MENGTSEAB INDUSTRIAL AND COMMERCIAL PLC

KUYU CEMENT FACTORY

PRODUCTION DEPARTMENT

ASSIGNEMENT TWO: RAW MILL SYSTEM

FOR TRAINEE CHEMICAL ENGINEER
Name Muleta Mekonnen
 Raw material proportioning
The homogenized limestone and clay/silcastone along with other raw materials like
sand, pumice, basalts are reclaimed into separate feed bins.
The proportional ratio of the raw materials is fixed using raw mix design and
determined from the chemical analysis of the raw materials.
The capacity of each silo can be calculated as follow
From this figure, let we take as limestone silo
• Hc = height of cylindrical shape = 15m
• L= length of the cone from large one to small
cone at output of feed; = 65cm
• D= diameter of the silo for upper cylinder = 10m
• r = radius of cone = 5m
• h= height of cone = 6.44m and number of stages of silo =10
• Sc1= side of cone the hold up to the cylinder = 6.80m
 Cont….
Sc= Total side of cone from the cylinder to the end of funnel’ = 8.15m From the given data, the height and radius of silo is
calculated by: -
D = 2r, r = D/r =10/2 = 5m
Now, height of the cone is calculated using Pythagoras theorem formula;

Actually, c2= a2+b2, the same is true that, Sc2= h2+r2,

Then, by re- arranging, h2= Sc2- r2 so, h= , h =6.44m

Then the total height of silos is, the height of cylinder plus the height of cone Total height
(Ht=Hc+h) = 15m+6.44m= 21.44m
The volume of cone and volume of cylinder is calculated by using formula,

(Vc)=𝜋𝑟
2ℎ
Volume of cone = 3.14*5*5*6.44 =168.5 m³ and

Volume of cylinder (Vci)=

M = 1687 ton
 Cont….

• But remember that: the silo is not full filled with raw material 100%, it must have free
space quiet.

•Note that: assume the safety factor for volume of silo is 10%

• Therefore, the calculation become, 10%*1687ton= 167.8ton, this is the safety factor
holding amount and know, the capacity of silo for limestone is 1678-167.8 = 1510.2
ton with regarding of safety factor.
 For other silo that hold like clay, pumice and coal can be calculated as same as limestone silo but
their difference are having different density . Eg, density of limestone =1253.34kg
 the clay silo capacity is 900.4 ton m3

 the capacity of pumice silo is 810 ton The Density of clay and pumice is 1550kg/m3 and 1390kg/m3 respectively.

