Beruflich Dokumente
Kultur Dokumente
Zysk,
Loesche GmbH, Duesseldorf, Germany
SUMMARY ZUSAMMENFASSUNG
Cement production typically requires the grinding of three Im Zementherstellungsprozess mssen gewhnlich drei
separate types of material during the process: the raw ma- unterschiedliche Materialien fein gemahlen werden: vor dem
terials and coal before the kiln, and the final cement product Zementdrehofen die Zementrohmaterialien sowie die als
once firing is complete and the clinker cooled. Looking back Brennstoff verwendete Kohle und nach dem Klinkerkhler
on a century or more, ball mill systems were used for all der gebrannte Klinker zur Herstellung des Endprodukts
three grinding stages, but the development of more energy- Zement. Vor mehr als 100 Jahren wurden zur technischen
efficient vertical roller mills (VRMs) led to their replacement. Realisierung dieser drei Mahlprozesse fast ausschlielich nur
Initially, this focused on grinding coal and the cement raw Kugelmhlen eingesetzt, meist im Kreislauf mit einem Sich-
materials, with the adoption of vertical roller mills for cement ter, bis diese Mhlen durch die Entwicklung der energieeffi-
product grinding with its finer grinding requirements com- zienteren Vertikal-Wlzmhlen immer mehr verdrngt wur-
ing more recently, in the late 1990s. The main reason for den. Zuerst vollzog sich dieser Wandel bei der Kohlemahlung
the delay in uptake of VRM technology for cement grinding und der Rohmehlerzeugung, bis in den spten 1990er Jahren
was the concerns of producers that their product qualities die Vertikal-Wlzmhle auch bei der Zementmahlung mit
would not meet market requirements, specifically in three ihren spezifisch hohen Anforderungen an die Mahlfeinheit
key areas: water demand, strength development and set- den Einzug hielt. Der Hauptgrund fr die spte Akzeptanz
ting times. Over the past 15 years, however, it could be der Vertikal-Wlzmhle bei der Zementmahlung war die ver-
demonstrated that these concerns are unfounded, and that breitete Skepsis bei den Zementherstellern, dass die Qualitt
the quality of cement obtained from VRM grinding is as des in der Vertikal-Wlzmhle hergestellten Finalprodukts
good as, or in some cases better than, that produced in a Zement den Marktanforderungen nicht entsprechen knnte,
ball mill. In consequence, most of the worlds major cement speziell was die Anforderungen an den Wasserbedarf, die
producers now use vertical roller mills for cement grinding Festigkeitsentwicklung und die Verarbeitungszeiten betrifft.
with no hesitation.3 ber die letzten 15 Jahre konnte jedoch der Nachweis
erbracht werden, dass die bisherigen Bedenken unbegrndet
waren und der in einer Vertikal-Wlzmhle erzeugte Zement
hinsichtlich seiner Qualitt einem Kugelmhlenzement nicht
nachsteht, fallweise sogar besser sein kann. Im Ergebnis die-
ser Entwicklung entscheiden sich deshalb heute die meisten
Zementhersteller weltweit ohne jegliche Bedenken bei der
PROCESSING
90 system being lifted up by the rotating shell, then dropped back onto
80
the charge and other balls. There is some attrition as well.
70
60 Loesche
50 VRM system There is also a major difference in terms of the average resi-
40 dence time the time the material particles remain in the mill
30 system before they leave the classifier as product. Including
20
both grinding in the mill body and a circulation factor, the res-
3 500 3 000
4 000 4 500 5 000
idence time for a VRM is less than one minute, while parti-
Fineness acc. to Blaine [cm2/g]
cles can remain within a ball mill system for 20 to 30 min-
Figure 1: Specific power consumption of ball mill system v/s vertical
utes. Individual cement particles will be ground from one to
roller mill system for OPC grinding three times in a VRM before being offered to the classifier,
whereas repeat grinding in a ball mill is virtually uncounta-
Fundamentally, ball mills use proportionately more energy ble because of the grinding mechanism. Finally, while a ball
to produce a finer ground product than do VRMs, and while mill will have a recirculation factor of 2 to 3, this increases
the energy consumption in a VRM obviously does increase between 6 to 20 for a VRM, depending on the pressure
with product fineness, it does so much less rapidly. Indeed, height, the grinding tools configuration, the grindability of the
while the difference in energy efficiency is significant when material and the required product fineness. The differences
a VRM is used for grinding OPC, the energy benefit is even in all of these parameters are shown in Table 1.
