Slag vertical roller mill

Slag vertical roller mill also known as vertical grinding mill is an equipment widely used in the cement grinding station. Slag vertical roller mill is a kind of grinding equipment integrating powder drying, powder selection and transportation. It is widely used in cement building materials, mineral processing, metallurgy and other industries. It is also suitable for grinding a variety of material such as clinker, coal, blast furnace slag, steel slag, furnace slag, manganese slag, nickel slag, metallurgical slag, limestone, dolomite, calcite, gypsum, pozzolan, clays, silica sand, non-metallic minerals, and other raw materials. 

Slag vertical roller mill Introduction

Slag vertical roller mill also known as vertical grinding mill is an equipment widely used in the cement grinding station. Slag vertical roller mill is a kind of grinding equipment integrating powder drying, powder selection and transportation. It is widely used in cement building materials, mineral processing, metallurgy and other industries. It is also suitable for grinding a variety of material such as clinker, coal, blast furnace slag, steel slag, furnace slag, manganese slag, nickel slag, metallurgical slag, limestone, dolomite, calcite, gypsum, pozzolan, clays, silica sand, non-metallic minerals, and other raw materials. Slag is an important building material, the main components are silica, alumina and calcium oxide, slag can replace part of cement, and can also improve the strength and durability of cement, so it is more and more widely used in cement and concrete.

Slag vertical roller mill structure

The main components of the Slag vertical roller mill include the grinding table, grinding rollers, grinding roller shaft, grinding roller wheel hub, grinding roller tyre, rocker arms, separator, transmission system, base frame. 

Grinding Table: The grinding table is a rotating part of the Slag vertical roller mill responsible for grinding materials. It is mounted on a gearbox-driven spindle and can be tilted to control the product fineness and optimize the grinding process. The detailed structure of the grinding table includes guide ring, air ring, retaining ring, liner, disc body, scraper.

Grinding Rollers: Grinding roller is the main part for crushing and grinding materials. The grinding roller is composed of cast steel roller sleeve, forging shaft and wear-resistant surfacing bushing. The grinding roller is installed on the rocker arm of the Slag vertical roller mill, under the action of external force, it is pressed tightly on the material of the grinding table, as the grinding table rotates the material is crushed. The grinding roller is equipped with a limit device to ensure that it does not directly contact the grinding table during operation

Grinding Rollers shaft: A forged shaft could refer to various components such as the main shaft that supports the grinding rollers or other critical shafts within the mill's structure. These components need to withstand significant mechanical loads and stresses, and using forged shafts can ensure the necessary strength and durability. The term "forged shaft" refers to a shaft that has been manufactured using a forging process, this process enhances the mechanical properties of the metal, such as strength, durability, and resistance to impact and fatigue.

Grinding Rollers wheel hub: The grinding roller wheel hub is a metal casting part that is mounted on the outside of the grinding roller shaft. The wheel hub refers to the central part of the grinding roller that connects it to the driving mechanism of the mill. The wheel hub is designed to transmit the rotational motion and force from the mill's drive system to the grinding roller, allowing it to rotate and exert pressure on the material.

Grinding roller tyre: The grinding roller tire of a vertical roller mill is a crucial component that directly contacts the material being ground during the milling process. It's also commonly referred to as the grinding roller or roller shell. This component is made up of a cylindrical shell or tire-like structure that rotates around a central shaft. The grinding roller tire is typically equipped with segments or studs that aid in grinding and pulverizing the material as the mill's table or bowl rotates.

Rocker Arms: The function of the rocker arm device of the Slag vertical roller mill is to transmit the pressure provided by the hydraulic cylinder to the grinding roller, so that it can be transformed into the grinding force act on the material bed. The rocker arm device is mainly composed of upper rocker arm, lower rocker arm, rocker arm shaft, bearing and bearing housing and other components. The upper rocker arm is used to install the grinding roller, the lower rocker arm is connected to the hydraulic system, and the two rocker arms are connected as a whole through shafts, taper sleeves and taper pins.

Classifier: Powder classifier (also known as coarse powder separator) of the slag vertical roller mill plays a vital role in the selection of powder during grinding. The ground material is carried by the high-speed rotating airflow in the mill and enters the powder classifier through the stationary blades. The material is screened under the high-speed rotation of the cage rotor, and the screened fine particle material is taken out by the exhaust gas and enters the cyclone. The coarse particle material falls into the grinding disc through the lower cone tube for re-grinding.

Middle shell: The middle casing of the slag vertical roller mill is a welded structural part, which supports the weight of the entire separator. There are 4 inspection doors on the middle casing for roll overhaul. The door is designed with a sealing sheath that is in close contact with the grinding roller to Prevent air leakage. The inner wall of the middle shell is laid with a wear-resistant lining to protect the inner shell.

