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    Chuong 2-Roller Mill

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    Amit Sharma
    The vertical roller mill is a key equipment in cement production and is often the limiting factor in production capacity. Upgrades to existing mills include upgrading the integrated separator or installing a new roller press. The mill operates by grinding raw materials into a raw meal between a grinding table and multiple rollers. The internal separator then separates fine and coarse material. Proper control of gas flow, separator speed and hydraulic systems is important for operation and maintenance focuses on wear of internal components like rollers, liners and the separator.

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    Chuong 2-Roller Mill

    Uploaded by

    Amit Sharma
    381 views24 pages
    The vertical roller mill is a key equipment in cement production and is often the limiting factor in production capacity. Upgrades to existing mills include upgrading the integrated separator or installing a new roller press. The mill operates by grinding raw materials into a raw meal between a grinding table and multiple rollers. The internal separator then separates fine and coarse material. Proper control of gas flow, separator speed and hydraulic systems is important for operation and maintenance focuses on wear of internal components like rollers, liners and the separator.

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    The vertical roller mill is a key equipment in cement production and is often the limiting factor in production capacity. Upgrades to existing mills include upgrading the integrated separator or installing a new roller press. The mill operates by grinding raw materials into a raw meal between a grinding table and multiple rollers. The internal separator then separates fine and coarse material. Proper control of gas flow, separator speed and hydraulic systems is important for operation and maintenance focuses on wear of internal components like rollers, liners and the separator.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    381 views24 pages

    Chuong 2-Roller Mill

    Uploaded by

    Amit Sharma
    The vertical roller mill is a key equipment in cement production and is often the limiting factor in production capacity. Upgrades to existing mills include upgrading the integrated separator or installing a new roller press. The mill operates by grinding raw materials into a raw meal between a grinding table and multiple rollers. The internal separator then separates fine and coarse material. Proper control of gas flow, separator speed and hydraulic systems is important for operation and maintenance focuses on wear of internal components like rollers, liners and the separator.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 24

    CEMENT PRODUCTION PROCESS

    The Challenge
    The capacity of the vertical raw mill is often the limiting factor for clinker output when a plant upgrades the kiln system, the raw mill frequently becomes a bottleneck. Rather than investing in an entirely new vertical mill to keep pace, there is a very limited set of possibilities in upgrading existing mill capacity in smaller steps. For example, older mills can achieve a modest capacity increase by upgrading the integrated separator

    ROLLER MILL

    Vertical Roller Mill (VRM) - 3 Sections


    Transport
    Exhaust gases Raw meal

    1. Separation

    Drying

    Separation

    Feed Material

    Grinding

    2. Grinding

    Hot gases

    Drive

    3. Drive

    Energy

    Vertical Roller Mill (VRM) - Details


    feed gate (air lock) mill exhaust product discharge mill outlet duct separator cage rotor separator guide vanes tailings cone separator discharge flap mill casing water injection roller with tyre or segments rocker arm roller axle table liner hot gas inlet nozzle of louvre ring grinding table

    dam ring

    hydraulic cylinder clutch and motor speed reducer with table bearing

    material scraper

    VRM - Working principle


    Vertical roller mill

    Grinding force = Roller weight + (pressure) Force


    Material bed Feed material

    Roller rolls freely with table

    Table moves with drive Max Particle size in feed: 5-8 % of roller diameter
    Feed size: f (Roller )

    VRM - Material Flow inside


    Separator: removes fine material rejects coarse material Internal gas flow Separator Rejects Internal Circulation Large Material falls through to scraper
    Material

    Gas & Product Material Feed Material

    Material & Gas


    Gas

    VRM - Some Common Mill Configurations

    G.Pfeiffer

    Loesche

    FLS Atox

    Polysius

    VRM - Built-in Separator


    static separator Static type
    P

    conventional rotor type Conventional

    cage rotor type Cage Rotor type with guide vanes


    P

    Rotor type

    F T

    T F F P T F

    Separation control:

    1. Vane adjustment
    2. Speed control
    TF FT

    F= P= T=

    Feed Product Tailings

    Separators of

    rd 3

    Generation

    (Vertical roller mill)


    Reject cone

    Cage rotor

    Guide vane system

    VRM - Separator Fotos


    Angle affects product sizing

    Rotor speed affects product fineness

    Rotor seal affects separator efficiency

    Potential Problems/clogging
    Cage rotor separator casing
    partly clogged guide vane system

    Material deposits due to insufficient airflow or airflow distribution

    VRM - External Circulation


    fresh feed

    bucket elevator

    louvre ring

    scraper

    Used for reducing gas flow pressure lost over the mill

    (less pneumatic internal circulation)


    collecting conveyor

    VRM - Example flow-sheet


    Control points

    1 gas flow
    2 pressure difference 3 return gas flow pressure 4 outlet temperature 5 external recirculation

    VRM - Control & Maintenance


    Control
    Gearbox

    - Vibration monitor - Temperature monitor

    Gas flow Hydraulics

    - Temperatures & pressures - Pressures

    Maintenance
    Wear

    - Rollers & Table

    - Separator (sealing!) & Housing


    Lubrication & Hydraulics (filters and seals)

    VRM - Control
    [kW] grinding aid DEG [l/h] [t] [C]
    [mbar]

    [%]

    [min-1] [l/min]

    [mbar] [%]

    [min-1]

    [t/h]
    [mbar]

    [min-1]

    Clinker [t] [%]

    Gypsum [t] [%]

    sampler [cm2/g] [%R] [mbar] [C]

    [bar]

    [l/h]

    to cement silo

    Hot gas [C]

    [t/h]

    [t/h]

    [kW]

    [%] fresh air

    Vertical roller mill internals suffering from wear


    Outlet duct Separator Separator cone

    Inlet chute

    Mill housing

    Armour & nozzle rings Scrapers

    Rollers and table liners

    Roller and grinding track liners

    Grinding track liners:


    Monobloc Segments

    Roller liners:
    Monobloc Segments

    Wear resistance material alternatives


    Nihard 4
    %C % Cr % Ni Weldable

    < 3.5

    < 10

    < 6.5

    yes

    High Chromium alloys


    %C % Cr % Other Weldable Example
    Chromodur, FMU18, VegalineV16s

    < 3.6
    < 2.6 < 3.5

    < 17
    < 20 < 28

    Mo + Ni
    Mn < 1.2

    yes
    No No

    FMU 52 FMU 46

    Wear resistance material alternatives


    Metallic inserts roller liner

    Soft material base

    Hard metallic insert

    Wear resistance material alternatives


    Ceramic inserts roller and grinding track liners
    Metallic base (High Cr)

    Ceramic insert

    Wear rate monitoring

    2500 [h] = 50 [mm]

    40 [mm] = ~ 2000 [h]

    Minimum allowed thickness

    Wear resistance material alternatives


    Surface reconditioning on grinding track and roller liners
    %C <5 < 5.5 % Cr < 29 ~ 22
    % Others

    Weldable yes yes

    Example Vautid 100, HC-O CN-O, CNV-O

    Ni, Mo 6 7 Ni

    VRM - Accessories
    Rotary valve
    Reduces false air entering with feed material. Good for dry, small size material.

    Pendulum valve
    Reduces false air entering. Better for lumpy or humid feed material.

    Weigh belt

    Metal extraction
    Metal objects damage the roller & table. The magnet removes them

    Weighs the passing material ensuring a continuous grinding bed in the mill

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