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Vertical roller mills are used in cement industry for grinding of clinker, coal/petcoke, raw materials and cement. The mill comprises 2-4 conical rollers that are hydraulically pressed onto a horizontal rotating grinding table. Material is ground using both contact and impact grinding as the axes of rollers and table do not intersect. Finely ground material is carried by air to an integral classifier which separates fines from coarse material. Material drying also occurs in the mill. Roller mills are prone to vibration but this can be mitigated by spraying water onto the grinding bed.
Vertical roller mills are used in cement industry for grinding of clinker, coal/petcoke, raw materials and cement. The mill comprises 2-4 conical rollers that are hydraulically pressed onto a horizontal rotating grinding table. Material is ground using both contact and impact grinding as the axes of rollers and table do not intersect. Finely ground material is carried by air to an integral classifier which separates fines from coarse material. Material drying also occurs in the mill. Roller mills are prone to vibration but this can be mitigated by spraying water onto the grinding bed.
Vertical roller mills are used in cement industry for grinding of clinker, coal/petcoke, raw materials and cement. The mill comprises 2-4 conical rollers that are hydraulically pressed onto a horizontal rotating grinding table. Material is ground using both contact and impact grinding as the axes of rollers and table do not intersect. Finely ground material is carried by air to an integral classifier which separates fines from coarse material. Material drying also occurs in the mill. Roller mills are prone to vibration but this can be mitigated by spraying water onto the grinding bed.
Vertical Mills used for Pre-grinding of clinker (lumps to coarse powder) Finish grinding (lumps to powder) of Coal/Petcoke for kiln Raw materials for kiln Cement, OPC or mixed Slag, pure or mixed VRM Functions Vertical Roller Mill (VRM) - Details feed gate (air lock) mill casing water injection dam ring louvre ring nozzle of material scraper mill outlet duct speed reducer with table bearing and motor clutch grinding table hot gas inlet hydraulic cylinder table liner roller with tyre or segments roller axle rocker arm discharge flap separator tailings cone separator guide vanes cage rotor separator product discharge mill exhaust Working principle Vertical mills comprise 2-4 conical rollers which are hydraulically pressed onto a horizontal rotating grinding table. The roller axis is inclined at 15 o to the table and, as axes of rollers and table do not intersect in the plane of the table. the relative motion involves both rolling and sliding which enhances comminution.
Feed material is directed onto the centre of the table and is thrown outward by rotation under the rollers and into a rising air current at the periphery which is directed by means of a louvre ring. The air sweep passes through an integral rotary classifier; fines pass out with the air current while coarse material falls back onto the feed table. Material drying occurs in air suspension between table and classifier. Circulating load is typically 800%. Roller mills are prone to vibration due to an unstable grinding bed. A major cause of material instability is fine, dry mill feed which can usually, be mitigated by spraying water directly onto the bed.
VRM - Working principle Vertical roller mill Feed size: f (Roller ) Material bed Feed material Max Particle size in feed: 5-8 % of roller diameter Grinding force = Roller weight + (pressure) Force Table moves with drive Roller rolls freely with table VRM - Material Flow inside Gas & Product Material Feed Material Separator Rejects Internal Circulation Large Material falls through to scraper Internal gas flow Material & Gas Material Gas Separator: removes fine material rejects coarse material VRM - Some Common Mill Configurations G.Pfeiffer Loesche FLS Atox Polysius static separator conventional rotor type cage rotor type with guide vanes F T P F F F T T P F F T P T F P F = P = T = Tailings Product Feed F T VRM - Built-in Separator Cage Rotor type Conventional Rotor type Static type Separation control: 1. Vane adjustment 2. Speed control Separators