en-D000091-2D-3J-A Grinding Plan For Raw Meal

Operating manual
en-D000091-2D-3J-A
Grinding plant for raw meal
Code word
SAMANFA
Order number
D000091
POLYSIUS Order Code (POC)

2D - 3J
Contents
Grinding plant for raw meal
Contents
1 Technical Data......................................................................................... 1-1

1.1 Technical data of the plant........................................................................ 1-1
1.2 List of machines ........................................................................................ 1-3
2 Safety ....................................................................................................... 2-1
3 Components and mode of functioning ................................................. 3-1
3.1 Process-technological functions of the plant components........................ 3-1
3.2 Material conveyance to the mill feed bins................................................. 3-2
3.3 Raw material dosing system ..................................................................... 3-2
3.4 Flaps/dampers in the grinding plant.......................................................... 3-5
3.5 Control loops of the grinding plant ............................................................ 3-5
3.6 Deviations compared to normal operation ................................................ 3-7
3.7 Electrical interlock ..................................................................................... 3-7
4 Commissioning ....................................................................................... 4-1
4.1 Checking the mechanical equipment........................................................ 4-1
4.2 Checking the electrical equipment ............................................................ 4-2
4.3 Test run ..................................................................................................... 4-2
5 Starting the plant..................................................................................... 5-1
5.1 General information about starting up ...................................................... 5-1
5.2 Setting the plant ........................................................................................ 5-1
5.3 Starting...................................................................................................... 5-2
6 Shutting down the plant ......................................................................... 6-1
6.1 Shutting down from interconnected operation .......................................... 6-1
6.2 Shutting down for a lengthy stoppage ...................................................... 6-1
6.3 Shutting down for a short stoppage .......................................................... 6-1
6.4 Shutting down in case of emergency........................................................ 6-2
7 Operation ................................................................................................. 7-1
7.1 Fundamental principles of operation......................................................... 7-1
7.2 Checks during operation ........................................................................... 7-2
7.3 Plant operation monitoring ........................................................................ 7-3
7.4 Optimisation of the plant ........................................................................... 7-5
7.5 Inspection and maintenance ................................................................... 7-11
8 Trouble shooting..................................................................................... 8-1
9 Appendix.................................................................................................. 9-1
en-D000091-2D-3J-A
Operating manual Technical Data
Grinding plant for raw meal 1-1
1 Technical Data
NOTE
The descriptions and technical data of the individual machines are included in
the machine manuals or in the operating instructions for the respective
machines. The principal machines are listed with reference to their associated
item numbers (POLYSIUS Order Code, POC) under point 1.2. To find the
documentation of the respective machines, use the Table of contents of the
folders.
For the technical data of machines not supplied by POLYSIUS AG Beckum,
consult the technical documentation of the respective manufacturer or supplier.
1.1 Technical data of the plant
NOTE
All data and values given in this operating manual are to be regarded as
recommended values only.
The relevant warranty data are contained in the contractual documents.
Information regarding the compilation of records and notes, as well as the
performance of analyses, is to be regarded as a recommendation only. The
information must not be understood as a basis for the preparation of
acceptance reports for the verification of performance figures.
Specification of the intended use of the grinding plant

Composition .............................................................marl, limestone, sand, iron ore
Feed grain size.......................................................... 95 % < 70 mm, max. 100 mm
Moisture content of the mill feed material ............................. min. 2 % / max. 9.5 %
Moisture content of the finished product ........................................................ < 1 %
Finished product fineness ..........................................................max. 15 % R90 µm
Throughput .................................................................................................... 300 t/h
Specific energy consumption*................................................................. 16.5 kWh/t
* Mill drive, system fan, rotor drive, coarse feed valve
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Technical Data Operating manual
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1-2 Grinding plant for raw meal
Principal machines of the grinding plant
Roller mill
Quantity .................................................................................................................. 2
Raw mill size .............................................................................................RM 54/27
Installed power ........................................................................................... 3280 kW
Gear unit
Type designation ........................................................................ planetary gear unit
Power ......................................................................................................... 3130 kW
Speed ..................................................................................................... 23.25 min-1
Separator
Type........................................................................................... SEPOL® 435-RMR
Installed power ............................................................................................. 202 kW
Separating air flow rate .......................................................... 680.000 m3/h (90 °C)
Cyclones
Type................................................................ 4 x high-efficiency cyclone 4600 mm
Mill exhaust gas fan

Gas flow rate ............................................................................. 750 000 m3/h (90 °)
Pressure increase ....................................................................................... 90 mbar
Installed drive power .................................................................................. 2800 kW
Hot gas producer

Capacity .......................................................................................................20 GJ/h
Temperatur.................................................................................................... 800 °C
Air flow rate ........................................................................................ 17,550 Nm3/h
Water injection system

