INSTRUCTION for COMMISSIONING of UM27.

3 at
KBZI..

Following is the instruction for the commissioning of the raw

mill at Cemex, Columbia.

Before Start Up of the Mill.

1. Inspect that the mill and the classifier is correctly installed

and collect the final erection report, where the tolerances
are measured.

2. Check the height of the dam ring. Before the first start the
dam ring is recommended to be set to 80 mm.

3. Check the opening area of the louver ring. With an

expected air flow of 150,000 cum/hr and a velocity of 70
m/s the opening area shall be 0.8 – 0.85 sqm.

4. Check the angle of the armour ring. It shall be 15 to 20 dg.

And the height shall be 250 mm to 350 mm.

It is important that these procedures are done before start of the

mill.

Starting Up the Mill..

1. The fist start of the mill shall be with 60 tph. The classifier
RPM shall be 102 RPM and the gas flow shall be
approximately 150,000 cum/hr or a load of the motor of
the mill fan of approximately 85% of full.

With this condition the mill shall be kept operating until the
correct fineness has been obtained by adjustment of the RPM of
the classifier. If the product is too fine the RPM shall be
reduces, and if the product is too fine the RPM shall be
increased.
The gas flow is determined from the kw of the mill fan and the
pressure after the cyclones by using the formula

Kw = 2.72 * 10(-5) *Flow*mbar/.75

Flow is cum/hr

If you need a continuous measure of the flow, then you can

insert the above equation unto the control system..

At this point where the residue is as requested, all operation data

has to be recorded every hour.

Until the residue is stable it is expected, that this first period is

taking at least 6 hours.

2. After the required fineness has been obtained, then

increase the feed in steps of 2 tph. Between each step it is
important to have patience, and it is not recommended that
interval between the increase is shorter than 30 min.

3. Continue to increase the feed in steps of 2 tph until there is

showing some small reject.

If during any of the adjustments of feed the mill starts to reject

material it is important to increase the grinding pressure. This
has to be done in co operation with the plant staff, and in steps
of maximum 2% increase, and never more than the maximum
95% of allowed grinding pressure.

When the point has been met, where it is not able to feed more
because of the limit of mill motor power following assessments
have to be made.

a. Are the vibration levels within an acceptable value.

 b. Is the grinding pressure below the maximum allowable
value.

c. Is the reject very low, which shall only be a few kg per

hour.

If all these factors are still acceptable, then the dam ring shall be
reduced by approximately 3 mm.

This is expected to reduce the kw of the mill approximately 20

kw.

After the reduction of the dam ring start the mill as before the
dam ring was reduced and operate for two hours during which
period the reject shall be observed. If the reject has increased
then increase the grinding pressure as above.

It is not expected, that the dam ring shall be reduced below 75

mm.
Commissioning Guide Lines, KBZI.

Limestone Crushing.

The limestone crusher consists of a two stage crushing, primary crusher

is a jaw crusher and the secondary crusher is an impact crusher.

The gab in the jaw crusher will initially be set to produce product size of
maximum 300 mm.

From the jaw crusher the limestone is going to the impact crusher,
where the limestone is crushed to a product size of maximum 60 mm.

The only control function of the limestone crushing is the feeding

velocity of the laminated feeder to the primary crusher, which must be
adjusted manually by the operator.

The limestone is transported to an open stock pile, conical stock pile

with bottom extraction. To minimize the development of dust it is
important to keep as much stock as possible in this stockpile, and an
amount of less than 5,000 ts livestock shall be avoided.
Shale, Gypsum, and Coal Crushing.

Even the crushers are different types, Roller Crusher for shale, Impact
Crusher for Gypsum and Hammer Crusher for coal, the principles for all
the operations are the same.

The lump material is fed into a receiving hopper with front end loader.

From the hopper the material is fed to the crusher by extraction belt
and the feed is controlled by varying the speed of the extraction belt.

As for the limestone, the product size for the individual products shall
be obtained by adjustment of the crushers during commissioning.

Following are the required product sizes,

Shale max. 60 mm

Gypsum max. 25 mm

Coal max. 40 mm.

Raw Mill Department.

Before starting the raw mill following departments must have been
tested and found fully able to operate from the PLC system in the CCR..

Feed to the Raw Mill.

Raw Mill.

Raw Mill Fan.

Transport on the Top of the Homogenizing Silos.

Main Bag House with Fan.

Complete Extraction System from Homogenizing Silos.

Hot Gas Generator.

Feed to the Raw Mill.

