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*Google* automatically generates html versions of documents as we crawl the web. Nov 12, 2004 Frank Lu _PROCESS CONTROL OF LURM MILLS_ *1.0 PREFACE* This document is intended used only as a guideline for describing basic concept of the process control of the LURM vertical roller *mill* especially for the limestone grinding system. The particular process control system should be designed according to the individual condition. A safe and economic operation is not only dependent on the condition of the *mill* itself as well as of peripheral equipment such as feeding system, system fan, bag filter, hot gas generator, product conveying system and ductings in mechanical respect but also the condition of the process control measures in electrical respect. *2.0 *MILL* PERFORMANCE INDEXES* *2.1 *Mill* Feeding Rate* The *mill* throughput should be controlled constantly in continuous with suitable incremental mass rate until reach a maximum rate for absorbing the maximum *mill* motor horsepower but operating in a safe and reliable long-term condition and producing the qualified product according to the quality control standard of the product. The *mill* feed mass rate is measured by a measuring screw or a beltweighing feeder under the feeding hopper and controlled by the *mill* *differential* *pressure*. The maximum lump size of the feed shall be maintained according to the outside diameter of the grinding rollers, the gripping angle of the material ground and the thickness of the grinding bed. The segregation of the fed material during the dosing process should be absolutely minimized for keeping the even feed lump size distribution for maximizing the *mill* throughput and minimizing abnormal *mill* vibration. Furthermore foreign matter such as iron and metal pieces should be separated before entering the *mill* proper for avoiding damage of the grinding elements. In case of too low or interrupted feed mass flow, the grinding rollers shall be lifted if necessary.

On the contrarily if the gas flow rate through the *mill* is decreased.*2.3 Moisture Content Of Product* There is no need for installing an extra hot gas source while the moisture content of the feed material is below around 1% because the heat generated during grinding shall dry the material to an accepted with the higher specific surface area . thus leads to a higher circulation load and provokes a sharper slope in the RRSB chart. if the classifier speed is faster. Lower grinding *pressure* results to a higher circulation load and narrower particle size distribution. * Moreover if the gas flow rate through the *mill* is increased. In the meanwhile. thus leads to a lower circulation load and provokes a flatter slope in the RRSB chart. * With the same reason.2 Fineness of Finish Product* The fineness of the finish product. Increasing circulating load within the *mill* by adjusting the following parameters generates the narrower particle size distribution: * Higher classifier speed * Lower grinding *pressure* on the material bed * Higher gas flow rate through the *mill* In other words. we could observe that: * The higher grinding *pressure* results to a lower circulation load and wider particle size distribution. if we interpret from the standpoint of the internal circulation load within the *mill*. *2. is mainly decided by: * Grinding *pressure* * Gas flow * Classifier speed In general the finer product (mm2/g) is obtained by: * Higher grinding *pressure* * Lower gas flow * Higher classifier speed Normally the fineness of the product is controlled by the classifier speed only while the *mill* operates at the optimum grinding *pressure* and the optimum gas flow rate. On the contrarily if the classifier speed is slower. the circulating load within the *mill* influences the particle size distribution. naturally decrease to a lower circulation load thus may provokes at lower Blaine value. naturally increase to a higher circulation load thus may provokes a higher Blaine value as well. which were obtained during the commissioning and should be kept constant during normal operation. representing not only the specific surface area but also the required particle size distribution.

4 Specific Power Consumption* The power consumption of the grinding system is the key issue of the production cost of the grinding plant. The optimum value of the specific power consumption shall be obtained through optimization of the control parameters of the grinding system including: * * * * * * * *Mill* gas flow rate *Mill* *differential* *pressure* *Mill* inlet gas *pressure* Grinding *pressure* Classifier speed Grinding bed thickness *Mill* vibration level *3. In order to prevent from clogging of the bag filter.0 *MILL* CONTROL PARAMETERS* *3.level. The *mill* outlet temperature can be . *3. If the moisture of the material exceeds a certain value. The main contribution of the power consumption consisting of: * * * * *Mill* Classifier System fan Auxiliary equipment such as feeding and conveying system. The moisture content of product is mainly influenced by the following parameters: * * * * Gas temperature at *mill* outlet Gas temperature at *mill* inlet Gas flow rate and temperature from recycling Heat input from hot gas generator.2 Gas Temperature At *Mill* Outlet* The gas temperature at *mill* outlet is a measurement of the drying process accomplished in the *mill*. Otherwise a special construction shall be made by a heat resistance design for the *mill*. the operating temperature of the *mill* exhaust gas should be about 20 Γäâ above the dew point. the temperature should not exceed 300Γäâ for protecting main gearbox and grinding rollers from overheating. then the *mill* inlet temperature should be adjusted by the other heat input from a hot gas generator or other heat source according to the moisture content of the feed material.1 Gas Temperature At *Mill* Inlet* Unless special design is made. *2.

