Operation Traianing

Operation description for LM56.
3+3 C/S with LSKS 87 CS / UCC

(UAE) P.S.C. Ras Al Khaimah Cement Plant
Operation Training
Loesche Raw Material Grinding Mill

LM 56.3 +3 C/S
for
Union Cement Company ( P.S.C.)
Ras Al Khaimah
Loesche GmbH Hansaaallee 243 D-40549 Düsseldorf phon +49 211 5353 0 www.loesche.com e-mail loesche@loesche.de
Operation description for LM56.3+3 C/S with LSKS 87 CS / UCC
Franz Heuken
Loesche Senior Commissioning Engineer
since November 1975
Loesche GmbH has celebrated
100th anniversary
in September 2006
Table of content
Pages Designation
• 01 Cover sheet
• 03 Table of content
• 04 - 08 Introduction
• 09 - 18 Loesche mill LM 56.3+3 C/S +Classifier LSKS 87 CS r
• 19 Loesche Mill
• 20 - 23 Table
• 24 - 27 Grinding roller
• 28 - 29 Rocker arm
• 30 - 57 Spring system HSLM
• 58 - 62 Supporting Rollers and HSSW
• 63 - 66 Roller lubrication HSMS
• 67 - 73 Water-and Grinding Aid Sprinkling
• 74 - 80 Seal air system
• 81 - 84 Flow sheets
• 85 - 91 List of electrical consumer and Instrumentation list
( sections )
• 92 - 94 Start and stop sequence
• 95 -103 Control loops
• 104-105 Wear Parts
Loesche has supplied over 600 modern mills for grinding

Materials other than coal since 1960
• Largest Loesche mill size to date are LM 63.4
• These very large mills grind Cement raw materials
• Mill installed motor power approximately 5 MW
• The very large mills have LSKS dynamic classifiers

with diameters larger than 11 m
General Pre-Conditons for UCC Ras Al Khaimah Cement Plant
Raw Material
Country: United Arabic Emirates
District: Ras Al Khaimah
Client: Union Cement Company
Climate: Continental/Dry
Temperature: 5°C average 33°C + max 44°C
Atmopheric huminity: max 90% H2O
Height above sea level: ~31 m
Mill layout data for UCC Ras Al Khaimah Cement Plant
Material Components OPC-CEM 1 EN 197:

initial moisture feed grain size
Material: 91 % Clinker max. 100 mm
5 % Gypsum max 3 % 100% max. 100 mm
4 % Limestone max 2 % max. 100 mm
0 % Slag
Blaine cm2/g: min. 3400

Product Rate: 210 t/h
Residue on 45 μm: max. 10%
Product moisture: max 0.1 % H2O
Cement temperature: max. 100°C
Specific Power consumption at counter 22.6 kWh/t at mill motor shaft and gearbox
Principle of
Loesche Grinding Mill
LM 56.3+3 C/S
with
LSKS 87 C/S
Classifier
Group Classifier LSKS
Classifier Drive
The „Classifier cpl.“ assembley

is susbstantilly composed of
 Classifier Housing cpl.

 Rotor cpl.
 Classifier lining cpl.
 Flap Positioning cpl.
Flap Position
 Classifier Drive cpl.
 Classifier Lubrication Line
Rotor
Classifier Housing
Group Classifier LSKS

Function of the Classifier
The LOESCHE studded basket classifier is an air-flow classifier. The ground and dried material flows
into the classifier from below together with the carrier air.
The guide flaps integrated into the classifier lower housing redirect the dust/air mixture from an upward
flow into a tangential flow. The ribbed rotor rotates in the same direction as the tangential flow.
In the gap between the guide flaps and the blades of the rotor a field of centrifugal forces forms in which
the dust/air mixture is classified. Larger (oversize) particles are flung outwards and sink under the
influence of gravity. After leaving the gap, oversize particles are collected in a grit collector and are
returned into the mill for repeated grinding. Finished material passes through the ribbed rotor together
with the carrier air and leaves the classifier via the outlet pipe to the cyclones.
The fineness of the finished material depends on the adjustment of the classifier flaps inside the classifier
upper housing and the rotor speed. Changing the adjustment of the flaps outwards (more tangential)
and/or increasing rotor speed results, after classifying, in a finer finished material, lowering the rotor
speed and moving the flaps inward (more radial) in a coarser material.
The flaps are held in pivots and can be adjusted by hand.
The direction in which the rotor turns depends on the flow vortex of the louvre ring. The directions of
rotor rotation and the vortex of the louver ring are identical.
The conical grit funnel creates an orderly circulation of coarse particles within the mill. On the one hand
it separates the rising dust/air mixture from the coarse particles flowing back on its inside, and on the
other hand it passes them into the centre of the table where they are reground.
Loesche mill LM 56.4
Lining cpl.
Sealing Air Pipeline cpl. Mill-Upper Housing cpl.
Rocker Arm Sealing cpl.
Roller cpl. Mill-Platform cpl.
Rocker Arm cpl.
Table cpl. Mill-Lower Housing cpl.
Machine/Assembly Group:
Swinging-Out Device
Mill-Drive cpl.
Spring Assembly cpl.
Ring Pipeline cpl.
Table
Grinding
roller
Louver
ring
Dam ring
Clamp ring
scraper
Grinding plate
segments
Table
Function
The assembly "Table cpl." consists basically of:
- the table foundation,
- the segmented grinding plate as wear resistant lining,
- the clamping ring consisting of several parts,
- the dam ring,
- the louvre ring and
- the scrapers.
The primary function of the table is to support the grinding bed and transmit the force
generated by the rollers into the gearbox below. It also transmits the torque of the
gearbox into the grinding zone. Together with the ring duct (mill lower housing cpl.) the
table creates a circular chamber out of which the primary gas flows over the louvre ring
into the grinding chamber.
As one of the two grinding tools of the mill - the second tool are the rollers - the table is
of such importance in view of the various spare part.
For more information please refers BA 911060-10-4 en “Table cpl.”
Table
Armour Ring
Roller
Damring
Grindingbed
Grinding table
wear segment
Grinding table
Louver Ring
Table
Grinding Plate and Clamping Ring

