VRM SUMMARY REFERENCE TABLE

REQUIREMENTS TOO LOW TOO HIGH TYPICAL LEVEL

Feedrate Strategy 1 - Maximise to reduce Power Consumption
High Power Consumption Mill filling and overload
Strategy 2 - Keep pace with kiln minimise kiln upsets
Vibration Maintain at a safe level - Risk damage to mill parts 2-3 mm/s
Bed depth Maintain at level to keep vibration at safe level High vibration low grinding efficiency 50 - 80 mm
Dam ring To be adjusted as table wears to keep bed depth under normal Low bed depth, high vibration Excessive bed depth and 50 - 150 mm Pol/Loesche/FLS
condition and high elevator power high mill power Pfeiffer 0 - 50mm
Mill Drive Power Max feed will be close to maximum (tends to increase as table Mill may not be optimised risk of mill trip
wears) 80 - 90 % installed
Hyd Press Matched to bed depth deep grinding bed, high thin grinding bed, low
circulating load and high circulating load and low
pressure loss pressure loss 80 - 90% of maximum
Airflow Maintain just above minimum (start up with high airflow) mill will fill up, potential Mill not optimised 1.8 - 2.2 nm3/kg with low moisture
overload trip
False Air Minimise false air (benchmark 15% mill fan volume). Regular N/A Reduced production, high 15 - 25% mill fan volume
checks combined with regular leak identification and repair power consumption and
possible operational issues
Nozzle Ring Velocity A low as possible, but keep rejects <50% fresh feed. Adjust Excessive rejects/ elevator High mill pressure loss and 25 - 60 m/s w recirc 60 -
airflow distribution around mill to increase at roller discharge power high power consumption 90 m/s w/out recirc
Pressure drop Minimised by nozzle ring and dam ring adjustment Mill empty - not optimised mill filling and risk of overload 3.5 - 5 kPa w recirc 6-
trip 10 kPa w/out recirc
Fan Speed Sufficient to maintain airflow Inadequate process control Inadequate process control 90 -95 % on a well sized system
loop / underdesign of fan loop
Elevator Power Equivalent to 50% fresh feed Mill may not be optimised High external load can 50% fresh feed
destabilise mill and make Elevator power is normally calibrated
restarts difficult due to large as tph
pile on table
Power Consumption minimise according to operating strategy Suspect calibration of power Mill not optimised for power Mill only 5- 8 kWh/t
meters or mill feedrate consumption Total 13 -17 kWh/t
Product Residue control separator speed/ guide vanes to achieve target Excessive power Poor control, separator 10 -12 % residue 90µm <1
consumption, liner wear and problem and difficult % residue 212 µm
high preheater dust loss burnability in kiln
Water addition Table sufficient to stabilise bed Increased vibration, difficulty Increase liner wear and 1 - 3% of mill feed
in keeping stable bed on increased mill power
table consumption
Plough (if fitted) maintain clearance from table to avoid excessive rejects Excessive material hold up Excessive rejects Pfeiffer - 250 mm feedsize 70mm
and high mill power Polysius 70mm - Feedsize 40mm