By:

Mostafa Abdel Aziz

NCC Project Manager

Basic Arrangement of Roller Mills

Loesche, Fuller
F

A
Conically Tapered Grinding Rollers
Basic Arrangement of Roller Mills

Pfeiffer F

A
Roller Mill With Convex-Surfaced Rollers
Basic Arrangement of Roller Mills

Polysius F

Roller Mill With Convex-Surfaced Rollers

Basic Arrangement of Roller Mills

FLS F

Roller Mills With Flat-Surfaced Rollers

Basic Arrangement of Separators for Roller Mills

Dynamic Separator
DESIGN FEATURES
 Roller
Mills with
Conical
Rollers
 Roller
Mills with
Convex-
Surfaced
Rollers
The grinding elements in the roller mill
should develop a good draw-in action.

The grinding elements should have

adequate pressure.

A stable bed of material to be

formed over the grinding table
 Draw-in
Action of
the
Grinding
Elements
Area subjected to grinding pressure
P = constant
m = grinding bed
thickness
h= initial height

Grinding bed
thickness
Grinding Speed, Time of Roller Passage

The time of action of the grinding pressure k

z .P 2
k = ( kg .sec/ m )
v a
where : z = number of rollers (-)
p = total contact force (kg)
v = angular velocity rolling circle radius
(m/second)
a = effective width of rollers (m)
Regular &
Planned Mill Maintenance

Cleaning

Visual Monitoring

Lubrication
The mill inspection is carried out in two phases:

Measurements are carried out and

visual observations are made during
stable operation and optimum
production.

Gear unit, mill and separator are

inspected both on the inside and on the
outside while the mill is stopped..

This inspection is supplemented by specific

measurements and tests carried out on particularly
exposed structural elements
5-1 Inspection During Production
5-1-1 Gear Unit
Gear
Unit

Right-angle gear box

Spectrogrammes
The safety equipment, which is distributed on the
gear unit itself and on the pump station, can be
subdivided into the following components:

Thermal sensors
Pressure switches
Flow monitors
Level switches
Switches for shut-off valves
Vibration monitor
5.1.2 Mill
The mill and the separator are
inspected from the outside and any
leakages through seals and
expansion joints are localized.

All auxiliary machines are checked and

their function is tested. This will typically
involve pressure and temperature
measurements on hydraulic installations
and fans as well as additional vibration
measurements on the mill air circulation
fan
5.2 Inspection During Mill Stoppage
 Tooth contact prints.

Correct

Incorrect

Incorrect
5.2.2 Mill

Grinding roller
Hydro-Pneumatic Spring System
Lubrication
unit for
grinding
rollers
Sealing
air
system
 Roller
suspension
system
wear situation of the following
parts to be examined:
Separator casing Damper plates
Outlet flue gas pipe Rotor plates

sealing parts between stator & rotor

are to be checked
Damper plates position can be changed
due to vibration To be checked
frequently
Some suppliers weld strips to fix after
commissioning
HARDFACING THE ATOX AND OK MILLS
Tyre Wear

Roller Size:
1750 mm x 435 mm
Original Weight:
3,085 kg
Final Weight:
771 kg
Material Consumed:
75 percent
Wear Rate:
15.2 gmIMT
OK 33-4 Grinding
blended cement 6000
hours operation

OK 27-4 Grinding
blended cement
Hardfaced with HC-O
 9-2 Material of Hardfacing

9-2-1Base Material suitable for Harding

9-2-2 Hardfacing Material

9-2-3 Welding Application

Arrangement
of welding
M/C for roller
Hardfacing
Arrangement
of welding
M/C for table
Hardfacing