VRPM 230-3

HYDRAULIC SYSTEM IN
VERTICAL ROLLER
PRE-GRINDING MILL
 Basic Grinding Process

 High pressure vertical roller mill

 Clinker grinding by exerting force through the
roller on clinker between table & roller
 Fine grinding of clinker is done in tube mills.
 The efficiency of finish mill line is there by
improved.
Operating principle of clinker pre-grinding mills

 Clinker is fed to the center of

the rotating table.
 Rotation of the table generates
centrifugal force.
 Centrifugal force causes
clinkers to spread over the
table in uniform layer.
 Rollers are subjected to very
high compressive forces
generated through a hydraulic
system.
 Clinker is caught between
rollers & table & subjected to
very high compressive
stresses.
Opeating principle of clinker pre-grinding mills

 Compressive stresses
produce crushing action
on the clinker.
BENDING
MO MENT

 Friction causes roller to G RINDING

PRESSURE

rotate on clinker bed &

generate shearing HYDRAULIC
FO RC E

stresses .
 Shearing stresses
produce grinding action
on the clinker.
 HYDRAULIC
SYSTEM IN VRPM

Why Hydraulics?
Requirement of Hydraulic system
In VRPM
 Roller compressive force
easily adjustable.
 Precise & individual
control of roller forces.
 Sturdy & compact design.
 Adjustment of particle
size (Fineness)
 Function similar to a
“Shock Absorber” in a
automobile
 Ease of maintenance.
 Hydraulic swing out of
roller.
Compression Mechanics In Pre-grinding Mills

R Radius of the roller

 Roller synchronous RPM
Vr Table velocity in m/sec
Grinding bed thickness
Ho
before over rolling
Grinding bed thickness
H
after compression.
 Pressurising Arrangement
 Each roller is
connected to 2 nos.
hydraulic cylinders by
connecting rods.
 Roller Force
 Roller force is the force applied on the grinding
bed by roller through hydraulic system.

Roller
Force

Hydraulic
cylinder
Force
 Roller force calculation


 2 2
F  D  d p2
4

F Roller force

D Bore diameter of the cylinder=350 mm

d Rod diameter of the cylinder= 180 mm

p Hydraulic pressure
Hydraulic Cylinder
 Cylinder pressure rating
Max. Hydraulic pressure= 135 bar (short term)
Max. Hydraulic pressure = 110 bar (long term)

Hyd. Cyl pressure 70.5 82.5 97.5 112.5 124.5 136.5

(bar)
Cyl. Comp force 50950 58800 68600 78400 86250 94100
(Kg)
Roller comp. force 101900 117600 137200 156800 172500 188200
(Kg)
60 Facial pressure 260 300 350 400 440 480
(bar)
Force Distribution In Clinker Pre Grinding Mills
 Adjustment of roller force
 Grinding pressure is transmitted from the
hydraulic cylinder to the roller & then to clinker.
 Grinding performance varies, depending upon
the hydraulic pressure applied to the roller.
 Pressure setting of the hydraulic cylinder can be
changed by means of the pressure switch &
pressure relief valve in the hydraulic unit.
 Hydraulic system as “shock absorber”
 Grinding process requires the hydraulic force to be
exerted on continuous basis on a clinker bed.
 Hydraulic system needs to be capable of adjusting
gap between roller & table continuously &
simultaneously exerting the required
crushing/grinding force.
 To achieve above objective, each cylinder is
connected in parallel with hydraulic accumulator.
 Sudden increase in gap because of oversize particle
in between the roller & table causes oil from rod-side
to move to accumulator & oil shortage on piston side
is filled with oil supplied through “Pre-fill valve”.
 For roller compression / reduction of gap between
roller & table, oil from accumulator moves to the rod-
side of the hydraulic cylinder.
 Roller swing out
 For replacement of roller or for any type of
maintenance work inside the mill, The
VRPM is provided with a swing out
cylinder.
 Swing-out cylinder operation swings the
roller to horizontal position for ease of
maintenance.
 Major components in Hydraulic System
 Reservoir with breather, oil heater &
magnetic tank cleaner, suction & return filter
 Piston Pump & Vane pump
 Relief, check, direction control, flow control,
ball, needle & gate valves
 Pressure gauges, level gauge
 Solenoid valves, Pre-fill valve, accumulator
 Temperature & pressure controller, pressure
switches, float switch & heat exchanger.
 Pressure transmitter, accumulator charging
kit, etc.
 Hydraulic Accumulator
 It works like a “flywheel” as in a
mechanical system. It stores energy
when under utilised & delivers
instantly when required.
 Compressibility of nitrogen(N2) is
utilised for storing energy.
 Charging medium i.e. N2 gas is stored
in a bladder / rubber diaphragm
 Accumulator is Connected in parallel
with the hydraulic cylinder.
 Accumulator draws in fluid when
pressure increases & the gas is
compressed. When the pressure
drops, the compressed gas expands
& forces the stored fluid into the
circuit.
 Gas pre-charge pressure shall be 65
bar for VRPM 230-3.
Hydraulic Circuit
Hydraulic Schematics
 Cylinder pressure chart at roller retire

 Rate of displacement of oil

for 40 mm retire
 Rod side=2.8 / 0.07 Pressure Kgf/cm2
= 40 lps = 2400 lpm Abnormal
retire
 Piston side=3.8 / 0.07 40 mm-160

= 54.2 lps = 3260 lpm Normal retire

10 mm - 120

Basic roller
pos.100

sec sec. cover sec. sec. cover

Time (sec.)