GRINDING SYSTEM AND CIRCUIT OF VRM

1. PROCESS DATA
1.1. PLANT DATA
The vertical roller mill type SLM4750 is used for grinding cement
raw meal and the raw material for building, chemical and ceramic
industries. It is rated for the combined grinding and drying of
cement raw material according to the following data:
Feed material: cement raw material with the following

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composition:
Lime stone =88.45%
Clay = 9.04%
Sand =2.51%
Moisture ≤12%
Feed size: ≤95mm
 Finished product fineness <12%R 0.09mm
Bulk density: 1.4t/m3
Grinding capacity = 260t/h
Grinding bowl center nominal diameter = 4750 mm
Speed of grinding bowl =24rpm
Inching speed of grinding bowl=0.5rpm
Main motor Type: YRKK800-6

{ Power: 2500kW
Voltage: 6000V
Speed: 994rpm
Auxiliary motor
Power: 90Kw
Speed: 990rpm
Allowable volume of injection water into the mill (for three
nozzles) : <2.5m3/h
(The actual volume of injection water into the mill is determined by
the craft)
Pressure of injection water: 0.3Mpa

{ Temperature of injection water:

Total volume of using water: 80m3/h
<25 °C

Total installed power: 2750kW (approx.)

1.2 TECHNICAL CHARACTERISTICS FOR EACH COMPONENT
1.2.1. Grinding rollers
Number of rollers: 3
Diameter of roller: 2650mm
Width of roller: 900mm
Grinding power of roller (one roller):1900kN
1.2.2. Tension device

{ Hydraulic tension cylinder (with accumulator): 3

sets
Structure of oil cylinder: double function cylinder
Nitrogen pre-pressure of accumulator :( 0.33-0.66)
×20Mpa
Oil cylinder working pressure: 14~16 Mpa
1.2.3. Motor of hydraulic station:
Power: 5.5kW
Speed: 980rpm
Power of electric heater: 2×2kW
1.2.4. Volume of cooling water through
Cooler: 72m3/h
Pressure of cooling water: 0.2~0.4MPa

{
Temperature of cooling water: <30 °C
1.2.5.Classifier
Number of classifier vanes: 108
Range of speed: 90rpm
Motor type: YP2280M—4
Power: 90kW
Frequency conversion range: 3～100Hz
1.2.6. Sealing air fan
Power of motor: 30kW
Speed: 2940r/min
Air flow: 2800 m3/h
Air pressure: 8000Pa
1.2.7. Auxiliary reducer (supplied by Flender , Germany)
{
Input speed: 990rpm
Nominal transmission ratio: 45
Output speed: 22r/min
Speed of grinding plate: 0.53r/min
 1.3. PROCESS DESCRIPTION
The plant can be operated either in by-pass mode (mill off line)
or with the mill running normal operation.

BY-PASS MODE
The shut- off dampers before and after the grinding plant is
closed so that maintenance and repaired work can be carried
out.
{
The bag filter serves to dedust the kiln exhaust gas.

COMPOUND OPERATION
The shut- off dampers before and after the grinding plant is
open enabling the exhaust gas from the kiln to pass through the
grinding plant.
The proportioning weigh belt feeders withdraw metered quantity
of material from the bin, belt conveyor then take the material into
the mill. A metal detector is located over the belt conveyor that
transfers the material to the mill. A two way chute either takes the
material to a triple gate arranged up stream of the mill to provide
an air seal or to an intermediate bin if metal detected.
Kilns exhaust gases or a flue gas from a hot gas generator serves to
dry the material
The material is grounded to the required target fineness in the mill

{
while being dried simultaneously. The target fineness is set by
adjusting the speed of separating wheel.
Material split from the mill is returned to the mill feed material by
bucket elevator.
The finished product is carried out of the classifier with the gas
flow from which it is largely separated by double cyclone. The
downstream bag filter dedusts the exhaust gas flow.
The mill fan is arranged downstream of the double cyclone.
The gas volume flow is set by modifying the position of louver
flap upstream of the fan.
For taking away any spillage material, the mill is equipped with
an external material recirculation.
Any material falling through the nozzle ring is conveyed by
scrapers arranged below the grinding bowl to the reject chute.
The reject chute is fitted with a two-flap gate lock serving as an
airtight seal and preventing the inlet of false air.

