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Performance Evaluation of Vertical Roller Mill in Cement Grinding: Case Study

ESCH Cement Plant

Conference Paper · September 2017

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Deniz Altun Namik Atakan Aydogan

Hacettepe University Hacettepe University
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Performance Evaluation of Vertical Roller Mill in Cement
Grinding: Case Study ESCH Cement Plant
D. Altun, N.A. Aydogan, O. Altun, A.H. Benzer

Hacettepe University, Ankara/Turkey

Abstract: In this study, an extensive sampling study was carried out at vertical roller mill of ESCH Cement Plant in Luxemburg.
Samples were collected from mill inside and around the circuit to evaluate the performance of each operation in the system,
individually. Particle size distributions of collected samples were determined by the combination of dry sieving and laser
scattering method down to 500 µm. Data obtained from two surveys were used to obtain best estimates of mass flow rate and
size distribution of each stream by mass balancing. Grinding and separation efficiency of vertical roller mill were evaluated. In
addition to these, performance figures of vertical roller mill and conventional closed ball mill circuit were compared. It was
concluded that vertical roller mill circuit has an advantage over conventional ball milling circuit in terms of energy consumption.

Keywords: Vertical roller mill, cement grinding, performance evaluation

INTRODUCTION evaluate the overall performance and additionally the

Cement production is highly energy consuming process
with energy utilization of around 110-150 kWh/t (Villa,
2005). Majority of this energy (40 %) are consumed for
finish grinding. High energy consumption, increasing
demand and the emission of CO2 necessitate the
efficient grinding technologies. Among these
technologies, vertical roller mills have an important
position in cement industry.
grinding and separation mechanisms individually.
Schematic view of a typical vertical roller mill with the
streams is illustrated in Figure 1 and Table 1 gives the
names of the streams. Broadly, the vertical mill
operation is separated into three stages that are; feeding,
static classification (transportation of the material from
the table to the dynamic classifier) and dynamic
classification.

Vertical roller mills are widely used for especially

grinding of coal, cement raw materials, clinker and
minerals like bauxite, phosphate, magnesite, etc. These
machines consist of grinding and separation parts.
Grinding operation takes place between the grinding
table and the rollers by compression force.
Classification operation is carried out by high efficiency
dynamic air classifiers inside the vertical roller mill shell.
Also, vertical roller mills combine drying, grinding and
separation operations in one unit. Beside this property
of this system, other features like low specific energy
consumption, low wear rates, handling material with
high moisture, coarser feed cause gaining an advantage
of vertical roller mills over conventional grinding
systems.
FIGURE 1. Schematic view of vertical roller mill and
Control and optimization of the vertical roller mill streams
systems have become important with the widespreading
application. Performance evaluation of vertical roller TABLE 1. Name of the streams
mill operation is crucial for control the system and
improvement of the efficiency. Based on this, sampling
studies were performed at vertical roller mill of ESCH Stream Stream name
Cement Plant, which is located in Luxemburg. 1 Fresh Feed
Performance evaluation results of vertical roller mill in 2 Table Feed
cement grinding application are presented. 3 Table Product
4 Static Class. Reject
SAMPLING STUDIES 5 Static Class. Fine (Dynamic Class. Feed)
In this study, a new sampling method developed by 6 Dynamic Class. Reject
Aydogan (2015) was used to obtain data. The
7 Dynamic Class. Fine (Product)
methodology is based on collection of samples from
both mill inside and around the system in order to Prior to performing sampling campaign, operating
conditions should be followed from the control system
to determine whether the system is at steady state During the sampling surveys, operational parameters
condition. In this context, the trends of mill, fan and measured were recorded at the control room. Control
elevator powers, differential pressure of the mill and room data are given in Table 3.
feed tonnage are followed. The sampling campaign is
commenced when the steady state condition is TABLE 3. Operating conditions of the surveys
established. Sampling points are illustrated in Figure 2.
Fresh feed (1) and product (7) streams are outer streams Survey 1 Survey 2
and could be sampled easily. Initially, final product
Name of feed composition CEM I CEM I
stream is sampled while VRM is running. Afterwards,
the mill is crash stopped to collect samples from fresh Clinker (t/h) 113.01 116.3
feed conveyor belt, mill discharge and mill inside. For
Limestone (t/h) 2.65 2.72
the fresh feed, the whole material is collected from
certain length of the belt and then weighed to calculate Gypsum (t/h) 4.83 4.74
the flow rate by considering the belt speed. Static
Limestone-2 (t/h) 3.38 3.46
classification stage reject (4), was not sampled because
the buckets of the elevator were empty. This results Clinker (%-H2O) 0.1 0.28
from the material transportation mechanisms of the
mill. All material is transported by air because of the Limestone (%-H2O) 4.76 4.69
high air flowrate inside the mill. As a final step of Gypsum (%-H2O) 2.7 4.96
survey, sampling studies are performed inside the mill.
The materials just before and after the rollers were Mill differential pressure (mbar) 52.07 54.45
assumed as total table feed (2) and product (3), Air flow filter outlet (m³/h) 322000 354365
respectively.
Working press. M-roller (bar) 94 94
Classifier rotor speed (1/min) 108 111
Spec. power total (kwh/t) 28.74 29.85

