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Hajo Reiners
Agenda
1. Cement Grinding with Loesche Vertical Roller Mills 2. Other Systems for Cement Grinding 3. Former Concerns regarding VRM Cement Qualities 4. The Proven Reality 5. Short Conclusion
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Worldwide nearly 240 mills with the 2+2 / 3+3 system About 170 of them are in operation
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kWh/t
5000
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kWh/t
6000
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~ 60% of Mills for more than 1 product ~ 40% of Mills for more than 3 products
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Agenda
1. Cement Grinding with Loesche Vertical Roller Mills 2. Other Systems for Cement Grinding 3. Former Concerns regarding VRM Cement Qualities 4. The Proven Reality 5. Short Conclusion
2012
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Characteristics
Comminution by: Retention time (min): Comminutions before separation: Circulation factor: Wear rate (g/t):
Ball mill
(closed circuit)
Vertical roller mill pressure and shear forces <1 1-3 6-10 3-6
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Agenda
1. Cement Grinding with Loesche Vertical Roller Mills 2. Other Systems for Cement Grinding 3. Former Concerns regarding VRM Cement Qualities 4. The Proven Reality 5. Short Conclusion
2012
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due to
Steeper Particle Size Distribution (Slope n) Different Particle Shape Lower Gypsum Dehydration
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Agenda
1. Cement Grinding with Loesche Vertical Roller Mills 2. Other Systems for Cement Grinding 3. Former Concerns regarding VRM Cement Qualities 4. The Proven Reality 5. Short Conclusion
2012
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slope n = tan
More fine material (Over Ground) in the cement produced by Ball Mill system due to high number of impacts and mill inefficiency
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Grinding Pressure Dam Ring Height Mill Airflow Classifier Rotor Speed Table Speed for very high Blaine cements
Dam Ring
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Steep ==>
<== Shallow
Slope n
Same Slope n Same Water Demand A PSD as needed can be easily produced within a VRM System
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Not True!
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More spherical shaped particles in cements produced with ball mill systems
compared to
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The maximum particle size in cements is usually between 45 and 55 m depending upon the fineness of the final product and the slope n. 95% of all cement particles are usually below 20 and 45 m depending upon the fineness of the final product and the slope n.
52 m
Circularity of cement particles are similar for cements produced in a ball mill or VRM system. The only notable differences appear at higher particle sizes >50 m who have no influence on the strength development!
Circularity
Not True!
Not True!
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Gypsum Dehydration in Ball Mill Systems is different compared to VRM systems. This is due to Higher mill outlet temperature Longer residence time in mill system Different gas humidity (negative factor)
resulting in
(Plaster)
(Gypsum)
(Anhydrite)
Better drying of the gypsum, hence conversion into a higher content of reactive plaster, necessary as a setting regulator
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Increase mill exit temperature Increase gypsum content (0,5 1%) Add a small amount of plaster Add a small amount of natural Anhydrite Decrease humidity of mill gas flow
resulting in
Same setting behaviour, i.e. same Setting Time and Compressive Strength Normal optimisation process by works quality department
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Technical Properties
Mill Separator Fineness acc. to Blaine Standard consistency Setting time, begin Setting time, end Compressive strength (W/C 0,5) [2d] [7d] [28d] MPa MPa MPa 29,8 38,9 57,1 29,9 38,6 54,1 ./. ./. cm/g % min min VRM LSKS 4258 28 130 175 BM O-SEPA 4095 28,5 125 175
Not True!
Not True!
2012
Agenda
1. Cement Grinding with Loesche Vertical Roller Mills 2. Other Systems for Cement Grinding 3. Former Concerns regarding VRM Cement Qualities 4. The Proven Reality 5. Short Conclusion
2012
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Short Conclusion
With Loesche Vertical Roller Mills Cement can be produced with the same Particle Size Distribution, Particle Shapes and Setting Behaviour as Cements produced in ball mill systems! Therefore, cements produced with the Loesche Vertical Roller Mill will totally meet the required local market demands, regarding Water Demand, Setting Times and Compressive Strength. BUT much more Energy Efficient, Cost Effective and Flexible
2012
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