Flow rate................................................................................................... 10,300 l/h
Operating manualen-
1.2 List of machines
Figure 1 Feed bins
POLYSIUS
Qty. Designation
Order Code
1 Feed bin 3D
1 Bag filter 3D1.BF01
4 Bin weighers 3D1.BN01 - BN04
4 Feed bins 3D1.FB01 - FB04
Figure 2 Raw meal dosing system
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POLYSIUS
Qty. Designation
Order Code
1 Conveyors to raw grinding plant 1 3E1
1 Apron weighfeeder 3E1.AW01
1 Conveyor belt 3E1.BC01
1 Bag filter 3E1.BF01
1 Diverter gate 3E1.CF01
1 Magnetic separator 3E1.MS01
1 Metal detector 3E1.MT01
3 Weighfeeders 3E1.WE01 - WE03
Figure 3 Raw mill
Operating manualen-
POLYSIUS
Qty. Designation
Order Code
1 Raw grinding plant 1 3F1
1 Bucket elevator 3F1.BE01
1 Diverter gate 3F1.CF01
4 Cyclones 3F1.CN01 - CN04
1 Coarse feed valve 3F1.CV01
1 Dismounting device RM01 3F1.DM01
1 Fan 3F1.FN01
1 Flap valve RM01 3F1.FV01
1 Hot gas producer 3F1.HG01
3 Monorail trolleys 3F1.MC01 - MC03
1 Permanent magnet RM01 3F1.PG01
4 Rotary airlocks 3F1.RF01 - RF04
1 Roller mill DOROL 3F1.RM01
1 Dynamic separator RM01 3F1.SE01
5 Shut-off flaps 3F1.SF01 - SF05
1 Water injection system RM 3F1.WJ01
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Figure 4 Conveyors to the raw meal silo
POLYSIUS
Qty. Designation
Order Code
1 Conveyors to the raw meal silo 3J1
1 Pneumatic vertical conveyor AEROPOL 3J1.AC01
2 Bag filters 3J1.BF01 - BF02
1 Sampling system 3J1.QS01
3 Rotary blowers 3J1.RB01 - RB03
3 Fluidor pneumatic trough conveyors 3J1.TC01 - TC03
Operating manualen-
Operating manual Safety
2 Safety
NOTE
Be sure to comply with the general safety instructions in the supplement
Important notes on the documentation.
Use
• The plant is exclusively intended for the grinding of the components specified
in secsection Technical data.
Be sure to comply with the specification of the intended use in secsection
Technical data.
• Any use other than the intended use, such as grinding minerals which may
produce combustible or toxic gases or vapours during grinding, is forbidden.
POLYSIUS AG is not responsible for damage resulting from any use other
than the intended use. All other use is at the owner's own risk.
• The intended use also includes observance of the instructions in the machine
manual and compliance with the maintenance instructions.
Operation
General
• Hearing protectors have to be worn in the mill building because the noise level
exceeds 90 dB(A).
• Any safety checks before or during operation depend on the relevant national
regulations. The plant management is responsible for the performance and
recording of such checks.
• If changes in the plant or its operating behaviour relevant to safety occur, shut
it down immediately.
• Be sure to stay at an adequate safety distance from all moving plant
components.
Roller mill
• Never operate the roller mill without feed material being between the grinding
rollers and the grinding table.
SEPOL® separator
• If the exhaust gas temperatures are too low (<80 °C), excessively moist feed
material causes incrustations in the rotor system, which may result in
dangerous unbalances.
• The feed material must be free from tramp material (e.g. metal pieces, wood,
rubber, etc.).
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Safety Operating manual
Maintenance
• Before you enter the mill, make sure that the mill and all machines in the
material route upstream and downstream of the mill, as well as the hot gas
producer are safeguarded against restarting. If the dampers in the hot gas
duct are not absolutely tight, insert slide plates and flush the grinding
compartment with fresh air.
• Be sure to comply with all warning signs and safety instructions on and around
the machines, as well as in the machine manuals and operating instructions.
• Ensure that all machines and motors whose operation might endanger
persons or equipment are switched off and safeguarded against restarting for
the entire duration of maintenance work.
• Ensure that all rotating parts of the machine have come to a complete
standstill before you remove any protection devices or open any flaps.
• Before performing any work on the machine, make sure that there is no
danger of suffering burns when touching the machine and that no hot material
is in the machine when inspection and service covers are opened.
• Directly after the machine has been shut down you are only allowed to enter
the interior wearing respiratory equipment with independent ventilation. You
are not allowed to enter the interior without respiratory equipment until you
have sufficiently flushed it with fresh air. Make sure that there is sufficient
oxygen inside the machine and that no hot gases can enter it.
• When work is being performed inside the machine, make absolutely sure that
fresh air is supplied continuously (by injection or suction), so that the inhaled
air remains free from noxious constituents.
• Keep the machine free of oily and combustible substances and materials.
Never use gasoline or other easily inflammable substances for cleaning the
machine.
• Switch off the power supply to the electrical components before beginning any
maintenance work.
• Make sure that the pneumatic piping is relieved of pressure before
disconnecting it.
• Before carrying out work on the central lubrication system with pneumatically
operated barrel pump, you must disconnect the barrel pump from the
compressed air supply system.
• Make absolutely sure that the piping of the central lubrication system has
been relieved of pressure.
• The hydraulic system is specially designed for the supplied machine and may,
therefore, not be used for any other machine without the express consent of
POLYSIUS AG.
• Only use hydraulic oil that complies with the requirements in the sub section
Lubrication.
• Make sure that the hydraulic piping is relieved of pressure before
disconnecting it.
Operating manualen-
Operating manual Safety
• Never use the pumps of the hydraulic system for emptying or filling the oil
tank.
• If you drain hydraulic oil at operating temperature, you risk scalding yourself.
• Only use pure nitrogen (99.9 %) and never oxygen or other technical gases
for filling the piston accumulators.
• After all maintenance work, check that there are no leaks in joints and
connections.
• Strictly observe the welding instructions when performing any welding work.
• When electric arc welding or cutting are being performed, you must ensure
that personnel cannot come into contact with electrically conductive
components. Use insulating underlays for this purpose.
• Never situate the source of the welding current in a confined space where
walls have conductive properties.
• If you carry out electric welding on any part of the machine, never conduct the
welding current through plain or antifriction bearings, other moving connecting
elements or measuring devices. Always directly connect the welding current
return lead to the part being welded.
• Remount all protection devices and properly close all inspection and service
covers when maintenance work has been finished.
• Make sure that the interior of the machine has cooled down so far that the
personnel will not suffer any burns on entering.
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Operating manual Components and mode of functioning
3 Components and mode of functioning
NOTE
In the following, mainly grinding plant 1 is described representatively for the two
raw grinding plants. The functioning of grinding plant 2 is identical, but an own
hot gas producer is not installed in this plant with the effect that the hot gas
producer of grinding plant 1 is used if necessary.
Exact descriptions of the individual machines are included in the machine
manuals or in the operating instructions for the respective machines.
For the descriptions of machines not supplied by POLYSIUS AG Beckum,
consult the technical documentation of the respective manufacturer or supplier.
3.1 Process-technological functions of the plant components
Exhaust gas
• Dedust ing
• Gas conveyanc e
B - to preheater
Electrostatic filter (direct operation)
Filter dus t
• Material separation
• Gas conveyance A - to silo
(compound operation)
Fines
Cyclones
Electrical energy • Material separation

Dynamic • Class ifying
separator
External circulation
Return gas
I nt ernal circulation
Mill feed material components

Roller mill
W at er
Electric al energy
Hot gas
from Kiln
Hot gas generator
• Gas conveyanc e
• Material separation
• Comminut ion
• Drying
Figure 5
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Components and mode of functioning Operating manual
3.2 Material conveyance to the mill feed bins

This plant secsection is not included in the scope of supply of POLYSIUS AG.
The following bins of each grinding plant are filled:
• a mill feed bin for limestone marl (600 t, 3D1.FB01)
• a mill feed bin for limestone (200 t, 3D1.FB02)
• a mill feed bin for sand (200 t, 3D1.FB03)
• a mill feed bin for iron ore (200 t, 3D1.FB04)
3.3 Raw material dosing system
Feed bin (raw material feed bin 3D1)