 the capacity of pet coke or coal silo is 553 ton

Figure of raw material storage capacity
 Weighting and level control mechanism
The depth of silos has level control sensor, which it is installed at the top of the silos.
The level control sensor instrument is called radial level sensor,
which is working by sensor, means the light reflection in the silos like conical shape or
light from the sensor is strike the corner or diagonal form, then the transmitter light is
reflect and back, and read the level or transmitter light minus reflection light indicator
the level of silos.
Weigh feeder
weigh feeder is a closed-loop control system, which controls the flow of material from
each silos(6 different silos in KCF)
Each weight feeders have its own capacity. Weight feeder that used for limestone has
1-30 ton per hour of capacity while that of pumice, clay and basalt have the same
capacity flow that is 1-25 ton per hour.
Mechanical component of weigh feeder
•Drive motor: The function of the drive motor is to energize the belt through an
electric motor. The electrical motor will in turn provide energy to the gearbox that
will provide motion to the belt of weigh feeder.
• Gear box: also known as the main drive gear box, to reduce the speed of motor
or to achieve the target speed of rotation.
• Belt: it is used for handling or conveying raw material rises from silo on the
weight feeder.
• Rollers: to support the belt and direction of the material toward.
• Tension device: to adjust the belt direction
• Belt cleaner: to clean the belt both side upper and under return belt
• Drum (at end and start): to move or drive the belt and they are drive (by gear
motor) and non- drive
• Chute: : to feed the raw material into the long belt
 Bag filter
 Dust is one of the big problems in cement
industry.
 This dust have numerous adverse effects
including effects on employee health.
 So adopting a de-dusting system in plant
secure reliable operation and a long life time.
 Bag filters are the most applicable in de-
dusting for cement factory
 Recovery of particulate matter dust is vital for
any industry from two aspects
 To avoid pollution problems
 Recovery of finished product-increasing the plant
yield
• Types of bag filter
• Based on the dust dislodging system bag filters are divided in to:
1. Jet and Plenum pulse filter
2. Mechanical Shaker Bag Filter
3. Reverse air filter
• Jet and Plenum pulse filter
Is an automatic bag filter which is used for cleaning dust-
laden air.
Dust from its source is entering through the baffle plate
Some part of the de-dusting is performed in the baffle
plate by dropping its speed
The parts of dust settle on outer side of the filter.
An increased dust layer on the bags leads to increased
pressure loss across the filter
To avoid an acceptable pressure loss the bags are cleaned frequently.
The cleaning is performed when the solenoid valve sends a message to
the membrane valve
Frequently the air is send from the compressed air manifold tank
through the pulse valve
When the P or t in the filter reaches max the elevation valve will be
closed
Jet and plenum filters may have many modules or compartment based
on the bag amount
Parameters that affect cleaning include the amplitude and frequency of
the shaking motion
there must be no positive pressure inside the bags during the shake
cycle.
The air to close ratio for shaker bag houses is relatively low
 hence the space requirements are quite high.
• What kind of bag filter KCF adopts
Currently world cement industries are conscious on
environmental safety.
 one of the environmental concerning points is adopting well
handling of dust, so higher efficiency of bag filters are most
selective like jet and plenum pulse filter
KCF also in most of areas of dust handling adopts jet and
plenum pulse filter b/C their efficiency reaches up to 99.6% for
the raw mill and Cement mill areas
Inlet concentration of gas ~1000g/m3 and outlet
concentration below 30mg/m3
• Bags for jet and plenum pulse filter
• The most widely used filter bags located in cement plant are:
Polyester fabric
Polyacrylonitrile fabric
Poly aramid fabrics
Bags for jet and plenum pulse filter
The most widely used filter bags located in cement
plant are:
Polyester fabric
Polyacrylonitrile fabric
Poly aramid fabrics
 Working principle
dust-bearing air enters the dust collector via the inlet, flows into the dust hopper

Due to slow speed and the inertia & deadweight of the dust, the coarse grain
drops in the dust hopper
The fine grain moves upwards with the air flow and is absorbed on the external
surface of the filter bag
Upon filtration by the filter bag, clean air enters the clean air chamber

As filtration continues, more the system suffers from increasing resistance

In order to ensure normal operation of the system, the resistance is limited.

When the resistance reaches its limit the solenoid valve sends a message to
membrane valve and open the pulse valve as well as close the elevation valve.
•Raw Mill Function
• Horizontal raw mill or ball mill is a mill type of grinder used to grind and blend
materials for use in several of ball mill works on the principle of impact size
reduction is done by impact as the ball drop from near the top of the shell.
• The ball mill consists of a metal cylinder and a ball the working principle is that
when the cylinder is rotated the grinding body ball and it is installed in the
cylinder form rotated by the cylinder under the action of friction and centrifugal
force.
•Ball mill is transmitted, working with gear and it can work in open circuit or
closed circuit with separator. In KCF ball mill work by closed circuit .

•The materials are transferred to the grinding chamber through the quill shaft
uniformly. The fine materials are discharged through the out let, thus the
grinding process is finished.
 Cont…..
Open circuit
•An open circuit is the one in which the material at the outlet of the mill
has the required size and it goes directly to the storage silos.

Closed Circuit
• A closed circuit is the system in which the material at the outlet of the
mill passes through a separator, driving the material with the required
fineness to the storage silo and the coarse particles back to the mill inlet.
 KCF raw mill(ball mill type)
Outer diameter mill: 3.5m

Inner diameter mill: 3.35m

Capacity of mill: 60ton/hr.

Length of mill: 9m

Types of raw mill or ball mill and compartments

1st compartment and 2nd compartment (1st and 2nd chamber)
Raw mill has two chamber that where the grinding, separation and attrition is take place.
Each chamber charging with the balls based on the size of ball.
First chamber

The first compartment is to prepare the material before to go in the second

chamber.
the ball charge is a gradation of balls diameter: 90mm, 80mm, 70mm,
60mm.
Second chamber

The second chamber is the finishing chamber. It means an attrition

work in order to produce fineness.

The ball charge will consist in a gradation of balls: 60mm, 50mm,

40mm, 30mm, 25mm, 20mm diameter.
•Material and gas flow system
 Mill Ventilation Measurement: - The ventilation of a ball mill is extremely
important and this for several reasons:
 removal of the very fine particles,

 de-dusting of the internal equipment,

 keeping an acceptable temperature,

 avoiding coating on balls and/or linings,

 Better drying of the material for the raw mills.

