Vertical Roller Mill

Operation and
Optimization
 Used in Cement Industry
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
 Working Principle
 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.
 Working Principle
 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.
 Working Principle
 grinding force = roller weight + pressure(force)

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

 Common Types of VRM
 G. Pfeiffer
 Loesche
 FLS Atox
 Polysius
 Separator
 static type
 conventional type
 cage rotor type
 Separator control
 Vane adjustment
 Speed control
 Rotor seal affects efficiency
 Raw Material Characteristics
 Feed Size
 product fineness
 moisture content
 Grind ability
 abrasiveness
 Feed Size
 Ball mill maximum 5% + 25 mm
 VRM up to 150mm
 Product Fineness
 5 % to 25 % +90um
 1 % to 2 % +212um
 Moisture Content in Raw Materials
 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
 Operational Aspects
 material granulometry
 roller pressure
 Dam ring
 Louvre ring
 external circulation reducing gas flow

pressure lost over the mill

 Parameters to be observed
during operation
 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
 Additional parameters to be monitored

 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
 How the nozzle ring velocity
corresponds to reject rate
and pressure drop
 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
 Vertical Roller Mill for Finish
Grinding
 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
 VRM versus BALL MILL for cement
grinding
 VCM vs. RPCM
 Grinding Systems Comparisons
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
Nozzle Ring Velocity versus Material Rejects
and Pressure Drop

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%
 Air flow
 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
 Feed
 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
 Vibrations
 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
 Operation problems
 changes in feed material properties
 Equipment problems
 deficiency of control elements
 control signal errors
 external effects
 Problems Action
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 Action
Mill outlet temperature too high  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

Mill outlet temperature too low  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

Grinding pressure decreases  check hydraulic system, piping is leaking

 oil pump fault
 oil level in tank for hydraulic minimum
 oil temperature in hydraulic minimum
 malfunction of valves

Sealing air pressure minimum  filter blocked

 check electrical equipment
Type of problems Action
Starting the without grinding layer  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
 Vertical roller mill calculations
 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
VRM Hydraulic Operation
 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)
17.2 is on
95
& 11.1 off, B1 B2 B3 Pre ba
so oil Tension r
from 20a 24.
24.
pump is 5
connected
to rod end W bar
320 EN W
6

26.3
C B A T
D

bar)
(315
of cyl
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

2
drained to )( E1 (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
W

Tension pr
P = 5.5 kw T (P1)
1500 rpm
n=
2 PPump offbar
if set pt = 145 bar is
After 5 sec pump
Re-starts for Roller
pump flow = reached lifting
 17.2 off, 95
27.1 & B1 B2 B3 Lift - ba
27.2 on.
r
So pump
oil flows to
20a ph-1
24.
24.
cyl cap end 60 5
by-passing 320
W bar bar EN W
6

26.3
20 (Rotary
C B A T
D

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

)(
27.a3
valve) is
27.1

25.3
27.
pilot closed
to stop cap 29.3

2
end oil from
)( E1 (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
Pump off after lift
bar 6.1 245
W

pr (P3) reaches
Cyl rod end oil is
T 60 bar
P 17.2 offbar
blocked from
flowing to tank as
11.1 & 18 are on. 2 for Lift
 27.1 & 27.2 95
are off. So B1 B2 B3 Lift - ba
pump oil
ph-2 r
flows to cap
end cyl via
20a ph-1
24.
24.
20 (rotary (170bar)160
(60 60 5
flow divider) W bar
320
mm) bar bar EN W
6

26.3
C B A T
D

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

)(
27.a3
Equal amount
27.1

25.3
27.
of oil supplied
to all 3
29.3

2
cylinder by
)( E1 (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 oil is blocked from
T 11.2 draining to tank 1 6.2
2
W

269 M 20 9.2
bar 6.1 245
W

17.1 is off. So
check valve25.3 is T
piloted to close to
block cap end oil 2 P Pump bar
off after 170 mm
flow to tank
 95
Check valve
B1 B2 B3 Lift - ba
25.3 is Cylinder
piloted to
ph-2 r
close block 20a ph-1
24.
24.
ing cyl cap
(170bar)160
(60
Levellin 60 5
end oil from
drain ing to
320
W bar mm) bar
g bar EN W
6

26.3
tank. C B A T
D

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

2
from rod end
)( E1 (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 If 28.3 is on

bar 6.1 245 momentarily cap
W

Pressure @ cap T end cyl oil is

end cyl remains
intact by check 2 P Pump-2 bar
is Level diff < 20
drained to tank via
29.1 & cyl lowers to
valve (6.1) level.
off mm
 when
95
lowering cyl, B1 B2 B3 Lift
Cylinder
- ba
cap end oil
ph-2 r
is not
drained to
20a ph-1
Lowerin
24.
24.
tank via 25.3 (170bar)40
(60
g 160
60bar 5
as cyl 320
W bar mm) bar bar EN W
6

26.3
lowering
C B A T
D

bar)
(315
speed
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),
29.3

2
(20), (27.1),
(19) flow )( E1 (26
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
W

Item (19) is a
T when cap end pr <

P Pump-2 isbarCheck
variable orifice to 10 bar so that no
valve 25.3 is
control lower ing
speed of roller/ 2 off pilot closed.
counter pressure is
there when grinding
 17.2
95
Set is on
& 11.1 off, B1 B2 B3 MILL in
Increasin ba
Set
point =
so oil 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 bar
320 Pr bar EN W
6

26.3
C B A T
D

bar)
(315
of cylbar
180
C B A 120 Lpm
(11.1),
17.1 is on, so
Reduce
25.3 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 29.3
(27.2),
n

2
)(
drained to
(28.3) are E1 (26
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
regulates (17.2)
tank& (18)
tooil
11.2 1 6.2
draining
T flowingare to ON
tank
2
W

269 20
M 9.2
Pump IfN2Tension
pr = 0.5PrX=
bar 6.1 245
W

Tension
set pt + pr
5 = 185
Restarts if
P = 5.5 kw
P T (P1)
tension prn == bar bar, (18)
Pump is OFF
On as
set ptrpm
1500 – 5 bar 2 Pump off if set pt = 180 bar is momentarily
counter to
Pr is less
pump flow = reached reduce
than pressure
10 bar