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

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HGRS SEPT-07
Workshop
 Content
 Feed Properties

 Feed Inlet and Distribution

 Dam Ring Modifications

 Operation

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Keep correct feed size for roller diameter

Limited maximum feed

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

[%]

Particle size distribution:

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

Particle size [mm]

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 Impact of feed which is too fine

Vibrations and reduced

production
Reasons:
R

 Draw in of feed reduced

D

d  Material aeration

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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

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 Impact of feed which is too coarse
Symptoms:
 High kW absorption of main drive

R
D
 Vibrations

Measures: d

 Modify cooler crusher or install a crusher

 Sieving of crusher product

 Try to work with higher hydraulic pressure

Experience: At Rohoznik too coarse feed leads to permanent

overload of the motor to achieve the required
production
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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.

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 Content
 Feed Properties

 Feed Inlet and Distribution

 Dam Ring Modifications

 Operation

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Feed distribution

Basic Rule: Feed on Center of table

product extraction

fresh feed

internal
circulation tailings
(pneumatical)
coarses

fall through
material

gas gas

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 Content
 Feed Properties

 Feed Inlet and Distribution

 Dam Ring Modifications

 Operation

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Workshop
Dam Ring
Main tasks:
 Control of material retention on table

 Control of bed depth

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 Dam ring
 Increase the level of material roller

on the table through an Controls material flow

leaving the grinding

increase of the dam ring height zone

dam ring
 Optimum dam ring height to be grindin
Controls material bed
thickness
found through trial & error bed

 Modify dam ring height by at roller

least 10 [mm] each time
 As the table wears, the dam Vibrations [mm/s] Low dam ring
nozzles
ring height should be reduced table liner
3.5
accordingly Medium dam ring
3.0
dam ring
 In Loesche & Fuller mills, High dam ring
possible additional solution is: 2.5 grinding
10 [mm] bed
100 115 Op. pressure [%]

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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):
 Low bed depth
 Vibrations
 Increased water demand
 Low power absorption of main drive
 Lower production
 Higher PSD steepness

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 Grinding efficiency on different bed depths

Hydraulic Pressure

Roller
Area 1

Pressure Distribution in bed

Area 2

A1 < A2 Pbed1 > Pbed2

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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!

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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.
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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 18
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 Content
 Feed Properties

 Feed Inlet and Distribution

 Dam Ring Modifications

 Operation

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 Statistically every 2nd VRM reducer fails

Holcim vertical roller mill distribution vs. reducer damages

100 This seriously 93

90
80 affects Holcim’s
performance
Numbers of

70 58
60
VRM
50
40 Damaged
28 Reducer
30
16
22 20 23
20 12 13 10
10 4 3
0
Polysius

Pfeiffer

Others
F.L.Smidth

Loesche

Total
Gebr.
Loesche
/ Fuller-

Mill Supplier
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 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 High operating
pressure
Feeder blockage Worn grinding
tools High table speed

… …

But, vibrations can also become a cause for others failures

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Interlocking and Protection Loop are a MUST

Protection of
Mill Main
Drive

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