The grinding plate forms the grinding path lining of the mill and consists of highly wear resistant
casting. The grinding plate is divided into segments. Each segment has a smooth underside to
guarantee perfect support on the table upper surface.
Dam Ring
The dam ring is bolted onto the outer collar of the grinding table body from above. The dam ring
height determines the required thickness of the layer of grinding material on the table which is
normally referred to as the grinding bed.
As a deep grinding bed leads to a higher energy consumption of the mill without increasing the
grinding effect correspondingly, the dam ring should be kept as low as possible. At the same time,
however, it must be considered that with a low dam ring less material will be held on the table so
that the material thrown off by the centrifugal force will increase the load on the louvre ring.
The various qualities of the feed material such as grindability factor, feed size and feed moisture
content demand in many cases a height adjustment of the dam ring when commissioning. The
dam rings equipped with flat steel wear ring inserts, the entire wear ring can be replaced.
For faultless mill operation it is important that the rollers run as near as possible to the wear ring in
the dam ring.
Grinding roller
Grinding roller
Quantity and Arrangement
The mill is equipped with several rollers, each of which is clamped in its own rocker arm. The
rollers are equidistantly spaced relative to each other and are supported in the zero position at a
low roller axis inclination to the horizontal grinding plate.
Construction
Each roller consists in essence of the rotating hub, cover disc, rolling bearings, bearing sealings,
roller axle, roller tire as wearing part, hub cover, sealing sleeve and lubrication system.
Lubrication
The rolling bearings are usually lubricated by an oil-recirculating system powered by the pumps of
the hydraulic cabinet HSMS. A radial drillhole in the centre of the roller hub guarantees a constant
minimal oil level within the roller.
Adjusting of Rollers
The position of each roller relative to the table (distance to the dam ring) can be changed by
means of a ring. This ring is inserted between the conical sleeve of the rocker arm and the
relevant axle shoulder. The ring should not always be fitted but only when the roller contacts the
inner diameter of the dam ring (see drawing).
Grinding roller sealing
Sealings
Each roller has a number of different sealings.
The annular gap gas-flushed seal prevents dust from the grinding space contaminating the roller
bearings.
(See operating instructions "Sealing Air Pipe cpl.")
The roller bearing chamber is at atmospheric pressure because it is connected with the exterior of
the mill by a bore in the roller axle. This bore is equipped with an oil-wetted air filter. Because the
pressure within the roller is higher than that of the mill interior no dust can get into the bearings.
The rolling bearings space is protected by mechanical sealings from the dust-loaded atmosphere
in the mill as follows:
- An O-ring seals the hub cover relative to the hub.
- The sealing sleeve is screwed to the hub with the use of a sealing paste.
- The rotating parts of the roller are sealed relative to the stationary axle with a system of
slip-ring sealings:
(see operating instructions "Slipring Sealing cpl.")
Grinding roller slip ring sealing