{
From the reject chute the material is returned to the mill feed by
means of weigh belt feeder and bucket elevator.
For emptying the mill in case of maintenance work, the material
can be conveyed into the buffer silo by means of weigh belt
feeder and bucket elevator.
The mill is fitted with a water injection system that can be
switched on whenever required.
 1.4. PROCESS FLOW
The raw material batch house consists of 2 batch silos of Φ6m
and 1 Φ8m one. They are clay silo, 280t, sandstone silo, 280t
capacity, limestone silo with 550t capacity.
At the silo bottom is set with a system of discharging, where
each raw material is proportioned as designated. The rod valves
or silo dischargers and weigh belt feeder measure the materials
{
before them go to belt conveyer (1412.BC02). Above the belt
conveyer is set with iron separator (1413.MS01) and metal
detector (1414.MT01), which can prevent iron blocks etc. falling
into the mill. Quality control personnel on duty shall control the
proportioning ratio of raw materials.
The raw meal grinding employs SLM4750 vertical mills that
made in China. Material drying, grinding and separating are
finished by the vertical mill itself thus its energy consumption is
relatively lower.
The mixture out of the batch house is carried to the raw meal
grinding department by belt conveyor (1412.BC02). Iron
separator (1413.MS01) and metal detector (1414.MT01) play as a

{
protective role for the roller surface of vertical mill. Iron
separator (1413.MS01) removes iron in the material and metal
left behind by the Ironing separator shall be found by metal
detector (1414.MT01) and discharged by by-pass pneumatic Tee
(1501.VV01) interlocking reverse, to prevent the roller from
damage.
Discharged material will enter a buffering bin（1506.BI01）at
whose bottom there are rod gate and belt weighed （
1508.WF02).More over Ironing separator（1509.MT01）is attached
to the dosing scale. Material undergoing second de-ironing process
is fed into circulation elevator （1511.BE01) via startup three-way
valve（1510.VV02）
Material without any metal is fed into vertical mill (1503.RM01) via
Pneumatic tee (1501.VV01) and 3 valves (1502.PG01) .Qualified
material after dried up and grinded in vertical mill is then collected
by binocular cyclone dust collector and then carried into the raw
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meal silo via air chute （1515.AS01). Unqualified material is
discharged by the vertical mill from tapping hole and then fed into
the vertical mill by belt conveyor via heavy hammer flap valve（
1504.FV01）, belt conveyor（1505.BC01）and circulation elevator
（1511.BE01）
Material granularity 95%＜55mm, feed moisture ≤12.0%，, product
spec is 90μm, residue of sieve R12%, moisture≤1.0%，designed
output is 260t/h
Waste gas brought by hot fan (1534.FN10) from kiln inlet pre-
heater is used as a drying source for the VRM system.
When hot gas is not available at the kiln inlet, the hot gas
generator (1542.HG01) will be the provider. There is cold air
valve (1537.VM06) set at the pipe before the VRM, which can
adjust hot gas temperature.
Set a system of quality control, keeping raw meal out of the
grinding and fed into the kiln under supervision, control and
{
adjustment.
When the raw mill is on, the high temperature waste gas (left
over by the raw mill)from Hot fan by-pass and waste gas
extracted by recirculation fan(1523.FN07) from the raw mill
jointly enter kiln inlet bag filter (1545.BF04) with filtering
area16200m2, filtering air speed 0.95m/min. the dust content in
the
cleaned gas is ≤30mg/Nm3. The air treated by kiln inlet dust
collector is emitted into the atmosphere via the stack.
When raw mill stopped but burning system in operation, raw
mill inlet valve (1536.VM05) must be closed. High temperature
waste gas out of the kiln inlet will enter into bag filter
(1545.BF04) in the kiln inlet via high temperature fan
(1534.FN10) and air converging box （1525.AC01）
{
Kiln dust collected by bag filter, is carried to homogenization
silo via chain conveyer, air chute and elevator (1601.BE01) or
directly taken into kiln inlet pre-heater via elevator (1701.BE01).
{
2. TECHNICAL DESCRIPTION OF VRM
2.1. OPERATING PRINCIPLES OF VERTICAL ROLLER MILLS
The SLM4750 vertical roller mill is an air-swept vertical roller
mill consisting of several constructional components. The
main components -mill and classifier - form a single and
compact unit. The principal feature of the SLM4750 roller
mill are three stationary grinding rollers which roll on a
slowly rotating grinding plate. Together with one pressure
frame and three pull rods the grinding rollers form a
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statically determined system which provides a uniform load
distribution over the grinding bed and the segmented thrust
bearing of the gearbox. Each grinding roller is flexibly
connected to the pressure frame by means of a pressure yoke
which allows lateral rocking movements of the grinding
rollers. An accumulator is fitted in each hydraulic tension
system as a shock absorbing system.
{

