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Specialized Tools · Cement Mill · No. 02

Where along your mill does the grinding stop?

The mill was relined, the charge topped up, the separator checked, and still the tons will not come. A dead stretch of mill is turned, lined, filled with steel and paid for in power, and it does nothing. From outside the mill looks normal. Only the axial test shows where the grinding stops, and a sieve sheet read by eye rarely does.

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

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 figures in: every result graded GOOD, WATCH or ACT, Today against What if

How this file helps

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

1Find outEvery dead or slow stretch, sieve by sieve, and whether the first chamber finishes its job before the diaphragm.
2MeasureThe ball size each metre of mill asks for, against the balls carried in each chamber.
3CorrectWhere to open the mill, what to look at, and which top-up sizes to change.

What it gives you

One sieve sheet, read like a specialist would read it.

Dead and slow stretches found sieve by sieve, with where to look
Where the coarse job really finishes, against the diaphragm
The ball size every metre asks for, against the balls carried
Sieving and sampling faults caught before they cost a shutdown

See it working

Worked on a demonstration plant.

Your figures in: every result graded GOOD, WATCH or ACT, Today against What if
Your figures in: every result graded GOOD, WATCH or ACT, Today against What if
The chart drawn for you, ready for the report
The chart drawn for you, ready for the report
What to do first, and why
What to do first, and why

Worked out for you

9 results from the figures you already measure.

Dead and slow stretchesCoarse work done in the first chamberFine work done in the second chamberCoarse job finished at (m)Half the fine work done by (m)Ball needed at the inlet, the diaphragm and the outletSmallest ball against need, each chamberFilling where the ball level was measuredSieve and sampling faults

What is inside the file

Axial TestThe mill and the balls carried, every result graded, the residue profile and the ball size along the mill, and what to do first.
SamplesUp to 10 sampling points on 6 sieves, with the ball level where it was measured.
MethodHow every result is obtained, and the references each grade is read against.
LicenseYour name, your company and your email, in the heading of every sheet.

What you need

  • 1Mill diameter, speed and chamber lengths
  • 2Up to 10 scoops along the mill after a crash stop
  • 3Each scoop on the same 6 sieves, cumulative residue
  • 4The smallest and largest ball of each chamber; the ball level where it can be measured
Industry methodsThe methods used across the cement industry, worked out step by step.
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 mills?

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

What is the What-if column?

Type a new figure beside today's and see every result change, before anything is changed in the plant.

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.

Where along your mill does the grinding stop?

Have the answer with your next figures.

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

The other files of this package

Separator Performance · Tromp Curve, a worked example
Cement Mill · No. 01
Separator Performance · Tromp Curve

Is your separator sending finished cement back to the mill?

The mill runs hard, the power climbs, and the tons will not come. Often the reason sits on top of the mill: a separator sending finished cement back to be ground again.

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

  • 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
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 →

See every file