VERTICLE ROLLER MILL

PRESENTED BYMAHESH KUMAR NYATI

GET-ME

Agenda

Theory of VRM
Working Principle of VRM
Ball mill v/s VRM
Optimization of Operation of VRM
Troubleshooting of VRM

VERTICAL ROLLER
MILL

Grinding Theory of VRM

In a Roller mill bed of loosely packed
material is compacted and ground
between two rolling surfaces that are
pressed hard against each other.
Two Rolling surfaces are Grinding
table and Rollers.

Grinding Theory of VRM

MATERIAL MOVEMENT
ON THE TABLE
In vertical mills the
grinding table not only
acts as a grinding
member, but also as a
spreader dish that
distributes and
transports fresh material
to the rollers. The speed
of the table is so high
that the centrifugal force
exceeds the material's
friction against the table

Grinding Theory of VRM

The material
approaches the roller
with a tangential velocity
that is less than the
surface speed of the
roller and the table.
From AA to BB the
material is accelerated
to the surface speed
without becoming
compressed. At BB the
material is gripped and
the compression begins.

Compression in a Roller Mill

In a roller mill material is
grinded mostly by
compression
The high-energy, high-wear
method of attrition is largely
avoided, resulting in a more
economical process.

Shear in VRM
The High-Pressure treatment in VRM is
supplemented by the effect of shear
stresses.
The shear is Created by Difference in
Velocities of roller surface and
grinding table.
Only at one specific point at about middle
surface of grinding roller, will the roller
surface and grinding table will have
identical velocity.

Shear in VRM
On the outer surface of roller the
surface of grinding table will run
faster than the surface of roller
causing shear stresses on material.

Shear in VRM
These shear stresses also eliminates
tendencies of caking formation.
This easily separates the fine
material in the grinding bed when
the material enters into the air
stream at the edge of grinding table.

WORKING
PRINCIPLE
VERTICAL ROLLER MILLS ARE
BASICALLY DESIGNED TO WORK AS
AIR SWEPT GRINDING MILLS
REQUIRED A LARGE VOLUME OF AIR
FOR TRANSPORTING AND CLASSYING
WITH BUILT IN SEPARATORS.

PKT/VRM

11

WORKING
PRINCIPLE
1. THE FEED MATERIAL IS FED IN TO
THE MILL THROUGH AN AIR LOCK OR
TRIPLE GATE.
2. THE MATERIAL SLIDES IN TO
GRINDING TRACK DUE TO THE
ROTATION OF GRINDING TABLE
(CENTRIFUGAL FORCE) WHERE IT IS
GROUND BY THE PRESSURE AND
WEIGHT OF GRINDING ROLLERS.
PKT/VRM

12

WORKING
PRINCIPLE
3.THE GROUND MATERIAL MOVES TOWARDS
THE PERIPHERY OF THE GRINDING TABLE
AND LIFTED BY THE STREAM OF HOT
GASESPASSING THROUGH NOZZLE RING
AND CARRIED TO THE SEPARATOR.
4.FROM SEPARATOR COARSE MATERIAL IS
FED BACK TO THE GRINDING TABLE FOR
FURTHER REDUCTION IN SIZE.
5.FINE PARTICALS ARE LIFTED TOTHE
CYCLONES OR ESP/BAG FILTERS/BAG
HOUSE.
PKT/VRM

13

WORKING PRINCIPLE
IN ADDITION TO ABOVE VRM IS EQUIPPED
WITH EXTERNAL RECIRCULATION
SYSTEM FOR THE MATERIAL WHICH
FALLS THROUGH THE NOZZLE RING.
THIS EXTERNAL RE-CIRCULATION SYSTEM
TRANSPORT THE COARSER MATERIAL BY
AN ELEVATOR TO THE FRESH FEED.

VRM V/S BALL MILL

Ball mill works on Impact and
attrition where as VRM work on
Compression.
VRM has low specific energy
consumption compared with Ball mill.