From the feed bin for limestone marl premixture the material is discharged via the
apron weighfeeder 3D1.AW01 and is fed to the conveyor belt 3E1.BC01.
From the feed bin for limestone the material is discharged via the weighfeeder
3D1.WE01 and is also fed to the conveyor belt 3E1.BC01.
From the feed bin for sand the material is discharged via the weighfeeder
From the feed bin for iron ore the material is discharged via the weighfeeder
This plant secsection is dedusted by bag filter 3D1.BF01. The collected filter dust
is returned to the system by means of conveyor belts.
Conveyors to the mill

The conveyor belt 3E1.BC01 feeds the material via a chute and a coarse feed
valve 3F1CV01 to the raw mill.
Protection against tramp metal

A magnetic separator 3E1.MS01 is installed above the conveyor belt 3E1.BC01
which removes ferro-magnetic tramp metal from the stream of material. After the
magnetic separator and for additional detection of possible metal objects a metal
detector 3E1.MT01 is installed which controls the changeover flap 3E1.CF01
after the belt discharge point: If the metal detector triggers a signal, the material
flow will be temporarily diverted into a collecting container, in order to safeguard
the roller mill.
Operating manualen-
Grinding process in the raw mill

The mill feed material is conveyed via the heatable coarse feed valve 3F1.CV01
to the raw mill. As a result of the rotating movement of the grinding table, the
material is drawn under the grinding rollers and ground.
The ground material is discharged over the edge of the grinding table to the
nozzle ring where it is entrained in the hot gas stream and conveyed to the
SEPOL® separator 3F1.SE01 (internal circuit) which is arranged directly over the
grinding compartment. The separator is equipped with non-rotating, setting-angle
adjustable guide vanes and a rotating rotor to adjust the fineness of the finished
product.
• You carry out the presetting with the guide vanes. The more tangential the
adjustment of the guide vanes, the finer is the finished product.
• Precise adjustment is made via the speed of the rotor; the fineness increases
when the rotor speed is increased.
Coarser lumps of material that cannot be carried by the hot gas stream to the
separator fall through the nozzle ring and are conveyed via the discharge device
from the mill into a chute. A discharge device 3F1.PG01 with permanent magnet
is installed in this chute as protection against circulating tramp metal. A flap valve
3F1FV01 serves as airlock. Finally, the externally circulating material is conveyed
to the bucket elevator 3F1.BE01 which returns the material in normal operation to
the mill. By using the changeover flap 3F1.CF01, you can also withdraw the
recirculating material from the circulation, in order, for instance, to empty the
grinding system for maintenance work.
The separator separates the feed material into fines and grit. The grit falls back
via the grit cone onto the centre of the grinding table and is ground again. The
fine material is carried by the gas stream to the high-efficiency cyclones, where
the major portion is collected and conveyed via the rotary airlocks and the
conveyors of the raw meal conveying equipment to the raw meal silo. The
residual dust in the mill and kiln exhaust gases is collected in a bag filter. In mill
bypass operation, the hot kiln exhaust gas is previously cooled down in a
spraying tower to protect the filter bags.
Raw meal conveying equipment

The raw meal separated in the cyclones is discharged via FLUIDOR® pneumatic
trough conveyors 3J1.TC01-TC02. Via the trough conveyors the raw meal is
conveyed to the pneumatic vertical conveyor AEROPOL 3J1.AC01.
Screw sampler 3J1.QS01 is installed upstream of the vertical conveyor in order to
take, at regular intervals, samples of the homogenised raw meal.
The vertical conveyor conveys into a further trough conveyor TC03 which
conveys into the distributor 3K1.BL01.MDS01 on the raw meal silo.
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Hot gas supply - operating modes

In interconnected operation, the hot gas required for drying and conveying the
material is supplied from the kiln system to the mill. The mill system fan
3F1.FN01 forces the gas through the mill and through the cyclones. By adjusting
the position of the flaps 3F1.FN01.TVJ01, 3F1.SF01 and 3F1.SF02, you can
regulate the gas flow volume as required for the combined grinding and drying
process. The shut-off flaps between the kiln plant and the grinding plant are open.
The additional hot gas producer 3F1.HG01 is available for starting up and for
operation of the mill without hot gases from the kiln.
In mill bypass operation, the roller mill is not operated. The shut-off flaps are
closed. The exhaust gases from the preheater are supplied to the electrostatic
precipitator 4E1.EL01 via the evaporation cooling tower 4E1.ET01.
Heating up the grinding plant

Before hot gases may be drawn through the roller mill, all rotating components of
the grinding plant, such as the rotor of the SEPOL® separator and the coarse
feed valve, must be turning, in order to avoid unilateral deformation and thermal
stresses of these components.
The heating-up of the grinding plant is finished when the temperature after the
roller mill is approx. 120 °C. Make absolutely sure that the plant is heated up
slowly (approx. 40 - 50 minutes), in order to ensure adequate heating up of the
grinding table, the grinding rollers and the separator.
The hot gas producer 3F1.HG01 is available for heating up and operating the raw
mill in the case of lacking or too few hot gas flow volumes from the kiln plant. The
gas route from the hot gas producer to the hot gas duct between kiln plant and
raw mill can be closed by means of the shut-off flap 3F1.SF05.
Water injection system

The water injection system stabilises the grinding bed and ensures low-vibration
operation of the mill. Via injection piping from the water injection plant 3F1.WJ01,
water is injected onto the material spread on the grinding table and in front of the
grinding rollers in the roller mill. The injection pipes are directed towards the
centre of the grinding table and one towards each grinding roller. The water is
supplied via the water tank to the injection lances. The necessary water pressure
is generated by the motor pump unit. The mounted fittings measure and control
the water flow rate to be injected.
Operating manualen-
3.4 Flaps/dampers in the grinding plant

The following table gives an overview of the flaps/dampers in the grinding plant
for raw meal.
Designation Item Adjustable Positionable Function
Shut-off flap 3F1.SF01 No Yes (open / Changeover from

(after mill system fan to closed) interconnected
evaporation cooling operation to mill
tower) bypass operation
Shut-off flap 3F1.SF02 Yes Yes (open / Setting the
(return gas duct) closed) pressure before
mill
Shut-off flap 3F1.SF03 No Yes (open / Changeover from
(from preheater to closed) interconnected
tower) bypass operation
Shut-off flap 3F1.SF04 Yes Yes (open / Changeover from
(from preheater via closed) interconnected
tower to electrostatic bypass operation
precipitator)
Shut-off flap 3F1.SF05 No Yes (open / Distribution of hot
(after hot gas producer closed) gas producer
preceding mill) gases to line 1 or 2
3.5 Control loops of the grinding plant

Control of the mill's differential pressure (interconnected operation)
A constant filling ratio in the mill is a prerequisite for uniform mill operation. The
differential pressure between mill inlet and outlet is used as an indicator for the
filling ratio.
Control of the temperature after the mill (interconnected operation)

