Modeling and optimization of PEA- combined grinding aids effect in grinding circuit of cement ball mill

Abstract

In this study, while introducing the new combination of by-products of petrochemical companies as a GAs and their combination with water, the optimization and modeling of essential parameters affected by GAs in ball mills have been discussed. According to Central Composite Design, the experiment was designed and implemented with Response Surface Methodology, and a quadratic model for regression analysis (R2 = 0.969) was developed. The effects of essential parameters, including feed rate of the mill, Blaine and dosage rate of GAs, were investigated to find the best efficient conditions and were found to be 121ton/hr: 388.578 l/t and 3650 cm2/gr, respectively. Under these conditions, the power consumption of the mill was found to be 4228.61 kW. Also, optimal conditions were established in industrial grinding processes. The results demonstrated that mill feed rate capacity changes could be obtained at approximately 12.69%. Sieve residue under 90µ in different fractions shows that grinding aid usage has raised the fineness product of the mill by inserting cement PSD and Blaine in a suitable range. Also, using the study done in two similar cement ball mills in the same cement plant, almost 1000000-ton cement was produced.