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2
Indonesia Cement and Concrete Institute
HOPER
GasEXHAUST
Ke CoolingGAS
TowerTO
COOLING TOWER
CYCLONE
PEMISAHAN
Produk
Silo
RAWRaw
MIXMix
TOke
CFCF
SILO
3
VERTICAL MILL +
CLASSIIER
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Indonesia Cement and Concrete Institute
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Indonesia Cement and Concrete Institute
Elemen-elemen VRM
feed gate
(air lock)
mill exhaust
product discharge
mill outlet duct
separator
cage rotor
separator
guide vanes
tailings cone
separator
discharge flap
mill casing
water
injection
rocker arm
roller axle
table liner
dam ring
grinding table
hydraulic cylinder
material scraper
clutch
and motor
Polysius: Doroll
Loesche: LM
Kobelco: OK
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Indonesia Cement and Concrete Institute
G.Pfeiffer
Loesche
FLS Atox
Polysius
Indonesia Cement and Concrete Institute
Feed
separator
Hydraulic system
Asesoris VRM
Pendulum valve
Rotary valve
Menurunkan
false air yang
masuk bersama
material. Cocok
untuk material
kering
Weigh belt
Menurunkan
false air yang
masuk bersama
material. Cocok
untuk material
lumpy
Metal extraction
Metal
membahayakan
roller & table.
Magnet
membuang
material ini
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Indonesia Cement and Concrete Institute
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Indonesia Cement and Concrete Institute
Internal gas
flow
Separator Rejects
Internal Circulation
Material kasar jatuh melalui
scraper
Material
Material & Gas
Gas
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Indonesia Cement and Concrete Institute
Internal VRM
Tepung baku berbentuk
gas keluar Raw Mill
Classifier
Bahan Umpan
Roller
Drive
Meja
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Indonesia Cement and Concrete Institute
Feed material
Feed size:
Max Particle size in
feed: 5-8 % of roller diameter
f (Roller )
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Indonesia Cement and Concrete Institute
separator
Staticstatictype
Rotor type
F T
T F
F
Separation control:
1. Vane adjustment
2. Speed control
TF
FT
F=
Feed
P=
Product
T=
Tailings
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VRM - Separator
Sudut
mempengaruhi
ukuran produk
Kecepatan rotor
mempengaruhi
kehalusan produk
Rotor seal
mempengaruhi
efisiensi separator
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Indonesia Cement and Concrete Institute
bucket elevator
louvre ring
scraper
collecting conveyor
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Indonesia Cement and Concrete Institute
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Indonesia Cement and Concrete Institute
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Indonesia Cement and Concrete Institute
Detail
1.
Proses
2.
Feed system
3.
Drying
4.
Grinding
5.
6.
Separating (pemisahan)
7.
8.
Kualitas produk
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Indonesia Cement and Concrete Institute
Material dihaluskan di
antara roller dan meja
Drying
Pemanasan material dg gas
panas
Transport
Dari table ke separator
melalui gas
Separating
Produk halus dipisahkan
dari yang kasar dan
mengembalikan yang kasar
ke table untuk digiling lagi
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Indonesia Cement and Concrete Institute
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Indonesia Cement and Concrete Institute
1.2. Drying
95
85
Hot gas
150
75
T [C]
350
25
Material
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Indonesia Cement and Concrete Institute
1.3. Transport
Material ditransport
meja ditransport
secara mekanikal
melalui nozzle ring
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Indonesia Cement and Concrete Institute
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Indonesia Cement and Concrete Institute
Feed materials
d < 5 8 [%] DR
[%]
Metal detector
Triple gate
Triple gate
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Indonesia Cement and Concrete Institute
Feed chute
Feed
sticky
Feed
Hot gas
Hot gas
Feed chute
Sudut inklinasi > 45 []
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Indonesia Cement and Concrete Institute
3. Drying
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Indonesia Cement and Concrete Institute
> 90 - 95 [C]
Cold air
Mill motor
power
Hot gas
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Indonesia Cement and Concrete Institute
Material
meninggalkan
table
Hot gas
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Indonesia Cement and Concrete Institute
Cooler gas
all sealings
of casing
openings
doors +
covers
Compensator
Compensator
External reject
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Indonesia Cement and Concrete Institute
4.Grinding
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Indonesia Cement and Concrete Institute
Roller specific
operating pressure
Nozzle ring
Armour ring
KecepatanTable
1.
