Scribd Logo
Upload

Welcome to Scribd!

  • FLS Comminution Manual New PDF

    Uploaded by

    Ventrue Leong
    670 views80 pages

    Original Title

    314840157-FLS-Comminution-Manual-New-pdf.pdf

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    670 views80 pages

    FLS Comminution Manual New PDF

    Uploaded by

    Ventrue Leong

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 80
    Giismiotn Comminution manual © 2001 Comminution manual Contents AS Bail mill Charge and power Calculation of charge Calculation of power Specific charge Torque factors Example. Max charges Drying compartment Grinding media Equilibrium charges .. Charges - Large balls. Charges - Small balls. Charges - Cylpeps Standard charge compositions. Standard charge compositions. Wear on grinding medi Piece weight and specific surface Sampling of grinding media ... Grinding and fineness Transport through mill. Normal fineness in mill Heat balance, Example Closed Circuit grinding, Layout. B: Roller press Layout Pre-grinding . Semi-finish grinding . Finish grinding .... Roller press calculations Symbols. Formulas .. Typical values...... Cc: Vertical Mills Layout, Alternatives.. Vertical mill calculations Symbols. Power consumption Grinding pressure .. Mill internals Nozzle ting... Dam ring Heat balances, Example ako aud Comminution manual Contents D: Closed circuit grinding Grinding theory Comminution index... Circulation factor By sieve residues or weight .. Separator efficiency Description... Power reduction. Max power reduction. Vs values... Tromp curve Description Example. Factors of influence .. E: Various Fans Air and heat Densities and Cp-values.. Various formulas. Wet and dry temperature Water vapour in air Pitot tube measurements Pitot tube measurements II False air calculation Moisture calculations. Sieve to mesh conversions Unit transformation: A: Ball mill Ball mill Page A.1 Charge and power Calculation of charge D: Effective diameter of compartment Im] Ie Effective length of compartment (m] V: Volume of compartment Ven/4-OF-L (m>] hs Centre distance (h/D used in page A.4) h=H-D/2 (m] n/D = H/D - % “ H: Free height H=(N/D + 4)-D (m] q: Specific charge (from page A.4) [%] w: Bulk weight (from page A.5) (ums F: Charge Fs qi00-w-V wr Page A.2 Bail mill Charge and Power Calculation of power Compartment power consumpti a: Armof gravity in relation to mill diameter a n: Rotational speed of the mill (rpm] g: Acceleration of gravity (mvs?] a: Angle of displacement C) N: Power consumption by compartment at mill shell N=F-g-D-a-sina- m- 1/60 [kW(net)] sina is the torque factor p.. Standard values from page A.4. N=0514-F-n-p-O-a [kW(net)] Where the constant 0.514 is (g- 77/60) Critical speed: The critical speed nz is the speed, where the centrifugal force at the mill lining is equal to the gravitational force: (rpm Normal mill speeds are 70 - 80% of the critical speed. Ball mill Page A.3 Charge and power Specific charge i) a q hiD) a q 0.000 0.425 50.0 0.200 0.647 25.2 0.005 0.430 49.4 0.205 0.653 24.6 0.010 0.435 48.7 0.210 0.659 24.1 0.015 0.441 48.1 0.215, 0.665 23.5 0.020 0.446 47.5, 0.220 0.670 22.9 0.025 0.452 46.8 0.225 0.676 22.4 0.030 0457 46.2 | 0.230 0682 21.8 0.035 0.462 45.6 0.235 0.688 21.2 0.040 0.468 44.9 0.240 0.693 20.7 0.045 0.473 44.3 0.245 