Base Frame: The support base of the slag vertical roller mill is generally four peripheral support pedestal and a central support base, and the support base and the installation foundation are connected and fixed by anchor bolts. All the slag vertical roller mills of Tongli will be pre-assembled and leveling calibrated before leaving the factory to ensure that the equipment can be installed smoothly on site.

Transmission device: The transmission device of the slag vertical roller mill is composed of a planetary gear reducer, a motor and a coupling in the middle of 4 supporting beams. The planetary gear reducer is a reduction device with a vertical output shaft, and the output end is connected to the grinding table with a flange. The vertical downward force is supported by the hydraulic thrust bearing on the top of the reducer during operation.

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PLC control system: A PLC is a digital computer-based system that is designed to control various industrial processes automatically. In the context of a vertical roller mill, a PLC is used to monitor and control parameters such as temperature, rotation speed, air flow, fuel flow, and other critical variables that affect the performance of the kiln and the quality of the products being processed. Tongli vertical roller mill is controlled with PLC control system which is capavle of monitoring temperature, vibration, filling rate, output rate. Tongli vertical roller mill also equipped with CO, O2 real-time gas analyzer to ensure save production.

Design principles of slag vertical roller mill

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Working principle: The raw material is lifted by the bucket elevator and then pass through the iron remover to remove the other object, after that the raw material is fed into the slag vertical roller mill through a star airlock valve, once the material drops down form the top of the slag vertical roller mill landed at the center of the grinding table, through centrifugal force, the raw material will be thrown to the edge of the grinding table.

A hydropneumatics spring tension cylinder pulls on the rocker arm and exert a vertical force on the grinding roller and the grinding table, as the grinding table rotates cause the material to be crushed under the compressive force and the shear force. Fine particle will be taken to the classifier by a upstream, coarse particle will return to the grinding table for regrinding, also there is a exit chute on the edge of the grinding table for iron to exit in case it is not removed by the iron remover in the previous step. Foreign object and bulks of raw material exit from the chute will be sent to the bucket elevator and pass through the iron remover again. This raw material vertical roller mill system also integrates drying, it has a portal that can utilize the waste gas from the rotary kiln, or if no heat source it also can connect to the hot air generator through this portal.

Advanced design: As one of the leading vertical roller mill manufacturers, Tongli slag vertical roller mills are advanced in design, integrating the functions of crushing, drying, grinding, classifying, conveying. Adapt to fluctuating raw material qualities, adapt to different product qualities.

High grinding efficiency: The stand-alone production capacity of the slag vertical roller mill is large, low energy consumption compared with ball mills, the energy consumption is usually 40%-50% lower than the ball mill;

Dust-free operation: The slag vertical roller mill system adopts a fully enclosed system, and the whole system operates under negative pressure without dust spillage, which can meet the requirements of clean production

Customized deisgn: Tongli’s slag vertical roller mill has two types of grinding rollers, one is cone-shaped and the other is tire-shaped. According to different materials and different technological processes, we customized the equipment that meet your specific need.

Adaptability: Tongli slag vertical roller mill can process kaolin, barite, fluorite, talc, water slag, lime calcium powder, wollastonite, gypsum, limestone, phosphate rock, marble, potassium feldspar, quartz sand, bentonite, Manganese ore and other materials with a hardness below 7 on the Mohs scale.

Compact layout: the occupation area is only 50% of that of a ball mill and It can be arranged outside, no workshop needed. Due to this reason, it can effectively reduce construction costs and helping enterprises reduce initial investment costs.

Pre-assembling: the base frame is pre-assembled in our workshop and marked with number so that when it comes to installation on site, it is a lot of more easier, the owner can put it together like Lego.

Separator Balance test: All the separator need to pass the balance test before assemble, we have a balance test machine that test the vibrate and concentricity when the cage rotor rotates, Tongli make sure all the separator is running smooth.

Gas sealing system: Tongli slag vertical roller mill is equipped with a high-speed centrifugal blower to send high-speed air into the seal of the roller bearing to form a gas seal to prevent dust from entering the roller bearing. By doing this we can greatly improve the bearing service life.

Water spray system: The slag vertical roller mill of Tongli is equipped with a water spray system, one is to reduce the outlet temperature of the mill, and the other is to speed up the accumulation of the material layer on the grinding table.

Lubrication system: Tongli rslag vertical roller mill is equipped with a forced lubrication device to ensure the service life of bearings and key components during operation.

PLC control system: Real-time monitoring of the slag vertical roller mill with operating parameters. Highly automatic, features remote control and touch screen control, Siemens control system.

