Producteur d'équipement de cimenterie abordable
1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR
Are you managing persistent bottlenecks in your cement production line? The reliability and efficiency of your core processing equipment directly dictate plant profitability. Pour les directeurs d’usine et les entrepreneurs en ingénierie, the wrong or underperforming machinery for critical size reduction and material preparation leads to measurable losses. Êtes-vous actuellement confronté:
Temps d'arrêt excessif: Unplanned maintenance on grinding equipment halts the entire kiln feed line, coûtant des milliers de dollars par heure en perte de production.
Matériau d'alimentation incohérent: Fluctuations in raw mix or clinker hardness cause output variability, compromising final product quality and increasing reject rates.
Consommation d'énergie non durable: Inefficient comminution processes can consume over 50% of a plant's electrical power, making energy costs the primary operational expense.
Coûts élevés de remplacement des pièces d’usure: Frequent shutdowns for hammer, roller, or liner changes drive up maintenance budgets and labor hours.
System Integration Failures: New equipment that doesn't interface correctly with existing crushers, convoyeurs, or separators creates new bottlenecks instead of solving old ones.
Selecting the right partner for robust, efficient cement plant equipment is not a procurement decision—it’s a strategic investment in operational continuity and margin protection.
2. APERÇU DU PRODUIT: VERTICAL ROLLER MILL (VRM) FOR RAW MEAL AND CEMENT GRINDING
This Vertical Roller Mill (VRM) is engineered for the dry grinding of raw materials, charbon, and cement clinker. It is a core piece of comminution equipment designed to replace traditional ball mill circuits, offering superior efficiency in a compact footprint.
Flux de travail opérationnel:
1. Présentation du flux: Prepared raw mix (calcaire, argile, additifs) or clinker with gypsum is fed centrally into the mill table.
2. Affûtage & Séchage: The rotating table centrifugally moves material under heavy rollers. Simultanément, hot gas from a kiln or auxiliary heater is introduced, drying the feed while grinding occurs via compression and shear forces.
3. Classification & Séparation: Ground material is carried by the gas stream to an integrated dynamic classifier. Oversize particles are rejected back to the grinding table; fine product proceeds.
4. Product Collection: The fine material (raw meal or cement) exits with the gas to a downstream baghouse or electrostatic precipitator for collection.
Champ d'application: Ideal for new greenfield plants or major upgrades seeking energy efficiency. Suitable for grinding raw materials, charbon, and slag/pozzolanic cement blends.
Limites: Requires consistent feed size (50mm). Operational expertise for vibration control is necessary. May have higher capital cost than simple ball mill systems for smallcapacity applications.
3. CARACTÉRISTIQUES PRINCIPALES
4+2 Grinding Roller Configuration | Base technique: Modular roller assembly with swingout capability | Avantage opérationnel: Allows grinding continued operation with reduced rollers if one module is offline for maintenance | Impact sur le retour sur investissement: Minimizes production loss during scheduled wear part inspection and replacement.
Integrated HighEfficiency SLS Classifier | Base technique: Adjustable rotortype separator with finite element analysisoptimized blades | Avantage opérationnel: Provides precise particle size control (Blaine fineness) and rapid adjustment for different cement grades | Impact sur le retour sur investissement: Reduces overgrinding energy waste and ensures consistent product quality meeting specifications.
HydroPneumatic Spring System | Base technique: Automated pressure control on grinding rollers versus mechanical springs | Avantage opérationnel: Maintains stable grinding pressure despite feed fluctuations; dampens vibrations from tramp metal | Impact sur le retour sur investissement: Protects mechanical components from shock loads, reducing failure rates and extending operational lifespan.
Planetary Gearbox Drive | Base technique: Torque splitting across multiple gear stages from a single motor | Avantage opérationnel: Delivers high torque at low mill table speed with exceptional mechanical efficiency (>97%) | Impact sur le retour sur investissement: Réduit la consommation d’énergie spécifique (kWh/t) compared to conventional reducers and reduces longterm drive train maintenance.
Remote Condition Monitoring Ports | Base technique: Standardized sensor ports for vibration, température, and pressure at bearing points & hydraulic units | Avantage opérationnel: Enables predictive maintenance scheduling based on realtime data trends rather than fixed intervals | Impact sur le retour sur investissement: Empêche les pannes catastrophiques, optimizes spare parts inventory, and extends mean time between repairs (MTBR).
Material Recirculation System | Base technique: Optimized airflow geometry within mill housing | Avantage opérationnel: Promotes internal recirculation of semifinished material, increasing residence time on grinding table without external recycling | Impact sur le retour sur investissement: Improves grinding efficiency and particle size distribution without additional conveying equipment or power draw.
4. AVANTAGES CONCURRENTIELS
| Mesure de performances | Norme de l'industrie (Circuit de broyeur à boulets) | This VRM Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Consommation d'énergie spécifique| 4050 kWh/t (cement finish grind) | 2835 kWh/t| 2530% Réduction |
| Drying Capacity| Limité; requires separate dryer for highmoisture feed| Direct drying with ≤8% moisture feed gas| Eliminates standalone dryer capex & opex |
| Particle Size Adjustment| Slow; requires system stop & media charge change| Realtime adjustment via classifier rotor speed| Operational flexibility increased by ~70% |
| Empreinte physique| Large building requirement for mill + séparateur + convoyeurs| Compact vertical design with integrated separator| Space savings of approximately 4050% |
| Noise Emission Level| Typiquement >100 dB(UN) à 1 mètre|< 85 dB(UN) à 1 mètre| Significant reduction in noise pollution |
5. SPÉCIFICATIONS TECHNIQUES
Plage de capacité: Modèle dépendant de 50 tph à plus 400 tph raw meal; 30 tph to 200 tph OPC cement.
Exigences d'alimentation: Moteur d'entraînement principal de 1000 kW à plus 5000 kW; auxiliary drives for classifier fan hydraulic unit.
Spécifications matérielles: Grinding rollers & table segments manufactured from highchromium alloy cast iron with hardness >600 HBW; welded steel housing with abrasionresistant liners.
Dimensions physiques (Example Model VRM3840): Mill diameter: ~4,2 millions; Total height including drive ~12m; Foundation loading >800 tonnes métriques.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; capable of processing hot gas up to 450°C for drying.
6. SCÉNARIOS D'APPLICATION