Raw Grinding t/h

Mill Motor 6.7 kWh/t 485

Material size
80% passing
Hard stone 1.50% of roller diameter
Soft stone 2.50% of roller diameter

Louvre ring velocity Reject dP

m/s %Feed Relative
75~85 0 100%
60~65 5~10 84% Less wear
40~45 20~30 60% Fan Power saving 15~30%

Roller Load
Horizontal Vertical
Table Track Roller Roller Specific
Michael Clark:
Table speed Diameter Diameter Pi.D.n/60 Pressure Force This
T is a variable
n (rpm) D (m) m/s k (kN/m2) ~160 bar……….
97 3 2.4 12 160 951.608
112 4 3.2 19 160 1092.765
125 5 4 26 160 1326.832
137 6 4.8 34 160 1675.254
 kW
3249.5 Roller Weight

0.84446

Table Speed

Power n.µ.Dr.W.Dm.Pi.s n
µ
Dr
Vertical W
Michael Clark:
Pressure/roller Dm
This isRoller P Width
a variable Diameter k.D.W
~160 bar……….k W (m) D (m) kN Roller Wei
881.1186 0.6 1.8 951.608 0.104 213.2541 2899.724 1205.628 11
569.1482 0.8 2.4 1092.765 0.104 583.6908 5536.776 1598.642 25
442.2773 1 3 1326.832 0.104 1274.582 9395.315 2170.179 49
387.7903 1.2 3.6 1675.254 0.104 2412.694 15593.66 3001.587 85
Number of rollers 3
Friction coefficient 0.09 (rawmix) 0.1 (coal), 0.06 (cement)
Roller diameter 0.6D
Roller width 0.2D Bed Depth (mm)
Grinding track diameter 0.8D
s table speed 56D0.5 Max Pressu
kN Capacity Mass Retention Time
103.378 109.119200877 0.916088 0.81 30.22308 26.72307 11296
244.5345 224 2.171469 1.92 34.89861 30.85714 7297
478.602 391.311896062 4.24115 3.75 39.01783 34.49933 5670
827.0243 617.271415181 7.328707 6.48 42.74189 37.79213 4972
 50

F-1 kWh/t C

0.876096 0.458182
1.168128 0.394609 16.21857
1.46016 0.383307
1.752192 0.403302
 Michael Clark:
1. The table diameter can be varied in this green cell.

Michael Clark:
2. Data on the corresponding rollers is povided in these pick cells
Table Diameter (m) 5.2 (based on FLS).
Roller Diameter (m) 3.12
Roller Width (m) 1.04 Michael Clark:
3. The fritcion coefficient can be varied here. (0.09 +/-0.02 for raw
Grinding Track Diameter (m) 4.16
material), (0.10 +/-0.02 for coal). (0.06 +/-0.01 for cement.
Roller Weight (t) 55
Friction Coefficient 0.09
Michael Clark:
Bed Depth (mm) 50 4. Hydraulic pressure app

Hydraulic Pressure (bar) Michael Clark:

5. The specific roller pres
150 155 160 165 170 175 calculated for you in thes
Roller Pressure (kN/m2) 411 419 427 435 443 451
Michael Clark:
Power Drawn (kW) 1923 1962 2000 2038 2076 2115
6. In these green cells en
Capacity (t/h) 287 293 298 304 310 316 mill motor.

Michael Clark:
7. In these green cellls e
consumption of 6.7 kWh/
7.3 kWh/t at a bed depth
s green cell. VRM Motor kW = 0.844 x Friction Coefficient x Table Diameter2.5

vided in these pick cells

re. (0.09 +/-0.02 for raw

/-0.01 for cement.

Michael Clark:
4. Hydraulic pressure applied to the rollers is varied in these yellow cells. 356
1208
Michael Clark: 0.294702
5. The specific roller pressure at the different hydraulic pressures is
calculated for you in these pink cells.

Michael Clark:
6. In these green cells enter a formula to calculate the power drawn by the
mill motor.

Michael Clark:
7. In these green cellls enter a formula for the production capacity of the mill using a specific electricity
consumption of 6.7 kWh/t material with a bed depth of 50mm, 7.0 kWh/t with a bed depth of 60mm,
7.3 kWh/t at a bed depth of 70mm, etc.
Diameter2.5
 Volume (Nm3/kg clinker) = (kJ/kg

↑ Volume (Am3/kg clinker) = (kJ/kg

↑
↑
↑
↑

Kiln & Raw Mill Filter ←←← Conditioning Tower

↑
↑
↑ →→→ →→→ →
Raw Mill Exit Temp. 110 ↑ 0% ↓
Raw Mill Exit O2 6% ↑ Mill Outlet Dust Load (g/m3)
Volume (Nm3/kgClinker) ↓
Volume (Am3/kgClinker) Raw Mill ↓
Volume (Am3/s) ←←← ←←← ←←←
Velocity (m/s)
Consumption Rate t/d Michae
Production Rate t/d 4. Calcu
t/h Michae
Table Diameter m 5. Calcu
Mill Body Diameter 1.0 m
Michael
6. Calcul

Michae
7. Calcu

Michael
8. Calcul

Michael
9. Apply a

Michael
10. Vary
velocity th
kg clinker) = (kJ/kg clinker x 0.000275 + 0.284) x (1 + (%O 2/(21% - %O2))

g clinker) = (kJ/kg clinker x 0.000275 + 0.284) x (1 + (%O 2/(21% - %O2)) x (Temperature + 273.

