Materials Today: Proceedings 44 (2021) 4621–4627

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Review on vertical roller mill in cement industry & its performance

parameters
Praveen Pareek a,⇑, Dr.Vijayendra Singh Sankhla b
a
GITS, Udaipur, India
b
DME, GITS, Udaipur, India

a r t i c l e i n f o a b s t r a c t

Article history: India is the world’s second largest producer of cement and produces more than 8 per cent of global capac-
Received 10 October 2020 ity. Due to the rapidly growing demand in various sectors such as defense, housing, commercial and
Received in revised form 26 October 2020 industrial construction, government initiative such as smart cities & PMAY, cement production in India
Accepted 30 October 2020
is expected to touch 550–600 million tones per annum (MTPA) by the end of year 2025.
Available online 6 January 2021
With recent growth and success journey there is also a threat approaching to cement industry that its
input cost is increasing. Power cost, fuel cost, raw material cost have doubled up in recent years whereas
Keywords:
cement price has not hiked in that fashion. Also 40% of the cement production costs are energy costs out
Vertical roller mill
VRM
of which more than 60% of the total electricity is used in grinding circuits. In order to survive and sustain
Grinding in the market they need to increase their profitability which can only be achieved by increasing produc-
Cement mill tivity and reducing power consumption. High productivity and low power costs can be achieved by
increasing output, lowering breakdowns and optimizing the energy consuming grinding process.
The objective of the study, is to draw attention to the need of Cement grinding process optimization to
minimize power consumption and achieve higher productivity. In the study the advantages of vertical
roller mill are discussed over ball mills. VRM construction, its process and parameters which affects
the performance and productivity of vertical roller mill are discussed. Also the consequences of variations
in parameter explained. With proper optimization of these parameters, the productivity of vertical roller
mill can be improved and performance stability can be achieved by addressing root causes.. This study
can benefit the organizations using VRM and are not able to utilize its full productivity due to some bot-
tlenecks or constraints.
Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Confer-
ence on Advances in Materials Processing & Manufacturing Applications.

1. Introduction
The Indian cement industry have many major players in the lea-
gue. The top 20 cement companies produces almost 70% of the
total installed production capacity in the country. There are 210
large cement plants having total capacity of 410 MT cement pro-
duction, with 350 small plants account for the rest. Out of 210
large units, 77 are situated in the states of Andhra Pradesh,
Rajasthan and Tamil Nadu [13].
There are three types of cement manufacturing processes - wet,
semi-dry and dry processes. In the wet/semi-dry process, the raw
materials are produced by mixing limestone and water (called
⇑ Corresponding author.
E-mail address: praveen.parieek@gmail.com (P. Pareek).
slurry) and blended with soft clay. In dry process technology,
crushed limestone and raw materials are ground and mixed with-
out addition of water. Dry and semi-wet processes are more
energy-efficient. The wet process requires 0.28 tons of coal and
110 kWh to produce one ton of cement, while the dry process
requires only 0.18 tons of coal and 100 kWh of energy [4].
In India many types of cement is produced based on different
compositions according to specific end applications such as Ordi-
nary Portland Cement (OPC), Pozzolana Portland Cement (PPC),
White Cement, Portland Blast Furnace Slag Cement and Specialist
Cement. The basic difference is the percentage of clinker & addi-
tives used [4].
Now a days Cement plants are producing 75–80% PPC & 20–25%
OPC due to high market demand of PPC. Production of PPC is
cheaper and it’s market rate is also lower than OPC by nearly 25

