This is the html version of the file

http://www.luzim.com.cn/lite/LURM-CONTROL-e.doc.
*Google* automatically generates html versions of documents as we crawl
the web.

Nov 12, 2004

Frank Lu

_PROCESS CONTROL OF LURM MILLS_

*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*
* Gas flow
* Classifier speed

In general the finer product with the higher specific surface area
(mm2/g) 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:

* 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 Γäâ 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 300Γäâ
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 120Γäâ 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*

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.

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.

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.