There are 4 feeders.

Limestone is fed directly from storage by pan conveyor of variable

speed controlled by a belt weigher on the belt after this pan conveyor.

There are three other feeders each under a feed bin.

Before commissioning it is important that all feeders are calibrated by
leading the material through the gate DG01 to a truck for weighing on
the truck scale.

When starting the mill this is important that the feeders are correct, so
that we can be sure of the chemical composition.

Raw Mill.

The mill itself is equipped with 6.3 kV motors.

Before staring the machine it is important that the motor are operated
in no load condition and that all the safety devices are correctly tested.

After this has been done, the motor can be connected to the mill gear
box.

For other items to be checked before start production of the mill, the
following are the most important.

The Hydraulic System must be flushed until it is completely free from

dirt.

All Lubrication Systems must be checked, that they have lubricants.

Dam Ring Height shall be set at 3% of table diameter, or ap. 80 mm.

Opening of Nozzle Ring shall be at 0.8 sqm to 0.85 sqm, corresponding

to 70 m/s, as the mill has no external circulation system.

Check that the louvres in the nozzle ring are between 38 and 45 dg to
horizontal.

Classifier must be rotated at minimum 90% of maximum RPM for at

least 2 hours.

These are the main points to be checked, before the mill can be started
with production.

Raw Mill Fan.

The mill fan shall be run minimum 24 hours with closed damper before
the mill system can be started with production.

Raw Meal Transport on the Top of the Silos and Main Bag House and
the Bag House Fan.

Check all air slides are clean before start and run for 24 hours no load.
When all these functions are tested then the entire raw mill
department shall be started from the PLC in the CCR.

Complete Extraction System from the Homogenizing Silos.

Before starting the production of raw meal, the entire extraction

system from the homogenizing silos must be tested. First all the air
slides and connections inside of the silo must be checked with soap
water for leakages as well as any leakages in the silo itself.

After these checks has been found to be ok, then the silos are to be
closed, and if these tests have been carried out successfully, then it will
not be necessary to open the silos again for more than 10 years.

Hot Gas Generator.

The final check before the start of the production will be, that the hot
gas generator can operate.

Start Up and Operation of the Raw Mill.

See separate instruction for this operation.

Raw Meal Homogenizing and Kiln Feed.

For the first 1000 t of production of raw meal, all the raw mill product is
taken only to silo number 01. During this operation an hourly average
sample of raw meal is collected and analyzed, and an average
composition of the 1000 t is calculated.

When the production of raw meal has reached 1000 t, the extraction of
raw meal from the silo starts, and the raw meal is circulated to silo 02.
During this extraction an hourly sample is taken and analyzed, and the
result is compared with the analysis from the raw mill output filled into
the silo.

If the analysis result from the filling into the silo is similar to the result
from the extraction, it shows, that the sampling is correct. If there is a
deviation on the LSF of more than 2 units, the it is necessary to find out
of the reason to the error.

After circulation of 500 t from silo 01 to silo 02 the raw mill can be
started again, and this time the product from the mill is taken to both
silos. During this operation it is recommended to continuously circulate
raw meal from the silos back to the silos.
When the raw meal level reaches 70% on both silos, the raw mill is
stopped, but circulation of raw meal continues. By hourly samples the
average chemical composition of the product in the silos are
determined, and it is important that this average composition is within
1% deviation from the decired value.

The raw mill can now be started again, and the silos must be filled to
between 90 and 95% filling, after which the stock of raw meal is
sufficient to start the kiln.

The extraction of raw meal from the silos and circulation must continue
as much as possible during the entire time until the kiln production can
start.

Chemical Composition of the Kiln Feed.

The chemical composition for the kiln feed will be given in a separate
instruction.
Kiln.

Before the heating up of the kiln following must be checked and/or

operated from the PLC system in the CCR.

Kiln Feed.

Pre Heater.

ID Fan.

Kiln Drive, Baring Device and Main Motor.

Clinker Cooler.

Clinker Transport.

Cooler Excess Air.

Coal Mill.

Kiln Feed.

The operation of the kiln feed circulation is as described above. The last
12 hours of the heating up of the kiln, the kiln feed is circulated through
BW01 and BE01, and returned to the raw meal silos through gate GD01.
To avoid any raw meal from going into the pre heater during this
heating up of the kiln it is necessary to keep SC09 closed during the
entire period as well as operate all equipment until this gate
continuously. During these 12 hours the amount of kiln feed is set at a
rate of 20 tph, which is the expected amount on which the first feed to
the kiln will take place.