https://doi.org/10.1016/j.matpr.2020.10.916
2214-7853/Ó 2020 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the scientific committee of the International Conference on Advances in Materials Processing & Manufacturing Applications.
P. Pareek and Vijayendra Singh Sankhla
rupees per bag, so general consumer are attracted towards PPC
cement. Cement companies also want to produce more and more
PPC grade. Now the OPC grade is only manufactured for Govt &
Institutional supplies.
2. Cement manufacturing process
2.1. Mining
The cement manufacturing process starts from the mining of
raw materials like limestone, clay used mainly in the manufactur-
ing process. A limestone mines are opencast type and is nearby
plant area and clays mines also found nearby to save transporta-
tion cost. After drilling and blasting, the limestone is excavated
from open cast mines and loaded into dumpers and transported
to crusher se4ction for crushing. The excavated clays from open
cast mines are unloaded to open yard storage. It is then transported
by dumpers and unloaded to the hopper of the clay crusher. To
design the kiln feed some other raw materials are also used to line
sand, and iron ore. The sand and iron ore are sourced from different
vendors & transported by trucks and unloaded into open yard
piles. By continuous lab testing these raw materials are mixed
together in desired ratios to be able to make chemical reaction to
make cement [1,2,9,14].
2.2. Crushing, stacking, and reclaiming of raw materials
After mining the limestone is sent to first crusher called a jaw
crusher and then into the secondary crusher (impact crusher))
with clay to reduce particle size less than 50 mm. The other addi-
tives like high purity limestone is also crushed separately in pri-
Fig. 1. Cement Manufacturing Process - Graphical Representation.
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Materials Today: Proceedings 44 (2021) 4621–4627
mary & secondary crusher for particle size less than 50 mm.
These all raw materials are stored in open area into a longitudinal
storage unit called stockpile through Stacker or Stacking machine.
Finally, the kiln feed mix or raw mix is extracted transversely from
the stockpile by means of reclaimer and through conveyors trans-
ported to raw mill bin, called the limestone bin, for grinding
[1,2,9,14].
2.3. Raw meal drying, grinding, and homogenization
Raw mix, high grade limestone, sand and iron ore are trans-
ported from their bins to raw mills for drying and further fine
grinding. The raw mill is either a Ball mill with two chambers or
Vertical roller mill with inbuilt classifier. The hot gases from the
pre heater enter the mill and are used for drying material in the
mills. The ball mill and VRM are explained in further sections of
this thesis. The hot gas and dry fine ground material are fed to
the mill outlet to a separator, which separates the fine and coarse.
The second, called reject, is sent to the mill inlet via an air slide for
further grinding. Hot gas and fine materials enter the cyclone sep-
arator and separate the fine materials and gases. This very fine
material is called Kiln feed and stored in blending silo for buffer
stock and blending. By means of compressed air this kiln feed
material is extracted which is fed to the top of the pre heater
cyclone section by a bucket elevator for pyro processing [1,2,9,14].
2.4. Pyro processing & clinkerization
To make clinker, pyro processing of kiln feed is done in Kin-Pyro
section. Kiln - Pre heater section has a multi-stage pre heater with
cyclones, calciner, riser ducts, rotary kiln, and clinker cooler. In pre
P. Pareek and Vijayendra Singh Sankhla Materials Today: Proceedings 44 (2021) 4621–4627

