Pricast Mill Scan Dsp Lnvt

Replace Mill Sound level Instrument by this Pricast Mill Scan

1. 29 de Julio de 2008
MillScanMillScan
Using vibration to measure the fill level of Ball MillsUsing vibration to measure the fill level of Ball Mills
K V ANJANI KUMAR

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Presentation sequence
1.MillScan – Introduction and
advantages
2.Installation and calibration
3.Operational examples
4.Case studies
5.Conclusion

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MillScan IntroductionMillScan Introduction
and Advantagesand Advantages

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•MillScan is a field instrument that measure the mill fill level using
the vibration signal of the Mill bearing housing or table.
•MillScan can be used in Ball Mills.
MillScan - Introduction
•Due its technology, MillScan yields a
highly accurate and instantaneous mill
fill level signal that can be used to run the
mill under automated loop control or
greatly assist control room operators
under manual control.

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MillScan Advantages
Higher resolution (more than two times) compared with traditional
sound bases instruments;
Is not affected by other equipments or services in the area (system
100% digital);
Easy installation, setup and calibration (DON’T need to stop the mill
for installation and calibration);
Option for customize the equipment for different products;
No additional equipment in the existent plant control system is
needed (communication via a 4-20mA output).

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System Components
Main Unit
Sensor
USB Adapter

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System Configuration in a ball mill

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Installation in a ball mill
Sliding shoe bearing mill
Standard bearing housing

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Easy calibration (only 3 steps)
System calibration

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System calibration
Eliminating interferences from other equipments
and mechanical problems.

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Signal ExamplesSignal Examples
Looking into the “future”Looking into the “future”

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20:30 21:00 21:30 22:00 22:30
63.833
68.833
73.833
78.833
83.833
88.833
93.833
58.833
99.779
8.0227
13.606
8.0227
13.606
80.227
136.06
80.227
136.06
1560.5
1672.1
29.4164
49.8895
Looking into the “future”
Total Feed
Mill kW
MILLSCAN
MillScan – Signal example

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Motor power
MILLSCAN
Elevator
Returns
Looking into the “future”
Aprox.
15min
MillScan – Signal example

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MillScan DSPMillScan DSP
Case StudiesCase Studies
The real benefits of using MillScanThe real benefits of using MillScan

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Mill characteristics
Cement Mill

2 single compartment finish mills
Dimensions: 4,0m diameter; 6,4m long; 2.000HP
 First generation separators;
 Blaine: 5500-4000;
 4 Different cements produced.
MillScan – Case Study I

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12:00 14:00 16:00 18:00 20:00 22:00 0:00 2:00
20
40
60
80
100
0
120
0
15
0
15
0
150
0
150
1400
1700
0
55
Bucket El 2 kW
Bucket El 1 kW
Total Feed
Mill kW
Separator 2 kW
Separator 1 kW
Step 1: Mill under Manual control
MillScan – Case Study I

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0:001:002:003:004:005:006:007:008:009:0010:0011:0012:0013:00
20
40
60
80
100
0
120
0
15
0
15
0
150
0
150
1400
1700
0
55
Bucket El 2 kW
Bucket El 1 kW
Total Feed
Mill kW
Separator 2 kW
Separator 1 kW
Step 2: Mill under kW control
MillScan – Case Study I

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15:00 17:00 19:00 21:00 23:00 1:00 3:00 5:00
20
40
60
80
100
0
120
0
15
0
15
0
150
0
150
1400
1700
0
55
Bucket El 2 kW
Bucket El 1 kW
Total Feed
Mill kW
Separator 2 kW
MILLSCAN
Step 3: Mill under MillScan control
MillScan – Case Study I

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 Reduction In kWh/ton (Overall Cements) : 6%
Some Results (after MillScan installation)
MillScan – Case Study I
Cement Type A
Reduced Ave Blaine 4,6%
Increased Ave 325 Mesh Passing 0,25%
Reduced St Dev at 28 day strength 37%
Cement Type B
Reduced Ave Blaine 5,4%
Increased Ave 325 Mesh Passing 0,7%
Reduced St Dev at 28 day strength 28%

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MillScan – Case Study II
Mill Characteristics
Cement Mill (nominal 80 ton/h)

2 single compartment finish mills

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MillScan – Case Study II
Ajuste em tempo
real dos parâmetros
do PID, ganhos e BM
Indicação de enchimento –
Mill Scan
Alimentação total,
controlada somente
pelo nível de
enchimento

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MillScan – Case Study II
MillScan Signal
(fill level in %)

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MillScan – Case Study II
Fresh feed to the mill
(in ton/h) – Mill in auto control

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MillScan – Case Study II

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MillScan – Case Study II

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Manual Control
Production
average
73,88 ton/h
Finesses (0,044mm) 12,3
Auto Control with MillScan
Production
average
77,80 ton/h
Finesses (0,044mm) 12,2
Results
Production increase 5,01 %
Production costs decrease4,77 %
Cement finesses decrease1,00 %
MillScan – Case Study II
Comparing before and after MillScan

