MENGSTEAB INDUSTRIAL AND COMMERCIAL PLC

KUYU CEMENT FACTORY

PRODUCTION DEPARTMENT
ASSIGNMENT TWO(PROPORTION AND RAW MILL AREA)

NOV 2024
 Out lines
Raw material proportioning
Raw mill system
 Raw material proportioning
Raw materials transported by bucket elevator into separate feed silo.
The raw materials stored in individual feed bins are proportion on belt
conveyor.
Advantage of raw material proportioning
 To achieve desired product.
 Optimized Performance of clinker produce.
 Quality control.
Durability of the final product.
 Function of weight feeder
Control flow rate of material .
Quality control.
Accurate Measurement.
Capacity of weight Feeder
 Refers to the maximum amount of material it can transport or measure over a
specific time period.
 Mechanical parts of weight feeder

 Belt: it is used for conveying raw material rises from silo on the weight
feeder.
 Drive motor: used to energize the belt through an electric motor.
 Rollers: to support the belt
 Drum : to move or drive the belt and they are drive (by gear motor) .
 Chute: to feed the raw material into the long belt conveyor of ball mill.
Weighting Method
◦Belt cut : it involves weighing materials in batches before mixing and
ensures precise control over the amount of each component based on chemical
analysis.
Belt cut=*3.6ton
Material Ratio Control Mechanism
 Control Systems PLC: Programmable Logic Controllers it receive
information from load cell and they adjust feeders.
 VFD:are focused on controlling the speed of motors that drive the feeders,
enabling precise flow control based on commands from the PLC.
 Raw mill system
There are two types of ball mill circuit
1. Open circuit ball mill : the grinding process occurs without the material
being circulated back through the mill. This means that the feed material and the
ground product are discharged directly from the mill, without any additional
classification or separation.
2. Closed circuit ball mill:- where the material is recirculated through the mill
 Cont.…
Raw mill have two compartment both compartment have different liner.
1st compartment have step liner
2nd compartment have wave liner
Liner used for.
 Protection of Mill Shell
 Improved Grinding Efficiency:
Control of Material Flow:
 Bags filter function
Bag filter is a type of air pollution control device that uses a series of bags to
remove particulate matter from gas stream.
Function
Air Pollution Control: They help reduce emissions of harmful pollutants into
the atmosphere; by filtering out dust thereby minimizing environmental impact
Dust Collection: is to collect fine particulate matter (dust).
Product Recovery: Bag filters can, allowing dust material for their reuse in the
production process.
 Types of bag filter
1) Mechanical Shaker Bag Filter
2) Reverse Air Bag Filter
3) Pulse Jet bag filter
But in case of KCF we use pulse jet type of bag filter
As air flows through a series of fabric filter bags, the larger dust particles are
captured on the outer surface of the bags, while cleaner air passes through the
filter media and exits the system.
The cleaning is performed when the solenoid valve sends a message to the
membrane valve
 Separator
Separator is to increase the efficiency of the grinding process and ensuring
that the final product keep the quality standards.
dynamic separator :- It used to separate coarse particles from fine based on
their size and density.
Cyclone separator :- It used to separate fine particles from the gas stream by
creating vortex and due to density
 Drying
Drying is the process of removing moisture from raw material.
In case of KCF drying was done in mill by passing hot gases from burner to
ball mill. the main controlled variable is temperature based on
 ball mill working condition and
raw material moisture content
Raw mix design and chemistry control
 raw mix design is to determine the quantitative proportions of the raw
component in order to give the desired chemical and mineralogical composition
of the clinker.
 The raw mix design parameter are lime saturation factory (LSF), Silica
modulus (SM), Alumina modulus (AM) of desired clinker.
 Cont….
 In order to produce good clinker, the LSF is usually kept
between (92 .6 -98)%
 If the LSF is above 98% :
 The raw mix CaO become harder to burn, higher fuel
consumption, excess CaO in the clinker.
 If LSF below 92%
The clinker is easy to burn
Clinker burning hard with high fuel consumption
Free lime content is low
 Cont…
It characterizes the ratio of solid to liquid in the clinker and
the silica ratio falls between 1.9-3.2
When SM high:
 more difficult the raw mix to burn due to lower content of
Al2O3 and Fe2O3
Difficult to combine with CaO
Produces dusty clinker and More fuel consumption
When SM low
Easy burning for the raw mix and Liquid phase high Al2O3
and Fe2O3
 Cont…
The Alumina modulus it is used to determine the viscosity of liquid phase
The alumina ratio are in range from 1.5 to 2.5
When AM high:
Viscous Slag, hard burning, high early cement strength with low sulfate
resistance
When AM low:
Easier burning and Low early cement strength with high sulfate resistance
✓ High Fe2O3 content (less viscous clinker melt)
✓ Hard to grind due to formation of less porous clinker form dark in color of
clinker
Major Mechanical components of raw mill
Feeding device: Delivers raw materials into the mill for grinding.
Slide shoe bearing: side control for high load and support the
mill
Girth gear: rotating the mill.
Mill line plate: Protects the interior of the mill from wear and
tear bolts: used for to hold liners
Man hold: Inspection door during maintenance
Mill diaphragm: separates different sections of the mill and
controls the flow of material
Hollow discharge device: Allows the ground material to exit the
mill while preventing larger particles from escaping.
Steel ball: used as grinding media
Motor: provides the necessary power to drive the mill
High- and low-pressure pumps and its function
High Pressure: is the bottom of the sliding shoe
bearing before the Ball Mill is set in motion.
It is lubricant lifts the mill to enable and avoid
damaging metal to metal surfaces.
Low Pressure : is circulated from a reservoir to
the top of the sliding shoe bearing
It is used for showering and lubrication
Filtration: used to remove contaminants likes
dust, wear particles, water and other.
Heat exchanger: used to transfer heat from higher
to lower temperatures.
 Raw meal conveying system
Belt conveyor: Transports bulk materials or products from one location to
another
Bucket elevator :Elevates bulk materials vertically using buckets attached to
a chain
Drag chain: moves bulk materials along a trough using a chain and it is
commonly used for heavy materials
Air slide: is pneumatic conveyors that are mainly suitable to convey
pulverized dry products in a cement plant
Screw conveyor: Moves bulk materials through a rotating helical screw
within a tube.
 The components of bucket elevator
Inspection Door: - A door that provides access for maintenance and inspection
of the internal components.
Back Stopper: - A device that prevents reverse movement of the buckets when
the elevator is not in operation.
Casing: The enclosing structure that houses the elevator components and
protects them from external elements.
Chain Transmission: A chain system that transfers power from the motor to
the buckets.
Gear: A mechanical component that adjusts speed and torque in the drive
system.
Coupling: A device that connects two shafts, allowing for power transmission
between them.
Components of Air Slide and drag chain
Components of Air Slide
 Material Chamber: -Holds bulk material for transport
Air Chamber:- Contains upward-blowing air for
fluidization.
Fan: - Generates airflow to move material.
Motor: - Powers the fan and other components.
Components of Drag Chain
 Driving Device: - Powers the system to move material.
 Conveying Chain: -Chain that transports material along
the system.
 Material Inlet: -Opening where material enters the
system.
 Driving Sprocket: -Gear that engages the chain to drive
it.
Component of screw conveyor
Support: Provides structural stability to the
conveyor system.
Screw Shaft: Central component that rotates
to move material along the conveyor.
Gear motor: it used to drive the screw shaft.
cover: Safety feature that protects operators
from moving parts.
Coupling: Connects the screw shaft to the
drive mechanism, allowing for torque
transfer.
Grinding Media Charge (different size), wear rate