heater, the kiln feed is pre heated by hot air which is coming from
the calcination chamber and kiln. Through cyclones the kiln feed is
pre heated up to 850–900 degree centigrade temperature and then
fed to Calciner chamber where pre calcination of raw mix is done,
finally it is fed to rotary kiln where final calcination is done at 1400
degree centigrade & clinker components C3A, C4AF, C2S, and C3S
are formed. The main source of heat is coal burning. Coal is fired
as a main fuel (100%) in the rotary kiln and calciner chamber. Coal
is burnt to provide the required heat for calcination and to convert
the kiln feed into clinker. This red hot clinker further goes to clin-
ker cooler for cooling the clinker from 1400 degrees to 200 degrees.
For cooling clinker, cooler fans are used which supplies natural
fresh air with high pressure and fluidize the clinker bed in cooler
which actually cools clinker. The cooled clinker is fed to deep metal
pan conveyor and it is sent to the clinker storage pile (CSP). The
clinker cools further naturally in CSP and extracted and sent
through deep pan conveyors to Cement mill for final finished
grinding [1,2,9,14].
2.5. Cement grinding and storage
Extracted cooled clinker and other additives like gypsum, fly
ash etc. are fed to the cement mill in a controlled manner in speci-
fic quantity. The cement mill is either a Ball mill with two cham-
bers or Vertical roller mill with inbuilt classifier. Material is
ground till desired Blaine is achieved and then final product is
stored in concrete silos for further blending. In silos cement is
stored separately according to their grades so that mixing doesn’t
happen [1,2,9,14]. Cement extracted from silos is conveyed to the
automatic electronic packers where it is packed in 50 kg bags
and dispatched in trucks or trains. Now a day loose cement is also
supplied by cement companies to their major customers in large
quantity and also for in-house use supply through capsules (Fig. 1).
From the above table we can understand that Grinding activity
covers a major part of cement manufacturing process. Bold marked
stages are grinding activities. Limestone crushing and size reduc-
tion, Limestone and additives grinding, Coal Grinding, Finished
cement grinding are major grinding activities. It consumes more
than 60% of energy of total process (Table 1).
the future is to reduce the specific energy consumption in grinding
process [7] (Fig. 2).
Grinding systems in the cement industry play a crucial role in
particle size distribution and particle shape. This affects the reac-
tion of the clinker and the temperature dependence of the dehy-
drated gypsum which is also ground together with the clinker.
These factors affect the mortar properties of cement viz water
demand, early and final setting time and strength development.
The grinding process does coarse size-reduction by breaking
crushing as well as fine grinding with interesting size fractions.
All grinding processes in the cement industry are operated dry.
The capacities of grinding mills range from 300 1000 TPH for
Limestone and for cement grinding it varies from minimum 50
TPH while larger installations are up to 450 TPH [8].
Many technologies are in use today for grinding processes in the
manufacturing of cement, which have been developed over the
years. Ball mills have been used as the main grinding tool for
cement production for over 100 years. Although easy to operate
and competitive compared to other technologies, the poor effi-
ciency of ball mills has been one of the main reasons for research
and development of more efficient grinding processes in recent
years. Vertical Roller Mills (VRM), High Pressure Grinding Rolls
(HPGR), Vertical Shaft Impact Crushers (VSI) and more recently,
Horizontal Roller Mill (Horomill) have saved the specific power
by 45–70% when compared with a ball mill circuit [8,10]. Now a
days Ball mills and HPGR are installed together as a common unit.
As per European cement research academy’s project ‘‘Future
grinding technologies”, out of 1036 orders of grinding mills in
5 years, 58% were for Vertical Roller mill and 40% were for Ball
Mill + HPGR circuit. Hence Ball Mill & VRM are major technologies

3. Cement grinding

Cement is an energy-intensive industry in which more than 60%

of the total electricity is used in grinding circuits and also bears Fig. 2. Power Distribution in Cement Plant.
most of the construction cost. The need of the cement industry in

Table 1
Process & Machines in Cement Manufacturing.

S. Process / Stage Machine / Equipment Used Purpose of Process

No.
1 Lime stone Crushing
2 Stacking & Reclaiming
of Raw material
3 Raw Meal Grinding &
Homogenization
4 Coal Grinding
5 Pyro Section,
Clikerization
6 Clinker Cooling
7 Clinker Storage
8 Cement Grinding
9 Packing of Cement Bags
Double impact crusher with Extracted limestone of big size from Mines is crushed in the crusher to reduce particle size below
wobblers 50 mm
Swing type stacker & Limestone & other raw material are stored in open area into a longitudinal storage unit called stockpile
Reclaimer through Stacker. These are then extracted transversely from the stockpile through reclaimer
Grinding Mill - Vertical The reclaimed raw mix fed to Raw Mills, for drying and fine grinding of Raw meal for kiln feed
Roller Mill or Ball Mill
Grinding Mill - Vertical Coal is ground in Coal mill, which is a fuel for use in Kiln firing
Roller Mill or Ball Mill
In line calciner six stage Cement clinker is made by pyro processing of kiln feed into the preheater-kiln system
preheater & Kiln
Cooler with roller crusher High temperature Clinker is cooled to 200 degrees
Peter Silo Storage of Hot clinker and natural cooling
Grinding Mill - Vertical Grinding of Clinker with other additives to achieve final product as Cement
Roller Mill or Ball Mill
Rotary packer Packing of Cement and sent to Market