FIG. 1 Vertical Roller Mill Structure Diagram

 This flexibility of movement and the pneumatic suspension of
the tensioning system ensure an optimum adjustment of the
grinding rollers to the grinding bed. The material, carried in by the
feeder, is drawn in and crushed between grinding rollers and
grinding plate. The forces required for the grinding are produced
by pressing the grinding rollers onto the grinding plate. The
contact pressure is created by a hydro-pneumatic tensioning
system and can be varied during operation if necessary.

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The material is ground and conveyed toward the ported air
ring by COMPRESSION AND SHEAR. The gas flowing up
through the ported air ring mixes with the material and so forms a
rotating fluidized bed above the ported air ring. The coarser
particles with high specific gravity to fall down through the nozzle
and discharged out of the mill by scraper. And back onto the
grinding plate and undergo again the grinding process.
 The fine-ground particles are caught by the gas stream and
carried up to the classifier. In the separation zone a rotating
separating wheel separates the material into fine finished product
and coarse particles (grits) where the oversize is separated out by
gravity and centrifugal force. The separating wheel is fitted with a
variable speed drive to adjust the rotation speed to the required
finished product fineness.
{
The separated finished product is carried by the gas stream to
the dust collector arranged after the mill. The coarse material falls
back onto the grinding plate and is taken back into the grinding
process
Compared with ball mill, the major advantages of SLM4750 mill
are: higher grinding efficiency, shorter process flow and lower
specific power consumption. Furthermore, the grinding of
material is done under limited pressure.
Since the mill housing is large, low flow rate can be obtained
through the inlet air volume is large. Based on this, the wear
caused by injection and loss of pressure is reduced; therefore the
mill can be fitted with a small capacity hot gas fan.
{
The grinding parts on grinding rollers and grinding track are
replaceable segments which are made of wear-resistant material.

2.2. MECHANICAL EQUIPMENT AND INSTRUMENT FUNCTIONS

Description of the main component
FOUNDATION FRAME:
The complete mill (mill and classifier) including the mill
drive is based a Section steel construction which is
embedded in the mill foundation .The three pull rod anchors
for the fastening of hydraulic tensioning cylinder are welded
to the foundation frame. The forces required for the
grinding process are transmitted into the foundation frame
through the mill gearbox and the hydro-pneumatic
tensioning system.

{
MILL DRIVE:
A special gearbox- driven by an electric motor –transmits
the required torque to the grinding bowl and at the same
absorbs the forces that are created by the grinding process
affecting the grinding bowl. The gearbox bearing are
connected to a pressure circulating system with oil pump
and oil cooler.
SLM4750 mill driver consists of main motor, conical planetary
reducer, low-speed auxiliary reducer and auxiliary motor.
The main motor is three-phase asynchronous electric motor, air
cooling, started by liquid resistance
The first stage of conical planetary reducer is of conical gear
and second stage planetary gear. The second stage is parallel
shaft gear; the third stage is planet gear. The output shaft is
vertically mounted. Under the bottom of the output shaft there
are several Babbitt thrust bearings. The reducer bears the

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gravity of grinding parts and the vertical component force
produced by tension system. The shell of the reducer is of
welding construction.
The first stage of auxiliary reducer is of conical gear and the
second and third stage cylindrical gear. The auxiliary drive
slowly rotates the main drive via auxiliary reducer and
overrunning clutch. After the starting of main drive, the
overrunning clutch disengaged and auxiliary driving system
shut down.
{

Fig.2 Maine Drive Gear Box

SERVICE DRIVE:
The main mill drive is fitted with a maintenance drive. The
maintenance drive is used for the precise position of the grinding
plate for inspection and servicing purposes as well as for repair
works.
GRINDING BOWL:
The grinding bowl is positioned the gearbox output flange which is
based on an adequately dimensioned segmented thrust bearing. The
bottom zone of the grinding bowl is closed against the interior of the
mill by a horizontal flat floor. The clear inner zone of the grinding
bowl is covered by a steel plate cape which prevents the material from
falling in.

