Reducing the Energy Required in Grinding Clinker to Cement—Benzer Aydogan Dundar and Lynch

1Reducingtheenergyrequiredingrindingclinkertocement:somecasestudies

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

HACETTEPEUNIVERSITYMiningEngineeringDepartment

2Reducingtheenergyrequiredingrindingclinkertocement

1.INTRODUCTION

MetPlant 201189August2011,Perth,WesternAustralia

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Worldcementproduction(milliontonnes)

The effect of change in ball size

Optimizing circuits containing HPGRs, ball mills and separators

The use of high intensity grinding

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2.OUTLINE

MetPlant 201189August2011,Perth,WesternAustralia

4Reducingtheenergyrequiredingrindingclinkertocement

3.THEEFFECTOFCHANGEINBALLSIZE

MetPlant 201189August2011,Perth,WesternAustralia

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3.THEEFFECTOFCHANGEINBALLSIZE

MetPlant 201189August2011,Perth,WesternAustralia

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3.THEEFFECTOFCHANGEINBALLSIZE

MetPlant 201189August2011,Perth,WesternAustralia

Capacity (tph)

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

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4.HPGRAPPLICATONSANDENERGYEFFICIENCY

MetPlant 201189August2011,Perth,WesternAustralia

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4.HPGRAPPLICATONSANDENERGYEFFICIENCY

MetPlant 201189August2011,Perth,WesternAustralia

(2) (3)

(1)

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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

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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

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5.VERYFINEGRINDINGUSINGVBM

MetPlant 201189August2011,Perth,WesternAustralia

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Finish cement 28 37.6

End-product 35 38.1

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6.CONCLUSION

MetPlant 201189August2011,Perth,WesternAustralia

Optimizingtheballsizedistributioninfinishmillingofcementusingmodelling andsimulation resultedinhigherproductionrate,reducedoverallspecificenergyconsumptionandlowercost ofmetalwear.

TheuseofHPGRsinfinishmillingcircuitsaspregrinders increasesthecapacityoftheexistingcircuitsbyreducingtheworkdonebythedownstreamballmills.ClosedcircuitHPGRs reducesignificantlytheoverallspecificenergy consumptionofthecircuit.

Vibratory ballmillsusedafterfinishcementproductiontoreshapethefinalproduct whentheadditivesareincreased resultsinacosteffectiveprocess.HoweverforhighcapacityfinishmillingcircuitstheapplicationoftheVibratoryBallMillsisnotpracticalduetotheirlowcapacity.

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7.ACKNOWLEDGEMENTS

MetPlant 201189August2011,Perth,WesternAustralia

IzmrCementPlantfortheirpermissiontopresentthiswork

HacettepeComminutionGroupmembersfortheirsupportinconductingthesurveys

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