Principle- -- n- - . - .

- - - --

Pressure and friction. That's what

the Fuller-Loesche Mill uses for its
economical size reduction. Material
on a rotating grinding table is
crushed and ground beneath sta-
tionary hydro-pneumatic rollers.
Ground material spills over the
edge of a louver retention ring,
where it is carried by a rising gas
stream to a classifier on top of the
mill. Hot gases cause immediate
evaporation of the material's
moisture. The classifier rejects
oversize particles and returns them
for regrinding. The desired product
travels to a dust collector via the
gas stream. The material is sepa-
rated and clean air released into
the atmosphere.

Hydro-pneumatic loading of grinding rollers.

Design - -- - -

Preparing natural materials individual characteristics of system -for feeding, sepa-

from a variety of rocks and
clays. That's what our mill
is designed for. And the
worldwide experience of our
engineers has been translated
into an extremely economical
design. They understand the
important factors for success:
raw materials, special require-
ments of the products, prevailing
economic conditions, adapt-
ability of the mill to conditions
before and after the main
process, and possible combi-
nation of the mill with other
machinery of the grinding
ration, dust collection, air
heating and conveying.
The roller mill takes all
these requirements into account
and is flexible enough to meet
many other variables arising
from special process
applications.

Schematic of a central grinding system

w ~ t ha partial gas return, arranged to Schematic of a grinding plant working in
conserve heat for drying and to reduce conjunction w ~ t ha rotary kiln, preheater,
Schemat~cof a central g r ~ n d ~ n
system.
g investment cost for dust collection. cooler and possibly with a dryer.
8 - -
Features
Design
W Classifier with bearing cartridge
and outlet duct for dust -laden air.
W Classifier with bar-type rotor
with variable speed drive.
W Mill body with easy-access
maintenance and inspection
doors.
W Rocker arm with swivel axle and
roller shaft support.
W Grinding roller with mounted
wear ring.
Grinding roller in swing-out
position for maintenance work,
swing-out cylinder and cylinder
support frame.
W Grinding table with grinding
ring, louver ring and dam ring.
W Hydro-pneumatic spring with
spring rod, cylinder and
hydraulic accumulator.
W Mill stand with rocker arm bear-
ing housings and bearing
supports for working cylinder.
I Hot gas inlet opening.
Mill gear box.
W Structural support frame.
Construction
Swing-out device permits worn
parts to be quickly replaced
without dismantling the mill.
Hydro-pneumatic spring system
keeps grinding pressure uniform.
Automatic hydraulic
lifting of rollers
prevents metal
contact between
grinding table
and roller.
No auxiliary
drive necessary
because rollers are lifted
for start-up. Mill can be
started even when full
of material.
1Economical foundations
permitted because the mill
weight and grinding loads
are distributed evenly over
the support frame.
W Gear box is easily accessible in
the mill tunnel.
m Mill body and grinding table
remain intact when disassembling
the gear box.
Process
Flash drying of feed material by
hot gases.
Internal recirculation of oversize
particles between classifier and
grinding table without mechani-
cal conveying.
1 Particle size distribution of product
can be varied by adjusting
classifier speed.
W Variation of product fineness is
controllable while mill is
operating.
Control Response
Short residence time in mill
permits:
W Stable operation in approxi-
mately one minute from
start -up.
Uniform chemical composition
of the product with on-line
analysis and process computer
control.
I Readjustment in as little as
15 seconds when varying the
amount of feed.
1Readjustment of entire grinding
system in as little as two minutes
if feed components are changed.
Environmental Control
Low noise level.
INo dust emission. Mill operates
below atmospheric pressure.
Pressure-type mills for coal
grinding are equipped with
special air seals.
Moving parts are guarded for
accident prevention.
W SO2 in the combustion gases is
absorbed by feed when grinding
materials such as calcium
carbonate.
Adjustment Capability
Capacity: Can be reduced to
60-70% of nominal capacity.
W Depth of grinding bed: By
adjusting height of damming
ring or grinding table.
Grinding pressure: By changing
tile operating pressure of hydro-
pneumatic spring system.
Gas quantity: By using dampers
or varying fan speed.
W Amount of heat: By controlling
gas volume and temperature.
Product Fineness: By adjusting
the classifier speed.
Dew Point Considerations:
Avoid condensation with auxiliary
heat insulation, increase the
moisture content with waterspray.
 Product Fineness

The roller mill can grind a wide
range of materials- including
rocks and clays with natural crys-
tallographic, fibrous and stratum
structure; products resulting from
sintering processes; and organic
substances. Materials that are
homogeneous and heterogeneous
in structure-with brittle, cohesive,
brittle-cohesive and wet plastic
properties. Mixed or unmixed.
In particle sizes from 0 - 6 inched
edge length. In freshly quarried
or dry state.
As a result of the grinding
procedure, all types of dry, pulver-
ized materials can be produced -
from coarse to extremely fine par-
ticle sizes. If necessary, several
products can be processed in
one grinding plant.
 System Economy
Operation Economy
The pressure-friction technique
of this roller mill reduces all soft,
brittle and cohesive materials
quickly, with low power consumption.
Inside the mill, simultaneous
grinding and drying offers further
economy -allowing hot gases to
dry the crushed product.
During grinding, materials with
up to 12% moisture can be reduced
below 1%. Some materials with up
to 50% moisture can be ground
without pre-drying when special
material flow circuits are used.
Adjusting the speed of the classi-
fier or modifying the vanes permits
a wide range of product fineness.
Compact system design reduces
cost of buildings and foundations.
The mills are designed for ease
of repair and maintenance-
featuring quick dismantling of
grinding elements and immediate
access to grinding space.
Wear cost in cents per ton is
low -approximately 2% to 5% of
the total grinding cost. Roller tires
and liners can be worn up to 50%
Our mills can be fed material grinding mill feed with up to 50%
ranging up to 5% of the size of the moisture, coarse materials can be
roller diameter- reducing invest- recirculated to reduce moisture in
ment costs for secondary andlor the mill feed. This usually makes
tertiary crushers. The pressure- pre-drying unnecessary and
friction grinding technique prevents reduces operating cost.
overgrinding of fines.
In coal firing systems: Positive
Process Economy or negative pressure mills can
In central grinding plants: The be used for direct or indirect
grinding circuit consists of the air coal firing of steam boilers and
heater, feeder, mill, dust collector rotary kilns.
and mill fan. For heat economy,
recirculation of mill air is permis-
sible and useful in many
applications.
In compound grinding plants:
Using the kiln exit gases for drying Demonstration of easy gr~ndlngroller
removal for fast maintenance
in the mill permits
a common dust col-
lector to be used
for kiln and mill.

