Vertical Mills used for
Pre-grinding of clinker
Finish grinding of
Coal
Raw materials
Cement
Slag
Roller Mill:
Definition:
A roller mill is characterised in that a bed of loosely
packed material is compacted and thereby ground
between two rolling surfaces pressed against each
other, and that at least one of the rolling surfaces is a
roller.
The gap between the rolling surfaces is not fixed but
varies with change in the material properties.
Evaluation and calculations are
based on
Theoretical considerations
Basic data obtained from test work
mainly with roller presses
Operational data:
Table speed (rpm)
Grinding press. (bar) or (kN/m2)
Product fineness
(sieve residue, Blaine, etc.)
Capacity (tph)
Mill Motor (kW)/Friction factor (-)
Grinding bed thickness (mm)
Vibration level (mm/s)
Process inside the roller mill
Evaluation of:
Max pressure pmax (MPa)
Max grinding bed thickness (mm)
Mass flow through roller gap (tph)
Spec. Power per roller pass (kWh/t)
Circulation factor for roller (-)
Friction factor (-)
Retention time in mill (sec)
Flow of material on the table
Slip between roller and table
Wear
Roller Press, basic considerations
L: length of
compaction zone
R: roller radius
W: roller width
T: roller force
: nip angle [radian]
: gripping angle
[radian]
small, therefore tg
1 1
= 1 + 2 = L +
R1 R2
Illustration of the gripping angle and the nip angle .
Specific grinding pressure kT
R: roller radius
D: roller diameter
W: roller width
T: roller force
T
kT = (kN/m )
2
W D1
Roller press
Vertical mill Ring roller mill
Formulas and general characteristics
of vertical mills.
Vertical Roller Mill
DO Table diameter [m]
Friction coefficient [radian]
T Roller pressure per roller [kN]
kT Spec. roller pressure [kN/m2]
DR Roller diameter [m]
W Roller width [m]
DM Mean diameter of track [m]
n Table speed [rpm]
v Velocity at DM [m/s]
i Number of rollers [-]
N Power [kW]
P Production [t/h]
Vertical and horizontal components of roller load
Vertical Roller Mill
DO Table diameter [m]
Friction coefficient [radian]
T Roller pressure per roller [kN]
kT Spec. roller pressure [kN/m2]
DR Roller diameter [m]
W Roller width [m]
DM Mean diameter of track [m]
n Table speed [rpm]
v Velocity at DM [m/s]
i Number of rollers [-]
N Power [kW]
P Production [t/h]
N = i T v = i k T D R W D M n 60
For the standard Atox mills i=3, DR=0.6*D0, W=0.2*D0,
DM=0.8*D0 and n=56*D00.5, which inserted gives:
N = 0.844 k T D O2.5
Friction coefficient
Cement raw material 0.09 +/- 0.02
Coal 0.10 +/- 0.02
Cement 0.06 +/- 0.01
Calculations based on identical rolling point
Material movement on the table
Radial and tangential velocity influenced by
Friction coefficient of material (mat. type, moisture content,
granulometry, aeration level)
Surface condition of grinding elements
Shape of grinding table (flat, spherical, dam ring height)
Table speed
Material movement on the flat table
Material tracks, absolute movements
Material movement on the flat table
Material tracks relative to table
Material thickness and flow on the flat grinding table.
Material layer in percent of Net layer fed to the rollers
table diameter
(tangential speed for material
lower than table speed)
Material layer on curved grinding surface.
Grinding bed thickness limited by vibrations
Optimisation of mill operation.
Increase of friction coefficient of material: Inject water on table
Higher power uptake
Lower vibration level
Increase thickness of material: Increase height of dam ring
Higher power uptake
Lower vibration level
Decreased grinding efficiency
Increase thickness of material: Reduce table speed (to 80-100%)
Lower vibration level (for finer materials)
Increased friction factor but lower power uptake
Slip between roller and table
Determination of roller-table slip
Slip between roller and table
Polysius
Slip between roller and table
MPS RM
Slip between roller and table
Loesche ATOX
Wear profiles in an Atox Mill hard, dry material
Wear profile on roller segment
Centre
Max. wear Rolling point
Max. wear
Wear profile on table segment
Highest table Lowest table
speed speed
Slag grinding on OK mill
with typical wave
pattern from squeezed
out material
Clinker grinding. Smooth wear surface
