LEARNING MORE ABOUT

ROLLER PRESS

PROCESS KNOW-HOW

A TECHNICAL WORKSHOP BY
HUMBOLDT WEDAG INDIA

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 Process know-how

I. Introduction

II. Specification

III. Working Principle

IV. Operational Aspects

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

The Roller Press is most efficient comminution machine

of grinding applications involved in cement
manufacturing process.

This machine is being used for clinker, raw material, slag

and mineral grinding applications.

Size reduction of the material takes place under high

pressure between two rotating rollers.

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Better comminution efficiency

than Ball mills and Vertical
Roller mills (VRM) achieved by
getting uniform press forces on
grinding bed between rollers.

Better energy utilization than

the Ball mills and Vertical Roller
mills.

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

KHD Roller Press is denoted as:

RP 13-140/140
Roller width [cm]
Roller diameter [cm]
Press force [MN]

Roller Press

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Bulk material is fed to the gap by mean of

dosing gate between two rollers which are
driven in counter-rotation.

The necessary press force is created by a hydro-

pneumatic system which works like a spring.

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

After reaching between the rollers, the

particle bed is pressed to a bulk density
of up to 1.8 times of the actual material
bulk density.

This compression is achieved by

applying the high pressure on to the
material bed between rollers.

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Nitrogen Accumulator

Gap Opening
Pressure Relief Valve

Hydraulic
Pressure

Fixed Roll Movable roll

Sketch of Roll- and Pressure System

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

The Breakage process can be classified in to

the following two discrete stages:
 Nipping/Compression
 Attacking/Compaction

The choke-fed material of density ρ0 enters to

the space between two rollers.

Due to narrowing gap between the rollers,

gradual compression of material starts at
nipping angle ‘α’ and the larger pieces and
particles are pre-crushed.
Guide values for ‘α’ are ;
α = Nipping angle/Compression  6.9-9.2o for clinker
β = Attack angle/Compaction  9.2-12.6o for raw material
γ = Feed angle  5.7-7.5o for slag.
F = Press force
ρ0 = Feed Density A certain degree of particle re-arranging
ρG = Slab/Flakes density occurs which fills the inter-particle voids
Vu = Circumferential speed

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Attacking/Compaction:
Pre-crushed material then enters to
compaction zone

Compaction zone involves a gap between the

rolls defined by a sector with an angle ‘ẞ’
[Attack angle]

Guide values for ‘ẞ’ are ;

 2.3-2.85o for clinker
 2.85-4.0o for raw material
 1.7-2.3o for slag

The pressure force is acting principally on all

particles passing the compaction zone through
multiple point contacts between the particles in
the compressing bed.

This comminution principle makes roller press

more efficient comminution machine than Ball
mill and Vertical roller mill.
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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Specific Press Force:

Specific Press Force (N/mm2):

F
Ps =
W * D

Where:

F = Force, N

W = Roller Width, mm

D = Roller Diameter, mm

Guide value for specific Force: ≤ 7.0 N/mm2

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Cement Clinker Cracked Alite Crystal

Cracks due to
high pressure

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Compaction of feed material

results-in the disintegration of Clinker sample after comminution in a
laboratory Jaw crusher and roller press
most of the particles. At this
point material converted to the
slabs of density (ρG). Crushed in Crushed in
Roller press jaw crusher
The high press force in the
material bed promotes
differential stresses locally
within the feed material and
micro cracks are generated
within the particles.
Micro-cracks

The micro fractures result in a

reduction of energy for further
grinding of clinker / raw
materials.
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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Roller press is often used in Two types of circuits:

1) Semi-finish grinding:

Under this configuration the

roller press is installed in
closed circuit with a V
separator and SKS separator
at the same time the ball mill is
connected in closed circuit with
SKS separator.

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

2) Finish grinding:

Under this configuration the

roller press is installed in close
circuit with V-separator and
SKS separator.

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Operational Sequences
All transport equipment to start first and proper air
flow is to be maintained.
Roller Press drive is started after fulfilling all safety
requirements.
Fresh feed is fed to V-separator
Fines will be recovered and lifted to SKS separator
for classification.
SKS fines will be collected as finish product and the
rejected coarse material comes back to combine with
VS rejects and fed to pre-bin for next cycle.
Coarse collected from V-separator consists of fresh
feed and grits disintegrated from RP slabs.
Above admixture is fed into RP bin for uniform
feeding to Roller press.

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Operational Sequences

Once RP Bin is maintained to 30-40% of its total

capacity the feeding to roller press is started.

Initially the opening of feed regulating gate is kept

minimum to avoid frequent flushing/surge of feed to
the roller press due to lower filling.

Once the outgoing and incoming equilibrium is

established in the system the opening of feed
regulating gate is increased gradually.

At this stage the draw power of Roller press will be

stable and now the fresh feed will be regulated with
respect to RP bin level. i.e. if bin is getting empty
the feed will be increased and if bin is getting full
the feed will be reduced.

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Operation

Maintain balanced separator operation :

Recommended air/material ratio and optimum
speed of separator cage to be maintained for
achieving the better efficiency of the separators.
Better separator efficiency results in lower
circulating load and less fines circulation to Roller
press.

Feed granulometry :
Maximum feed size = 2 x gap opening;
However, for better life of roller profiles the
maximum feed size to be restricted to 50 mm.

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Operation
Speed of rollers :

A strong relation exists between the granulometry and

circumferential speed of rollers. If the feed contains a
high amount of very fine material and the speed of
rollers is high, the press tends to vibrate and a smooth
operation is not possible.

Adjustable feed gate:

An important influence on the press operation (material

intake, gap opening) has the feed regulating gate. Feed
gate ensures to feed uniform layer of grinding bed
between rollers.

This arrangement also ensures the venting off the air

released from clinker pores to ensure smooth operation.

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Operation
V-Sep
Discharge
chute
Homoginised material feed:

An important influence on the roller press operation is

the feed homoginisation to the roller press and this is
done at advance stages before feeding to roller press
for this purpose following corrections usually made;

 Reducing the V-separator material discharge chute

opening to make choke feed which pre-mixes the
fines with grits before entering to RP bin.

 Installation of Pre-mixing box at RP bin:

This is a rectangular box installed at RP bin to
reduce surges and velocity of falling material from
V-separator and also reduces material
segregation in RP bin.

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Operation
Adjustment of Lateral sealing /Cheek plate : Cheek plate gap 2 mm

Roller press operation is greatly govern by:

Maintaining perfect clearance between cheek plate and roller
lateral surface; optimum clearance is recommended to
maintain 2-4 mm.

 More clearance means more uncrushed material bypass to

the rollers resulting in;
 Higher circulation load in RP circuit results in increased power
consumption of RP Elevator.
 Higher circulation of fines results in filling of the RP bin thus
reduced output rates.
 Fines escape from one end creates skewing of rolls results-in
unstable operation.
 Continuous passage of clinker results in wear of roller lateral
surface.

 Less clearance results-in high wear of Lateral Seals and

roller sides as well.
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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

For Effective Operation:

Roller Press grip:

Maintaining perfect line profiles for better draw-in effect of the material in-between the
rolls and also forms the autogenous layer of crushed material

Roller with worn-out profiles Roller with Profiles

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Process Know-How
Working Operational
Introduction Specification
Principle Aspects

Roller Press Grip

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Thank you very much for your patient hearing.....

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