A comparative analysis of the recent cement grinding systems with particle-based influences on cement properties

Fidan, Berkan
The conventional cement grinding system, the ball mill, has very poor efficiencies in spite of innovative improvements. For this purpose, development of new techniques, which allow proper size reduction and uniform particle size distribution with less specific energy consumptions, have become a necessity. The aim of this study is to make a comparative analysis of the fairly new cement grinding technologies, COMFLEX® Grinding System, Roller Press and HOROMILL®, at the same cement production plant with the same raw materials. In this context, CEM I 42.5 R type cement was produced with a fixed Blaine fineness of 3600 (±100) cm2/g at three different grinding units. The same raw materials, clinker and gypsum, and identical feeding ratios, 95% and 5%, were used to produce cement. Accordingly, these different grinding techniques were inspected with respect to the microstructural properties of cement particles, and the relative chemical, physical and mechanical properties of products. It was found that the main cement grinding parameters, specific surface area and sieve residue, do not show expected relation and change with each grinding system due to differences in the size reduction technique. Moreover, strength and other hardened mortar properties are directly affected by the liberation conditions of reactive grains at grinding stages.High capacity and low specific energy consumption i.e. the breaking and cracking efficiency of the roller press and higher grinding performance of the ball mill promoted the COMFLEX® system. On the other hand, the roller press was clearly advantageous at early strength performances with moderate specific energy usages during grinding. Nonetheless, it also had drawbacks like higher water demand and earlier setting times (which mean higher hydration temperatures). When the wideness and sharpness of classification results were considered, HOROMILL® gave better results with high circulation and efficient air classification design; although there were weaknesses of the system such as lower capacity and higher specific energy consumption rate.


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An industrial comparative study of cement clinker grinding systems regarding the specific energy consumption and cement properties
Hoşten, Çetin; Fidan, Berkan (2012-05-01)
This paper is concerned with a comparative analysis of modern cement grinding systems, namely, combined grinding (Comflex (R)), high-pressure roll mill (HPRM) grinding, and horizontal roller mill (Horomill (R)) grinding. Cement production trials were run with these grinding systems in the same cement plant by using the same clinker/gypsum feed to produce cements of almost identical chemical compositions and similar Blaine fineness values of about 3600 cm(2)/g. The grinding systems were compared in terms of ...
A study on blended bottom ash cements
Kaya, Ayşe İdil; Yaman, İsmail Özgür; Hoşten, Çetin; Department of Cement Engineering (2010)
Cement production which is one of the most energy intensive industries plays a significant role in emitting the greenhouse gases. Blended cement production by supplementary cementitious materials such as fly ash, ground granulated blast furnace slag and natural pozzolan is one of the smart approaches to decrease energy and ecology related concerns about the production. Fly ash has been used as a substance to produce blended cements for years, but bottom ash, its coarser counterpart, has not been utilized du...
Citation Formats
B. Fidan, “A comparative analysis of the recent cement grinding systems with particle-based influences on cement properties,” M.S. - Master of Science, Middle East Technical University, 2011.