LUCEEN POWDER TECHNOLOGY

PROCESS CONTROL OF LURM MILLS

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Nov 12, 2004

Frank Lu

1.0 PREFACE
This document is intended used only as a guideline for describing basic concept of
the process control of the LURM vertical roller mill especially for the limestone
grinding system. The particular process control system should be designed according
to the individual condition.
A safe and economic operation is not only dependent on the condition of the mill itself
as well as of peripheral equipment such as feeding system, system fan, bag filter, hot
gas generator, product conveying system and ductings in mechanical respect but
also the condition of the process control measures in electrical respect.

2.0 MILL PERFORMANCE INDEXES

2.1 Mill Feeding Rate
The mill throughput should be controlled constantly in continuous with suitable
incremental mass rate until reach a maximum rate for absorbing the maximum mill
motor horsepower but operating in a safe and reliable long-term condition and
producing the qualified product according to the quality control standard of the
product.
The mill feed mass rate is measured by a measuring screw or a belt-weighing feeder
under the feeding hopper and controlled by the mill differential pressure.
The maximum lump size of the feed shall be maintained according to the outside
diameter of the grinding rollers, the gripping angle of the material ground and the
thickness of the grinding bed.
The segregation of the fed material during the dosing process should be absolutely
minimized for keeping the even feed lump size distribution for maximizing the mill
throughput and minimizing abnormal mill vibration.
Furthermore foreign matter such as iron and metal pieces should be separated
before entering the mill proper for avoiding damage of the grinding elements.
In case of too low or interrupted feed mass flow, the grinding rollers shall be lifted if
necessary.

2.2 Fineness of Finish Product

The fineness of the finish product, representing not only the specific surface area but
also the required particle size distribution, is mainly decided by:
Grinding pressure
PROCESS CONTROL OF LURM MILLS

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Gas flow
Classifier speed
In general the finer product with the higher specific surface area is obtained by:
Higher grinding pressure
Lower gas flow
Higher classifier speed
Normally the fineness of the product is controlled by the classifier speed only while
the mill operates at the optimum grinding pressure and the optimum gas flow rate,
which were obtained during the commissioning and should be kept constant during
normal operation.
In the meanwhile, the circulating load within the mill influences the particle size
distribution. Increasing circulating load within the mill by adjusting the following
parameters generates the narrower particle size distribution:
Higher classifier speed
Lower grinding pressure on the material bed
Higher gas flow rate through the mill
In other words, if we interpret from the standpoint of the internal circulation load
within the mill, we could observe that:
The higher grinding pressure results to a lower circulation load and wider particle
size distribution. Lower grinding pressure results to a higher circulation load and
narrower particle size distribution.
Moreover if the gas flow rate through the mill is increased, thus leads to a higher
circulation load and provokes a sharper slope in the RRSB chart. On the
contrarily if the gas flow rate through the mill is decreased, thus leads to a lower
circulation load and provokes a flatter slope in the RRSB chart.
With the same reason, if the classifier speed is faster, naturally increase to a
higher circulation load thus may provokes a higher Blaine value as well. On the
contrarily if the classifier speed is slower, naturally decrease to a lower
circulation load thus may provokes at lower Blaine value.

2.3 Moisture Content Of Product

There is no need for installing an extra hot gas source while the moisture content of
the feed material is below around 1% because the heat generated during grinding
shall dry the material to an accepted level. If the moisture of the material exceeds a
certain value, then the mill inlet temperature should be adjusted by the other heat
input from a hot gas generator or other heat source according to the moisture content
of the feed material.
The moisture content of product is mainly influenced by the following parameters:
PROCESS CONTROL OF LURM MILLS

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Gas temperature at mill outlet

Gas temperature at mill inlet
Gas flow rate and temperature from recycling
Heat input from hot gas generator.
In order to prevent from clogging of the bag filter, the operating temperature of the
mill exhaust gas should be about 20 above the dew point.

2.4 Specific Power Consumption

The power consumption of the grinding system is the key issue of the production cost
of the grinding plant. The main contribution of the power consumption consisting of:
Mill
Classifier
System fan
Auxiliary equipment such as feeding and conveying system.
The optimum value of the specific power consumption shall be obtained through
optimization of the control parameters of the grinding system including:
Mill gas flow rate
Mill differential pressure
Mill inlet gas pressure
Grinding pressure
Classifier speed
Grinding bed thickness
Mill vibration level

3.0 MILL CONTROL PARAMETERS

3.1 Gas Temperature At Mill Inlet
Unless special design is made, the temperature should not exceed 300 for
protecting main gearbox and grinding rollers from overheating. Otherwise a special
construction shall be made by a heat resistance design for the mill.

