Optimizing the operation of a vertical roller mill (VRM) requires careful monitoring of key performance parameters. Below are the best operational data points to track for efficiency, product quality, and longevity:
1. Grinding Process Parameters
– Mill Feed Rate (t/h) – Optimal range depends on mill size and material hardness.
– Grinding Pressure (bar) – Typically 50–150 bar (adjust based on material grindability).
– Classifier Speed (rpm) – Controls product fineness; adjust to meet desired particle size.
– Mill Vibration (mm/s) – Should be < 2.5 mm/s to avoid mechanical stress.
– Differential Pressure (mbar) – Indicates material bed stability; ideal range: 5–20 mbar.
2. Power Consumption & Efficiency
– Specific Power Consumption (kWh/t) – Target: 15–30 kWh/t for raw meal, 30–50 kWh/t for cement.
– Mill Motor Load (%) – Should operate at 70–90% of rated capacity for efficiency.
– Fan Power Consumption (kW) – Impacts overall system energy use.
3. Product Quality Metrics
– Blaine Fineness (cm²/g) or Residue on 45µm (%) – Adjust classifier speed to meet specifications.
– Particle Size Distribution (PSD) – Ensure optimal distribution for strength development.
4. Airflow & Temperature Control
– Mill Inlet Temperature (°C) – Typically 200–300°C for drying raw materials.
– Mill Outlet Temperature (°C) – Should be kept below 100–120°C to avoid dehydration of gypsum in cement mills.
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Flow Rate (m³/h) – Affects material transport and drying efficiency.
5. Wear & Maintenance Indicators
– Roller & Table Wear Rate (mm/1,000h) – Monitor to schedule timely hardfacing/replacement.
– *Lubrication Oil Condition* – Regular checks for contamination and viscosity.
Best Practices for VRM Operation:
✅ Maintain stable bed thickness (~10–20 mm).
✅ Optimize grinding pressure vs. throughput balance.
✅ Avoid excessive vibration through proper dam ring height adjustment.
✅ Regularly inspect classifier blades and reject cone wear.
Would you like specific recommendations based on your material type (e.g., limestone, slag, cl