VRM Cement Pre-grinding system

Cement Manufacturing Services / HGRS Mechanical Process Technology department / Grinding Technology group

Content
 Feed Properties  Feed Inlet and Distribution  Dam Ring Modifications  Operation

HGRS

Tikaria_Mill Workshop

2
SEPT-07

Content
 Feed Properties  Feed Inlet and Distribution  Dam Ring Modifications  Operation

HGRS

Tikaria_Mill Workshop

3
SEPT-07

Keep correct feed size for roller diameter

d
[%]

Limited maximum feed sized < 3 [%] DR for hard materials and < 5 [%] DR for soft material

D

R

Particle size distribution: Fraction below 1 [mm] to be kept < 30 [%]

Particle size [mm]

HGRS

Tikaria_Mill Workshop

4
SEPT-07

Impact of feed which is too fine Vibrations and reduced production
Reasons:
R

 Draw in of feed reduced
d

D

 Material aeration

HGRS

Tikaria_Mill Workshop

5
SEPT-07

Actions limiting impact of feed which is too fine
 Table speed adaptation (slower rotation)  Increase dam ring height if material hard (e.g. slag)  Increase hydraulic pressure of rollers  Inject water

HGRS

Tikaria_Mill Workshop

6
SEPT-07

Impact of feed which is too coarse
Symptoms:
 High kW absorption of main drive  Vibrations
D
R

Measures:
 Modify cooler crusher or install a crusher  Sieving of crusher product  Try to work with higher hydraulic pressure
Experience: At Rohoznik too coarse feed leads to permanent overload of the motor to achieve the required production
Tikaria_Mill Workshop

d

7
SEPT-07

HGRS

Positive results to lower top size
 Experiences from India where the vertical raw mill

performance was significantly better with finer crusher settings / lower top size:
- Bhatapara, Dorol: 4% production rate increase when hammer crushing setting decreased from 50mm to 25 mm (no change on % particles <2mm) - Bargarh, Loesche: 8% production rate increase when hammer crushing setting changed from 80mm to 50mm - Ambuja, 10% production rate increase when the top size was reduced from 100 mm to 75 mm.

HGRS

Tikaria_Mill Workshop

8
SEPT-07

Content
 Feed Properties  Feed Inlet and Distribution  Dam Ring Modifications  Operation

HGRS

Tikaria_Mill Workshop

9
SEPT-07

Feed distribution
Basic Rule: Feed on Center of table
product extraction fresh feed

internal circulation (pneumatical)

tailings

coarses fall through material gas gas

HGRS

Tikaria_Mill Workshop

10
SEPT-07

Content
 Feed Properties  Feed Inlet and Distribution  Dam Ring Modifications  Operation

HGRS

Tikaria_Mill Workshop

11
SEPT-07

Dam Ring
Main tasks:
 Control of material retention on table  Control of bed depth

HGRS

Tikaria_Mill Workshop

12
SEPT-07

Dam ring
 Increase the level of material
roller
Controls material flow leaving the grinding zone

on the table through an increase of the dam ring height
 Optimum dam ring height to be

dam ring
Controls material bed thickness

found through trial & error
 Modify dam ring height by at

grindin bed

least 10 [mm] each time
 As the table wears, the dam nozzles

roller
Vibrations [mm/s] 3.5 3.0 2.5

ring height should be reduced accordingly

Low dam ring Medium dam ring
liner

table

dam ring  In Loesche & Fuller mills,
possible additional solution is:
10 [mm]

grinding bed
100 115

High dam ring

Op. pressure [%] 13
SEPT-07

HGRS

Tikaria_Mill Workshop

Dam Ring
 Impact of too high dam ring:
    

High bed depth Increased power absorption (reduction of pressure required) Reduced grinding efficiency (lower production) Vibrations Lower steepness of PSD Low bed depth Vibrations Increased water demand Low power absorption of main drive Lower production Higher PSD steepness
14
SEPT-07

 Impact of too low dam ring (also inadequate design):
     

HGRS

Tikaria_Mill Workshop

Grinding efficiency on different bed depths
Hydraulic Pressure

Roller
Area 1

Pressure Distribution in bed

Area 2

A1 < A2
HGRS Tikaria_Mill Workshop

Pbed1 > Pbed2
15
SEPT-07

Problems - Solutions
Situation: During the operation of the San Sebastian raw mill, a capacity drop was observed over the time of wear of the table. The necessary cut of the dam ring was not done. Experience: After the replacement of the table liner with original thickness a significant capacity increase was observed. Message: Cut the dam ring as the table wears to maintain optimal material retention and bed depth!
HGRS Tikaria_Mill Workshop
16
SEPT-07

Problems - Solutions
Situation: During the operation of the Cartago raw mill, a capacity drop was observed over the time of wear of the dam ring (height was NOT affected). Experience: After the repair of the dam ring, the capacity was brought up to the original level. This leads to the conclusion, that primarily the gap contributes to the material retention on the grinding table and not the height of the dam ring. Message: Keep the gap between rollers and dam ring small.
HGRS Tikaria_Mill Workshop
17
SEPT-07

Problems - Solutions
Situation: During the commissioning of the Ras El Ma cement mill (LM 46 2+2), operation without water let to a reduced production. A Loesche Suggestion was to decrease the dam ring height (removal of 6+8) to reduce vibrations and water injection. Experience: After the removal of two dam ring segments the vibrations increased and the production dropped significantly – the water injection had to be increased. Message: Lower bed depths do not necessarily lead to an improved grinding performance 18
SEPT-07

HGRS

Tikaria_Mill Workshop

Content
 Feed Properties  Feed Inlet and Distribution  Dam Ring Modifications  Operation

HGRS

Tikaria_Mill Workshop

19
SEPT-07

Statistically every 2nd VRM reducer fails
Holcim vertical roller mill distribution vs. reducer damages
100 90 80 70 60 50 40 30 20 10 0

Numbers of

This seriously affects Holcim’s performance
28 16 22 12 20 23

93

58 VRM Damaged Reducer

13

4

10

3

Polysius

Gebr. Pfeiffer

F.L.Smidth / FullerLoesche

Loesche

Others

Mill Supplier
Tikaria_Mill Workshop
20
SEPT-07

HGRS

Total

Identification of the root cause of a recurrent stoppage is the first step for solving the problem
Symptom Consequence Causes Feed change Lack of feed Low temperatures Feeder blockage … Hydraulic failed
Worn grinding tools
High operating pressure

Vibrations Mill stoppage Operation Maintenance Design

High table speed

But, vibrations can also become a cause for others failures
HGRS Tikaria_Mill Workshop
21
SEPT-07

Interlocking and Protection Loop are a MUST
Protection of Mill Main Drive

HGRS

Tikaria_Mill Workshop

22
SEPT-07

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