greater in the case of blastfurnace slag which is hard to grind,
as can be seen in Fig. 2. 3 Outlining the issues
Having demonstrated the energy advantage of the VRM The first modern Loesche Mill for cement and slag grinding,
concept over ball milling, the remainder of this paper a mill with the designation LM 46.2+2, was sold to Taiwans PROCESSING
focuses on various aspects of cement quality, with the aim Lucky Cement Corp. in 1993 and commissioned in 1994, for
of putting to rest once and for all the outdated, disproven grinding cement at its Pu Shin plant. While producers were
ideas that cements produced in a VRM differ markedly from initially concerned that the quality of the cement produced
those produced in traditional ball mill systems. The arti-
cle looks first at the various grinding systems that are avail-
able for cement producers today, then takes each of the pur- 160
ported product quality issues in turn to show that these are Ball mill
140
Power consumption [kWh/t]
system
neither justified nor valid.
120
Product Product
Figure 3: Alternative flow sheets using vertical roller mills and ball mills
would not meet their clients specifications, results from the Fig. 4 shows that in this case, n for the VRM cement sys-
first installations showed that the cement qualities are indeed tem is steeper than for a cement produced in a ball mill. This
acceptable to the market. From the late 1990s, the majority is caused by the higher proportion of fine (over-ground) ma-
of cement producers changed their preference towards the terial present in the ball mill cement, which in turn reflects
vertical roller mill system. the greater number of impacts and the inherent inefficiency
of ball mill grinding.
Table 1: Comparative performance parameters for the two systems
when used for grinding cement In more general terms, a typical particle size distribution
Ball mill for a ball mill system in closed-circuit operation with a high-
Characteristics Vertical roller mill
(closed circuit) efficiency, third-generation classifier would be between 0.75
Pressure and and 0.98. The equivalent would be between 0.82 and 1.05
Comminution by Impact and attrition in a Loesche vertical roller mill system. These ranges may
shear forces
differ when different types of laser sizers are used.
Residence time [min] 20 to 30 <1
Crushings before The area of concern in the past was that the steeper particle
1 to 3
separation size distribution for VRM cements would lead, for example,
Circulation factor 2 to 3 6 to 20 to their having higher water demand and lower early strength
development. This could, of course, generate problems,
Wear rate [g/t] ~ 50 3 to 6
especially in precast concrete manufacturing with its sophis-
ticated production processes regarding cycle and stripping
The producers concerns were centred on three specific times.
areas: that cement produced in a VRM would have a higher
water demand when mixed to a workable paste; that the The question then has to be asked as to the reason for the
setting times would differ drastically; and that the compres- different slopes in the particle size distribution diagrams.
sive strength would be lower when compared to the same Firstly, and as explained above, the different grinding behav-
cement produced in a ball mill system. The supposed reasons iour of the vertical roller and ball mill systems means that
for these concerns were, respectively: a steeper particle size particles remain in a ball mill system for about 20 to 30 min-
distribution, the different particle shape produced by a VRM, utes before they leave the classifier as product. They are
PROCESSING
and a lower gypsum dehydration. In point of fact, operating impacted repeatedly during that time, with the result that
experiences since then have shown conclusively that none of some particles are ground more than necessary. By con-
these concerns is justified, and that the cements produced by trast, the limited amount of grinding for each particle in the
grinding in a VRM meet market requirements in all respects. VRM system before classification avoids any unnecessary
over-grinding.
