Physicochem. Probl. Miner. Process.

, 56(1), 2020, 24-33 Physicochemical Problems of Mineral Processing

ISSN 1643-1049
http://www.journalssystem.com/ppmp
© Wroclaw University of Science and Technology

Received July 22, 2019; reviewed; accepted September 12, 2019

Modeling and simulation of vertical roller mill using population

balance model
Rasoul Fatahi, Kianoush Barani
Department of Mining Engineering, Lorestan University, Khorramabad, Iran

Corresponding author: [email protected] (Kianoush Barani)

Abstract: There are few studies concerning the process simulation of vertical roller mills (VRMs). In
this research work, the application of population balance model for simulation of a VRM in a cement
clinker grinding circuit was investigated. The residence time distribution (RTD) was measured, and
the tank-in-series and Weller models were employed to describe the residence time distribution. Two
sampling surveys were carried out on the VRM circuit. The data from the first survey were used for
model calibration, and the specific breakage rates were back-calculated. The model parameters
obtained were used for simulation of the second survey, and validation of the model. The results
showed that the clinker particle spent a short time inside the VRM and the mean residence time is
about 67s. The tanks-in series model compares to Weller model was more proper to describe the
residence time distributions in the VRM. The simulation results showed that the specific breakage
rates increased with increasing particle size. However, the particles larger than 25.4 mm particles sizes
are too large to be properly nipped by master rollers. Finally, it can be concluded that the grinding
process of the VRM is very well-predictable with the population balance model.

Keywords: vertical roller mill, modeling, simulation, cement grinding, residence time distribution

1. Introduction
Grinding operation is one of the important parts of the cement production processes. Almost
producing one ton of cement requires 1.5 tons of raw materials. The electrical energy consumed in the
cement production process is approximately 110kWh/ton, about 30% of which is used for the
preparation of the raw materials and about 40% for clinker grinding (Jankovic et al., 2004).
The grinding energy consumption in a cement plant is a major issue which most of this energy is
wasted as heat and noise. The application of vertical roller mills (VRMs) for ore grinding is a part of
the strategies against rising energy consumption (Reichert et al., 2015).
The VRM technology was introduced in the mid-'90s for grinding clinker and slag by LOESCHE
(Schaefer, 2001). Fig. 1 illustrates the grinding parts of a Loesche vertical roller mill.
The grinding material is comminuted in the Loesche roller grinding mill between the rotating
horizontal grinding track and stationary grinding rollers. Grinding is affected primarily by
compression. A certain amount of shear force increases the number of fine particles in the grinding
material. This effect is created by tapered rollers, whose axes are angled at 15˚ with respect to the
horizontal grinding track. Hot gas is supplied to the combined drying and grinding process to
evaporate material moisture. In the classifier above the grinding chamber, the finished material is
separated from the grit, which can drop back onto the grinding table to be comminuted again
(Schafer, 2003).
The VRMs have advantages compare to conventional grinding technology. In the VRMs, the
particles are ground in a particle bed; the bed breakage is more energy-efficient and usually produces
a narrower particle size distribution (Fuerstenau, 1992; Viljoen et al., 2001). The breakage predomi-

DOI: 10.5277/ppmp19064
25 Physicochem. Probl. Miner. Process., 55(6), 2020, 24-33

Fig. 1. Schematic operation principle of a vertical-roller-mill

nantly occurs by particle-particle-contacts or phase–phase-contacts(Fandrich et al., 2007). Both

