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

HGRS

Tikaria_Mill

2
SEPT-07

Content
Feed Properties
Feed Inlet and Distribution
Dam Ring Modifications
Operation

HGRS

Tikaria_Mill

3
SEPT-07

Keep correct feed size for roller diameter

Limited maximum feed

sized < 3 [%] DR for hard
materials and < 5 [%] DR
for soft material

[%]

Particle size distribution:

Fraction below 1 [mm]
to be kept < 30 [%]

Particle size [mm]

HGRS

Tikaria_Mill

4
SEPT-07

Impact of feed which is too fine

Vibrations and reduced
production
Reasons:
Draw in of feed reduced
d

HGRS

Material aeration

Tikaria_Mill

5
SEPT-07

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

HGRS

Tikaria_Mill

6
SEPT-07

Impact of feed which is too coarse

Symptoms:
High kW absorption of main drive
Vibrations
d

Measures:
Modify cooler crusher or install a crusher
Sieving of crusher product
Try to work with higher hydraulic pressure
Experience:

HGRS

At Rohoznik too coarse feed leads to permanent

overload of the motor to achieve the required
production

Tikaria_Mill

7
SEPT-07

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.

HGRS

Tikaria_Mill

8
SEPT-07

Content
Feed Properties
Feed Inlet and Distribution
Dam Ring Modifications
Operation

HGRS

Tikaria_Mill

9
SEPT-07

Feed distribution
Basic Rule: Feed on Center of table
product extraction
fresh feed

internal
circulation
(pneumatical)

tailings

coarses
fall through
material
gas

HGRS

Tikaria_Mill

gas

10
SEPT-07

Content
Feed Properties
Feed Inlet and Distribution
Dam Ring Modifications
Operation

HGRS

Tikaria_Mill

11
SEPT-07

Dam Ring
Main tasks:
Control of material retention on table
Control of bed depth

HGRS

Tikaria_Mill

12
SEPT-07

Dam ring
Increase the level of material

roller

on the table through an

increase of the dam ring height

Controls material flow

leaving the grinding
zone

dam ring

Optimum dam ring height to be

grindi
bed

Controls material bed

thickness

found through trial & error

Modify dam ring height by at

roller

least 10 [mm] each time

As the table wears, the dam
nozzles

ring height should be reduced

accordingly

dam
In ring
Loesche & Fuller mills,
possible additional solution is:

table

3.5

liner

Medium dam ring

3.0

High dam ring

grinding
bed

2.5

10 [mm]
100

HGRS

Low dam ring

Vibrations [mm/s]

Tikaria_Mill

115

Op. pressure [%]

13
SEPT-07

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):

HGRS

Low bed depth

Vibrations
Increased water demand
Low power absorption of main drive
Lower production
Higher PSD steepness

Tikaria_Mill

14
SEPT-07

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!
HGRS

Tikaria_Mill

16
SEPT-07

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.
HGRS

Tikaria_Mill

17
SEPT-07

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

HGRS

Tikaria_Mill

18

SEPT-07

Content
Feed Properties
Feed Inlet and Distribution
Dam Ring Modifications
Operation

HGRS

Tikaria_Mill

19
SEPT-07

Statistically every 2nd VRM reducer fails

This seriously
affects Holcims
performance

93

58
VRM

HGRS

13

10

3
Total

12

20 23

Others

22

Damaged
Reducer

Gebr.
Pfeiffer

16

Polysius

28

Loesche

100
90
80
70
60
50
40
30
20
10
0

F.L.Smidth
/ FullerLoesche

Numbers of

Holcim vertical roller mill distribution vs. reducer damages

Mill Supplier
Tikaria_Mill

20
SEPT-07

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

Feeder blockage

Worn grinding
tools

High operating
pressure

High table speed

But, vibrations can also become a cause for others failures

HGRS

Tikaria_Mill

21
SEPT-07

Interlocking and Protection Loop are a MUST

Protection of
Mill Main
Drive

HGRS

Tikaria_Mill

22
SEPT-07