Adjust the hot gas flow volume for drying the raw meal depending on the moisture
content of the mill feed material and the drying gas temperature. The gas
temperature after the mill is used as the controlled variable. Adequate drying of
the material has been achieved when the gas temperature after the mill does not
fall below 85 °C. The purpose of this control function is to keep the gas
temperature after the mill constant at a predetermined setpoint. The manipulated
variable is the position of the control damper upstream of the evaporation cooling
tower. If the kiln exhaust gases for drying are insufficient, the hot gas producer
can also be switched on.
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Uniform separating conditions require a constant volume flow in the mill. The
negative pressure upstream of the mill which must be kept constant at a certain
value (defined by the commissioning personnel) is an indicator for the volume
flow through the mill. Fine adjustment of the volume flow is attained by keeping
the differential pressure Δp across the cyclones constant. It can be assumed that
the flow rate is approximately constant when the pressure difference of the
cyclones is constant. The manipulated variable in this control loop is the position
of the fan damper. Pressure drop changes across the cyclones caused by
changing material quantities are comparatively small and experience has shown
that they have no negative effect on the control function. The control loop is not
activated until the mill has reached its stable operating point.
Figure 6 Control loops
Operating manualen-
Control of water injection

When the mill feed material has certain properties, its flow behaviour and the
formation of the grinding bed on the grinding table can be considerably improved
by injecting a certain quantity of water into the grinding compartment. The water
contributes to the formation of the grinding bed, especially when the material is
very dry and fine.
The water flow rate to be injected depends on the mill size and the material
properties, such as the feed moisture content, grit quantity and granulometric
distribution of the material, and is defined during commissioning.
3.6 Deviations compared to normal operation

Provided that maintenance work is properly carried out and that the grinding plant
is correctly operated, faults should not occur. If operating trouble nevertheless
occurs, proceed according to the instructions on fault elimination included
in secsection 8 Trouble shooting.
3.7 Electrical interlock

The drives of the machines in the plant or in a plant component are interlocked
with one another. If one machine fails (e.g. due to overloading), then all the drives
in the process sequence upstream of the failed machine are switched off
automatically. This arrangement prevents blockages and machine damage.
The sequence for switching the individual drives on and off is stated in the
process functional diagrams. In case of emergency, you can shut down the plant
instantaneously by means of an EMERGENCY OFF pushbutton.
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Operating manual Commissioning
4 Commissioning
NOTE
It is a prerequisite of our warranty that the first commissioning is carried out in
the presence of specialists from POLYSIUS AG and in accordance with their
instructions.
4.1 Checking the mechanical equipment
NOTE
Be sure to also perform the checks specified in the machine manuals of
POLYSIUS AG and in the operating instructions of the respective
manufacturers.
After completing the assembly work and prior to the first test run, be sure to
remove all material remnants, tools and assembly appliances and check and/or
adjust the plant components again. Be sure to carry out the following particularly
important checks and actions:
When checking the hydraulic piping, make sure that the pressure outlets are
provided with a spiral hose to prevent vibration transmission.
Prepare measurement records (log books) as specified in the machine
manuals.
Fill the machines and plant components with the required consumables (e. g.
oils, greases).
The qualities and quantities are specified in the respective machine manuals.
Visually inspect all piping, screwed pipe joints and welds for leaks.
Check that all the necessary protection devices (e. g. guards) and warning
signs have been properly mounted.
Check all flaps, dampers and discharge devices for proper functioning and
adjust them as necessary.
Check the compressed air supply system (e. g. water separator, lubricator).
Check the anti-runback devices for correct installation (blocking direction).
Check that all manholes, inspection doors and covers are correctly closed.
Check the cooling water supply of all machine coolers.
Check the adjusting flaps of the dedusting system.
Check the conveying routes of the finished product for moisture.
Wear measurement
To allow assessment of the progressing wear, it is necessary to carry out an
initial measurement on the grinding rollers and on the grinding table before
commissioning. The measuring method and the wear record are described in the
machine manual for the grinding rollers.
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Commissioning Operating manual
4.2 Checking the electrical equipment

The drives of the machines in the plant or in a plant component are interlocked
with one another. If one machine fails (e.g. due to overloading), then all the drives
in the process sequence upstream of the failed machine are switched off
automatically. This arrangement prevents blockages and machine damage.
In case of emergency, you can shut down the plant instantaneously by means of
an EMERGENCY OFF pushbutton.
To ensure perfect functioning of the interlock system, you must check the signal
transmission. This includes:
• correct assignment of the measuring point to the control system or control
panel display
• adjusting the measuring transmitters
• checking the drive motors for correct direction of rotation
4.3 Test run
NOTE
The first test run must be carried out in the presence of representatives from
POLYSIUS AG and in accordance with the instructions given by them.
CAUTION
There is potential danger for both the personnel and the plant.
Do not start the test run before all checking and adjusting work has been
completed.
During the test run, pay special attention to the following:

• abnormal noise at plant components
• higher temperatures than normal at bearings, gear units, motors or other plant
components
• severe vibrations at rotating plant components
CAUTION
The plant may suffer serious damage.
Interrupt the test run immediately if one of the abnormal conditions
mentioned above occurs.
Eliminate the cause without delay.
• correct interlocking and proper functioning of individual plant components and

machine groups which are started up together
• tightness of all piping and screwed pipe joints
Operating manualen-
Operating manual Commissioning
Roller mill groups

All roller mill groups must be subjected to a test run of eight hours. First, check
the interlocks and comply with the separate instructions of the individual
suppliers.
• Gear oil supply system
• Confining air fan
• Outward conveying equipment
• Bucket elevator, coarse feed valve and changeover flap
• SEPOL® separator (stop work in the mill, close inspection doors)
• System fan (close control damper upstream of fan)
• Hydraulic unit (ATTENTION: Possible overheating of the hydraulic oil, which
may cause damage to the pumps!)
NOTE
After you have checked the proper functioning of the mechanical interlocks, you
may operate the roller mill in no-load condition.
To prevent damage to the roller pair units and to the grinding table, only operate
the mill without material after the roller pair units have been lifted.
During no-load operation of the roller mill by means of an auxiliary drive unit, pay special
attention to the following points:
• grinding table free of tramp material, tools etc.
• proper functioning of the discharge device without abnormal noises
• proper contact between grinding table seal and grinding table
• check for correct annular gap between the grinding table and the nozzle ring
• clutch completely engaged
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Operating manual Shutting down the plant
5 Starting the plant

