Professional Documents
Culture Documents
Systems
Training Department
Indonesia Cement and Concrete Institute
September 2007
Objectives
1
Grinding with vertical roller mill systems
2
Introduction : Vertical Roller Mill
Transport
Exhaust gases
Raw meal
Feed
Material
Grinding
2. Grinding → Hot
gases
Drive
Energy
3. Drive →
5
separator
guide vanes
tailings cone
separator
discharge flap
hydraulic cylinder
3
VRM - Working principle
Vertical rollerforce
Grinding mill =
Feed
Max Particle size in size:
feed: 5-8 % of roller diameter
f (Roller Ø ) 7
rejects coarse
material
4
VRM - Some Common Mill Configurations
Rotor type P
F T F F T T F
F F
P T
Separation control:
1. Vane adjustment
F= Feed
2. Speed control P= Product
T= Tailings
TF FT 10
5
VRM - Separator Fotos
Angle affects
product sizing
fresh feed
bucket elevator
louvre ring
Used for reducing
scraper gas flow pressure
lost over the mill
(less pneumatic
internal circulation)
collecting conveyor
12
6
VRM - Example flowsheet
Control points
1 gas flow
2 pressure
difference
3 return gas flow
pressure
4 outlet
temperature
5 external
recirculation
13
VRM - Accessories
Rotary valve Pendulum valve
Reduces false Reduces false
air entering with air entering.
feed material. Better for
Good for dry, lumpy or
small size humid feed
material. material.
Weigh belt Metal extraction
Metal objects
damage the
roller & table.
Weighs the passing material The magnet
ensuring a continuous grinding removes them
bed in the mill 14
7
Grinding with Vertical Roller Mill Systems
Detail
15
Details
1. Main Parts
2. Processes
3. Feed and feed system
4. Drying
5. Grinding
6. Mill ventilation and transport
7. Separating
8. Mill operation and control
9. Product quality
16
8
1. Main parts of a vertical roller mill
Mill body Feed
separator
9
Vertical roller mill: rocker arm type
Loesche: LM Kobelco: OK
19
20
10
2.1.Grinding: material distribution on the table
21
2.2.Drying
95 85
Hot gas
150 75
T [°C]
350 25
Material
22
11
2.3. Transport
Pneumatic transport to
the separator of the
material leaving the
table
Mechanical transport
of the material falling
down through the
nozzle ring
23
2.4. Separating
24
12
3. Feed and Feed System
25
Feed materials
R
D
[%]
13
Feed system arrangement
Foreign bodies protection
Good handling
Short reaction time
- < 90 [s] oscillating
around set point
- < 10 [s] interruption
Variable speed belts
Triple gate
[%] H2O > 8
Very sticky materials
Triple gate
28
14
Feed chute
Feed Heating for sticky materials
Feed
Hot gas
Hot gas
29
Feed chute
Sufficient inclination
> 45 [°]
30
15
4. Drying
31
Cold air
Mill motor
power
Hot gas
32
16
4.2.Where does most of drying happen?
Material
leaving the
Evaporation table
Hot gas
33
Kiln gas
1.5 [Nm3/kg clinker]
< 350 [°C]
6 – 7 [%] H2O
Cooler gas
0.4 [Nm3/kg clinker]
~ 300 [°C]
1 – 1.5 [%] H2O
additional
Hot gas generator
- < 450 [°C] at mill inlet
- Up to 20 [%] H2O
34
17
4.4.Required hot gas rate and mill feed moisture example
4.0
3.5
3.0
2.5
Mai-98 Jun-98 Jul-98 Aug-98 Sep-98 Okt-98 Nov-98 Dez-98 Jan-99 Feb-99 Mrz-99 Apr-99 Mai-99 Jun-99 Jul-99 Aug-99
Date
35
18
4.6.Mill false air entries
feed
air seal
Compensator
all sealings
of casing
openings
doors +
covers
Compensator Compensator
External reject
37
5.Grinding
38
19
5.1.On what depends the grinding efficiency?
