We have a cement mill of 70tph, but we run it nearly 80tph. Main motor rating is 2925kW. We have a Sepex separator. Power consumption of main motor before ball charge was 3015kW (average) after 10 ton ball charge power consumption rises 3103kW (average). Ball charge calculation based on h/d ratio calculation, where h=empty height from charge to the mill centre and d=effective diameter of the mill. Blaine also increase. But after nearly 135 hours of operation Min motor power consumption rises to average 3200kW.
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The power drawn by the mill main motor is principally a function of the amount of media in the mill. Superimposed on that is some inverse variation due to the amount of material in the mill.
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We have three 120tph cement mills. All of them are equipped with Sepax separators. We are looking at reducing the power consumption in cement grinding by installing roller presses. For market reasons, any increase in capacity is not necessary. The downstream conveying equipment are also limiting factor for increase in capacity. Under such constraints, in order to use most of the existing equipment but without heavily investing into new ones, which roller press grinding process would be the best for us to achieve our objective?
admin
There is not a straight-forward answer to this question. There are many possibilities and circuits for combinations of ball mills, roller presses and Sepax separators. You need to make a study of the performance of these various combinations and decide which one is best for your factory and particular constraints. A key questions is whether the circuits are only grinding clinker and cement or whether there are other requirements such as slag, fly ash or pozzolan? As a first suggestion a roll press might be used to pre-crush all the clinker into an intermediate storage which then feeds to two of the existing three ball mills. With pre-crushed clinker the two remaining mills should be able to more than cope with your existing production rate.