0.699 20.1 0.050 0.479 43.6 0.250 0.705 19.6 0.055 0.484 43.0 0.255 0.711 19.0 0.060 0.490 42.4 0.260 0.717 18.5 0.065 0.495 41.8 0.265 0.722 17.9 0.070 0.501 4t4 0.270 0.728 17.4 0.075 0.507 40.5 0.275 0.734 16.8 0.080 0.512 39.9 0.280 0.740 16.3 0.085, 0.518 39.2 0.285 0.746 15.8 0.090 0,523 38.6 0.290 0.751 15.3 0.095 0.529 38.0 | 0.295 0.757 _—*14.8 0.100 0.534 37.4 0.300 0.763 14.2 0105 0.540 36.7 | 0.305 0.769 «13.7 0.110 0.546 36.1 0.310 0.775 13.2 0.115, 0.551 365.5 | 0.315 0.781 12.7 0.120 0.557 34.9 | 0.320 0.786 12.2 0.125, 0.562 34.3 0.325 0.792 11.8 0.130, 0.568 33.6 0.330 0.798 11.3 0.135, 0.574 33.0 0.335 0.804 10.8 0.140 0.579 32.4 0.340 0.810 10.3 0.145, 0.585, 31.8 0.345, 0.816 9.87, 0.150. 0.591 31.2 0.350 0.822 9.41 0.155, 0.596 30.6. 0.355 0.828 8.95 0.160 0.602 30.0 0.360 0.833 8.51 0.165 0.608 29.4 | 0.365 0.839 8.07 0.170 0.613 28.8 | 0.370 0.845 7.64 0.175 0.619 28.2 0.375 0.851 7.22 0.180 0.625, 27.6 | 0.380 0.857 6.80 0.185, 0.630 27.0 | 0.385 0.863 6.39 0.180 0.636 26.4 0.390 0.869 5.99 0.195, 0.642 25.8 0.395 0.875 5.59 acan also be calculated as: a = 0.009 - (96.7-q) fl Page A.4 Ball mill Charge and power Torque factors Media Material] Grinding | Lining vernal type ore 9 yee tumy| None | Balls | 4.3 | 073 Coarse None | Rods | 6.0 | 0.55 and | Steel . Danula | Balls | 4.3 | 0.75 medium Sonex | Balls | 43 | 0.66 Cement | None | Balls | 4.5 | 0.69 and None | Cyipebs| 4.7 | 0.73 raw meal None |Minipebs| 4.7 | 0.64 Fine | Steel (dry) Danula | Balls | 4.5 0.71 Danula | Cyipebs | 4.7 | 0.75 Danula |Minipebs| 4.7 | 0.66 Al Steel | None | Ceramic | 7.9 | 0.75 Silex | None | Stone | 1.5 | 0.75 None | Balls | 4.3 | 0.66 Coarse None | Rods | 6.0 | 0.50 and | Steel , Danula | Balls | 4.3 | 0.67 medium Sonex | Balls | 43 | 0.59 Slurry | None | Balls | 45 | 0.66 (wet) | None | Cyipebs} 4.7 | 0.66 Fine | Steel | Danula | Balls | 4.5 | 0.67 | | Danula | Cyipebs| 4.7 | 0.67 | | None | Ceramic | 1.9 | 0.85 an Steel | None | Stone | 1.5 | 0.85 Wash Silex | / Lifters | Stone | 1.5 | 0.85 drum | | | Coarse None | Balls | 4.3 | 0.69 | Medium None Balls | 45 | 0.69 Coal | Steel “| Medium | | None | Cyipebs| 4.7 | 0.69 Medium | Danula | Cyipebs | 4.7 | 0.71 Ball mill Page AS Charge and power : Example Example: In a UMS 42 x 13 mill running with 16.0 rpm, the following was measured: First compartment: D=401m L=3.89m H=2.75m Second compartment: D=413m L=838m H=2.81m Calculations for first compartment: V=1/4: (4.01 my? -3.89m= 49.1 m* W/D = 2.75/4.01 - % = 0.186 From page A.4: q = 27.0%; from page A.5: b = 4.3 Ym? E227.0/100 4.9 m2. 49.1m3= 57.01 Calculations for second compartment: Vem/4- (4.13 m)? 838m =112.3m? WD = 2.81/4.13 - % = 0.180 From page A.4: q = 27.6%; from page A.5: b = 4.5 vm? E.227.6/100 4.5 Ym. 112.3 m3 = 139.41 Power calculations N=0514°-F n-u-Da [kW(net)]} First compartment: From page A.4: a = 0.630; From page A.S: y= 0.73 N = 0.514 - 57.01 16.0 rpm - 0.73 - 4.01 m- 0.630 N= 865 kW(net Second compartment: From page A.4: a = 0.625; From page A.5: y = 0.69 N=0.514- 139.4 t. 16.0 rpm - 0.69 4.13 m- 0.625 N= 2042 kW(net Page A.6 Bail mill Charge and power Max charges Drying compartment Mil Maximum specific charge [%] Balls | Cylpebs Dy 36 33 uM Wet > 5 kWhit 34 31 Wet <5 kWhit 28 26 TUM 2-compartments 32 29 1-compartments 28 ™ 2-compartments 28 26 Rod 35 Silex Ceram. 