Operation and

Optimization
vertical mill used for
 pre grinding of clinker (lumps to coarse
powder)
 finish grinding (lumps to powder ) of
- coal/petcoke for kiln
- raw material for kiln
- cement, OPC or mixed
- slag, pure or mixed
 vertical mills comprise 2-4 conical rollers which
are hydraulically pressed onto a horizontal
rotating grinding table
 the roller axis is inclined at 15o to the table and,
as axes of rollers and table do not intersect in
the plane of the table the relative motion involves
both rolling and sliding which enhances
comminution
 feed material is directed onto the centre of the
table and is thrown outward by rotation under
the roller and into a rising air current at the
periphery which is directed by means of Louvre
ring.
 the air sweep passes through an integral
rotary classifier, fine pass out with the air
current while coarse material falls back onto
the feed table.
 material drying occurs in air suspension
between table and classifier. circulating load
is typically 800%. Roller mills are prone to
vibration due to an unstable grinding bed
 A major cause of material instability is fine,
dry mill feed which can usually, be mitigated
by spraying water directly onto the bed.
 grinding force = roller weight + pressure(force)

 max particle size in feed : 5 to 8 % of roller diameter

 G. Pfeiffer
 Loesche
 FLS Atox
 Polysius
 static type
 conventional type
 cage rotor type
 Vane adjustment
 Speed control
 Rotor seal affects efficiency
 Feed Size
 product fineness
 moisture content
 Grind ability
 abrasiveness
 Ball mill maximum 5% + 25 mm
 VRM up to 150mm
 5 % to 25 % +90um
 1 % to 2 % +212um
 normal moisture content 3% to 10% H2O
 Possible to dry >20% H2O in vertical mills
 Up to 6 to 7 % H2O with kiln gases
 Above 7% H2O supplementary heat from
auxiliary furnace or cooler
 material granulometry
 roller pressure
 Dam ring
 Louvre ring
 external circulation reducing gas flow
pressure lost over the mill
 production rate, tones per hour
 grinding pressure (bar) or (kN/m2)
 Mill Motor kW
 grinding bed thickness
 Vibration level (mm/s)
 pressure drop across the mill
 mill outlet temperature
 Fan flow
 Rejects (If external recirculation present)
 water flow
 operating hours
 involuntary downtime hours
 kWh/tonne (mill motor + fan + separator)
 product fineness on 90/212 microns for raw
mill, coal mill and blaines for cement mill
 feed moisture, %
 product moisture, %
 feed size
 running with high velocity in the nozzle ring
gives a high pressure loss, but also a low
reject rate
 however lower pressure drop with e.g. 45m/s
is to prefer and will both give considerable
power savings on the fan and less wear in the
mill body
 proven technology
 very suitable for grinding blended cement or
slag
 compact grinding installation
 energy saving up to 30 to 40 % kWh/Mt
 suitable for grinding moist feed
 easy maintenance and optimum utilization of
wearing rollers
 VCM vs. RPCM
Grinding VCM pre RP pre VCM RP&CM VRM Closed
system grinding grinding combinatio circuit ball
n mill (raw
mill)
Mill kWh/Mt 24 21 34 39 19 29
of clinker

Separator and 5.5 3.5 7 5.5 9.5 7

fan kWh/Mt

Auxiliary 2.5 7 5 9 3 7
(kWh/Mt)

Maximum 55 60 34 63 80 63
output

Source-Birla White
N/R Velocity Reject Rate Relative Pressure
drop
m/s % fresh feed %
75-85 Trace 100
60-65 5-10 84
40-45 20-30 60

lower pressure drop

less wear of mill body liners
fan power savings of 15-30%
 a correct air flow in the mill is important, because
the air is transporting the material and important
factor for efficient separation
 air flow is kept constant through the mill and
cyclone/ filter by operating the mill fan with
constant power consumption on the motor
 this is normally done by the help of an automatic
loop between the mill fan damper position and
the power consumption of the mill main motor.
alternatively by the help of an automatic loop
between the speed of the mill fan motor and
power consumption of the mill main motor
 A correct feed rate in the mill is important. if the
feed rate is too high and the mill filled up with
material and trip on vibration, because the mill
fan don’t have the capacity to transport material
out of the mill
 if the feed rate is too low the mill emptied out
and trips on vibration, due to low grinding bed.
the feed rate depends on the applied grinding
pressure and the grind ability of the material
 the mill differential pressure or the mill motor
power consumption is an indication of how much
material inside the mill. Normally the feed rate is
controlled by the mill motor power consumption
through an automatic loop
 a constant and acceptable level of vibrations
is important
 if vibration are too high then the mill be
stopped by the safety interlocking of the mill
in order not to damage the machine
 the vibrations are minimized by injecting
water. The injected amount according to
experience
 changes in feed material properties
 Equipment problems
 deficiency of control elements
 control signal errors
 external effects
Type of problems Action