breakage modes enhance the liberation of the valuable mineral phases, which may lead to further
improvements in the beneficiation process (Reichert et al., 2015). Also, Due to a dry grinding process,
no process water is required, which will become more critical in the next decades. VRM’s are widely
used in the coal and cement industry today (Reichert et al., 2015). However, a disadvantage of VRMs
is the vibration of the rolls that is caused by the frictional characteristics (Fujita and Saito, 2006).
Simulation is the best way to optimize a grinding circuit to achieve economical operation. There
are few studies on the simulation of VRMs.
The matrix model was used to simulated vertical roller mills in cement clinker and coal grinding
lines. The pressure breakage function, B, was determined from the laboratory test data with a hammer
device. The results showed that materials are crushed in more than one stage under the vertical roller
mill. However, in the paper, it is unclear that the selection functions, S values, was obtained from the
test data, back-calculation ,or literature (Wang et al., 2009).
The matrix model was used for simulation of a VRM with high-efficiency slat classifier in OMYA’s
limestone processing plant in Eger, Hungary, on a technology with Pfeiffer’s 2800 C vertical roller
grinding mill. The B breakage matrices were simply determined by the well-known Broadbent-Calcott
function. A systematic test was carried out to grind the limestone samples in a laboratory Hardgrove
mill to verify this assumption. The selection matrix, S, and the number of breaking stages, v, were
determined by the iterative computer simulation processing using the measured data(Faitli et al.,
2014).
Optimization, modeling, and simulation of VRM in a cement raw mix grinding circuit with the
perfect mixing ball mill model were studied. A series of samplings were conducted around the raw
mix grinding circuit, and clinker samples were taken. The data obtained from the plant sampling was
fitted with the perfect mixing ball mill model using the steady-state mineral processing software, the
JKSimmet. The breakage function and the breakage rate function for VRM were determined during
the model fitting process. The Broadbent and Callcott equation was used as the breakage function. It
was found that raw mix grinding in a VRM could be described by the perfect mixing model. In a
perfect mixing ball mill, the feed entering the mill would be distributed along with the mill, thus being
subjected to the probability for breakage. A similar situation was encountered in a VRM, where the
feed that had fallen on the grinding table was being subjected to the breakage process by the rollers,
and the entire particles would have some probabilities for breakage (Palaniandy et al., 2006).
26 Physicochem. Probl. Miner. Process., 55(6), 2020, 24-33

Application of the perfect mixing model for simulation of a VRM in a cement clinker grinding
plant was investigated. The breakage distribution function of the material was determined by the
compressed bed breakage test in a piston-die cell device. The model parameters were back-calculated
using the feed and product size distribution data and the breakage distribution function. The
simulation results showed that the simulated product size distribution curve fitted the measured
product curve quite well (Shahgholi et al., 2017).
In the industrial grinding processes, the output particle size strongly depends on the mill residence
time. The residence time distribution (RTD) must be measured to evaluate mill performance and
identify breakage rates. In none of the previous studies, the RTD in simulation has not been
considered. Almost no work has been done to measurement and modeling of residence time
distribution of VRMs. RTD estimation in a VRM is complex due to different components in the mill,
the mass transport characteristics, and solid segregation. In the present research, we have done a
survey to determine mill RTD to understand the mixing regime better, and simulate the VRM with
population balance model.

2. Materials and methods

2.1. Surveying and sampling
This study was performed in Ilam cement plant. Ilam cement plant is located in Ilam province, west
Iran. The plant has two cement production lines and totally produces 5300 t/day cement. In this
study, the second production line was surveyed. The cement raw materials (lime, silica and iron ore)
enter the circuit through two apron feeders. The raw materials are crushed in a hammer crusher to D95
of 80mm. The raw materials are mixed in a certain proportion and fed into a vertical roller mill
(LOESCHE mill). The vertical roller mill grinds the marital to D85 of 90µm. The ground product is
calcined in a preheater to 850-900℃. After calcination, the materials enter to a rotary kiln and heated to
1450℃ to become clinker. The clinkers are cooled by six fans and entered the clinker bins. The D90 of
clinkers are 32mm. The clinkers and gypsum with a ratio of 97 to 3% are interred to a vertical roller
mill (LOESCHE mill). The feed rate of the clinker VRM is 160t/h. The VRM has four rollers including
two big rollers (master rollers) and two small rollers (slave roller), which respectively perform
grinding and make material layering on the grinding table. Fig. 2 shows the simplified flow sheet of
the VRM grinding circuit at Ilam cement plant.

Fig. 2. The VRM grinding circuit at Ilam cement plant

Two surveys were carried out on the grinding circuit. The data collected from the first survey
(feed and product) was used for modeling and simulation of the circuit, and the second survey was
used for validation of the model parameters. For any survey, samples weighing 100 kg were collected
from the conveyor feed belt and the mill product for two hours with 10 minutes interval. The mill
outlet is a channel that the ground product sucked at high speed by an air separator. Sampling from
27 Physicochem. Probl. Miner. Process., 55(6), 2020, 24-33

this channel was a challenging task. For this purpose, a sampler was designed and manufactured (Fig.
3). The sampler was a steel tube with a length of 1.2m (The width of the channel) and a diameter of
50mm. A hole was embedded in the channel. There was a slot at the end of the tube where the
particles trapped and fall into the end due to the gravity. The sample of feed was riffled and sized by
screening and also the sample of the product analyzed by laser particle size analyzer.

