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
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Tikaria_Mill
HGRS SEPT-07
Workshop
Content
Feed Properties
Feed Inlet and Distribution
Dam Ring Modifications
Operation
3
Tikaria_Mill
HGRS SEPT-07
Workshop
Keep correct feed size for roller diameter
Limited maximum feed
R
D sized < 3 [%] DR for hard
materials and < 5 [%] DR
for soft material
d
[%]
Particle size distribution:
Fraction below 1 [mm]
to be kept < 30 [%]
Particle size [mm]
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Tikaria_Mill
HGRS SEPT-07
Workshop
Impact of feed which is too fine
Vibrations and reduced
production
Reasons:
R
Draw in of feed reduced
D
d Material aeration
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Tikaria_Mill
HGRS SEPT-07
Workshop
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
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Tikaria_Mill
HGRS SEPT-07
Workshop
Impact of feed which is too coarse
Symptoms:
High kW absorption of main drive
R
D
Vibrations
Measures: d
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
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Tikaria_Mill
HGRS SEPT-07
Workshop
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.
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Tikaria_Mill
HGRS SEPT-07
Workshop
Content
Feed Properties
Feed Inlet and Distribution
Dam Ring Modifications
Operation
9
Tikaria_Mill
HGRS SEPT-07
Workshop
Feed distribution
Basic Rule: Feed on Center of table
product extraction
fresh feed
internal
circulation tailings
(pneumatical)
coarses
fall through
material
gas gas
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Tikaria_Mill
HGRS SEPT-07
Workshop
Content
Feed Properties
Feed Inlet and Distribution
Dam Ring Modifications
Operation
11
Tikaria_Mill
HGRS SEPT-07
Workshop
Dam Ring
Main tasks:
Control of material retention on table
Control of bed depth
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Tikaria_Mill
HGRS SEPT-07
Workshop
Dam ring
Increase the level of material roller
on the table through an Controls material flow
leaving the grinding
increase of the dam ring height zone
dam ring
Optimum dam ring height to be grindin
Controls material bed
thickness
found through trial & error bed
Modify dam ring height by at roller
least 10 [mm] each time
As the table wears, the dam Vibrations [mm/s] Low dam ring
nozzles
ring height should be reduced table liner
3.5
accordingly Medium dam ring
3.0
dam ring
In Loesche & Fuller mills, High dam ring
possible additional solution is: 2.5 grinding
10 [mm] bed
100 115 Op. pressure [%]
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Tikaria_Mill
HGRS SEPT-07
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
Impact of too low dam ring (also inadequate design):
Low bed depth
Vibrations
Increased water demand
Low power absorption of main drive
Lower production
Higher PSD steepness
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Tikaria_Mill
HGRS SEPT-07
Workshop
Grinding efficiency on different bed depths
Hydraulic Pressure
Roller
Area 1
Pressure Distribution in bed
Area 2
A1 < A2 Pbed1 > Pbed2
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Tikaria_Mill
HGRS SEPT-07
Workshop
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!
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Tikaria_Mill
HGRS SEPT-07
Workshop
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.
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Tikaria_Mill
HGRS SEPT-07
Workshop
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
Tikaria_Mill
HGRS SEPT-07
Workshop
Content
Feed Properties
Feed Inlet and Distribution
Dam Ring Modifications
Operation
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Tikaria_Mill
HGRS SEPT-07
Workshop
Statistically every 2nd VRM reducer fails
Holcim vertical roller mill distribution vs. reducer damages
100 This seriously 93
90
80 affects Holcim’s
performance
Numbers of
70 58
60
VRM
50
40 Damaged
28 Reducer
30
16
22 20 23
20 12 13 10
10 4 3
0
Polysius
Pfeiffer
Others
F.L.Smidth
Loesche
Total
Gebr.
Loesche
/ Fuller-
Mill Supplier
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Tikaria_Mill
HGRS SEPT-07
Workshop
Identification of the root cause of a recurrent stoppage
is the first step for solving the problem
Symptom Vibrations
Consequence Mill stoppage
Causes Operation Maintenance Design
Feed change
Lack of feed
Low temperatures Hydraulic failed High operating
pressure
Feeder blockage Worn grinding
tools High table speed
… …
But, vibrations can also become a cause for others failures
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Tikaria_Mill
HGRS SEPT-07
Workshop
Interlocking and Protection Loop are a MUST
Protection of
Mill Main
Drive
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