1Reducingtheenergyrequiredingrindingclinkertocement:somecasestudies

H. Benzer,N. Aydogan ,H. Dundar andA. J. Lynch

HACETTEPEUNIVERSITYMiningEngineeringDepartment

2Reducingtheenergyrequiredingrindingclinkertocement

1.INTRODUCTION

MetPlant 201189August2011,Perth,WesternAustralia

0

500

1,000

1,500

2,000

2,500

3,000

3,500

2006 2007 2008 2009 2010

Worldcementproduction(milliontonnes)

The effect of change in ball size

Optimizing circuits containing HPGRs, ball mills and separators

The use of high intensity grinding

3Reducingtheenergyrequiredingrindingclinkertocement

2.OUTLINE

MetPlant 201189August2011,Perth,WesternAustralia

4Reducingtheenergyrequiredingrindingclinkertocement

3.THEEFFECTOFCHANGEINBALLSIZE

MetPlant 201189August2011,Perth,WesternAustralia

5Reducingtheenergyrequiredingrindingclinkertocement

3.THEEFFECTOFCHANGEINBALLSIZE

MetPlant 201189August2011,Perth,WesternAustralia

0

10

20

30

40

50

50 60 70 80 90

w

e

i

g

h

t

%

ballsize(mm)

1st chamberbefore

after

0

10

20

30

40

50

17 20 25 30 40 50

w

e

i

g

h

t

%

ballsize(mm)

2nd chamber

before

after

6Reducingtheenergyrequiredingrindingclinkertocement

3.THEEFFECTOFCHANGEINBALLSIZE

MetPlant 201189August2011,Perth,WesternAustralia

Capacity (tph)

Product type Before optimization After optimizationA 155 180B 178 205C 162 195D 142 160

7Reducingtheenergyrequiredingrindingclinkertocement

4.HPGRAPPLICATONSANDENERGYEFFICIENCY

MetPlant 201189August2011,Perth,WesternAustralia

8Reducingtheenergyrequiredingrindingclinkertocement

4.HPGRAPPLICATONSANDENERGYEFFICIENCY

MetPlant 201189August2011,Perth,WesternAustralia

(2) (3)

(1)

9Reducingtheenergyrequiredingrindingclinkertocement

4.HPGRAPPLICATONSANDENERGYEFFICIENCY

MetPlant 201189August2011,Perth,WesternAustralia

Case study 1 2 3

Raw materials fed Clinker (95%) Clinker (74%) Clinker (94)

Capacity (tph) 55.3 71.7 132.0

Specific energy use (kWh/t)HPGR - 8.9 8.02

HPGR-Ball Mill 32.7 29.5 21.6

Final product size (m) 30 68 28

10Reducingtheenergyrequiredingrindingclinkertocement

5.VERYFINEGRINDINGUSINGVBM

MetPlant 201189August2011,Perth,WesternAustralia

Vibration frequency (rpm) 1160

Motor power (kW) 50

Internal Diameter (m) 0.78

Internal Length (m) 1.2

Operational ball load % 90

11Reducingtheenergyrequiredingrindingclinkertocement

5.VERYFINEGRINDINGUSINGVBM

MetPlant 201189August2011,Perth,WesternAustralia

0

10

20

30

40

50

60

70

80

90

100

0.001 0.01 0.1 1

p

a

s

s

i

n

g

%

p.size(mm)

tot.FeedtoVBM1

VBM1discharge

VBM2discharge

sp.en.consumption(kWh/t)

28 days strength(MPa)

Finish cement 28 37.6

End-product 35 38.1

12Reducingtheenergyrequiredingrindingclinkertocement

6.CONCLUSION

MetPlant 201189August2011,Perth,WesternAustralia

Optimizingtheballsizedistributioninfinishmillingofcementusingmodelling andsimulation resultedinhigherproductionrate,reducedoverallspecificenergyconsumptionandlowercost ofmetalwear.

TheuseofHPGRsinfinishmillingcircuitsaspregrinders increasesthecapacityoftheexistingcircuitsbyreducingtheworkdonebythedownstreamballmills.ClosedcircuitHPGRs reducesignificantlytheoverallspecificenergy consumptionofthecircuit.

Vibratory ballmillsusedafterfinishcementproductiontoreshapethefinalproduct whentheadditivesareincreased resultsinacosteffectiveprocess.HoweverforhighcapacityfinishmillingcircuitstheapplicationoftheVibratoryBallMillsisnotpracticalduetotheirlowcapacity.

13Reducingtheenergyrequiredingrindingclinkertocement

7.ACKNOWLEDGEMENTS

MetPlant 201189August2011,Perth,WesternAustralia

IzmrCementPlantfortheirpermissiontopresentthiswork

HacettepeComminutionGroupmembersfortheirsupportinconductingthesurveys

Slide Number 1Slide Number 2Slide Number 3Slide Number 4Slide Number 5Slide Number 6Slide Number 7Slide Number 8Slide Number 9Slide Number 10Slide Number 11Slide Number 12Slide Number 13