Ball mill inspection procedure
Ball mill
Ball mi ll in
insp
inspe
insspe
pecti
ect
ctio
ction
ion
on
n pr
proce
procedure
ocedu
dure
re
General
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
Ventilation
Weighfeeder
Instrument
on ro oop
Navigation
r
I.E.E.E
I.E.E.E West
West Coast e
Conference 2009
8th –
– 9th October
Tim Nowack f
f
i
e
f
P
n
Victorville/
Victorville/ CA
U.S.A
Senior Process Engineer a
i
t
s
i
r
h
C
The Green Tree
Convention
Convention Center
Christian
Christian Pfeiffe
Pfeifferr Maschinenfab
Maschinenfabrik
rik GmbH ©
Ball mill inspection procedure
General:
General
Material
The proce
proc ess engin
ng ine
eer sho
s houl
uldd be
b e the
th e
sampling
Longitudinal
.
sampling
Filling degree The “ doctor” is require
required
d for:
Material level
Internals
condition 1) impl
im ple
ement
mentaation
ti on of
of “ Health
lt h che
check
cks”
s”
Ball charge
Regular action
actio n
Trompcurve
Ventilation 2) urge
ur gent
nt inve
in vest
stig
iga
ation
ti ons
s of act
actua
uall
Weighfeeder process probl ems
Instrument Non-regular action
on ro oop
Navigation
I.E.E.E
I.E.E.E West
West Coast
This prese
p resentation
ntation focuses
foc uses on t he regular
regular
Conference 2009
8th –
– 9th October
“ Health check” procedure.
procedure.
Victorville/
Victorville/ CA
U.S.A
The Green Tree
Convention
Convention Center
Ball mill inspection procedure
General:
The “ Health checks” consist o f standard
General
measurements on a frequent b asis
Material
sampling
Longitudinal
sampling Circuit mat. granulometry
Filling degree Mill longitudinal sieving
Material level
Internals
condition Mill material level
Ball charge Mill internal conditions
Trompcurve
Ventilation
Weighfeeder
Separator Tromp curve
Instrument Separator ventilation
on ro oop ven a on
Navigation Weigh feeder calibration
I.E.E.E West Coast
Conference 2009 Instrument verification
8th –
– 9th October
Victorville// CA
Victorville
U.S.A
Control loop verification
The Green Tree
Convention Center Main annual audit
Ball mill inspection procedure
General:
General
“ Healths checks” are important in order to:
Material
sampling
Longitudinal
sampling
• build up a knowledge and data base about the
Filling degree system performance
Material level
•
Internals
condition and easy diagnostic of problems
Ball charge
Trompcurve
Ventilation
e ma n a van age:
Weighfeeder
Instrument Knowledge basis allows to investigate the root
on ro oop
cause of problems and to avoid pr oblems by
Navigation early reaction based on the trend result s.
I.E.E.E West Coast
Conference 2009
8th –
– 9th October
Victorville// CA
Victorville
U.S.A
The Green Tree
Convention Center
Ball mill inspection procedure
General:
General
For each measurement make sure you have:
Material
sampling
Longitudinal
sampling
• design data of the machines/equipment available.
Filling degree
• constant/stable operation condition for at least 2 hours.
Material level
Internals • recorded the actual operation data like:
condition
Ball charge • Production rate [t/h], Product type, composition [M-%]
Trompcurve
Ventilation
• c ua an arge neness o pro uc a ne or es ue
Weighfeeder
• Actual mass flow rate (e.g. separator grits, water demand,
Instrument
etc.)
on ro oop
Navigation
• Electrical power consumption of the main equipment
I.E.E.E West Coast
Conference 2009
8th –
– 9th October
• Actual operation parameter of the main equipment
Victorville// CA
Victorville
U.S.A
(e.g. separator speed, damper positions)
The Green Tree
Convention Center
Ball mill inspection procedure
Circuit material granulometry:
General Sampling points
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
Ventilation
Weighfeeder
Instrument
on ro oop
Navigation
I.E.E.E West Coast
Conference 2009
8th –
– 9th October
Victorville// CA
Victorville
U.S.A
The Green Tree
Convention Center
Ball mill inspection procedure
Ball charge filling degree:
General Measurement by free height
Material
sampling
Longitudinal
sampling
Filling degree M
Material level
Internals
condition
Ball charge
Trompcurve 1. Measure avera e internal diameter, D
Ventilation 2. Measure height, h, in three different points along
Weighfeeder axis for each grinding compartment
Instrument
on ro oop
Navigation empty mill (mill feed stopped for approx. 10 min).
I.E.E.E West Coast
Conference 2009
8th –
– 9th October
Victorville// CA
Victorville
U.S.A
The Green Tree
Convention Center
Ball mill inspection procedure
Mill material level:
General Inspection only at crash stop
Material Record the material level approx. each meter along axis
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
Ventilation
Weighfeeder
Too high =
Instrument
above charge
on ro oop
Good = ½ Ø
Navigation below charge
I.E.E.E West Coast
Conference 2009
8th –
– 9th October => Good material level
Victorville// CA
Victorville
U.S.A below charge for 1st compartment
The Green Tree
Convention Center
Ball mill inspection procedure
Mill material level:
General Inspection only at crash stop
Material Record the material level approx. each meter along axis
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
Ventilation Too high = > 50mm
Weighfeeder above charge
Instrument
Good = a rox. 20 mm
on ro oop
above charge
Navigation
I.E.E.E West Coast Moderate = equal with
Conference 2009
8th –
– 9th October ball charge Good material level
Victorville// CA
Victorville
U.S.A Too low = >> 50 mm for 2nd compartment
The Green Tree below charge
Convention Center
Ball mill inspection procedure
Mill material level:
General Inspection only at crash stop
Material Record the material level before and after transfer points
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Trompcurve
Ventilation
Weighfeeder
Instrument
on ro oop
Navigation
I.E.E.E West Coast
Conference 2009
8th –
– 9th October
Victorville// CA
Victorville
U.S.A
The Green Tree
Convention Center
Ball mill inspection procedure
Control loop Verification:
General 1) Operation check
Material
sampling • record process parameters with
Longitudinal con ro oop n opera on over
sampling period of e.g. 6-8 hours with
Filling degree constant production
Material level • record mill ower consum tion
Internals at counter (kWh)
condition
Ball charge
Adjust control loop
Trompcurve
parame ers necessary
Ventilation
Weighfeeder
Instrument
Information on:
on ro oop
• Available information at the CCR
Navigation
• Control system
I.E.E.E West Coast
Conference 2009
8th –
– 9th October
• Control strategy
Victorville// CA
Victorville
U.S.A • First impression on operation
The Green Tree • Circuit stability
Convention Center
Ball mill inspection procedure
Thank you for your attention
General
Material
sampling
Longitudinal
sampling
Filling degree
Material level
Internals
condition
Ball charge
Questions?
Trompcurve
Ventilation
Weighfeeder
Instrument
on ro oop
Navigation
I.E.E.E West Coast
Conference 2009
8th –
– 9th October
Victorville// CA
Victorville
U.S.A
The Green Tree
Convention Center