38 Wash Drum 34 Duodan, 28 2 34 32.7 38 31.5 UMS ail 42 30.4 compartments 46 29.4 50 28.6 54 28.6 34 34.9 Second 38 33.5 compartment 42 32.3 UMS w. Stanex 46 31.3 Diaphragm 50 30.4 54 30.4 Power consumption of drying compartment: Doc — Nominal diameter of drying compartment {m] Loc Nominal length of drying compartment [mj Noc Power consumption of drying compartment —_{kW(net)] The power consumption of a drying compartment can be calculated as follows: For raw and cement mills Noc = 1.5 Doc** - (Loc - 0.4) For coal mills Noc = 0.8 Doc? 5 (Loc - 0.4) Bail mill ikW(net)] (kW(net)] Page A.7 Grinding media Equilibrium charges Equilibrium charge, definition An equilibrium charge is the distribution of ball sizes that will be realised when operating a ball mill for a long time, compensating the wear by adding bails of one specific size, and removing the balls, which are smaller than half the diameter of the ball size used for compensation. The equilibrium charge is characterised by the diameter of the ball size used for compensation. Equilibrium charges may be mixed to adjust the required piece weight and surface area. Two or more balll sizes are then used for compensation. The average piece weight and the specific surface of an equilibrium charge with normal steel balls can be calculated according to’ 0.001913-D,? (al oes [mat] 0: where Deis the diameter in mm of the ball size used for compensation Page A.8 Bail mill Charges - Large balls Grinding media “wu6lem Aq syunowe jenbs ul peonpontul ase Aay) ‘pares ase UOWeSUadWOD Jo} S9zZIS 01 BIBUM ‘e est|srijger|zer[ezt[ozler[zofzor] 26 | e6 | 68 | vw | “unbe eoepns oyoeds Lvileet|zerjeruiezjermieorlror| se | ze | o's | pe | yew | jem eoepns oyioads 20S | 9s9 | gaz | 626 | zee |isit|seet lero: fever [serzlorsz|zze2| 6 NDA 1yBiam adaId Sos | Z19 | 808 |poo! | ogg |eztt lover |zest |szer|otizlesez|oszz| 6 femur yBiem acai e | 2 Wew gsz JO 1Lb IW OF gfu}2zfe}t2zfe|e2 ew ze |6 zz Ww OF oe} iz] zt fer}srjor| se |2z]e}e } 2] t pews joerg juwos ge | ze | te | zz} sz} er} |i | 6 | zi ols fewec [Soe Ww OS si | 62 | ce | oe | sz | ez {iz |er [oe [ae for] e@ fvewort [Go0r1 fuwoz €l | 92 | 91 | 62 | ze | zz | ez | et | pt | et jvewoe [Gec0z bwwos zi | 2 | ez | zz | ve | 92 | iz | or fvewse |Ses6z juw 06 orf te | 2 | ez | be fvewsz [Booty jwwoot OL | 6 | ez vewoz [6zsrs fuwolt 6 wg [6 seor WwW OZL oe | 0€ | ov | ov | oF | ov | or | os | os | og | os | os fou] oa eus ui sazis ea oz | o4 | 08 | o8 | 06 | 06 | 06 | oor | oot | ort | oF | oz: | xew 09 OL oz | o8 06 oo! ont oc | ™ | og | | 06 | o6 | % foot | Jour |! Joe | | Fee seq eG1e7 nba Joy sabseyo jeniu!l papuawwosay __ Page Ao Ball mill Charges - Small balls Grinding media “yyBiem Aq syunowe jenba ul peonpouqul ase Aayy ‘payers eve UoesuadWOd JO} SEZs 0} BBUM *+ so] 6s | 1s | or | iy | ze | te | oe | Se | ce [roe]zerfozt]vew] wnbe aoepns oyiods co [es | or | zr | ge | te | te | ze | ez | tz Jeet i zi lest] yew | pent aoepns oyoeds go] te st | oz | oc | ee | zs | ez Jzzr | zor Jeez eoe jerr| 6 tinbe 1yB1em 808d as | or | ot | tz | 92 | op | es | e8 | zzr|ezt | ove |ece |err| 6 yentu! yyBtem 898Id z yew pst [6 so ws geliz} ao] }2 ew 2 |6r UW OL zgles|er|oe|uz{ul + | ews |6rr — juwst gz [is |or [ir fre fiz}a|e ewer [Bee Ww OZ oz | or | or | op | zz} er] e}e vere [Brg wwe si|se|se|ec|tzler| 6 | so fewoe [Gin mwoe gz] is | zp | er | ze | 02 fveweer |B zoe juwor 12 | ep | te | oF fewest [Gers — fuwos gi | se wet [Gee ju og s [or | or | or | or | st | st | 02 | 02 | sz | sz | o¢ | og Ju st [oz | oz | sz | sz | oc | ¢ | or | or | os | os | 09 ozs [xew] “eye SAE Pe st 02 Sz oe OF 0s St | oz | % | ge | & | oe | 0 | oy |” fos |S | 09 og |ww |. (s)ezis uonesuadi09 | syeg yews wuiniiqyinba 40} sabsey jenlul pepuawwo0sey _ Bail mill Page A.10 Charges - Cylpeps Grinding media jyBiem Aq siunowe jenba ul paonponul aie Aayy ‘pares a4 uoHesuadwo> Jo} SazIS 0} 8J2UM | ce] se] ez] va] es] os] os] oper] i] ze | ve | ee | oe | vew | ‘nbs oepns oyioads se | 6z|z9|es| ss | is | zp | vp | iy | ge | se | ec | oc | 82 | ve | temul aoepns oyroads ge} s | zai] st} oz| tz] te | oc] sr | zo | ec | se jez} © tinba 1yGiem Bald velvs|e | zi | ot | es | v2 | oz | gc | | es | eo | ce [srt] 6 yentul Gre eoald zi ewect [6e1 fww oxo pe} iz}e7]e}e} 2 wewos j6e jww exe zp |or|zzjz|e]o]r 2 yew 22 {69 [ww oLxoL zi|{se|se}|ee|rz}orj2}|el|z{rj ete} ew pg |S br ww zixzt oztes|er|rr|se}sz|oz}sr}ur] 2] s | 2 fewer [Occ fuwotxot at} ze|se| ge] oc | zz} gr }or] 8 | 9 jvewor jSzr fuw 6ix6t riftezlic| else} orler| 6 jewse |6s9 jw coxze zi}se|ez|ie| v2 | zt fveweoe [B96 jww sexse zi | ve | se | ze fewarse |B soi fuw oexoe rt | 62 vewoze |S e9z jww sexse | o9fofele|eslfe fo lfofa|a]a)eje) or jum zt_| zi| ou | on | 61 | 6t | zz | zz | sz | se | o€ | o€ | se | se | xeul seaweno Ul Seed ot zt a a a 6L ° zz 2 sz ee oe ee ce | ww J, (s)ezis uonesuedwo sdadjAD winuigyinba 20) saBseyo [eniul papuawiwo0s9y ; Page A.11 Ball mill [Grinding media Standard charge compositions First compartment initial charge: Cement & raw mill: Ball size 90 mm 80 mm 70 mm. 60 mm 23% 32% 21% 24% Compensation: 90 mm Initial piece weight: 1540 g Equilibrium piece weight: 1395 g Coal mill: Ball size 50 mm 40 mm 30mm__| 25%. 40% 35% | Compensation: 50 & 40 mm Initial piece weight: 193g Equilibrium piece weight 1629 Intermediate compartment initial charge (three compartment mills) Ball size somm_ [40mm 30 mm 42% | «42% 16% Compensation: 50 mm Initial piece weight: 260g Equilibrium piece weight: 239 g Page A.12 Ball mill Grinding media Standard charge compositions Fine grinding compartment initial charge: Non-classifying lining: Ball size Mill system 25 mm 20 mm 15mm ‘Open 20% 40% 40%. Closed 40%. 40% 20% Open Closed Compensation: 20& 25mm 25mm Initial piece weight: 239 30g Equilibrium piece weight: 20g 30g Classifying lining: Ball size 50mm. 40 mm 30 mm 25mm 20mm 15mm. 10% 10% 5% 30% 30% 15% Compensation: 50mm 25% 25mm 75% Initial piece weight: 399 Equilibrium piece weight: 38g Raw mill with classifying lining (one compartment mills): Ball size 30mm | 80mm [70mm [ 60mm | 30mm | 25mm | 20mm 14% | 19% [| 13% [ 14% | 14% | 16% | 10% Compensation 90mm: 60% 30mm: 40% Initial piece weight: 139 g Equilibrium piece weight: 122g Coal mill with classifying lining (one compartment mills): [ Ball size 50mm | 40mm [30mm | 25mm | 20mm | 15mm 11% [18% 16%. 