5.1 General information about starting up
Always put the various control loops as early as possible into the "Automatic"
operating mode in order to facilitate the operator's work.
After the raw meal conveying equipment, the auxiliary units of the roller mill and
the mill system fan have started and are operating, the next step is to heat up the
mill. To prevent mechanical damage, limit the heating temperature at the roller
mill inlet to approx. 250 °C. You should heat the mill up slowly (for a period of
approx. 40 - 50 minutes). The heating-up period ends as soon as a gas
temperature of approx. 120 °C is reached downstream of the mill.
The new material quantities to be fed in during the start up procedure are
determined and defined during commissioning.
5.2 Setting the plant
Start up the roller mill with the following initial settings

(Approximate values, which are precisely determined during commissioning):
• Material feed rate: approx. 60 - 70 % of the rated throughput
• Hydraulic system: initial nitrogen filling pressure of the piston accumulators
approx. 90 % of the start-up pressure
• Start-up pressure approx. 50 - 55 bar
• Working pressure; see machine manual "Hydraulic system of the roller mill"
• Speed of the mill system fan: 90 - 100 %
• Position of the guide vanes in the SEPOL® separator approx. 70 °
(see Figure 7)
• Separator rotor speed approx. 70 - 75 % of the maximum speed
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Shutting down the plant Operating manual
Figure 7 Position of the guide vanes
5.3 Starting
Like the entire plant, the roller mill is started up and shut down in successive
groups. Various operating modes are implemented. The start-up, stoppage and
operation are linked with the following 3 types of condition:
• Starting conditions: a starting condition must be fulfilled before a group or
operating mode can be started.
• Permanent conditions: the permanent condition must be fulfilled in order for
the group to remain in operation.
• Stopping conditions: the corresponding group is stopped when a stopping
condition is fulfilled.
CAUTION
The following conditions must be fulfilled before hot gas may be supplied
to the roller mill:
• The coarse feed valve is in operation.
• The separator rotor is in operation.
• All inspection covers and doors of the mill are closed.
• The system fan is in operation.
NOTE
Start the fans only when the dampers are closed. Otherwise the drive motors of
the fans will be overloaded.
Operating manualen-
Start sequence
The exact procedure of the mill starting sequence is shown in the process
functional diagrams. The stated sequence is the fundamental operational
sequence of a starting procedure:
Grp. Start Starting condition Permanent condition
1 Raw meal conveying equipment • Dedusting system of the • Dedusting system of the
raw meal silo in operation raw meal silo in operation
2 Gear lubrication
• Operating temperature • T > Tmin • T < Tmaxmax
• Low pressure pump • Operation signal T5 sec • Operation signal
• flow rate • after 5 secsec: secF > Fmin • F > Fminmin
• Cooling and heating system • Temperature • Tmax > secT > Tmin
Tmax > secT sec> Tmin
3 Auxiliary units of the roller mill: • Operation signals • Operation signals
for groups 1 and 2 for groups 1 and 2
• Confining air fan
for roller pair units • Filling level of hydraulic • Working pressure P of
reservoir: hydraulic system:
• Recirculating bucket elevator
L > Lmin Pminmin < P < Pmaxmax
(changeover flap set in
direction of the mill) • Motor of coarse feed valve • Confining air pressure P:
available Pminmin < P < Pmaxmax
• Coarse feed valve
• Coarse feed valve
in operation
4 Separator • Frequency converter for • Separator speed:
separator available S > Smin
5 Mill exhaust air fan • Gas routes set to • Dedusting system of the
interconnected operation raw meal silo in operation
6 Start heating up
7 Hydraulic system • Hydraulic oil temperature: • Filling level of hydraulic
T < Tmax reservoir:
• Hydraulic pump available L > Lmin
• Hydraulic oil temperature:
T < Tmaxmax
8 Auxiliary drive (plus water
injection system if necessary)
9 Main drive and mill feed system • Dedusting system of the
raw meal silo in operation
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6 Shutting down the plant

6.1 Shutting down from interconnected operation
Always shut down the grinding plant in reverse order of the switching-on
sequence. For normal stopping of the roller mill, first reduce the material feed rate
to approx. 60 - 70 % of the rated throughput. Also reduce the hydraulic pressure.
Simultaneously with the stopping of the material feed equipment, the main drive
of the roller mill is also switched off.
For the detailed program for shutting down the plant under normal circumstances
and after EMERGENCY OFF, refer to the process functional diagrams.
CAUTION
In order to prevent damage to the wear parts due to a temperature shock,
the roller mill must not be opened immediately after stopping.
Furthermore, never inject water as this might cause the roller tyres to
crack.
The waiting time until the roller mill may be opened depends on the local
climatic conditions. When the ambient temperatures are low, the waiting
time is governed by the temperature after the roller mill, which should be
below 50 °C.
6.2 Shutting down for a lengthy stoppage

The program for shutting down the plant corresponds to the program described
under point 6.1, in reverse order of the switching-on sequence. In the case of a
longer stoppage of the grinding plant (longer than a week), it is necessary to start
the complete grinding plant once per week as a prevention against corrosion (in
particular corrosion of the gear unit and the bearing assemblies of the rollers).
For this purpose, you have to lift and fix the roller pair units of the mill in such a
way that there is no contact between the grinding table and the rollers. Only in
this position may the mill be operated without feed material using the main drive.
As an alternative, you can rotate the grinding table very slowly with a provisionally
installed auxiliary drive. In this case it is not necessary to lift the roller pair units.
Be sure to also start the lubrication system of the gear unit.
6.3 Shutting down for a short stoppage

If the grinding plant is only stopped for a short time, it may be sensible to only
stop the mill feeding system and the main drive of the mill.
With this operating mode, the mill is kept at operating temperature and can be
started immediately whenever the need arises.
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Shutting down the plant Operating manual
6.4 Shutting down in case of emergency

The control and monitoring devices installed in the system are designed to
ensure continuous plant operation on a permanent basis. Nevertheless,
unforeseen circumstances can lead to operating trouble.
EMERGENCY OFF
If personnel are in danger or damage to the plant threatens, shut down
dangerous parts of the plant or even the complete plant as quickly as possible to
prevent accidents. To shut down in case of emergency, actuate the
EMERGENCY OFF devices on the control panel or on the machines.
If danger threatens, proceed as follows:

