GEBR.
PFEIFFER
The grinding process
and
mill operation
Progress is our tradition
MPS vertical roller mill
MVR vertical roller
mill TP/ Ne- 08 / 04
PFEIFFER Vertical roller mills for the cement
industry GEBR. PFEIFFER
Unchanged Changed / Improved
• Process Design • Capacity Range
• Safety Factors • Number of rollers
• Levels of spec. • Roller Suspension
grinding force • Flat Table
• Nozzlering • Cylindrical Rollers
• Gas Velocity Design • Parallel Grinding Gap
• Classifier • MultiDrive® with variable speed
• Wear Protection • Active Redundancy
TP/ Ne- 08 / 04
MVR mill
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fine product
raw material
hot gas
TP/ Ne- 08 / 04
MPS vertical roller mill
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Pneumatic conveying
Mechanical conveying
Classifying
Compression grinding in material bed in
between rollers and table
Drying (calcining), mixing, conveying in fluidized
bed above nozzle ring
TP/ Ne- 08 / 04
MPS v Processes in MPS vertical roller mill
GEBR. PFEIFFER
Max. feed size: 3-5 % dR
Much finer feed may destabilize
material bed
TP/ Ne- 08 / 04
Grinding: Compression of material bed
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TP/ Ne- 08 / 04
grinding roller
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Aim:
Always stable material bed during
compression, no sudden changes
grinding roller
(water spray)
dam ring
material on table
air flow through nozzle ring
TP/ Ne- 08 / 04
MPS grinding zone
GEBR. PFEIFFER
(1) P = Wm x m needed
(2) P = x FR x z x V introduced in
material bed
Wm spec. power consumption depending on
material, product fineness, (dam ring), (wear)
friction factor depending on
material, product fineness, (air volume)
Grinding force FR to be adapted, maximum given by
mechanical design,
number
Power of rollers
absorption z and
P during table speed
compression of v given by design
TP/ Ne- 08 / 04
material bed GEBR. PFEIFFER
TP/ Ne- 08 / 04
testing - MPS 40 BC and
wear determination equipment GEBR. PFEIFFER
TP/ Ne- 08 / 04
testing - MPS 40 BC
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6 1000
Wm mill in kWh/t
mF in kg/h
5 900
kWh/t
4 800
design
3 kg/h 700
2 600
10 11 12 13 14 15 16 17 18 19 20 21 22
R 90µm in %
dustload: < 750 g/m³ in this case
TP/ Ne- 08 / 04
Grinding test
GEBR. PFEIFFER
Industrial MPS-mills with high efficiency classifier SLS,
not limited by heat balance or kiln process
1000
900
800
700
dust load in g/m³
600
500
400
300
MPS-mills with SLS-classifier
200
Mills with competitors' classifier
100
0
4 5 6 7 8 9 10 11 12
spec. power consumption in kWh/t
TP/ Ne- 07 / 05
Dustload (air flow) depending on spec. energy
consumption (grindability) GEBR. PFEIFFER
Blaine for OPC, slag cements and slag
residue on sieve from joint grinding of
mixed cements containing components
with good grindability (e.g. limestone,
puzzolana)
TP/ Ne- 07 / 05
determination of the product fineness :
specific surface (Blaine) / sieve method GEBR. PFEIFFER
drive Check of gap
fine product between rotor and
static classifyer part
feed material
rotor
louver
Adjustment of fineness by
rotor speed: Higher rotor
speed gives higher
fineness
grit cone
TP/ Ne- 08 / 04
classifier - type SLS
GEBR. PFEIFFER
coal mill
raw mill coal cement mill
cement raw material cement
calcium carbonate (CaCO3)
silicon dioxide (SiO2) = cement clinker
aluminium oxide (Al2O3) + extenders
iron oxide (Fe2O3) + gypsum
cement clinker
TP/ Ne- 08 / 04
MPS in dry cement production line
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material Raw meal Coal Cement Slag
