Per f or manc e of Ver t i c al Rol l er Mi l l s

at
Bhar at hi Cement Cor por at i on Pvt . Lt d.,
Nal l al i ngayapal l i
Ol i vi er Thomas
Per f or manc e Di r ec t or

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2 Loesche India Round Table 2012
Li ne #1 Commi ssi oni ng i n Sept ember 2009:
- LM 54.6 for raw mix grinding.
- LM 26.3 for coal grinding.
- LM 63 3+3 for clinker grinding.
Li ne #2 - Commi ssi oni ng i n Febr uar y 2011:
- LM 54.6 for raw mix grinding.
- LM 26.3 for coal grinding.
- LM 53 3+3 for clinker grinding 2 units.
Cement Pl ant :
- Budget of 2.46 M Tons Cement of dispatch in 2012.
- A-Grade Cement positioned on the south Indian market and MH.
- Cement Ratio OPC : PPC : PSC = 45 : 55 : 5.
- PPC with an addition of 27 28% of fly ash.
- Consumption of Indian, Indonesian, SA coal and petcoke (6% sulphur content)
- Usage of secondary fuels Up to 10% substitution rate (wood chips and
pharmaceutical wastes).
Technical Configuration

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Commissioning Phase
Foc us Poi nt LM 53 3+3 Suc c essf ul Lear ni ng Cur ve
Think, Study, Feel, Measure and Observe Start-up to nominal capacity in 45
days
Phase #1 St ar t -Up:
Ensure a thorough cold commissioning and testing Control management pressure to
delay the start-up if necessary.
Work up properly all pre-conditions between parties, especially regarding clinker C3S,
temperature and content of additives.
Make sure commissioning engineers have a dedicated operating station.
Start the mill in complete manual mode. Set a lower fineness target Objective to
observe and feel the mill.
Proceed with frequent in-the-field inspections with Loesches commissioning
engineers.
Adjust hydraulic settings accordingly after this first phase to ensure a sustainable
capability of successful start-up when pressing the start button for the next times.

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Phase #2 Obser ve & Feel :
We are entering a testing phase to determine if the mill can respond to our demand
Increase material output and achieve fineness.
Increase grinding pressure If main motor kW do not increase, material is being
flushed out of the table by the rollers. It is a way to determine if the dam ring height is
adapted.
Increase grinding pressure dP (mill) is decreasing since we are grinding faster and
more finer particles are leaving the system faster than coarser particles.
Optimize total air volume so that rejects stay at a minimum.
Determine if sudden dP variations are linked to a change in the clinker quality
(granulometry and/or temperature) Do not fight it!
Measure fineness after a few hours Adjust grinding pressure and draft. Keep in mind:
Rollers and grinding pressure give Blaine.
Separator gives rejects.
A lower draft (or total flow) increases the efficiency of the separator Never overlook
this aspect.
Commissioning Phase

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Per f or manc e Conver si on Fac t or
Compare to suppliers specification
Cl i nk er Gr i ndi ng:
Expected Output (t/h) = Nominal Output / (Targeted Blaine / Original Blaine) ^ 1.4
Formula can be applied to power consumption (or at motor shaft only)
e.g. LM 53 3+3 in OPC at 3,200 Blaine.
Specification = 230 t/h at 3,000 Blaine and 25.4 kWh/Ton Cement.
Expected Output = 230 / (3,200 / 3,000)^1.4 = 210 t/h.
Expected Power Consumption = 25.4 * (3,200 / 3,000)^1.4 = 27.8 kWh/Ton
Cement.
Raw Mi x Gr i ndi ng:
See next slide for Polysius conversion factor.
e.g. LM 56.4.
Specification = 21.85 kWh/T at R90 = 14% or R212 = 2%.
Expected Power Consumption at R90 = 19% Nominal Value * (1.04 / 1.14).
(See next slide)
Commissioning Phase

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Commissioning Phase

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Per f or manc e Cont r ol Loop
Cl i nk er Gr i ndi ng:
1.Recirculation Damper Position = f (Mill Inlet Pressure).
2.Feed Rate = f (Mill Differential Pressure).
3.Booster Fan Speed = f (Mill Outlet Temperature).
4.Draft Fan Speed = f (Total Air Flow).
Water injection does not control mill outlet temperature for a cement mill (not
simply manageable).
Raw Mi x Gr i ndi ng:
1.Recirculation Damper Position = f (Mill Inlet Pressure).
2.Feed Rate = f (Mill Differential Pressure).
3.Water Injection = f (Mill Outlet Temperature) See control philosophy between table
and top section injection.
4.Draft Fan Speed = f (Total Air Flow).
5.Baghouse Inlet Damper = f (Draft Fan Outlet Pressure).
Commissioning Phase

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Loesc he Opt i mi zat i on Pl an - Cement Mi l l LM 53 3+3
and LM 63 3+3
Tar get s:
Increase mill output.
Reduction in Specific Power Consumption.
Consistency of produced cement quality.
Stability of operation.
Optimize water consumption for bed formation (Important in India).
Performance Improvement