The gas flow should be always kept constant and independent of the fluctuations in *pressure* and temperature of the system.3 *Mill* Gas Flow Rate* The gas flow can be measured behind the bag filter and controlled at constant value by adjusting the opening of the gas damper and/or the rotating speed of the system fan during commissioning. However excessive gas flow causes higher wear within the *mill* resulting uneconomical maintenance work and power consumption. The gas flow through the grinding system is a combination of: * * * * * Fresh air Hot gas False air Evaporated water Recycling gas Inadequate gas flow through the *mill* causes a decrease of the *mill* capacity and operating disturbances.elevated by increasing the recycling gas or supplementary hot gas and also can be cooled down by opening the tempering air. grinding *pressure* and classifier speed are maintained at the similar condition according to the pre-adjustments during previous operation unless the characteristics of the raw material such as the grindability of the material has been changed. *3. On the contrarily. which indicates the *mill* is in overloading.4 *Mill* *Differential* *Pressure** The *mill* *differential* *pressure* measured as a difference between the static *pressure* at *mill* inlet and *mill* outlet representing a loading condition of the *mill*. Normally the *mill* should be stopped automatically at 120Γäâ for preventing the bearing and sealing of the grinding rollers from overheating. Special cooling system with heat resistant sealing shall be adopted should the temperature is higher than the above-mentioned value. The *mill* is subject to sever vibration and higher reject amount resulting an uneconomical operation. The *differential* *pressure* of the *mill* depends on the following parameters: * * * * Feed mass rate Gas flow rate Grinding *pressure* Classifier speed Usually only the *mill* feed mass flow rate has a decisive influence on the *differential* *pressure* while gas flow rate. when the *differential* *pressure* is too low which . When the *differential* *pressure* is too high. *3.

5 Grinding *Pressure** The grinding *pressure* exerted by the grinding rollers against the vertical is a decisive factor for the efficiency of the communition process. As the rule of thumb. is applied for protecting the key mechanical components from damage. The optimum condition of the *mill* shall be achieved by obtaining the maximum *mill* throughput in accordance with the qualified product standard but in an acceptable vertical *mill* vibration level.7 *Mill* Vibration* The *mill* vibration level. will be adjusted during commissioning. representing the spring constant of the hydraulic system. *3.6 *Mill* Inlet *Pressure** The *mill* inlet *pressure* should be maintained at constant value. the feed will be stopped. While the *pressure* of the hydraulic system drops below a certain limit the *mill* will stop. the filling *pressure* of hydraulic accumulator should be recommended as follows: * The the * The the maximum minimum minimum maximum filling *pressure* of hydraulic accumulator = 80% of operating hydraulic *pressure* filling *pressure* of hydraulic accumulator = 25% of operating hydraulic *pressure* *3. The again while the normal value is restored. usually measured at the input shaft of the gearbox. rough *mill* operation and higher power consumption. the certain limit value *mill* shall be started in partial loading and is operated in also an When the *differential* *pressure* is reduced to such as 50% . The relationship between the grinding *pressure* and the corresponding nitrogen *pressure* in the accumulator. The *mill* motor should be stopped while the *mill* occurs excessive . However too low negative inlet *pressure* influences the steady gas flow within the system and leads the grinding system into disturbances. The static *pressure* measured at the *mill* inlet gas duct is influenced by the gas flow entering into the *mill* by mean of: * Recycling gas damper * Hot gas generator * Fresh air inlet damper Too high negative *pressure* before the *mill* increases the energy consumption of the *mill* system fan.indicates the *mill* is uneconomical condition. *3.60%. However too high *pressure* causes higher abnormal wear on the grinding elements. However too low grinding *pressure* reduces the *mill* capacity and changes in the fineness of the product resulting an uneconomical operation.

*4. is adjustable by the height of the dam ring the grinding *pressure* and *mill* circulation load during commissioning. defined as the minimum gap between the grinding rollers and the grinding table during the operation.vibration for securing the long-term safety of the equipment. *3. * For heating process. the burner of the hot gas generator or the amount of steam vapor controls *mill* outlet gas temperature. * The *mill* *differential* *pressure* or the kilowatts of the *mill* motor controls feed mass flow rate. the grinding system can be installed with the following PID control loop: * For cooling process. Nevertheless the thinner grinding bed gives wider particle distribution but with lower power consumption and rougher operation.0 PROCESS CONTROL LOOP* Generally speaking. . The thicker grinding bed gives narrower particle distribution but results with higher power consumption and softer operation. * The recycling gas damper controls *mill* inlet *pressure*.8 Grinding Bed Thickness* The grinding bed thickness. The optimum grinding bed thickness shall be decided during commissioning. * The rotating speed or the gas damper of the system fan controls gas flow rate through the *mill*. the fresh air damper or the amount of the water and grinding aid solution controls *mill* outlet gas temperature.

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