RCCPL Kundangunj

Grinding with VRM system

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 VERTICAL ROLLER MILL

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 Transport
Exhaust gases
Raw meal

1. Separation  Drying Separation

Feed
Material

Grinding

2. Grinding  Hot
gases

Drive
Energy

3. Drive 

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 Typical Grinding Principle

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 Separator: Gas & Product Material
Removes fine
material Feed Material
Rejects coarse
material

Internal gas Separator Rejects

flow
Internal Circulation
Large Material falls through
to scraper
Material
Material & Gas
Gas
 How does a vertical mil work?
• The raw materials are fed directly to the centre of the grinding plate, from
centrifugal forces and the pushing effect of the incoming materials
themselves (both fresh and separator coarse material), are distributed
evenly under the grinding rollers.

• The turning speed of the grinding plate, together with the pressure of the
grinding rollers, create the necessary friction for grinding the materials.

• The grinding process starts with the preparation of grinding bed, where the
coarse material is crushed. Then the material in compressed and ground by
the grinding rollers.

• After being ground, the material is transported to the dynamic separator by

the (more or less hot) gas flow, where the selection of the material takes
place.

• The coarse material coming from the separator is directed back to the center
of the grinding plate in order to be ground again.

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 Parameters to be monitored during Operation

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 Grinding force =Roller weight + (pressure) Force

Roller rolls
freely with table
Material bed

Feed material Table moves with drive

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 TROUBLE SHOOTING

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 Common aspects of operation with regard to the grinding process and generally
exhibits the following characteristics.

Trouble Probable cause

Excessive vibration
• Sudden change to high moisture feed
• Improper feed distribution
• Sudden change to fine product
• Sudden change to oversize feed
• Dam ring height not uniform

• Excessive air flow sweeping the table

• Rollers contacting the stoppers
• Excessive feed

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  Mill feed size
 Preferably wide distribution of particle sizes. The largest particle size to
be maximum 3 - 4% of the roller diameter. Typical feed size distribution :
 100% passing 100mm
 95% passing 60 mm
 Maximum 10% passing 1 mm

 Impact of Incorrect Feed Size

 Abnormal feed size and/or distribution may increase the level of vibration
and destabilise the mill.
 Large feed size in any case will reduce the mill production rate.
 Excessive fines in the feed material or recirculated from the separator
can make the rollers slip and adversely affect the stability of the grinding
bed.

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 Controlling Vibration and control measures

 Match grinding pressure to mill throughput – establish relationship between

feed rate and hydraulic pressure.
 Maintain an even bed, avoid excessive fines in mill feed, avoid uncontrolled feed
variations, even distribution of material to each of the rollers, feed to the centre of
the table, adjustment of feed chute and or use of guide vanes.
 Apply stable water spray to the control bed, normally fed to the feed side of each
roller, check flow consistency on each spray
 Know the critical level of gas flow and pressure drop for your mill
 Maintain stable mill gas flow to keep internal circulation consistent.

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 Trouble Probable cause

High Mill DP
• Low grinding pressure

• Feed rate too high

• High internal circulating load

• High air flow

• Excessive water spray

• High inlet temp

• Low exit temp

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 Trouble Probable cause

Low Mill DP • Feed rate too low

• Product too coarse

• Dam ring height too high

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 Trouble Probable cause

Product too course • Classifier speed too low

• Air flow too high

• Louver ring velocity too high

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 Trouble Probable cause
High rejects
• Mill air flow too low

• Sudden increase in feed rate

• Grinding pressure too low

• Low dam ring height

• Louver ring velocity too low

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 Trouble Probable cause

Feed material • Lower exit temperature

too wet
• Material agglomeration on the grinding bed

High roller vibration

• High Dp

• High drive motor amps

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 Trouble Probable cause

High internal
• Higher Dp
Circulating load
• Product fineness too high
• Classifier choked
• Lower grinding pressure
• Low air flow

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 Operational Measures and their utilization in process.
 Air flow measurement through Pitot Tube.
• To find out material to air ratio.
• To calculate fan efficiency .
• To calculate False air in circuit.
• To measure Nozzle velocity

 Mill Outlet Temperature.

 DP across Mill.

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Maintenance Of VRM