Скачать или смотреть 2 Sets of 5000 TPD Cement Plant Coal Vertical Roller Mill Pulverizer Kiln Clinker Firing System

https://cementl.com/ The project includes 2 sets of coal vertical roller mill pulverizers installed in a 5000 TPD cement plant. These mills are designed to prepare pulverized coal for the rotary kiln clinker firing system, ensuring a steady and safe fuel supply for continuous cement production. Each mill is sized to deliver enough pulverized coal for one kiln line, but both systems are also interconnected for backup operation.

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Mill Design and Capacity

Each coal vertical roller mill has a grinding table diameter of about 3.8 meters, equipped with four rollers applying grinding pressure of 140–160 bar. The normal throughput of one mill is 35–38 tons of pulverized coal per hour, which is sufficient to support the fuel demand of a kiln producing 5000 tons of clinker per day. The product fineness is controlled at less than 12% residue on 90 μm sieve, which is the standard requirement for stable kiln combustion.

Feeding and Drying

Raw coal is delivered from the coal yard to the mill feed system using belt conveyors and weigh feeders. The moisture content of raw coal is typically 8–12%, and drying is necessary before fine grinding. Hot gases from the clinker cooler or from a hot air generator are directed into the mill, keeping the outlet gas temperature at 80–85°C. This ensures complete drying while avoiding the risk of fire or ignition inside the mill.

Pulverizing Process

Inside the vertical roller mill, raw coal passes between the rotating grinding table and the rollers. The material is crushed by both pressure and shear forces. An integrated separator on top of the mill classifies fine particles, which are carried with the gas flow to the bag filter, while oversized particles fall back to the grinding table for further crushing. The separation cut size is typically P90 Less than 75 μm for stable kiln combustion.

Kiln Firing System Integration

The pulverized coal is collected in a baghouse filter and then conveyed pneumatically to the kiln burner and calciner burner. Each burner is equipped with a coal dosing system and safety interlocks. The firing rate for a 5000 TPD clinker line is about 12–14 tons of coal per hour, depending on coal quality and kiln operation. The vertical roller mill system is designed to operate with both high-volatile bituminous coal and lower-grade fuels.

Safety Systems

Coal grinding systems carry a risk of fire and explosion, so the design includes multiple safety features. Each mill is equipped with an inert gas injection system using CO₂ or N₂ during startup and shutdown. Temperature sensors are installed at the mill inlet, outlet, and bag filter to detect abnormal conditions. Pressure relief valves and explosion flaps are also provided. Regular mill purging is done before maintenance work.

Operation and Maintenance

The vertical roller mills are controlled from the central Distributed Control System (DCS). Operators monitor parameters such as mill vibration (kept below 1.5 mm/s), differential pressure, and separator speed. Rollers and table liners are wear parts that typically last 10,000–12,000 hours depending on coal abrasiveness. Maintenance includes regular inspection of the hydraulic system, lubrication units, and gearboxes.

Plant Integration

With two sets of coal vertical roller mills, the cement plant ensures redundancy in fuel preparation. If one mill is down for maintenance, the second mill can continue to feed pulverized coal to the kiln. Both mills are connected to the same coal silo and bag filter system but operate independently with separate drives and feeders. This setup improves plant reliability and avoids kiln stoppages caused by fuel shortages.

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