Pre Heater.

The pre heater has no moving parts, which can be tested before
heating up. For this department is is necessary to inspect, that all
cyclones are complete clean from foreign material, and that all material
pipes are free, so that there will be no obstruction of the flow of raw
meal, when the feeding of raw meal starts.

All instruments such as temperature and pressure as well as the gas

analyzer must be checked and calibrated before heating up.

ID Fan.

As for the raw mill fan, the ID Fan has to be operated for minimum 24
hours with closed damper before the heating up of the kiln is started.
Kiln Drive System.

After the refractory has been installed in the kiln, it is not advisable to
rotate the kiln with the main drive at higher RPM.

The testing of the kiln drive system will therefore be for the baring
device with the kiln and the main drive without being connected to the
kiln gear box.

Before the rotation of the kiln it is essential to check that all bearings
are lubricated as well as the lubrication of the girth gear is functioning
correctly.

Clinker Cooler.

All function test of the clinker cooler as well as testing of all cooling air
fans shall be done before heating up.

Before the heating up is started, it is necessary to place 2 ts of crushed

limestone at the inlet end of the cooler with a thickness of about 300
mm layer. This is to protect the cooler grate plates from the fall of the
first clinker to the cooler when the kiln is started.
Clinker Transport and Cooler Excess Air.

All equipment in these departments must be tested and run without

load for at least 24 hours before heating up of the kiln, and they have
to operate during the entire time of the heating up. When the heaqting
of the kiln is started, the clinker must be diverted to the silo for
unburned clinker.

Heating Up of the Kiln and Starting Up of the Kiln.

See Separate Instruction for this Operation.

Coal Mill.

Before starting the coal mill all equipment in the department must be
operated with no load for at least 24 hours. Before the start of the coal
mill with coal, it is necessary to operate the mill for at least two hours
with limestone to fill up all ,,dead corners,, with limestone dust. After
these two hours of operation a visual inspection has to be done inside
of the ducts wherever possible as well as in the bag filter. If during this
inspection there are any suspicion of the possibility of coal dust to be
accumulated, these corners must be corrected.
Start Up and Operation of the Coal Mill.

See Separate Instruction for this Operation.

Cement Mill Department.

Before starting this department it is important to do similar check of

the cement silo as for the homogenizing silos. After this check the silos
shall be closed ready to receive cement.

Before starting the cement mill department it is necessary to test and

operate following from the PLC system in the CCR.

Before starting the cement mill it is necessary to operate and to

calibrate the feeders, clinker feeder, gypsum and 3rd (limestone)
material similar to for the raw mill.

Cement mill must operate without ball charge for at least 30 minutes.
During this time all checks of the lubrication system has to be done and
all safety equipment must be checked.
Transport and classifier system must operate minimum 24 hours
without load before production is started.

Starting Up of the Department.

See Separate Instruction for the Cement Mill Department.

General Start Up Procedures.

During startup of a department following procedure must be followed

strictly.

1st Step. Individual operation if single equipment in local.

All equipment is operated from local where the purpose is to check the
mechanical functions of the machines together with all safety and
protection equipment belonging to each machine. At the same time all
signals are tested to the CCR to verify the correctness of all signals.
2nd Step. Group and Sequence Testing from the CCR.

When all equipment belonging to a group has been tested as above a

group test has to be performed from the CCR, where it is verified that
all equipment in that group starts according to interlocking diagram and
that all other functions.

3rd Step. Total Testing of a Department from the CCR.

When all individual groups have been tested a start without material
for the entire department must be performed. As it is not possible or
advisable to operate the big machines, the equipment under such
category will be either disconnected from the motor (which means that
only motor operates) or the motor will be put into test position in the
MCC (which means that the motor will not run, but send signal to the
CCR as if it is running)

4th Step. Final Test.

After 3rd Step is satisfactorily finished, the entire department is started

without load and shall be allowed to operate as an entire department
for at least 8 hours shall be kept running like this.
5th Step. Start of Production.

After the final 8 hours operation the entire department is ready to start
production.

There are individual instructions for each main department as

mentioned above.

During this first start it is important, that a meeting is held just before
the start with material to explain all concerned parties about the start
procedures and to place persons at each machine to follow what
happens, when the equipment starts to operate with material.

As it is clearly expected that something unforeseen will happen it is

not advisable to start any department with production after 2 pm,
expect from feeding the kiln must always be done during the morning
hours, where all staff are well rested and ready to work extended
hours.
Instruction
For
Raw Mill, 27.3
at KBZI.
Preparation for Start Up.

