Training Design of Vertical Roller Mill Polysius Headquarters Germany Raw material preparation Roller mill RM 6629555 – THALOFA Roller mill RM 6629555 – BAZIFA Schematic movement of material on the grinding table Doublegroove grinding system Roller mill feed shute with preseparation Mill housing Roller pairs
Page Design of Vertical Roller Mill Training Polysius Headquarters / Germany 19 May – 13 June 2008 Training THALOFA Training THALOFA Page Page 2Raw material- preparation Clinkerproduction Raw materialpreparation Cementproduction 6 Crushing Burning Storage, Mixing Cooling Dosing Storage 10 11 Raw Grinding 10 Cement Grinding Homogenising 11 Storage, Packing and Loading Preheating, Calcining Training THALOFA Page Raw Material (Mixture) Raw Meal THALOFA raw mixture properties: THALOFA raw meal properties: • crushed material grain size 95% < 80mm • raw meal particle size 12% < 90µm • feed material moisture max 8% • raw meal moisture max 1% Page Training THALOFA Roller mill RM 66/29-555 – THALOFA Exhaust gas Return air Hot gas Mixed gas before mill Page Training THALOFA Roller mill RM 66/29-555 – BAZIFA High drying capacity Grinding, drying and separating in only one unit Compact arrangement Low energy requirement Proven wear protection Does not necessarily need a proper mill building Page Training THALOFA Roller mill RM 66/29-555 – BAZIFA Roller Mill Assemblies Feed chute Mill housing Grinding roller pair Confining air Grinding table Tie rods & hydraulic system Mill main drive & auxiliary drive Page Training THALOFA Roller mill RM 66/29-555 – THALOFA Capacity: 500 t/h raw material at 12% R 90µm Initial moisture content: max 8.0% SEPOL separator 5,550 mm cage diameter External material circuit: 100% of nominal mill output Mill fan sizing: 1,000,000 m³/h 90 mbar required 3,762 kW 2,900 mm roller diameter with bypass lubrication system for roller bearings 6,850 mm grinding table diameter with quick changeable dam ring arrangement Required 4,830 kW Page SilzR 13 Jun 2008 S:\Team\Training\THALOFA\CD-for-Customer\03-01-RollerMill-DesignMechanical.ppt Lifting device Separator Roller pairs Feed Chute Main drive Mill housing Grinding table Tie rods Page Schematic movement of material on the grinding table Training THALOFA Training THALOFA Page Double-groove grinding system 10 Turning point of roller pair inside Mill center line roller and table Different speed between outside table Movement of grinding roller Material bed Training THALOFA Page 106 Inspection Maintenance - Separator drive No Work to be performed Frequency General visual check for - cracks - leaks - damage every weeks Check for abnormal noises at the - electric motor (1) - gear unit (3) daily Check of the temperatures at the - electric motor (1) - gear unit (3) daily Inspection work on - electric motor (1) - gear unit (3) Remarks According to manufacturer’s instructions Training THALOFA Page 107 Maintenance - Separator drive Inspection No Work to be performed Check of oil level in gear unit (3) Check of - the coupling (2) - the connecting element (6) Frequency Remarks every weeks According to manufacturer’s instructions Training THALOFA Page 108 Maintenance - Separator drive Servicing No Work to be performed Remarks Frequency Servicing work on gear unit (3) According to manufacturer’s instructions Servicing work on electric motor (1) According to manufacturer’s instructions If the torsional clearance at the coupling (2) as required is too large, the coupling packs have to be replaced According to manufacturer’s instructions Servicing work on connecting element (6) According to manufacturer’s instructions Training THALOFA Page 109 Maintenance - Separator drive Fault Cause Rectification Page 110 Training THALOFA Water spray system Items in the drawings Injection pipes 1.1 Piping 1.2 Hose 1.3 Straight way valve 1.4 Water meter (horizontal) 1.5 Water meter (vertical) 2.0 Water tank 2.1 Shut off valve (water supply) 2.2 Drain valve 2.3 Float switch Change over filter 4.0 Motor pump unit 4.1 Motor 4.2 Coupling 4.3 Overflow valve 4.4 Drain plug Contact pressure gauge Drain and vent valves Solenoid valve Motorised control valve for injection pipe Flow meter for injection pipe 10 Pressure gauge for injection pipes Training THALOFA Page 111 Lifting device Separator Roller pairs Feed Chute Main drive Mill housing Grinding table Tie rods Page 112 Training THALOFA Lifting device Page 113 Training THALOFA Lifting device Dismantling of a roller pair in progress Page 114 Training