MUĞLA SITKI KOÇMAN UNIVERSITY

Effect of pre-crushing with a ­vertical shaft impactor (VSI) crusher on ­the performance of an industrial cement ball mill ­classification circuit

1 Flowsheet of the cement closed grinding circuit operating without a VSI crusher(1) Clinker feed; (2) Trass feed; (3) Gypsum feed; (4) Mill feed; (5) Mill discharge (air-swept); (6) Mill discharge (­overflow); (7) Air classifier (separator) feed; (8) Air classifier reject; (9) Air classifier fine (cement)
1 Flowsheet of the cement closed grinding circuit operating without a VSI crusher
(1) Clinker feed; (2) Trass feed; (3) Gypsum feed; (4) Mill feed; (5) Mill discharge (air-swept); (6) Mill discharge (­overflow); (7) Air classifier (separator) feed; (8) Air classifier reject; (9) Air classifier fine (cement)
2 Flowsheet of the closed cement grinding circuit operating with a VSI crusher (semi-finish grinding)(1) Clinker feed; (2) Trass feed; (3) Gypsum feed; (4) VSI crusher discharge; (5) Air classifier (separator) feed; (6) Air classifier reject; (7) Mill discharge (overflow); (8) Air classifier fine (cement)
2 Flowsheet of the closed cement grinding circuit operating with a VSI crusher (semi-finish grinding)
(1) Clinker feed; (2) Trass feed; (3) Gypsum feed; (4) VSI crusher discharge; (5) Air classifier (separator) feed;
(6) Air classifier reject; (7) Mill discharge (overflow); (8) Air classifier fine (cement)
3 Experimental and mass balanced (calculated) particle size distributions around the circuit operating without a VSI impact crusher
3 Experimental and mass balanced (calculated) particle size distributions around the circuit operating without a VSI impact crusher
4 Experimental particle size distributions around the circuit operating with a VSI impact crusher
4 Experimental particle size distributions around the circuit operating with a VSI impact crusher
5 Comparison of particle size distributions of mill feed materials for both grinding cases
5 Comparison of particle size distributions of mill feed materials for both grinding cases
6 Particle size distribution along the long axis of the first compartment of the ball mill without using a VSI impact crusher
6 Particle size distribution along the long axis of the first compartment of the ball mill without using a VSI impact crusher
7 Particle size distribution along the long axis of the first compartment of the ball mill using a VSI impact crusher
7 Particle size distribution along the long axis of the first compartment of the ball mill using a VSI impact crusher
8 Particle size distribution along the long axis of the second compartment without ­using a VSI impact crusher
8 Particle size distribution along the long axis of the second compartment without ­using a VSI impact crusher
9 Particle size distribution along the long axis of the second compartment with using a VSI impact crusher
9 Particle size distribution along the long axis of the second compartment with using a VSI impact crusher
10 Comparison of fineness variation on the basis of 0.090 mm and 0.045 mm passing % along the grinding compartment length for both grinding cases
10 Comparison of fineness variation on the basis of 0.090 mm and 0.045 mm passing % along the grinding compartment length for both grinding cases
11 Comparison of ball mill feed particle size distributions for both grinding cases
11 Comparison of ball mill feed particle size distributions for both grinding cases
12 Empirical single particle impact breakage function (appearance function) of mill fresh feed
12 Empirical single particle impact breakage function (appearance function) of mill fresh feed
13 Closed circuit two-compartment ball mill model structure
13 Closed circuit two-compartment ball mill model structure
14 Specific discharge rate functions in compartment-1 and compartment-2 for both grinding cases
14 Specific discharge rate functions in compartment-1 and compartment-2 for both grinding cases
15 Specific breakage rate functions in compartment-1 and compartment-2 for both grinding cases
15 Specific breakage rate functions in compartment-1 and compartment-2 for both grinding cases
16 Particle size distri­butions at the compartment-2 inlet for both grinding cases
16 Particle size distri­butions at the compartment-2 inlet for both grinding cases
17 Efficiency curve for the dynamic air classifier
17 Efficiency curve for the dynamic air classifier
All author
All author

Grinding performance and circuit capacity change were investigated when an industrial scale VSI crusher was integrated into the two-compartment ball mill closed circuit. Semi-finish grinding application of a VSI crusher could result in 8 % capacity increase in cement throughput rate and thus, 7 % energy saving in specific energy consumption.

1 Introduction

High pressure grinding roller (HPGR) crushers are used conventionally as a pre-crusher ahead of the ball mill to reduce the specific energy consumption of the grinding stage or to increase the grinding capacity of the circuit in cement grinding circuits [3, 4, 5]. A vertical shaft impactor (VSI) type crusher can also be used as a pre-crushing unit in cement grinding circuits to carry out an efficient grinding process. This type of application will reduce the total grinding energy requirement by increasing the grinding capacity. VSI type crushers have various advantages such as...

Find out more in

ZKG 7-8/2016

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ZKG 7-8/2016

Ressort:  Process
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TEXT Ömürden Genç, Assistant Professor, Muğla Sıtkı Koçman University, Faculty of Engineering, Dept. of Mining Engineering, Muğla/Turkey

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