Mill vibration too high  reduce feed supply if differential pressure is high
 increase feed supply if differential pressure is low
 check water injection
 reduce grinding pressure
 lift rollers at excessive vibration
Mill output too low  check grinding pressure
 check differential pressure
 product fineness very fine
 coarser raw material
 grindability of raw material changed
 raw material too wet
 table and roller segments are worn
Mill product too coarse  increase speed of separator rotor
 check seiving of samples
Mill product too fine  decrease speed of separator rotor
 increase feed supply
Type of problems
Mill outlet temperature too high
Mill outlet temperature too low
Grinding pressure decreases
Sealing air pressure minimum
Action
 hot air amount too high
 hot gas temperature higher than normal
 adjust hot gas damper
 decrease oil for heat generator
 open cold air damper
 increase water injection
 raw material moisture increased
 increase hot air amount
 adjust hot gas damper
 adjust mill fan damper
 increase oil for heat generator
 close cold air damper if open
 decrease water injection
 check hydraulic system, piping is leaking
 oil pump fault
 oil level in tank for hydraulic minimum
 oil temperature in hydraulic minimum
 malfunction of valves
 filter blocked
 check electrical equipment
Type of problems
Starting the without grinding layer
Action
 fill mill with material before start
 use automatic program for mill filing
 the filling must be done manually by
starting transport devices in correct
sequence
 fill in 300 to 500 kg of material
  Calculation of the capacity of the mill

Generally speaking the production capacity refers to grinding capacity

and drying capacity of grinding mill
The material grind ability will affect the grinding capacity, the roller
pressure and the type of grinding mill
G = K1 * D2.5
where G is the capacity of the mill
K1 is the coefficient which is relevant to the type of roller mill, the
selected and used pressure, the performance of grinded material.
Different specification of roller mill so the K1 is different.
K1 of Loesche Mill series roller mill is 9.6 and for Atox Mill is 7 and for
MPS Mills is 6.6
D is the table diameter
Example for MPS 2800 mill with table dia 2.25m
G = 6.6 * 2.252.5 = 50.11875 ~ 50 tph
 List of components in simulated Hydraulic circuit
Description T.P NO. in Circuit Description T.P NO. in Circuit

Pump 2 Flow control 29.3

(adjustable)
Check valves 6.1, 6.2, 27a.3 Flow control (fixed) 18a

Relief valves 9.1, 9.2 & 26.3 Pilot operated check 25.3
valve (piloted to both
close & open)
2 X 2 normally open 11.1, 11.2, 18 & Rotary flow divider 20
solenoid valve 27.1

2 X 2 normally 27.2 & 28.3 Manifold containing 20a

closed solenoid valve of check valves, relief
valve & anti
cavitational valves
4 X 2 solenoid valve 17.1 & 17.2 N2 accumulator 24.5
(bladder type)
Meter out flow 19
control (adjustable)
 95
17.2 is on
& 11.1 B B B Pre ba
off, so oil 1 2 3 Tension r
from 20a 24.
24.
pump is 5
connected
to rod end W
320 EN W
6
C B A Tbar
D

26.3
of cyl

bar)
(315
C B A 120 Lpm
17.1 is on, so
25.3 pilot 20 B3 28.3
E2 E

)(
27.a3
opens & cap 27.1

25.3
27.
end cyl oil is 29.3
E1

2
drained to )( (26
tank A E Lpm) T
145
bar
19 )( 18 Y X
11. )( 18
1 17. a end oil
18 is on, so rod
17.
9.1 of cyl is blocked from

11.2 1 6.2
draining to tank
T
2
W

269 M
20 9.2
N2 pr = 0.5 X
bar 6.1 245 T Tension pr
W

PPump offbar
P = 5.5 kw (P1)
n = 1500 rpm After 5 sec pump
pump flow = 10 2 if set pt = 145 bar is Re-starts for Roller
Lpm reached lifting
 17.2 off, 95
27.1 & B B B Lift - ba
27.2 on.
1 2 3 r
So pump
oil flows to
20a ph-1
24.
24.
60 5
EN W
cyl cap end
by-passing
W
320
bar 6
20 (Rotary
C B A Tbar

26.3
D

bar)
(315
flow
divider) C B A 120 Lpm
17.1 off. So
25.3 (check 20 B3 28.3
E2 E

)(
valve) is

27.a3
27.1

25.3
pilot closed

27.
to stop cap 29.3
E1

2
end oil from )( (26
flowing to
tank.
A E Lpm) T
145
bar
19 )( 18 Y X
11. )( 18
1 17. a
17.
9.1
T 11.2 1 6.2
2
W