 Raw Meal Drying and Grinding Process

•Drying and Grinding: - When grinding raw materials and coal, it is also
necessary to dry moisture in them. Normally this is done by passing through
the grinding system hot gases from preheater or heating room/burning house/.
However, when starting from cold, such gases are not available. There-fore Hot
gas Generators are essential for drying to provided Raw Mill and Coal Mill used
to provide hot gases of requisite capacity and temperature. As they are used only
occasionally, they would be oil fired.
 Flow chart of drying and grinding of ball mill system

Where F= fresh feed, C= coarse return, P= product, 1= feeder belt, 2= pendulum

flap valve, 3= raw mill/ ball mill/, 4= chute, 5=elevator, 6= separator, 7= chute
 Mill critical speed
The speed of rotation is often expressed as a percentage of the critical speed.

 Normal critical speed of raw mill is between 70-75%.

In simple, the critical speed is defined as the rotational speed where centrifugal
forces equal gravitational forces at the mill shell's wall.
The grinding ball is subjected to two forces

I. Centrifugal force: Fc

II. Gravitational force: Fg

• The centrifugal force is given by the following formula
Fc = mω2Di/2
 The gravitational force is given by the following formula
F = mg
 Raw Mix Design

The purpose of calculating the composition of the compound in the raw mix is to
determine the quantitative proportions of the raw component in order to give the desired
chemical and mineralogical composition of the clinker.

By using the parameter like lime saturation factory [LSF),

Silica modulus (SM), Alumina modulus(AM) etc.

1. Lime saturation factor (LSF):

Is the amount of CaO which is enough saturated or combine SiO2, Al2O and Fe 2O3 to form
Portland cement clinker:
Cont….
 In order to produce good clinker, the LSF is usually kept between 92 .6%. If the LSF is above 99% the
raw mix CaO Become harder to burn, higher fuel consumption, excess CaO in the clinker.

 Desired value 92-98 %

•If LSF below 92%:

 the clinker is so easy to burn the refractory brick may be washed out,

 infiltrate with coating rings. Free lime content is usually low Form less porous & bally clinker and
Results, hard to grind,

 Excess of liquid phase in the burning Zone, there is a tendency to ring formation and coating washing,

 The potential C3S is lowered and the C2S is increased proportionally and reduce early strength of

cement
Cont….
•high LSF has following effect

 Fuel consumption increases

 Burning zone temperature increase and heat loss by radiation increases.

 Presence of free CaO affects the quality of clinker and produce unsound cement.

 Clinker burning hard with high fuel consumption.

 Free lime content is low and the high the early strength of the cement.

 Difficult to combine with other oxide (hard to burn)….. a tendency to high free
lime
1. Silica Modulus (SM)

•It’s the ratio sum of Fe2O3 and Al2O3

•The major effect of silica ratio is one the quantity of flux or liquid phase
potentially present at clinkering temperature.

The silica ratio falls between 2.0-2.4.

Cont,,,
•When SR high:

 more difficult the raw mix to burn due to lower content of Al 2O3 and Fe2O3

 Clinker is hard to grind

 Low cement strength

 Difficult to combine with CaO and hard to burn

 Produces dusty clinker

When SR low:
 Easy burning for the raw mix

 Liquid phase high Al2O3 and Fe2O3

 Kiln unstable and slow hardening cement

 Excessive coating formation (ring formation)

Alumina Modulus (AM)

•The Alumina modulus establishes the relation between alumina and iron to
determine the viscosity of liquid phase

•AR= Al2O3/Fe2O3

•Desired value 1.4 – 1.60

•When AM high: Viscous slag, hard burning, high early cement strength with
low sulfate resistance

•When AM low: Fluid slag, easier burning and Low early cement strength with
high sulfate resistance and low heat of hydration.
Major mechanical component of raw mill
Bearing: is literally enable devices to roll which reduce
the friction between the surface of bearing and
surfaces of motion. This means to smooth motion and
to decreasing friction and to support the shaft
Gears: is a device that is used to enable rotational or
linear movement while reducing friction and handling
stress
gear is used for transporting force or torque and
speed reducer or increases plus to adjust direction of
motion
 External
elements
Mill feed Mill Mill discharge Mill
arrangement Mill head Mill shell bearing arrangement drive

