat Pltot tube measurements I

I
~

Pel: Dynamic pressure [mmWG]

+--+---t-i---:-+-+ -t-b:=- Ps: Static pressure [mmWG]
"1~ --+ "-1 1+ -j :.:--~ p: Specific gravity of gas
1_ ...J ...J ...J J et ,.-
-=+- ~cn~~~ R=- 273 b/bo .10333 + Ps
' P = Po . 273 t'
B c
'~~EEE
000 I "~ 10333 [kg/m3]
' \..! O§88~_,
N (")
v: Velocity of gas
-.:;~\ : : '--;:: o
... [m/s]
- \ \ ! j ,=
v= ~2g~ Pd
:~ D: Inside diameter of duct [m]

-. -
;I~"
.1 - '..~u !
"i{ .~ g 1-' =-~
Q: Volume flow of gas
Q= i.D2.V [m3/s]
..- r-' .a
!!! ~~ Mass flow of gas
Q) [kg/s]
'-F--- _____ Co Qt=i.D2. v.p
-.::;= :-': I --- :5 E
S Quantity in Nm3
~- I- C [Nm3/s]
Qo =Q..£..
I __ 1 '_ = '0
Co
Po

== ~ Measuring points must as far as possible be situated on a straight

t :: . ___t-- ':- ~
o... cQ) stretch of pipe with uniform flow. without obstructions like blends or
dampers, There should be a straight stretch of minimum 5xD before
and 2xD after the measuring point.
-.- -
-. un ~.\ ! -t- Connections:
I , , ~ Pd Manometer branches to both nozzles
Ps One manometer to branch marked '-'
-. ; "V-
;---""@. ~: D ) t
: I _ 7 :;y;: D
I

- I '..;' ",,\_ _ .;;:-.

! '. -
' , I.. . .----
1-L- -' '-. ;. ~'- '.\ ~
'" '"
o ;; on
o o o o
o
o
o
-=-
kg water per kg dry gas -- Normal pitot tube S-type pitot tube is used, if the gas stream is
dust filled. The dynamic pressure is corrected
Kiln Gases: with a factor of 0.86 before the normal formulas
Subtract 2.5 .C from the actual dewpoint and use the graph.
~~ are used.

Page E.6 Various .~--- Various Page E.7

 Pitot tube measurements II -=- Air and heat False air calculation
I Air and heat I

The gas flowin a pipe is never uniform throughout its cross section, The false air between two points can be calculated based on O2 and
and Pdshould be calculated as an average value of the measured C02 measurements, if the main gas stream is kiln gas. False air in
values taken at the tabulated points below. the mill lowers the temperature and thereby the drying capacity.
False air at the outlet does not directly influence drying but
Pd,average= (~L ~Pd,measured ) "..:' increases the load on fans and filters. In extreme cases false air
where n is the number of measurements included. may bring this load to a point where sufficient air can no longer be
0
drawn through the mill.
0
0
0
0
0 0 _-:-
0 0 Ii) '<t '<t False air is expressed in percent of unmixed gases at the inlet. The
0
C')
t- ...... N C')
0 amount of false air through the mill and cyclones may b~ calculated
0 0 0
0 0 from the contents of C02 and O2 in the gas. Atmospheric air
(mm) v v v v
v 0 0 0 contains 0% C02 and 21 % O2. In the calculations the term "gas"
0 0 0 0 0
C') 0 Ii) '<t
t- ...... N signifies the unmixed gases and the term "mixture" the mixture of
false air and gases.
points 2x2 2x4 2x6 2x8 2x10 From C02-measurements:
al 0.85,0 0.93,0 0.96,0 0.97,0 0.97,0
a2 0.15'0 0.75'0 0.85'0 0.90'0 0.92'0
CO2(gas)-C02(mixture) .100 [%]
a3 0.25,0 0.70-0 0.81,0 0.85'0 x= C02(mixture)
a4 0.07'0 0.30'0 0.68'0 0.77'0
0.15-0 0.32,0 0.66,0 -~ From 02-measurements:
as
a6 0.04-0 0.19,0 0.34,0
x= 02(mixture)-02(gas) .100 [%]
a7 0.10,0 0.23,0
21- 02(mixture)
a8 0.03,0 0.15,0
a9 0.08,0
...;:~
a10 0.03,0

For rectangular cross sections a fictive diameter of 0=Y:z(H+B) is

calculated, and use the number of tabulated measuring points as
indicated in the table. In a rectangular duct, the measuring points
are evenly distributed in the cross-section.
Example:
A duct measures inside: H = 800 mm, B= 500 mm
0= Y:z. (800+500) = 650 mm
Corresponding to a 650 mm circular duct or 8
measurements as indicated.

Page E.8 Various Various Page E.9

Moisture calculations

F:
P:
Wj:
wp
Feed (wet)
Production(dry)
Moistureof feed
Moisturein product
[t/h]
[t/h]
[%]
[%]
..
== ISieve to mesh conversions

Sieve size
[IJ]
2000
1700
BS
Mesh no.
8
10
ASTM
Mesh no.
10
12
E: Water evaporated [t/h] 1400 12 14
A: Dryproportionof component [%]
1180 14 16
B: Wet proportionof component [%]
1000 16 18
Productionof a millsystem withmoist feed:
850 18 20
P=F.100-Wf [t/h]
100 710 22 25
Feed necessary to produce P is 600 25 30
F=P'~ [t/h] 500 30 35
100-Wf
425 36 45
Theaveragemoistureof feedwithdifferentcomponents:
- 100 355 44 40
wf = 100- A [%] 300 52 50
L--L
tOO-wi 250 60 60
or in terms of the wet proportions: 212 72 70
Wf =LBi.wj/100 [%] 180 85' 80
where Ai is the dry proportion of the i'th component and Withe 150 100 100
moisture of the same component.
125 120 120
The wet proportion of the n'th component is calculated as:
An 106 150 150
90 170 170
Bn= 100-wn .100 [%]
L 100-& Wi 75 200 200
63 240 230
The dry proportion is calculated from the wet proportions as:
53 300 270
A =B . 100-wn [%]
n n 100 -" ~ B.I 'w,I /100 45 350 325