Jumlah
2.
Distribusi
3.
Fineness
Material escapes
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Indonesia Cement and Concrete Institute
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Indonesia Cement and Concrete Institute
Dam ring
roller
Controls material
flow leaving the
grinding zone
dam ring
Mengontrol
grinding
ketebalan material
bed
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Indonesia Cement and Concrete Institute
Airspeed melalui
nozzle ring
mengendalikan
jumlah material
pada external
recirculation
Armour ring
inklinasi
mengontrol jumlah
material yang
dikembalikan ke
table
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Indonesia Cement and Concrete Institute
Nozzle ring
The nozzle ring
evens the air
distribution all
around the table
The airspeed
through the nozzle
ring can be modified
by selective
opening/closing the
free surface
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Indonesia Cement and Concrete Institute
6.Separating
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Indonesia Cement and Concrete Institute
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Indonesia Cement and Concrete Institute
Siklus 2 : preseparasi di
atas louvre ring
(perbedaan energi
kinetik)
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Indonesia Cement and Concrete Institute
Material di separator
Rotor
Guide vanes
Dynamic seal
Grits cone
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circumference
Dynamic seal state
Jumlah udara pemisah
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Indonesia Cement and Concrete Institute
Separator type
105 - 110 [%]
100 [%]
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Indonesia Cement and Concrete Institute
Selective closing
of the nozzle
ring opening can
help even
material
distribution on
the rotor
circumference
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Indonesia Cement and Concrete Institute
Dynamic seal
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Indonesia Cement and Concrete Institute
Memaksimalkan produksi
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Indonesia Cement and Concrete Institute
Drying process
Tmo = Constant & > 90 [C]
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Indonesia Cement and Concrete Institute
Grinding process
Mill load
Mill motor absorbed power kept constant through fresh feed (preferred)
Mill differential pressure kept constant through fresh feed
Water injection used to keep material bed on the table stable
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Indonesia Cement and Concrete Institute
8.Product quality
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Indonesia Cement and Concrete Institute
chemical composition
Feed system
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Indonesia Cement and Concrete Institute
Good
(modern)
separator
Bad (old)
separator
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Good
(modern)
separator
[%] R 90 [um]
< 0.05
Bad (old)
separator
Separating process
[%] R 90 [um]
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Indonesia Cement and Concrete Institute
Achieved
product PSD
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Indonesia Cement and Concrete Institute
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Indonesia Cement and Concrete Institute
4. Sirkulasi material
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Indonesia Cement and Concrete Institute
dipengaruhi oleh :
Granulometry material
Tekanan roller
Dam ring
Louvre ring
2. Ekternal Sirkulasi
3. Final separasi yang
diperankan oleh
separator (prinsip ideal :
material halus semuanya
menjadi produk dan
material kasar
dikembalikan ke table)
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Indonesia Cement and Concrete Institute
Temperatur
Draft
Laju gas
Kehalusan material
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Indonesia Cement and Concrete Institute
Kinerja VRM
1. Kapasitas Mill, bergantung pada :
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Indonesia Cement and Concrete Institute
Energi Mill
Grindability material
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Indonesia Cement and Concrete Institute
II.
Mill Feed
1. Feed
2. Kadar air
Mill
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
13.
VRM 2
VRM 3
VRM 4
Unit
RM IIIC
RM 5R1
RM 5R1 (m od)
RM 5R2
tph
%
240-300
4-8
180-190
4-6
330-380
4-6
330-380
4-6
-mBar
mBar
o
C
o
C
3
m /jam
mm/s
bar
bar
kW
kW
%
4-5
75-85
85-95
200-210
410-425
4-8
40-45
25
1200-1500
1850-1950
95-97
10-14
60-63
80-85
200-235
690000
10-14
42-45
20
1380-1400
2050-2200
60-63
5-7
60-62
80-85
220-275
708000
5-8
80-90
50
2080-2220
2030-2145
60-65
5-7
62-64
80-85
220-275
600000
4-6
80-90
50
2130-2300
1790-1900
70-72
%
%
%
15-18
1.2-1.8
0.3-0.5
20-24
5-8
0.3-0.4
12-14
2.5-2.8
0.3-0.4
12-14
1.6-1.9
0.3-0.4
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Indonesia Cement and Concrete Institute
II.