This instruction is meant as a guide line for the first start up of the raw
mill at KBZI.

Before the first start of the mill, it is important that all the system has
been tested as described in the Commissioning Guide Lines.

Besides the adjustments of the dam ring, the nozzle ring and other
parameters already given it is important that the minimum roller
position allows the mill to transfer full grinding force to the material at
all time, which means that the setting of minimum roller position for
both hydraulic system and mechanical stopper shall allow the roller to
freely move to 10 mm from the table.

For the start of the mill following procedure shall be followed.

1. Start the Transport of Raw Meal to the Silo.

This will allow the product to be sent to the homogenizing silo.

 2. Start the Main Bag House Fan and the Dust Transport to
the Homogenizing Silo.

Regulate the damper in front of the bag house fan and/or regulate the
RPM of the bag house fan to always keep negative pressure at the raw
mill gas circuit.

3. Start the Raw Mill Fan.

Regulate the flow of the fan by opening the damper DA01 in front of
the fan and the damper DA02 until the fan absorbs 80% - 85% of the
full power/ampere.

Before proceeding further get familiar with the reaction from the mill
fan and the pressure in the different points when regulating the
dampers in the gas flow circuit.

4. Start the Classifier.

Adjust the RPM to 102 RPM.

 5. Start Mill Table.

Start the mill table with lifted rollers. At the same time activate the
lubrication system and hydraulic system as of the program interlocking
system.

6. Start the Hot Gas Generator.

Start the hot gas generator at minimum fuel.

Keep the inlet temperature at between 90 dg.C and 100 dg.C by the
opening of fresh air damper DA04. Continue this procedure until outlet
temperature is stable between 80 dg.C and 90 dg.C. and continue for
another 2 hours.

When this temperature profile been met, it is time to start feed.

7. Setting of Hydraulic Pressure.

Set the set points for the hydraulic pressure at 0.8 – 1.2 MP at the
lower pressure and 6.2 – 6.6 MP at the active grinding pressure. This
pressure will allow the mill to absorb approximately 600 kw to 650 kw,
which will be enough for a capacity of 70 tph minimum.
 8. Start the Feed.

Put the set points for the different feeders at the percentages for the
different materials given from the laboratory. Make sure the total sum
of the feeders is 100%.

Start the feed at 60 tph. 30 s after the feed has reached the mill,
activate the rollers to go down for grinding. During this time it will be
necessary to increase the damper of the mill fan to maintain the
loan/ampere of the mill fan, which shall be kept at 80% to 85%.

9. After feeding.

During the first time after the feed it is important to find a feed, where
the mill will not vibrate. When this has been reached the mill shall be
allowed to operate at this condition for at least 1 hour, where the only
adjustment will be to maintain the out let temperature at 80 dg.C by
regulating the fuel to the hot gas generator.

After 30 minutes operation a sample of the product must be taken and

the residue on 90 micron must be measured. The required residue is
12% on 90 micron sieve. If the result is too coarse, the RPM of the
classifier shall be reduced, and if it is too fine, the RPM shall be
increased. During this time the change in RPM shall be 2 RPM of the
classifier for every 1% difference in residue from the desired 12%. This
procedure is repeated with samples taken every hour.

When the 12% +/- 1% residue has been reached for two consecutive
hours it is the time to try to increase capacity, which will be done
according to instruction for mill operation.
Instruction
for
Kiln, 3.2 m times 45m
at KBZI .
This instruction is meant as a guide line for the commissioning of the
kiln at KBZI. All values are approximate and the actual values must be
found during the actual commissioning.

Heating Up of Kiln.

Before the heating up of the kiln with diesel oil, following must be
done.

Place 2 ts of limestone equally distributed throughout the 15 meters

from the outlet of the kiln.

Open all dampers below the cyclones manually, and block them in open
position.

All equipment with regards to the kiln system must have been checked
as described in the general instruction for commissioning of KBZI.

Fan for main Bag House Fan must be run and damper adjusted to
maintain negative pressure at kiln hood.

The drive of the kiln is on auxiliary drive.

The stroke length of the cooler must be set at 280 mm except for the
two lanes close the the cooler walls, where the lengths must be 240
mm. This is to slow the transport along the walls, where it is normal to
have red rivers of hot clinker.

Clinker transport must be running.

Burner pipe must be in center position of the kiln and the burner tip
shall be 250 mm inside of the kiln

Start the Primary Air Fan.

