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Tanjung Jati B TrainingVERTICAL BALL MILL
REAGENT PREPARATIONVERTICAL BALL MILL
Tanjung Jati B Training
Tanjung Jati B Training
PT Central Java PowerTanjung Jati B Units 1 & 2Flue Gas Desulfurization (FGD) System
Absorber Area DewateringArea
Reagent PreparationArea
Limestone JettyAnd Conveyor
Tanjung Jati B Training
THE INTENT OF THIS SECTION IS TO DISCUSS BASICPROCEDURES FOR STARTING UP THE VERTICAL BALLSYSTEM.
THIS SECTION, BY NO MEANS ESTABLISHES OPERATINGPROCEDURES, THEREFORE IT IS THE RESPONSIBILITYOF THE OPERATORS TO FULLY UNDERSTAND THEOPERATING PROCEDURES PROVIDED IN THEOPERATION & MAINTENANCE MANUALS.
Reagent PreparationVertical Ball Mill
Prior to starting the Vertical Ball Mill section, letsfirst review the Reagent Preparation flow paths andrelated components.
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Tanjung Jati B Training
LimestoneSilo
Bin Activator
LimestoneFeeder Limestone
Pre-Crusher
VerticalBall Mill
MillHydroclone
MillRecirculation
Sump
Limestone SlurryStorage Tank
Mill OutletSump
Mill RecyclePump
Seawater
Reagent PreparationVertical Ball Mill
The function of Reagent Preparation is toprocess raw limestone stored in the LimestoneSilos into a limestone slurry which is ultimatelystored in the Limestone Slurry Storage Tank.
Limestone Slurry, produced by the Vertical Ball Millsand classified by the Hydroclones, will have a solidscontent of 30%.
95% of those solids will pass through a 325 meshscreen.
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Tanjung Jati B Training
LimestoneSilo
Bin Activator
LimestoneFeeder Limestone
Pre-Crusher
VerticalBall Mill
MillHydroclone
MillRecirculation
Sump
Limestone SlurryStorage Tank
Mill OutletSump
Mill RecyclePump
Seawater30%
SOLIDS
95% of solidsthrough a 325 mesh screen
Reagent PreparationVertical Ball Mill
The Limestone Slurry produced by the ReagentPreparation System, by design, will have asolids content of 30%.
Control of the Reagent Preparation Systemis from the main control room. The system isoperated most efficiently as a batch processwith a constant design feed rate of limestoneto the vertical ball mills.
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
The Hydroclone is an integral part of the ReagentPreparation system as well as being integral to theoperation of the Vertical Ball Mill.
Lets first take a look at the Vertical Ball Millcomponents.
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
BALL FILL
DRIVEMOTOR
MILLRECIRCULATION
SUMP
GEARREDUCER
RAWMATERIAL
INLET
SCREW
TO MILLOUTLET SUMP
TO MILLRECIRCULATION
PUMP
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
DRAIN
WASH CONNECTION
SLURRY FEED
BALLDISCHARGE
LOW LEVELSWITCH
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
AGITATOR
AGITATOR(300 RPM)
MILL RECYCLE SUMP(PLAN VIEW)
AGITATORMOTOR
SLURRYOUTLET
AIRVENT
CLAMPASSY
BLADES
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
RAWMATERIAL
INLET SLURRY OUTLETTO RECIRC SUMP
RECYCLE SLURRYFROM RECIRC PUMP
VERTICAL BALLMILL FLOW PATH
Tanjung Jati B Training
VERTICAL BALL MILL INTERNALS @ TJ-B
Reagent PreparationVertical Ball Mill
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
An Oil Lubrication Unit is required for the operationBall Mills Gear Reducer. This Lube Oil Unit requiresa cooling water source and has instrumentation formeasuring oil flow, temperature and differentialpressure.
The source of cooling water is Service Water. Thecooling water exiting the Lube Oil Unit goes tothe drain (trench).
