FAULT TRACING CHECK LIST FOR OPTIMIZATION - PRODUCT

Indication Possible reason Analysis to be given priority

Action.

Too coarse Mill over-filled Chamber sampling Low mill feed rate

Separator Adjustment Tromp curve analysis. Proper sep. adjustment

Mill feed very coarse. Feed granulometry curve Improper precrushing.

Filter dust very coarse Air flow measurement Adjust static sep venting rate.

Less efficient liner Mill internal insp. Replace liner.

Too fine Mill under loaded Chamber sampling Increase feed rate

Separator adjustment Tromp curve analysis Proper sep. adjustment

Mill feed very fine Feed granulometry curve Further investigation required

Filter dust very fine Air flow measurement Adjust static separator.

Wrong chemical composition

Wrong feed proportions Weight feeder calibration test

Adjust proper proportion.

Wrong feed components Chemical testing Change component quality

Technical services Mill optimization

Indication Possible reason Analysis to be given priority Action.

Sound dull Mill overfilled Chamber inspection Lower mill feed rate

Chamber sample analysis Improve crushing in chamber by adjustment in balls and /or changing liner.

Mill dimensional check Adjust chamber length

Sound loud Mill under loaded Chamber inspection Increase mill feed rate

Chamber sample analysis Adjust level of material by changing diaphragm position and/or grinding media adjustment.

Mill dimensional check Adjust chamber length

Adapt LCD.

Technical services Mill optimization

FAULT TRACING CHECK LIST FOR OPTIMIZATION - SOUND

Indication Possible reason Analysis to be given priority

Action.

Too high Clinker temperature too high.

Feed checking Check clinker cooling

Low mill/ separating venting

Air flow measurement Adjust venting rate

Lack of water injection

Heat balancing Adjust water flow rate

Cement cooler failure

Mechanical adjustment

Repair of cement cooler.

Technical services Mill optimization

FAULT TRACING CHECK LIST FOR OPTIMIZATION – CEMENT

TEMPERATURE

Indication Possible reason Analysis to be given priority

Action.

Too low Unsuitable ball charge composition or badly worn balls

Chamber sample analysis Adjust ball charge

Diaphragm unsuitable or clogged

Mill internal inspection Replace or clean diaphragm

Unsuitable or worn out liner

Replace liners

Change of feed grindability

Grindability test Further investigation required

Coating of balls Airflow measurement Improve ventilation in mill

Lots of re-circulation of fines

Separator tromp curve analysis

Adjustment in separator

Operators error Training/ Instruction

Technical services Mill optimization

FAULT TRACING CHECK LIST FOR OPTIMIZATION – CEMENT

TEMPERATURE

Indication Possible reason Analysis to be given priority

Action.

Too high Inlet/Outlet clogged Mill internal inspection Clean inlet /outlet trunion of the mill

Diaphragm clogged Clean diaphragm

Too low Diaphragm broken Replace broken plate

Major false air penetration

False air testing Seal sources.

Technical services Mill optimization

FAULT TRACING CHECK LIST FOR OPTIMIZATION – MILL

EXHAUST PRESSURE

Service How? Goal

Suggesting optimum size distribution of ball charge.

Initial loading of ball charge.

Increase in productivity.

Make-up suggestion base on process study.

Reduction in operation cost.

Suggesting optimum metallurgical grade.

Our metallurgical expertise.

Low wear rate.

Mark ball test. Low grinding media cost.

Service in optimum size distribution maintenance

Ball sorting machine. Increase in productivity.

Make up charge recommendation.

Reduction in operation cost.

Service in lower inventory targets

Ready stock at works Lower inventory cost.

Warehouses at selected locations

Sustained production.

Reliability Lower wear rate. Minimum break down

Safety against de-shaping and Breakage.

Technical services Ball charge Management BALL CHARGE MANAGEMENT