GEBR.

PFEIFFER AG

The grinding process

Control of the grinding process
Operation

Mai 2010

Progress is our tradition

 fine product

raw material

hot gas

MPS vertical roller mill

TP/ Ne- 08 / 04

GEBR. PFEIFFER AG
 Pneumatic conveying

Mechanical conveying

Classifying

Compression grinding in material bed in

between rollers and table

Drying,
Drying, mixing,
mixing, conveying in fluidized bed above
nozzle ring

09/2001

Processes in MPS vertical roller mill

GEBR. PFEIFFER AG
 Max. feed size: 3-5 % dR
Much finer feed may destabilize
material bed

Grinding: Compression of material bed

Gebr. Pfeiffer AG
grinding roller
TP/ Ne- 08 / 04

GEBR. PFEIFFER AG
 Aim:
Aim:
Always stable material bed during
compression,
compression, no sudden changes

grinding roller
(water spray)
dam ring
material on table
air flow through nozzle ring

MPS grinding zone

GEBR. PFEIFFER AG
(1) P = Wm x m needed

(2) P = β x FR x z x V introduced in
material bed

Wm spec
spec.. power consumption depending on
material, product fineness,
fineness, (dam ring), (wear
(wear)
wear)
β friction factor depending on material, product
fineness,
fineness, (air
(air volume)
volume)

Grinding force FR to be adapted,

adapted, maximum given by
mechanical design,
design,
number of rollers z and table speed v given by design
Power absorption P during compression of material bed
Gebr. Pfeiffer AG
 TP/ Ne- 08 / 04

testing - MPS 40 BC and

wear determination equipment GEBR. PFEIFFER AG
 TP/ Ne- 08 / 04

testing - MPS 40 BC
GEBR. PFEIFFER AG
 6 1000

Wm mill in kWh/t

mF in kg/h
5 900
kWh/t
4 800

design
3 kg/h 700

2 600
10 11 12 13 14 15 16 17 18 19 20 21 22
R 90µm in %

dustload: < 750 g/m³ in this case

09/2001

Grinding test GEBR. PFEIFFER AG

 Industrial MPS-mills with high efficiency classifier SLS,
not limited by heat balance or kiln process

1000
900
800
dust load in g/m³

700
600
500
400
300
MPS-mills with SLS-classifier
200
Mills with competitors' classifier
100
0
4 5 6 7 8 9 10 11 12
spec. power consumption in kWh/t

Dustload (air flow) depending on spec. energy

TP/ Ne- 07 / 05

consumption (grindability) GEBR. PFEIFFER AG

 Blaine for OPC, slag cements and slag

residue on sieve from joint grinding

of mixed cements containing
components with good grindability
(e.g. limestone, puzzolana)

determination of the product fineness :

TP/ Ne- 07 / 05

specific surface (Blaine) / sieve method GEBR. PFEIFFER AG

 drive Check of gap
fine product between rotor and
static classifyer
part

feed material

rotor

louver

Adjustment of fineness
by rotor speed: Higher
rotor speed gives
higher fineness
grit cone

classifier - type SLS

TP/ Ne- 08 / 04

GEBR. PFEIFFER AG
 coal mill

raw mill coal cement mill

cement raw material cement

calcium carbonate (CaCO3)
silicon dioxide (SiO2) = cement clinker
aluminium oxide (Al2O3) + extenders
iron oxide (Fe2O3) + gypsum
cement clinker

MPS in dry cement production line

TP/ Ne- 08 / 04

GEBR. PFEIFFER AG
 material Raw meal Coal Cement Slag

customer Ambuja, India Ambuja, India Dalmia, India Lafarge, China

grindability 9.0 kWh/t 45 HGI 15.4 kWh/t abt. 30 kWh/t
mill size MPS 5600 B MPS 3070 BK MPS 5600 BC MPS 5600 BC
Pinst 5400 kW 800 kW 5400 kW 5300 kW
throughput 566 t/h 64 t/h 300 t/h abt. 130 t/h
grinding fineness 1% R0.212 mm 11% R0.090 mm 3200 cm²/g 5300 cm²/g
spec.power cons. 14.6 kWh/t 20.7 kWh/t 24.2 kWh/t abt. 33 kWh/t
(measured on counters) (mill + fan) (mill + fan) (mill + fan) (mill +
separator)
TP/ Ne- 01 / 07

biggest mills commissioned

GEBR. PFEIFFER AG
 air flow gas pressure

temperature

dp

gas pressure

Raw material grinding plant with Pfeiffer MPS mill

TP/ Ne- 07 / 05

dust collection in cyclone GEBR. PFEIFFER AG

 temperature air flow

dp

gas pressure

grinding plant with Pfeiffer MPS mill

TP/ Ne- 07 / 05

dust collection in filter GEBR. PFEIFFER AG

 Most of vibration problems are caused by
feed problems: lack of feed, sticking,
sudden change of feed size

cement grinding plant

TP/ Ne- 08 / 04

GEBR. PFEIFFER AG
flowsheet
TP/ Ne- 08 / 04

GEBR. PFEIFFER AG
monitoring equipment for
TP/ Ne- 08 / 04

the avoidance of vibrations GEBR. PFEIFFER AG

Operation problems
Sudden vibrations
Sudden vibrations after increase of dp
Higher vibrations after decrease of dp
Higher kWh/t, lower throughput
Operation
reasons/solutions
sudden lack of feed (component),
water or air or sudden change of
feed size (or moisture)
mill too full, so lower feed rate
and/or higher hydraulic pressure
and/or higher air flow
mill too empty, so higher feed rate
and/or lower hydraulic pressure
may be caused by wear, so
measurement, EVA anlaysis by
Gebr. Pfeiffer, then may be
reduction of dam ring or change/
hardfacing of wear parts
Gebr. Pfeiffer AG
 TP/ Ne- 03 / 06

Hardfacing at Holcim (Italia) SpA, Merone plant

MPS 4250 BC GEBR. PFEIFFER AG
GEBR. PFEIFFER AG

Thank you

Progress is our tradition