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Mill Characteristics
Cement Mill (nominal 20 ton/h)

2 single compartment finish mills
MillScan – Case Study III

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MillScan – Case Study III
Comparing before and after MillScan
Motor Power control MillScan Control

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MillScan – Case Study III
Production average
Normal control 20,60 ton/h
MillScan control21,75 ton/h
Results
Increase production in 5,5%
Decrease specific consumption in 5,3%
Pay-back in 2 months !!!
Specific Consumption
Normal control38,03 kWh/ton
MillScan control36,02 kWh/ton

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MillScan – Case Study IV
Cement Mill-02 (170 -185 TPH)

Single compartment finish mills
 Blaine: 3200-3500;
 2 Different cements produced.
- OPC
- PPC
Jk Lakshmi Sirohi -Mill Characteristics

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Cement Mill-02 Circuit

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45 Micron residue with Sound level and Millscan

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Rejects with Sound level and Millscan

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Mill power with Sound level and Millscan

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Production with Sound level and Millscan

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Separator Speed with Sound level and Millscan

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MillScan – Case Study V
Cement Mill-05 (75 -84 TPH)

2 Compartment finish mills
Dimensions: 3.8 m diameter; 12.5 m long; 2700 Kw
 Blaine: 3200-3500;
 OPC 53 is produced.

Jk Lakshmi Sirohi -Mill Characteristics

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Cement Mill-05 Circuit

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Production Report

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Separator Speed (Rpm) Before Vs After

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Separator Reject (TPH) Before vs After

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Product Residue on 45 mic Before vs After

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Mill Main Drive Power (KW) Before vs After

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Mill Feed Rate (TPH) Before vs After

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Mill Outlet Bucket Elevator (KW) Before vs After

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MillScan – Case Study VI
Cement Mill-01 (125 -130 TPH)

2 compartment finish mill
 Blaine: 3300-3500;
 Two Different cements produced.
- OPC
- PPC
Madras Cement R R Nagar -Mill Characteristics

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Cement Mill-01 Operating Curves

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CEMENT MILL NO.1 MILL SCAN AUTO OPERATION DATE : 24.09.09
DESCRIPTION TIME11 12 13 14 15 18 19 20212223 24 1 2 3 4 5 6 AVG
1 - FEED UOM
CLINKER FEED - 1 MT/HR 27 47 45 45 45 41 36 393942 65 776143 39 43 42 64 39
CLINKER FEED - 2 MT/HR 47 30 29 29 30 40 36 393842 12 01236 33 37 35 10 36
TOTAL CLINKER FEED MT/HR 74 77 74 74 75 81 72 787784 77 777379 72 80 77 74 76
GYPSUM FEED MT/HR 8 9 9 8 11 12 10 1111 9 10 9 910 11 8 10 10 9
F.ASH FEED MT/HR 27 28 24 21 25 26 23 242421 22 192226 27 29 28 26 25
TOTAL FEED (PPC) MT/HR109114 107 103111119105113112114109105104115110117115110109
BLAINE 320 341 345341338334341331327341320324341345338345327335
Production(TPH) MILL SCAN OPERATION :-
Minimum 103
Maximum 119 START STOP
Average 111 10.0015.35
Std Deviation 4.593 17.40CONTI.
Blaine(m
2
/kg)) VRPM FINES ADDITION :-
Minimum 320
Maximum 345 STOPSTART
Average 335 13.0513.45
Std Deviation 8.707 15.4016.05
21.0022.05
Clinker (TPH)
Minimum 72
Maximum 84
Average 76
Std Deviation 3.238
Fly Ash (TPH)
Minimum 19
Maximum 29
Average 25
Std Deviation 2.812
* Grinding Aid : ON
TIME (hrs)
TIME(hrs)
MILL SCAN AUTIO OPERATION
0
50
100
150
200
250
300
350
400
123456789101112131415161718
RUNNING HOURS
TPH/BLAINE
PRODUCTION (TPH)
BLAINE (M2/KG)
Operating Conditions

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Operating Curves

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MillScan References
TOTAL OF 210 UNITS AROUND THE WORLD
Buzzi Unicem
Cal Portland
Cementir
Cementos Portland
Cemex
Cimpor
Colacem
GCC
Hanson
Heidelberg
Holcim
Italcimenti
Lafarge
Lehigh
Mitsubishi
Nuh Beton
Secil
Votorantim
and others ...

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MillScan Conclusions
MillScan
Optimum
operation point
Limits
P1
P2
Operator
Better
information
Repetitibility
Stable process
Better control
…

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MillScan high sensibility detects variations in the Mill Fill Level
almost instantaneously when other typical signals used for Mill
control are not affected or delay to accuse variations.
Acting with more precision and earlier gives the operator the
possibility to improve operation.
MillScan – Conclusions
Pricast Equipamientos Industriales S.L.
Calle Paris, 71, 1/4 - 08029 – Barcelona, Spain
Tel: [phone] Fax:[phone]
[email protected]
www.pricast.es/millscan
Visit us at:
www.pricast.es/millscan