Comparative Energy
Consumption

Comparative Energy
Consumption

Vertical Raw Mills

Provisions for Optimisation of Operation

Dam ring
Air nozzle ring
Separator design
Water injection

Dam ring Height

AIR NOZZLE RING

Nozzle ring is
installed throughout
the periphery of the
grinding table.
This nozzle ring
increases the
velocity of the gas
that enters in the
mill.

Velocity Enhancement

Velocity Enhancement

Conventional
Separator

LVT Separator

AIR VELOCITY THROUGH MILL HOUSING

AIR VELOCITY THROUGH MILL

HOUSING
Reduces pre-classification
Increase work done by Separator
Reduces Mill gas flow requirement
Stabilizes Grinding bed
Increases Grinding efficiency

Adjustable Guide Vanes

Gap

The guide vane angle is adjustable. Increasing the angle may increase
separation efficiency, but separator motor power will increase. Set the
gap to the drawing recommendation.

Separator Top Rotor Seal

The top seal must be kept as tight as possible to avoid coarse

particles finding their way into the product.

WATER SPRAY
SYSTEMS

Table spray system

Used for stabilizing grinding bed to eliminate high

mill vibrations.

The water increases the efficiency of the grinding

process when the material is very dry and fine

WATER SPRAY SYSTEM

Improper use of the water spray damage
the mill.
Water should be injected only when the
material is being ground in the mill and the
flow of air is above the minimum value.
Without adequate material and air flow,
the water can chill the tires and cause
them to break.

Troubleshooting of VRM
Failure

Reason- What to do

Mill
Vibrations,
Too high

Reduce feed supply if differential pressure is high.

Increase feed supply if differrential pressure is low.
Check water injection.
Reduce grinding pressure.
Lift rollers at excessive vibrations.

Mill output,
Too low

Check grinding pressure.

Product fineness very fine.
Coarser raw materials.
Grindability of raw material changed.
Raw materials too wet.
Table and roller segments are worn.

Mill product,
Too coarse

Increase speed of separator rotor.

Troubleshooting of VRM
Failure

Reason-What to do

Mill product,
Too fine

Decrease speed of separator rotor.

Increase feed supply.

Mill outlet
temperature,
Too high

Hot air amount too high.

Hot gas temperature higher than normal.
Adjust (close) hot gas damper.
Open cold air damper.
Increase water injection.

Mill outlet
temperature,
Too low

Raw material moisture increased.

Increase hot air amount.
Adjust (open) hot gas damper.
Adjust (open) mill fan damper.
Close cold air damper, if open.
Decrease water injection

Troubleshooting of VRM
Failure

Reason- What to do

Grinding
pressure,
decreases

Check hydraulic system. Piping is leaking.

Oil pump fault.
Oil level in tank is minimum.
Malfunction of valves.

Sealing air
pressure,
Minimum

If Filter blocked; clean filter.

Check electrical equipment.

Starting the mill

without grinding
layer

Fill mill with material before start.

Use automatic program for mill filling.
The filling must be done manually by starting
transport devices in correct sequence.
Fill in 300 500 kg of material.

Troubleshooting of VRM
Failure

Reason- What to do

Supply of hot gases

from kiln
interrupted

Mill operation must be stopped.

Check position of kiln (hot) gas damper.

Feeder units
disturbed

Stop the mill, if feed transport fails.

Feed bins almost

empty

Feed bins must be filled up.

Stop the mill.

Oil pressure or oil

flow through mill
gear minimum

Stop the mill immediately.

Check leakage in piping.
Oil pump fault.
Oil level minimum.
Electrical fault.

Troubleshooting of VRM
Failure

Reason- What to do

Oil pressure or oil

flow through the
separator gear
minimum

Stop the mill and Separator immediately.

Check leakage in piping.
Oil pump fault.
Oil level minimum.

Mill fan bearing

temperature
maximum

Automatic stop of fan and mill.

Check supply of bearing cooling fan.
Check greasing of fan bearings.