Cement industry : grinding process of ball mill

this is the presrntation which i made when i was in traning in ultratech cement hirmi , i got project on studying the process and operations of grinding process of ball mill in the cement industry , after the clincker formation.

1. PRESENTATION ON CEMENT MILL PROCESS AND OPERATION ‘BALL MILL’ MADE BY : PANKAJ VERMA [BIT, RAIPUR] Roll no. : 309303716022 Enrolment no. : BA7212 VOCATIONAL TRANING PROJECT

2. 1.1. INTRODUCTION TO THE ORGANIZATION ABOUT ULTRATECH: Ultratech cement, india’s largest and the world’s 10 th largest manufacturer of cement, Ultratech’s parent company is the aditya birla group Ultratech cement provides a range of products that cater to all the needs from laying the foundation to delivering the final touches. The range includes ordinary portland cement, portland blast furnace slag cement, portland pozzalana cement, white cement, ready mix concrete, building products and a host of other building solutions. In ultratech cement hirmi,balodabazar .the cement produced are: 1) OPC 43 - ordinary Portland cement 2) PPC – Portland pozzolana cement Annual Production :4.20 million tonnes of cement Established in : 1994

3. INTRODUCTION TO CEMENT Cement is made by heating limestone (calcium carbonate) with small quantities of other materials (such as clay) to 1450°C in a kiln. The resulting hard substance, called 'clinker', is then ground with a small amount of gypsum into a powder to make 'Cement', the most commonly used type of cement. This cement is called Ordinary Portland Cement Ordinary Portland Cement (OPC) is the most common cement used in general concrete construction when there is no exposure to sulphates in the soil or groundwater. To retard the faster setting time of cement  resulted from (C3A) compound a percentage of raw gypsum (selenite) is added during the grinding of the clinker. OPC is environment friendly as well as economical. The Portland Pozzolana Cement is a kind of Blended Cement which is produced by either inter grinding of OPC clinker along with gypsum and pozzolanic materials in cetain propertion ,. The pozzolanic materials commonly used are: Volcanic ash Calcined clay Fly ash Lica fumes

4. Flow diagram

5. Flow diagram of cement manufacturing process

6. BALL MILL A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis of the shell may be either horizontal or at a small angle to the horizontal. It is partially filled with balls. The grinding media is the balls, which may be made of steel (chrome steel), stainless steel, ceramic, or rubber. The inner surface of the cylindrical shell is usually lined with an abrasion-resistant material such as manganese steel or rubber. Less wear takes place in rubber lined mills. A ball mill is a type of grinder used to grind and blend materials. It works on the principle of impact and attrition : size reduction is done by impact as the balls drop from near the top of the shell.

7. Operation principle of the ball mill 1 2 3

8. Ball mill

9. Cross-section view

10. Working In case of continuously operated ball mill , the material to be ground is fed from the left through a 60° cone and the product is discharged through a 30° cone to the right . As the shell rotates, the balls are lifted up on the rising side of the shell and then they cascade down (or drop down on to the feed), from near the top of the shell. In doing so, the solid particles in between the balls and ground are reduced in size by impact.

11. Applications The ball mill is used for grinding materials such as coal, pigments, and feldspar for pottery . Grinding can be carried out either wet or dry but the former is performed at low speed. Blending of explosives is an example of an application for rubber balls. For systems with multiple components, ball milling has been shown to be effective in increasing solid-state chemical reactivity . Additionally, ball milling has been shown effective for production of amorphous materials.

12. Size : The smaller the media particles, the smaller the particle size of the final product. At the same time, the grinding media particles should be substantially larger than the largest pieces of material to be ground. Density : The media should be denser than the material being ground. It becomes a problem if the grinding media floats on top of the material to be ground. Hardness : The grinding media needs to be durable enough to grind the material, but where possible should not be so tough that it also wears down the tumbler at a fast pace. Composition : Various grinding applications have special requirements. Some of these requirements are based on the fact that some of the grinding media will be in the finished product. Others are based in how the media will react with the material being ground. Material properties taken in consideration

13. Advantages of the ball mill Ball milling boasts several advantages over other systems: the cost of installation and grinding medium is low ; it is suitable for both batch and continuous operation , similarly it is suitable for open as well as closed circuit grinding It is applicable for materials of all degrees of hardness.

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