MATERIAL CHARACTERIZATION
STUDIES
As part of the characterization studies, the particle size
distributions of collected samples were determined. All
samples taken from the circuit were screened from 75
mm to 500 µm. The particle size distributions of the
minus 500 µm materials were determined by laser sizing
method. The particle size distributions of collected
samples are shown in Figure 3 and Figure 4 for survey
1 and 2, respectively.
FIGURE 2. Industrial scale vertical roller mill sampling
points
Design parameters of the vertical roller mill are
summarized in Table 2.

TABLE 2. Design parameters of vertical roller mill

Table diameter (m) 4.6

Table speed (rpm) 24.21
Number of master and slave rollers 2 M+ 2 S
Max. working press (bar) (M-roller) 100
Min. working press (bar) (M-roller) 55
Maximum throughput (t/h) 4000 cm²/g (GBFS) 120
Maximum throughput (t/h) 4000 cm²/g (CEM I) 110
Classifier diameter (mm) 4300 FIGURE 3. Particle size distributions of collected
Classifier max. rotor speed (rpm) 150 samples (Survey 1)
Max. fan capacity (kW) 1750
Min. fan capacity (kW) 416
 A and b: Model parameters
X: Particle size (mm)
Figure 5 and Figure 6 shows the t10 values as a function
of specific comminution energy level (ECS) and particle
size.

Survey-1
60

50

40

t10 (%)
30

20

Experimental
10
FIGURE 4. Particle size distributions of collected Calculated
samples (Survey 2) 0
0 5 10 15 20
ECS*X (kWh*mm/t)
Bond work indices and breakage characteristics under
compression were determined. Calculated Bond work FIGURE 5. ECS*X-t10 relationships of the clinker-1
indices of clinkers from survey 1 and survey 2 is 14.2
kWh/t and 13.45 kWh/t, respectively. Survey-2
60
Material characterization studies were performed by 50
using piston-die test equipment. Throughout the
studies the narrow size fractions were prepared for all 40
t10 (%)

