Grinding plants - Optimization and modelling
Grinding plants - Optimization and modelling
FCB has been researching grinding, focusing on digital simulation of ball mills. This research, in collaboration with Société des Ciments Français, was presented in 1989 and published in 1991. It led to the development of the FCB Index for grindability testing and a computation program for simulating grinding plants.
Blaine Model: Computes the Blaine specific surface area from particle size distributions, enhancing material characterization and enabling simulation of desired Blaine values.
Partition Curve Model: A universal formula for classifier efficiency, using parameters with physical meanings to simulate any classifier type.
Residence Time Distribution: Models the complex flow in mills using a sectional approach, enhancing flexibility and accuracy.
Ball Charge Recommendation: For a Belgian cement producer, simulations led to a new ball charge and classifier installation, resulting in a 7% production gain.
Grinding with Overfilling: In Canada, overfilling in a grinding plant was modeled, accurately predicting grain size distributions.
Grinding with Balls Coating: Simulations improved accuracy in a plant with ball coating issues.
Quantifying Classifier Influence: Simulations for a raw meal plant in Great Britain and coal grinding plants showed potential production increases with TSV classifiers.
Two methods are used: audits for existing plant optimization and precise definition of new plants. The FCB Index and simulator are key tools, allowing throughput determination without industrial operation data.
- The model is reliable for various configurations in grinding plants for cement and other materials.
- It allows for the simulation of plants with malfunctions and can quantify complex phenomena such as mill overfilling and ball coating.
- The model is applicable to a wide range of materials including clinker, coal, raw mix, limestone, slag, coke, and phosphate rock.
- FCB plans to extend the model's application to the bed grinding process, aiming to integrate roll presses and new machines based on similar principles, expected to be introduced by the end of the year.
Catalog excerpts
R esearch C enter C ement & M inerals Industries >
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2.1.2. Means A systematic study of the correlations between the Blaine specific surface area and the size distribution for different products has shown that it was impossible to achieve a model independent of the material being investigated. The solution requires a complement of calculation in addition to the grindability test (FCB Index) and to the determination of the S and B function (see figure 1). > FBS Mill Simulator FCB index SIZEDistributionsBLAINE CalculatedSizeDistributions Grinding PlantSimulationMODELISATION Without Blaine ModelWith Blaine Model BlaineModel Figure 1 : The Blaine model...
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tr.row {} td.cell {} div.block {} div.paragraph {} .font0 { font:11.00pt "Arial", sans-serif; } .font1 { font:6.00pt "Times New Roman", serif; } .font2 { font:7.00pt "Times New Roman", serif; } .font3 { font:8.00pt "Times New Roman", serif; } .font4 { font:9.00pt "Times New Roman", serif; } .font5 { font:20.00pt "Times New Roman", serif; } 2.2. Partition Curve Model of size classifiers FCB has developed, tested and now validated a mathematic universal formulation of the partition curve of a classifier (see figure 1). This funtion gives the efficiency value Ri for the mesh Xi. It consists in the...
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V : Simulation of ventilation and/or bypass (overfilling) D : Simulation of a grate and/or coating M : Elementary mill section assimilated to a perfect mixer. This sectional mill approach has permitted a simple and modular programming of the simulator and gives a high flexibility of use. > For a Belgian cement producer who want to optimize the operation of his grinding plant for a cement of 3700 Blaine with 48.5 % slag, we have achieved a complete modelling including a balance of the industrial operation, a simulation of the existing plant and several theoretic simulations whose purpose was to...
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Industrial Production Modelised Industrial Production Mod. with TSV - RL 2.5 FCB Index > Sieve Residue at 90 յm SE kWh/t >
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The model is reliable for any configurations encountered in the grinding plants for cement or other materials. The model allows for the simulation of plants with malfunctions. We do not simulate perfect standard grinding plants only ! We can also simulate and > QUANTIFY such complex phenomena as mill overfilling, ball coating or also high air flows. The model can be applied to and is today applied to many materials such as clinker, of course, but also coal, raw mix, limestone, slag, coke, phosphate rock, etc. Stimulated by these results obtained with the classical grinding process in ball mill,...
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