Easy Maintenance: Swing-out feature allows the maintenance of the grinding roller to be easy and fast. Grinding roller can be rolled out of the machine by hydraulic device, and the replacement of the roller sleeve liner and the maintenance of the mill is very convenient; No need to arrange material layer on the grinding table before starting the machine, Tongli slag vertical roller mill can be started without load.

Specifications of slag vertical roller mill

Specification:

Capacity: (t/day)

Grinding table diameter(mm)

Grinding roller diameter(mm)

Feeding size(mm)

Power: (kw)

ZJTL800

3~5

800

300

≤30

100~250

ZJTL1300

9~15

1300

400

≤40

200~300

ZJTL1500

15~19

1500

600

≤40

500~600

ZJTL2250

35~40

2250

800

≤50

800~1000

ZJTL2820

50~65

2820

1200

≤65

1600~1800

ZJTL3030

70~85

3030

1300

≤80

2000~2200

ZJTL3230

90~120

3230

1500

≤80

2400~2600

ZJTL3440

120~140

3440

1200

≤90

2800~3000

ZJTL3640

130~150

3640

1300

≤90

4000~4200

ZJTL3840

150~160

3840

1400

≤100

4800~5000

ZJTL4040

170~190

4040

1500

≤100

4800~5000

ZJTL4240

190~210

4240

1600

≤100

4800~5000

ZJTL4540

210~230

4540

1700

≤110

5000~5500

ZJTL4840

220~240

4840

1800

≤110

5000~5500

ZJTL5040

230~250

5040

2000

≤110

5400~6000

ZJTL5240

240~260

5240

2000

≤130

5400~6000

ZJTL5440

270~290

5440

2200

≤130

5400~6000

ZJTL5640

275~295

5640

2200

≤130

5800~6400

ZJTL6040

280~300

6040

2500

≤150

6200~6800

ZJTL6240

300~320

6240

2500

≤150

6600~7200

ZJTL6440

320~350

6440

2500

≤170

7000~7600

ZJTL6640

340~360

6640

2800

≤180

7500~8000

Note: *The diameter is middle diameter of the grinding table

HIGH-TECH ENTERPRISES

Modern intelligent processing base integrating R&D, production and sales.

Zhejiang Tongli Heavy Machinery Manufacturing Co., Ltd (Formerly known as Tongxiang Coal&Mining Machinery Factory) established in year 1958 is a member of the Chinese National Building Material Machinery Association. Tongli is on the vendor list of designated production enterprise of the Ministry of Coal Industry. ISO9001、ISO14001、ISO45001 certified, accredited as High-tech & new technology enterprise of Zhejiang Province. With 65+ years of experience, Tongli has earned first class R&D and manufacturing capabilities, dedicated to provide satisfactory manufacturing equipments for global customers.   

3

Machines & Equipments

After years of development, there are more than 650+ sets of heavy machinery manufacturing equipments in our workshop, some of them are as follows:

Ф12m CNC Horizontal Lathe
Ф12m CNC Horizontal Lathe

One of the largest equipment in our factory, the maximum processing diameter is 12 meters, and the maximum processing length can reach 26 meters. This Lathe is specially crafted for processing mega cylinders.

Ф12m CNC Vertical Lathe
Ф12m CNC Vertical Lathe

One of the super-large equipment in our factory, the maximum processing height can reach 6 meters, and the maximum processing diameter can reach 12 meters, which ensures that the accuracy of the cylinder flange can reach the required level.

Ф5.3x18M CNC Horizontal Lathe
Ф5.3x18M CNC Horizontal Lathe
One of our advanced equipment for machining the Barrel, milling the end face and out surface with precision 0.05mm.
180mm CNC Universal Bending Machine
180mm CNC Universal Bending Machine
Numerical control with high precision, Maximum Bending Thickness : 180mm
Ф6.5х20m large annealing furnace
Ф6.5х20m large annealing furnace
Annealing will make the metal inner organization reach or near equilibrium, to obtain the good performance .By this large Furnace, we can anneal the shell by whole.
Ф6.5х20m Sandblasting room
Ф6.5х20m Sandblasting room
Remove all the rust and other impurities on the surface by sandblasting in this room to prolong the service life of the Painting.
4x12m Gantry CNC boring and milling machine
4x12m Gantry CNC boring and milling machine
  • Workbench effective size: 4000*12000mm;

  • Gantry Width: 4900mm;

  • Processing height: 4000mm;

  • Three angled milling heads, square ram;

  • Load-bearing 350 tons;

  • CNC system: SIEMENS 840D.