THALOFA Lifting device Lifting apparatus for dismounting device Type x EH 75 S Air requirement x 11m³/min Air pressure bar Lifting capacity x 1.470 kN Lifting height appr 9.000 mm Weight (Lifting apparatus) 5.000 kg Tightening torque for connecting bolts of mounting hoist beams with housing 3.800 Nm Tightening torque for connecting bolts of mounting hoist beams with the fish plates 1650 Nm Page 115 Training THALOFA Lifting device 2.1 Two mounting hoist beams, internal 2.2 Mounting hoist beam, external 2.3 Lifting apparatus 2.4 Safety stops 2.5 Fish plates 2.6 Compressed - air hose Page 116 Training THALOFA Lifting device Page 117 Roller Training THALOFA mill RMK 33 / 16 – 370 THALOFA Flow Sheet THALOFA Page 118 Training THALOFA Coal Grinding Coal Grinding Plant with Roller Mill Training THALOFA Page Coal Grinding 119 Nozzle ring Grinding table Hot gas channel Discharge device Air lock Tramp metal discharge Page 120 Training THALOFA Thank you for your attention [...]... with grinding track Page 28 Roller pairs Mill housing Training THALOFA Feed Chute Page 29 Training THALOFA Roller Pair Page 30 Training THALOFA Roller Pair Page 31 Training THALOFA Roller Pair Basic data Outside diameter of grinding rollers: 2.900 mm Material of roller tyres: wear resistant cast iron Weight of one roller tyre: 16,2 t Weight of one complete roller pair unit: 107,8 t Setting values for... Wear on top of the sealing strips Wear inside the housing Training THALOFA Page 17 Material Feed Chute Heated feed chute Hot gas Training THALOFA Page 18 Feed Chute Material flow Feed chute Hot gas 20°C max 350°C 259°C 261°C Training THALOFA Page Roller mill feed shute with pre-separation 19 Material Hot gas Page 20 Training THALOFA Feed Chute Mill housing Page 21 Training THALOFA Mill housing Mill doors... pre tensioning of the grinding roller bearings 0.1 mm (Difference between the dimension „X” and the height of the intermediate ring, see 7.4 Repair) Training THALOFA Page 32 Roller Pair Components • • • • • • • Roller carrier Shaft Bearing tension cover Roller bearing Clamping ring Roller body Roller tyre Page 33 Training THALOFA Roller Pair Item No relating to the roller pair unit 1 Roller carrier... Material Hot gas Page 20 Training THALOFA Feed Chute Mill housing Page 21 Training THALOFA Mill housing Mill doors Page 22 Training THALOFA Mill housing Rubber seal Mill doors Page 23 Training THALOFA Mill housing Training THALOFA Page 24 Adjustable nozzle ring Page 25 Training THALOFA Mill housing POSITIONS FOR THE NOZZLE RING 6.1 Cover box 6.2 Nozzle ring segment 6.3 Cover plate 6.4 Carrier 6.5 Nozzle...Page 11 Training THALOFA Feed Chute Training THALOFA Page 12 Feed Chute with chute optimised Training THALOFA Page 13 Material Coarse Feed Valve Hot gas Hot gas outlet Hot gas inlet Training THALOFA Page 14 Coarse Feed Valve Basic data Maximum moisture content Construction size Diameter of the housing (internal) Length of the valve (internal) Overall height with base frame Rotational speed of the vane... velocity of the hot air in the valve vmin 18 m/s Minimum hot air volume at Vmin 28.800 m³/h Nominal width of the supply pipe 800 mm Minimum temperature of the hot air at the valve 200 °C Maximum permissible temperature of the hot air 350 °C Training THALOFA Page 15 Coarse Feed Valve Overload coupling Type Syntex 50 TD1 Rotex GS48/50 Overload torque set when being delivered 225 Nm Training THALOFA Page... pin 25 Roller tyre 3 Slide ring 26 Stud 4 Bearing, inner 28 Washer 5 Intermediate ring 29 Retaining ring 6 Bearing, outer 35 Oil drain plug 7 Bearing tension cover 36 Cover for oil probe 8 Roller body 36.1 Cover 9 Inner bearing cover 10 Air chamber cover 11 Radial shaft seal 12.1 Hose pipe for radial shaft seal Page 34 Training THALOFA Roller Pair Confining air system P Page 35 Training THALOFA Roller. .. Training THALOFA Page 26 Adjustable nozzle ring wear protection for nozzle ring segment adjustable segment of nozzle ring (box) nozzle ring adjusting device inner part of nozzle ring Training THALOFA Page 27 Adjustable nozzle ring Adjustable nozzle ring segment Cross-section with the highest velocity Nozzle ring Adjustment distance Hot gas Hot gas chanel Grinding table with grinding track Page 28 Roller. .. chamber cover 11 Radial shaft seal 12.1 Hose pipe for radial shaft seal Page 34 Training THALOFA Roller Pair Confining air system P Page 35 Training THALOFA Roller Pair Confining air system Training THALOFA Page 36 Roller Pair Confining air system view