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P. Pareek and Vijayendra Singh Sankhla Materials Today: Proceedings 44 (2021) 4621–4627

in cement grinding. Their technological comparison is done inclination angle between roller axis and table, include sliding and
beneath [8]. rolling in relative motion.
The feed is fed to the feed pipe via a feed belt conveyor that
delivers composite raw materials. With the help of the louver ring,
4. Comparison among grinding technologies - Ball mill V/s VRM
the mill inside air flow is guided; as the rollers rotate, the material
moves in the centre of the table and is thrown with centrifugal
For the past three decades the vertical roller mill has emerged
force to grinding area under the grinding rollers. A dam ring on
to be the preferred choice for grinding raw materials. With the
the periphery of the grinding table make the mill feed into a layer
grinding capacity of a vertical roller mill and the ability to dry,
called the grinding bed. The ground fine material spills over the
grind and sort in a single unit, the vertical roller mill offers a def-
boundary of the dam ring retention zone. The mill inside upwards
inite advantage over the ball mill system [10].
airflow lifts the material to the rotary classifier above the mill cas-
A two-compartment ball mill with a highly efficient separator is
ing, where it separates the coarse particles from the fine particles
still procured for new cement grinding units installation, although
[17].
the vertical roller mill has now become a true competitor and
Coarse material fall onto the feed table for further size reduc-
alternative for ball mill and has increased its market share in the
tion, whereas fine material passes through rotating classifier with
cement mills in recent times. These both are procured according
transport air. The classifier /separator is used to control the desired
to the choices and preferences. There are many explanations for
product sizes. After the final feed input, the material grinds
issues such as cost, operation, installation cost, maintenance cost,
between the roller and the mill due to the relative motion of the
ease of maintenance, product quality and expertise. The grinding
mill and roller [17].
process in ball mills and vertical roller mills is fundamentally dif-
In between these all processes feeding, classifying & grinding,
ferent [15]. Following are advantages of VRM over Ball Mills with
material gets dry and unable to form stable bed. The dried material
reference to these issues: -
unstable grinding bed causes vibration in VRM and can stop the
mill. To avoid the situation water is directly sprayed into the bed
 Strong drying ability - Inlet hot air from Kiln can dry materials
via water nozzles to make dry mill feed wet, which improves
with 20% water content. (max moisture 20% vs. 3% in ball mill)
grinding bed and material stability [17].
[15,16].
 Big feed size - The vertical roller mill can grind the material of
5.1. Process stages in VRM
particle size of 5% of the grinding roller diameter. The feed size
is generally 40 to 100 mm and can reach 120 mm in case of
 Drying -Takes place when the hot air carries the material up to
large VRM. In turn it simplifies the grinding system [15,16].
the separator.
 The effect of the thickness of the material layer between the
 Grinding -Takes place due to pressure and friction between
rollers and the grinding table (called grinding bed). The thick-
roller and table.
ness of the grinding bed will be as small as 1–2% of the roller
 Separation - Effective separation takes place in separator while
diameter [15,16].
major coarse separation takes place in nozzle ring area and mill
 The retention time of the material inside the vertical mill is less
housing.
than one minute.
 Feeding and Recirculation - Feed material enters the mill via air
 The blaine size adjustment of the finished product is very flex-
tight rotary sluice and directed on to the grinding table by the
ible, reliable and convenient. It can be achieved by adjusting the
feed chute. Rejected material during pre-separation conveyed
speed of the classifier.
back to the mill via Bucket elevator, Belt conveyors etc.
 Noise is quite lower in VRM when compared to a ball mill. The
 Transport - Fully ground and classifier passed material is our
noise is just 20 to 25 dB which is lower and environment
final product called cement and is transported through Mill
friendly [15,16].
Fan Air to Bag House for further separation from Air and
 Lower specific power consumption per ton of cement. It is just
storage.
50% to 65% of the ball mill consumption [19].
 The metal wear of the unit product is low. The wear is generally
6. Parameters affecting productivity of VRM [11,15,17].
only 5 to 15 g/t, and even only 3 to 5 g/t. Therefore, the wearing
parts have long service life; the metal powder resulted from
6.1. Mill feed size
metal wear is small, so vertical roller mills can also grind the
white cement raw material [15,16].
 The particle size of the mill feed material and its size distribu-
 Installation of vertical roller mill system requires less space
tion impacts upon the performance of a vertical mill.
than a closed system Ball mill circuit. Capital investment is just
 Abnormal feed size and/or distribution may increase the level of
70% of the closed ball mill system [16].
vibration and destabilize the mill.
 Higher grinding capacity availability
 Large feed size in any case will reduce the mill production rate.
 One single machine embodies all functions, i.e. simultaneous
 Excess fines in the feed material or reject from the separator can
drying, grinding, homogenizing, separation and transportation
adversely affect the stability of grinding bed and can cause
[15].
vibrations.
 Fast change from one cement type to another (20 min)
 Mill feed size can normally be reduced by adjustment of bars on
the crusher, or fitting a screen with recycle.
5. Vertical roller mill
6.2. Feed to mill (Feed rate variation & feed Position)
The feed is ground by pressure and friction between the hori-
zontal rotating table and 4 to 6 grinding rollers in the VRM. These  The main aim is to have consistent feeding to the mill.
rollers are hydraulically pressed against the table as shown in  Variations in feed rate increase vibrations of the mill, destabiliz-
Fig. 3. ing operation and in the extreme resulting in mill stoppages.
To enhance grinding operation, the rollers and axes of the table
should not move through the plane of the table. There is 15 degrees
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P. Pareek and Vijayendra Singh Sankhla Materials Today: Proceedings 44 (2021) 4621–4627

