Vertical roller mills Vs ball mills has long been a raging debate in the cement industry. In spite of the fact that vertical roller mills have been around for over ten years now and have gradually become the standard as far as cement manufacturing goes, several cement manufacturers still prefer ball mills for cement production when they want to design new grinding plants or a new integrated cement plant.
Some members of the cement manufacturing industry, it appears, is stuck in the past rather than embracing newer, energy saving and better technological advancement. They should notice the following differences and make an informed choice.
Mill Operation and Maintenance
Operating a ball mill is quite simple as it lacks any moving mechanical parts within the mill. The system is quite versatile and is designed to accommodate variation in mill feed quantity and quality. On the other hand, the vertical roller mills (VRM) is quite a complicated and sophisticated equipment with hydraulics that controls the rollers.
The material between the table and the rollers is quite thin, and it is important that the rollers and the table are not in contact with each other. If the material bed is variable, it results in vibrations in the mill.
In VRMs, the effect of this vibration is reduced as the feed is larger than that in cement mill feed. The amount of moisture in the kiln raw materials is higher than that of the cement mill. To reduce the vibration effect and prepare the materials, the rollers of the VRM are suitably modified.
Sometimes, grooved rollers are used to establish and remove the air content of the materials within a low-pressure area before it is passed on to a high-pressure grinding area where the material are then fractured. Sometimes, smaller rollers may be used to before the first rollers to achieve the same outcome.
Regarding operations, in a ball mill, the grinding media has a higher rate of wear about the rollers and table in the VRM. In ball mills, it is essential to monitor its performance via axial testing to ascertain that the media grading is right and that there are enough top-size media to grind the mill feed materials. If not so, high, underground materials (referred to as nibs) will collect around the edge of the first chamber.
In ball mills, the main repairs that occur are replacing the diaphragms and liners. The lifespan of the liners is about five years for the liners in the first chamber and up to eight years for those in the second chamber. They, therefore do not require frequent replacement.
The diaphragm plates, however, need to be replaced more often, though not annually. On the other hand, the major repairs in vertical roller mills are replacing the rollers (or turning it) and the table. Though you may not have to replace the worn parts of the VRM yearly, however, work needs to be done on them. This could involve either reverse its roller segments or hard-facing the rollers and table.
Eventually, you just would have to replace the worn parts. Thus, VRM requires higher maintenance than ball mills. On the whole, the maintenance costs are almost at par. The rate of wear is greater in a ball mill but the cost of replacement is lower. On the other hand, the wear rate is lower in VRM, the cost of replacing the parts is significantly higher.
When VRM was first mooted as an alternative in cement production, one of its seeming challenges was its particle size distribution (PSD). Due to their high separation efficiency and its high circulation factor, VRM tends to produce cement with a steep PSD curve unlike those generated by ball mills.
Cement with a steep PSD is one with a high water demand. To address this issue, VRM manufacturers have come up with a more conventional raw mill VRM design.
VRM has been a more compact unit is quite smaller about the ball mills thus significantly reducing civil engineering cost about a ball mill plant. Ball mills are factory made and transported to the plant site of the buyer while VRM is built on the site of the cement plant. This helps to reduce cost and complicated logistics issues. The equipment cost is, however, higher for a VRM than a ball mill.
So these are the pros and cons of the two technologies and a cement manufacturing company mus consider to make the suitable choice that matches their requirements.
Staying on Schedule When Traveling With Family
There is a lot of planning that goes into traveling with your family, especially if you are trying to stick...
Do You Need a Lawyer When Filing for Divorce?
Since divorce is a relatively common legal proceeding, some couples opt for a DIY approach. They decide to download the...
Unique First Home Gifts For Your Loved Ones
If one of your loved ones is moving into their first home, we have the perfect gifts for you. Each...
Should Your Business Offer International Shipping?
In today’s world, many businesses have the opportunity to reach a global audience and find new ways to grow. But,...
Why Isn’t Your Company Website Seeing Traffic?
Are you hooked? Do you check your website’s Google Analytics frequently, only to be disappointed every time you see it? ...
Resources and Assistance For The Parents Of Children With Autism
Raising a child with autism can be a challenge. For most neurotypical people (i.e., those who do not have autism),...
How to Improve Your Company Parking Lot Safety For Your Employees
When your workers park in the corporate lot, you want them to feel comfortable and protected. Your staff shouldn’t have...
Legacy Application Modernization – The Enterprise Perspective
The global application modernization services market size is expected to grow from USD 11.4 billion in 2020 to USD 24.8...
What You Need to Know Before Sending Important Packages
Many of us have at least once in our life faced the task of sending something to another city or...
4 Most Efficient Drainage Systems For Flat Roofs
The matter of drainage is the essential function of your roof. In fact, the very shape of a roof (a...
Google Algorithm Updates to Expect by The End Of 2021
Google’s algorithm updates tend to come with a lot of uncertainty and questions, and getting ahead of them is the...
Cozy Home Office Setup Tips For 2021
Whether you work from home or have set out a place for something you like such as crafting, studying, or...
Garden Party Ideas For Everyone
No one can make “a perfect’’ garden party, but we are all able to throw an amazing one. Of course,...
How To Find Low Competition Long Tail Keywords Using Free Tools
Keywords are the most fundamental and highest ROI activity when it comes to SEM and SEO. Having the right keywords,...
Top Tips For Healthy Family Meals On A Budget
A healthy diet is not very difficult to follow since there is a lot of information available on the Internet...
Tech7 years ago
Creating An e-Commerce Website
Tech7 years ago
Design Template Guidelines For Mobile Apps
Business6 years ago
The Key Types Of Brochure Printing Services
Travel9 years ago
Who Else Wants Also Nfl Hat
General6 years ago
Kobe Bryant With His Unique Nba Jerseys
Tech7 years ago
Why Small Businesses Can't Ignore Mobile Technology
Tech7 years ago
Climb Google Using These Checklists
Health8 years ago
Health Supplements For Sports Activities Nutrition