VRM Operations

VARTICAL ROLLER MILL
CONTROL
Ranjeet singh
GET - PROCESS
GMAIL :- ranjsingh8349@gmail.com
KJS CEMENT (I) LIMITED MAIHAR SATNA (MP)
MILL CIRCUIT
VRM CONTROL PARAMETERS
 GRINDING PRESSURE
 COUNTER PRESSURE
 FEED RATE
 GAS FLOW THROUGH MILL (NORMALLY
CONST , INDICATED BY FAN MOTOR KW)
 WATER SPRAY
 SEPARATOR SPEED
GRINDING PRESSURE
IMPACT OF INCREASED GRINDING PRESSURE
• HIGHER POWER ABSORPTION ON MILL MOTOR

• LOWER GRINDING CUSHION
• LOWER DIFFERENTIAL PRESSURE ACROSS THE
NOZZLE RING
• INCREASED VIBRATION LEVEL IF THE GRINDING
CUSHION IS TOO LOW
TOTAL FEED TO MILL
IMPACT OF INCREASE IN FEED RATE TO MILL
• A THICKER GRINDING CUSHION

• INCREASED DIFFERENTIAL PRESSURE ACROSS THE
NOZZLE RING AND GRINDING TABLE
• A LOWER DISCHARGE TEMP FROM MILL
• A HIGHER SIEVE RESIDUE FOR THR RAW MEAL
PRODUCED
WATER SUPPLY TO MILL
FOR AN INCREASE IN WATER VOLUME TO THE MILL
• LOWER DISCHARGE TEMPERATURE FROM MILL

• THICKER GRINDING CUSHION
• LOWER VIBRATION LEVEL DUE TO THICKER GRINDING
CUSHION
• A DECREASE IN DIFFERENTIAL PRESSURE
IMMEDIATELY AFTER THE INCREASE IN WATER
VOLUME SINCE THERE WILL BE A LARGER
CONCENTRATION OF MATERIAL ON THE GRINDING
TABLE
DAMPER SETTING / VELOCITY FOR
PRECIPITATOR FAN
INCREASE IN DAMPER SETTING/VELOCITY OF FAN
• INCREASED POWER ABSORPTION ON THE

PRECIPITATOR FAN
• AN INCREASE IN THE UNDER PRESSURE AHEAD OF
THE MILL
• AN INCREASE IN THE DIFFERENTIAL PRESSURE
ACROSS NOZZLE RING AND GRINDING TABLE
• HIGHER SIEVE RESIDUE FOR THR RAW MEAL
PRODUCED
CIRCULATING AIR DAMPER
IF DAMPER IS OPENED
• THE UNDER-PRESSURE AT THE MILL OUTLET WILL

DROP
• POWER ABSORPTION OF THE FAN WILL BE
INCREASED
• TEMPERATURE AHEAD OF MILL WILL DROP
• DIFFERENTIAL PRESSURE ACROSS NOZZLE RING
AND GRINDING TABLE WILL INCREASE
• HIGHER SIEVE RESIDUE FOR THR PRODUCED RAW
MEAL
SEPARATOR VANES
IF VANES ARE CLOSED
• LOWER SIEVE RESIDUE FOR THE RAW MEAL

• HIGHER DIFFERENTIAL PRESSURE ACROSS NOZZLE
RING AND GRINDING TABLE DUE TO AN INCREASE
IN THE INTERNAL CIRCULATION OF THE MATERIAL
COLD AIR DAMPER
IF DAMPER IS OPENED
• LOWER TEMPERATURE IN MILL INLET AND OUTLET
HOWEVER DURING NORMAL OPERATION , THE

COLD AIR FLAP WILL NORMALLY BE FULLY CLOSED
VRM CONTROL LOOPS
 MAINTENANCE OF CONSTANT DIFFERENTIAL

PRESSURE ACROSS GRINDING TABLE AND NOZZLE
RING IN THE MILL . THE DIFFERENTIAL PRESSURE
REGULATES THE FEED TO THE MILL
 MAINTENANCE OF CONSTANT TEMPERATURE

AFTER THE MILL . THE TEMPERATURE REGULATES
THE RATE OF WATER INJECTION TO THE MILL
VRM CONTROL LOOPS
 MAINTENANCE OF CONSTANT AIR STREAM

THROUGH THE MILL . CIRCULATING AIR DAMPER
MAINTAINS A CONSTANT LOAD ON THE
PRECIPITATOR FAN
 MAINTENANCE OF CONSTANT UNDER-

PRESSURE BETWEEN THE KILN EXHAUST GAS FAN
AND THE MILL . VELOCITY / DAMPER OF THE
PRECIPITATOR FAN MAINTAINS A CONSTANT
UNDER-PRESSURE AT THIS POINT
VRM CONTROL
CONTROL PARAMETERS
• KEEP GAS FLOW FROM KILN CONSTANT

( KEEP DRAUGHT AT PH FAN OUTLET CONSTANT BY
CONTROLLING MILL FAN)
VRM CONTROL
OPERATING CONDITIONS
• DIFFERENTIAL PRESSURE
• TEMPERATURE AT MILL OUTLET (90-100 0 C)
• VIBRATION
• MILL MOTOR KW
• SEPERATOR RPM
• PRODUCT RESIDUES (15-18 % ON 90 µ )
VIBRATIONS IN ROLLER MILL
MONITORED BY MEANS OF A VIBROMETER PLACED