4 Particle size distribution
The particle size distribution of a cement is
usually plotted on the well known RRSB- VRM
System
Sum of passing Q (x) [mass %]
diagram. Fig. 4 shows size distribution Slope n = tan (Slope n: 0.82 to 1.05)
curves for cements produced by grinding
in VRMs and in ball mills. The inclination
of each curve, the slope n, is measured
at the positioning parameter that repre-
Position parameter
sents the particle diameter at which the Ball mill
system
residue, in terms of mass, is 36.8 %. A Particle size [m] (Slope n: 0.70 to 0.98)
higher n-value produces a steeper curve,
whereas the lower the slope, the more
fine and over-ground particles are in the
finished product at a constant Blaine value,
2
measured in cm /g. Figure 4: Different particle size distributions
coming out of a ball mill are always much rounder then those
lower lower higher higher coming out of a VRM, which are more shallow and elongated.
Slope n
Grinding Height of Mill air Classifier This again, together with fewer fine particles, would result in
pressure dam ring flow speed increased water demand for the cement paste.
higher higher lower lower
<== Shallow
If a similar product to one from an existing ball mill system is Fig. 8 illustrates the particle size distribution of a cement
2
needed, however, the VRM can be adjusted to achieve this. with a product fineness of about 4 100 g/cm acc. to Blaine.
As shown in Fig. 5, adjustments can be made to the grind- This shows that the size of the smallest particle is about
ing pressure, the dam ring height, the mill airflow, the clas- 0.1 m and the size of the largest particle is about 52 m
sifier rotor speed and, for cements with a very high Blaine for this particular cement. In general, while a wide variety of
value, the table speed. Fig. 6 shows the effects on the cements are ground to different finenesses, the largest par-
slope of the particle size distribution curve by adjusting each ticles are usually between 45 and 55 m.
of these parameters.
In addition, 95 % of all the cement particles are below 45 m
A higher grinding pressure will result in more intense grind- in size, again depending on the final product fineness and
ing with the development of more fine material, and hence the slope of the particle size distribution curve.
a shallower particle size distribution. The higher the dam
ring, the longer the material remains on the grinding table, Testwork undertaken by the VDZ in its role as Germanys
and the more it is ground in one cycle. This again results in Cement Research Institute compared the particle shapes PROCESSING
the generation of more fines, and a shallower particle size produced in different types of milling systems. Fig. 9 shows
distribution. In addition, the airflow and the classifier set- a plot of the shapes of cement particles from high-pressure
tings can be adjusted in order to produce the desired prod- grinding rolls, ball mills and vertical roller mills, with the par-
uct characteristics. ticle size being shown on the x-axis and the circularity on
the y-axis [2].
Residue [mass %]
Of course, commissioning any new mill requires the system
to be optimised, including adjusting the amounts of gypsum
and the other additives needed to achieve the required set-
ting and strengthening behaviour. The same applies when
changing from a ball mill system to a vertical roller mill sys-
tem, when the operator needs to increase slightly the amount
of gypsum put into the cement, or substitutes the gypsum to
Particle size DK [m] 52 m increase the solubility by hemihydrate or anhydrite.
37 m
Other optimisation measures include increasing the mill
Figure 8: Particle sizes in cements mostly below 55 m and 95 % below exit temperature and/or reducing the moisture content of
45 m the mill gas flow, both of which will enhance the drying pro-
cess of the added gypsum. As summarised in Fig. 10 these
are standard process-optimisation procedures that can also
Blaine-value B 3 000 cm2/g
be used to ensure that the cements produced in vertical
1.0
roller mills have comparable setting times and compressive
0.8
strength development to those from ball mills. Because it is
partly true that cement produced in a vertical roller mill has
0.6 lower gypsum dehydration, this can be adjusted through
Circularity
0.0
Table 2 presents a summary of the results obtained from
0.1 1 10 58 100 the comparative milling tests at the Montalieu plant in France.