Function
Sealing Sleeve
(rotary) The slip-ring sealing
Slip-Ring Sealing
Elastomer-O-Ring has the task of
Slip-Ring Sealing Sealing Ring keeping the lubricant
Sliding Ring (rotary) in the roller bearing
chamber of the
Fixing Ring
grinding roller.
Therefore the
Roller Axle rotating parts of the
(stationary)
roller are sealed
against the static
axle by a slip-ring
system.
When they are new, the two rings sliding on one another are lapped. Under elastic load
they do not let any lubricant through.
It is not the task of the slip-ring sealing to keep dust away from the roller bearings. This is
rather the task of the sealing air system (see operating instructions "Sealing Air System").
Extreme fouling in the roller bearing chamber consisting of grinding material always shows
inadequate functioning of the sealing air system.
(UAE) P.S.C. Ras Al Khaimah Cement Plant Rocker arm
Roller bore
Rocker arm
axle
Fork
Rocker arm
Function
The rocker arm has the task of transmitting the force produced by the hydraulic double acting
cylinder(s) of the assembly "Spring Assembly cpl." onto the roller and the grinding bed. The
force is thereby led from a jointed pin for the spring rod(s) in the lower part of the fork via the
split sleeve / pin joints into the hubs, the central rocker arm and the rollers. The torque arms
for transmitting these forces (distance between swivel pin in the fork and the rocker arm
bearing / rocker arm bearing to the centre point of the roller) are so dimensioned that the
bearing reaction forces are always directed into the pedestal.
The separation of the central rocker arm and the fork allows to keep the fork and cylinder of
the springing device in position during the swinging-out process of the rocker arm/roller unit.
Dismounting of these components is not necessary.
The internal sealing system between the roller and rocker arm is protected against the ingress
of dust by an air seal. The air is fed to a coaxial gap between the roller and the rocker arm via
a bore in the middle of the rocker arm.
The sealing between the rocker arm and the mill body is achieved via the sealing box with its
vertical sides and rounded upper and lower surfaces. The rounded surfaces rotate
concentrically about the rocker arm axle (see "Rocker Arm Sealing cpl.).
PRINCIPLE LAYOUT
HYDROPNEUMATIC SPRING
SYSTEM
Group Spring Assembly cpl.
Commissioning / Startup and Operation

Commissioning and Initial Start-up of Hydraulic System
Adjustment of the proximity limit switches on the rocker arms as shown in drawing "Rocker Arm
Monitoring, complete" (see mill parts list). These proximity switches are provided on each rocker arm.
Checking of the positioning of hand-operated valves within the hydraulic system according to drawing
"Hydraulic Scheme HSLM ..."
Electrical monitoring and interlocking systems are to checked according to the Electrical
Documentation.
The hydraulic system has to be bled frequently until all the entrained gas has been removed
PRINCIPLE LAYOUT HYDROPNEUMATIC SPRING SYSTEM

HSLM
M
Tank
N2
OPERATING
PRESSURE
N2
SOLENOID VALVE
COUNTER
PRESSURE
(UAE) P.S.C. Ras Al Khaimah Cement Plant SCHEME: HYDRAULIC HSLM
Function table for Hydraulic system
(UAE) P.S.C. Ras Al Khaimah Cement Plant HSLM Cabinet
SCHEME: HYDRAULIC HSLM PIPING
Piston Accumulator Bladder Accumulator
Gas Valve
N2 Piston
Piston Packing
Oil
Shell
Oil
Function
During mill operation the rollers are raised by the material to be ground on the table, as a function of layer
thickness. The rocker arm rotates slightly and the pistons of the hydraulic cylinder move up, forcing the oil
on the piston rod side out of the cylinder chamber through hoses and piping into the hydraulic bladder
accumulators. The oil flowing into the accumulator flasks compresses the nitrogen-filled accumulator
bladder. The non-homogeneity of the grinding bed sets up vertical movement in the rollers, as when a car
wheel runs along a rough road. If the rollers run into a "grinding bed trough", the accumulator bladder
expands and pushes a corresponding amount of oil from the accumulator housing back into the cylinder.
This means that there is a continual exchange of oil between cylinder and accumulator, with a very rapid
response. In a similar manner the piston accumulators are connected with the piston chamber side of the
hydraulic cylinder.
The hydraulic cylinders of opposite rollers are interconnected on the oil side so that the rollers will exert the
same force on the grinding bed irrespective of their deflection thus ensuring a uniform loading of the thrust
bearing in the mill gearbox.
For starting and stopping the mill, it is possible to lift the rollers hydraulically off the grinding bed. This
is effected by directing the oil of the pump from the piston rod side to the piston side chamber of the
hydraulic cylinder. Owing to the different resistances in the hydraulic system, the rollers are not lifted
simultaneously but one after another. The roller movements upwards are mechanically limited. As soon
as all rollers have reached their top limit position, this state is electrically signalled.
With the rollers lifted it is possible to start a mill when filled. When starting a filled mill, the mill motor is
loaded to appr. 40 % of the operational torque. Upon lowering the rollers, the remaining grinding stock
on the table is then ground quickly. The lowering of the rollers occurs with a time delay with respect to
the feeder. This increases the grinding bed depth slowly and the motor torque rises correspondingly to
100 %. With this mode of operation the full load condition will be attained after about 30 seconds.
Group Spring Assembly cpl