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The molten grinding track is placed and bolted on top of the reducer
according to transmitting torque moment. The removable grinding
liner is supported by the grinding track. The segments rest against the
wedge-shaped rim on the outer edge of the grinding track. On the
opposite side towards the inner hollow in the grinding track, they are
fastened by clamping plates. The geometry of segments determines
the inclination of the grinding rollers, the angle between the normal
and vertical line at the contact point of grinding roller with segments
is 15 degrees.
Dam Ring

Grinding

{ bowl

Material scraper
Central column of
lifting-and swing Gear Box
system

Fig.3 Grinding Bowl

GRINDING PLATE:
The grinding plate (wear part) is fastened onto the grinding bowl.
The three stationary grinding rollers roll in trough-shaped track of
the grinding plate.
As a result of the rotating movement of the grinding bowl, the
material is drawn in and ground between grinding plate and
grinding roller.
The grinding plate consists of various segments and is fitted onto

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the grinding bowl by means of clamping elements

GRINDING ROLLER:
The three stationary grinding rollers are arranged equidistantly on
the grinding plate. Each grinding roller is fixed to the pressure
frame by means of a pressure yoke.
 Each grinding roller is borne on the axe of pressure yoke by
two special roller bearings.
The grinding rollers are fitted with crowned parts.
The wear parts ate segmented and fastened by means
clamping elements
ATTENTION!
Make sure the grinding roller always roll on a material bed
and never directly on the grinding plate. (Increased wear
{
/risk of fractures)

Note:
The grinding plate and the grinding roller wear parts are subject to
natural wear .when certain wear limit is reached, these parts have
to be replaced.
 Pressure
Frame

Pressure
{
Yoke

Roller

Fig.4 Grinding Roller

HYDRAULIC TENSION SYSTEM:
The contact pressure required for the grinding rollers is
created by hydro pneumatic tension system. The pressure
frame which has the shape of an equilateral triangle transmits
the forces created by the tension system onto the pressure
yokes with the grinding rollers. Fitted to the corner of the
pressure frame are the pull rods which transmit the forces from
the hydraulic tension cylinders.
The three hydraulic tension cylinders are supplied with oil by
{
one common hydraulic unit which also produces the pressure
required for the pre- tensioning of the grinding rollers.
Each hydraulic tension cylinder is fitted with a bag –type
pressure accumulator filled with nitrogen gas which absorbs
the pressure and shocks occurring during mill operation.
The hydro-pneumatic tensioning system is designed in such a
way that the grinding rollers can be lifted for start-up purposes
{

Fig.5 Accumulator
Accumulator

{
Pull Rod

Fig.6 Pulls Rods Located Outside the Housing

The tensioning system for Mill has four basic functions namely:-
 Pre-tensioning of Rollers

 Lowering of Rollers
 Grinding

The tensioning system consists of

solenoid operated valves and two
electrically driven pump. (One pump is
just for flushing) These valves and

{ pump are switched on and off in

predefined sequence and configuration
to perform operations. As a user we
should have 3 modes of operation such
that we can perform all the above
mentioned functions in each of these
modes.
Modes of operation will be:-
Remote Auto:
In this mode all the above mentioned functions will be performed
automatically one after another depending on whether the mill is
running or is in stopped condition. An interlock should be given to
the mill stating that the mill should run only if the Tensioning system
is in Remote Auto Mode.
Remote Manual:
This mode can be made active by the operator (Egg. User) if the mill is
in stopped condition. Only lifting and lowering functions as
mentioned above can be performed individually by the operator in

{
this mode using soft keys from DCS. This mode will be a great asset
during zero setting and pressure releasing operations.
Local:
This is a maintenance mode where the above mentioned functions
will be performed by the maintenance staff from the local panel given
at site.
All the three functions in Tensioning system as mentioned above
should be performed in a particular sequence when operated in
Remote Auto mode.
NOZZLE RING:
The nozzle ring is located between grinding plate and mill housing.
The guide channels of the nozzle ring show an oblique arrangement
and so create a spiral gas flow. The spiral flow carries the fine material
upwards into separating zone.
The gas stream enters the mill through an inlet duct which located
below the nozzle ring

{
Particles falling through the nozzle ring are convoyed by a scraper to
the reject duct in the mill base and are discharged.
The nozzle ring and the top-mounted air guide cone are lined.
In case of material spillage the cross-section of the nozzle ring can be
reduced by covering the nozzles and thus air velocity and lifting force
can be increased.
Nozzle Ring

