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Performance of Vertical Roller Mills at Bharathi Cement Corporation Pvt. Ltd., Nallalingayapalli Olivier Thomas Performance Director
Technical Configuration Line #1 – Commissioning in September 2009: - LM 54.6 for raw mix grinding. - LM 26.3 for coal grinding. - LM 63 3+3 for clinker grinding.
Line #2 - Commissioning in February 2011: - LM 54.6 for raw mix grinding. - LM 26.3 for coal grinding. - LM 53 3+3 for clinker grinding – 2 units.
- Budget of 2.46 M Tons Cement of dispatch in 2012. - A-Grade Cement positioned on the south Indian market and MH. - Cement Ratio OPC : PPC : PSC = 45 : 55 : 5. - PPC with an addition of 27 – 28% of fly ash. - Consumption of Indian, Indonesian, SA coal and petcoke (6% sulphur content) - Usage of secondary fuels – Up to 10% substitution rate (wood chips and pharmaceutical wastes). Loesche India Round Table 2012
Commissioning Phase Focus Point – LM 53 3+3 – Successful Learning Curve Think, Study, Feel, Measure and Observe – Start-up to nominal capacity in 45 days Phase #1 – Start-Up: • Ensure a thorough cold commissioning and testing – Control management pressure to delay the start-up if necessary. • Work up properly all pre-conditions between parties, especially regarding clinker C3S, temperature and content of additives. • Make sure commissioning engineers have a dedicated operating station. • Start the mill in complete ‘manual’ mode. Set a lower fineness target Objective to observe and feel the mill.
• Adjust hydraulic settings accordingly after this first phase to ensure a “sustainable” capability of successful start-up when pressing the ‘start’ button for the next times.
• Proceed with frequent in-the-field inspections with Loesche’s commissioning engineers.
Commissioning Phase Phase #2 – Observe & Feel: We are entering a testing phase to determine if the mill can respond to our demand Increase material output and achieve fineness. • Increase grinding pressure If main motor kW do not increase, material is being flushed out of the table by the rollers. It is a way to determine if the dam ring height is adapted. • Increase grinding pressure dP (mill) is decreasing since we are grinding faster and more finer particles are leaving the system faster than coarser particles. • Optimize total air volume so that rejects stay at a minimum. • Determine if sudden dP variations are linked to a change in the clinker quality (granulometry and/or temperature) Do not fight it!
• A lower draft (or total flow) increases the efficiency of the separator Never overlook this aspect. Loesche India Round Table 2012
• Measure fineness after a few hours Adjust grinding pressure and draft. Keep in mind: Rollers and grinding pressure give Blaine. Separator gives rejects.
Commissioning Phase Performance – Conversion Factor Compare to supplier’s specification
Clinker Grinding: Expected Output (t/h) = Nominal Output / (Targeted Blaine / Original Blaine) ^ 1.4 Formula can be applied to power consumption (or at motor shaft only) e.g. LM 53 3+3 in OPC at 3,200 Blaine. Specification = 230 t/h at 3,000 Blaine and 25.4 kWh/Ton Cement. Expected Output = 230 / (3,200 / 3,000)^1.4 = 210 t/h. Expected Power Consumption = 25.4 * (3,200 / 3,000)^1.4 = 27.8 kWh/Ton Cement.
See next slide for Polysius conversion factor. e.g. LM 56.4. Specification = 21.85 kWh/T at R90µ = 14% or R212µ = 2%. Expected Power Consumption at R90µ = 19% Nominal Value * (1.04 / 1.14). (See next slide)
Commissioning Phase Performance – Control Loop Clinker Grinding: 1.Recirculation Damper Position = f (Mill Inlet Pressure). 2.Feed Rate = f (Mill Differential Pressure). 3.Booster Fan Speed = f (Mill Outlet Temperature). 4.Draft Fan Speed = f (Total Air Flow). Water injection does not control mill outlet temperature for a cement mill (not simply manageable).
1.Recirculation Damper Position = f (Mill Inlet Pressure). 2.Feed Rate = f (Mill Differential Pressure). 3.Water Injection = f (Mill Outlet Temperature) See control philosophy between ‘table’ and ‘top section injection’. 4.Draft Fan Speed = f (Total Air Flow). 5.Baghouse Inlet Damper = f (Draft Fan Outlet Pressure).
CM2/CM3 LSKS 87 Rotor Circonferential Velocity Motor
Motor power
Performance Improvement Bharathi - CM2/CM3 - Specific Grinding Pressure (1 Roller): kN kN kg kN kN/m2 m2
Mr Operational pressure Counter pressure Dcyl Drod Cylinder number per roller Roller diameter Roller width A (projected) Fr Fh F Kt Loesche maximum value
Performance Improvement Operation of vertical mills for clinker grinding: 1. Performances are achieved in a reliable manner. 2.Increase of mill output is noticeable during longer operational runs. 3.‘Specific Power Consumption’ has decreased (expect 1 to 2 kWh/Ton Cement). 4.Rejects below 45 µm and [3 – 30]µm range
are consistent and there is room for
adjustment with the separator Check water demand on a regular basis. 5.‘LM 53 3+3’ operates with stability and is to be considered as a good system when analyzed thoroughly and operated properly. 6.Water injection remains too high (3.5% of total mill output) and needs to decrease to 2.5%. 7.Hardfacing on the rollers and table remains an expensive maintenance operation.
9.Optimization of clinker granulometry and temperature is also part of getting the best out of a ‘LM 53 3+3’.