Various Various Page E.11

Page E.10
IUnit transformations
Distance:
1 km =0.621 miles 1 mile =1.609 km
1m =1.094 yards 1 yard =0.914 m
1m =3.281 ft 1 foot =0.305 m
1 mm =0.0394 inch 1 inch =25.4 mm
Weiaht:
1t =1.102 short ton 1 sh. t =0.907 t
1 kg =2.205 Ib 1 lb. =0.454 kg
19 =0.035 oz 10z =28.35 9
Pressure:
1 Pa =0.102 mm H2O 1 mmH20 =9.81 Pa
1 mBar =10.2 mm H2O 1 mm H2O =0.098 mBar
1 mBar =0.75 mmHG 1 mmHG =1.333 mBar
1 atm. =1013 mBar
1 mBar =100 Pa 1 Pa =0.01 mBar
1 Bar =1.033 atm. 1 atm. =0.969 Bar ~~
1 psi =0.0690 Bar 1 Bar =14.5 psi
1 kgf/cm2= 0.98Bar 1 Bar =1.02 kgf/cm2
1 kgf/cm2 = 1 kp/cm2

Force. power. enerav and toraue:

1N =
0.102 kp 1kp =9.8 N
1 kpm =9.81 J 1J =0.102 kpm
=
1 kpm/s 9.81 W 1W = 0.102 kpm/s
1 hp =0.736 kW 1 kW = 1.36 hp
1 kWh =860 kcal
1 kcal =3.97 BTU 1 BTU = 0.252 kcal
1 kcal =
4.186 kJ 1 kJ = 0.239 kcal

Temperature:
Y(°C) = 5/9 . (X(OF) -32) Y("F) = 9/5' X(OC)+ 32

Y(°C) = X(K) - 273 Y(K) =X(OC) + 273

Page E.12 Various ~---

Index A-E I
..
8i8 Iindex F-L

A
A.2
.:. -F
falseaircalculation E.9
arm of gravityin relationto milldiameter
average moisture of feed
B
E.10
-=- fancalculations
fan efficiency
fan power consumption
E.1
E.1
E.1
barometricpressure E.4
D.4
all fanspeed E.1
A.16
Bmax finenessofgrindingmaterialinthe mill
bulkweight
bypass
A.1,A.4
D.? -=- finishgrindinglayout
free height
B.3
A.1
C -=- G
calculationof false air
centredistance
charge
A.1
A.1
A.5
E.9
.- gas flowmeasurement
grinding bed
grindingmedia,pieceweightandspecificsurface
E.?,E.8
B.6
A.14

..--
chargeandpower,example H
charges - cylpeps
charges - large balls
A.10
A.8
A.9
.:II hID
heat balance for a ball mill
A.3
A.1?
charges - small balls C.?
circulationfactor D.1 heat balance for a verticalmill
circulationfactor for rollerpress B.5 heat of evaporation of water E.4
circulationfactorfrommassflows D.2 heat transmission E.4
D.2
circulationfactorfromresidues
comminutionindex
Cp-valuesof gasesandmaterials
critical speed
D.1
E.3
A.2
.. ideal separator
initialcharge,coalmillwithclassifyinglining
D.4
A.12
A.12
cut-size
D
D.?
a initialcharge,finegrindingcompartment
initialcharge,firstcompartment
initialcharge,intermediatecompartment
A.11
A.11
damringheight
delta
densitiesof gases
C.6
D.?
E.3
-=- initialcharge,rawmillwithclassifyinglining
K
A.12

-=-
..
E.4 kappa D.?
density of a gas
dryingcompartment A.6 L
dynamicpressure E.?
layoutof dosed circuitgrinding A.18
E layoutof finishgrinding B.3
E.1 B.1
efficiency,fan
efficiency,separator D.3,D.4
E.4
A layoutof pre-grinding
layoutof semi-finishgrinding
layouts of the VRM system
B.2
C.1
electricalenergyto heat
equilibriumcharge,definition
examination of a grinding media charge
A.?
A.14 -=-
Index Iindex s-z

M S
max charges sampling of grinding media, examples A.15
semi-finish grinding layout 8.2
max power reduction
maximum power reduction separator efficiency D.3, DA
measurement of gas flow separator efficiency as recovery of fines D.3
mesh to sieve conversions separator efficiency as reduction in power consumption DA
moisture calculations sieve to mesh conversions E.11
moisture from wet and dry temperature specific charge A.3
specific density of a gas EA
N CA
specific grinding pressure for vertical mill
nozzle ring area specific power consumption for ball mill D.1
specific power consumption of roller press 8.5
p
specific roller pressure 8.5,8.6
piece weight specific surface A.14
piece weight for equilibrium charge specific surface for equilibrium charge A.7
pitot tube measurements standard charge compositions A.11
power consumption by compartment T
power consumption N of roller press
power consumption of drying compartment torque factor A.2, 804,B.5, 8.6
power consumption of vertical mill torque factors A.4
power consumption, fan transport capacity of material through grates A.16
pre-grinding layout transport capacity of material through mill body A.16
tromp curve D.7
R
U
recovery of fines
roller press circulation factor unittransfonnations E.12
roller press parameters V
rotational speed of the mill
velocityofgas E.7
volumeof compartment A.1
Vs and Bmax D.3
W

water vapour in air from dew point E.6

wear on grinding media A.13