Fig.7 Nozzle Ring

SEAL AIR SYSTEM:
The seal air system prevents dust from passing through the sealing
into the grinding roller bearings and so protects the sealing from
premature wear.
The seal air fan located outside the mill sucks air through a filter and
carries it through a ring-shaped ducting to the connecting points on
the pressure yoke. The connecting ducts to the pressure yokes are
flexible and can adjust to the movement of the grinding roller. Inside
the pressure yoke, the seal air flows into an annular gap arranged
before the sealing of the grinding roller bearing and is discharged

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through a labyrinth gap into the interior of the mill.
The correct functioning of the seal air system is checked by
monitoring the seal air pressure and the power consumption of the
fan motor.
Since there is negative pressure in the mill and sealing air escapes
from the ring-shaped area, no dust can get into the sealing and
bearing part. The pressure of sealing air is monitored by means of
contact manometers and pressure of sealing air should not be lower
than 5000Pa
 During the service period and with wear progressing, seal air
pressure drops constantly. Once it his gone down to about 70% of the
rate measured at the time of commissioning, the seal air system will
have to be checked .when seal air pressure has dropped to 50%, mill
operation must be stopped because otherwise dust might get into the
bearings and destroy them.

CLASSIFIER:
The classifier housing is fitted on the top of the mill housing and
screwed to it. The bearing of the classifier shaft, the classifier shaft

{
with lamella wheel (separating wheel), the louver with the obliquely
arranged blades and the grit cone are fitted into classifier housing.
The variable speed drive of the separating wheel is installed outside
the classifier.
The separating wheel turns clockwise when viewed from the top
The ground product carried the gas stream is taken through the
louver into the separating zone. The oblique arrangements of the
louver blades give the particles an additional spin. A pre-separation of
the coarser particles is provided due to the centrifugal force.
The fine product having the required fineness is separated by
means of separating wheel. The gas stream carries the separated
fine product out of the classifier and into the dust collector
arranged downstream.
The coarse particles (coarse material) which do not have the
required fineness do not pass through the separating wheel.
Together with material rejected by the louver, they fall through the
grift cone back onto the grinding plate.
The required end fineness of the product is infinitely variable

{
within a wide range by changing the speed of the separating
wheel. Speed increase leads to higher product fineness; speed
reduction leads to a lower product fineness.
The bearing is protected from dust by means of a seal air sealing.
For this purpose, a ducting is installed from the outside up to the
connection socket on the classifier shaft. Due to the depression in
the mill, air is sucked in from the outside, entering the interior of
the classifier through an annular gap located in the classifier shaft
sealing and thus preventing the penetration of dust.
The bearings are periodically lubricated by grease.
The classifier is provided with a lining in the area of the classifier top
and bottom part and of the outlet duct.
The higher of the classifier speed, the finer of the finished product and
vice versa. Since the fineness of the finished product is also affected
by such factors as temperature humidity and air pressure. It is
impossible to find out the relationship between speed of classifier and
the fineness of finished product. The relationship can only be
determined during commissioning
{
 Fine Poduct

Drive

Feed Material

{ Louver

Rotor

Grift cone

Fig.8 Classifier
SEPARATING WHEEL DRIVE:
The separating wheel is driven by an electric motor with gearbox
arranged downstream. Flexible couplings are provided between
electric motor and gearbox, and between gearbox and classifier shaft.
Step-less variation of the gear motor is carried out by means of a
frequency converter the speed ensured by a frequency convertor.

Fig.9 Classifier Drive

MILL HOUSING:
Being completely closed the principle function of SLM roller mill
housing is to guide the gas stream .withe the force created by the
grinding process being transmitted through the mill gearbox and
the tensioning system into the foundations and into the torque
support of the pressure frame the housing is largely relieved.
The mill housing is provided with a partial lining.
For checks and maintenance, the following points are provided
with doors:
{ 


Mill housing bottom (grinding bowl zone)
Mill housing top (grinding roller zone)
 Mill housing top (pull rod housing zone)
 Classifier housing top(separating wheel zone)

Attention: Don’t open the door unless the mill is stopped!!

MATERIAL FEED:
The feed material is conveyed into the mill by means of a triple gate.
The triple gate is located above the material chute and prevents false
air from entering the mill. The triple gate is driven by motor.