Place the ignition gas burner just below the tip if the burner pipe.

Start the diesel oil at 80 l/hr and maintain this amount for the first 8
hours. During this time the kiln is rotated 120 dg. Every 15 minutes.
recording of the temperatures in calciner as well as in all the cyclones
are recorded every hour.

At the end of the 6 hr period it is expected that the temperature at the

outlet of the lowest cyclone has reached around 150 dg. C. At this time
it is not necessary to keep the gas ignition burner in the kiln any longer
and it can be taken out.
During the following 24 hours the fuel is gradually increased to
approximately 150 l/hr. The increase in oil is done based on the
increase in temperature at the outlet of the lowest cyclone, which shall
be increased 6 dg. C per hour, and the temperature at the outlet of the
top cyclone, which shall be increased by between 3 dg. C and 4 dg. C
per hour. During this first 30 hours period the draft in the kiln is entirely
to maintain the negative pressure at the kiln hood regardless of the
oxygen readings at the outlet of the pre heater. During this time the
kiln is rotated 120 dg. Every 10 minutes.

At this time start the kiln feed at 20 tph by circulating the entire feed
back to the homogenizing silos.

Start of Coal Firing.

After the 30 hours, the kiln shall now be hot enough to support a flame
from coal and the coal firing is started at a minimum flow of not more
than 250 kg/hr maintaining the oil at a minimum to stabilize the flame
from the coal. Once there is control of the coal flame the oil can be
stopped, and the amount of coal shall be added to support the increase
in temperature as described above.
When the coal flame is stable, and the kiln is deemed hot enough to
support this coal, following is to be done. This condition is expected to
be when the temperature at the outlet of the lowest cyclone is 400 dg.
C.

a. Open the damper in the tertiary air duct to 30%.

b. Start the blower of the fixed inlet with 50% damper opening.

c. Start the excess air fan with closed damper. When the conditions
are stable with these new conditions, open the damper of the
excess air fan to 15%.

The Heating up Shall now Continue by Adjustment of the

amount of Coal as well as of the Draft.

Until the temperature at the outlet of the lowest cyclone reaches 500
dg. C the equipment as mentioned above is kept running as described.

After reaching the temperature 500 dg. C the kiln will be running
continuously at auxiliary drive and the cooler grates will now be started
at 1 stroke per minute and kept at this sped throughout the remaining
part of the heating up period.

The ID Fan shall be started at lowest RPM with the damper at the ID
Fan now used to adjust the draft.
Kiln drive is changed to main drive and the kiln is kept running
continuously at 0.2 RPM. to 0.3 RPM

During this period it is expected, that the oxygen level at the outlet of
the pre heater will be not more than 6%.

The heating up now continues like this until the temperature of 650
dg. C is reached in the lowest cyclone after which the kiln feed can be
started. It is expected, that the coal to the burner at the end of the
heating up will be between 1.2 tph to 1.5 tph.

Start of Kiln Feed.

From 48 hours after the heating up has started there must be a manual
inspection of all departments as well as the pre heater every hour, and
any abnormal situation must be reported and immediately taken care
of.

Procedures for the first kiln feed is following

a. Increase the kiln feed to 30 tph, still circulating back to silos.

 b. Increase the coal gradually to 2.5 tph.
c. Keep oxygen at 4% after pre heater.
d. Keep under pressure at kiln hood at -2 mbar by means of excess
air fan/damper.
e. Keep negative pressure after the ID Fan at -3 mbar by means of
fan for the main bag house.

When the temperature after the pre heater reaches 380 dg. C, then
change the kiln feed from circulation to feed to kiln.

The commissioning engineer must arrange to have persons stationed at

cyclone 4 and cyclone 5 to report from visual inspection, that the kiln
feed reaches these cyclones. This must be within 30 seconds after the
kiln feed is shifter to kiln.

When feeding the kiln and increase the feed the expected approximate
amounts of kiln feed, coal firing and RPM of the kiln are shown in a
table below.

The kiln is initially fed with 20 tph and 3.0 tph of coal to the main
burner. RPM during this initial feed is 0.6 RPM.

During this first feed it is important to keep a high oxygen level of at

least 8% afer the pre heater. This is kept until the raw meal reaches the
burning zone, which can be seen by visual inspection. If in this condition
it is not possible to keep the temperature at the outlet of the top
temperature below 420 dg. C, it is necessary to increase the feed to
around 25 tph.