Fig. 3. The designed and manufactured sampler

2.2. RTD measurement

The RTD was measured by carrying out an impulse test using zinc concentrate powder (zinc sulfide)
(35% Zn) as a tracer. Zinc sulfide powder was chosen for this purpose because there is no zinc in
cement raw materials, and zinc can be analyzed by a traditional analytical method such as AAS and
ICP. The powder was mixed with cement, some water, and pelletized. The tracer was carefully
prepared so that its size distribution was similar to the size distribution of the clinker in the feed of the
VRM. The weight of tracer impulse was calculated in such a way that after dilution and mixing with
the mil content is measurable at the VRM product. 100 Kg of the pellets was suddenly injected in the
feed stream entering the mill. Approximately every 10-20 seconds the sampler enters the mill outlet
channel for two seconds and one sample was taken. The samples were analyzed for zinc by using
atomic absorption spectrometry (Agilent, 240FS AA model).
If the tracer is injected as a pulse, then the fraction of tracer that remains in the mill at any time
(assuming constant flow rate through the mill) can be defined by the distribution function E(t)
mathematically as follows (Makokha et al., 2011):
'(()
E(t) = , (1)
∫- '(().+(

where C(t) is the tracer concentration in the outlet stream as a function of time and C(t)dt defines the
area under the curve.
The first and second moment of the RTD function around the origin gives the mean residence time
(MRT or 𝜏01 ) and the variance (𝜎 3) (𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑡𝑟𝑎𝑐𝑒𝑟 𝑐𝑢𝑟𝑣𝑒 3) respectively, where the latter is a measure
of the spread of the RTD curves about the mean value.
E
𝑀𝑅𝑇 = 𝜏01 = ∫F t. E(t). dt (2)
E
σ3 = ∫F (t − τ)3 . E(t). dt (3)
The MRT represents the mass transfer phenomenon, which equals to the vessel volume to
volumetric feed rate, and the variance refers to the degree of mixing which occurs within the vessel. It
is particularly useful for fitting experimental curves to the theoretical curves.
In this research, the tanks-in-series and Weller models were evaluated. The models were applied to
obtained experimental data to evaluate their applicability. Parameters of every model were optimized
by minimizing the squared error between experimental tracer response data and model predictions.
Data analysis and modeling were carried out using the solver tool in the Excel spreadsheet.
Weller model proposes a different approach representing the mill mixing regime as several
perfectly mixed reactors in series either with equal or different sizes. This model allows the mill
behavior to be described by a condition between a plug-flow and a perfect mixing regime. It
28 Physicochem. Probl. Miner. Process., 55(6), 2020, 24-33

comprised one large perfect mixer (τL) and two small perfect mixers in series (τS), including a dead
time or plug- flow regime (τPF) (Eq. 4):
J NOKPQ NOKPQ NOKPQ NOKPQ
E(t) = K [− KR
exp (− KV
) − α exp X− KV
Y + α exp X− KL
Y] (4)
L

where a = tL/(tL - tS).

The tanks-in-series model is a good model to describe turbulent flow in pipes, laminar flow in very
long tubes, flow in packed beds, shaft kilns, long channels, screw conveyors, etc. The tanks-in-series
model is simple, can be used with any kinetics, and it can be extended without too much difficulty to
any arrangement of compartments, with or without recycle (Levenspiel, 1962). Eq. (5) describes the
tanks-in-series model mathematically:
_](d)
\ ] (^)]_` abc ( )
e
E(t) = f ] (\Og)!
(5)
where n is number of tanks and τ is means residence time.

2.3. Breakage distribution function

The breakage function used in this study was obtained from our previous study data (Shahgholi et al.,
2017). In our previous study, the breakage function was determined by the well-explored lab-scale
compressed bed breakage test in a piston-die cell device. The data were fitted by Eq. (6)(Austin et al.,
1984).
m m
𝐵j,g = 𝜑(m n )o + (1 − 𝜑)(m n )q (6)
` `

where xi and x1 are the size of friction i th and the first fraction respectively, and φ, γ and β are model
parameters, and R is relative size (x/x)ratio of i-th and first size fraction. By fitting the Eq. (6) to the
previous data the model parameters were calculated (φ = 0.966, γ = 0.31863 and β=0.31862).

