Connect with us

General

Ball Mills Or Vertical Roller Mills: Which Is Better For Cement Grinding?

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.

Ball Mills Or Vertical Roller Mills: Which Is Better For Cement Grinding?

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.

Product Quality

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.

Investment Cost

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.

Continue Reading

Recent Posts

Autos5 hours ago

4 Reasons to Replace Your Car’s Engine With Performance Parts

Performance parts are the best kind of upgrades you can make to a car. Performance cars have a higher price...

Maximum Power: Update Your Old House For Modern Electrical Needs Maximum Power: Update Your Old House For Modern Electrical Needs
Home Improvement4 days ago

Maximum Power: Update Your Old House For Modern Electrical Needs

An outdated electrical system can wreak havoc on your energy bills and greatly increase your risk of structural damage. If...

Key Techniques To Learn On A First Aid Course Key Techniques To Learn On A First Aid Course
Health2 weeks ago

Key Techniques To Learn On A First Aid Course

Introduction First aid training is an incredible qualification that can enable one to offer life saving assistance in an emergency....

Best Tips For Managing Your Building and Construction Projects Best Tips For Managing Your Building and Construction Projects
General3 weeks ago

Best Tips For Managing Your Building and Construction Projects

Building and construction projects consist of many tasks, from job-site duties to office paperwork. Juggling it all can oftentimes be...

How To Choose The Best Locksmith For The Job How To Choose The Best Locksmith For The Job
Home Improvement3 weeks ago

How To Choose The Best Locksmith For The Job

The existence of a locksmith is very crucial for society because they help out countless people on a daily basis....

5 Modern Conservatory Ideas To Create A Serene Escape 5 Modern Conservatory Ideas To Create A Serene Escape
General4 weeks ago

5 Modern Conservatory Ideas To Create A Serene Escape

Having a serene and relaxing conservatory is the dream, especially in the summer months. Creating an extension of your home...

4 Different Types Of Lifting Equipment For A Construction Site 4 Different Types Of Lifting Equipment For A Construction Site
Business4 weeks ago

4 Different Types Of Lifting Equipment For A Construction Site

One of the biggest challenges on a construction site is the problem of lifting heavy materials and tools to a...

5 Tips That Can Help Your Business Flourish 5 Tips That Can Help Your Business Flourish
Business1 month ago

5 Tips That Can Help Your Business Flourish

Many, both small and big, businesses were affected by the outbreak of the novel coronavirus, no one was spared. Overnight,...

Why First Aid Training Is Essential For Your Business Why First Aid Training Is Essential For Your Business
Education1 month ago

Why First Aid Training Is Essential For Your Business

Introduction All employers, depending on the establishment, should organize and provide basic appropriate conditions for lunch breaks as well as...

Are You Covered? Tips For Finding Affordable Health Insurance For Your Whole Family Are You Covered? Tips For Finding Affordable Health Insurance For Your Whole Family
Lifestyle1 month ago

Are You Covered? Tips For Finding Affordable Health Insurance For Your Whole Family

If you are in the market for health insurance, you may be overwhelmed by the many different features and the...

How to Prevent Potential Hazards In A Lab How to Prevent Potential Hazards In A Lab
General1 month ago

How to Prevent Potential Hazards In A Lab

Unfortunately, lab accidents can happen. When they do, the consequences can be very serious. Some of the most common lab...

How to Extend Your UK Spouse Visa How to Extend Your UK Spouse Visa
Travel2 months ago

How to Extend Your UK Spouse Visa

The UK spouse visa is also known as a UK marriage visa. The UK spouse visa allows married partners of...

How Best Is Automation Helping The Retail Industry to Survive? How Best Is Automation Helping The Retail Industry to Survive?
Business2 months ago

How Best Is Automation Helping The Retail Industry to Survive?

“In the post Covid-19 world, the only place cos are willing to invest is in automation. The return on investment...

Best Artificial Intelligence Trends to Watch Out In 2021 Best Artificial Intelligence Trends to Watch Out In 2021
Tech2 months ago

Best Artificial Intelligence Trends to Watch Out In 2021

Technologies are getting advanced day by day, and according to that, the developers and the mobile app development companies should...

Keeping Your Assets Safe — Crypto Insurance May Soon Become The Norm Keeping Your Assets Safe — Crypto Insurance May Soon Become The Norm
Markets & Finance2 months ago

Keeping Your Assets Safe — Crypto Insurance May Soon Become The Norm

Many people all over the world have compared the cryptocurrency market to the wild West, largely because of the fact...

Categories

Archives

Trending