of 3 rd Generation (Vertical roller mill) Guide vane system Reject cone Cage rotor VRM - Accessories Rotary valve Weigh belt Metal extraction Reduces false air entering with feed material. Good for dry, small size material. Weighs the passing material ensuring a continuous grinding bed in the mill Metal objects damage the roller & table. The magnet removes them VRM - External Circulation Used for reducing gas flow pressure lost over the mill (less pneumatic internal circulation) collecting conveyor fresh feed louvre ring scraper bucket elevator VRM - Example flow-sheet Control points 1 gas flow 2 pressure difference 3 return gas flow pressure 4 outlet temperature 5 external recirculation VRM MAINTENNACE Maintenance
Wear resistance material alternatives % C % Cr % Ni Weldable < 3.5 < 10 < 6.5 yes % C % Cr % Other Weldable < 3.6 < 17 Mo + Ni yes < 2.6 < 20 Mn No < 3.5 < 28 < 1.2 No Example Chromodur, FMU18, VegalineV16s FMU 52 FMU 46 Wear resistance material alternatives Metallic inserts roller liner Hard metallic insert Soft material base Ceramic inserts roller and grinding track liners Wear resistance material alternatives Metallic base (High Cr) Ceramic insert Operation and Optimization of Vertical Roller Mills Raw material characteristics Feed Size Product Fineness Moisture Content Grindability Abrasiveness Ball Mill Maximum 5% + 25 mm
Vertical Roller Mills Up to 150 mm Feed Size 5% - 25% + 90 m
1.0% - 2.0% + 212 m Product Fineness Normal moisture content: 3% - 10% H 2 O
Possible to dry >20% H 2 O in vertical mills
Up to 6 to 7%-H 2 O Drying with kiln gases
Above 7% H 2 O Supplementary heat from auxiliary furnace or cooler Moisture Content in Raw Materials
OPERATIONAL ASPECTS
Material granulometry Roller pressure Dam ring Louvre ring External circulation
PARAMETERS TO BE MONITORED DURING OPEARATION Production rate, tonnes/hour Grinding press. (bar) or (kN/m2) Mill Motor (Kw) Grinding bed thickness (mm) Vibration level (mm/s) Pressure drop across the mill Mill outlet temperature Fan flow Rejects (If external recirculation present) Water flow
Additional paramters to be monitered Operating hours Involuntary downtime hours kWh/tonne (mill motor + fan + seperator) Product fineness on 90/212 microns for raw mill ,coal mill and blaines for cement mill Feed moisture, % Product moisture, % Feed size
How the nozzle ring velocity corresponds to reject rate and pressure drop Running with a high velocity in the nozzle ring gives a high pressure loss, but also a low reject rate. However the lower pressure drop with e.g. 45 m/s is to prefer and will both give considerable power savings on the fan and less wear in the mill body
Operational problems Vertical roller mill for finish grinding PROVEN TECHNOLOGY
VERY SUITABLE FOR GRINDING BLENDED CEMENT OR SLAG
COMPACT GRINDING INSTALLATION
ENERGY SAVING - UP TO 30%-40% kWh/Mt
SUITABLE FOR GRINDING MOIST FEED
EASY MAINTENANCE AND OPTIMUM UTILIZATION OF WEARING ROLLERS VRM versus BALL MILL for CEMENT GRINDING Blaine Surface, cm2/g: 4000 0 10 20 30 40 50 60 70 V R M B a l l
M i l l V R M B a l l
M i l l Mill Fan, etc. Cement (OPC) Slag Grinding systems comparison Power Consumption when grinding to 3800 cm 2 /gm for 150 tph capacity GRINDING SYSTEM CLOSED CIRCUIT BALL MILL ROLLER PRESS PREGRINDER ROLLER MILL PREGRINDER ROLLER PRESS SEMI FINISH FINISH GRINDING IN ROLLER PRESS OK VRM Mill (kWh/t) 38.2 29.7 28.0 20.8 / 21.8 Separator and Fans (kWh/t) 4.5 3.9 3.9 6.1 14.2 7.2 Roller Press/Pregrinder (kWh/t) / 4.5 10.0 9.7 20.5 / Auxiliary (kWh/t) 0.6 1.0 1.0 1.5 1.6 0.2 Total (kWh/t) 43.4 39.0 42.8 38.0 36.3 29.2 Maximum Output (t/h) 200 (300) 275 - 300 275 - 300 300 - 350 < 150 450 tph
Operational Guidelines for Process Optimization LOWER PRESSURE DROP LESS WEAR OF MILL BODY LINERS FAN POWER SAVINGS OF 15-30% Nozzle Ring Velocity versus Material Rejects and Pressure Drop N/R Velocity Reject Rate Relative Pressure Drop (m/s) (% Fresh Feed) (%) 75-85 Trace 100 60-65 5-10 84 40-45 20-30 60