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Performance Improvement

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Not done
Performance Improvement

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Dam Ring
Water Injection
Performance Improvement

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Cone Stump Classifier Static Blades
Performance Improvement

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Bed formation with S-Roller for
effective grinding on a specific
surface or width of the M-Roller
Performance Improvement

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Verification of louver ring
blinding pattern
Impact of too much water
injection
Performance Improvement

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Tec hni c al Cal c ul at i on Pl ant Level :
CM2/CM3 LSKS 87
Motor
power % Speed
Motor
Speed Reducer Speed
Rotor Circ.
Velocity
Standard
Value
Rotor Circonferential
Velocity kW VFD rpm n1 (rpm) n2 (rpm) m/s m/s
Motor 250 100 1500 1500 95.6 26.8 25 - 30
600 38.3 10.7
Ratio 15.6904
Diameter Perimeter Height
Peripheric
Rotor Area
m m m m2
Rotor Diameter 5.35 16.8 3.273 55.0
Mill Output PPC 230t/h Standard Value
Specific rotor load 4.2t/hm2 10t/hm2
Air Amount 550000m3/h
Specific air load 0.42kg/m3 <0,75kg/m3
Air ratio 2.4m3/kg
Performance Improvement

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Bhar at hi - CM2/CM3 - Spec i f i c Gr i ndi ng Pr essur e (1 Rol l er ):
Grinding force kN F =Fr +Fh
Roller grinding force kN Fr =(Mr*9,81)/1000
Roller weight kg Mr
Hydraulic grinding force kN Fh
Specific grinding pressure kN/m2 Kt =F/A
Roller projected area m2 A
Mr 27000 kg
Operational pressure 86 bar
Counter pressure 20 bar
Dcyl 0.4 m
Drod 0.16 m
Cylinder number per roller 2
Roller diameter 2.24 m
Roller width 0.71 m
A (projected) 1.5904 m2
Fr 265 kN
Fh 931 kN
F 1196 kN
Kt 752 kN/m2
Loesche maximum value 1200 kN/m2
Performance Improvement

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Bhar at hi - CM2/CM3 - Cal c ul at i on - Absor bed Pow er - KWh/t :
N (kW) = k
T
*A*z*v*
Master Rollers - M (z) 3
Slave Rollers - S (z) 3
Friction Coefficient () 0.1
Roller Diameter - Max =2,5m -
Min =2,15m 2.5m 1.47m
Roller Width] 0.71m 0.48m
Projected Area (A) 1.775m2 0.7056m2
Table Diameter 5.3
Grinding Path Diameter 5.3m 4.6
Table Speed 22.6tr/mn 1.18m/s 22.6tr/mn 1.18m/s
Roller Speed (v) 47.9tr/mn 6.27m/s 70.7tr/mn 5.44m/s
Mechanical Coupling - Yield 0.95
Electrical Motor - Yield 0.960
Mill Specified Output 208t/h PPC 3600cm2/g
Theory
Actual
Limestone &
Gypsum Clinker
M-Rollers'
path
S-Rollers'
path Sum
Power at
motor's mtr Forecast
kN/m2 kN/m2 kN/m2 kW kW kW kW kWh/t
Specific Grinding Pressure 752 650 800
Absorbed Power - Table 2798 352 3149 3453 16.6
Installed Power - Table 4700
Performance Improvement

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Per f or manc e Fi gur es
Raw Mi l l #2 LM 56.4:
Specification 21,85 kWh/Ton Material at R90 = 14%.
Expected power consumption = 20.47 kWh/Ton Material.
Expected mill production output = 375 t/h.
Actual grinding fineness at R90 = 17 to 18%.
Actual Performance.
17.5 kWh/Ton Cement.
415 t/h.
Cement Mi l l #2 LM 53 3+3:
Specification.
PPC = 29.2 kWh/Ton Cement and 203 t/h at 3,600 Blaine.
PG Test.
PPC = 21.38 kWh/Ton Cement and 217 t/h at 3,625 Blaine.
Daily Plant Operation.
PPC = 26.9 kWh/Ton Cement and 201 t/h at 3,570 Blaine.
Performance Improvement

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Oper at i on of ver t i c al mi l l s f or c l i nk er gr i ndi ng:
1. Performances are achieved in a reliable manner.
2.Increase of mill output is noticeable during longer operational runs.
3.Specific Power Consumption has decreased (expect 1 to 2 kWh/Ton Cement).
4.Rejects below 45 m and [3 30]m range are consistent and there is room for
adjustment with the separator Check water demand on a regular basis.
5.LM 53 3+3 operates with stability and is to be considered as a good system when
analyzed thoroughly and operated properly.
6.Water injection remains too high (3.5% of total mill output) and needs to decrease to
2.5%.
7.Hardfacing on the rollers and table remains an expensive maintenance operation.
8.Commissioning needs always to be combined with an analysis of clinker grindability.
9.Optimization of clinker granulometry and temperature is also part of getting the best
out of a LM 53 3+3.
Performance Improvement
Thank You