Table 2 Monitoring Data of Screen Residue in Ball Mill Mill (October 21, 2021) Table 3 Performance Indicators of Cement Grinding System Operation (2) High power consumption per unit product of roller press, high current of circulating bucket elevator, and large original roller gap; The roller gap fluctuates greatly, the accumulator pressure is high, and the work of the roller press is unstable; The hydraulic system frequently releases pressure, causing the roller press to suddenly stop.

Taking the Production of P · O42.5 Cement as an Example.

2.

The comparison of electricity consumption for ball mill grinding cement before and after optimizing the loading capacity of the grinding body is shown in Table 4.

The power consumption of the ball mill was 3112kW · h/h, and the feeding rate was 199t/h.

Configuration and Existing Problems of Cement Grinding System: A Southern Cement Production Line with an Annual Output of 900000 tons of Cement Grinding adopts a “160 140 Roller Press+ ϕ 4.2m × The 13m ball mill “open flow grinding system is not equipped with a dynamic powder selection machine, with a designed production capacity of 180t/h.

Figure 1 “Roller Press+Ball Mill” Grinding System Process Flow Table 1 Main Equipment and Performance Indicators of the Grinding System The cement production line mainly produces P · O42.5 and P · II52.5 cement.

Optimization and Transformation of Grinding System Process Equipment 2.1.

In the fourth quarter of 2021, the production line experienced high process power consumption and sudden shutdown of the roller press due to large hydraulic system pressure relief, seriously affecting the safe production and operation of the grinding system.

The grinding system mainly has the following problems: (1) high operating current, low efficiency, and high power consumption per unit product of the ball mill; The material flow rate in the mill is too fast, the arrangement of the activation ring is unreasonable, and the quality is prone to be substandard; By monitoring the screen residue data inside the mill, it was found that the grinding material inside the mill is not the optimal grading.

The operational performance indicators of the cement grinding system are shown in Table 3.

1.

Optimizing the Loading Capacity of Ball Mill Grinding Body and Reducing the Power Consumption of Ball Mill.

The process flow of the grinding system is shown in Figure 1, and the main equipment and performance indicators of the system are shown in Table 1.

Before optimization, the loading capacity of the grinding body in the first bin of the ball mill was 61.9t, and the loading capacity in the second bin was 182.5t.

Fixing Socket

After optimization, the loading capacity of the steel section in the second warehouse is reduced by 15t, the electricity consumption of the ball mill is reduced by 83kW · h/h, and the electricity consumption per ton of cement in the ball mill is reduced by 0.28kW · h.

The monitoring data of screen residue inside the ball mill is shown in Table 2.

Table 4 Comparison of power consumption of ball mill for grinding cement before and after optimizing the loading capacity of grinding body Table 5 Comparison of power consumption of ball mill for grinding cement before and after optimizing the activation ring 2.2 Optimization of the arrangement of activation ring, reduction of material flow rate in the mill, improvement of grinding efficiency of ball mill Before the reform, the ball mill had a phenomenon of low specific surface area of phased output materials, which may be caused by too fast material flow rate in the mill
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