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
DUPLEXFILTER
MOTOR
THERMOMETER(WITH SWITCH)
OILPUMP
FLOWMETER
OILCOOLER
DIFFERENTIALSWITCH
OILINLET
OILOUTLET
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Prior to discussing the start-up of the Vertical BallMill, lets look at the Alarms Mill Trip Recycle Pump Trip Recirculation Sump Agitator Trip Mill Liquid Level Low Mill & Mill Motor Bearing & Winding Temperatures High Mill Motor Current (amps) High Gear Reducer Lube Oil Pump Trip Gear Reducer & Bearing Temperatures High Gear Reducer Lube Oil Flow Low Gear Reducer Lube Oil Temperature High
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
The Reagent Preparation System is started in thefollowing sequence. Note, the Limestone SlurryStorage Tank must be ready to receive slurry
1. Mill Outlet Sump, Agitator & Pump
2. Tower Mill System Lube Oil System Mill Main Drive Mill Recycle Pump & Recirc Sump Agitator Limestone Pre-Crusher Limestone Weigh Feeder & Silo Gate Valve Limestone Bin Activator
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
The Reagent Preparation System is started in thefollowing sequence
3. Limestone Slurry Storage System
Slurry Storage Tank (Level not Hi-Hi) Tank Agitator Limestone Slurry Feed Pumps
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
We have discussed system alarms and the start-upsequence, now lets look at the basic steps for startingthe Vertical Mill and related equipment
Please consult the O&M Manuals for the details forstarting and stopping the Vertical Mill and relatedequipment.
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Starting the Ball Mill System (Mill Outlet Sump)
Open the Mill Outlet Sump Recycle Valve
Close Sump Pump Common Discharge Valve
Open manual Feed Valve to the Hydroclone
Verify that the manual Flushing Valve to theHydroclone Overflow is closed
Verify that the manual seawater Flushing Valve isclosed
Tanjung Jati B Training
From Vertical MillRecirculating Sump
(Flush Water)
Seawater Flush
MillHydroclone
FLUSH
FEED
Pumps A & B
To Vertical MillRecirculating Sump
To LimestoneSlurry Tank C
O
CO
C
Reagent PreparationVertical Ball Mill
Seawater Fill C*
SUMP VALVEARRANGEMENT
DURING START-UP
* Open Valve if sumplevel is low
C
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Starting the Ball Mill System (Mill Outlet Sump)
Place the Mill Outlet Sump Pump in Automatic
Place the Mill Outlet Sump Agitator in Automatic
Once Sump level is achieved, the Pump & Agitatorwill start.
The Sump Pump discharge flow will remain in theRecycle Mode until the entire mill system is in operation.
Tanjung Jati B Training
From Vertical MillRecirculating Sump
(Flush Water)
Seawater Flush
MillHydroclone
FLUSH
FEED
Pumps A & B
To Vertical MillRecirculating Sump
To LimestoneSlurry Tank C
O
CO
C
Reagent PreparationVertical Ball Mill
Seawater Fill C
SUMP PUMP ANDAGITATOR TO AUTO(SHORT RECYCLE)
C
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Starting the Ball Mill System (Hydroclone)
Verify that 4 of 5 Cyclone Isolation Valves are open
Mill Hydroclone Recycle Valve to manual and open
Open Sump Pump Common Discharge Valve
Close Mill Outlet Sump Pump Recycle Valve
Mill Hydroclone Recycle Valve to automatic
Tanjung Jati B Training
From Vertical MillRecirculating Sump
(Flush Water)
Seawater Flush
MillHydroclone
FLUSH
FEED
Pumps A & B
To Vertical MillRecirculating Sump
To LimestoneSlurry Tank O
O
CO
C
Reagent PreparationVertical Ball Mill
Seawater Fill C
MILL HYDROCLONEIN THE
RECYCLE MODE
O
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
MILL HYDROCLONEMILL HYDROCLONE
(PLAN VIEW)
CYCLONES
CYCLONE
4 of 5 Cyclones openfor normal operation
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
INLET
UNDERFLOW
OVERFLOW
MILL HYDROCLONE
Tanjung Jati B Training
MILLHYDROCLONE
orCLASSIFIER
KREBS U.S.A.
LOWERLAUNDER
UPPERLAUNDER
CYCLONESReagent PreparationVertical Ball Mill
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Starting the Ball Mill System (Lube Oil Unit)
Verify Lube Oil Shutoff Valves are Open
Verify Cooling Water Shutoff Valve is Open(Observe cooling water discharging into trench)
Start the Lube Oil Pump
Verify Lube Oil Flow is above minimum, temperaturebelow maximum and differential pressure belowmaximum
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
DUPLEXFILTER
MOTOR
THERMOMETER(WITH SWITCH)
OILPUMP
FLOWMETER
OILCOOLER
DIFFERENTIALSWITCH
OILINLET
OILOUTLET
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Starting the Ball Mill System (Vertical Mill)
Verify Mill Flush & Drain Valves are closed
Seawater Flow Control Valve to manual and open fully
Open Seawater Make-Up Isolation Valve
If Mill is empty, open seawater isolation valve.Fill Mill until water is seen overflowing into theMill Outlet Sump
Verify Seawater Valve to Mill Hydroclone Underflowis open
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
MILL OUTLET SUMP
SEAWATERMAKE-UP
O
O
O
O
MILL HYDROCLONE
VERTICAL MILL
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Starting the Ball Mill System (Vertical Mill)
Once water from the Mill Recirculating Sump is seendischarging into the Mill Outlet Sump, the Mill can bestarted (manually).