269 M
20 9.2
bar 6.1 245
Pump off after lift
T pr (P3) reaches
W

Cyl rod end oil is

P 17.2 offbar
blocked from 60 bar
flowing to tank as
11.1 & 18 are on. 2 for Lift
 27.1 & 27.2
95
are off. So B B B Lift - ba
pump oil
1 2 3 r
flows to cap
end cyl via
20a ph-2
ph-1
24.
24.
(170bar)
(60 160
60 5
20 (rotary
flow divider) W
320
mm) bar bar EN W
6
C B A Tbar

26.3
D

bar)
(315
C B A 120 Lpm
17.2 off for
Lift 20 B3 28.3
Equal amount E2 E

)(
27.a3
of oil supplied 27.1

25.3
27.
to all 3 29.3
E1

2
cylinder by
)( (26
rotary flow
divider (20)
A E Lpm) T
145
bar
19 )( 18 Y X
11. )(18
1 17. a
11.1 & 18 on. so rod end 17.
9.1
11.2 1 6.2
oil is blocked from
T draining to tank

2
W

269 M
20 9.2
bar 6.1 245 T
W

17.1 is off. So

P Pump bar
check valve25.3 is
piloted to close to
block cap end oil 2 off after 170 mm
flow to tank is lift
 95
Check valve
B B B Lift - ba
25.3 is Cylinder
piloted to 1 2 3 r
close block 20a ph-2
ph-1
Levellin
24.
24.
ing cyl cap (170
(60
g bar) 160
60 5
end oil from
drain ing to W
320
mm) bar bar EN W
6
C B A Tbar

26.3
D
tank.

bar)
(315
C B A 120 Lpm
11.1 & 18 are
on 20 B3 28.3
E2 E

)(
27.a3
preventing
27.1

25.3
27.
flow of oil
29.3
from rod end E1

2
)( (26
cyl to tank A E Lpm) T
145
bar
19 )( 18 Y X
11. )( 18
1 17. a
17.
9.1
T 11.2 1 6.2
2
W

269 M
20 9.2
bar
If 28.3 is on
6.1 245 T
momentarily cap
W

Pressure @ cap end cyl oil is

end cyl remains
intact by check 2 P Pump-2bar
is Level diff < 20
drained to tank via
29.1 & cyl lowers to
valve (6.1) mm level.
off
 when
95
lowering cyl, B B B Cylinder
Lift - ba
cap end oil
1 2 3 r
is not
drained to
20a ph-2
Lowerin
ph-1
24.
24.
(170bar)
g
(60 160
40
60bar 5
EN W
tank via 25.3
as cyl
W
320
mm) bar bar
6
lowering
C B A Tbar

26.3
speed
D

bar)
(315
cannot be C B A 120 Lpm
controlled.
Cyl is lowered
by draining oil 20 B3 28.3
E2 E

)(
27.a3
@ cap end to
27.1

25.3
27.
tank via (20a),
(20), (27.1), 29.3
E1

2
)( (26
(19) flow
control&
A E Lpm) T
(17.2). 145
bar
19 )( 18 Y X
11. )( 18
1 17. a
17.
9.1
T 11.2 1 6.2
2
W

269 M
20 9.2 Next operation
bar 6.1 245 tension mode starts
T
W

Item (19) is a when cap end pr <

P Pump-2 isbarCheck valve 25.3 is

variable orifice to 10 bar so that no
control lower ing
speed of roller/ 2 off pilot closed.
counter pressure is
there when grinding
cylinder
 95
Set is on
17.2
& 11.1 = B B B MILL in
Increasin ba
Set
point
off, so oil 1 2 3 Operatio
g r
180 bar
point
from = 20a 24.
24.
Pump
180 bar
pump off
is n
Tension
8 5
if tension
connected
pr = end
to rod W
320 Pr bar EN W
6
C B A Tbar
D

26.3
180
of cylbar

bar)
(315
C B A 120 Lpm
(11.1),
Reduce
17.1
25.3
is on, so
pilot 20 B3 28.3
(11.2), E2 E

)(
27.a3
Tensio
opens
(27.1),& cap 27.1

25.3
27.
end cyl oil is
(27.2), 29.3
n E1

2
)(
drained to (26
(28.3) are
tank
Pressur A 180
OFF 185 E Lpm) T
e bar
bar 18 Y X
19 )(
11. )( 18
1 17. aend oil
Orifice (17.1),
18 is on, so rod
(18A) 17.
9.1 of cyl is blocked from
(17.2)
tank& (18)
11.2
regulates to oil
T
draining
flowingare
to ON
tank 1 6.2
2
W

269 20 M 9.2
IfN2Tension
pr = 0.5PrX=
bar
Pump
6.1 245 T Tension
set pt +pr5 = 185
W

Restarts if
P = 5.5 kw
tension
n = 1500 prrpm=
P bar (P1)
bar, (18)
Pump On asis OFF
set
pumppt flow
– 5 =bar
10 2 Pump off if set pt = 180 bar is momentarily
counter to
Pr is less
Lpm reached reduce
than pressure
10 bar