MillScan Using vibration to measure the fill level of Ball Mills K V ANJANI KUMAR
Presentation sequence <ul><li>MillScan – Introduction and advantages </li></ul><ul><li>Installation and calibration </li><...
MillScan Introduction and Advantages
<ul><li>MillScan is a field instrument that measure the mill fill level using the vibration signal of the Mill bearin...
MillScan Advantages <ul><li>Higher resolution (more than two times) compared with traditional sound bases instruments; </l...
System Components Main Unit Sensor USB Adapter
System Configuration in a ball mill
Installation in a ball mill Sliding shoe bearing mill Standard bearing housing
Easy calibration (only 3 steps) System calibration
System calibration Eliminating interferences from other equipments and mechanical problems.
Signal Examples Looking into the “future”
Looking into the “future” MillScan – Signal example Total Feed Mill kW MILLSCAN
Motor power MILLSCAN Elevator Returns Looking into the “future” Aprox. 15min MillScan – Signal example
MillScan DSP Case Studies The real benefits of using MillScan
Mill characteristics <ul><li>Cement Mill </li></ul><ul><li>2 single compartment finish mills </li></ul><ul><li>Dimension...
Step 1 : Mill under Manual control MillScan – Case Study I Bucket El 2 kW Bucket El 1 kW Total Feed Mill kW Separator ...
Step 2 : Mill under kW control MillScan – Case Study I Bucket El 2 kW Bucket El 1 kW Total Feed Mill kW Separator 2 kW...
Bucket El 2 kW Bucket El 1 kW Total Feed Mill kW Separator 2 kW MILLSCAN Step 3 : Mill under MillScan control MillSc...
<ul><li>Reduction In kWh/ton (Overall Cements) : 6% </li></ul>Some Results (after MillScan installation) MillScan – Case ...
MillScan – Case Study II Mill Characteristics <ul><li>Cement Mill (nominal 80 ton/h) </li></ul><ul><li>2 single compartmen...
MillScan – Case Study II Ajuste em tempo real dos parâmetros do PID, ganhos e BM Indicação de enchimento – Mill Scan Alim...
MillScan – Case Study II MillScan Signal (fill level in %)
MillScan – Case Study II Fresh feed to the mill (in ton/h) – Mill in auto control
MillScan – Case Study II
MillScan – Case Study II
MillScan – Case Study II Comparing before and after MillScan Manual Control Production average 73,88 ton/h Finesses (0,044...
Mill Characteristics <ul><li>Cement Mill (nominal 20 ton/h) </li></ul><ul><li>2 single compartment finish mills </li></ul>...
MillScan – Case Study III Comparing before and after MillScan Motor Power control MillScan Control
MillScan – Case Study III Results Increase production in 5,5% Decrease specific consumption in 5,3% Pay-back in 2 mont...
MillScan – Case Study IV <ul><li>Cement Mill-02 (170 -185 TPH) </li></ul><ul><li>Single compartment finish mills </li></ul...
Cement Mill-02 Circuit
 
45 Micron residue with Sound level and Millscan
Rejects with Sound level and Millscan
Mill power with Sound level and Millscan
Production with Sound level and Millscan
Separator Speed with Sound level and Millscan
MillScan – Case Study V <ul><li>Cement Mill-05 (75 -84 TPH) </li></ul><ul><li>2 Compartment finish mills </li></ul><ul><li...
Cement Mill-05 Circuit
Production Report
 
Separator Speed (Rpm) Before Vs After
Separator Reject (TPH) Before vs After
Product Residue on 45 mic Before vs After
Mill Main Drive Power (KW) Before vs After
Mill Feed Rate (TPH) Before vs After
Mill Outlet Bucket Elevator (KW) Before vs After
MillScan – Case Study VI <ul><li>Cement Mill-01 (125 -130 TPH) </li></ul><ul><li>2 compartment finish mill </li></ul><ul><...
Cement Mill-01 Operating Curves
Operating Conditions
Operating Curves
MillScan References TOTAL OF 210 UNITS AROUND THE WORLD Buzzi Unicem Cal Portland Cementir Cementos Portland Cemex Cimpor ...
MillScan Conclusions Better information Repetitibility Stable process Better control … MillScan Optimum operation point Li...
<ul><li>MillScan high sensibility detects variations in the Mill Fill Level almost instantaneously when other typical sign...
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Pricast Mill Scan Dsp Lnvt