As soon as the feed, coal and the top temperature is under control the
feeding of coal to the calciner shall be started. Before the coal is added
to the calciner it is important that the temperature after the 4th cyclone
is at least 600 dg. C, which is enough to ensure ignition of the coal, but
to be sure the coal ignites it is necessary to start the diesel ignition
burned. As soon as the coal ignites, the temperature after the calciner
shall be increased to 820 dg> C – 840 dg. C.

This condition will be kept until the feed reaches the burning zone. It
will be very difficult to get clinker from the first moment, and it is very
normal that the kiln will be very dusty with unburned, but there is no
reason to panic and do any changes.

As soon as the material reaches the cooler, all the remaining cooling air
fans shall be started with 40% open damper.

During the entire process the damper position of the tertiary air duct
shall be maintained at 30%.

When the burning zone starts to clear up the feed, RPM and coal shall
be increased as indicated in below table until a total feed of 70 tph,
corresponding to 1,050 tpd of clinker.

It is recommended to keep this feed for one day, before the kiln feed is
increased to 85 tph during the next period, which shall be during the
day time with steps of 3 tph every approximate one hour.

The kiln is designed to 1,250 tpd with ample safeties, and it is important
to reach this capacity within 4 days.
Table for Kiln Commissioning.

Kiln Feed RPM Clinker Coal kg/kcal.

Kiln Calciner

Tph. Tpd. TPH. TPH.

20 0.6 300 2.9 - 1280

25 0.6 375 3.0 0.6 1250

30 0.7 450 3.0 1.2 1220

35 0.9 525 3.0 1.7 1200

40 1.2 600 3.0 2.2 1150

45 1.5 675 3.0 2.5 1100

50 1.8 750 3.0 2.8 1050

55 2.1 825 3.0 3.2 1000

60 2.4 900 3.0 3.5 950

65 2.7 975 3.0 3.7 900

70 3.0 1050 3.2 3. 6 850

Stabilize for 24 hours

75 3.2 1125 3.4 3.6 830

80 3.4 1200 3.4 4.0 810

From the feed of 30 tph (450 tpd of clinker) the strokes of the cooler
shall be increased to approximately 2 strokes/min and increased as
necessary to keep 500 to 600 mm clinker bed.

Safety.

During the first start and operation it is often necessary to visually

inspect inside cyclones, kiln and cooler. It is very important to be aware
of the danger, as there are very hot conditions inside.

Apart from cyclones, there is no material accumulations inside which

can flush out, but there can be puffing of hot gas, which can cause
some inconvenience, as well as the material is of basic nature, so that
any dust from the kiln system coming into eyes must be cleaned
immediately.

If a blocked cyclone is to be inspected, it is necessary to show high

degree of cautiousness when opening an inspection hole, and in no
cases it is allowed to open a big door or to cut a hole in a cyclone with
material accumulation inside. Cleaning of cyclones must only be done
under supervision, and it is important to inform all workers about the
dangers during cyclone cleanings.
Coal Mill,
Raymond Type, KBZI.
The coal mill is a Verical Coal Mill, Raymond Type, which is a spring
loaded mill, where the grinding pressure is transferred through springs
and nor hydraulic.

The mill is over sized from a grinding point of view, as it must be able to
dry a very high moisture content in the dry coal.

As it is only expected, that the mill will absorb less than 150 kw of the
installed 250 kw, it is recommended that the springs for the first
commissioning is only loaded to make the mill able to absorb 150 kw.

Before commissioning make sure that all the system is correctly tested
from the CCR and that especially all safety systems are functioning
correct.

First Start.

Before starting the kiln operating, the coal mill shall be operated for at
least 2 hours with limestone to fill up all dead corners with limestone
dust. The mechanical stop shall be set to 10 mm from roller low
position to the table. Make sure that the feeding belt is filled up to the
inlet of the mill from a feed of 10 tph.
When Starting the Mill with Limestone.

Start the mill fan, FN02 and increase the flow by opening the damper
DA02 to 50%.

Open the damper DA03 to 50%.

Start the Classifier at 150 RPM.

Start fan FN01 and open the damper to 40%.

Adjust the dampers to obtain mill fan power to 60% of installed power
and maintain under pressure in the mill inlet.

Start the mill motor.

Start the transport away from the mill and the bag filter transport.

Start the mill feed.

Operate the mill at 10 tph feed for 2 hours and inspect the system as
described in general instruction.

Sample the limestone dust from the the first hour of operation shall be
analyzed for the residue on 90 micron. For every 1% the 90 micron is
different from 15% the classifier shall be reduced or increased by 5
RPM to get the 15% residue for limestone and of the end of second our
of operation one more sample shall be analyzed. From this sample it
will be possible to estimate the correct RPM to obtain 15% residue for
grinding limestone dust.