a) Roller Lowering (Automatic Operation)
Upon opening of the valves (7.5 and 7.6), the oil will be returned from the piston side hydraulic
system to the tank, until the pressure has been reduced to that which was preset for the counter
pressure system. The lowering speed of rollers will be determined by the LOESCHE
commissioning engineer by appropriate adjustment of throttles (18.5 and 18.6). Vale 7.6 will
close first with the counter pressure value of setpoint +∆p+3 bar while 7.5 closes with actual
counter pressure is equal to the setpoint of counter pressure. At that time is “grinding mode”
Valve 7.5 with throttle valve 18.5

and 7.6 with throttle valve 18.6
b) Increase (Raising) of Operating Pressure
The required operating pressure and the control characteristics can be pre-selected within the PLC.
During mill operation the pump unit will automatically run until the chosen value is attained. The oil
from the pump is led through a throttle in order to reduce troublesome pressure surges within the system.
ELECTRIC MOTOR
FROM TANK
7.11

c) Reduction (Lowering) of Operating Pressure
The required operating pressure and the control characteristics can be pre-selected within the PLC. Solenoid
valve (7.2) will be opened automatically during mill operation so that the oil may return to the tank. The
returning oil is led through a throttle (18.2) to control the rate at which the pressure decreases. The solenoid
valve (7.2) is closed as soon as the lower pressure has been attained.
Please check on the basis of the Spring Diagram whether the ratio between the N2-charging pressure and the
hydraulic operating pressure is still within the admissible tolerance.
Valve 7.2
d) Increase (Raising) of Counterpressure-System
The required pressure and control characteristics can be pre-selected via the PLC. Solenoid valve (7.10)
opens and oil flows from the operating system to the counter pressure system. The oil is led through a
throttle (18.10) to control the rate at which the pressure increases in the system. The valve shuts as soon
as the higher counter pressure has been attained.
Valve 7.10 with throttle

18.10
e) Reduction (Lowering) of Counter pressure System
The required pressure and control characteristics can be pre-selected within the PLC. Solenoid valve
(7.5) opens and allows oil to flow back to the tank. The oil is led through a throttle (18.1) to control the
rate at which the pressure decreases. The valve closed as soon as the lower pressure has been attained.
Valve 7.5 with throttle

valve 18.5

e) Roller Raising
With automatic control the solenoid valves (7.11, 7.21 and 7.22) will be switched into their appropriate
position according to hydraulic diagram. With local operation it is instigated by depressing the "Roller
Raising" pushbutton.
Both pump units will start automatically, pump 2.10 with speed 2 and continue to run until all rollers
have reached their uppermost limit position which will be monitored by electrical proximity switches on
the rocker arms. Thereafter, the pump unit will be stopped automatically
Pump 2.10 and 2.20
Valve 7.11 and 7.21 Valve 7.22

f) Retaining of Rollers in their top Positions (Automatic Operation)
Should one or several rollers leave the appropriate uppermost end positions due to leakage within the
hydraulic system, the pump unit will be started automatically in the same way as described under "Roller
Raising".
Attention: For safety reasons no persons shall be allowed to stay within range of the movable
components of the milling force transmission system.
g) Relieving of Pressure (manual mode)
If the entire hydraulic system has to be relieved to atmospheric pressure, e.g. in case of charging pressure
measurement with the accumulators or in case of maintenance work, the system must switched from
"Remote" to "Local" mode.
In this mode, the control system will be inoperative.
Upon opening of the ball valves 5.5 and 5.2 by manual operation, the oil will return to the tank.
h) Retaining of Rollers in their top Positions for Service Work
Automatic lifting of rollers.
Clearance for local operation from CCR. Pressure control system is no longer active.
After reaching “roller in top position” the ball valves 5.2, 5.4 and 5.5 have to be closed.
components of milling force transmission system unless additional mechanical safety precautions (e.g.
distance pieces between roller and table) will prevent any accidental movement of the rollers.
i) Relieving of Pressure (manual mode)
If the entire hydraulic system has to be relieved to atmospheric pressure, e.g. in case of charging pressure
measurement with the accumulators or in case of maintenance work, the system must switched from
"Remote" to "Local" mode.
In this mode, the control system will be inoperative.
Upon opening of the ball valves 5.5 and 5.2 by manual operation, the oil will return to the tank.
j) Retaining of Rollers in their top Positions for Service Work

Automatic lifting of rollers.
Clearance for local operation from CCR. Pressure control system is no longer active.
After reaching “roller in top position” the ball valves 5.2, 5.4 and 5.5 have to be closed.
components of milling force transmission system unless additional mechanical safety precautions (e.g.
distance pieces between roller and table) will prevent any accidental movement of the rollers.
k) Parallel Flow Filter
When valve 7.1 is in its neutral position and the pump is started, the tank contents are (in addition to the
main filtration) circulated over the filter at certain time intervals.
The operational demands of the machine have priority over those of the parallel flow filter system.
Pump 2.20
Valve 7.22
Spring Characteristics
General
The hydro pneumatic spring system with the HSLM hydraulic cabinet permits the roller force to be
adapted to the material to be ground and to keep the grinding bed thickness constant within close
tolerances.
It consists of two separate systems, the so-called operating system which provides pressure to the rod-
side of the cylinder and the counter pressure system which supplies pressure to the piston side. The
control system is controlled according to the mill feed rate.