Replace Mill Sound level Instrument by this Pricast Mill Scan
Published on: Mar 4, 2016
Source: www.slideshare.net


Transcripts - Pricast Mill Scan Dsp Lnvt

  • 1. MillScan Using vibration to measure the fill level of Ball Mills K V ANJANI KUMAR
  • 2. Presentation sequence <ul><li>MillScan – Introduction and advantages </li></ul><ul><li>Installation and calibration </li></ul><ul><li>Operational examples </li></ul><ul><li>Case studies </li></ul><ul><li>Conclusion </li></ul>
  • 3. MillScan Introduction and Advantages
  • 4. <ul><li>MillScan is a field instrument that measure the mill fill level using the vibration signal of the Mill bearing housing or table. </li></ul><ul><li>MillScan can be used in Ball Mills. </li></ul>MillScan - Introduction <ul><li>Due its technology, MillScan yields a highly accurate and instantaneous mill fill level signal that can be used to run the mill under automated loop control or greatly assist control room operators under manual control. </li></ul>
  • 5. MillScan Advantages <ul><li>Higher resolution (more than two times) compared with traditional sound bases instruments; </li></ul><ul><li>Is not affected by other equipments or services in the area (system 100% digital); </li></ul><ul><li>Easy installation, setup and calibration (DON’T need to stop the mill for installation and calibration); </li></ul><ul><li>Option for customize the equipment for different products; </li></ul><ul><li>No additional equipment in the existent plant control system is needed (communication via a 4-20mA output). </li></ul>
  • 6. System Components Main Unit Sensor USB Adapter
  • 7. System Configuration in a ball mill
  • 8. Installation in a ball mill Sliding shoe bearing mill Standard bearing housing
  • 9. Easy calibration (only 3 steps) System calibration
  • 10. System calibration Eliminating interferences from other equipments and mechanical problems.
  • 11. Signal Examples Looking into the “future”
  • 12. Looking into the “future” MillScan – Signal example Total Feed Mill kW MILLSCAN
  • 13. Motor power MILLSCAN Elevator Returns Looking into the “future” Aprox. 15min MillScan – Signal example
  • 14. MillScan DSP Case Studies The real benefits of using MillScan
  • 15. Mill characteristics <ul><li>Cement Mill </li></ul><ul><li>2 single compartment finish mills </li></ul><ul><li>Dimensions: 4,0m diameter; 6,4m long; 2.000HP </li></ul><ul><li>First generation separators; </li></ul><ul><li>Blaine: 5500-4000; </li></ul><ul><li>4 Different cements produced. </li></ul>MillScan – Case Study I
  • 16. Step 1 : Mill under Manual control MillScan – Case Study I Bucket El 2 kW Bucket El 1 kW Total Feed Mill kW Separator 2 kW Separator 1 kW
  • 17. Step 2 : Mill under kW control MillScan – Case Study I Bucket El 2 kW Bucket El 1 kW Total Feed Mill kW Separator 2 kW Separator 1 kW
  • 18. Bucket El 2 kW Bucket El 1 kW Total Feed Mill kW Separator 2 kW MILLSCAN Step 3 : Mill under MillScan control MillScan – Case Study I
  • 19. <ul><li>Reduction In kWh/ton (Overall Cements) : 6% </li></ul>Some Results (after MillScan installation) MillScan – Case Study I Cement Type A Reduced Ave Blaine 4,6% Increased Ave 325 Mesh Passing 0,25% Reduced St Dev at 28 day strength 37% Cement Type B Reduced Ave Blaine 5,4% Increased Ave 325 Mesh Passing 0,7% Reduced St Dev at 28 day strength 28%
  • 20. MillScan – Case Study II Mill Characteristics <ul><li>Cement Mill (nominal 80 ton/h) </li></ul><ul><li>2 single compartment finish mills </li></ul>
  • 21. MillScan – Case Study II Ajuste em tempo real dos parâmetros do PID, ganhos e BM Indicação de enchimento – Mill Scan Alimentação total, controlada somente pelo nível de enchimento
  • 22. MillScan – Case Study II MillScan Signal (fill level in %)