2.4. Population balance model

For the modeling of continuous steady-state mills, the breakage equation is combined with the
material residence time distribution. The two extremes of residence time distributions are plug flow
and fully mixed. For plug flow, all materials have the same residence time, and hence the batch
grinding equation is applicable when integrated from time zero to the residence time. The solution to
this integration was originally proposed by Reid (Reid, 1965) and is known as the Reid solution.
The general form of the solution is:
𝑚j (𝑡) = ∑jtug 𝑎jt 𝑒 vw ^ 𝑓𝑜𝑟 𝑁 ≥ 𝑖 ≥ 1 (7)
where
⎧ 0 𝑖 < 𝑗
⎪ 𝑚j (0) − ∑•ug jOg
𝑎j• 𝑖 = 𝑗
𝑎jt = j‚g (8)
⎨ g
⎪ v Ov ∑jOg •ut 𝑆• 𝑏j• 𝑎•t 𝑖 > 𝑗
⎩ n w

For i > 2 the number of terms in the expression expands rapidly.

For a fully mixed mill at steady state, the equation becomes

𝑃j = 𝐹j + ˆ 𝜏 ∑jOg
tug 𝑏jt 𝑆t 𝑚t ‰ − 𝑆j 𝑚j 𝜏 𝑓𝑜𝑟 𝑁 ≥ 𝑖 ≥ 𝑗 ≥ 1 (9)
j‚g
Šn‹∑n_`
wŽ` Œnw vw f•w
𝑃j = g‹vnf
(10)
where τ = mean residence time.
According to Eq. (10), to measuring the size distribution of product the mill (𝑃j ), mean residence
time (τ), selection functions of different classes (𝑆j ), breakage functions (𝑏jt ), and mass in the screen
classes (𝑚j ) must be determined.
By placing, 𝑏jt , 𝐹j and 𝑃t in the Eq. (10) for the 𝑆t values can be back-calculated in the Excel
spreadsheet environment or Matlab.
29 Physicochem. Probl. Miner. Process., 55(6), 2020, 24-33

3. Results and discussion

3.1. RTD measurement
Fig. 4 illustrates the deviation of experimental data from the estimated values using tanks-in-series
model Weller models. The shape of obtained RTD curves depends on the combined effect of the flow
behavior and mixing performance inside the mill, which was usually related to the RTD function
parameters, i.e., MRT and variance. Table 1 presents the statistical parameters of RTD models for the
experimental data. As seen the R2 of the tanks-in- series model was higher than that by Weller model,
’
and also the relative variance (𝑅10•j0\•‘ = “”•) resulted from the tanks-in- series model was lower than
that by Weller model. In other words, it can be stated that the tanks-in- series model is more suitable
for experimental data compared to Weller model then the tanks-in-series model was used for
modeling of mixing regime and estimate the means residence time.
The results showed that the clinker particle spent a short time inside the VRM, and the mean
residence time is about 67s. The short time residence time shows that the number of breakages for
particles in the VRM is one to three times, which avoids any unnecessary over-grinding.
The long tail in this curve is a result of the recycling of tracer, and presence of stagnant volume
with exchange or both. The fine particles maybe after 2-3 times breakage are sucked by air separator
and exited the VRM. Coarse particles are too large to be properly nipped by master rollers then they
are forced to the edge of the table and fallen to the circulate stream or moved to the stagnant regions.

0.016

0.014 Weller model

Experimental
0.012
tanks-in-series model
0.01
E(t)

0.008

0.006

0.004

0.002

0
0 50 100 150 200 250 300 350
Time(s)

Fig. 4. Fitting the tank-in- series and Weller models to th practical data at feed rate 160t/h

Table 1. Statistical components of the tanks-in-series and Weller RTD models

Model Term value

τpf(s) 10.597
τl(s) 31.504
τs(s) 16.445
Weller
Means residence time (s) 74.991
R square 0.925
Relative variance 0.273
Means residence time (s) 67.23
N 5
tanks-in-series
R square 0.955
Relative variance 0.2
30 Physicochem. Probl. Miner. Process., 55(6), 2020, 24-33

3.2. Model calibration

Fig. 5 shows the measured particle size distribution of the VRM feed and product. The Rosin-Rammler
particle size distribution function was fitted to the feed and product size distribution from Fig. 2, and
the mathematical feed and product size distributions for 28 size classes were calculated (column 3 and
4 in Table 2). The non-cumulative breakage function was calculated from Eq. (6) (φ = 0.96582, γ =
0.31863 and β=0.31862) (column 5 in Table 2). From Eq. (10) (τ=67s) the selection function values (Si)
were back-calculated (column6 in Table 2).
100
90
80 Feed
Cumulative passing (%)

70 Product
60
50
40
30
20
10
0
0.1 1 10 100 1000 10000
Particle size (µm)

Fig. 5. Measured particle size distribution of feed and product of the VRM

Fig. 6 shows specific breakage rates (S values) plotted against particle size. It can be seen that the
maximum breakage rate is at the particle size of 25.4 mm. The specific breakage rate of the particles
size of 31.75 mm is to the right of maximum in the curve; it means the particles sizes are too large to be
properly nipped by master rollers then they are forced to the edge of the table and fall to the circulate
stream or move to the stagnant regions. The specific rate of breakage was decreased with decreasing
the particle size from 25.4 mm to zero so that the specific rate of breakage of particles under 100µm is
about zero. Particles with a size smaller than 100µm have no chance to be ground, and even
agglomeration may occur.

