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VERTICAL

ROLLER MILLS

Confederation of Indian Industry

Vertical Roller Mills (VRM)


An advancement over ball mill
Roller mill Grinding by Compression
Rollers / Balls on ring
Presently for Raw meal, Coal &
Cement
More Energy efficient
Confederation of Indian Industry

VRM - Features
VRM Drive - 40% of ball mill
Dry moisture up to 15 %
More compact & Less space
Fan Power consumption - High
Separator - Integral Part of Mill
Confederation of Indian Industry

Features of VRM
Energy Efficient Grinding System
Mill drive 40% less consumption

Most suited for drying upto 15%


moisture
More compact & occupies less space
More amenable for Controls
Confederation of Indian Industry

Comparison of Ball Mill & VRM


Ball Mill

Moisture (%)
Mill Drive (units/ton)
Fan + separator
Total

VRM

3.0

7.0

3.0

7.0

14.0

14.0

6.5

6.5

1.9

5.0

7.5

7.5

15.9

19.0

14.0

14.0

Ideal choice for high moisture material


Confederation of Indian Industry

ENERGY SAVING IN VRMs


Fine tuning of louvres
Mechanical Recirculation system
High efficiency classifier
High Level Control system

Confederation of Indian Industry

Install Variable Area Louvre Ring


Air flow inside VRM not uniform
Material leaves in a definite pattern
around table
Max. material behind and in front of each
roller

Confederation of Indian Industry

Install Variable Area Louvre Ring


Uniform area louvre ring
Uniform gas system
Uneven bed of material
Gas prefers path of least resistance
Higher gas flow rates essential

Confederation of Indian Industry

Install Variable Area Louvre Ring


Variable area louvre ring
Larger area at points of larger
concentration
Gas flow directed to material
Potential open area higher
Lower Pr.Drop and lower gas flow
Reduced fan power consumption

Confederation of Indian Industry

Install Variable Area Louvre Ring


Presently fixed area louvre ring
Pr.Drop across mill 870MM WG
Flow thro mill 3,40,000 M3 / HR
Mill output 155 TPH
Recommended to install variable area
louvre
Confederation of Indian Industry

Install Variable Area Louvre Ring


Pr. Drop across mill 820 MM WG
Flow thro mill 3,10,000 M3/HR
Mill output 155 TPH
Annual savings 15000 USD

Confederation of Indian Industry

Re
je

ct s

Area 1.132 m2

Ga
s

ct s

C D

Velocity 83 MPS
E

F
E

E
F

D
C

1 Roller

F
E
D
C
B
A

B
A
A

4 Roller

2 Roller

B
C
D

3 Roller

A
B

E
F

D
E
M
ot
or

Re
je

Mill Door

Re
je

E
F

D C B

A B

Confederation of Indian Industry

D
Ga
s
Re
je

ct s

ct s

Fan Power Consumption in VRM


High in comparison to Ball Mill
Major Reason
Higher pressure drop
400 900 mm WG

Higher air flow rates

Confederation of Indian Industry

Pressure drop in a VRM


Ranges from 400 - 900 mm Wg
Pressure drop
75% - Mill louvre
25% - Housing & classifier

Confederation of Indian Industry

Why High Pressure Drop ?


High louvre velocity : 55 85 m/sec
Why high louvre velocity ?
Lift particles of higher sizes
Grinding table to separator

Reduction of louvre velocity


Reduction of mill - P
Higher quantity of rejects at mill bottom

Confederation of Indian Industry

Mechanical Recirculation System


Rejects handled mechanically
Recirculated back to mill through BE
Tremendous reduction in pressure
drop & energy consumption

Confederation of Indian Industry

Installation of Mechanical Recirculation

Confederation of Indian Industry

Louvre velocity vs. Mill power


Louvre velocity (m / sec) 75

50

35

Mill P (mm Wg)

900

630

450

Reject rate (% of fled)

5 15% 150%

Fan Power (units / ton)

6.9

5.5

4.7

Mill power (units / ton)

6.5

6.6

7.2

Total power

13.4

12.1

12.1*

* Includes power for mechanical recirculation


Confederation of Indian Industry

Louvre velocity How much reduction


possible ?
Air flow through mill depends on
Louvre velocity
Drying requirement
Separator requirement

Reduction of louvre velocity to lower levels


Large material handling equipment
Large mill housing
Leads to pre-separation
Less stability & Table vibration

Optimum louvre velocities with mechanical


recirculation : 45 55 m/sec
Confederation of Indian Industry

Reduce Recirculation Air in VRM


Recirculation air 60 kM3/Hr
High recirculation air
High velocity At louvres
High P
High power consumption

Confederation of Indian Industry

Reduce Recirculation Air in VRM

Trial taken
Recirculation reduced by 20 kM3/HR
RPM of class red.
Same residue maintenance

Confederation of Indian Industry

Reduce Recirculation Air in VRM


R/M Fan power consumption
reduced by 150 kW

Savings -

48000 USD

Confederation of Indian Industry

Separators for VRMs


I stage

Static separator

II stage

Dynamic
conventional
separator

III stage -

High efficiency
separator

Confederation of Indian Industry

High Efficiency Separators


Air requirement lower
High eff. - 0.6 0.8 kg matl / kg of air
Conv.