fresh feed samples collected during surveys. Prepared 30

samples were subjected to compression breakage under 20
3 different force levels. Piston-die test conditions are
Experimental
given in Table 4 10
Calculated
0
TABLE 4. Piston-die test conditions 0.0 5.0 10.0 15.0 20.0
ECS*X (kWh*mm/t)
Force (kN)
Size Fraction (mm) 100 500 1200 FIGURE 6. ECS*X-t10 relationships of the clinker-2
-9.5+8.0    A, b breakage model parameters were back calculated
-6.7+5.6    and then Axb was determined that is used as ore
-2.36+1.7    hardness index. Calculated A and b breakage
parameters are given in Table 5. When the two clinkers
are compared based on ore hardness index, it can be
During the piston die tests, the applied force and the concluded that resistance to compression force of two
displacement of material bed were recorded. Then, clinkers are similar.
work done during compressed bed breakage test was
calculated by drawing force-displacement curve initially. TABLE 5. Calculated breakage parameters
The area under the curve was calculated and noted as Survey 1 Survey 2
the energy of the breakage test. After calculating the
specific comminution energy (ECS) for each test, A 52.50 51.27
particle size distributions of broken products were b 1.54 1.56
determined by sieve analysis. From the particle size
Hardness index (Axb) 80.75 80.21
distributions of the samples t10 values were determined.
t10 parameter is the fineness index that is defined as the
percent passing of one tenth of the original mean
MASS BALANCE STUDIES
particle size.
Mass balancing is required to estimate the flowrates and
ECS-t10 data were fitted to size dependent breakage the particle size distributions of unknown streams.
model (Equation 1) developed by Eksi, et.al. (2011). Thus, performance evaluation of a circuit or an
equipment is possible. During the sampling studies,
𝑡10 = 𝐴 ∗ (1 − 𝑒 −𝑏.𝐸𝐶𝑆 .𝑋 ) (1) some errors arise from the dynamic nature of the
system, physical conditions, measurement and human.
Mass balancing involves statistical adjustment of raw
data to obtain best fit estimates of flowrates and particle
size distributions. Data obtained from two surveys was
used to calculate the particle size distributions and After reconciliation procedure, flowrates around the
flowrates of each stream. Statistical adjustment of the vertical roller mill system and particle size distributions
raw data was made by reconciliation procedure for survey 1 and survey 2 were calculated. Balanced data
presented for vertical roller mills (Aydogan, 2015). are presented in Figure 7 - Figure 10.

122.88 tph
1536.94 tph
1536.94 tph 1536.94 tph 122.88 tph
Static Dynamic
Grinding
Classification classification

0 tph

1414.06 tph

FIGURE 7. Mass balanced flowrates around the circuit for Survey 1

126.52 tph
1693.26 tph 1693.26 tph
1693.26 tph 126.52 tph
Static Dynamic
Grinding
Classification classification

0 tph

1566.74 tph

FIGURE 8. Mass balanced flowrates around the circuit for Survey 2

FIGURE 9. Mass balanced particle size distributions FIGURE 10. Mass balanced particle size distributions
around the circuit for Survey 1 around the circuit for Survey 2

Accuracy of the results was assessed by plotting the

experimental and mass balanced cumulative passing
percentages on a graph (Figure 11). Experimental and
calculated data set are good in agreement. This situation
corresponds to an accurate sampling.
FIGURE 11. Comparison of measured and calculated data for Survey-1 and Survey 2

It can be seen from Figure 12 and Figure 13 that particle

PERFORMANCE EVALUATION size distributions of table product is parallel to table
STUDIES feed. This parallel shifting is observed in other grinding
technologies as ball mill or High Pressure Grinding
In this part of the study, performance of the grinding Rolls.
and separation sections are evaluated separately.
Separation Section
Grinding Section
Calculated table feed and table product size Performance of the classification operation for each
distributions are compared to investigate the grinding survey was evaluated by plotting efficiency curve
operation in vertical roller mill. In Figure 12 and 13, (Napier-Munn et.al., 1996). Actual and corrected
presents the particle size distributions of total table feed efficiency curves of classifier for two survey are given
and products for two surveys. in Figure 14 and Figure 15.

Survey 1
100 Actual Efficiency Curves
90
Cumualative Undersize (%)

Feed Reporting to Coarse Product (%)

100
80
90
70
80
60
70
50
60
40
50
30
Table feed 40
20
Table product 30
10
20 Survey 1
0
0.001 0.010 0.100 1.000 10.000 100.000 10 Survey 2
0
Particle Size (mm)
0.001 0.01 0.1
Particle Size (mm)

FIGURE 12. Particle size distributions of table feed and FIGURE 14. Actual efficiency curves of separator for
product (Survey 1) two surveys

Survey 2
Corrected Efficiency Curves
100
Feed Reporting to Coarse Product (%)

90 100
Cumualative Undersize (%)

80 90
70 80
60 70
50 60
40 50
30 40
Table feed 30
20
10 Table product 20 Survey 1
0 10 Survey 2
0.001 0.010 0.100 1.000 10.000 100.000 0
Particle Size (mm) 0.001 0.01 0.1
Particle Size (mm)

FIGURE 13. Particle size distributions of table feed and

product (Survey 2) FIGURE 15. Actual efficiency curves of separator for
two surveys
If two classification behaviors of separator were 100
investigated for two surveys, classification activity are 90