It contains balls of different sizes.

Size Distribution is used to fill the gaps between larger balls by smaller
The maximum and minimum ball sizes size distribution depend on
 Max. feed size of the material to be ground
Mill diameter and mill length
Grind ability and mineralogical structure of the feed material
Mill system (closed circuit, number of compartments, circulating load)
Wear is loss of material from a solid body by movement against other surface.
It is resulted in a lower the operational efficiency of machinery and its
components.
 Mill operation and operational parameters

Operation Steps
Material Feeding:
✓ Raw materials are fed into the ball mill through a feed chute
Grinding Process: The grinding media (steel balls) collide with the material,
causing it to break down into finer particles by rotation of the mill
The force used at the first compartment are:
Impact :moving particles strike against stationary surface
Compression: material crushed between two roller by pressure
Cont.…
Second compartment
Attrition: breaking down of materials
by rubbing action between two surface
Shear: Force that acts parallel to the
surface of a material, as opposed to
perpendicular (normal) forces
Operational Parameters
Ball size:larger balls in first compartment
enhance coarse grinding, while smaller
balls in the second improve fine grinding.
 Cont…
Material Characteristics: The
Feed Rate: should be balanced hardness, moisture content, and
with capacity of both compartments particle size distribution of the feed
to prevent overload and ensure material can affect the efficiency.
efficient operation. Residence Time: the more it stay
in the mill the more it become
finer ,so it has to be adjusted with
finess required
 Cont…
Temperature and pressure :The temperature parameter to be
monitored are
Temperature of firing hood entering to the mill, oil stations for
mill slides shoe bearing, mill gear box, main motor oil station,
main motor gear box, main motor bearing and their pressure also
has to be controlled
Fan damper opening
Fan damper position of the mill fan and circulation fan requires
adjustment
 Types of Interlocking and its function

Safety Interlocks :These interlocks prevent people or things from receiving

harm while the machine is running
Start Interlock: Prevents the system or machinery from starting under unsafe
conditions.
Operational Interlocks: Maintains safe operation sequence of productivity of
the machinery or system.
For raw mill system
Change divertor Air slide bucket elevator air slide and drag chain
separator circulation fan bucket elevator screw conveyor bag
filter oil station raw mill belt conveyor weight feeders silo’s bag
filer
 Cont…
protection interlock: prevent equipment from operating under unsafe
conditions, it helps to avoid costly repairs.
For mill Start the equipment in respectively
311FN04/05 311BE02 311AS01 311DC01 311SR01 311FN02 with damper
‘zero’ position & slowly increasing to 50-100% after start up 311FN03 with zero
damper position, after start up increase damper position to 50- 100%. 311BE01
311SC01/02 and 311BF02 stations(311ST01,02,03&04) mill motor ( 311BM01)

feed after observing all parameters, like 311BC01, 311WF01,02/03,04,05&06

 Challenge Face During Raw Mill Operation and their solution

Challenge Face Possible solution

Wearing of steel ball Select the material steel ball made up

of and replace the wearied
Blockage of slot Has to be frequently cleaned

High moisture content Select, dry, and build stock of the raw
material
overload Control moisture, dumper position and
feed rate
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