The limestone dust is blown into the calciner by the SC06 and following
equipment after finishing grinding of the limestone.
Start with Coal.

When the kiln has been heating up for 10 hours it is time to start the
coal mill with coal and fill up the bin, BI02.

Follow the same start up procedure for limestone described above.

When the kiln is running it is important to start the coal mill as of the
entire safety operation.

a. Start the mill fan, start the booster fan as descried above.
b. Start the classifier and adjust the RPM to 40% higher value that
the estimated value to obtain 15% on 90 micron for limestone as
above.
c. Circulate the gas from filter outlet to mill inlet to reduce the
oxygen in the mill to below 10%.
d. Start the mill motor.
e. Start transport away from the mill, the bag house, and the mill
feed.
f. Start coal feeding at 14 tph wet product.
g. When the coal grinding is normal, keep minimum outlet
temperature of the mill between 80 dg. C and 84 dg. C.
 h. After sampling the coal dust, adjust the classifier to obtain 15%
residue of 90 micron by increasing the RPM of classifier if the coal
is too coarse and decrease RPM if the coal is too fine.

When the kiln is operating normal, it is recommended to let the coal

mill operate 24 hours by keeping a constant level in the Bi02 at 90% of
full capacity by adjusting the mill feed based on the level in this bin.
Cement Mill
for
KBZI, 3.0 m times 11 m with
1250 kw.
Before Starting the Commissioning the Following Steps Must Be
Taken.

Make sure the entire system can operate from the PLC through the
CCR.

Operate the cement mill without feed for 30 minutes.

Check and confirm the opening of the sloths in the diaphragm to be 6

mm.

Filling of Initial Charge into the Mill.

The initial charge will be 80% of nominal charge, which will be 20 t in

the first compartment and 50 t in the second compartment.

First Compartment.

Before the filling of balls into the first compartment 2 t of clinker will be
charged into the first compartment to protect the lining when the big
balls are dumped into the mill. This will also protect the lining during
the first operation just after the start up. It is not necessary to fill any
material into the second compartment before adding the ball charge.
Initial Ball Charges Will Be

4.6 t of 90 mm balls, 23%

6.4 t of 80 mm balls, 32%

4.2 t of 70 mm balls, 21%

4.8 t of 60 mm balls, 24%

in the first compartment and

20 t of 25 mm balls, 40%

20 t of 20 mm balls, 40%

10 t of 17 mm balls, 20%

in the second compartment.

With this ball charge the mill is expected to absorb 1,000 kw, and the
production is expected to reach 30 tph to a Blaine value of 3,200 and a
residue of less than 8% on 45 micron.

Filling up of the mill to full charge will be described below.

Before the production is started following must be done.

Cement silos must be checked as described in the general instruction.

When Production Is Started the Steps Are Following

a. Start the transport to the cement silos.

b. Start the Classifier Fan and open the damper until 85% load of the
fan as well as open the fresh air dampers at the inlet to the
classifier.
c. Start the classifier and adjust the RPM to 140 RPM.
d. Start the mill fan and open the damper to 60%.
e. Start all lubrication pumps for the mill and the mill gear box.
f. Start the mill.
g. Start the feed to the mill with 90% clinker, 5% gypsum and 5%
limestone.

After one hour a sample is taken and analyzed for Blaine and residue of
45 micron. This Blaine value will not be very representative, and is only
indicative. After two hours another sample is taken and this value will
be used for evaluating, which adjustments shall be done to the
classifier RPM to obtain the required Blaine.
If the Blaine is higher than the desired value, then the RPM of the
classifier shall be reduced 5 RPM for every 100 Blaine difference, and if
the Blaine is too coarse then the classifier RPM will be increased by 10
RPM for every 100 Blaine value difference. The reason for different
changes of RPM is, that it is important that the cement quality is kept at
a high standard.

After two hours operation the mill is stopped and all liner plates and all
bolts in the diaphragm are tightened.

Second operation will be 8 hours after which the mill will be stopped
for bolt tightening.

Third operation will be 12 hours after which the bolts are tightened,
and forth a period of 18 hours will be operated. After another 100
hours operation, all bolts will be tightened a final time and all bolts are
spot welded.