GKU40Ex80 Moving Beam Gantry Five-sided Machining Center
GKU40Ex80 Moving Beam Gantry Five-sided Machining Center
  • Workbench effective size: 3000*8000mm;

  • Gantry width: 4100mm;

  • Load-bearing: 80t;

  • Spindle speed: 2000RPM

  • CNC system: SIEMENS 840D.
2x4m Newway PM2040HA Moving Beam Gantry Machining Center
2x4m Newway PM2040HA Moving Beam Gantry Machining Center
  • Workbench effective size: 2000*4000mm; 

  • Processing Width: 2800mm;

  • Processing Height: 1100mm;

  • Full-CNC milling heads;

  • PLC: Siemens.
5x14M Vertical Boring&Milling Machine
5x14M Vertical Boring&Milling Machine
  • Workbench effective size: 4500x5000mm

  • Processing Length: 14000mm;

  • Processing Height: 5000mm;

  • CNC system: SIEMENS 840D.

6.3x11M VERTICAL BORING&MILLING MACHINE
6.3x11M VERTICAL BORING&MILLING MACHINE
  • Workbench effective size: 5000x5000m;

  • Processing Length: 11000mm;

  • Processing Height: 6300mm;

  • CNC system: SIEMENS 840D.
Ф12m and Ф10m Gear Hobbing Machine
Ф12m and Ф10m Gear Hobbing Machine
The required equipment to machine the girth gear, the maximum diameter of our gear-hobbing machine is 10m and the maximum module is 40.
Ф16х5m CNC Cutting Machine
Ф16х5m CNC Cutting Machine
Ensure precision of steel plate and other raw materials, avoid the error of manual operation.
Ф16х5m Edge Planer
Ф16х5m Edge Planer
Remove the burrs to make the welding preparation of steel plate have good roughness and ensure the angle of welding preparation angle.
Three-Phase Electric Arc Furnace
Three-Phase Electric Arc Furnace
Raw Materials for casting is produced from our own workshop to ensure the quality of the casting. 

Honors and Qualifications

Features of Tongli slag vertical roller mill

01



Energy Efficiency

Tongli cement vertical roller mill consumes less energy than traditional ball mills. This is because of its unique design and high grinding efficiency, which leads to lower power consumption per ton of cement produced, Usually the power consumption is 40~50% less than the traditional ball mills.


02



Space-saving

 Compared to traditional ball mills, the vertical roller mill has a smaller occupation area, making it easier to fit into existing cement plants and reducing the need for extensive plant modifications. It can be exposed outside therefore greatly reduce the construction cost. 


03



Easy Maintenance

Tongli vertical roller mill is equipped with multiple hydraulic oil cylinder, during the maintenance,the grinding roller can be swing out of the vertical roller mill through the maintenance portal which leads to lower downtime and operational cost. 


04



Versatility

Tongli cement vertical roller mill can handle a wide range of materials, including raw materials, cement clinker, and additives, making it highly versatile for different cement production needs.


Industry knowledge extension

What is the difference between ball mill and vertical roller mill?

Both ball mills and vertical roller mills plays a vital role in the cement grinding plant. Ball mills are versatile and cost-effective, suitable for various materials and simple to maintain. On the other hand, vertical roller mills offer superior energy efficiency and particle size control, making them ideal for cement and ore grinding applications. The choice between the two depends on specific requirements, budget constraints, and technical expertise.

What is the relationship between vertical roller mill and rotary kiln?

In the cement production line, the vertical roller mill is widely used. The vertical roller mill can be used not only as the grinding equipment for raw materials, but also as the grinding equipment for finished cement clinker. When the raw material is broken into small pieces by the crushers, it enters the vertical roller mill. The ground limestone powder and other additives enter the clinker rotary kiln for calcination to produce clinker, and the calcined clinker enters the vertical roller mill or ball mill for final grinding.

What is the application of blast furnace slag in cement industry?

Enhanced Cement Performance: Incorporating blast furnace slag into cement can improve various properties of the final product. It can enhance the workability of fresh concrete, increase long-term strength, and improve resistance to chemical attack and sulfate exposure.

Reduced Environmental Impact: Using blast furnace slag as a cement replacement reduces the need for clinker production, which is energy-intensive and emits a significant amount of CO2. By using BFS, the carbon footprint of cement production is lowered.

Lower Heat of Hydration: Blast furnace slag contributes to lower heat generation during the hydration process compared to pure Portland cement. This is particularly important in massive concrete structures, where excessive heat generation can lead to cracking.

Increased Durability: The use of blast furnace slag can lead to more durable concrete due to its ability to improve resistance to chloride ingress, sulfate attack, and alkali-aggregate reactions.

Reduced Permeability: The incorporation of BFS can result in a more compact microstructure within the concrete, leading to reduced permeability. This can improve the concrete's resistance to water penetration and chemical attack.