Head Grinding Shell Intermediate Retention Discharge

liners media liners diaphragm ring diaphragm
Internal
elements
Main components of raw mill
1.Sliding shoe bearing
Movable slide-shoe bearings are used at the inlet end of mill
Fixed slide-shoe bearings are used at the outlet end
Two pillows of the slide-shoe bearings will support the mill rolling ring with an angle of
30 degree
2. Shell or rotary part
The rotary part consists of intermediate diaphragm, outlet diaphragm, shell and
liner plates
3.Mill Liner plates Liners are made up of anti-wear resistance metal
fixed in the internal mill shell for the purpose protect shell from wear
Drives of Mills

There is a gear box in between motor and pinion shaft. Sometimes the girth gear and pinion are avoided by
connecting gear box output shaft directly to mill. This is known as 'central drive' and requires a large gearbox with
high ratio of Reduction.
4.Mill Diaphragm
Diaphragms are fitted in the intermediate and outlet position of the ball mill
for the purpose of separates grinding media sizes among the chambers
intermediate diaphragm controls of material flow from one chamber to
another.
5.Ball charge
A mills grinding media charge contains balls of different sizes and of different
material qualities
The ball size distribution depend on:
Max. feed size of the material to be ground

Product fineness

Mill diameter, mill length

Ball charge calculation
the steel ball charged in the compartments
is calculated its tonnage and size of the balls
In ball charge calculation two concepts are necessary
Piece Weight
Piece weight is used to know the weight of ball in first compartment for creating a
relative impact force in the coarse grinding compartment
i, = i.-piece weight of ball(t/piece) for spherical balls
And also for the cylpebs structure balls is as follows:
i.= d-diameter of ball and L is length
-density of steel ball (7.8g/cm3 or 7.8t/m3)
6. Lubrication system with its control mechanism
The lubrication system is used in cement industry and it’s applied as oil.

There will also be greased bearing on both the device end and non-drive end as well as on tension
rollers in between.
Greasing which can help to keep dust out of the races and prevent rapidly wear rates.
The important things that keep in mind that the system of lubrication must be inspected on a
regular, to ensure they are working properly.
Lubricating gear boxes: around the raw mill the oil station or oil reservoir tank is installed, in
order to driven the motors with gear.
These gear boxes generally are quite large and have a sustainable oil capacity.
The job of lubrication system is to distributing oil into the moving parts to reduce friction
between surfaces which rub against each other.
 Cont…
 Parts of lubrication system or oil station are: -

 Oil pump

 Oil filter

 Piston cooling

 Oil cooler/ heat exchanger/

 Oil heater

 Temperature level sensor

 Divert control valve

 Relief valve

 Pressure gauge

 Flow meter

 Magnet filter

 Non-return valve and etc.

Working principle of high and low- pressure pumps (oil station) and its
function.
The high-pressure function is to up or rise the level of raw mill of the sliding
shoe bearing, that oil is flow through the pour line the oil enters it for the sock of
reduce the friction between two surfaces.
High pressure is used as axially piston, this means as level control.

The ability to rise up the mill is 0.15mm, by high pressure and oil is flow on the
white metal.
The high pressure of its workable is 7-10Mpa.
The low pressure, used for smoothly to motion the mill, the suction oil is
showering and lubrication by the low pressure.
 The low pressure is continuously done until the raw mill was stopped and it is
workable 0.2-0.5Mpa
 separator
Separator is one of the main equipment using in cement industry to
separate the fine and coarse material through motion and static way.
Dynamic separator
 is type of separator which, have rotary parts to do the separation, that pick-up
small and big particles.
The majority of the mechanical air separators generate the circulating air inside
the separator itself.
The types of dynamic generation are-
o Turbo separator: - first generation

o Cyclones separator: - second generation

•The static separator .This type of separator has no rotary parts to do the separation. The

separation is done with the help of air, which carries and introduces the material inside the
separator. Static separator separates the small particles but it does not pick them up.
its commonly used in the grinding circuits to remove relatively large particles from gas streams.