ON THE GEAR BOX FOUNDATION
VIBRATION ALARMS
ACOUSTIC ALARM AFTER 5 SEC AT MORE THAN 3

mm/s
MILL STOPPAGE AFTER 5 SEC AT MORE THAN 4
mm/s
INSTANTANEOUS STOPPAGE AT MORE THAN 8
mm/s
• IF POWER CONSUMPTION IS MORE
• CHECK BED THICKNESS
• REDUCE WATER INJECTION
• MEASURE AIR QUANTITY
• IF MATERIAL SPLILLAGE IS MORE

• CHECK AIR VELOCITY ( IE. NOT SUFFICIENT
TO LIFT THE MATERIAL)
• IT IS ADVANTAGEOUS TO REDUCE THE AREA OF
NOZZLE RING BEHIND THE ROLLERS TO HAVE
MORE VELOCITY AND EASY FLOW OF MATERIAL
• GRINDING PRESSURE TO BE LOW AS FAR AS

POSSIBLE TO REDUCE POWER CONSUMPTION AND
MECHANICAL WEAR ON ROLLER AND TABLE
• AVOID FOREIGN MATERIAL IN MILL

LOWER OUTPUT FROM MILL PROBABLE
REASONS
• AIR FLOW NOT OPTIMUM
• COARSE FEED MATERIAL
• GRINDING PRESSURE LOWER THAN NORMAL
• UNEVEN WEAR OF PARTS
• INSUFFICIENT DRYING CAPACITY
• POOR EFFICIENCY OF CLASSIFIER
• FEEDERS OUT OF CALIBRATION
• DIFFERENTIAL PRESSURE TOO LOW
• GRINIDNG BED TOO THICK
• SIEVE RESIDUE MAY BE LOWER THAN THAT FROM
LAB RESULTS
GRINDING BED THICKNESS TOO LOW
HEIGHT OF DAM RING LOWER
IRREGULAR FEED RATE
NON UNIFORM FEED QUALITY
FAILURE OF WATER INJECTION
TABLE SPEED TOO HIGH
POOR EFFICIENCY OF SEPARATORS
GRINDING BED THICKNESS TOO HIGH
TOO MUCH FEED
LOWER GRINDING PRESSURE
INSUFFICIENT DRYING CAPACITY
TOO LOW TABLE SPEED
INCREASE IN HEIGHT OF NOZZLE RING
WILL RESULT IN
• AN INCREASE IN THE NOZZLE RING AREA
• A REDUCTION IN THE AIR VELOCITY IN THE NOZZLE
RING ON THE SAME FAN LOAD
• REDUCED DIFFERENTIAL PRESSURE ACROSS
• RISK OF SUBSTANTIAL AMOUNT MATERIAL FALL
THROUGH ON THE NOZZLE RING
INCREASE IN HEIGHT OF DAM RING WILL
RESULT IN
• A REDUCTION IN THE NOZZLE RING AREA

• AN INCREASE IN THE AIR VELOCITY ACROSS THE
NOZZLE RING ON THE SAME FAN LOAD
• INCREASED DIFFERENTIAL PRESSURE ACROSS
• A THICKER GRINDING CUSHION
HIGH VIBRATIONS LEVELS
PROBABLE REASONS
• WEAK FOUNDATION
• IRREGULAR FEED RATE
• NON-UNIFORM FEED QUALITY
• TABLE SPEED TOO HIGH OR TOO LOW
• UNEVEN WEAR ON TABLE OR ROLLER
• TOO LOW OR TOO HIGH BED THICKNESS
• INSUFFICIENT DRYING CPACITY
• GRINDING PRESSURE NOT OPTIMUM
• MISALIGNMENT OF GEAR BOX DRIVE
• MALFUNCTIONING OF VIBROMETER
VERTICAL ROLLER MILL - PROCESS
CONTROL
• Feed control - depending on diff . pr
• Grinding control - diff. pr and bed thickness
• Outlet temp. control - water injection
• Vibration control - maintaing uniform bed
thickness
• Residue control - adjusting separator louvre
damper and centre pipe
• Inlet gas temp. control - adjusting fresh air
damper
• Inlet gas volume control - adjusting fan speed
or recirculation damper
• Arresting false air inﬁltration
THANK YOU

VRM Operations

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VRM Operations

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VARTICAL ROLLER MILL

IMPACT OF INCREASED GRINDING PRESSURE

• HIGHER POWER ABSORPTION ON MILL MOTOR

IMPACT OF INCREASE IN FEED RATE TO MILL

• A THICKER GRINDING CUSHION

FOR AN INCREASE IN WATER VOLUME TO THE MILL

• LOWER DISCHARGE TEMPERATURE FROM MILL

• INCREASED POWER ABSORPTION ON THE

• THE UNDER-PRESSURE AT THE MILL OUTLET WILL

IF VANES ARE CLOSED

• LOWER SIEVE RESIDUE FOR THE RAW MEAL

• LOWER TEMPERATURE IN MILL INLET AND OUTLET

HOWEVER DURING NORMAL OPERATION , THE

 MAINTENANCE OF CONSTANT DIFFERENTIAL

 MAINTENANCE OF CONSTANT TEMPERATURE

 MAINTENANCE OF CONSTANT AIR STREAM

 MAINTENANCE OF CONSTANT UNDER-

• KEEP GAS FLOW FROM KILN CONSTANT

MONITORED BY MEANS OF A VIBROMETER PLACED

ACOUSTIC ALARM AFTER 5 SEC AT MORE THAN 3

• IF MATERIAL SPLILLAGE IS MORE

• GRINDING PRESSURE TO BE LOW AS FAR AS

• AVOID FOREIGN MATERIAL IN MILL

• A REDUCTION IN THE NOZZLE RING AREA

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