22% 23% 10% __| Compensation 50mm: 22.5% 40mm: 22.5% 30mm: 55% Initial piece weight 70g Equilibrium piece weight 75g Ball mill Page A.13 Grinding media Wear on grinding media Cast Media Chrome alloy % 2-28 % Mn 1.0-1.2 Analysis % Cr 12-28 % Mo 02-05 Hardness | HAC 50-56 Wear in g/kWh taken up by compartment Jo arge balls [10-20 +~'| Wet | Small bails 15-30 | Cylpebs 15-30 Large balls 2-5 Raw Smail balls 1-3 Cylpebs 1-3 (Targe balls 2-5 Cement | Small balls 1-3 | Oylpebs 1-3 | fo Se Page A.14 Bail mill Grinding media Piece weight and specific surface a: Diameter of ball [mm] p: Specific weight of material [g/cm*} it Piece weight i=Z.a?-p ig] If p=7.8 g/cm? (normal steel): i =0.0041.q? (al o: Specific surface: $000 [mat] pd If p=7.8 g/cm? (normal steel) pee {m7} d AB [m?/t] For examination of a grinding media charge, take out not less than 200 pieces from each sampling spot in compartment 1, and no less than 2000 form compartment 2. Extract from under the centreline and dig as deeply as possible. Broken media is sorted ‘out. Separate in fractions as shown in examples on page A.6. Calculation of surface is based on the average piece weight and on the assumption that all the media are of spherical shape. This assumption also applies to cylindrical cyipebs. Piece weight and specific surface of the charge is calculated from the main fraction by disregarding media less than haif the diameter of the largest size used for compensation for wear. In compartments with classifying lining the charge normally consist of two equilibrium charges constituting a coarse-grinding and a fine-grinding charge, their proportions being determined during the dimensioning and adjusted during running in. The classifying effect is most clearly expressed in the proportion between the piece weights in the inlet end and outlet end of the compartment Ball mill Page A.15 Grinding media Sampling of grinding media Example 1: Ball charge Compartment 1 - compensated for wear with 90 mm balls. Fraction] Weight | 2. | ay i ° Og (mm) (kg) ° "| (gram) | (met) | (m*) 90-85 | 70.52 | 25.0 | 24 | 2938 | 858 | 0.605 85-75} 81.87 | 29.0] 38 | 2154 | 9.52 | 0.779 75-65 | 60.08 | 21.3 | 44 | 1365 | 11.08 | 0.666 65-55} 40.34 | 143] 40 | 1009 | 12.26 | 0.495 55-45| 23.88 | a5 | 49 487__| 15.63 | 0.373 <45 | 291 | 1.0 | 13 224 | 20.25 Broken |_3.02 | 1.14 Z 431__|_ 16.28 Total_| 282.62 215 2.918 Main fraction >45 mm: 276.69 kg ~ 0.27669 ton ~ 97.9 % ~ 195 media 276690 Piece weight iat 4t9 9 Specific surface: 9 = 9789 _19.5 m?/ 0.27669 7 Example 2: Cylpebs charge Compartment 2 - compensated for wear with 25 x 25 mm cylpebs. Fraction | Weight | o. ] yy, 1 Q On (mm) (kg) ° (gram) | (mit) | (m*) 25-235 | 223 |222| 26 | 9857 | 27.89 | 0.062 23.5-20.5| 365 | 364] 58 | 63.0 | 30.90 | 0.113 20.5-17.5| 210 | 209] 48 | 43.8 | 34.88 | 0.073 17.5-14.0| 1.49 | 14.8] 56 | 266 | 41.19 | 0.061 [44.0-125/ 038 | 38 | 30 | 127 | 52.70 | 0.020 <125 | 0.104 | 1.0 16 6.5 65.88 Broken | 0.09 | oo | 7 12.6 | 52.84 Total | 10.04 L241 0.330 Main fraction >12.5 mm: 9.85 kg ~ 0.00985 ton ~ 98.1 % ~ 218 media Piece weight j= 9853 _ 45> 218 a _ 0.330 © m/ Specific surface 0 = = =33.5 4 Page A.16 Ball mill Grinding and fineness Transport through mill Normal fineness in mill Transport capacity of material through grates: Width of slots Open circuit ~=6mm Closed circuit__8 - 12 mm ist. partition Dry | 2nd. partition appro. 5 V(dm?-h) Qutlet grate Width of slot Normaily 6mm Wet | tst. partition 8 m?y(dm?-h) 2nd. partition 9 mam’ h) Outlet grate 40m (dm?