Basics Grinding Pressure

VRM Workshop San Sebastian 2008

Author: Karl-Heinz Boes CMS/MPT

2007 Holcim/Switzerland
 Overview Hydraulic system VRM - Loesche

Roller
Accumulator

Accumulator

Piston

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 Pressure and Counter Pressure

Hydraulic Pressure

Counter Pressure
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 Function of Counter Pressure
Avoids cavitations in hydraulic systems in case of
heavy vibrations
Supports stable pressure distribution

If counter pressure and working pressure are

identical, roller is slowly lifted (effect of piston rod
which reduces area on working pressure side)
Counter pressure is typically 10-15 [%] of working
pressure
Too low counter pressure can lead to increased
vibration problems

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 Working Pressure Diagram Example Loesche

Optimum settings
for this mill:
47 bar Operational
pressure
10 bar counter
pressure
Result: 760 kN of
working pressure
(weight of roller not
considered)

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 Leverage of Rockerarm Example Loesche

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 Leverage of grinding Pressure Polysius / Pfeiffer

Here Leverage = cos (0.98) Here Leverage = 1 7

2007 Holcim/Switzerland Basics Grinding Pressure 30.07.2007 KHB
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 Grinding Pressure
The Grinding Pressure is the result of:

Roller weight
(plus frame
Hydraulic pressure etc.)
- Counter pressure
= Working Pressure

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 Specific grinding Force
Grinding Pressure per Roller:

GP = Hydr. Force [kN] + Roller weight [kN] + Frame weight [kN]

Specific Pressure =
WR GP

DR WR * D R

Guide Value: < 800 kN/m2

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 Accumulator (Nitrogen) Pressure

Springs in the
hydraulic system
Typically 50-60 [%] of
operational pressure
Effect on vibrations,
shocks, stresses of
mechanical equipment

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 Loesche Tension Diagram of Accumulator Pressure

Operating
Pressure
(P2)

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 Guidelines accumulator pressure
Settings of accumulator pressure allow for certain
working pressure range (+/- 15 %) only
Uneven nitrogen pressure distribution can affect
grinding tools (uneven wear) and increase
vibrations
Too high accumulator pressure can have negative
draw backs on vibration peaks (become larger,
shock effect on equipment is bigger)
Too low accumulator pressure pressures can lead
to high tensions in mechanical equipment
If it is intended to change working pressure
significantly, accumulator pressure has to be
adapted first (requires mill stop)
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 Example

Operating
Pressure
(P2)

Example:
Pressure old 115 bar now 95 bar
N2- pressure must be reduced from 70 to 45 bar 13
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 Vertical Roller Mill Calculations

HGRS VRM Calculation Sheet

Plant :
Mill :
Standard
RM
Date :
Visa :
May 07
KHB
Roller mill characteristics
Supplier Loesche Plant altitude: 0 [m]
Size of Mill LM46.4 factor: 1 [-]
Material Rawmaterial
Production G 330 [t/h]
Fineness f 10 [%] R 90 m
Moisture m 12.0 [%] H2O
Spec. energy consump. mill E sp 7.3 [kWh/t] motor shaft
Motor power (installed) Pi 3000 [kW]
Roller Mill Data
Table diameter nominal Dn 4.64 [m]
Grinding track diameter D m1 3.71 [m] 80 [%] D n
D m2 [m] - [%] D n
Roller diameter Dr 2.08 [m] 45 [%] D n
Roller width Wr 0.88 [m] 42 [%] D r
Number of rollers ir 4 [-]
Table speed n 25.5 [min-1]
spec. speed (relative to D m) c 49.1 [-] Zf= 13.23 [m/s]
Hydraulic cylinders number ic 4 v= 4.95 [m/s]
Diameter cylinder dc 560 [mm] Main pr. 78 [bar]
Diameter piston rod dr 229 [mm] Count. pr. 10 [bar]
Rocker arm leverage l1/l2 0.750 [-] Differ. 66 [bar]
Weight of compl. roller Gr 26 [t]
Gas flow estim. (fan operation) V fo 670'000 [m/h] V fo spec. 2.03 [m/kg]
Gas flow estim. (fan dimens.) V fd 737'000 [m/h] Dust ex mill 542 [g/m]
Casing diameter Dc 6.30 [m] vc 5.4 [m/s]
Open nozzle area, max. An 4.54 [m] vn 37 [m/s]
Material characteristics
out of hydr. pressure out of spec. energy
Hydraulic pressure operation ph 66 [bar]
Grinding force per roller F1 1'271 [kN] F2 1'271 [kN]
Spec. grinding force k1 695 [kN/m] k2 695 [kN/m]
Material pressure L1 5 [N/mm] L2 5 [N/mm]
Power absorbed operation P ab1 2'409 [kW] P ab2 2'409 [kW]
Power ratio: absorbed - installed 0.80 [%] 0.80 [%]
Reference values
Density before roller r1 1.45 [t/m]
Density after roller r2 1.90 [t/m]
Alpha/Beta ratio a/b 2.8 [-]
Bed thickness s 120 [mm] s/Dr 0.058 [-]
Nip angle a 15.33 [] 0.096 [-]
Attack angle b 5.49 [] 14
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 Conclusions
Correct settings of grinding and accumulator
pressure are vital for stable operation
Far too low or too high accumulator pressures can
lead to
Increased vibration
Mechanical failures
Too high hydraulic pressure increase the
fluctuations of torques and micro vibrations in the
main reducer and must be avoided (increased risk
of mechanical failure in main reducer)
Too low counter pressures can lead to mechanical
failures and increased vibrations

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