Working Pressure (Spring Stiffness)
General
The spring characteristic line, i.e. the spring stiffness, can be selected upon the rod side by adjusting the
ratio of the hydraulic operating pressure p2 to the N2-charging pressure of the accumulator bladder p1
and, without variation of the N2-pressure, the spring stiffness can even be varied during operation of the
mill. The "Diagram: Roller Spring Stiffness" indicates the limits which have to be observed.
Operation
In the "Diagram: Roller Spring Stiffness" the roller stiffness cwf (= spring stiffness related to the roller) is
plotted against the nitrogen-charging-bladder pressure p1. The parameters are the various hydraulic
operating pressures p2 and the roller forces FW, respectively.
c wf
Spring
of the Roller
[kN/mm]
Operating Range
Operating Pressure p 2 [MPa]
Charging Pressure of Hydraulic Accumulator p1 [MPa] [0,1 MPa = 1 bar]
Determination of spring stiffness of the roller cwf
1) Selection of operating pressure p2 (with reference to "Diagram: Roller Load" (see
documentation parts list "HSLM")).
2) Selection of charging pressure of hydraulic accumulator p1 within the operating

range.
(please note: p1max = 0.8 * p2min p1min = 0.25 * p2max)
3) Follow the vertical axis of the accumulator charging pressure p1 until it intersects the
operating pressure curve p2 .
4) From the intersection follow the horizontal axis left to read the corresponding spring
stiffness (cwf) of the roller.
The roller stiffness value is a measure of the amount by which the roller force increases for a roller
deflection of 1 mm (0.04 in).
The smaller the difference between p2 and p1, the softer the spring. This means that with a soft spring, the
force increase is low when deflecting the roller. The max. p1 value of the N2-charging in the accumulator
must not exceed 80 % of the operating pressure p2, as otherwise the rubber bladder could be destroyed.

Starting of Mill in Empty or Filled Condition
Before lifting the rollers, the working pressure has to increase to the level of Pr (minimum working pressure
to raise rollers ).
Than the rollers have to be liftet until the mechanical stop is reached (the stop is given by the proxi
switches). Remember: The rollers will be lifted one after the other.
After all rollers have been reached their upper position, the appropriate pump motor is switched off by the
proximity switches. (Just before the mechanical stop has reached)
Note: While the pistons move out during the lifting of the rollers, the oil is displaced into the hydraulic
accumulators and the piston accumulators; as the nitrogen filling is not released, the pressure in both
systems is increased relative to the set pressures for the mill operation. The normal control system is then
inoperative. The electronic controllers do not function whilst the rollers are being lifted or lowered. The
higher oil pressure (piston rod side) can be read from the pressure gauge (4.2), whilst the oil pressure which
is used for the lifting process in the lower (piston side) cylinder chamber is indicated on the pressure gauge
(4.3).
With lifted rollers, the appropriate pump will be re-started automatically in case of oil leakage, if one or
more of the rollers have moved downwards to the switching point of the "lower" proximity switch: valve
(7.1) in position "I".
During the procedure "Lowering Rollers" the rollers move downwards onto the table because of gravity and
the additional force of the gas filling in the accumulators. Whilst the rollers are being lowered the control
system is inoperative.

For smooth lowering of the rollers onto the grinding bed the return oil from the piston side cylinder
chambers is initially fed back into the tank through the adjustable throttle.
After the command “lowering the rollers” and the “grinding mode” one time delay starts.
The prerequisites to be satisfied for activation of the individual functions may be gathered from the
sequence chart forming part of the LOESCHE electrical documentation.
Shutdown of Mill in Case of Normal Operation