Particle size [m] (VDZ 2007) While key features include the very similar particle size distri-
bution, positioning parameter and the fineness acc. to Blaine,
Figure 9: Similar particle shapes of cement produced on vertical roller the results show that the setting times for the two cements
mill systems are the same. Setting begins after about 125 minutes and
stops in both cases after 175 minutes. In addition, the
6 Gypsum dehydration optimisation compressive strength and the strength development meas-
ured after 2, 7 and 28 days are basically exactly the same.
Gypsum is mainly added to cement to act as setting regu-
lator, with the precise amount and type of gypsum being This proves that cements produced in a ball mill or in a ver-
chosen in relation to its solubility and the individual clinker. tical roller mill can have the same characteristics and qual-
A producer will work out the correct proportion and type of ities when required to do so by local markets, particularly in
sulphate to be used through product optimisation in order to terms of the water demand of the cement paste, the set-
fulfil optimal requirements. ting times, the compressive strengths and strength devel-
opments of mortars.
The energy input into the mill and the hot gases will heat
the cement, with the gypsum being partially dried and con- Today, out of the 260 Loesche mills sold around 185 are used
PROCESSING
verted to hemihydrate, so-called bassanite or plaster. Mixed worldwide for grinding cement products. On a regional basis,
together with water, hemihydrate dissolves better than gyp- the largest proportion of the total is in eastern Asia, with sig-
sum, so the dilution is more reactive in regulating the cement nificant numbers of the machines in Europe and the Amer-
set. Partial dehydration is intended within the milling process, icas as well. It is also significant that around 60 % of these
but if it exceeds or underruns a certain value, it can result in mills are used for grinding more than one grade of product,
accelerated setting behaviour. This in turn can lead to prob- with around 40 % being used for more than three products.
lems such as with the workability of the cement paste. Indeed, the flexibility of this mill system is such that today
coming out of a ball mill are always much rounder then those
lower lower higher higher coming out of a VRM, which are more shallow and elongated.
Slope n
Grinding Height of Mill air Classifier This again, together with fewer fine particles, would result in
pressure dam ring flow speed increased water demand for the cement paste.
higher higher lower lower
<== Shallow
If a similar product to one from an existing ball mill system is Fig. 8 illustrates the particle size distribution of a cement
2
needed, however, the VRM can be adjusted to achieve this. with a product fineness of about 4 100 g/cm acc. to Blaine.
As shown in Fig. 5, adjustments can be made to the grind- This shows that the size of the smallest particle is about
ing pressure, the dam ring height, the mill airflow, the clas- 0.1 m and the size of the largest particle is about 52 m
sifier rotor speed and, for cements with a very high Blaine for this particular cement. In general, while a wide variety of
value, the table speed. Fig. 6 shows the effects on the cements are ground to different finenesses, the largest par-
slope of the particle size distribution curve by adjusting each ticles are usually between 45 and 55 m.
of these parameters.
In addition, 95 % of all the cement particles are below 45 m
A higher grinding pressure will result in more intense grind- in size, again depending on the final product fineness and
ing with the development of more fine material, and hence the slope of the particle size distribution curve.
a shallower particle size distribution. The higher the dam
ring, the longer the material remains on the grinding table, Testwork undertaken by the VDZ in its role as Germanys
and the more it is ground in one cycle. This again results in Cement Research Institute compared the particle shapes PROCESSING
the generation of more fines, and a shallower particle size produced in different types of milling systems. Fig. 9 shows
distribution. In addition, the airflow and the classifier set- a plot of the shapes of cement particles from high-pressure
tings can be adjusted in order to produce the desired prod- grinding rolls, ball mills and vertical roller mills, with the par-
uct characteristics. ticle size being shown on the x-axis and the circularity on
the y-axis [2].
Loesche GmbH
Hansaallee 243
40549 Dsseldorf
Tel. +49 - 211 - 53 53 - 0
Fax +49 - 211 - 53 53 - 500
Email: loesche@loesche.de