  • 23. MillScan – Case Study II Fresh feed to the mill (in ton/h) – Mill in auto control
  • 24. MillScan – Case Study II
  • 25. MillScan – Case Study II
  • 26. MillScan – Case Study II Comparing before and after MillScan Manual Control Production average 73,88 ton/h Finesses (0,044mm) 12,3 Auto Control with MillScan Production average 77,80 ton/h Finesses (0,044mm) 12,2 Results Production increase 5,01 % Production costs decrease 4,77 % Cement finesses decrease 1,00 %
  • 27. Mill Characteristics <ul><li>Cement Mill (nominal 20 ton/h) </li></ul><ul><li>2 single compartment finish mills </li></ul>MillScan – Case Study III
  • 28. MillScan – Case Study III Comparing before and after MillScan Motor Power control MillScan Control
  • 29. MillScan – Case Study III Results Increase production in 5,5% Decrease specific consumption in 5,3% Pay-back in 2 months !!! Production average Normal control 20,60 ton/h MillScan control 21,75 ton/h Specific Consumption Normal control 38,03 kWh/ton MillScan control 36,02 kWh/ton
  • 30. MillScan – Case Study IV <ul><li>Cement Mill-02 (170 -185 TPH) </li></ul><ul><li>Single compartment finish mills </li></ul><ul><li>Blaine: 3200-3500; </li></ul><ul><li>2 Different cements produced. </li></ul><ul><li>- OPC </li></ul><ul><li>- PPC </li></ul>Jk Lakshmi Sirohi -Mill Characteristics
  • 31. Cement Mill-02 Circuit
  • 33. 45 Micron residue with Sound level and Millscan
  • 34. Rejects with Sound level and Millscan
  • 35. Mill power with Sound level and Millscan
  • 36. Production with Sound level and Millscan
  • 37. Separator Speed with Sound level and Millscan
  • 38. MillScan – Case Study V <ul><li>Cement Mill-05 (75 -84 TPH) </li></ul><ul><li>2 Compartment finish mills </li></ul><ul><li>Dimensions: 3.8 m diameter; 12.5 m long; 2700 Kw </li></ul><ul><li>Blaine: 3200-3500; </li></ul><ul><li>OPC 53 is produced. </li></ul>Jk Lakshmi Sirohi -Mill Characteristics
  • 39. Cement Mill-05 Circuit
  • 40. Production Report
  • 42. Separator Speed (Rpm) Before Vs After
  • 43. Separator Reject (TPH) Before vs After
  • 44. Product Residue on 45 mic Before vs After
  • 45. Mill Main Drive Power (KW) Before vs After
  • 46. Mill Feed Rate (TPH) Before vs After
  • 47. Mill Outlet Bucket Elevator (KW) Before vs After
  • 48. MillScan – Case Study VI <ul><li>Cement Mill-01 (125 -130 TPH) </li></ul><ul><li>2 compartment finish mill </li></ul><ul><li>Blaine: 3300-3500; </li></ul><ul><li>Two Different cements produced. </li></ul><ul><li>- OPC </li></ul><ul><li>- PPC </li></ul>Madras Cement R R Nagar -Mill Characteristics
  • 49. Cement Mill-01 Operating Curves
  • 50. Operating Conditions
  • 51. Operating Curves
  • 52. MillScan References TOTAL OF 210 UNITS AROUND THE WORLD Buzzi Unicem Cal Portland Cementir Cementos Portland Cemex Cimpor Colacem GCC Hanson Heidelberg Holcim Italcimenti Lafarge Lehigh Mitsubishi Nuh Beton Secil Votorantim and others ...
  • 53. MillScan Conclusions Better information Repetitibility Stable process Better control … MillScan Optimum operation point Limits P1 P2 Operator
  • 54. <ul><li>MillScan high sensibility detects variations in the Mill Fill Level almost instantaneously when other typical signals used for Mill control are not affected or delay to accuse variations. </li></ul><ul><li>Acting with more precision and earlier gives the operator the possibility to improve operation. </li></ul>MillScan – Conclusions Pricast Equipamientos Industriales S.L. Calle Paris, 71, 1/4 - 08029 – Barcelona, Spain Tel: (+34)93.444.31.23 Fax:(+34)93.419.87.71 [email_address] www.pricast.es/millscan Visit us at: www.pricast.es/millscan

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