Shut down the affected part of the plant immediately with EMERGENCY OFF.
Subsequently, shut down the plant components upstream of the switched off
plant component via the programmed control system.
Shut down the other secsections of the plant in accordance with the normal
shutdown sequence.
Operating manualen-
Operating manual Operation
7 Operation
7.1 Fundamental principles of operation
The following requirements must be optimally fulfilled by the plant components:
• Drying of the raw material
• Obtaining of the necessary raw meal fineness
• Reliable and troublefree operation (minimisation of wear)
• Minimisation of auxiliary energy consumption, for example minimisation
of secsecondary energy consumption (e.g. in the form of compressed air or
ultimately
• in the form of electrical energy),
• Elimination of health risks for the operating personnel
All these requirements and conditions are fulfilled and complied with by observing
the operating instructions, by a technical system of process interlock functions
and by the installed control system.
A virtual image of the entire plant is displayed on the control panels in the central
control room. All relevant information of analog or digital nature, such as
operation signals, filling level signals or status messages, is made available
there. All important variables are provided with alarm limits. Corresponding
messages and / or acoustic warnings are given when the variables are exceeded
or fall below an alarm limit value. The operating personnel must then react and
take suitable measures to ensure that the normal and intended operating range of
the plant is restored.
Visual inspection by trained operating personnel is a further important means of
diagnosis and is indispensable, even in plants equipped with modern technology.
The personnel must inspect the plant at regular intervals and immediately
eliminate all faults and defects. For instance, advance warning of bearing
damage is often provided by changes in temperature, noise or vibrations.
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Operation Operating manual
7.2 Checks during operation

In the initial phase, only operate the plant with 60-70 % of the rated capacity.
When, after first commissioning, the mill operates smoothly with vibration values
of < 1-2 mm/s, you should first monitor the operating behaviour of the mill for
several hours, paying particular attention to the mechanical equipment (mill, gear
unit, separator, hydraulic system).
During the first operating hours, constantly make the following checks:
• Gas temperature before and after the roller mill
• Oil temperature and oil level indicators in the roller pair units
• Drip lubrication for roller bearing seals
• Oil temperature at the tilting-pad thrust bearing of the gear unit
• Negative pressure in the gas duct before the roller mill
• Differential pressure of the roller mill
• Vibrations of the roller mill
• Material falling through the nozzle ring
• Current consumption of the bucket elevator drive
When the mill operation has remained stable for a period of approximately 3 to 5
hours, you can increase the throughput rate step by step.
Proper monitoring, however, also necessitates constant on-the-spot checking of
the machines by the operating personnel.
Experience has shown that it is very important to have the operating personnel
keep an operating data sheet. They must also record all malfunctions and
failures.
When the running-in period specified by the gear unit manufacturer, ( i.e.
operation with partial-load) has ended, you can start the systematic optimisation.
For this purpose, the operating values have to be recorded in accordance with
the data sheet, evaluated and represented in diagrams. This is the basis for the
subsequent specific optimisation steps, in which you should only change the
parameters one by one, so that you can see the effects of every alteration.
After every change, be sure to record the average values of a representative
period of continuous mill operation.
Operating manualen-
7.3 Plant operation monitoring

Good plant monitoring is essential to ensure a trouble-free production process.
The installed measuring devices, whose signals are transmitted to the control
room, enable you to monitor and suitably control each phase of grinding plant
operation. Proper monitoring also necessitates constant on-the-spot checking of
the machines by the operating personnel.
Experience has shown that it is very important to have the operating personnel
keep operation logs of the grinding plant.
The purpose of the operation log is to provide information about the operation of
the grinding plant. You should keep hourly records, including all important data
such as throughput, fineness of finished product, temperatures, pressures,
electrical data etc.
The following list contains all the data which must be known to assess the
operation of the raw meal grinding plant.
Mill feed material
Throughput tph
Finished product fineness %
R 90 secµm
Finished product fineness %
R 200 secµm
Material to be ground, raw material %
Maximum feed grain size mm
Moisture content of feed material %
Finished product moisture content %
Power consumption and specific power requirement
Power consumption of roller mill kW

Power consumption of SEPOL® high-efficiency separator kW
Power consumption of mill system fan kW
Power consumption of bucket elevator kW
Power consumption, total kW
Specific power requirement of roller mill kWh/t
Specific power requirement of separator kWh/t
Specific power requirement of mill system fan kWh/t
Specific power requirement of bucket elevator kWh/t
Specific power requirement, total kWh/t
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SEPOL® high-efficiency separator
Speed min-1
Temperatures
Hot gas temperature at roller mill inlet °C

Temperature at roller mill outlet °C
Pressures
Pressure before the roller mill mbar

Pressure after the roller mill mbar
Differential pressure of the roller mill mbar
Differential pressure of filter mbar
Differential pressure across the cyclones mbar
Gas flow rates
Exhaust air volume (if measured) Nm3/h
Roller mill
Nozzle ring; open area m2

Hydraulic grinding pressure, maximum bar
Hydraulic grinding pressure, minimum bar
Grinding force, total kN
Height of dam ring heightener / inward situated dam ring mm
Grinding bed depth (roller pair units 1 & 2) mm
Operating manualen-
7.4 Optimisation of the plant
Introduction
The correct setting of the roller mill largely depends on the properties of the
material to be ground.
Therefore, it is almost impossible to indicate exact values for the operating
parameters in the planning and/or order-processing phases. For this reason, it is
absolutely essential to maintain accurate records of all operating data from the
very start of operation onwards. The following passages explain the process
technological relationships, so that you can use the various operating data as
criteria for decisions about the alteration of the individual settings.
Capture of operating data

You can adjust the mill by changing the following parameters:
• Gas flow rate

• Gas velocity in the nozzle ring
• Gas temperature
• Grinding force
• Height of the layer of material / dam ring
• Setting of the separator
• Differential pressure of the mill
Since the a.m. parameters are linked with each other, you can only judge the
result of an adjustment after you have checked the operating data directly
connected with the changed parameters.
Checking the performance data

Before you make purposeful changes, compare the attained fan values and the
specific power requirement for grinding calculated on the basis of the fan values
with the design values.
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Circulating mill air fan

To simply check the working point of the fan, measure the static pressure
before and after the fan.
You can calculate a theoretical value for the operating flow rate with the aid of
the following factors:
P x 1000 x η VB = Operating flow rate [m3/s]

VB =
∆pst P = Power input at shaft [kW]
η = Efficiency of the fan
∆pst = Total pressure increase [Pa]
Check the calculated gas flow rate with the values from the characteristic curve
and the design data. (For the characteristic curve of the fan, refer to the
documentation of the fan manufacturer.)
For checking the gas flow rate more precisely, you can carry out a flow rate
measurement with the aid of a Prandtl pitot tube.
Specific power requirement for grinding

