Comparison between

currently applied cement

grinding technologies
Hajo Reiners

Agenda

1. Cement Grinding with Loesche Vertical Roller Mills

2. Other Systems for Cement Grinding
3. Former Concerns regarding VRM Cement Qualities
4. The Proven Reality
5. Short Conclusion

2012

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Cement Grinding with Loesche VRM Mills

Loesche cement mills worldwide

LOESCHE Ref.
C/S Mills 11-2011
LM 63.3+3
LM 56.3+3
LM 56.2+2
LM 53.3+3
LM 46.2+2
LM 41.2+2
LM 35.2+2

Worldwide nearly 240 mills with the 2+2 / 3+3 system

About 170 of them are in operation
2012

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Cement Grinding with Loesche VRM Mills

kWh/t

Power consumption of ball mill system v/s LOESCHE VRM system

(mill, classifier, fan) - OPC grinding

100
90
80
70
60
50
40
30
20
3000

Ball mill
system

LOESCHE
VRM system

3500

4000

4500

5000

cm/g

2012

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Cement Grinding with Loesche VRM Mills

Power consumption of ball mill system v/s LOESCHE VRM system
(mill, classifier, fan) - slag (GBFS) grinding

160
Ball mill
system

140

kWh/t

120
100
80
60

LOESCHE
VRM system

40
20
3000

4000

5000

6000

cm/g
2012

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Cement Grinding with Loesche VRM Mills

Loesche cement mills worldwide

~ 60% of Mills for more than 1 product

~ 40% of Mills for more than 3 products
2012

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Agenda

1. Cement Grinding with Loesche Vertical Roller Mills

2. Other Systems for Cement Grinding
3. Former Concerns regarding VRM Cement Qualities
4. The Proven Reality
5. Short Conclusion

2012

Page 7 / 28

Other Systems for Cement Grinding

Different Systems

2012

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Other systems for Cement Grinding

Main Differences of grinding process parameters:

2012

Ball mill

Roller press

Vertical roller
mill

Characteristics

(closed circuit)

Comminution by:

impact

pressure

pressure and
shear forces

Retention time (min):

20 - 30

<0,1

<1

Comminutions before
separation:

not countable

1-3

Circulation factor:

2-3

>10

6-10

Wear rate (g/t):

~ 50

5 - 10

3-6

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Agenda

1. Cement Grinding with Loesche Vertical Roller Mills

2. Other Systems for Cement Grinding
3. Former Concerns regarding VRM Cement Qualities
4. The Proven Reality
5. Short Conclusion

2012

Page 10 / 28

Former Concerns re. VRM Cement Qualities

Compared to traditional Ball Mill systems

It was said that Cements produced

in a VRM System have a
Higher Water Demand (Standard Consistency)
Retarded Setting Time
Lower Compressive Strength

due to
Steeper Particle Size Distribution (Slope n)
Different Particle Shape
Lower Gypsum Dehydration

2012

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Former Concerns re. VRM Cement Qualities

Compared to traditional Ball Mill systems

Steeper Particle Size

distribution?

Different Particle
Shape?

Lower Gypsum
Dehydration?

2012

Page 12 / 28

Agenda

1. Cement Grinding with Loesche Vertical Roller Mills

2. Other Systems for Cement Grinding
3. Former Concerns regarding VRM Cement Qualities
4. The Proven Reality
5. Short Conclusion

2012

Page 13 / 28

The Proven Reality

sum of residue Q (x) (w.-%)

Different Particle Size Distribution

slope n = tan

position
parameter d
particle size (m)

VRM
System
(Slope n: 0,9 - 1,1)

Ball Mill
System
(Slope n: 0,8 - 1,05)

More fine material (Over Ground) in the cement produced by

Ball Mill system due to high number of impacts and mill inefficiency
2012

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The Proven Reality

Operational parameters

Grinding Pressure
Dam Ring Height
Mill Airflow
Classifier Rotor Speed
Table Speed for very high Blaine cements

Dam Ring

2012

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The Proven Reality

<== Shallow

Slope n

Steep ==>

Options to adjust the inclination n in the PSD Curve.

lower
Grinding
Pressure
higher

lower
Height of
Dam Ring
higher

higher
Mill Air
Flow
lower

higher
Classifier
Speed
lower

Simple adjustment options to achieve the desired product

2012

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The Proven Reality

Operational Results regarding Particle Size Distribution:
Technical Properties
Mill

VRM

BM

Separator

LSKS

O-SEPA

Density

g/cm

3,164

3,152

Blaine

cm/g

4258

4095

0,93

0,92

Position parameter, d'

11,7

12,6

Water Demand
(Standard consistency)

28

28,5

Slope, n

Same Slope n
Same Water Demand
A PSD as needed can be easily produced within a VRM System
2012

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The Proven Reality

Compared to traditional Ball Mill systems

Steeper Particle Size

distribution?