The target for the cement fineness will be both Blaine and residue at 45
micron. Blaine shall not be less than 3,200 as well as the residue of 45
micron shall not be higher than 8%. These values will be kept until the
first 7 days cement strengths have been obtained, after which the
values will be evaluated together with the quality department and
eventually adjusted.
During the second operation period, the increase of feed will begin.

From 20 tph, the feed is increased by 2 tph every hour, and the load of
the bucket elevator is followed. Every increase in feed will result in a
corresponding increase in the load of the bucket elevator. As long as
this load remains stable and does not increase beyond 75% of installed
power, the feed is increased until 28 tph feed is obtained aafter which
the increase in feed in decreased to 1 tph.

During the final hour of the 4th period of operation, a complete set of
sampling is made in the cement mill circuit. This means a sample of
cyclone outlet for mill de dusting, a sample for feed to classifier, a
sample for the return from classifier to mill and a sample for the
finished product. These samples are used to calculate the circulating
load as well as the efficiency of the classifier. When the mill is stopped
it is stopped as a crash stop by stopping all the equipment suddenly.

When the mill has been cooled down, samples from the material in the
mill are taken to evaluate the grinding performance of the mill.

There must be taken 4 samples in the first compartment, one at inlet,

one at outlet and two with equal distances as well as 6 samples in the
second compartment with equal distance through the length.

Before the mill is started for the operation of its 100 hour period,
another 2 t of balls are added to the 1st compartment and 6 t to the 2nd
compartment in the same percentages as for the first filling.
This additional amount of grinding media will increase the mill motor
power by 100 kw and allow an additional production of 3 tph.

At the end of the 100 hr operation another set of sampling is

performed and the result from this sampling is used for the final filing
of grinding media.

If the residue of 2 mm at the outlet of the 1st compartment shows less

than 4%, then the final filling will be only 6 t of balls in the s2nd
compartment.

If the residue is more than 4% on 2 mm, then another 4 t of balls will be

added into the 1st compartment and 4 t in the second compartment.

Distribution of the ball size shall be as at the initial filling.

After this a mill production of minimum 35 tph can be obtained to a

Blaine value of 3200 and a residue on 45 micron of less than 8%.

For future filling of the mill with balls as compensation for wear, it is
recommended initially to add 500 kg 90 mm balls into the first
compartment and 1 t of 25 mm balls into the second compartment for
every 500 hours of operation. The period of 500 hours can be changed
based on the experience in the future.
Control of Chemical
Composition
of
Raw Meal/Clinker
at KBZI.
There are four main components in clinker, which are normally used to
control the chemical composition. The components are CaO, SiO2,
Al2O3, and Fe2O3.

When controlling the chemical composition of raw meal, it is normal to

control following modules

LSF = CaO/(2.8SiO2+1.18Al2O3+0.65Fe2O3)

SiM = SiO2/Al2O3+Fe2O3

AlM = Al2O3/Fe2O3

To be able to control all three modules, it is necessary to have four raw

materials, and generally it is necessary to have one number of raw
materials more than the number of modules, which shall be controlled.

When using coal as a fuel, the coal ash, which is normally rich in SiO2 is
absorbed into the clinker, so that the chemical composition of the
clinker must be calculated as the components from the raw materials
as well as from the coal ash. Therefore the LSF of raw meal is normally
higher than LSF in clinker, and SiM is normally higher in clinker than in
Raw Meal. Typically the difference between the clinker and the raw
meal is 3 - 5 in LSF and 0.15 – 0.25 for SiM.
The initial set points for the raw meal composition shall be

LSF = 102

SiM = 2.2 – 2.4

AlM = 1.4 – 1.6

The chemical composition of the raw meal will be approximately

SiO2 = 13.5%

Al2O3 = 4.0%

Fe2O3 = 2.4%

CaO = 45.2%

Titration will be 80.7% (45.2/56)

With expected coal ash in the clinker of 1.6% with a chemical
composition of the coal ash of SiO2 = 54%, Al2O3 = 11%, Fe2O3=6% and
CaO = 20% the chemical composition of clinker will be

SiO2 = 22.0%

Al2O3 = 6.3%

Fe2O3 = 3.7%

CaO = 69.4%

LSF = 97, SiM = 2.2, AlM = 1.7 and C3S = 63 with Free CaO less than 1%.

With this composition and the Blaine of 3200, the strengths of the
cement will be more or less as the strengths of cement from Thailand.

When the plant is operating in stable conditions, then it can be

discussed how to alter the chemical composition, but only small
changes are expected, mainly it ay be an idea to increase the SiM by 0.1
to 0.2 to 2.35.