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Specialized Tools · Cement Mill · No. 01

Is your separator sending finished cement back to the mill?

The mill runs hard, the power climbs, and the tons will not come. From the control room it looks like a mill that has lost its strength. Very often the mill is fine: a worn rotor seal, coated guide vanes or feed dumping on one side make the separator return finished cement, and the mill grinds the same tons twice.

What it savesStops the mill grinding cement that was already fine.

US$30One-time · yours to keep
See the sample report (PDF)
  • Excel 2013 or later, Windows and Mac
  • No macros, no internet
  • Updates for life
  • Updates for life
  • Your name on every sheet
Your sampling in, every result out, graded and explained

How this file helps

Find out if it is happening to you, how much it costs, and what to correct.

1Find outFines recovery, bypass, cut size and sharpness from one sampling, each graded against a separator in good condition.
2MeasureThe tons coming back and what the mill really handles, so the loss has a size.
3CorrectWhat to check first, and why: rotor seal, guide vanes, air, feed spread. The Before vs After sheet proves the repair paid off.

What it gives you

From one sampling to a clear decision.

Know in minutes if the separator is the reason the mill is slow or uses too much power
Know what to fix first: guide vanes, rotor seal, air or feed spread, with the reason
Prove that a repair paid off: Before and After on one page
One clean page for the management, ready to print

See it working

A worked sampling from a demonstration plant.

Your sampling in, every result out, graded and explained
Your sampling in, every result out, graded and explained
What to do first, what to check, and why
What to do first, what to check, and why
Before and After: did the repair pay off?
Before and After: did the repair pay off?

Worked out for you

11 results from the figures you already measure.

Fines recovery (efficiency)Coarse returned to the millCut size d50BypassSharpness (imperfection)Circulating loadCirculation factorMaterial returned, t/hTotal through the mill, t/hTromp curve drawn size by sizeFive checks: what to do first, and why

What is inside the file

Tromp CurveYour sampling in, every result out, graded GOOD, WATCH or ACT, with the curve and the list of what to do first.
Before vs AfterThe sampling after a repair or a new setting, against the first one: each figure, the change and the verdict.
Method & SamplingHow to take the three samples so the balance closes, and how each result is obtained.
LicenseYour name, your company and your email, shown in the heading of every sheet.

What you need

  • 1Fresh feed to the mill (t/h)
  • 2Three samples taken together: separator feed, rejects, fine product
  • 3Residue of each sample on one sieve (45 µm is usual)
  • 4A sieve analysis of the three samples, 6 or 7 sieves from about 200 µm to 20 µm
Industry methodsMass balance of the three streams, the curve size class by size class, and the cut read on the curve, as used across the cement industry.
Graded, not just calculatedEach result is marked GOOD, WATCH or ACT against the usual range, with the reason.
Ready for the reportPrint-ready pages with the charts drawn for you.
Yours to keepOne price, no subscription. Use it again and again.

Questions

Before you buy

Can I see it before I buy?

Yes. The sample report shows the whole first sheet of the file, worked on a demonstration plant: every result, the charts and what to do first.

Does it need the internet or macros?

No. It works on Excel 2013 or later, on Windows or Mac, with no macros and no connection. Nothing to install.

Can I use it for several separators?

Yes. Save one copy per separator and per test. The file is yours to use for as long as you like.

Who may use my copy?

One engineer or one plant. Your name is written on every sheet.

How do I pay?

Press Buy. We reply on WhatsApp and by email with the bank details. When the payment arrives, your copy is ready to download from this page.

Is your separator sending finished cement back to the mill?

Have the answer after your next sampling.

US$30One-time · yours to keep
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More in the Cement Mill package

The other files of this package

Mill Axial Test, a worked example
Cement Mill · No. 02
Mill Axial Test

Where along your mill does the grinding stop?

The mill was relined and topped up, and still the tons will not come. Somewhere along the shell, a stretch of mill has stopped grinding.

What it savesFinds the metres of mill that turn, wear and draw power without grinding.

  • Dead and slow stretches found sieve by sieve, with where to look
  • Where the coarse job really finishes, against the diaphragm
US$30one-time · yours to keepSee the file →
Mill Power, a worked example
Cement Mill · No. 03
Mill Power

Is your mill drive pulling what the ball charge needs?

The drive pulls more power than last year for the same cement. Is the charge heavier than the records say, are the liners worn, or is the mill empty of work?

What it savesFinds the kW the drive takes for no grinding.

  • The power the charge should take, chamber by chamber, at the motor
  • The panel reading checked against it, with the reason when they differ
US$30one-time · yours to keepSee the file →
Ball Mill Volume Loading, a worked example
Cement Mill · No. 04
Ball Mill Volume Loading

How many tons of balls should go in at the next stop?

After the top-up the mill draws more power and grinds no more. Too much steel cushions the charge; too little wears the liners. Both cost output.

What it savesEnds the guesswork on top-ups: the exact tons, and the tape reading that proves they went in.

  • The filling of each chamber from one tape reading
  • The tons to add or take out to reach the target
US$30one-time · yours to keepSee the file →
Ball Charge Design and Check, a worked example
Cement Mill · No. 05
Ball Charge Design and Check

Is your ball charge still the one the mill needs?

The Blaine drifts down month after month and the same power buys less fineness. The charge sheet says nothing is wrong, but the steel inside has changed.

What it savesKeeps the steel grinding instead of just adding weight.

  • The average ball and the grinding surface of each chamber, graded
  • The filling from the recorded tons, and the tape reading it implies
US$30one-time · yours to keepSee the file →
Grinding Media Wear, a worked example
Cement Mill · No. 06
Grinding Media Wear

Where are your top-ups taking the ball charge?

The first chamber slowly fills with small balls nobody ordered. Each top-up adds the right tons and, quietly, the wrong grading.

What it savesStops paying for steel that ends up as small balls doing no work.

  • Each chamber worked through the coming top-ups, size by size
  • The sizes drifting off target, and the new sizes appearing
US$30one-time · yours to keepSee the file →
Max Ball Size, a worked example
Cement Mill · No. 07
Max Ball Size

Is your top ball big enough to break the feed?

A coarser feed arrives and the first chamber stops breaking it. Lumps circulate, the return climbs and the output falls.

What it savesAvoids a first chamber full of balls too small to break the feed, or bigger than it needs.

  • The top ball from the feed size, the work index and the mill speed
  • Rounded to a size that can be bought
US$30one-time · yours to keepSee the file →

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