Programs for Cement Processing

(Updated Feb.10.2011)

What are the programs able to do ?

1) For the grinding process: consisting of

A Grinding Process

MillProc

You may have a new grinding plant or you want to come to know the functions of your own plant. In this case this program can help you. There are two parts : one with preseparator before the filter and one without. The program is also usable for plants with roller mills. You can enter or adjust the parameters of the system and get a similar process as the original. Specially the functions of separation and grindability are regarded.

Millsimuulation

MueSi2 (Mill simulation)

The working model is a ball mill with one separator. Before the start you enter the parameters of any mill, the type of separator and the grindability. Then you enter the throughput and the speed of the separator and the spin rotor in %. As result you get the different throughputs, the specific surfaces, the specific power consumptions of the components and the circulation as well as the separator efficiancy. You can print the datas. The program is also applicable for training of operators or to get a critical view of the own system.

Property of equipment

GrindMix

GrindMix / BallMill Analysis:

Ball trajectories : The program explains chronologically the theories of the ball trajectories and allows to set parameters of the own system. Important for performace of cumminution, heat exchange and transport by pneumatic convayance. You can print the result.

Power to drive a mill : The calculation is regarding the number of compartments, the ball filling and material filling degree, the speed, motor efficiency, gear efficiency and lifters. You can print the result.

Charging a compartment : The calculation is based on a mill compartment with sorting plates and on the fact, that the RRSB line will change steadily from inlet to outlet. Then tzhe program can calculate the ball sizes according to Bond, using the work index.

Duration time in the mill : With a tracer experiment I found out that the local distribution of the duration time can be plotted as a staight line in the coordinates of a log normal distribution net and can be calculated according to O.Molerus with Momentes. The inclination of the straight line depends of the diffusion coefficient (cm²/min). This coefficient can be determined by a dimension analysis. The program gives the graph of the duration time within the mill and its standard deviation. You can print the result.

GrindMix / Separator Analysis:

You can enter the particle size distribution of feed, coarse and fine material by clipboard or by hand and save it. Then you can see and print the graphs of RRSB line, tromp courve and fractional distributions as well as the characteristics of the separator inclusive efficiency.

GrindMix / Merging of fine material :

STYLE="text-decoration: none">From a collection of datas you can select the particle size distributions of the components to be mixed. In the first graph you can see the RRSB line by changing the mixing percentage. In another graph you can see the changing fractional distribution. Additional you get a graph of all properties of the mixed product along the mixing percentages. You can print the results.

For checking your quality

NormTest:

You can insert the values either by clipboard or enter them by hand and save the lot. Then you destine the class width and get the histogram and a x² adjustment as well as a complete set of statistical characteristics. You can print the result including the graph.

2.) For the burning process :

KilnOpt

The analyses of raw materials are kept in a database. You can select them to create a new clinker quality and optimise the kiln operation.

KilnOpt /AnalMix: calculates about every second the complete analyse including characteristics by a selected number of raw materials and fuels. By scillfull selection you can design new qualities of clinker and improve the kiln operation.

KilnOpt / Automix: You select 4 (or 3) components for raw meal ( t ) and up to 9 components as additives directly to the kiln ( t/h ). Then you select the three moduli lime saturation, silica ratio, Al/Fe ratio. The program calculates the quantities.

3.) For saving your fuel costs

OfenKetten (KilnChains)

The program calculates 1.) the installation of garland chains for Wet Process Kilns, 2.) the installation of Thermochains in Wet or Dry Process Kilns, where the quantity of chains is calculated so that the amount of dust can be minimised.

Summarized : 3 programs:
1.) Grinding program
2.) Kiln program
3.) Kiln Chains