Not True!

Different Particle
Shape?

Lower Gypsum
Dehydration?

2012

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The Proven Reality

Different Particle Shape

More spherical shaped particles in cements

produced with ball mill systems
compared to

More shallow shaped particles in cements

produced with VRM systems
results in

Higher water demand for VRM systems

The particle circularity is determined with an L/ - ratio

2012

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The Proven Reality

Different Particle Shape

The maximum particle size in

cements is usually between 45
and 55 m depending upon the
fineness of the final product and
the slope n.

Fineness: about 4100 Blaine

95% of all cement particles are

usually below 20 and 45 m
depending upon the fineness of
the final product and the slope n.
52 m

Particle size in cements all below 55 m and 95% below 45 m

2012

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The Proven Reality

Different Particle Shape

Circularity of cement particles

are similar for cements
produced in a ball mill or VRM
system.

Circularity

Clinker B 3000 cm/g

VRM
Roller press
Ball mill

58
Particle size (m)

The only notable differences

appear at higher particle sizes
>50 m who have no influence
on the strength development!

(VDZ 2007)

Similar particle shapes produced on VRM systems

2012

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The Proven Reality

Compared to traditional Ball Mill systems

Steeper Particle Size

distribution?

Not True!

Different Particle
Shape?

Not True!

Lower Gypsum
Dehydration?

2012

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The Proven Reality

Lower gypsum dehydration
Ball mill
(closed
circuit)

Vertical
roller
mill

Retention time (min)

20 - 30

<1

Temperature (C)

90 -140

80 -110

Characteristics

Gypsum Dehydration in Ball Mill

Systems is different compared to
VRM systems. This is due to Higher mill outlet temperature
Longer residence time in mill system
Different gas humidity (negative factor)
resulting in

(Plaster)

(Gypsum)

(Anhydrite)

2012

Better drying of the gypsum, hence

conversion into a higher content
of reactive plaster, necessary as a
setting regulator

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The Proven Reality

Simple Counter Measures in a VRM system

Increase mill exit temperature

Increase gypsum content (0,5 1%)
Add a small amount of plaster
Add a small amount of natural Anhydrite
Decrease humidity of mill gas flow
resulting in

Same setting behaviour, i.e. same Setting Time and

Compressive Strength
Normal optimisation process by works quality department
2012

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The Proven Reality

Different Particle Shape

Technical Properties
Mill

./.

VRM

BM

Separator

./.

LSKS

O-SEPA

Fineness acc. to Blaine

cm/g

4258

4095

Standard consistency

28

28,5

Setting time, begin

min

130

125

Setting time, end

min

175

175

[2d]

MPa

29,8

29,9

[7d]

MPa

38,9

38,6

[28d]

MPa

57,1

54,1

Compressive strength (W/C 0,5)

Same Cement with the same characteristics

2012

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The Proven Reality

Compared to traditional Ball Mill systems

2012

Steeper Particle Size

distribution?

Not True!

Different Particle
Shape?

Not True!

Lower Gypsum
Dehydration?

Partially correct, but

simply adjustable!
(Normal Optimisation!)
Page 26 / 28

Agenda

1. Cement Grinding with Loesche Vertical Roller Mills

2. Other Systems for Cement Grinding
3. Former Concerns regarding VRM Cement Qualities
4. The Proven Reality
5. Short Conclusion

2012

Page 27 / 28

Short Conclusion
With Loesche Vertical Roller Mills Cement can be produced with the
same

Particle Size Distribution,

Particle Shapes and
Setting Behaviour

as Cements produced in ball mill systems!

Therefore, cements produced with the Loesche Vertical Roller Mill
will totally meet the required local market demands, regarding Water
Demand, Setting Times and Compressive Strength.
BUT much more Energy Efficient, Cost Effective and Flexible

2012

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