 Advantageous of static separators:

 Low capital cost

 Ability to operate at high temperatures and pressures

 Low maintenance requirements because no moving parts

 Disadvantageous of static separators:

Low efficiency especially for very small particles
NB a well efficient separator will always prevent the particles from over grinding which on
the other hand leads to wastes of energy
Static separators are divided in three sub-categories: these are

Cyclones,

static(grit) and

v-separators
Function Of Cyclones and Its Working principle
•Cyclones are used to removing solids from a stream of air .
 Working principle: First of all, the gas enters the separator feed air
distribution chamber from the feed inlet and flows to the cyclone inlet through
the collision and baffle of the cyclone sub branch pipe to make the air flow
Cont…
Raw meal conveying system
To transport of raw material and handling it from the one section to other
section by means of the following conveying system.
Belt conveyor

Bucket elevator

Drag chain

Air slide

Screw conveyor
 Air slide
The fine material from all cyclones, are lift into the air slide by gravity form. The fine
particles are flow on the canvas (like cloth) and air is flow under the materials by fan
pump to move fine from the upper part of canvas. Pulverized raw meal is conveyed. The
inclination angle for air slide must be 4-12 degree.
 Drag Chain

These are used almost exclusively to handle coarse material from the
cyclone separator to return into the raw mill. They are open trough
conveyors and it has chute as discharged to pass coarse material into the
raw mill to again crushing and grinding.
Interlocking (safety, operational….): - An inter lock is such a safely feature or device which makes
the functional of two mechanical devices interdependent & safe Interlock is

•1, starting: in order to avoid energy loss.

•2, operational: to kept the sequence of productivity function in each operational unit for instance to
operate the raw mill system the step should be start from homo silo →divert change→ air slide →
bucket elevator → air slide → separator→ circulation fan→ bucket elevator→ bag filter → screw
conveyor→ oil station→ raw mill → belt conveyor→ weight feeders → storage(silos)

•This means from end to start!!!!

•3. Protection interlocks: as name implies to save the operation of the machine. Too kept over load it
is needing protection it is used for emergently that under & over temperature and pressure with
voltage.
 Standard operational procedures (SOP
The start sequence alternately starts each equipment in the sequence from downstream to
upstream
1. Make sure the preparations are completed before start up the raw mill system.
 Contact with lab to confirm the material will go into which silo.
 Confirm the air compressor air supply system used for raw mill conveying is normal or not.
 Check the instruments Inform the relative departments to cooperate the operation
2. Raw mill proportioning silo (both limestone, coal, clay, pumice and basalt) is feeding
 Check stock level of raw mill proportioning silo
 Make sure the homo silo is ready for receiving
Check the homo silo level Stock
 lubrication system of ball mill is ready:
 confirm on site the choice of oil pump
 heat the oil container of thin oil station, if oil is low in temperature
5. lubrication system of mill starts up
 Choose oil pump to be started.
 Startup low-pressure oil pumps of main bearing.
 Startup oil pumps of main step-down gear.
 Startup oil pumps of main motor.
 High-pressure oil pump of main bearing is started automatically after the low-pressure oil pump of main
bearing runs normally.
 Beware of the oil supply and its pressure, which can be observed through the onsite peephole. Change
the oil filter in time.
6. Startup transportation system into the homo silo
 Start the top Homo silo air slide fan (RW311 FN 06 and RW311FN07)
 Start the top Homo silo bag filter system (RW311BF03 and RW311BF04)
 Startup bucket elevator （ RW311BE02).
 Start the Air slid fan (RW311FN04 and RW311FN05)
 Follow the bucket elevator Current and the diverter position.
7. Start the drag chain transportation
 If mill is stopped with material mill must be rotate with auxiliary motor for some minutes
8. Start dynamic separator (RW311SR01)
 Use the maximum speed of the separator until the first result of quality deliver
 Start the bucket elevator (RW311BE02)
9. Start the circulation fan (RW311FN03)
 Manipulate the damper opening accordingly
11. Start mill fan (RW311FN02)
 Manipulate the damper opening accordingly
12. Start the bag house system (RW311BF02)
13. Start mill （ RW311BM01 ）
 Stop the auxiliary motor and change in to main motor
 Beware of the startup current
 And the mill noise
 If the mill failed to start up for once, restart it after examination and with an optimum interval time.
 Start mill feeding system
 Start proportioning silos dust collector system (RW311BF01 and RW311FN01)
 Start the common belt, RW311BC01
 Start belt weighing scale （ RW311.WF01-1~RW311WF06)
 Set the raw material proportion according what required by the Lab.

 Challenges face during raw mill operation
mill blockage
feed and air enter in same chute (poor ventilation fan)(closed circuit)
Moisture
Factor affecting mill efficiency

 size of raw material(<25mm)

 moisture content (<3%)
 Ball distribution
THANK YOU