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CGB-Lab test 1 ( Power saving effect)

2020-08-10 17:36:32

As CGB technology has increasingly caught the eyes of the global cement industry thanks to its remarkable performance in power saving,we’d like to share the lab test a couple years ago ( 2016 ) in China, which gives better picture on how to put this new technology into use properly after replacing steel ball.

1.Equipment   

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φ700mm×700mm  Lab Batch mill

It is equiped with torquemeter that can read the power consumption directly.Below is the technical parameter tables:

Item

Description

Technical Data

1

Mill Shell Dimension

φ700×700mm  (Effective. 600×600mm)
2Gear reducer

XW‐6‐35       Raito:( 29:1)

3

Torquemeter

 HX-100

4

Motor

 Y132M‐4‐7.5  Power:7.5kW

5

Liner Shape

 Dragpeb

Inner liners drawing:

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2.Clinker and FGD gypsum

Literally minimum 2 raw materials shall be used. However in order to avoid deviation due to heterogeneous mixture , one-component clinker was applied as raw materials during the test. When it came to the cement quality test, ground FGD ( Fuel Gas Desulfurization)gypsum is blended for various performance test.The technical data of the raw materials are as follow:

Clinker bond: 13.3kWh/t

Milling method:Roller press

Clinker Blaine: 1133cm2/g

Clinker fineness:  R45um=57%

FGD gypsum blaine:9460cm2/g

3.Mill loading rate ( CGB -ceramic ball Vs steel ball)

During the test, both CGB and steel balls were set with loading rate at 24% with media scheme as below:

( steel balls=174kgs,CGB= 84kgs, clinker charge=20kg/ each time)

Dia. (mm)

30

252015

Ratio (%)5%23%33%39%

100%

Power consumption rate comparison:

Below chart demonstrate the power consumption variation curve:

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(Comparison between CGB and Steel ball)

Above chart suggests that given equal loading rate and rotation speed,CGB enjoy competitive edge in power consumption when the blaine is lower than 3300 cm2/g. However, when the blaine is higher than 3300cm2/g, the CGB doesn’t look better in power saving performance. It even goes higher.

Below table shows @ 40.5 rpm running rate , the relation between blaine and power saving rate when the blaine target is less than 3300cm2/g.

BlaineSteel ballCGB

Saving rate

cm2/g

kWh/tkWh/t

%

~3100

32.027.3

14.7

~325034.733.4

3.7

Based on this table, it suggests that for cement product @ same blaine, the CGB grinding will witness a power saving rate from 3.7-14.6% by contrast with steel balls. The higher blaine target,the lower the power saving rate.

Above test result is on the basis of same loading rate of grinding media ( both are at 24% ).This is the reason why when CGB technology is applied to replace steel balls, the loading rate must be set higher than steel balls so as to keep the power saving advantage.

In next article introducing lab test serie-2, we are going to share the comparison between various grinding media on cement residue.


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