-h Wash | Peripheral Grate 3.0 mM(dm=h) drum | Inclined outlet grate 2.5 mdm?h) Transport capacity of material through mill body: 20 - 30 th/n? Normal fineness of grinding material in the mill Two compartment mi The samples are taken inside or immediately in front of the partitions. 25-40% +0.2mm | - B-16% +0.5mm At partition 25-4% +1.0mm max. 0.5% +2.0mm Three compartment mill: 15-25% +0.5mm | . " 10-20% +0.6mm First partition 714% + 1.0mm | max. 4% + 2.0mm | 20-30% +0.2mm | Second partition max.5% +0.5mm_ Ball mill Page A.17 Heat balance Example An example of a heat balance for a ball mill (ball mill tube only). Flow Temp Cp Heat vh °C__keal/kg/?C__Mcal/h 85.0 95.9 0.186 = 1516 02 20.0 1.000 4 102.0 114.0 0.186 © 2163 2498 22.8 25.0 0.244 139 0.0 © 25.0 0.244 0 22 25.0 0.244 13 1.8 0.0 1.000 0 Return mat. Grinding heat Air Faise air,inlet False air, outlet Water inj TOTAL IN OUT Material total 187.0 119.7 0.186 © 4163 Water in product 0.0 116.0 1.000 0 Water evap 2.0 116.0 0.453 = 1295 Total air 23.9 116.0 0.244 676 Surface loss 199 TOTAL OUT Water evap : The water in the feed and the water from the water injection is evaporated at 0 °C and the steam is heated to 116 °C: 2.0-( + 0.453 116) Mcai/h = 1295 Mcai/h The amount of air out of the mill tube is 24.9 vh (Air in + Water evaporated). At the outlet the air has a density of : 0.90 kg/m?. The air amount is thus 7.7 ms. A @ 4.2 m mill will have a free area of 9.70m? (with 30% filling degree). The velocity in the mill tube is thus 0.80 m/s. For Co values Surface loss. page E.2 , grinding heat calculation and e page E.3. Page A.18 Bail mill Closed Circuit grinding Layout Typical layout of closed circuit grinding: Separator with product collection in cyclones: Offers maximum heat preservation for maximum drying in the mill, smailest possible filter and pressure drop over separator system. Separator with product collection in filter. Offers maximum cooling of the product: ap Both systems may be designed to offer partly recycling of the separator air for the best compromise between the two solutions. Bail mill Page A.19 Notes Page A.20 Bail mill Notes Ball mill Page A.21 Notes Page A.22 Ball mill Notes Bail mill Page A.23 B: Roller press Roller press Page 81 Layout Pre-grinding | Control NL gates = 1 | | Roller [fy | il Feed } press |i. 2 | | (7) Flow eel i r splitter YY | lecycled device i] day Magnet| | pressed | 2 || material,” | iS, paternal, Pressed } ( material to i bail mill Pre-grinding !ayout * Flow splitter controis ratio between material recycled to roller press and pressed material to ball miil + Roller press specific power consumption ~2 to ~5 kWhit material to ball mill + Roller press circulation factor = Roller press throughpunew feed: 1-24 Page B.2 Roller press Layout Semi-finish grinding — Metal detector | i} i 5 | | Roller) | press). i | material to | ball mill i [Seraraty Recycled coarse r material y Semi-finish grinding layout + Separator controls ratio between material recycled to roller press and pressed material to ball mill. * Deaggiomeration and separation may be combined in one machine + Roller press specific power consumption: ~6 to ~14 kWhit material to ball mill + Roller press circulation factor = Roller press throughput/new feed: ~2.5-6 Roller press Page 8.3 Layout Finish grinding