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What is VRM ??
Why VRM ??
How it works ??
In cement manufacture by the dry process it constitutes the final stage in the
production of raw meal (raw grinding ).
The clinker discharged from the kiln has to be ground to a fine powder which,
with the admixture of some gypsum, is the finished product of the whole process
cement.
What is grinding ??
The terms "pulverizing" and ''milling" are basically synonymous with "grinding",
but are mostly confined to the comminution of coal or lignite for use as
pulverized fuel.
Why grinding mills ??
The object of grinding is, more particularly, to increase the specific surface of the
material while conforming to a desired particle size distribution to such an extent as
to obtain adequate reactivity for the next stage in the cement manufacturing process
or adequate reactivity in the finished product (the cement ) itself.
What is VRM ??
Ball and tube mills tum on a horizontal axis. Vertical mills tum on a vertical axis.
There are two variants of the vertical roller mills.
VRM BM
Why VRM ??
Raw milling technology has been and is being driven by:
- Capital costs.
- Maintenance.
- Power consumption.
The raw meal preparation area of cement production facility consumes 15 – 25% of the
required power consumption of [90 – 110] kWh / t of cement. “J. M. Brugan (Germany
1992)”.
The Ball mill [BM] and the Vertical roller mill [VRM] represent 99% of all raw mill systems.
The VRM is clearly the dominant choice for raw milling as evidenced by 90-95% market
share for new milling systems.
Why VRM ??
Market in J.M.Brugan study:
The largest market growth has occurred in the pacific Rim countries where
approximately 40 million TPA of new capacity has been installed or
purchased in the last four years.
All of these producers are installing VRM for new meal production.
Why VRM ??
- Its dependability
- Its economy
- Its Versatility
This mill also has a built in separator above the rollers. It also has an annular ring which
admits air at velocity as high as 70 m/sec. Material is admitted through a feed chute on the
center of the table and passes under rollers by centrifugal action. Material gets partially
ground and as it falls over the edge of the table, it is picked up by the air/gas.
OK mill
Roller supporting system “Rocker Arm , Head Joint”
Roller seal “Adjustable”
Seal housing
Seal carrier
Seal carrier
Seal elastomer
O-ring
Adjusting bolt
Seal working
length
X
Roller seal “Fixed”
Machining faces
X
Roller seal “Split”
Table
Table
Table
Table
Dam ring
Dam ring function
Dam Ring
Dam ring
Dam ring
OR
Hydraulic nut “bolt tensioner”
Torque wrench
Material flow
inside VRM
1) Feed duct
2) VRM Table
3) VRM Roller
4) Table liner
5) Material to grinding
6) Grinded product
7) Material classifier
8) Heavy particles
Shape of table/
Liners of table
Shape of
rollers/
Liners of rollers
Flue gases
Dust Collector
Control gates
Fine product
Feed hopper
Flue gases
Separator Hot process gases
Rotary air lock feeder
VRM
Sealing air fan Hot gases generator
VRM foundation.
Dam ring.
Roller fixing.
Table segments.
Reject scraper.
separator blades, rings.
Bearing damage.
Gears damage.
Seals damage.
Mechanical damaged parts
VRM damage due to poor lubrication in grinding rollers:
Grinding rollers bearing damage, due Tapered roller bearing damage
to lubrication circuit malfunction:
Gear unit bearing damage Gear unit gear meshing & lubrication
Mechanical damaged parts