The size of the roller mill is determined by the required throughput, the fineness
of the finished product and the specific power requirement found in the grinding
tests.
To achieve the warranted throughput, the specific power requirement determined
by the grinding tests must approximately correspond to that of the industrial mill.
To determine the power requirement, you must take the following factors into
account:
• The throughput of the roller mill relates to a finished product of a specific
fineness. Therefore, the separator setting has to be such that the warranted
fineness is attained.
• When converting the mill feed values into finished product values, you must
take account of the moisture content of the feed material and the residual
moisture content of the finished product.
Operating manualen-
Computation of the throughput of finished product
100 % - Hfeed
Mdry = Mmoist sec x
100 % - Hresi
Mdry = Output in [tph]

Mmoist = Feed rate indicated in [t/h]
Hfeed = Feed material moisture content in [ %]
Hresi = Residual moisture content of mill feed material in [ %]
To obtain a representative value, you have to record the quantity of feed material
according to the counter readings of the mill dosing devices as well as the power
consumption of the mill motor according to the counter readings over a period of
several hours.
Calculation of the specific power requirement
Pmeter
Wsp =
Mdry
Wsp = Specific power requirement in [kWh/t]

Pmeter = Power consumption of mill motor at the counter in [kW]
Mdry = Output in [tph]
Measures for correct adjustment

The checks and process-technological measures listed in the following
description are already included in the checklists of the Machine manual. Our
intention here is only to draw your attention to possible sources of errors and their
consequences for the grinding process.
Gas flow rate

To obtain continuous operation of the roller mill with low vibrations, it is important
that the finely ground product leaves the mill as quickly as possible with the gas
stream.
A lower gas flow rate means a smaller specific power requirement.
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The specific gas flow rate largely depends on the grindability of the feed material.
Approximate values are shown in the following diagram:
Figure 8 Grindability as a function of the specific gas flow rate
To keep the gas flow rate constant, you must use the corresponding control loops
(differential pressure across the mill and negative pressure before the mill).
Grinding bed depth as a function of the dam ring height
1 = Material 1
2 = Material 2
3 = Material 3
Figure 9 Grinding bed depth as a function of the dam ring height
Operating manualen-
The grinding bed depth depends primarily on the dam ring height. However, since
material-specific properties (grindability, granulometric distribution, flowability
etc.) and constructional features of the mill (roller diameter) are also important, it
is very difficult to make a generally valid statement regarding the optimum
grinding bed depth.
The following figure shows that, under certain circumstances, a dam ring
optimisation should only be carried out in very small steps. For example, a dam
ring heightening by 10 mm for material 1 results in an increase in grinding bed
depth of approx. 30 mm, whereas for material 2, the material bed depth is only
increased by approx. 10 mm.
For a mill of this size, the initial setting of the dam ring height is 120 mm. The
installed dam ring height ensures that an adequate grinding bed depth is
available on the grinding table when the mill is started up for the first time.
1
Position für den vorgezogenen Stauring
3 Stauring
oberer
2
Stauringerhöhung Stauring4
Figure 10 Dam ring height = lower and upper dam ring plus dam ring heightener
1 Position of the inward situated dam ring

2 Dam ring heightener
3 Upper dam ring
4 Dam ring
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Grinding force
The grinding force is generated by the hydraulic system and is calculated on the
basis of the hydraulic pressures. The grinding force is decisive for the
effectiveness of grinding. With increasing hydraulic pressure the power
consumption of the mill also rises. The influence on the throughput depends on
the material to be ground. With certain types of mill feed material, an increase in
the power consumption does not lead to an equivalent increase in throughput. In
this case, the specific power requirement also increases.
The optimum working pressure is determined during commissioning. The initial
setting of the working pressure is 120 bar. To prevent damage to the roller mill,
the pressure must not exceed 160 bar. When this pressure is reached, an alarm
message is sent and when the pressure reaches 165 bar, the plant is shut down
automatically.
The machine is additionally protected by pressure limiting valves installed at the
hydraulic power unit (180 bar) and at the safety blocks (210 bar) between cylinder
and accumulator. The pressure limiting valves prevent mechanical overloading of
the system (see machine manual for the hydraulic system of the roller mills).
The grinding force applied to the roller pairs can be adjusted to suit individual
operating requirements. This is advantageous when running the mill under partial
load. Uniform operating economy is ensured over a wide performance range.
Differential pressure of the mill

The differential pressure Δp is used as an indicator of the filling ratio of the mill.
For this reason, it is very important that you always use the Δp-control from the
commencement of commissioning onwards. Since it is not possible to determine
the differential pressure of the mill in advance, you have to find out the value that
satisfies all requirements by purposeful testing. In doing so, you must take
account of the interaction of 4 factors:
• Feed rate
• Grinding force
• Power consumption of the mill
• Static pressure increase of the fan
As a rule, the plant is started with an initial mill feed rate which corresponds to
approx. 60 - 70 % of the rated capacity. Also the grinding force has to be set to a
correspondingly low value (60 - 70 % of the max. hydraulic pressure).
After the first operating hours, a differential pressure typical for the respective mill
is attained very quickly and has to be used as the basic value for further
optimisation.
If the differential pressure is so low (< 30 mbar) that reserves in the static
pressure increase of the fan are still available, you can slowly raise the setpoint
value of the Δp controller or manually increase the feed rate while maintaining the
same grinding force. The limit value for the differential pressure is reached when
the specified static pressure increase of the fan is attained.
Operating manualen-
Once the correct differential pressure Δp of the mill has been reached, you
should only change the throughput of the mill by altering the grinding force
(hydraulic pressure), as this ensures that the mill's operating economy is equally
good in the partial load ranges.
You can reduce the differential pressure of the mill either by increasing the
grinding force (better grinding) or by reducing the material feed rate.
Angle of the guide vanes

If you adjust the guide vanes in tangential direction, the grain size distribution
curves become steeper, i.e. there is a change in ratio between the residues on
90 µm and 200 µm. However, it also increases the pressure drop of the mill and if
the guide vane ring is closed too far, the mill throughput is reduced.
Separator rotor speed

During operation, the fineness is adjusted via the rotor speed (faster = finer,
slower = coarser).
7.5 Inspection and maintenance

The operating personnel is obliged to inspect the plant at least once per shift for
externally visible damage and faults. If any damage, fault or change in the
operating behaviour is detected, the operating personnel must immediately inform
the responsible superior member of staff. The superior must ensure that the
ascertained damage or faults are eliminated without delay.
Be sure to comply with the instructions concerning inspection of the individual
machines in the respective machine manuals and operating instructions.
The routine maintenance work also includes daily checking and cleaning of the
thermocouples and the pressure measuring points, as well as daily inspection of
all lubricating points and oil-level indicators. Proper functioning of all parts is the
indispensable prerequisite for troublefree operation.
In order to avoid future operating problems, make absolutely sure that the
maintenance and repair work is always carried out with the greatest care.
Maintenance times for the reclaiming machines