When the mill is to be stopped, the conveyor for the material to be ground will be disconnected. After a
time delay the automatic hydraulic control will be switch off, and the hydraulic pump will lift the rollers till
the signal “rollers in Top position” is reached.
Emergency Stop
In case of an Emergency Stop or a power supply failure the rollers will remain in contact with the material
to be ground. Braking of the table will take one revolution maximum.
Local Operation
For maintenance work the system must be switched to "Local Operation" in the control room. The remote
control system is then inoperative.
The rollers can be operated by the local push buttons.
Group Supporting Rollers
Supporting Rollers
The S-roller tire is a wear-resistant casting. The non-profiled surface has a working width corresponding
to that of the master roller.
The mill is equipped with 3 S-rollers, where each of it is opposite of a master roller.
The S-roller is no grinding roller but a preparation roller. It serves the purpose of pre-compacting
the aerated and non-homogenous grinding bed composed of grinding stock charged and recirculated
grinding stock, i.e. of preparing the grinding bed for the downstream grinding roller.
It is for this reason that the working plane of S-roller is substantially higher than that of the M-roller. The
position of S-roller above the table may be selected in two ways:
- by adjustment of the S-buffer spindle in that the S-roller rocker arm complete with the S-roller is
mechanically adjusted to a desired height
- by means of the S-roller hydraulics by way of positioning via a hydraulic cylinder which is the
more common way
- S-roller are serving either in position controlled mode
or in speed controlled mode
(UAE) P.S.C. Ras Al Khaimah Cement Plant Group roller lubrication HSMS
Group roller lubrication HSMS
Function
Purpose of the HSMS system is to grease the roller bearing, return the oil back to the tank, clean and
cool the oil.
Each roller has two pumps. One compression pump and one depression pump.
The adjusting of the the oil amount will be done during commissioning and is depending from the
length of the oil pipline and the oil temperature.
After start the mill the roller lubrication system starts app. 20 min later in order to heat up the oil in the
roller. The oil temperature in the oil tank kept constant by means of heat elements which are controlled
by thermostat. The adjusted Temperature should be app. 60 °C.
Further information please refer BA 911158-01-4 en in the Dokumentation Folder OM-01 HSMS
Group water- and grinding aid sprinkling
Group water- and grinding aid sprinkling
Group water – and grinding aid sprinkling

Water line to LM
Shut off valve
Return line to the tank
Electronic flow meter
Pressure relief valve
pump with VFD

controlled motor
Solenoid valve
Filter
Shut off valve
flow meter
water tank
grinding aid tank
pressure relief valve
grinding aid pump

with VFD motor
water pump with

VFD motor
General
The grinding plant is equipped with a water and grinding aid system to stabilize the material bed for an
optimum of grinding effect as well as to ensure the flow ability of the cement
Function
The group "Water Injection cpl." consists of the pumping unit and the piping on the mill including the
injector nozzles, control and mounting elements.
The piping connected to the pumping unit is divided into three feed lines. Each feed line is connected with
one water lance, having holes respectively nozzles for sprinkling the water onto the material bed.
At the inlet of the water lances a compressed air piping is connected. By means of a solenoid valve
compressed air will clean the water lances from remaining water in order to avoid material caking at the
water lances it self.
Each time the water pump/grinding aid pump unit is stopped, compressed air is cleaning the water lances for
about 5 minutes.
Pressure transmitter are installed in order to monitor the water sprinkling through the nozzles.
In case the pressure comes below the min. limit, the water pump has to stop as by this time water will come
into the mill uncontrolled, e.g. worn out lances or nozzles
General
As grinding aid we are using DEG, Diethylenglycole.
The most important negative effect during grinding is the agglomeration of particles which can be described
by the adhesion of separate individual particles. Furhtermore, this process can result in the formation of
coatings which than can result in a reduction of grinding efficiency.
Due to such a possible agglomeration the internal material circulation might increase as these particles are
more heavy and bigger, not reaching the classifier or might be rejected by the classifier.
The task of grinding aid is to encounter these negative effects and to assist the grinding action as well as
improves the flow characteristics of the ground cement
Group water injection
Seal air system
Seal air system
Sealairairsystem
Seal system
Rocker arm M-Roller
Seal air system
To avoid damage
occasioned by
ingress of dust
from the grinding
chamber into the
roller bearings
and the slip-ring
sealing of the
roller, the small
annular gap (circa
1 to 2 mm)
between the
rotating neck of
the roller and the
cast ring of the
stationary rocker
arm is pressurized
with sealing air.
(UAE) P.S.C. Ras Al Khaimah Cement Plant Seal air system
(UAE) P.S.C. Ras Al Khaimah Cement Plant Seal air system
Seal air
Seal air system
To avoid damage occasioned by the ingress of dust from the grinding chamber into the roller
bearing and the slip ring sealing of the M- and S-roller, a small annular gap between the rotating
interior ring of the rollers and the wear ring of the stationary M-andS-rocker arm, which surrounds
the neck of the roller, is pressurized with sealing air.
The sealing air feed, provided by a seal air fan, is arranged according to the type of mill through a
hole, positioned in the top respectively at the axel of the rocker and via the interior of the lever to
the sealing air chamber, from which the air streams out over the annular gap into the interior of
the mill.
The speed at which the air is drawn or blown through the sealing air gap into the grinding
chamber is the most important aspect of the system. Should the gap become worn then the rings
on both the rocker arm and the roller must be exchanged.
A monitoring system is provided in order to monitor the actual pressure of the seal air system at
the inlet of each single M-and S-roller.
In case the pressure drops below the limit, an alarm will indicate the need of check.
Limits have to be determined during commissioning
Control loop: Mill air volume flow