Air flow A correct airflow in the mill is important, because the air is transporting the material and also an important factor for efficient separation. Airflow is kept constant through mill and cyclone/ filter by operating the mill fan with constant power consumption on the motor. This is normally done by the help of an automatic loop between the mill fan damper position and the power consumption of the mill main motor. Alternatively by the help of an automatic loop between the speed of the mill fan motor and the power consumption of the mill main motor. Feed A correct feed rate in the mill is important. if the feed rate is to high and the mill be filled up with material and trip on vibration, because the mill fan dont have the capacity to transport material out of the mill. If the feed rate is to low will the mill emptied out and trip on vibration, due to low grinding bed. The feed rate depends on the applied grinding pressure and the grind ability of the material. The mill differential pressure or the mill motor power consumption is an indication of how much material inside the mill. Normally the feed rate is controlled by the mill motor power consumption through an automatic loop. Vibrations A constant and acceptable level of vibrations is important. If vibrations are to high then the mill be stopped by the safety interlocking of the mill in order not to damage the machine. The vibrations are minimized by injecting water. The injected amount according to experience. Operational problems Changes in feed material properties Equipment problems Deficiencies of control elements Control signal errors External effects
Problems -action Type of problem Action Mill vibrations, Too high Reduce feed supply if differential pressure is high. Increase feed supply if differential pressure is low. Check water injection. Reduce grinding pressure. Lift rollers at excessive vibrations. Mill output, Too low Check grinding pressure. Check differential 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. Check sieving of samples. Mill product, Too fine Decrease speed of separator rotor. Increase feed supply.
Type of problem Action Mill outlet temperature, Too high Hot air amount too high. Hot gas temperature higher than normal. Adjust (close) hot gas damper. Decrease oil for heat generator. 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. Increase oil for heat generator. Close cold air damper, if open. Decrease water injection Grinding pressure, decreases Check hydraulic system. Piping is leaking. Oil pump fault. Oil level in tank for hydraulics minimum. Oil temperature in hydraulics minimum. Malfunction of valves. Sealing air pressure, Minimum Filter blocked. Check electrical equipment.
Type of Problem Action 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. Heat generator is failing No oil/gas available. Oil/gas filter contaminated. Ignition gas bottle empty. Adjustment of ignition and main burner has changed. Pre-heating of oil not working. Supply of hot gases from kiln interrupted Mill operation must be stopped. Check position of kiln (hot) gas damper. Feeder units disturbed Feed supply from other feeders must be increased. Stop the mill, if feed transport fails.
Type of Problem Action Fee bins almost empty Feed bins must be filled up. Stop the mill. Oil pressure or oil flow through mill gear minimum Mill will be stopped automatically. Check leakage in piping. Oil pump fault. Oil level minimum. Electrical fault. Oil temperature too high. Check cooling water supply. Oil pressure or oil flow through the separator gear minimum Separator and mill will stop automatically. Check leakage in piping. Oil pump fault. Oil level minimum. Electrical fault. Oil temperature too high. Check cooling water supply. Mill fan bearing temperature maximum Automatic stop of fan and mill. Check supply of cooling water. Check greasing of fan bearings. Electrical fault.
Vertical roller mill caluclations Caluclation of capacity of the mill Generally speaking, the production capacity refers to grinding capacity and drying capacity of grinding mill. The material grindability will affect the grinding capacity, the roller pressure and the type of grinding mill. G=K1 * D 2.5
Where G is capacity of the mill K1 is coefficient, which is relevant to the typer of roller mill, the selected and used pressure, the performance of grinded material. Different specification of roller mill, so the K1 is different.
K1 of Loesche Mills series roller mill is 9.6 and for Atox mills it is 7 and for MPS mills it is 6.6. D is table diameter Example: for atox 50 mill The capacity of mill is G= 7 * D 2.5 = 7* 5^2.5 = 391 TPH~ 400TPH