Roller specific Roller & table
operating pressure wear profile
Nozzle ring
Armour ring
40
20
5.3.Material distribution on the table
41
[kN/m2]
21
5.5.Roller and table wear profile
Worn New
43
Dam ring
roller
Controls material
flow leaving the
grinding zone
dam ring
Controls material
bed thickness
44
22
Nozzle and armour ring
Airspeed through
nozzle ring controls
the amount of
material in the
external
recirculation
Armour ring
inclination controls
the amount of
material sent back
to the table
45
Water injection
slows the material
on the table and Water injection
increases the mill onto the table and
stability before the rollers
46
23
6.Material internal transport
47
Nozzle ring
The nozzle ring 11
12 13 14 15
16
10 17
evens the air 09 18
distribution all 08 19
07
21
05
22
04
23
03
24
02
25
01
26
48
27
The airspeed
47
28
29
ring can be
45
30
modified by
44
31
43
selective 42
32
33
opening/closing the 41
40 35
34
free surface 39 38 37 36
48
24
Air amount in the mill for grinding and transport
6 Gas/air at mill outlet to ensure the grinding
and the transport inside is material dependant:
5
4
Es [m3/kg]
Raw meal
< 5.5 [kWh/t] 1.6
3 Coal (1)
> 5.5 [kWh/t] 0.15 x Es + 0.75
2 Pozzolana
1 OPC
-- 3.2
Slag
MIC
-- Mix dependent (2)
cement
25
Material falling through the nozzle ring
Amount controlled by: If no external material
the gas flow passing recirculation:
through the nozzle ring Handling of rejects required
Start & stop sequence Dust generation
Feed size False air inlet
Higher fan consumption
80
60
dp- Mill (mbar)
40
20
Polysius
20 40 60 80
v- Nozzle ring (m/s)
51
7.Separating
52
26
Steps in the separating process
53
27
On what depends the separating efficiency?
Separator type
Design and position of the guide vanes
Design of the rotor blades
Air and material distribution on the rotor height and
circumference
Dynamic seal state
Amount of separating air
55
Separator type
56
28
Air and material distribution
Vrad
Mill casing design
to get even air
distribution on
rotor height
57
20
06
closing of the
21
05
nozzle ring
22
04
opening can
23
03
help even
24
02
material
25
01
distribution on
26
the rotor
48
27
circumference
47
28
46
29
45
30
44
31
43 32
42 33
41 34
40 35
39 38 37 36
58
29
Dynamic seal
59
60
30
Drying process
Tmo = Constant & > 90 [°C]
Grinding process
Mill load
31
Material transport and separation processes
Airflow rate = Constant
Pressure at mill outlet constant through fan operation (fix speed fan
damper opening, variable speed fan: fan speed)
63
9.Product quality
64
32
Dosing of raw meal components
Accurate dosing is a must achieving good meal
chemical composition
Feed system
65
Sampling
Sampler position
Sampler relative position with
material flow
Dedusting of sampling point
66
33
Raw meal typical particle size distribution (PSD)
[%]R200 [um] < 0.5 – 1.0
Good
(modern)
separator
Bad (old)
separator
67
Cement Manufacturing Course
Wider PSD:
Higher roller pressures
Higher dam ring height
Grinding process Lower air rate
34
Product PSD and separator operation (type)
Good separation (raw meal &
coal) Good
(modern)
[%] R 200 [um] separator
0.02 < < 0.05
[%] R 90 [um] Bad (old)
separator
69
0 – 120 [mm]
175 [kW]
15 [%]R90[um]
2’700 [kW]
90 [°C]
120 [bar]
0.5 [%] H2O
6’500 [l/h] water 70
35
Example of System flow sheet / Operating data
7’920 [h/a] operation 2’480 [kW]
0 – 40 [mm]
175 [kW]
85 [%]
2’590 [kW]
60 [bar] 17 [%]R90[um]
350 [°C]
6’500 [l/h] water 75 [°C]
High mill vibrations 1.2 [%] H2O
71
Target quality:
72
36
Example of Operational Data
73
37