Mill air volume flow
The volume rate of flow of gas through a mill per unit time influences the grinding, classifying and
dedusting process in a grinding plant and for this reason must be held constant.
The volume rate of flow per unit time depends on the design and capacity of grinding plant
In general:
During the normal grinding operation, the volume rate of flow must be held constant according to the design
criteria independent of pressure and temperature fluctuations in the system.
Measurement and control loop
The volume rate of flow in a grinding plant is deter mind by a venturi pipe or an orifice plate situated after
the pre-selection or dedusting system accordingly. Certain plants, because of their general arrangement,
prehibit such measurement. An alternative to this would be summing two separate measurements made in
the exhaust stack and recirculation duct.
The differential pressure measurement taken from the venturi or the orifice plate is transformed into the
standard 4-20 mA signal proportional to the flow and is required for the control loop. This signal must be
damped electronically and will be set accordingly during the commissioning.

The following regulation units could be used to control the flow
1) A damper at the fan inlet
2) A vane controller at the fan inlet
3) A variable speed fan drive motor
4) A combination of damper or vane control with the variable speed fan drive motor
For 1) and 2) a three point PID controller is required

For 3) a continuous PID controller is required
For 4) a three point stepping and a continuous controller or a multifunction controller is required
The mill air volume flow control loop is only active during grinding operation
Manual control is also possible.
Certain process situations may arise whereby the regulation unit is not in a position to retrieve the set
point. For this reason limit monitors are installed for alarm purposes and to take the necessary steps in
the process control logic to ensure the plant equipment is protected accordingly.
Limit values
MIN 1 at app. 75 % of rated flow warning
MIN 2 at app. 70 % of rated flow switch off or switch over the grinding plant
Control loops (Mill outlet temperature)

Mill outlet temperature
The mill outlet temperature is decisive for drying the material to be ground. The mill outlet temperature is
determined by the inherent raw material moisture content and the set value is adjusted accordingly during
commissioning.
The plant equipment, such as dedusting systems, fans etc. following the mill have to be designed to
withstand the mill outlet temperature.
Too high mill outlet temperature is not dangerous only for bearing and seals in the grinding rollers but also
for the plant equipment following.
Too low mill outlet temperature results in inadequate drying, has a negative influence on the grinding
process and runs a risk of a temperature fall below the water dew point. The mill outlet temperature must be
held constant.
Limit values
MIN Not enough heat is available and the grinding process can no longer be
guaranteed. If the heat source to the mill is already at maximum, the material
feed to the mill must be reduced.
MAX 1 Warning
MAX 2 Hot gas supply –OFF and the stopping or switch over sequence is initiated.

The mill outlet temperature is measured in the duct at the mill outlet.
The following regulating units could be used to control the temperature.
1) A control valve with solenoid valves and nozzle arrangement in a water injection system to the mill
2) A burner of an air heater
3) A damper in the cold air duct
4) A damper in the hot gas duct (Influence the heat flow)
5) A speed controlled booster fan
6) A control valve with solenoid valve and nozzle arrangement at the cooling tower.
7) A combination of the above mentioned arrangements is possible.
The control system is only operative while the mill is running. Manual control is also possible.
Certain process situations may arise whereby the regulation unit is not in a position to retrieve the set
point. For this reason limit monitors are installed for alarm purposes and to take the necessary steps in
the process control logic to ensure the plant equipment is protected accordingly.
Control loops (Mill inlet pressure)
Mill inlet pressure (for vacuum pressure driven plants)
The criterion that a medium flows between two points in a system is that a differential pressure exists.
The static pressure at the mill inlet as opposed to atmospheric pressure is a point for developing a
pressure difference to a previous system.
The mill inlet pressure depends on the air volume rate of flow in the plant, developed by the mill fan. For
this reason the mill inlet vacuum pressure is responsible for drawing process gases into the system.
For grinding plants which operate in compound with clinker producing plants, the mill inlet region is the
interface between grinding plant and kiln.
The difference in pressure between the mill inlet and the kiln outlet ensures that the kiln waste gases are
drawn in for the dry grinding process.
In plants where the kiln waste gas volume flow is too low that the grinding plant has to be run with
recirculation gases, the mill inlet pressure is decisive for guaranteeing the flow of recirculated gases.
Depending on operating conditions this recirculating gas may be supplement with fresh air.
In central grinding plants the mill inlet pressure influences the supply of gas from either of the following:
1) hot gas generator
2) fresh air supply
3) Recirculation gas supply
4) combination of the above (depending on the plant design)
In all of above mentioned systems the mill inlet pressure is a vacuum pressure.
The mill inlet pressure is maintained constant.
The regulation unit for the mill inlet pressure could be

control damper in the recirculation duct
control damper in the exhaust stack
fresh air damper in the mill inlet duct
damper or van controller from a fan parallel to the grinding plant