Fig. 3. Vertical Roller Mill.

 Sticky materials if not correctly handled may create problem in
hoppers extraction and jamming in transfer points which ulti-
mately results in feed rate variation.
 The mill feed material needs to be free of metal pieces.
 Higher the metal pieces frequent operation of diverting gate
and results in feed variation.
 Material is fed into the centre of the grinding table. Centrifugal
force then distribute the feed evenly to the grinding rollers.
 The dam ring is used to control the bed depth in order to impact
upon the grinding efficiency and vibration. Dam ring height
affects retention of material on the table.
 Too high Dam Ring –excessive bed depth, inefficient grinding
and high power consumption
 Too low Dam Ring –low bed depth, high vibration and high
external circulating load.

6.3. Hydraulic pressure

6.5. Table & roller liners
 Hydraulic pressure should be matched to the material load in
the mill.
 Wear of the grinding elements increases the material retention
 The corresponding Nitrogen pressure to be charged in accumu-
upon the table and tends to increase mill power drawn.
lator to have proper cushioning.
 Uneven wear of grinding elements tends to occur as the wear
 Insufficient hydraulic pressure for the mill load will result in
progresses in to the body of the metal which leads to reduced
high circulating load and high pressure loss with potential over
mill efficiency due to non-uniform transmission of grinding
filling the mill.
energy to raw material.
 Excessive hydraulic pressure for the load will result in a thin-
 Correct for table wear by adjustment of the dam ring to main-
ning of the bed and increased vibration /wear.
tain the same material bed depth.
 Use only the required amount of water on to the track for bed
6.4. Dam ring
stabilization, as excessive moisture in the bed will act as a
grinding paste and accelerate wear.
 It is adjusted with respect to life of the table & roller liners to
 Grinding pressure- also affects the wear, avoid excessive
compensate for the effect of wear which happens in table and
pressure.
roller liners due to regular grinding.