customer Ambuja, India Ambuja, India Dalmia, India Lafarge, China
grindability 9.0 kWh/t 45 HGI 15.4 kWh/t abt. 30 kWh/t
mill size MPS 5600 B MPS 3070 BK MPS 5600 BC MPS 5600 BC
Pinst 5400 kW 800 kW 5400 kW 5300 kW
throughput 566 t/h 64 t/h 300 t/h abt. 130 t/h
grinding fineness 1% R0.212 mm 11% R0.090 mm 3200 cm²/g 5300 cm²/g
spec.power cons. 14.6 kWh/t 20.7 kWh/t 24.2 kWh/t abt. 33 kWh/t
(measured on counters) (mill + fan) (mill + fan) (mill + fan) (mill +
separator)
TP/ Ne- 01 / 07
biggest mills commissioned
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Most of vibration problems are caused by
feed problems: lack of feed, sticking, sudden
change of feed size
TP/ Ne- 08 / 04
cement grinding plant
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TP/ Ne- 08 / 04
flowsheet
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targets of automatic plant control:
- steady and smooth operation of the grinding plant
- less observation and intervention by operators
- optimized energy consumption of the plant
- trouble-free and uninterrupted production
- constant quality of the product
TP/ Ne- 08 / 04
Machine Control - Targets
GEBR. PFEIFFER
TP/ Ne- 08 / 04
monitoring equipment for
the avoidance of vibrations GEBR. PFEIFFER
GEBR. PFEIFFER
Main Control Loops
of a
Grinding Plant with MPS Mill
Progress is our tradition
air flow gas pressure
temperature
90-100 °C
dp
gas pressure
TP/ Ne- 07 / 05
raw material grinding plant with Pfeiffer MPS mill
dust collection in cyclone GEBR. PFEIFFER
temperature air flow
90-100 °C
dp
gas pressure
TP/ Ne- 07 / 05
raw material grinding plant with Pfeiffer MPS mill
dust collection in filter GEBR. PFEIFFER
TP/ Ne- 08 / 04
Main Control Loops –
according to interlocking diagram GEBR. PFEIFFER
Main Control Loops
A – temperature after classifier => hot gas supply
B – mill differential pressure => mill feed rate
C – pressure before mill => position of recirculation gas damper
D – gas volume flow in grinding plant => position of mill fan damper
resp. speed of fan with VFD
TP/ Ne- 08 / 04
Main Control Loops –
according to interlocking diagram GEBR. PFEIFFER
Holcim Cementi Merone - MPS 4250 BC
guarantee Aug. 2004-
type: 32.5 II BM Feb. 2005
clinker 69.2 64.0 %
gypsum 5.7 6.0 %
slag 12.6 18.0 %
limestone 12.5 7.0 %
pozzolana: - 6.0 %
water sprayed into mill: 2.5 0.4 m³/h
Blaine: 4000 4400 cm²/g
throughput: 120 126 t/h
spec. power consumption
table: 16.5 13.6 kWh/t
fan: 6.0 7.0 - 4.5 kWh/t
classifier: 1.66 0.75 - 0.5 kWh/t
total: 28.15 25.35 - 22.7 kWh/t
spec. wear rate 8.0 3.3 g/t
(chromium alloy cast iron) TP/ Ne- 08 / 04
Potential of optimising power consumption of
fan GEBR. PFEIFFER
1314 kW to 1078 KW by
installation of frequency
converter for mill fan
230 kW
2040 kW
TP/ Ne- 08 / 04
flowsheet MPS 4250 BC, 120 t/h
San Rafael grinding plant in Latacunga, Ecuador GEBR. PFEIFFER
Operation problems reasons/solutions
Sudden vibrations sudden lack of feed (component),
water or air or sudden change of
feed size (or moisture)
Sudden vibrations after increase of dp mill too full, so lower feed rate
and/or higher hydraulic pressure
and/or higher air flow
Higher vibrations after decrease of dp mill too empty, so higher feed rate
and/or lower hydraulic pressure
Higher kWh/t, lower throughput may be caused by wear, so
measurement, EVA anlaysis by
Gebr. Pfeiffer, then may be
reduction of dam ring or change/
hardfacing of wear parts
TP/ Ne- 08 / 04
Operation
GEBR. PFEIFFER
GEBR. PFEIFFER
Thank you
Progress is our tradition