For preventive maintenance of the equipment, it is sensible to arrange fixed
times. For this reason, the raw material preparation system was designed under
the assumption that the maintenance would be carried out during one shift per
week.
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Operating manual Trouble shooting
8 Trouble shooting
NOTE
Also be sure to comply with the instructions regarding faults in the
POLYSIUS AG machine manuals and the subsuppliers' documentation.
Fault Cause Elimination
Excessive power Excessive grinding force Reduce the hydraulic pressure.

consumption of mill
motor Grinding bed too deep Reduce the dam ring height.
Mechanical damage (e.g. Repair the mechanical damage.
blocking of a roller)
Very high pressure drop Very high gas flow rates Reduce the gas flow rate.
in the grinding plant
Very high gas velocities in the Enlarge the cross- section of the
nozzle ring nozzle ring.
Guide vanes closed too far Open the guide vanes, provided that
(tangential) the rotor speed can still be
increased.
Rotor blades wrongly set Inspect the rotor blades.
Repair if necessary.
Excessive vibrations Material feed failure, too little Check the feeding and outward
or too much feed material conveying equipment.
Eliminate any blockages.
Check the control system.
Insufficient air in the grinding Increase the air flow rate.
plant Check the nozzle ring and hot gas
duct for blockages and clean if
necessary.
Tramp material on the Remove the tramp material.
grinding table Check the metal detector in the
mill feed equipment.
Grinding bed too shallow Increase the dam ring height.
Reduce the hydraulic pressure.
Grinding bed too deep Reduce the dam ring height.
Increase the hydraulic pressure.
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Trouble shooting Operating manual
Feed material too fine (finer Coarsen the feed material or

than normal) Increase the dam ring height.
Reduce the hydraulic pressure.
Control system for the Check the control system.
differential pressure of the mill
works poorly
Rising differential The roller mill is overfilled Check the mill control and
pressure of the roller measuring devices.
mill If permitted by the rated power of
the drive, increase the hydraulic
pressure.
Reduce the material feed.
Exhaust gas Excessive feed material Increase the hot gas temperature.
temperature falls moisture content Reduce the material feed rate.
Fault in the flap/damper Check the control system.
control system
Inleakage of false air Check the expansion joints and
replace faulty ones.
Hot gas temperature too low Check the hot gas temperature
and increase if necessary.
Exhaust gas Fall in moisture content of the Reduce the hot gas temperature:
temperature rises mill feed material Increase the gas recirculation.
Raise the material feed rate if
permitted by the rated power of
the drive.
Failure of mill feed system Check the feed material conveying
system.
Hot gas temperature too high Check the hot gas temperature.
Operating manualen-
Operating manual Trouble shooting

Finished product too Rotor speed of the SEPOL® Increase the rotor speed.
coarse dynamic separator not If the max. speed of the rotor has
optimally set already been set, adjust the guide
vanes to a more tangential
position.
Incorrect direction of rotor Set the rotor to the correct direction
rotation (connections of rotation (clockwise direction).
accidentally changed during
repair work on separator)
Grit cone of the SEPOL® Replace the grit cone.
dynamic separator worn out
Labyrinth seal wrongly set or Check the seal between rotor and
worn out (oversize particles) housing.
Adjust the seal if necessary.
Replace if necessary.
Material incrustations in Mill exhaust gas temperature Clean the piping and the
piping and/or in the close to dew point (< 85 °C) separator if necessary.
separator Operate plant with higher exhaust
air temperature.
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Trouble shooting Operating manual
Bucket elevator: Gas flow volume too low Open damper upstream of mill /
excessive current system fan.
consumption Open return gas damper.
Increase the fan speed.
Inadequate gas velocity Further reduce opening of nozzle
ring gate valve.
Lower the gas temperature.
Grinding rollers are Gradually reduce dam ring height.
"ploughing" (i.e. they are Reduce hydraulic pressure.
pushing the material in front of
themselves) Start to inject water or increase
water flow rate.
Check material guide plates.
Excessive differential pressure Set system fan to full power.
Open flaps / dampers of mill
and/or fan.
Reduce material feed quantity.
Optimise grinding pressure.
Grinding bed not stable Start to inject water or increase
flow rate.
Optimise dam ring height.
Optimise hydraulic pressure.
Check material feed (onto
grinding table centre).
Check material mixture.
Operating manualen-
Operating manual Appendix
9 Appendix
Designation Drawing No. Register

Flowsheet 65000414
Sheet No. 2D1 - 3J2
en-D000091-2D-3J-A

en-D000091-2D-3J-A Grinding Plan For Raw Meal

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Operating manual

Grinding plant for raw meal

POLYSIUS Order Code (POC)

1 Technical Data......................................................................................... 1-1

1.1 Technical data of the plant

Specification of the intended use of the grinding plant

* Mill drive, system fan, rotor drive, coarse feed valve

Principal machines of the grinding plant

Mill exhaust gas fan

Hot gas producer

Water injection system

1.2 List of machines

Figure 1 Feed bins

Figure 2 Raw meal dosing system

Figure 3 Raw mill

Figure 4 Conveyors to the raw meal silo

3 Components and mode of functioning

3.1 Process-technological functions of the plant components

Electrical energy • Material separation

Mill feed material components

Hot gas generator

3.2 Material conveyance to the mill feed bins

3.3 Raw material dosing system

Feed bin (raw material feed bin 3D1)

Conveyors to the mill

Protection against tramp metal

Grinding process in the raw mill

Raw meal conveying equipment

Hot gas supply - operating modes

Heating up the grinding plant

Water injection system

3.4 Flaps/dampers in the grinding plant

Designation Item Adjustable Positionable Function

Shut-off flap 3F1.SF01 No Yes (open / Changeover from

3.5 Control loops of the grinding plant

Control of the temperature after the mill (interconnected operation)

Figure 6 Control loops

Control of water injection

3.6 Deviations compared to normal operation

3.7 Electrical interlock

4.1 Checking the mechanical equipment

4.2 Checking the electrical equipment

4.3 Test run

During the test run, pay special attention to the following:

• correct interlocking and proper functioning of individual plant components and

Roller mill groups

5 Starting the plant

5.2 Setting the plant

Start up the roller mill with the following initial settings

Figure 7 Position of the guide vanes

Grp. Start Starting condition Permanent condition

6 Shutting down the plant

6.2 Shutting down for a lengthy stoppage

6.3 Shutting down for a short stoppage

6.4 Shutting down in case of emergency

If danger threatens, proceed as follows:

7.2 Checks during operation

7.3 Plant operation monitoring

Mill feed material

Feed material too fine (finer Coarsen the feed material or