Fig.10 Three-Flap Gate Valve

DISCHARGE LOCK:
When operating the mill with external material circulation a discharge
lock is required in order to prevent false air from entering during
continuous material discharge.
The discharged lock is designed as two-flap gate lock with two
flaps opening alternately. The flaps are closed by means of a joint
pull- back spring.
The operation of the flaps is controlled by a cam disk driven by a
gear motor.

{
LIFT-AND-SWING SYSTEM:
The mill is fitted with a Lift-And-Swing System for easy exchange
of the grinding rollers for repair works. Supporting arms are
mounted to a sinkable central column located in the mill center.
For the removal of a grinding roller, the pressure yoke is fastened
with the grinding roller to the column.
This done the connection between pressure frame and pressure
yoke is loosened and pressure frame lifted up.
The grinding plate is turned by means of the maintenance drive
allowing the positioning of each grinding roller exactly at the
maintenance door. When the lift-and-swing device is fastened to the
mill housing exterior, pressure yoke and grinding roller can be lifted
up, swung out and prepared for being carried away.

Fig.11 Lift-and-Swing System removal of grinding roller

MILL FAN:
The mill fan is arranged after the cyclone collector, it is rated for
the required gas volume flow of the grinding plant.
The gas volume flow is regulated by means of the louver flap
arranged a head of the mill fan.
EXHAUST GAS FAN:
After the mill fan the air stream goes exhaust gas stream directed
through a filter where any remaining dust is removed. There is no
a recirculation air stream.

{
A fan located after the filter draws the exhaust gases through the
system

FILTER UNIT:
A cyclone collector is used for the separation of the fines carried by
the air stream that comes from the VRM. The air leaving the
cyclone is directed to exhaust air because there is no recirculating
air system.
{

Fig.12 Double Cyclone Separator

Lubrication of mill gear box:
The mill reducer is lubricated by special lubrication oil station. It
consists of four high pressure (two are for trust bearing and two are
for gear box) and two low pressure pumps for cooling. Cooling
system equipped with shell and heat exchanger. There are two oil
filter i.e. fine and coarse oil filters.
The reducer is equipped with hydro-static lubrication system. All the
sixteen thrust bearing are equipped with hydro-static lubrication
pipes and the gears is lubricated by means of oil spraying.
The thrust bearing is immersed in oil pool. The oil level is above the
working surface and stable. The fresh oil is sprayed in through the

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ring-shaped nozzle in order to cool the thrust bearing

2.3.MEASURING AND REGULATING EQUIPMEN AND PARAMETERS

Regulation Fed Rate
The purpose of feed regulation is to keep the differential pressure
and thus the fill level in the mill at a constant level. The effect is
that the mill throughput rate is adjusted to the varying grind
ability of the material.
 The differential pressure is taken by a differential pressure
measuring transducer and led to a controller which varies the feed
velocity and thus the material quantity by means of a suitable
actuator. The measuring points for measuring the differential
pressure is located the gas inlet duct of the mill and ahead of the
classifier. For start-up and shut-down of the grinding plant the
feed quantity control manually.

Regulation gas volume flow

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The gas volume flow is measured in a suitable test section by a
measuring device. A differential pressure measuring transducer
coverts the pressure signal into an electric signal then taken to a
controller. The controller regulates the regulating device (radial
damper) in such a way that the gas volume flow in the plant is
kept at a constant level. . For start-up and shut-down of the
grinding plant the feed quantity control manually.
Regulation heat supply
The temperature after mill is kept at a constant level. This guarantees
that the finish product is dried to the required residual moisture. Any
deviation from the set exhaust gas temperature after the mill causes a
reaction of the controller. If the exhaust gas temperature is too low the
heat supply is increased. If it is too high, the heat supply is reduced.
For the protection of the components which are sensitive to
temperature such as bearings, dust collection filters, etc. limit values
are provided. These included in the interlocking and cause an

{
automatic switch-off of the hot gas supply in case the exhaust gas
temperature is too high.
Regulation depression ahead of mill
The depression ahead of mill is measured and taken to a measuring
transducer for conversion into electric signals. A limit value indicator
and a controller are arranged downstream of the transducer. If the set
limit values are reached alarm is released. The regulation of the
depression is affected by adjusting the position of the exhaust gas
flap.
Monitoring - temperature ahead of mill
The Temperature ahead of the mill is measured by means of a
resistance thermometer, a measuring transducer, a limit value
indicator and an indicator. If the temperature is too high the hot gas
supply must be interrupted.
Monitoring - temperature of classifier gear oil
The - temperature of classifier gear oil is monitored by means of a
resistance thermometer, measuring transducer, limit switch and
indicator.