Feed Reporting to Coarse Product (%)

similar except by-pass values. Efficiency curve 80

parameters corrected cut size (d50c ), by pass, dust load 70

60
and imperfection value (I=(d75c-d25c)/2d50c ) are given 50
in Table 6. 40
30
TABLE 6. Calculated efficiency curve parameters 20 Survey 1
10
Survey 1 Survey 2 Ball mill circuit
0
0.001 0.01 0.1 1
By pass (%) 42.3 47.2
Particle Size (mm)
d50c (µm) 26.5 28.0
Imperfection 0.27 0.25 FIGURE 16. Actual efficiency curves of ball mill circuit
Dust load (kg/m3) 4.77 4.78 and vertical roller mill classifiers

TABLE 8. Calculated efficiency curve parameters

COMPARISON OF VERTICAL ROLLER Survey 1
Ball mill
circuit
MILL AND CONVENTIONAL BALL
MILL CIRCUIT By pass (%) 42.3 16.3
Performances of vertical roller mill and closed ball mill d50c (µm) 26.5 36.8
circuit in cement grinding application (CEM I 42.5 R) Imperfection 0.27 0.44
were compared in terms of energy consumption and
Dust load (kg/m3) 4.77 1.24
separation efficiency. Fresh feed and final product size
are given in Table 7 with energy figures.
Regarding to classifier performances, by pass
TABLE 7. Performance summary percentage of vertical roller mill classifier is high in
comparison with ball mill circuit classifier. This results
Ball from the high internal circulation of vertical roller mill.
Survey 1 Survey 2 mill Dust loading of separator feed is 4.77 kg/m3 for vertical
circuit roller mill while ball mill circuit is 1.24 kg/m3. On the
Feed tonnage (t/h) 123 126 155 other hand, classification operation of the vertical roller
F80 (µm) 13000 7500 19500 mill separator is sharper than conventional circuit
separator.
P80 (µm) 20.1 20.1 35
Spec. motor power CONCLUSION
21.77 22.77 30.65
(kwh/t) Within the study, sampling studies were performed
Spec. Fan power inside and around the vertical roller mill circuit in
6.47 6.5 1.61
(kwh/t)
cement grinding successfully. Then material
Spec. Classifier
Power (counter) 0.61 0.68 0.52 characterization and mass balance studies were carried
(kwh/t) out. Performance evaluation studies were performed
Spec. classifier fan for grinding and separation units, individually. It is
motor power - - 1.26 indicated that particle size distributions of mill feed and
(kwh/t) mill product are parallel to each other. Efficiency curve
Spec. Power total concept was used to investigate the separation
28.85 29.95 34.03
(kwh/t) performance of the vertical roller mill classifier.
Separation efficiency is similar for two surveys except
Total energy consumption of the conventional ball mill by pass values. Finally, vertical roller mill circuit were
circuit is higher than vertical roller mill system in spite compared to conventional ball mill circuit in terms of
of the coarser feed of ball mill circuit. energy consumption and classification performance. It
was concluded that vertical roller mill circuit is more
Efficiency curves of classifiers of vertical roller mill energy efficient than conventional ball mill circuit.
system and ball mill circuit were plotted to make a Classifier of vertical roller mill has higher by pass values
comparison (Figure 13). Efficiency curve parameters of because of the high dust loading. Beside this, sharpness
two system are summarized in Table 8. of the classification of ball mill circuit is lower than
vertical roller mill circuit.

ACKNOWLEDGEMENTS
Authors would like to gratefully acknowledge Carsten
Gerold, Markus Stapelmann and Mathis Reichert from
Loesche GmbH for their valuable support. We would
 also like to show our gratitude to the ESCH Cement
Plant for providing the access to the plant.

REFERENCES
Aydogan, N.A., A simple sampling method for VRMs,
ZKG International, 2015, 3, 50-55.
Eksi, D., Benzer, H., Sargın, A., Genc, O., A new
method for determination of fine particle breakage,
Minerals Engineering, 2011, .24, 216-220.

Napier-Munn, TJ., Morrell, S., Morrison, RD., Kojovic,

T., Mineral comminution circuits-their operation and
optimization, JKMRC monograph series in mining and
mineral processing, Brisbane, Australia; 1996.

Villa, E., Spada, F., Santini, M., Italcementi Group

Crushing and Grinding Course, 2005.

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