M ill
1.
2.
3.
4.
5.
M ill
1.
Tyre
a. Dia. Tyre (kecil/besar)
b. tinggi tyre
2.
Gear Box
a. Jenis
2.
3.
4.
5.
IV .
Sys te m
Produs en
Kapas itas Design
Type
Table Revolution
Jumlah Roller
Load (p1/p2)
Speed driv e
Output s peed
Dia. Table
Tinggi damring
Hydraulic
a. Dia. Inner Cylinder
b. Operating area/cyl
c . Jumlah A cc umulator/cyl
d. V olume A c cum.
Pow er
a. Mill motor
b. Mill Fan motor
Se par ator
1.
Class if ier
a. Ty pe
b. Jumlah Flap
c . Sudut f lap
d. Tinggi f lap
2.
Pow er
3.
Type cyc lone
Unit
VRM 1
RM IIIC
VRM 2
RM 5R1
VRM 3
RM 5R1
(m od)
VRM 4
RM 5R2
(m od)
tph
rpm
unit
Loeche
240
LM 38.40
29.0
4
Loeche
310, min
LM 41.4
27.56
4
Loec he
310, min
LM 41.4
27.56
4
Loeche
310, min
LM 41.4
27.56
4
mm
mm
mm
mm
1625/1985
705
Flender
Bev el
Planetary
2000 / 2000
900
29
3800
95
1960/2228
708
Flender
Bev el
Planetary
2650 / 2650
990
27.56
4100
80
1960/2228
708
Flender
Bev el
Planetary
2650 / 2650
990
27.56
4100
95
1960/2228
708
Flender
Bevel
Planetary
2650 / 2650
990
27.56
4100
95
mm
cm2
unit
ltr
410
1065.8
6
32
430
1168.7
4
32
430
1168.7
4
32
430
1168.7
4
32
2250
2520
2900
2900
2900
2900
2900
2900
LJKS 70
132
LDKS 70
48
adjus table
1280
132
Z 14000 SRE
Design PTSP
48
60
2000
132
Z 14000 SRE
kW
unit
o
mm
kW
-
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Indonesia Cement and Concrete Institute
II.
Mill Feed
1. Feed
2. Kadar air
Mill
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
13.
Unit
RM IIIC
RM 5R1
RM 5R1 (m od)
RM 5R2
tph
%
240-300
4-8
180-190
4-6
330-380
4-6
330-380
4-6
-mBar
mBar
o
C
o
C
3
m /jam
mm/s
bar
bar
kW
kW
%
4-5
75-85
85-95
200-210
410-425
4-8
40-45
25
1200-1500
1850-1950
95-97
10-14
60-63
80-85
200-235
690000
10-14
42-45
20
1380-1400
2050-2200
60-63
5-7
60-62
80-85
220-275
708000
5-8
80-90
50
2080-2220
2030-2145
60-65
5-7
62-64
80-85
220-275
600000
4-6
80-90
50
2130-2300
1790-1900
70-72
%
%
%
15-18
1.2-1.8
0.3-0.5
20-24
5-8
0.3-0.4
12-14
2.5-2.8
0.3-0.4
12-14
1.6-1.9
0.3-0.4
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Indonesia Cement and Concrete Institute
Pengaturan
Kecepatan
Pengaruh
Laju umpan
Proporsi masing-masing komponen
Roller
Tekanan hidrolik
Tekanan penggilingan
Tebal bed di atas table
Classifier
Fan mill
Laju putar
Kehalusan produk
Posisi blade
Beban sirkulasi
Posisi damper
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Indonesia Cement and Concrete Institute
2. Kapasitas
sangat tinggi
LANGKAH PERBAIKAN
4. Vibrasi Roller
diatas
Normal
e. Kontrol feed
6. Beda tekanan
tinggi
7. Beda tekanan
rendah
f. Periksa classifier
9. Produk sangat
kasar
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Indonesia Cement and Concrete Institute
LANGKAH PERBAIKAN
a.
b.
c.
d.
e.
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Indonesia Cement and Concrete Institute
Power Consump
naik dari 11 kWh/t
ke 21 kWh/t
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Indonesia Cement and Concrete Institute