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Cement
grinding installation sizing






2


Nonexhaustive list of equipments to be sized







2.2

List of the equipments (suite 1):









Item N°7:








Metal extractor and metal detector.




These equipments are essential to avoid the presence of
metallic particles often being in the clinker in the press




feed and which would cause problems to the rollers.




These pieces come mainly from the kiln.




The metal extractor and metal detector are proposed in the
package of the pregrinding circuit.




Here below a picture of a metal detector:








These equipments will not be developed here.









Item N°8:








System of temporary bypass in the event of metal detection.




This system exists in all pregrinding circuits and should be
foresaw.




The fresh material directly feeds the ball mill.




This system will not be developed here.









Item N°9:








The roller press.




A presentation on this type of pregrinding is available here:




ROLLER PRESS




A calculator giving the absorbed power of the press is also
available here:




ROLLER PRESS SIZING




A deagglomerator is also essential at the output of the press
in the case where the cakes go in a high efficiency




separator.




Here below is an illustration of the roll press:








This equipment will not be more developed here.









Item N°10:








The press output conveyor (deagglomerator) to the bucket
elevator.




This system wherein the cakes deagglomerator is to be
incorporated will not be developed here.









Item N°11:








The bucket elevator.




This conveyor is ideal for raising materials beyond 150m in
restricted spaces.




A full presentation is available here:




BUCKET ELEVATORS




A small calculator was developed for sizing roughly a bucket
elevator:




BUCKET ELEVATORS SIZING




This bucket elevator is not sized into the main calculator.









Item N°12:








Dust collection system of the bucket elevator.




We choose a small bag filter.




The following values are generally accepted for sizing the
filter:





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The sketch below gives an idea to the realization of the
suction points:








This filter will not be dimensioned here.









Item N°13:








Airslide from the bucket elevator to the RP separator.




This air slide is subdivided according to the number of
separator feeds (typically 2).




A full presentation is available here:




AIRSLIDE




A small calculator is available here:




AIRSLIDE SIZING




This auxilary is not dimensioned here.









Item N°14:








Separator of the press circuit.




Manufacturers may offer different types of configuration.




This will not be developed in this presentation.









Item N°15:








Cyclones of separator.




A document on the cyclones can be found here:




CYCLONES




A calculator to size the cyclones is available here:




CYCLONES CALCULATION




This will not be developed in this presentation.









Item N°16:








Separator filter.




It will be a bag filter.





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Item N°17:








Separator filter fan









Item N°18:








Impact flowmeter




This equipment is configured in the transport of rejects to
the press system.




The type is defined with a supplier of these devices.









Item N°19:








Airslide of rejects of the press separator.









Item N°20:








Belt conveyor to the circuit of the mill.




The conveyor comes either:




* from the roller press circuit




* from the weighfeeders section




It is dimensioned in the calculator.









Item N°21:








The ball mill.




A presentation explains how to size a ball mill with the
method of Bond.




This presentation is available here:




BALL MILL SIZING EXPLANATION




Deux calculateurs sont également à disposition:




MONOCHAMBER MILL SIZING CALCULATOR




2 CHAMBERS MILL SIZING CALCULATOR




In the circuit design calculator, only the mill with 2
chambers is considered.









Item N°22:








The static separator.




Many existing grinding plants are still equipped with a static
separator.




When we want to modify these installations, there are three
possibilities:




* Keep the static separator




* Replaced it by a 3rd generation separator




* Eliminate it and send the product of the filter to the
bucket elevator




In all other cases, the static separator has become obsolete
and is no longer offered in the flowsheet of new




grinding plants.




This equipment is not included in the calculator.









Item N°23:








Mill filter.




In most cases, this is a bag filter.




To calculate the amount of air for dedusting the mill, the
following calculator is used:




MILL VENTILATION AND FAN SIZING




This filter is of course in the full sizing calculator.





Filters discharge is often constituted of endless screw
conveyors.




A full presentation is available here:




SCREW CONVEYORS





Here the link for the sizing of screw conveyor:




SCREW CONVEYORS SIZING









Item N°24:








Mill filter fan.




See item N°23 here above.









Item N°25:








The water injection system of the mill.




This equipment is not, strictly speaking, sized.




But the amount of water required is calculated.




To do this, we must do a heat balance of the mill.




Several documents are available on this topic:




BALL MILL HEAT BALANCE




INFOGRAPHY




The calculator is on this link:




CEMENT MILL HEAT BALANCE (CALCULATION OF THE WATER NEEDED)




As written above, the system is not detailed here, only the
calculation is performed in the full calculator.




Here below, a typical water injection system:









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