4499
Specific rate of breakage, Si (s-1)

3999
3499
2999
2499
1999
1499
999
499
-1
1 10 100 1000 10000 100000
Particle size(µm)

Fig. 6. Variation of specific rates of breakage versus particle size

31 Physicochem. Probl. Miner. Process., 55(6), 2020, 24-33

Table 2. Model fitting results

Mass retained
Sieve number
Sieve size (%) Breakage function Selection function
(i)
(µm) Feed Product (bi1) Si(s-1)

1 31750 8.25 0 0 1231.328

2 25400 25.25 0 0.069 3853.603
3 19050 16.05 0 0.081 2761.144
4 12700 13.6 0 0.103 2659.323
5 9525 7.35 0 0.072 1989.723
6 6300 8.25 0 0.077 2240.694
7 5000 3.45 0 0.042 1651.842
8 4000 2.8 0 0.038 1531.031
9 3150 2.7 0 0.037 1529.194
10 2500 4.2 0 0.034 1742.121
11 1190 4.03 0 0.093 1827.032
12 1000 2.77 0 0.019 1819.301
13 841 0.1 0 0.018 1366.591
14 297 0.38 0 0.088 1484.855
15 177 0.01 0 0.034 1593.665
16 138.038 0.61 0 0.014 1663.084
17 120.33 0.03 1.02 0.008 0.134
18 104.71 0.02 0.7 0.007 0.189
19 79.43 0.04 2.52 0.013 0.042
20 60.26 0.03 4.64 0.012 0.015
21 45.71 0.02 7.25 0.011 0.003
22 34.67 0.01 9.61 0.01 -0.002
23 30.2 0.01 5.4 0.005 0.005
24 22.91 0.01 11.13 0.009 -0.006
25 17.38 0.01 10.56 0.008 -0.007
26 10 0.01 16.7 0.014 -0.011
27 6.607 0.01 8.89 0.009 -0.009
28 3.311 0 9.56 0.013 -0.011

3.3. Validation of model

Sampling data from the second survey was used for validation of the model parameters. The grinding
condition such as the feed rate, operating pressure, and other mill setting parameters was the same as
the first survey. Thus, it was assumed that the S values were not changed. Fig. 7 shows the simulation
results. It could be seen that the size distribution of the simulated product fitted well on the measured
product (coefficient of determination or R-squared = 0.99), and the population balance model gave a
right prediction. The result of this work compared to our previous work (Shahgholi et al., 2017) shows
that population balance model compared with perfect mixing model gives a better prediction for
simulation of the VRMs in cement grinding processes.

4. Conclusions
In this study, the residence time distribution of a vertical roller mill in a cement clinker grinding
circuit was experimentally measured using zinc powder as a tracer. It was revealed that the tank-in-
32 Physicochem. Probl. Miner. Process., 55(6), 2020, 24-33

100
90
80
Cumulative passing (%)
70 Measured product

60 Simulated product

50 Measured feed
40
30
20
10
0
1 10 100 1000 10000 100000
Particle size (µm)

Fig. 7. Comparison between simulated and measured product size distributions

series model is appropriate to describe the residence time distributions in the VRM. The results
showed that the clinker particle spent a short time inside the VRM, and the mean residence time is
about 67s. The short time residence time shows that the number of breakages for particles in the VRMs
is one to three times, which avoids any unnecessary over-grinding. The RTD curve has a long tail that
can be due to the recycling of the tracer, the presence of stagnant volume with exchange or both.
The population balance model was used for modeling of the VRM vertical upon the survey data.
The results showed that the specific breakage rates increased with increasing particle size. However,
the particles larger than 25.4 mm is too large to be adequately nipped by master rollers. The
simulation results showed that the simulated product size distribution curves fit the measured
product curves quite well. It can be concluded that the grinding process of a VRM is very well-
predictable with the population balance model.
However, for the proper use of the population balance model for VRM simulation, further research
works with different feed in different plants are required.

Acknowledgments
The authors would like to thank the management and all staff of Ilam Cement Plant for their sincere
co-operation during plant visits and sampling campaigns

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