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CEMENT PRODUCTION PROCESS

The Challenge
The capacity of the vertical raw mill is often the limiting factor for clinker output when a plant upgrades the kiln system, the raw mill frequently becomes a bottleneck. Rather than investing in an entirely new vertical mill to keep pace, there is a very limited set of possibilities in upgrading existing mill capacity in smaller steps. For example, older mills can achieve a modest capacity increase by upgrading the integrated separator

ROLLER MILL

Vertical Roller Mill (VRM) - 3 Sections


Transport
Exhaust gases Raw meal

1. Separation

Drying

Separation

Feed Material

Grinding

2. Grinding

Hot gases

Drive

3. Drive

Energy

Vertical Roller Mill (VRM) - Details


feed gate (air lock) mill exhaust product discharge mill outlet duct separator cage rotor separator guide vanes tailings cone separator discharge flap mill casing water injection roller with tyre or segments rocker arm roller axle table liner hot gas inlet nozzle of louvre ring grinding table

dam ring

hydraulic cylinder clutch and motor speed reducer with table bearing

material scraper

VRM - Working principle


Vertical roller mill

Grinding force = Roller weight + (pressure) Force


Material bed Feed material

Roller rolls freely with table

Table moves with drive Max Particle size in feed: 5-8 % of roller diameter
Feed size: f (Roller )

VRM - Material Flow inside


Separator: removes fine material rejects coarse material Internal gas flow Separator Rejects Internal Circulation Large Material falls through to scraper
Material

Gas & Product Material Feed Material

Material & Gas


Gas

VRM - Some Common Mill Configurations

G.Pfeiffer

Loesche

FLS Atox

Polysius

VRM - Built-in Separator


static separator Static type
P

conventional rotor type Conventional

cage rotor type Cage Rotor type with guide vanes


P

Rotor type

F T

T F F P T F

Separation control:

1. Vane adjustment
2. Speed control
TF FT

F= P= T=

Feed Product Tailings

Separators of

rd 3

Generation

(Vertical roller mill)


Reject cone

Cage rotor

Guide vane system

VRM - Separator Fotos


Angle affects product sizing

Rotor speed affects product fineness

Rotor seal affects separator efficiency

Potential Problems/clogging
Cage rotor separator casing
partly clogged guide vane system

Material deposits due to insufficient airflow or airflow distribution

VRM - External Circulation


fresh feed

bucket elevator

louvre ring

scraper

Used for reducing gas flow pressure lost over the mill

(less pneumatic internal circulation)


collecting conveyor

VRM - Example flow-sheet


Control points

1 gas flow
2 pressure difference 3 return gas flow pressure 4 outlet temperature 5 external recirculation

VRM - Control & Maintenance


Control
Gearbox

- Vibration monitor - Temperature monitor

Gas flow Hydraulics

- Temperatures & pressures - Pressures

Maintenance
Wear

- Rollers & Table

- Separator (sealing!) & Housing


Lubrication & Hydraulics (filters and seals)

VRM - Control
[kW] grinding aid DEG [l/h] [t] [C]
[mbar]

[%]

[min-1] [l/min]

[mbar] [%]

[min-1]

[t/h]
[mbar]

[min-1]

Clinker [t] [%]

Gypsum [t] [%]

sampler [cm2/g] [%R] [mbar] [C]

[bar]

[l/h]

to cement silo

Hot gas [C]

[t/h]

[t/h]

[kW]

[%] fresh air

Vertical roller mill internals suffering from wear


Outlet duct Separator Separator cone

Inlet chute

Mill housing

Armour & nozzle rings Scrapers

Rollers and table liners

Roller and grinding track liners

Grinding track liners:


Monobloc Segments

Roller liners:
Monobloc Segments

Wear resistance material alternatives


Nihard 4
%C % Cr % Ni Weldable

< 3.5

< 10

< 6.5

yes

High Chromium alloys


%C % Cr % Other Weldable Example
Chromodur, FMU18, VegalineV16s

< 3.6
< 2.6 < 3.5

< 17
< 20 < 28

Mo + Ni
Mn < 1.2

yes
No No

FMU 52 FMU 46

Wear resistance material alternatives


Metallic inserts roller liner

Soft material base

Hard metallic insert

Wear resistance material alternatives


Ceramic inserts roller and grinding track liners
Metallic base (High Cr)

Ceramic insert

Wear rate monitoring

2500 [h] = 50 [mm]

40 [mm] = ~ 2000 [h]

Minimum allowed thickness

Wear resistance material alternatives


Surface reconditioning on grinding track and roller liners
%C <5 < 5.5 % Cr < 29 ~ 22
% Others

Weldable yes yes

Example Vautid 100, HC-O CN-O, CNV-O

Ni, Mo 6 7 Ni

VRM - Accessories
Rotary valve
Reduces false air entering with feed material. Good for dry, small size material.

Pendulum valve
Reduces false air entering. Better for lumpy or humid feed material.

Weigh belt

Metal extraction
Metal objects damage the roller & table. The magnet removes them

Weighs the passing material ensuring a continuous grinding bed in the mill

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