If the Mill is in Automatic, the Mill will start when thelevel in the Mill Recirculating Sump is above the lowlevel (switch).
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
MILL OUTLET SUMP
SEAWATERMAKE-UP
O
O
O
O
MILL HYDROCLONE
VERTICAL MILL
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Starting the Ball Mill System (Recycle Pump & SumpAgitator)
Verify Mill Flush and Drain Valves are closed.
Verify Mill Recycle Pump Isolation Valves are open
Verify Mill Recycle Feed Valve is open
Place Pump & Agitator in automatic. Both will startif the level within the Recirculating Sump is abovethe minimum (low level switch)
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
MILLRECYCLE PUMP
TO MILLOUTLET SUMP
MILLRECIRCULATING
SUMP
OOO
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Starting the Ball Mill System (System Dust Collector)
Verify Instrument Air Isolation Valve is open
Verify Isolation Valves at the Mill and LimestoneFeeder are open
Start the Dust Collector
Verify Differential Pressure is not excessive
Tanjung Jati B Training
LIMESTONE SLURRY TANK(UNDER CONSTRUCTION)
REAGENT PREPARATIONAREA DUST COLLECTOR
Reagent PreparationVertical Ball Mill
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
FROM TOWER MILL A
FROM LIMESTONE FEEDER A
FROM TOWER MILL B
FROM LIMESTONE FEEDER B
INSTRUMENTAIR
REAGENT PREPARATION SYSTEM DUST COLLECTOR
C
C
O
O
O
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
Starting the Ball Mill System (Crusher, Feeder andBin Activator)
Pre-Crusher will start after a short time delay afterthe Mill is started (automatic)
Verify Silo Discharge Gate Valve is open
Limestone Feeder will start after a short time delayafter the Pre-Crusher is started (automatic)
Bin Activator will start (if in automatic) when Feederis running and Gate Valve is open.
Tanjung Jati B Training
LimestoneSilo
Bin Activator
LimestoneFeeder Limestone
Pre-Crusher
VerticalBall Mill
MillHydroclone
MillRecirculation
Sump
Limestone SlurryStorage Tank
Mill OutletSump
Mill RecyclePump
Seawater
Slide Gate
Reagent PreparationVertical Ball Mill
Tanjung Jati B Training
When the Limestone Slurry Storage Tank Levelreaches the high level set point, the Mill OutletSump Pump will stop.
When the Sump Pump Stops, this will stop thefollowing equipment if in automatic mode
Pre-Crusher Limestone Feeder Bin Activator
The Vertical Mill will remain in service for flushingand proper shutdown (approximately 60 minutes).
Reagent PreparationVertical Ball Mill
Tanjung Jati B Training
LimestoneSilo
Bin Activator (4)
LimestoneFeeder
(3)Limestone
Pre-Crusher(2)
VerticalBall Mill
(5)
MillHydroclone
MillRecirculation
Sump
Limestone SlurryStorage Tank
Mill OutletSump Pump (1)
Mill RecyclePump
Seawater
SHUTDOWN ORDER
High LevelSet Point
Reagent PreparationVertical Ball Mill
Tanjung Jati B Training
The Vertical Mill is required to operate or run for60 minutes after the Mill Outlet Sump Pump hasstopped.
This is required so that the slurry within the Millwill become finer (smaller) and not settle rapidlyif the Mill were shutdown earlier.
The Mill will shutdown automatically after 60 minutesif the Mill is in Automatic.
Reagent PreparationVertical Ball Mill
Tanjung Jati B Training
The Mill Recycle Pump and Mill Recirculating SumpAgitator will continue to operate and slurry will berecycled back to the Vertical Mill.
It is recommended that the Vertical Mill be run for a5-minute period every 4 hours. This will prevent thecompacting of ground limestone within the Mill.
Reagent PreparationVertical Ball Mill
Tanjung Jati B Training
Reagent PreparationVertical Ball Mill
MILLRECYCLE PUMP
TO MILLOUTLET SUMP
MILLRECIRCULATING
SUMP
Tanjung Jati B Training
Emergency Shutdown of the Vertical Ball Mill
In case of emergency stop due to electrical failureor other cause, the Mill is to be drained and washedof all slurry to prevent the cementation of the hardparticles.
For next start-up, the Vertical Mill must be filled withwater until the water is seen overflowing into the MillOutlet Sump.
Reagent PreparationVertical Ball Mill
REAGENT PREPARATIONVERTICAL BALL MILL
(END)
Tanjung Jati B Training