Ball mill & roller press combined cement grinding solution
Capacity: 700 ~ 5,000 TPD
Main Grinding Equipment: roller press, ball mill
Material: limestone, calcite, talc and dolomite
Working Process: cement combined grinding system
Solution: EPC service providing including design, procurement, construction, and trial operation
Solution Introduction
In cement clinker grinding plants, roller press and ball mill combined grinding systems is a mainstream. Pre-grinding systems, combined grinding systems, and semi-final grinding systems are three types of roller press and ball mill combined grinding systems. The choice of which process to use depends on the capacity of the roller press and cement ball mill.
Ball mill and roller press combined grinding system and semi-final grinding system are considered the most effective methods of productivity elevation and energy consumption at this stage.
As the name indicates, a roller press and a cement ball mill are the main equipment in this combined grinding system. Before entering the ball mill for final grinding, the material first passes through the pre-grinding system with a roller press as the main equipment. Then the fine material that meets the requirements is classified and enters the ball mill for final grinding. This method is more efficient than the vertical mill & ball mill combined grinding system. The final product has good particle grading, particle surface shape, less water needed,
Less equipment and less maintenance work
Low system power consumption
Avoid wearing equipment
Cement grinding process with roller press
The main equipment needed in the process: roller press, cement ball mill, V separator, dynamic separator, and filter fan.
Crushing
Raw materials including gypsum and mixed materials are transported to the plant by trucks and storage in the warehouse. A hammer crusher is used to crush the raw materials. Crushed gypsum is transported to the warehouse by conveyor belt. Mixed materials are transported to the batching station by a forklift.
Cement batching
The bottom of the stockpile has two sets of quantitative feeding devices placed to release materials following predetermined ratios. The discharged materials are thereafter transported via a belt conveyor to the cement grinding equipment.
Cement grinding mills
One set of roller presses and a cement ball mill are equipped. The cement clinker and proportioned mixed materials are first squeezed by the roller press and then sent to the V separator for separation via bucket elevation. Fine particles enter the high-efficiency separator for secondary separation with materials after ball mill grinding. Coarse materials are further pressed by roller presses. Qualified particles are brought to the bag filter and then to the cement silo. A disqualified product may partially or completely recirculate to a roller press or ball mill if it does not meet the specified fineness, depending on the circumstances of production. Material at the mill’s outlet will be fed by an air slide and bucket elevator into a high-efficiency separator. Mill ventilation is handled by a different fan.
Note:
This process flow can achieve either full or partial open-circuit operation based on manufacturing needs. The material at the ball mill exit can be transported entirely or partially to the cement conveying air slide by regulating Valve A. By changing Valve B, fine powder collected by the bag filter can be fed entirely or partially to the ball mill.
clinker grinding mills
Originating from the 1980s, the roller press made progress in design, manufacturing, and technology during these years of development. In a clinker grinding system, a roller press is widely used for its high usage and the good grindability of the material it brings. The roller press plays the role of pregrinding which affects the capacity and total energy consumption to an extent of 80% or more.
Features of TRP roller press from SINOMA
The company never stops improving the critical parts of the roller press, especially the technology of roller surface and bearing performance.
The multi-row cylindrical roller bearing is adopted.
Roller surface with wear protection function.
Advanced roller manufacturing process.
Optimized hydraulic system.
Equipped with an alignment device to prevent material separation and feeding device of the expansion chamber.
The technology of roller surface
The high availability and dependability of the roller press are ensured by the solidity of the roller surface and its protection. For this reason, the foundation of our work is understanding how to reduce the wear on the roller surface.
Bearing
Multi-row cylindrical roller bearings are typically used in large roller presses. It has a better seal, a longer lifespan, and a larger carrying capacity than a spherical roller bearing.
Roller press configuration
| TRP220/160 | TRP200/160 | TRP180/170 | TRP160/140 | TRP140/140 | TRP140/140 | TRP140/120 | TRP140/110 | TRP140/100 | TRP140/80 | ||
| 2×2000 | 2×1800 | 2×1600 | 2×1120 | 2×900 | 2×800 | 2×800 | 2×710 | 2×630 | 2×560 | ||
| φ3.2χ13 1600 | P.O42.5 | 185 | 140 | 125 | 115 | 115 | 105 | 100 | 95 | ||
| P.C32.5 | 210 | 160 | 140 | 130 | 130 | 120 | 110 | 105 | |||
| P.C32.5 | P.O42.5 | 245 | 225 | 210 | 170 | 150 | 140 | 140 | 130 | 125 | |
| P.C32.5 | 280 | 260 | 240 | 190 | 170 | 160 | 160 | 150 | 140 | ||
| φ4.2χ13 3150 | P.O42.5 | 265 | 245 | 230 | 190 | 170 | 160 | 160 | 150 | ||
| P.C32.5 | 300 | 280 | 260 | 210 | 190 | 180 | 180 | 170 | |||
| φ4.2χ13 3550 | P.O42.5 | 275 | 258 | 240 | 200 | 180 | 170 | 170 | |||
| P.C32.5 | 310 | 290 | 270 | 225 | 200 | 190 | 190 |
Reference for system configuration
| Roller Press | V-Separator | Separator | Ball Mill | Filter Fan |
| TRP160/140 | TVS-96/20 | TESu-310 | Φ4.2×13m | gas flow 260000m3 /h |
| throughput：750t/h | gas flow: 220000m3 /h | gas flow: 240000m3 /h | Total pressure:7000Pa | |
| pressure loss：1200Pa | pressure loss： 2500Pa | Grinidng balls:210t | consumed Power:kW | |
| Installed Power: 3150kW | Feed: 960t/h | Feed: 600t/h | Installed Power:: 2×1120kW | Installed Power::800kW |
System performance
| Item | Unit | P.C32.5R | P.O42.5R |
| Capacity | t/h | 230-240 | 210-220 |
| Specific Surface Area | cm2 /g | 4250~4350 | 3650~3750 |
| Water Demand | % | 26.2 | 25.6 |
| System Power Consumption | kWh/t | 27-29 | 30-32 |