In special process '

circuitry: To simul-
taneously obtain
several products of
different fines with
-
of their original weight. different sizes,
Under average conditions, they numerous separa-
will last nearly two years. With abra- tors can be placed
sive feed, at least one year. And if in a series along
the abrasive component is finely with air stream to fl
divided in the feed, the grinding the dust collector.
parts may last several years. When d r y ~ n gand

a preheater krlrl.
Gr~ndingplant with two LM 28 mills working ln conjun~ctlonw ~ t h

The roller mill is a self-contained
system. The gas flow usually per-
forms three functions when entering
and leaving the mill: drying, separa-
tion and discharge of the finished
product. The result is smooth,
automatic control of the mill.
Control Action
Four automatic control loops are
required for the control of a grind-
ing system, whether the mill
operates alone or in conjunction
with other machinery:
Feed control loop - regulated by
sensors measuring the pressure
differential across the mill.
LM34 processing cement raw meal with 20% feed moisture
Temperature control loop- regu-
lated by sensors measuring the
gas temperature after the mill.
Gas volume loop control -
regulated by sensors measuring
the air flow.
Pressure control loop at mill air
entry - regulated by sensors
measuring static pressure pre-
vents process disturbances in
equipment such as the kiln,
cooler, dryer, etc., and vice versa.
Instrumentation
Proper instrumentation is essential
to the operation and control of a
grinding system. Fuller provides
Graphic control panel for drying and grinding arrangement in a modern
cement plant.
Control
such instrumentation for process
control, indication andlor
recording.
Supervision
For plant protection, an electrically
interlocked system is necessary to
control the sequence of start-up
and shut down - and to stop
appropriate equipment in the case
of malfunction. Dampers in the gas
ducts are also automatically posi-
tioned in case equipment is
switched in or out of the mill
operating circuit.
~~i~~
M~~~~~
Grinding rollers automatically lifted
from the table permit start-up of a
filled mill. Simple squirrel cage
motors are adequate to start
machines without the need for
inching drives. Only the capacity of
the power supply line may necessi-
tate the selection of other types of
drive motors.
Operator's Panel
Fuller supplies appropriate control
panels or control data for the
design of appropriate mill control.
It is unnecessary for the operator
to remain in the mill room. One or
several mills can be operated from
a central control room.
Construction

1. Large size, lour-

roller mill under
construction.

2. Grinding rollers
assembled and
sealed for
1
shipment.

X Classifier rotors >

are carefully I
balanced.

4.Millgearboxes
being
manufactured. 1
5. Installation of
roller mill. C
 i c ations

Cement raw materials, marl, H Minerals such as bentonite, feld-

clay, mixtures with sand and spar, calcium fluoride, kaolin, pyrite,
space requirements chalk. graphite, talcum, ocher, gypsum,
Limestone of any hardness to be magnesite, barite, clay, etc.

I ground to coarse, medium, fine

and superfine particles.
Quicklime, limestone for lime
Chemicals such as titanium
oxide, anhydrite, sulfate, etc.
Material for electrodes such as
burning, hydrated lime. petroleum coke, coke, anthracite
H Phosphate of any origin, fer- and graphite.
tilizer components such as Coal of any origin up to the
agricultural lime and calcium highest contents of ash and
cyanamide. moisture.
I 1
Particle size distribution curves of grinding products are shown as straight
lines. Angles of distribution lines between 35O and 60° are attained, depend-
ing on grindability, product fineness and other factors.

a)
Special products with a narrow
band of particle size distribution.
as a result of additional separation.
b)
Coarse grind of phosphate,
limestone and ores.
c)
Normal products of cement raw
mix, limestone. coal.
d)
Extremely fine grinds of chemicals
and minerals.
e)
Fine products as a result of
additional special separation.

Approximate
Space
Requirement

Mill A B
Type mm English mm English

LM 17 5 000 16'4" 6 500 21'3"


Simple
-because in the grinding com-
partment, only the grinding
elements are exposed to the dust.
Convenient
-because the grinding rollers com-
pletely swing out of the mill body
for replacement of wearing parts.
Simple replacement of grinding parts can usually be done in one working shift
Maintenance
Replacement of Wearing Parts
Standard tools and equipment can
be used to replace wearing parts.
Auxiliary drives, platforms and
extra space are not needed. For
safe and easy swing-out of the
complete grinding roller, the mill
has a hydraulic swing-out assem-
bly, which can be operated by the
mill's hydraulic system using a
simple plug-in hose. After removing
a few bolts, a wornout grinding tire
can be replaced by a new one.
Grinding ring segments fastened by
a clamp collar can be easily and
quickly replaced.
Compact roller
arrangement
demonstrates high
utilization of mill
volume.

LM32 processing abrasive cement raw meal. LM36 showing minimal enclosure requi~ell~ents.