Cement Grinding Technology Training

Introduction

This Course is designed to introduce the participants to the basics of the machine tools trade and the safe operation of machine tools. During this course, the fundamentals of machine tools operation will be discussed. The participants will learn how to perform basic set-up on the manual late including facing, center-drilling, turning and knurling operations, the milling machine, the grinder, and the saw. Basic machine discussion about the milling machine will include correct part set-up, cutter selection, cutter rpm, feed rate calculations, and machining sequences. The participants will also be shown how to select and correctly use a variety of precision measuring instruments such as micrometers, dial indicators, surface plates, Vernier, dial, and digital height gages, along with how to read drills and tap charts.

Objectives

Upon the successful completion of this course, each delegate will be able to:-

• Apply systematic operation and maintenance procedures in workshop tools including lathe, cutting, grinding, milling and drilling.
• Identify the potential safety hazards in the machine shop.
• Calculate the correct rpm for a lathe, milling machine or drilling press
• Perform the basic set-up for facing, center-drilling, tuning and knurling operations on a lathe
• Describe safe set-up and operating procedures when using the horizontal or vertical band saw.
• Explain the advantages and disadvantages of the various types of saws used by industry.
• Discuss the basic set-up on a vertical milling machine
• Use precision measuring tools and describe the primary function of a pedestal grinder
• Identify safety factors to remember when using the pedestal grinder
• Discuss basic engineering prints

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting. State-of-the-art business systems analysis methods and techniques are transferred by means of short, focused presentations which are followed by experiential learning workshop sessions. In these sessions, the knowledge gained is applied to real-world examples and case studies. Rapid learning of the methods and techniques is achieved by means of group work, individual work, participant discussion, facilitator interaction, and constructive feedback.

organizational Impact

• Reduced information technology development risk, costs, and time overruns
• Improved integration of information technology projects with business needs
• Improved communication between the business and the information technology department of the organization
• The correct fit between the requirements of the organization and information systems that are developed or procured

Personal Impact

• Work more effectively in or with a systems development project
• Have the ability to gather elicit business requirements from users
• Be able to comprehensively identify the requirements of the business
• Effectively communicate business requirements to developers

Who Should Attend?

The course addresses professionals who are involved in the operation and maintenance of workshop tools (lathe, cutting, grinding, milling & drilling) this includes engineers and other technical staff.

Course Outline

Introduction to Grinding.

• Why do we need to grind Raw Materials?
• Why do we need to grind Clinker?
• Effect of Fineness on Compressive Strength 1d, 28d.
• Why do we need to grind solid Fuels?
• What size of particles is required for RM, CK and cement?
• Definition of both Micrometer & Mesh.
• How is Fineness expressed?
• How to reduce the size?
  • Crushing.
  • Rubbing & filing.
  • Compressing or Squeezing.
• The 4 different types of Mills:
  • Ball Mills.
  • Vertical Mills.
  • Roller Mills.
  • HoroMills.
• Why are Ball Mills widely used?
• Ball Mills Weaknesses.
• Grinding Efficiency, Fineness vs Cost.
• Technology comparison between the 4 types of Mills.
• Factors affect Grind ability of Clinker.
• Open & Closed Circuits.
• Limitations of open-circuit Mills.
• Role of Separator.

Mill Technology.

• Purpose of mills.
• Reliability Factor of the mill.
• Average Efficiency of Ball Mill.
• Cataracting & Cascading effect.
• The different types of Ball Mill:
• Air Swept Mill.
• Bi-Rotor Mill.
• Compound.

Mill Components:

• Mill Shell.
• Feed Chute.
• Head Liner.
• Shell Liners:

Step Liners, Single Wave, Duo Lift & Classifying- Liners.

• Grinding Media.
  • Ball Charge Design.
  • Ball Charge Loading.

• Mill Partitions.
• Discharge Grates.
• Mill Supports.
• Mill Drive.
• Mill Lubrication Pump.

• Material Level.
• Mill Ventilation.
• Residence Time.
• Water Spray.
• Summary.

Air Separator. 

• Function of Air Separator.
• Different Technology.
  • Static Separator.
  • Dynamic Separator- First Generation.
  • Double Shaft Separator.
• Possible Adjustment with Dynamic Separator:
  • Diaphragm.
  • Speed of Main Fan.
  • No. of Fan Blades (Coarse adjustment).
  • No. of Selector Blades.
• Dynamic Separator – Second Generation.
• Advantages of this type of Separator.
• Dynamic Separator – Third Generation.
• Or High Efficiency Separator.
• Advantages of the Latest Generation.
• How to evaluate the Efficiency of the Separator.
• Circulating Load Calculation.
• Efficiency, TROMP curve.
• Circulating load

Mill Operation.

• Operator’s objectives.
• Factors that vary and impact the Mill operation.
• Foreseen Changes.
• Unpredictable Changes.
• Performance expected from Raw Mill.
• Performance expected from Cement Mill.
• How can Mill be Well Controlled?
• Dew-Point.
• Sensors & Actuators.
• The Power Decreases when the material is Filling up the Mill.
• Conclusion: The Mill Power Decreases with the Load.
• The most efficient adjustments to make to suit the Quality Targets:
  • Separator Fan Speed.
  • Selection plate speed.
  • Rotor Speed.
  • % opening Diaphragm.
• Safety Procedures.

Incidents.

Ball Mill operating problems.

• Objectives.
• Problems
• Agglomeration and ball coating.
• Clinker changes.
• Changing the cement quality.
• Material by-pass.
• Increase of material moisture.
• Wear of balls, liners and Separator.

Diagnosing Ball Mill problems.

• Objectives.
• Case studies.
  • Case A
  • Case B
  • Case C
  • Case D