Michael Clark:
1. Using the formulae above enter a formula in cells R16, R17, D17 and D18 to calculate the volume of gas pe
clinker using the kiln specific fuel consumption in T20 and the preheater and raw mill exit temperatures and
oxygen contents.

Michael Clark:
2. Enter a formula to calculate the daily raw meal consumption using the specific consumption in T19 and the d
kiln capacity in T21.
tioning Tower
Michael Clark:
3. Apply an overtaking capacity of 25% to the raw meal consumption rate.
↑
↑
← ←←← ←←← ←←← ← Preheater Exit Temp. 330
↓ 100% ↑ Preheater Exit O2 3%
↓ ↑ Volume (Nm3/kgClinker)

↓ Volume (Am3/kgClinker)

↓ Preheater
← Raw Meal Consumption
Fuel Consumption
Michael Clark: Production Rate
4. Calculate the hourly production rate.
Michael Clark:
5. Calculate the VRM table diameter required using the formula Production Rate = 7.D2.5.

Michael Clark:
6. Calculate the volume in Am3/s.

Michael Clark:
7. Calculate the gas velocity through the VRM body.

Michael Clark:
8. Calculate the dust loading in the gas at the mill exit.

Michael Clark:
9. Apply a factor for the gas recirculation rate around the raw mill.

Michael Clark:
10. Vary the gas recirculation rate until the mill outlet dust loading is <600g/m3 and the
velocity through the mill body is >6m/s.
(Temperature + 273.15)/273.15

calculate the volume of gas per kg

aw mill exit temperatures and

ic consumption in T19 and the daily

1.55 t/t Clinker

3100 kJ/kgClinker
3000 t/d
 Volume (Nm3/kg c

Main Stack O2 10%

Volume (Nm3/kgClinker) 1.95
3
Inleaking Air (Nm /kgClinker) 0.82
Inleaking Air (%) 42%
↑

Kiln & Raw Mill Filter

↑ ←
↑ ↓
Filter Inlet O2 8% ↓
Volume (Nm3/kgClinker) 1.65 ↓
Inleaking Air (Nm3/kgClinker) 0.52 ↓
Inleaking Air (%) 32% ↓
↑ ↓
Michael Clark:
↑ 1. In these green cells insert a formula to calculate the ↓
↑ volume of the exhaust gas using the unit thermal energy ↓
consumption in cell O24 and the formual at the top of the
↑ page. ↓
↑ ↓
↑ ↓
↑
↑ Raw Mill Inlet O2 5%
↑ Volume (Nm3/kgClinker) 1.34
3
↑ Inleaking Air (Nm /kgClinker) 0.21
↑ Inleaking Air (%) 16%
↑
↑ ↓
↑
↑ ← Raw Mill

Exha
Ga
Exha
Ga
Clean

Ra
 Volume (Nm3/kg clinker) = (kJ/kg clinker x 0.000275 + 0.284) x (1 + (%O 2/(21% - %O2))

Michael Clark:
4. In these green cells enter a formula to calculate
the inleaking air above the calcination and
Split 90% 10% combustion products and the excess air.

→ → → → Coal Mill
↑
← ← ← ← Coal Mill Exit O2

↑ Volume (Nm3/kgClinker)
Preheater Exit O2 3% Inleaking Air (Nm3/kgClinker)
Volume (Nm3/kgClinker) 1.33 Inleaking Air (%)
Inleaking Air (Nm3/kgClinker) 0.07
Inleaking Air (%) 5%
↑
Michael Clark:
e ↑ 2. In this green cell enter a formula to
gy calculate the excess air at the precalciner
the exit.
Preheater
↑
↑
Precalciner Exit O2 2% Fuel Consumption 3100 kJ/kgClinker
Volume (Nm3/kgClinker) 1.26
3
Excess Air (Nm /kgClinker) 0.12
Michael Clark
Excess Air (%) 11%
3. In this green
calculate the %
calcination and
↑ gases.

Raw Mill Precalciner ← Rotary Kiln

↑
↑
↑ ← ← ← ←

Exhaust Exhaust Fuel Exhau

Gas Gas Preparation Gas
Exhaust Exhaust Fuel Exhau
Gas Gas Preparation Gas
Cleaning Condition Cleani

Homo Rotary
Raw Mill Preheater Precalciner
Silo Kiln
/(21% - %O2))
↑
Coal Mill Stack O2 8% ↑
Volume (Nm3/kgClinker) 0.18 ↑
3
Inleaking Air (Nm /kgClinker) 0.06 ↑
Inleaking Air (%) 32% ↑
↑
↑
→ Coal Mill Filter → ↑

Coal Mill Exit O2 6%

Volume (Nm3/kgClinker) 0.16
3
aking Air (Nm /kgClinker) 0.03
Inleaking Air (%) 21%

Michael Clark:
5. In these green cells enter a formula to calculate
the % inleaking air above the calcination and
nter a formula to combustion products and the excess air.
ir at the precalciner

Michael Clark:
3. In this green cell enter a formula to
calculate the % excess air above the
calcination and combustion product
gases.

←
↑
↑

Grate Cooler

Fuel Exhaust
paration Gas
Fuel Exhaust
paration Gas
Cleaning

ciner Rotary Cooler

Kiln