Metal detector .., \ Finished product | | WT | | | | | | i eagglomerser | | i Seramio] Recycled |_| Finish grinding layout * Separator controls ratio between material recycied to roller press and pressed material to bail mill. + Deaggiomeration and separation may be combined in one machine * Separator may be divided into a grit separator and separator working in series + Roller press specific power consumption (cement grinding) ~14 to ~30 kWh/t finished product + Roller press circulation factor = Roller press throughput/new feed ~6 to 14 Page 6.4 Roller press Roller press calculations Symbols 4 3 ES Moveable Fixed roller 8 |- . D: Roller diameter {m] Roller width im} n: Roller speed [rpm] v: Roller peripheral velocity [mis] s: Grinding bed thickness im] F: Roller force [kN] B: Hydraulic pressure (bar] A Piston area [m] cS Number of hydraulic cylinders tl 5 Density of pressed material [kg/m3] u Torque factor tl kr: Specific roller pressure {kNim] M: Roller press capacity (uni N: Power consumption [kW] E: Specific power consumption (kwhit} C: Roller press circulation factor tl P New feed to roller press {vh] Roller press Roller press calculations Formulas Total roller force T is calculated from the hydraulic pressure and the number and area of the hydraulic cylinders: T=c AB 102 [KN] Specific roller pressure kris the total force divided by the projected roller area: kr = TD W) (kN/m2} Peripheral velocity v of the rollers is calculated from the roller speed and the roller diameter : v=P-D- (n/60) [m/s] Power consumption N of the roller press is calculated from the applied total force, the peripheral velocity and the rolling torque factor between material and roller surface : Nep-Tov {kW} or when using the specific roller pressure: N=ep-kr-D- Wey [kw] Throughput capacity M of the roller press is calculated from the thickness of the grinding bed, the density of the pressed material, the width of the rollers and the peripheral velocity M=3.6°s°5°W-v (wh Specific power consumption E4 applied to the material at each pass through the roller press is the power consumption divided by the throughput capacity: E1=N/M (kwhit] Roller press circulation factor C is the througnput capacity divided by the new feed rate: C=MP ip) Specific power consumption E apolied to the product from the roller press system (finished product »r product to ball mill) is the specific power consumption applied to the material at each pass through the roller press multiplied by the circulation factor: E=C €! (kWhit] Page B.6 Roller press Roller press calculations Typical values Typical roller press parameters Roller press velocity [mis] 1.3-1.6 | Specific roller pressure [kN/m4] 000 (Cement and slag) 4500 (Raw materials) Torque factor Fl 0.07 - 0.1 Grinding bed [% of D} 1.8-2.3 Density of pressed material [/m?] 2.2-2.7 Roller press Page 8.7 Notes Page B.8 Roller press Notes Roller press Page 8.9 Notes Page 8.10 Roller press C: Vertical Mills Vertical mill Page C.1 Layout Alternatives There are two basic layouts of the VRM system; product collection in cyclone(s) or product collection in filter. Below only the ducting used with the mill in operation is shown. Product collection in cycione(s): To dedusting —____4——______ Heat source wo Product collection in filter: A =

    You might also like