The mill inlet pressure signal is transformed into a standard 4 – 20 mA signal.
Should this signal be required to be electrically damped, this may take place during commissioning.
The pressure control loop only operates during mill operation. The controller (PID) may be switched to
manual at any time.
Certain situations may arise wherby the regulation unit is not in a position to retrieve the set point. For
this reason limit monitors are installed for alarm purposes. It is not normal to take any action in the
process control logic.
Limit values
MIN 1 warning MAX 1 warning
MIN 2 alarm MAX 2 Alarm
Grinding roller wear parts

Wear
The rollers are tools carrying out comminution and are therefore subject to wear. A tire is used as
the wearing part. The tire is a casting with a high resistance to wear and consists of a single part
ring with a conical running path. It is drawn on to the hub via a clamping ring on the face side
with tee-head bolts, disc springs and nuts. At the smaller diameter the tire sits on a cylindrical
seat of the hub whereas at the larger diameter it is held on by friction on a conical clamping
surface on the hub. The clamping surfaces of the tire and hub are machined with narrow
tolerances! The use of imprecisely machined tires would result in an increased risk of
breaks and destruction of the conical seats!
The wear rate is mainly responsible for the through put of the mill. If the grinding parts are worn
out, the capacity of the mill will reduced and the product quality degrade.
It is strictly recommended to use only original spare tires and table liners because only the
original parts respects the grinding profiles.
Grinding roller wear parts
COMPARASION OF LIFE TIME
1,8
1,6 MIN MAX
Ni hard 4 0,5 0,4 0,9
1,4
Cromadur 1 0 1
1,2 Cromafer 1,3 0,4 1,7
1,0
Life Time Multiplier 0,8
0,6
0,4
0,2
0,0
Ni hard 4 Cromadur Cromafer
Material Quality
End
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Operation description for LM56.

3+3 C/S with LSKS 87 CS / UCC

Loesche Raw Material Grinding Mill

Loesche Senior Commissioning Engineer

since November 1975

Loesche GmbH has celebrated

Loesche has supplied over 600 modern mills for grinding

• Largest Loesche mill size to date are LM 63.4

• These very large mills grind Cement raw materials

• Mill installed motor power approximately 5 MW

• The very large mills have LSKS dynamic classifiers

General Pre-Conditons for UCC Ras Al Khaimah Cement Plant

Mill layout data for UCC Ras Al Khaimah Cement Plant

Material Components OPC-CEM 1 EN 197:

Blaine cm2/g: min. 3400

The „Classifier cpl.“ assembley

 Classifier Housing cpl.

Group Classifier LSKS

Loesche mill LM 56.4

Sealing Air Pipeline cpl. Mill-Upper Housing cpl.

Rocker Arm Sealing cpl.

Roller cpl. Mill-Platform cpl.

Rocker Arm cpl.

Table cpl. Mill-Lower Housing cpl.

Ring Pipeline cpl.

For more information please refers BA 911060-10-4 en “Table cpl.”

Grinding Plate and Clamping Ring

Grinding roller sealing

Grinding roller slip ring sealing

Commissioning / Startup and Operation

PRINCIPLE LAYOUT HYDROPNEUMATIC SPRING SYSTEM

Function table for Hydraulic system

SCHEME: HYDRAULIC HSLM PIPING

Group Spring Assembly cpl.

Group Spring Assembly cpl.

Group Spring Assembly cpl

Valve 7.5 with throttle valve 18.5

Group Spring Assembly cpl.

d) Increase (Raising) of Counterpressure-System

Valve 7.10 with throttle

Group Spring Assembly cpl

e) Reduction (Lowering) of Counter pressure System

Valve 7.5 with throttle

Group Spring Assembly cpl

Pump 2.10 and 2.20

Valve 7.11 and 7.21 Valve 7.22

Group Spring Assembly cpl.

Group Spring Assembly cpl.

i) Relieving of Pressure (manual mode)

j) Retaining of Rollers in their top Positions for Service Work

Group Spring Assembly cpl.

k) Parallel Flow Filter

Group Spring Assembly cpl.

Group Spring Assembly cpl

Operating Pressure p 2 [MPa]

Charging Pressure of Hydraulic Accumulator p1 [MPa] [0,1 MPa = 1 bar]

Determination of spring stiffness of the roller cwf

2) Selection of charging pressure of hydraulic accumulator p1 within the operating