- 0.4 0.5 kg matl. / kg of air

Better separation efficiency


Lower P across mill
Higher output & lower specific energy
consumption
Confederation of Indian Industry

High efficiency
Separator

Old
Separator

Features of high efficiency Separator


Minimum pre-separation in mill
housing
Maximum separation in the
separator
Coarse return drops exactly in the
centre of the table

Confederation of Indian Industry

Features of high efficiency Separator


Benefits
Increase in output 10 to 30%
Reduction in specific energy
1.5 to 3.5 units/ton

Very attractive financially

Confederation of Indian Industry

Replacement with High Efficiency


Separator (Raw Mill)
Before
Capacity

After

250 TPH 290 TPH

Residue (90 )

11.5%

13.2%

Mill power (units / ton)

4.7

4.1

Fan power (units / ton)

8.5

6.2

13.3

10.3

Total Power

Confederation of Indian Industry

Effect of Roller to Table Dia

Confederation of Indian Industry

Effect of Roller to Table Dia


For the LM 38.4 the ratio
between diameter for roller and
table is 0.45, for the Ube LM 45.4
the ratio is 0.5, whereas for the
LM 56.4 the ratio is 0.40.

Confederation of Indian Industry

Effect of Roller to Table Dia


LM 38.4

LM 45.4(Ube)

LM 56.4

Diameter of Grinding Table

3.80 m

4.50 m

5.60 m

Diameter of Rollers

1.70 m

2.24 m

2.24 m

Width of Rollers

0.67 m

0.85 m

0.85 m

Kwh/ts, Mill

6.31

5.99

7.00

Kwh/ts, Fan

6.23

5.51

7.00

12/0.8

11/0.8

11/0.9

Dust Load (g/cum)

610

630

595

Delta P, Mill

83

56

87

3-5

2-4

5-8

Residue (90/212 microns)

Vibration of Mill

Confederation of Indian Industry

Effect of Operating Pressure


Ube LM 40.4
Grinding Pressure
kN/m2

650

662

675

687

700

Capacity

290

295

300

305

310

Kwh/ts, Mill

9.0

9.0

9.0

9.0

9.0

Vibration

4-5

4-5

4-5

4-5

4- 4.5

Delta P of Mill

54

53.5

53

52.5

52

Confederation of Indian Industry

Effect of Operating Pressure

10 % increase in Grinding pressure


Capacity increase by 7%
Mill drive SEC no change
Fan power 0.5 kWh / MT reduction
Confederation of Indian Industry

Influence of Feed Size for an LM


40.4 Raw Mill
Max 90 mm Max 30 mm
Capacity

240

262

Kwh/ts, Mill

8.05

7.41

Delta P, Mill

76

73

Vibration

5-7

4-6

Confederation of Indian Industry

High Level Control System for Mills


Conventional Open loop controls
I Generation
P vs Feed controls

Latest control system


Min. 3 to 5% improvement
Production & Energy
More stable operation of VRM
Confederation of Indian Industry

High Level Control System for Mills


Latest control system
Feed Based on P, Load &
Recirculation (B.E)
Mill flow kept constant
Mill Load, P, Recirculation load
Fineness predicted
Separator speed varied

Prediction mechanism varied depending


on actual fineness
Confederation of Indian Industry

BEST RAW MILL VRM SEC


Sl
no

Parameter

Plant 1

Plant 2

Output, TPH

403

320

Mill DP, mm WC

750

740

Sep Loading,
g/m3

536

495

Mill drive SEC,


kW /MT Material

9.25

6.00

Mill fan SEC,

5.69

6.40

kW /MT Material
Confederation of Indian Industry

Vortex rectifier for classifier


Vortex Rectifier

rotor

grit cone

low dp leading to a reduced specific energy


consumption
Confederation of Indian Industry

Vortex rectifier for classifier


Vortex kinetic
energy recuperation
Restores a linear
flow in the ductwork

Confederation of Indian Industry

Install Vortex rectifier for classifier

conventional design
high velocity
differences

LDC (new design)


homogeneous velocity
distribution

Confederation of Indian Industry

To Sum-Up
VRM Developing into an excellent
choice
Raw mill, Coal, Cement & Slag

Further improvement opportunities


Mechanical recirculation
High efficiency separators
High level control system
Confederation of Indian Industry

Confederation of Indian Industry

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