{
5 switch points are provided:
Switch points 1 LL: Classifier cannot be started
Switch points 2 L: Pump of cooling circuit OFF
Switch points 3 H: Pump of cooling circuit ON
Switch points 4 HH: Alarm
Switch points 5 HHH: Classifier drive OFF
Monitoring - lubrication of classifier bearing system
The lubrication of the classifier bearing system is affected by means of
a flow monitor who is installed in the grease supply line.
In addition, the fill level of the storage tank is monitored.
If the fill level falls below the set minimum values, an alarm is
released.
Monitoring – tensioning pressure
The tensioning hydraulic is fitted with an electric pressure switch
with measuring transducer. An indicator shows the actual value of the

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tensioning pressure.

Monitoring – of oil temperature of mill gear

For the monitoring of the gear oil temperature the gearbox is fitted
with two resistance thermometers which transmit the temperature to
a limit value indicator and an indicator by means of a measuring
transducer. The limit value indicators release alarm if a certain limit
value is exceeded. If a second limit value is reached the machine is
automatically switched off.
Monitoring – vibration level
The mill gearbox is fitted with a vibration for the vibration level.
Any vibration exceeding the standard level release alarm. If the
vibration level increases even further and the maximum limit
value is exceeded the mill is shut down. The limit value which
causes the mill to be shut down is determined during
commissioning.
Indication – classifier speed
The frequency set on the frequency converter is transmitted to the
PLC as an analogue signal parameterized by the frequency
converter as a speed signal.

{
2.4. PROCESS PARAMETER
 Grinding Bed Height (mm) and Variations (mm)
 Product Rate and Product Fineness (T/H)
 Classifier Speed (rpm)
 Grinding Force and N2 Pressure
 Power Consumption Main and Fan Drive (KW)
 Air Flow Profile (am3/h) and Pressure Profile (mbar)
 Availability (% relative to kiln)
 A. GRINDING BED
Grinding bed is the material layer between the roller and the table
It is the key issue to successful operating of a VRM!!!
 Determined by:

 Feed Material size

 Feed Material Moisture

 Dam Ring Height

 Grinding Fineness

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 Air Speed in nozzle ring

Grinding bed too low, -> Vibration High

Grinding bed, OK, ->little Vibration, Efficient Grinding
Grinding bed too high, ->Vibration Inefficient Grinding
B. Product Rate and Product Fineness
Correct Feed Rate to measured moisture
Check fineness on 63 micron
  Do not over grind
 Check burnability and 63 micron sieve
C. Classifier Speed
Check Screed Indication with Actual Speed
Fineness is not linear to Classifier Speed
Influenced by:
 Air Flow

 Target Fineness

 Material

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D. Grinding Force and N2 Pressure
Grinding Force as low as possible, as high as necessary for low specific
power consumption
N2 Pressure as low as possible, as high as necessary for soft running
Influenced by:
 Hardness of Feed Material
 Grain Size of Feed Material
 E. Power Consumption Mill Drive
Influenced by:
 Grinding Fineness
 Classifier Design
 Grinding Bed Height / Variations
 Dam Ring Height
 Air Flow
 Temperature Level
 Condition of Grinding Elements
 Grindability of Raw Material

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F. Power Consumption Fan Drive
Influenced by:
 Fan Efficiency
 Load on Fan
 Dust Load of Gases
 Temperature of Gases
 Total Air Flow at Fan Inlet
 Total Pressure at Fan Inlet
 G. Air Flow Profile
Check for False Air Leakage because:
False air after nozzle ring reduces grinding capacity
Any false air reduces drying capacity
Influenced by:
 Expansion Joints

 Flanges

 Pull Rod Seals

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 Negative Pressure

 Feeding Device to Mill

 Air Locks after Filter / Cyclones

H. Pressure Profile
Influenced by:
 Mill Inlet Pressure

 Nozzle Ring Coverage

  Classifier Speed
 Dam Ring Height
 Mill Load
 Material Blockage in Hot Gas Channel
 Size and Condition of Filter / Cyclone
 Air Flow

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I. Availability
Influenced by:
 Maintenance
 Analyze Mill Stops
 Schedule Maintenance
 Spare Parts Availability