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P. Pareek and Vijayendra Singh Sankhla
6.6. Water spray
 Water spray is used to help stabilize the grinding bed and main-
tain a low level of vibration and generally this is applied directly
to the material on the table, immediately before it passes under
the grinding rollers.
 The water has the effect of stabilizing the fine powdery material
rejected from the separator underneath the grinding faces.
 Excessive addition of water to the table can result in increased
wear and even thermal shock of the grinding elements.
 Low water due to blockage of spray nozzle may destabilize the
mill.
 Flow meters to be installed and calibrated to know the exact
flow into the mill.
6.7. Operation
 Mill Gas Flow - The three roles of the gas flow in the Vertical
Roller Mill are: Material drying, Material transport &
Classification.
 Constant gas flow through the mill to ensure constant lift for the
internal circulating material and to keep separator performance
constant to ensure a consistent product size distribution.
 High system pressure loss due to high internal re-circulating
load, and/or buildup in inlet gas ducts.
 High negative pressure makes minimizing false air a major
challenge
 Wear of the mill fan impellor can be an issue when there is sig-
nificant coarse grained quartz in the raw mix.
6.8. Separation / Classification
 Uneven gas flow distribution badly impacts the particle size dis-
tribution of the final product.
 Poor efficiency of the classifier resulting in higher rejection and
higher internal recirculation.
 Wear of sealing between stationary and moving parts, impacts
negatively the particle size distribution of final product.
 Regular inspection to check position and wear of guiding vanes.
Regular inspections to be done to check wear & tear at sealing
between stationary and moving part as well as wear on the grit
cone.
6.9. Grinding bed
 Grinding bed is the material layer formed between the roller
and the rotating table. It transmits the entire roller force and
mill power. It is the key factor for successful operation of a VRM.
 Determined by: Feed Material size, Feed Material Moisture,
Dam Ring Height, Grinding Fineness, Air Speed in nozzle ring.
6.10. Control & instrumentation
 Blockage of pressure tapping’s, particularly mill inlet and air
flow measurement points [6]
 Out of calibration bed depth monitors & other instruments like
PT, TT etc.
 One very common cause is excessive variation of fresh feed, due
the one of the following: 1) Poorly controlled Weigh feeders &
Solid Flow feeders. 2) Long feed belt to mill, resulting in long
lag time between quantity change at feeder and delivery to mill.
7. Conclusion
The future of grinding is high productivity and lower specific
energy consumption machines and machines having capabilities
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Materials Today: Proceedings 44 (2021) 4621–4627
of adapting to complex processes and new advancements in
technologies.
Vertical roller mill has proved to be a popular choice for finished
cement grinding over all other machineries due to advantages like
low power consumption, higher capacity, process simplifications
and compactness but it is also very sensitive to vibrations and
can deteriorate productivity if process optimization is varied
slightly. Hence to utilize its full capacity, achieve high productivity
and stability, it’s operation parameters should be optimized and
maintained in control.
8. Future scope
VRM are very prone to vibration if its parameters are varied
slightly. High vibration may create breakdowns and lower effi-
ciency and productivity. The problems of high vibration and low
productivity can be addressed using problem solving tools by iden-
tifying possible and responsible causes for vibration and process
deterioration, and working on to those causes by modifications &
Kaizens. With reduction in breakdowns and achieving stability,
power consumption can be further reduced. Also there are many
advancements and innovative products are being introduced for
higher productivity, like grinding aids.
CRediT authorship contribution statement
Praveen Pareek: Conceptualization, Methodology, Writing -
original draft, Writing - review & editing, Formal analysis, Investi-
gation. Vijayendra Singh Sankhla: Supervision.
Declaration of Competing Interest
The authors declare that they have no known competing finan-
cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
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Consulting Pvt, Limited, Sept 1998.
P. Pareek and Vijayendra Singh Sankhla Materials Today: Proceedings 44 (2021) 4621–4627

[5] L. GmbH, Mills for the world: Loesche’s 1906–2006 centenary, ZKG Research & Development (IJASRD) p-ISSN: 2394-8906 , e-ISSN: 2395-6089,
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Companies in South India”, International Journal Of Advanced Scientific

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