3.2 Gas Temperature At Mill Outlet

The gas temperature at mill outlet is a measurement of the drying process
accomplished in the mill. The mill outlet temperature can be elevated by increasing
the recycling gas or supplementary hot gas and also can be cooled down by opening
the tempering air. Normally the mill should be stopped automatically at 120 for
preventing the bearing and sealing of the grinding rollers from overheating. Special
cooling system with heat resistant sealing shall be adopted should the temperature is
higher than the above-mentioned value.

3.3 Mill Gas Flow Rate

PROCESS CONTROL OF LURM MILLS

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The gas flow can be measured behind the bag filter and controlled at constant value
by adjusting the opening of the gas damper and/or the rotating speed of the system
fan during commissioning.
The gas flow should be always kept constant and independent of the fluctuations in
pressure and temperature of the system. The gas flow through the grinding system is
a combination of:
Fresh air
Hot gas
False air
Evaporated water
Recycling gas
Inadequate gas flow through the mill causes a decrease of the mill capacity and
operating disturbances. However excessive gas flow causes higher wear within the
mill resulting uneconomical maintenance work and power consumption.

3.4 Mill Differential Pressure

The mill differential pressure measured as a difference between the static pressure at
mill inlet and mill outlet representing a loading condition of the mill.
The differential pressure of the mill depends on the following parameters:
Feed mass rate
Gas flow rate
Grinding pressure
Classifier speed
Usually only the mill feed mass flow rate has a decisive influence on the differential
pressure while gas flow rate, grinding pressure and classifier speed are maintained
at the similar condition according to the pre-adjustments during previous operation
unless the characteristics of the raw material such as the grindability of the material
has been changed.
When the differential pressure is too high, which indicates the mill is in overloading.
The mill is subject to sever vibration and higher reject amount resulting an
uneconomical operation.
On the contrarily, when the differential pressure is too low which indicates the mill is
in partial loading and is operated in also an uneconomical condition. When the
differential pressure is reduced to the certain limit value such as 50% - 60%, the feed
will be stopped. The mill shall be started again while the normal value is restored.

3.5 Grinding Pressure

The grinding pressure exerted by the grinding rollers against the vertical is a decisive
factor for the efficiency of the communition process.
PROCESS CONTROL OF LURM MILLS

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However too high pressure causes higher abnormal wear on the grinding elements,
rough mill operation and higher power consumption.
However too low grinding pressure reduces the mill capacity and changes in the
fineness of the product resulting an uneconomical operation.
The relationship between the grinding pressure and the corresponding nitrogen
pressure in the accumulator, representing the spring constant of the hydraulic
system, will be adjusted during commissioning. While the pressure of the hydraulic
system drops below a certain limit the mill will stop. As the rule of thumb, the filling
pressure of hydraulic accumulator should be recommended as follows:
The maximum filling pressure of hydraulic accumulator = 80% of the minimum
operating hydraulic pressure
The minimum filling pressure of hydraulic accumulator = 25% of the maximum
operating hydraulic pressure

3.6 Mill Inlet Pressure

The mill inlet pressure should be maintained at constant value. The static pressure
measured at the mill inlet gas duct is influenced by the gas flow entering into the mill
by mean of:
Recycling gas damper
Hot gas generator
Fresh air inlet damper
Too high negative pressure before the mill increases the energy consumption of the
mill system fan.
However too low negative inlet pressure influences the steady gas flow within the
system and leads the grinding system into disturbances.

3.7 Mill Vibration

The mill vibration level, usually measured at the input shaft of the gearbox, is applied
for protecting the key mechanical components from damage. The optimum condition
of the mill shall be achieved by obtaining the maximum mill throughput in accordance
with the qualified product standard but in an acceptable vertical mill vibration level.
The mill motor should be stopped while the mill occurs excessive vibration for
securing the long-term safety of the equipment.

3.8 Grinding Bed Thickness

The grinding bed thickness, defined as the minimum gap between the grinding rollers
and the grinding table during the operation, is adjustable by the height of the dam
ring the grinding pressure and mill circulation load during commissioning.
The thicker grinding bed gives narrower particle distribution but results with higher
power consumption and softer operation.
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Nevertheless the thinner grinding bed gives wider particle distribution but with lower
power consumption and rougher operation.
The optimum grinding bed thickness shall be decided during commissioning.

4.0 PROCESS CONTROL LOOP

Generally speaking, the grinding system can be installed with the following PID
control loop:
For cooling process, the fresh air damper or the amount of the water and
grinding aid solution controls mill outlet gas temperature.
For heating process, the burner of the hot gas generator or the amount of steam
vapor controls mill outlet gas temperature.
The rotating speed or the gas damper of the system fan controls gas flow rate
through the mill.
The recycling gas damper controls mill inlet pressure.
The mill differential pressure or the kilowatts of the mill motor controls feed mass
flow rate.

PROCESS CONTROL OF LURM MILLS

LUZIM POWDER ENGINEERING CO., LTD